Funky Headlight w/ Pics!

[Rhumba]

So I tore apart my headlight today trying to figure out why it was so dim. The wiring inside is definately hacked and the bulb in the unit is only a 25w/25w?!?!

So I go to the local APS and try to get a replacement in a higher wattage and the guys there never even seen this kind of setup before. And of course they had nothing to help me so...

The 3 wires coming from the headlight has bullet connectors that the PO squashed to insert into the black 3 prong receptacle. Also there are 3 connectors in the bucket that aren't connected to anything!?

See the pics and their captions:

http://picasaweb.google.com/Golflyer1/Headlight

Questions:

1. Is this a Stock Headlight unit?
2. What are the open connectors for?
3. What should I do next?

[TopCatGr58]

Hey Rhumba,

The headlight bucket looks close, but I think it's an aftermarket one. That piece of metal with the grommet is for connecting a bolt to the headlight bucket, there is supposed to be a slotted bracket that allows tilting and then locking the headlight bucket in a certain position of elevation/depression, and that bucket doesn't look like it has that....see the microfiche for example.

The other wires are difficult to tell, the double ended one with black is a ground, the single bullet looks like it's connected to a RED wire....if you put a meter on it, you'll probably find that it's either HOT all the time, or at least hot with the key on. Can't tell about the other wire. Yamaha put extra wires for connecting fairings and such.

The headlight plug should have a black/ground wire, and then a yellow/green which I think is the high beam, and a green/red or Grey/red wire for the low beam......or vice versa, can't tell from the XJ's wiring diagram??

Okay, the squashed connectors were to allow use of the OTHER bulb/socket with the OEM socket. Once you get a proper bulb/lens reflector assembly and the right bulb, the OEM plug will plug into it correctly, just throw that cheesy POS away!!!

MikesXS sells a CLEAR LENS conversion for the 7" round headlights....I think thats the size of the XJ's, I know the XS's Specials were that size!!!
T.C.

[wa407mpp]

I converted my bike to Halogen using a later XS lens housing and installed a Hella 100w/55w bulb, it puts out a lot more light then stock, without the extra work of installing HID. Warning! This conversion can cause the high beam wire to burn right behind the plug, from the extra amp load, especially if you run a fairing. I installed special duct-work to draw cooler outside air through the light housing and installed a heavier fuse and fuse holder,

[Rhumba]

Thanks for the help guys...

I looked at Mikes XS site and thought I would just get the Classic 7" HL complete assy w/ halogen bulb but it says for XJ650. I emailed them and asked if it would fit an XJ1100 just to be sure.

Do you guys know if the HL assy's were interchangeable among the different bikes? Any other years/models I can consider? I may not hear from them till Tuesday.

One thing is for sure...I am not looking forward to pulling all those wires apart to replace the bucket

Thanks again.

[Yahman]

The double plug (blue wire) is for the front park lights. I don't see any wires for the park lights coming from the turn signals though.

Larry

[Rhumba]

Well here's the reply from Mikes XS site regarding the HL assy for an XJ1100:


Tell XS11 site to take down that info. No parts for anything but XS650 1970-84 twins.

Mikesxs.com



Is OEM my only option for a complete HL assy?

[Yahman]

Sounds like the typical Mikesxs responce to me. Don't know why he doesn’t want our business.

Larry

[TopCatGr58]

Hey Rhumba,

Mikes XS doesn't want to be bothered with the hassles and any possible "PROBLEMS" from folks with other than 650's using their parts, so they won't tell you about any cross reference possibilities! We try to tell folks to DON'T BOTHER ASKING him about fitments for XS/XJ11's!!!!

The headlight bucket will fit just fine. The only thing is that the 650 bucket may be a bit smaller inside the bucket vs. the XJ/XS11's, and so you may have to get creative to position all of those wires you don't want to mess with around inside the bucket to get the headlght to be able to fit inside. Note, on the XS11, there are extra openings to allow the routing of the wires coming into and out of the bucket, not sure of the exact design of the XJ's, again, check the microfiche site for more details.

Take some masking tape and put it on each plug and connector you remove, and label them with matching labels, alphabets or #'s, or whatever, that way you can keep track on what plugs into what!
T.C.

[Rhumba]

Well, here is what I was looking at for a replacement headlight...

(item # 09-0064, 7" Classic)

http://www.mikesxs.net/mikesxs-elect...ategory_id=2.5

Only problem is that headlight does not have the square holes on the sides for the turn signal stalks.

I requested quotes from a couple salvage yards and they want $125 for an OEM HL assy. (joke)

So it seems my only option is to buy MikesXS HL and modify it to fit my XJ unless anyone out ther has a HL assy they aren't using.

Any ideas?

[TopCatGr58]

Hey Rhumba,

I know it adds a little more expense, but you could add these which have the round base instead?? Same Page as the headlight!

Turn Signal Lamp with Amber Lens. Fits: front or rear on 1973-84 TX/XS650’s.


Part #11-2186 $15.00 USD EA.

I think that the XJ's turn signal lens will even fit in place of the XS style so you could get closer to your Stock style!?

T.C.

[Rhumba]

Good suggestion.

BTW, can someone with a stock XJ1100 pop the cover off one of the front turn signals and let me know if the bulb is a single or double element?

I got a wiring diagram and it shows 3 wires going to the bulb (one ground which would be the body of the bulb) and two others, which seems to indicate that they are double element bulbs and that they operate as running lights AND turn signals.

I think the signal stalks on my bike are aftermarket too. The bulbs are single element and the wires are way too long.

Thanks to whomever checks this out for me.

[TopCatGr58]

Hey Rhumba,

The XJ IS supposed to have the dual filament bulbs up front, running and turn signals. However, you haven't had them anyways, so not a big loss. The blue wire inside the headlight bucket is the running light lead. IF people can't see your headlght, they certainly aren't going to see the little yellow running lights!!

IF you HAVE to have running lights you could put on an extra set of LEDs, JAT!?
T.C.

[Rhumba]

Well I just ordered two turn signals and stalks from Partsnmore.com.

I am trying to get this bike as stock as possible in addition to having a brighter headlight. (going from a 25w incandescent to a 55w halogen should be a great improvement.)

Thanks for all the help guys!