How do I put the ******* headlight back together? - Road Star Warrior Forum : Yamaha Star Warrior Forums

Reply
 
LinkBack Thread Tools
Old 08-30-2011, 02:49 PM   #1 (permalink)
Junior Member
 
ilcylic's Avatar
 
Join Date: Apr 2003
Location: Albuquerque, NM
Posts: 20
Default How do I put the ******* headlight back together?

In the course of tossing my '02 down the freeway on a lark, the plastic headlamp bucket shattered. Got a new one, trying to put it all back together, and there's more wire and connector than there is space.

Anyone got pics of what it's supposed to look like, or even just a writeup on how to do it? I am screamingly frustrated, feels like I've tried eleventy-hundred different ways and times and it just won't go!
ilcylic is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 08-30-2011, 03:38 PM   #2 (permalink)
Senior Member
 
scawein's Avatar
 
Join Date: May 2006
Location: Oakhurst, Ca
Posts: 4,574
Default

Quote:
Originally Posted by ilcylic View Post
In the course of tossing my '02 down the freeway on a lark, the plastic headlamp bucket shattered. Got a new one, trying to put it all back together, and there's more wire and connector than there is space.

Anyone got pics of what it's supposed to look like, or even just a writeup on how to do it? I am screamingly frustrated, feels like I've tried eleventy-hundred different ways and times and it just won't go!
First order of business......take a deep breath, a beer or whatever will let you get perspective back.

I will pull the headlight off and take a picture for you. I will try to have it up in just a few minutes....check back after the beer or ???

YOU WILL WIN.......
__________________
[FONT=Arial]
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Compliments of ArizonaWarrior

Service Manual can be found here (thanks Robriquez)
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


Proper way to check oil level
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
scawein is offline   Reply With Quote
Old 08-30-2011, 03:46 PM   #3 (permalink)
Senior Member
 
yodie001's Avatar
 
Join Date: Apr 2006
Location: cashiers nc
Posts: 1,510
Default

That's a class act! What other forum can you find such great members?

Icylic...are you having problems getting all the wire through the holes in the bucket, or just having trouble getting the light back in once everything is connected?
Quote:
Originally Posted by scawein View Post
First order of business......take a deep breath, a beer or whatever will let you get perspective back.

I will pull the headlight off and take a picture for you. I will try to have it up in just a few minutes....check back after the beer or ???

YOU WILL WIN.......
yodie001 is offline   Reply With Quote
 
Old 08-30-2011, 04:00 PM   #4 (permalink)
Junior Member
 
ilcylic's Avatar
 
Join Date: Apr 2003
Location: Albuquerque, NM
Posts: 20
Default

No, I managed to get all the wires through the very tiny hole in the bucket, but after reconnecting all the little plugs (So many colors! Whee!) it's just this sort of... tangled mess. And the picture in the factory service manual is a complete joke. Feh.

So, basically, the issue is that I don't know which wires / plugs to put on which side of the bucket, or through which wire clip to put which bundle, to hold it all in place so that the headlight unit will fit in place.

I've got to admit, I've been strongly considering just doing something aftermarket, because I'm not sure if the money it would cost would be worse than the ulcer I'm going to give myself over this.

Quote:
I will pull the headlight off and take a picture for you. I will try to have it up in just a few minutes.
That's very swank of you, scawein. I sure do appreciate it.

*does yoga or some **** to get all zen*

------

What was weird to me is, I searched, and couldn't find any other threads about this. Either everyone else has found this much easier than I am, or I suck at searching.

Last edited by ilcylic; 08-30-2011 at 04:10 PM. Reason: spelling
ilcylic is offline   Reply With Quote
Old 08-30-2011, 04:22 PM   #5 (permalink)
Senior Member
 
whajac's Avatar
 
Join Date: Nov 2006
Location: Springfield, Virginia
Posts: 2,152
Default

Here's an image from the Service Manual. Though it's in b&w, it may be of some help while waiting for the photo from Scawein.


whajac is offline   Reply With Quote
Old 08-30-2011, 04:53 PM   #6 (permalink)
Senior Member
 
robriguez's Avatar
 
Join Date: Jul 2006
Location: Edison, NJ
Posts: 7,301
Blog Entries: 1
Send a message via MSN to robriguez
Default

there is a TON of wiring and harnesses that need to go in the bucket. THATS the hard part getting it all in there AND the reflector/bulb.

