Cooked Headlamp Harness

[Don in Lodi]

Howdy,
I believe the root cause IMHO is that the headlight connector was poorly designed to be used in an area with limited air flow. Because of a "water" concern the back of the headlight does not get enough air flow to keep the OEM connector cool because it is part of the load. The point at which the connector and the bulb plug in is the load, that’s where the watts/power get consumed and that is where the heat is generated. By moving the OEM connector away from the load it is no longer part of the load and basically becomes just like a piece of wire in the harness. Ceramic is pretty much impervious to heat, think Space Shuttle, so the watts/power that is being consumed is isolated at the load. The plug and play replacements also have a higher gauge wire further isolating the load.
Later,
Norm

Just a POI; there are tens of thousands of autos out there from various makers with closed in light housings that don't melt down. Don't think air flow is 'it'. LOL, yes, there are even more with open air, gasketed systems that haven't had problems with water either. Something other than the twin H7 prolly would have been a good way to go...

 

[sail2xxs]

Does anyone have the number for Yamaha North America?
I know it's in a post around here somewhere, but nothing coming up on the search. I'm dropping my bike off to have the headlight looked at, and am already preparing for a fight on whether or not this is a warranty issue. During the first phone call, the service manager at my shop started telling how unlikely it will be that this will be replaced under warranty. I replied by saying horse$hit.
Says he, "I've never heard of this on any other Tenere that we've sold".
Says me, "Well you've only sold one, it's in my driveway, and the headlight connector is melted."
Says he, "Well we have a demo on the floor and it hasn't had any problems."
Says me, "It's only been there since last month and only has 1k miles. Mine has 13k in 9 months. I can't see what one has to do with the other."
He, "Well I've only heard of it on one other Yamaha ever. That was my R1, and they wouldn't cover it because I put in halogen bulbs"
Me "Mines not an R1, and it has the stock bulbs. I can't see what one has to do with the other. There are 41 pages about this issue on the Tenere forum, and multiple examples of this issue being warranted."
He, "You can bring it in and it'll take about a week to look at it"
There was then a long discussion about taking a week to look at a melted headlight connector, but I'll save you the details.
Thanks in advance for the help.

cb0802,

Call Romney Cycles in Romney, WV or TriCounty Honda/Yamaha in Petersburg, WV. Romney has replaced several headlight harnesses for me, and TriCounty just did my most recent one on Friday. All were done under warranty. Both dealers will get you in very quickly. Don't waste your time with the dealers around here. From past experience, calling Yamaha will get you a bunch of patient listening, and then the suggestion that you go to a dealer... or you might luck out and get contacted by a dealer rep.

Romney Cycles
51 Industrial Park Rd Romney WV 26757
Phone: 304-822-3933 Fax: 304-822-4122
Toll Free Phone: 866-766-1495
Ask for TJ (tech) and tell him what's up.

TriCounty
135 South Main Street
Petersbrug, WV 26847
304-257-4420
Ask for AJ in service

Best,

Chris

 

[Dallara]

...calling Yamaha will get you a bunch of patient listening, and then the suggestion that you go to a dealer... or you might luck out and get contacted by a dealer rep.

Well, that kind of depends on how recalcitrant and adamant you are once you get Yamaha Customer Service on the line... Check out post #65 in this thread...

http://www.yamahasupertenere.com/index.php?topic=2707.msg50271#msg50271

The point is simply this... Don't take "No" for answer. Keep calm and controlled, but firm and adamant, while on the line, and make them understand you simply will not get off the phone until somebody gives you a logical and relevantly coherent answer. Keep going up the line if necessary until you get somebody who not only has the power to make something happen, but who is also willing to do so.

I used to work as a mechanic at a Yamaha shop while I was going to college, and one day I overheard the owner of that shop, Joe Fisher, while he was on the phone with Yamaha trying to resolve a warranty issue... Each time he got exasperated with the person he was currently talking to on the phone he would say:

"Well, now I guess you better let me talk to the guy who signs your paycheck."

I'll never forget it, and I use it often.

Dallara



~

 

[sail2xxs]

I like that line Dallara. Will definitely keep it in mind for future use.

I never had an issue with the headlight harness and a dealer - that discussion was very simple, and was always taken care of without a hitch. The ongoing (basically 30k miles now) running issue I've been experiencing has led to some interesting discussions (and including yesterday, 4 dealers, 1 former dealer, and two Yamaha reps).

Best,

Chris

 

[snakebitten]

If you, Dallara, ever called in and I was the one who got you........
I'd just put you on hold and go tell the boss whatever he needed to hear to get it signed off.

