Cooked Headlamp Harness

[Dallara]

Allan, thanks for the explanation. You made it easy to understand. Now I understand the reason for two headlights (other than looks).

No problem, Tomatocity...

But just in case there is any confusion, the Super Tenere is not like some earlier Yamaha models where one lamp was low-beam (and the other "out" or "off"), and then both lit up on high-beam. That always made those bikes look kind of like they had a headlamp burned out. ::025::

No, with the Super Tenere *BOTH* headlamps are lit all the time, but each one has a mechanical "shutter" that flips down when on low-beam to cut off the beam to avoid blinding oncoming traffic. Then when you hit the high-beam switch a solenoid flips the "shutter" up out of the way exposes the entire projector lens on both sides and allows maximum lamp output.

You can actually hear the solenoid flip the "shutters" open and closed quite clearly if the engine isn't running, and it you stand in front of the bike while somebody else flips the high-beam switch you can see the "shutters" move up and down.

Dallara



~

 

[10 ER AY]

Thanks Dallara!

Guess I know how I'll be spending Friday night... ::008::

 

[creggur]

Stopped by my dealer this morning to have the headlight harness issue checked out. Explained the situation (and the solution) to the new service manager (thankfully the previous guy is gone - he was horrible), and he had his tech roll the bike in and have a look.

"Have you changed the bulb?"
"No, like I said, I know a number of guys who've had this issue and it's the harness that's causing the problem."
Tech walks in and asks, "Is it the left side that's going out? The bulb is working and looks fine, but the wires are cooking - have you changed the bulb - looks like the bulb is causing this?"
"No, that's the original bulb...." Then I go through the story for the tech.
Then he asks, "Is the left your high beam?"
So, I explain how the headlights on the Tenere work (the Service Manager looks understandably embarrassed that his young technician asked the question) and goes out to look at it closer himself.

He checks with parts to find out if he can just get a connector - nope - have to get the entire assembly. So I say, "Your tech said the wires looked 'cooked', why would I just want a connector? This should be covered under my YES warranty."

He agreed that it "likely" would be.

Finally I said, "Look, I'm the Service Director at a car dealership, and I know what it's like to have customers diagnose their cars via Internet forums, so I wouldn't even bring it up if I wasn't sure of the situation. This is a known problem, and it's being covered under warranty by Yamaha; I don't want a Band Aid put on the harness, I paid for the extended warranty and I'd like it repaired properly."

He said he'd verify YES coverage and get the part ordered - said he would call me Tuesday to let me know. They were really busy and I think he wanted to get me out of there...
I actually felt a little bad for the guy as he just stepped into the service manager position and seemed a bit overwhelmed (I know how what it's like to walk into a shit-pile that an incompetent manager has left behind) so I'm cutting him some slack.

If he doesn't call Tuesday I'll follow up with him, if he doesn't do the right thing I'll be going to a different dealership...

 

[BaldKnob]

Stopped by my dealer this morning to have the headlight harness issue checked out. Explained the situation (and the solution) to the new service manager (thankfully the previous guy is gone - he was horrible), and he had his tech roll the bike in and have a look.

Dropped my bike off Thursday with similar situation. Tech told me the harness would be replaced per YES but part was in Japan. $650.00 for said part, hopefully will be shipped next week.

 

[iridemotorbikes]

Dropped my bike off Thursday with similar situation. Tech told me the harness would be replaced per YES but part was in Japan. $650.00 for said part, hopefully will be shipped next week.

$650 for the headlight harness???!!!

 

[markjenn]

Dropped my bike off Thursday with similar situation. Tech told me the harness would be replaced per YES but part was in Japan. $650.00 for said part, hopefully will be shipped next week.

Someone isn't looking at the parts diagrams correctly - the entire headlight assembly is $600 or so, but the wiring harness for the headlights is about a $90 part.

- Mark

 

[BaldKnob]

Someone isn't looking at the parts diagrams correctly - the entire headlight assembly is $600 or so, but the wiring harness for the headlights is about a $90 part.

- Mark

I will have to give them a call Monday morning to confirm what exactly is being replaced. Thanks for pointing that out. Should have repaired it myself.