Hopefully Scawin's pic will help getting the correct wire plastered against the correct portion of the wall of the bucket.
__________________

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

***
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
***
robriguez is offline   Reply With Quote
Old 08-30-2011, 05:05 PM   #7 (permalink)
Senior Member
 
scawein's Avatar
 
Join Date: May 2006
Location: Oakhurst, Ca
Posts: 4,574
Default







There you go. You just have to get them to lie on the outside (inner) of the bucket. Once routed, most of them should fit in the little hold down clips on each side.

This would also be a good time to put dielectric grease on your connectors while it is open.

Yes some of the connectors look different then stock. I changed some when I internally wired my handlebars.....

Sorry it took a few, dang gmail took a while to pass them to me.

Holler if you need more help.
__________________
[FONT=Arial]
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Compliments of ArizonaWarrior

Service Manual can be found here (thanks Robriquez)
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


Proper way to check oil level
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Last edited by scawein; 08-30-2011 at 05:07 PM. Reason: more and more
scawein is offline   Reply With Quote
Old 08-30-2011, 05:16 PM   #8 (permalink)
Junior Member
 
ilcylic's Avatar
 
Join Date: Apr 2003
Location: Albuquerque, NM
Posts: 20
Default

Ok, those are great pics. I'll give it another shot and see what it gets me. Thanks very much. Hopefully yours goes right back together, I'll feel like a jerk if you took yours apart to show me how to fix it and then you can't rebuild yours!
ilcylic is offline   Reply With Quote
Old 08-30-2011, 05:23 PM   #9 (permalink)
Senior Member
 
scawein's Avatar
 
Join Date: May 2006
Location: Oakhurst, Ca
Posts: 4,574
Default

Quote:
Originally Posted by ilcylic View Post
Ok, those are great pics. I'll give it another shot and see what it gets me. Thanks very much. Hopefully yours goes right back together, I'll feel like a jerk if you took yours apart to show me how to fix it and then you can't rebuild yours!
No problem, it comes on and off very easy as long as the wires are dressed well. The main idea is to create a bowl shape with all the wires so they hug the outer areas of the bucket. If you look for a bit, you should see the natural way they want to lie in there since you are just putting them back.

Feel free to check in as you need to.
__________________
[FONT=Arial]
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Compliments of ArizonaWarrior

Service Manual can be found here (thanks Robriquez)
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


Proper way to check oil level
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
scawein is offline   Reply With Quote
Old 08-30-2011, 05:29 PM   #10 (permalink)
Senior Member
 
Caledonian Warrior's Avatar
 
Join Date: Jan 2011
Location: Scotland, UK.
Posts: 1,984
Default

Quote:
Originally Posted by scawein View Post
There you go. You just have to get them to lie on the outside (inner) of the bucket. Once routed, most of them should fit in the little hold down clips on each side.
These are first class pictures Scawein, well done for helping out
I wish mine looked as neat in there as yours.
I'll be having a copy of them for when I get the nerve to undo the bolts and let the lot pour out


Gav.
__________________

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


TO SEE OLD PHOTOBUCKET IMAGES WITH FIREFOX..
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


TO SEE OLD PHOTOBUCKET IMAGES WITH GOOGLE CHROME..
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.







Caledonian Warrior is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply

  Road Star Warrior Forum : Yamaha Star Warrior Forums > Warrior Forums > Technical Discussion

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -4. The time now is 02:56 AM.


Powered by vBulletin® Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
SEO by vBSEO 3.6.0
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
RSWarrior.com is an independent Yamaha enthusiast website. Content on RSWarrior.com is generated by its users and RSWarrior.com is not in any way affiliated with Yamaha Motor Corporation, U.S.A.