And I mean that as a compliment.

 

[Waiting]

I take my bike in today for a new headlamp harness...dealer is giving me a loaner because he's not sure how long it'll take. It's a very small shop and thier first harness replacement. I hope Yamaha comes up with a true fix soon...the old closed eyes, and fingers in the ears while chanting "first time we've heard of this problem" WILL loose them my business eventually. I am a very patient man...but I don't like to be lied to.

 

[sail2xxs]

Waiting -

You're very lucky that your dealer is giving you a loaner bike! I'm not sure that Yamaha is intentionally lying about the harness issue - I was at a shop in Ohio on Monday, and they too said "this is the first we've heard of it". As soon as I said, "Well, it seems similar to the problem with the FJRs a couple years ago", they were all ears.

I think much of the issue is that these bikes are not all that common. At least to date all my dealings with Yamaha regarding warranty issues have been addressed in relatively short order. I understand they are a big company with lots of products, and that they may have database information management issues that make them struggle with everything that's going on, but they definitely seem to be trying hard.

Best,

Chris

 

[vnp514]

I take my bike in today for a new headlamp harness...dealer is giving me a loaner because he's not sure how long it'll take. It's a very small shop and thier first harness replacement. I hope Yamaha comes up with a true fix soon...the old closed eyes, and fingers in the ears while chanting "first time we've heard of this problem" WILL loose them my business eventually. I am a very patient man...but I don't like to be lied to.

I think it was Dallera who went to get a new harness and found out it was the same setup that comes on our bikes. I too bought a new harness from Stadium Yamaha(still waiting for it and the ceramic connectors). I'll try the connectors first and if they still give me problems, I'll copy the new harness by replacing it with heavier duty wires(again like the OP suggests). I'm not going to put a new harness in my bike to have the same problems plague me down the road.

Pete

 

[TierHawg]

Okay,

My game plan is to go with the ceramic connectors. These are the ones I want-right?:

http://www.ebay.com/itm/HARNESS-H7-X-2-WIRES-CERAMIC-PLUG-CONNECTOR-HEAVY-DUTY-AFTERMARKET-LOW-HIGH-FOG-/160654238893?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item2567bd24ad

I'll splice them into my stock wiring but being electrically challenged, might I have a mini class on how to do this? (I probably don't just twist the wires together and tape them up with electrical tape.) Tell me how to do it right the first time.

Thanks

Pete

No, those would only transfer the bad connection to a point farther down the line. This is what you want, imho, and what I used. Cut off the oem connector and solder in the new one.
http://www.ebay.com/itm/2-Pcs-Right-Angle-H7-Ceramic-Headlight-Bulb-Connector-Plug-Socket-for-Car-Truck-/380569012856?pt=Motors_Car_Truck_Parts_Accessories&hash=item589bae4a78&vxp=mtr

Or Click HERE (same link)

I guess I didn't read good enough. I bought the ones linked by vnp514. My harness is perfect and shows zero signs of melting. All I did was unplug the harness from the bulb, plug in the ceramic jumper, tuck it up out of the way, and then closed up the compartment. Repeated for the other side. I would only cut and solder if I had a melted harness. Not even sure if I did anything other than spend $10.

 

[Longhaulpaul]

Add another right headlight connector melt down to the list.

6 months old 2012 model. 20,000 miles. Replaced right bulb in the middle of the night, did not know about this issue. A week later, bulb out again, actually looked at the connector, it was partially melted, I broke off the brittle plastic and then I crimped the blade connector tighter and reinstalled. Then I found this post in the forum. Lots of good info. I read ten pages of this post, but wondered if there was registry for this issue?

LHP

 

[cb0802]

I'm waiting to take mine in. I still have the problem, but it's been very irratic. Some start-ups I get both lights, some start-ups I get one or the other, and on one occasion I got neither. I don't expect the service manager to take my word for it, but at the same time worry that they'll both fail on a night ride.

 

[vnp514]

Add another right headlight connector melt down to the list.

6 months old 2012 model. 20,000 miles. Replaced right bulb in the middle of the night, did not know about this issue. A week later, bulb out again, actually looked at the connector, it was partially melted, I broke off the brittle plastic and then I crimped the blade connector tighter and reinstalled. Then I found this post in the forum. Lots of good info. I read ten pages of this post, but wondered if there was registry for this issue?

LHP

https://www-odi.nhtsa.dot.gov/ivoq/

Tried to link my complaint on the Cooked HL Harness but no-joy. Mine is the only complaint about the HL Harness. There are two other complaints about loose spokes.