 

[twinrider]

I could have pulled a markjenn and argued for them to only replace the headlight subharness but why would I do that for a warranty repair? My new headlight looks nice and shiny. ;D

It also presented a great opp for them to install the HID conversion kit at a reduce cost. Turns night into day with a nice clean beam pattern, highly recommended. ::008::

 

[creggur]

Does anyone have a part number for this sub harness?

 

[Dallara]

Does anyone have a part number for this sub harness?

Sure...


23P-84312-00-00


BTW, on Yamaha parts catalog for both 2012 and 2013 USA models that number is exactly the same. It is also the same exact part number for every Euro/South African/Australian/Etc. one ever made, and the part number has never been changed, updated, or superseded. If Yamaha is making changes to the them they are doing without changing the part number.

Just FYI...

Dallara


~

 

[creggur]

Sure...


23P-84312-00-00


BTW, on Yamaha parts catalog for both 2012 and 2013 models that number is exactly the same. It is also the same exact part number for every Euro/South African/Australian/Etc. one ever made, and the part number has never been changed, updated, or superseded. If Yamaha is making changes to the them they are doing without changing the part number.

Just FYI...

Dallara


~

Thanks, Dallara - I was looking at the parts catalogue at the dealership, and it looked like the only way to get that harness was with the headlight assembly. Admittedly, I was stretching over the parts counter while the service manager and parts girl were discussing it - she determined that #5 (the part number you noted) in the fiche only goes to the little marker lights, but not the headlight bulbs.

Looking at it more closely right now, I can see the dotted lines she missed that denote the continuation of the harness back around to the headlights.

Thanks again...

 

[Travex]

2012 ST - Purchased June 2012
14k Miles
Second set of headlamps (right one burned out at around 12k Miles). Now Using Silverstar Ultra (55w)

Was on a 300 mile ride and noticed the right headlamp out on the rear of a vehicle before me. Assumed the lamp was bad and purchased a set to have another backup.
Upon installing the new lamp I immediately noticed that the connector was severely deformed and was crumbling in my fingers when I pulled it off the lamp. There was barely any physical resistance to removing the connector which instantly indicated a poor connection. Rode home with a single lamp and checked our forum and found this great, informative thread. It also bears mentioning that a light burning smell has been emanating from the front of my bike throughout the spring and I just could never pinpoint it.

Not unlike creggur I've considerable service industry experience and didn't wish to "forum-bomb" my dealer's service manager, although I did mention a rather apparent trending issue noted in them. My ST is out of warranty by a couple of weeks or so and my dealer (Don George's Motorsports) and it's Service Manager took immediate ownership of the failing and promptly processed an order for replacement. They were amenable to handling this as a warranty issue and have made it clear they are on it. I was also given the option of doing the work myself or having it done there. I'm opting to have them do it as if this somehow is a recurring failure point I would prefer that the service be done by the book. Was told about a week or so for the replacement to arrive. Incidentally, when I initially approached them it was the SM's day off and my complaint was handled by a very courteous, interested mechanic who got the ball rolling quickly. He's done my tires every time and does excellent work... Glad he's not needed more often. Testimony to the quality of the ST. This is the 2nd new bike I've purchased from them and from sales to service and soup to nuts they leave no room for complaint. No headache whatsoever.

In closing, I was told by the SM that the replacement harness is not modified and that they've been instructed to do the installation using dielectric compound. Upon dropping the bike off for the replacement I will view it for protrusion of excess plastic/recessed connectors and tight tolerance of the female spades.

Thanks to all in this thread for ironing-out this wrinkle for everyone's benefit. ::003:: I always enjoy the voice of experience and a good, informative thread.

 

[tomatocity]

Travex,

Always good to hear a positive report about a dealership and a happy rider. Noticed you are using aftermarket headlights. If you are happy with them you would be even happier with the Yamaha approved PIAA Xtreme White Plus bulbs. They are rated at 110 w and 4,000 kelvins (a neutral color). Another thing to check is the height of your headlight adjustment. I have raised 3.5 turns and are not getting complaints from oncoming traffic on two lane roads. This has enhanced my night riding to the point I am enjoying night rides. Hope this helps.

