2010 - headlight completely dead

[Grape_salad]

Quick electrical question. This afternoon I noticed my headlight was out (2010 model). Both headlights and the small running lights too). Everything else electrical is fine though. I’m guessing the connector to the headlight has come loose, or perhaps a fuse has blown.

Anyone had that happen before? Suggestions for where to look for connectors that may have come loose? I haven’t started looking yet other than a cursory look around the dash (couldn’t see anything) but thought I’d ask here in case anyone’s had the exact problem before and could save me some time.

 

[Tenman]

There is a wiring recall for the headlights. Yamaha dealer can tell you if yours needs it. One of my connections was burnt out.

 

[Squibb]

A quick call & your dealer can check against your VIN to see if the original recall has been done.

Otherwise, assuming the fuses are all good, it may be worth checking the connectors; see this link: -

.............. https://yamahasupertenere.com/index.php?threads/light-harness-fix.24772/

 

[Grape_salad]

There is a wiring recall for the headlights. Yamaha dealer can tell you if yours needs it. One of my connections was burnt out.

Thanks, but i don't think that's my issue - doesn't look like that recall affects my year model, and both headlights and the running lights are out, which seems outside the scope of that issue.

I think @Squibb might have it though - I will pull off those covers and check that connector

 

[Grape_salad]

@Squibb is on the money. I pulled the side covers off. The headlight connector isn’t burnt out thankfully, but there’s definitely corrosion on the connectors and it’s on its way to burning out. Hopefully a clean will save them, otherwise I’ll replace the terminals

 

[bimota]

is this that connector do you think may be worth having

NEW 4 WAY PIN PLUG BRASS CONNECTORS SOCKET X 10 MOTORCYCLE FITS YAMAHA | eBay

NEW 4 WAY 4 PIN PLUG + BRASS CONNECTORS + SOCKET X 10 COMPLETE PLUGS. YOU GET 4 X BRASS FEMALE CONNECTORS AND 4 X MALE BRASS CONNECTORS X 10. FEMALE BRASS CONNECTORS ARE 4MM WIDTH. AND 1 X MALE PLUG AND 1 X FEMALE PLUG X 10.

www.ebay.co.uk

rob

 

[Grape_salad]

That’s slightly different to the one I have in my bike - the locking mechanism is different. Not that big a deal if you replace both sides, but if you later want to install a new harness it won’t fit that connector.

 

[RCinNC]

That happened to me about a year ago. It was the fuse.

 

[bimota]

That’s slightly different to the one I have in my bike - the locking mechanism is different. Not that big a deal if you replace both sides, but if you later want to install a new harness it won’t fit that connector.

looking at your picture this must be it

4 Way HM Series Motorcycle Wiring Loom Connector Unsealed

4 way unsealed wiring connector plug used on some Honda, Suzuki, Yamaha and Ducati wiring looms

kojaycat.co.uk

rob

 

[Grape_salad]

An update:

I had a closer look and there was definite heat damage to some of the contacts and plast housing. The contacts were also quite loose and intermittent.

I pulled out each female connector and cleaned it in vinegar (then rinsed in a bicarbonate solution, and again in fresh water), used a wire brush to clean corrosion where necessary.

I then very carefully used pliers to crush the connectors in to tighten them up for a better connection with the male side. I used Vaseline to lubricate the contacts to prevent moisture related corrosion

Not ideal, but it’ll keep me going until I can get some replacement connectors and silicone grease.

Thanks for everyone’s help - saved me a lot of time tracing cables and checking connections

 

[WJBertrand]

Did it work to restore your lights?


Sent from my iPhone using Tapatalk Pro

 

[Highwayman]

Not sure if your repair fixed it..... But I know in my case with a few bikes when I had issues with lights not coming on its been a bad ignition switch.

 

[Grape_salad]

@WJBertrand yes absolutely fixed it. Prior to be doing that, jiggling the connector would cause lights to flicker on/off. Now they stay on.

It's a temporary fix in that you can only restore the soundness of the connectors so much, so this will re-occur, maybe in a few months, or maybe a few years. I've got some replacement 4 way connectors on order so at some point i will pull the current connectors off and re-terminate the wires with the new connectors (i opted for generic waterproof automotive connectors rather than the ones used in the factory harness as suggested by @bimota, as those were just too expensive with shipping, and waterproof connectors are always a nice thing to have)