Pete

 

[EricV]

I'm waiting to take mine in. I still have the problem, but it's been very irratic. Some start-ups I get both lights, some start-ups I get one or the other, and on one occasion I got neither. I don't expect the service manager to take my word for it, but at the same time worry that they'll both fail on a night ride.

I suggest you remove the covers off the backs of the headlight assy and take a look at the connectors and wires. If you see melting of the connectors, don't wait any longer, just go in, describe what's been happening and that you noticed some melting of the connectors and anything else you noticed.

Alternatively, if you don't notice any melting, it gives you an opportunity to perhaps crimp the connecters a little tighter so they are more secure on the bulb prongs and that may help with the intermittent problem.

 

[sail2xxs]

I'm waiting to take mine in. I still have the problem, but it's been very irratic. Some start-ups I get both lights, some start-ups I get one or the other, and on one occasion I got neither. I don't expect the service manager to take my word for it, but at the same time worry that they'll both fail on a night ride.

Which dealer are you working with? Sometimes clearing off the burnt stuff and wiggling the connector a bit will buy you some time.

Chris

 

[iridemotorbikes]

I brought my headlight unit down and I changed out the harness at the service counter. The new harness was 100% the same as the cooked one so when I got home I used a razor blade and shaved the molded plastic off the end of the harness plug.
That allows the connectors to move freely out of the holder an I crimped them just a little, I could feel more pressure was needed to push them back on the bulb... A little elect grease an all is good now, entire process took minutes.

I have pics of the plug/connecter after I shaved some of the plastic off- will post up tomorrow night.

 

[cosmic]

I also noticed some time ago that the connector (left) was overheating. Took it to my friend elec., and he tightened the female part a bit. Since then it didn't get any worse.
Now the important part... A friend of mine with '11 WC had the harness replaced at our dealer. I happened to be there at the time and immediately noticed that his headlight glass was somewhat blurred.
My first thought was correct. It was from the smoke that entered the headlight while the connector was burning.
Anyways, he got also brand new headlight! Check your lights and compare it to the others... It was actually barely visible. I hope you can see what I mean from the pic.

©

 

[sail2xxs]

I also noticed some time ago that the connector (left) was overheating. Took it to my friend elec., and he tightened the female part a bit. Since then it didn't get any worse.
Now the important part... A friend of mine with '11 WC had the harness replaced at our dealer. I happened to be there at the time and immediately noticed that his headlight glass was somewhat blurred.
My first thought was correct. It was from the smoke that entered the headlight while the connector was burning.
Anyways, he got also brand new headlight! Check your lights and compare it to the others... It was actually barely visible. I hope you can see what I mean from the pic.

Wow! I thought my eyes were starting to go - have been using the LED lights more than in the past. After the number of harnesses that have been replaced on my bike, never thought of smoke residue on headlight glass leading to decreased performance.

Chris

 

[Obrianmcc]

Looks like I might be the next with harness issues.... found my right side bulb not working this afternoon... popped the cap and found some pretty discolored wires... notice no Blue/Brown .... more like a very faint Lt Blue/White. There is also a white coating on the inside of the cap.

The bike's a 2012 purchased new last Sept .... shortly after I found this thread and as a preventative I removed the plastic connector caps while
at the same time tightening the connectors for hopes of an improved connection to the bulb .... guess it didn't work.

 

[thfraser]

I have 25.5k miles on mine, not issues yet. But I did smell an electric burning smell the other day. I haven't pulled the headlight caps yet, but have a 26k service scheduled with Tri-County at the end of the month. So, I'll pull the caps, and let them know if there is something else that they need to address. I also have to show them my shock, where the preload is no longer adjustable, another known issue with these bikes.

My S10 has been trouble free and I'm totally enjoying this bike, but it does appear to have a few nuances that need attention, like almost anything else mechanical. These nuances do not appear to be ones that will kill trips, just ones that can be annoying.

 

[cb0802]

37.
That's the number of people on this thread that claim to have had the cooked harness problem (CHP ).
I went through every page of the thread to count them up. 3 people have had the problem twice, and three people have had lights go out but never reported the cause. It also appears that 2 riders have had the entire headlight assembly replaced (one in Italy and one in North America). I wasn't looking for that specifically, so may have missed one or two.
I go today to meet with my dealer. My initial phone call didn't go well, so I'm hoping a visit will help.
Statistically speaking, what’s the magic number required for Yamaha to address the issue? (that's a rhetorical question) And by “address the issue” I don’t mean a full recall. I simply mean that they report this as a potential problem via service bulletin?