 

[Travex]

tomatocity,

Thanks for your thoughts on the matter... Very much appreciated and will be put into practice. The angle has been bothering me of late and I'll adjust them tonight. A couple questions if you're up for it:

1. Have you had the opportunity to compare the Silverstars and PIAA's side-by-side or use of both?

2. How many revolutions or fractions of a turn would you suggest for incremental adjustment?

Of the many good things I've read on the PIAA's those posts had fallen short of a comparison of the two. Realizing the SS's have a reduced lifespan I've become used to the added lateral cast and improved light temp in my autos and thought I'd see how that translated over to the ST. An improvement to be sure, yet not as profound as in a cage. I'm assuming that's due to the lensing on the ST. If they're that much better than the SS's that would be a good thing as they're similarly priced. Another thing that nudged me toward the SS's is that they're typically available on the road.

As evidenced in the pic, the failure was typical with the standoff of plastic being clear on the lesser affected side of the connector. I only wish I'd have had the forethought at the time of taking pics of the housing dome cover, as when I removed it there was considerably more debris. This pic is after I had already blown it out with a stiff puff. I had also blown out the area around the lamp and connector which had a coating of the same dust-like material.

Glad the notes on the dealer weren't lost on you... They really are worth the mention. Thanks again. ::003::

 

[twinrider]

If you want excellent headlights, go with HID. The Morimoto Elite 35 watt HID kit I installed are incredibly bright on high beam, a huge improvement over the Philips X-treme Vision bulbs, which themselves were a good improvement over stock.

 

[Travex]

Thanks kindly twinrider. I do understand that HID is superior in cast, but I've decided it's not the way for me as a failure in the wrong place at the wrong time would further complicate things for me. As I do most distant/remote riding alone, simplicity and standardization dictate my approach. ::003::

 

[twinrider]

Thanks kindly twinrider. I do understand that HID is superior in cast, but I've decided it's not the way for me as a failure in the wrong place at the wrong time would further complicate things for me. As I do most distant/remote riding alone, simplicity and standardization dictate my approach. ::003::

I understand your concern (which is why I went with a high quality kit). But all you have to do is carry a spare H7 halogen bulb, which you probably do anyhow. The original connector remains intact so replacement is plug and play.

Not to mention that the lighting of one HID bulb only is probably brighter than two halogens... ::008::

 

[tomatocity]

I have not had a chance to compare Silver Star and the PIAA. As far as color goes the PIAA was a big improvement over the two year old OEM bulbs.

I started with 2 turns then would increase the height by 1/4 turn each time I would ride. I am at 3 1/2 turns with no complaints but that could vary per rider and suspension setup. You should be safe starting at 2 turns.

 

[Travex]

I understand your concern (which is why I went with a high quality kit). But all you have to do is carry a spare H7 halogen bulb, which you probably do anyhow. The original connector remains intact so replacement is plug and play.

Not to mention that the lighting of one HID bulb only is probably brighter than two halogens... ::008::

I'm aware of the connection and the ultimate interoperability of both styles and am at fault for not added that I'm prematurely becoming an old fart who tries to cover all of my miles before dusk, i.e. the intensity isn't the concern it once was. There are still a few bones I've managed not to break and it would be very considerate of me to limit the coroner from doing a complete inventory on them. You are of course right about this.

I have not had a chance to compare Silver Star and the PIAA. As far as color goes the PIAA was a big improvement over the two year old OEM bulbs.

I started with 2 turns then would increase the height by 1/4 turn each time I would ride. I am at 3 1/2 turns with no complaints but that could vary per rider and suspension setup. You should be safe starting at 2 turns.

Thanks for your considered advice. Onward to the shop... Two turns it will be.

 

[Travex]

Received a call from the dealer informing me that the replacement harness was received so we'll tidy that up this week.

Interesting thing happened today. I've been riding with one headlight until the replacement came, but as I pulled up behind a van I noticed both my lamps were lit. The right (obviously suffering a horrible connection) had apparently re-made contact. Although the right wasn't as bright as the left, it was still lit. Barely worth mentioning but thought I'd put it out there.