Author Topic: LH Headlight Connection (Read 10607 times)

alans1100 · « **on:** January 22, 2018, 07:02:55 PM »

For the past few months the left hand headlight has been playing up. Sometimes it works and sometimes it doesn't.

I had another look at tonight as I really don't like having one beam out even though I don't do a lot of night riding these days.

The plug/socket thing that gets the power to the globe was a little tight and when it did decide to move a small piece of plastic broke off of it. It now looks as if there is only one wire still in place and by sheer chance it's the high beam wire as the HID driving lights still work.

I had a quick look in the parts list and it looks like the full harness is needed but I'm sure any headlight plug should do the trick though one with a few inches of wire would make the job so much easier.

Time to call into a wrecking yard I think and get one of an old car.

alans1100 · « **Reply #1 on:** January 22, 2018, 07:21:48 PM »

Found a couple of plugs on eBay for $8.50

Will fix it after out Feb RTE

Brock · « **Reply #2 on:** January 22, 2018, 08:18:13 PM »

Repco should have one.

Shiney · « **Reply #3 on:** January 23, 2018, 07:53:11 PM »

I look forward to reading all about how you do this fix and I'm sure it'll be of use to a number of people as the bikes continue to age

alans1100 · « **Reply #4 on:** January 23, 2018, 08:21:42 PM »

It's going to be a pain in the proverbial butt.

I'm going to do both sides while I have it in pieces. Might even get to finally put the new clock globe in as well.

alans1100 · « **Reply #5 on:** January 24, 2018, 12:14:23 PM »

Something like this looks good for $10

https://www.ebay.com.au/itm/2x-H4-9003-HEADLIGHT-SOCKET-PLUG-extension-Female-connector-12V/252518271775?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20131017132637%26meid%3D02efdc772a874305a640103496fc488d%26pid%3D100033%26rk%3D4%26rkt%3D8%26sd%3D351349102473&_trksid=p2045573.c100033.m2042

s-l1600 by Alan, on Flickr

Biggles · « **Reply #6 on:** January 24, 2018, 12:48:29 PM »

At least it won't have that wretched tab that has to be depressed to get the OEM one off the bulb! Hopefully it stays firmly connected with needing that "latch".

alans1100 · « **Reply #7 on:** January 24, 2018, 03:05:57 PM »

Quote from: Biggles on January 24, 2018, 12:48:29 PM

At least it won't have that wretched tab that has to be depressed to get the OEM one off the bulb! Hopefully it stays firmly connected with needing that "latch".

Must be a 1300 thing as the plugs on mine have always just pulled off.

alans1100 · « **Reply #8 on:** January 25, 2018, 10:29:11 PM »

Quote from: alans1100 on January 22, 2018, 07:21:48 PM

Found a couple of plugs on eBay for $8.50

A seniors moment occurred and I ordered male instead of female plugs so contacted seller and the order was cancelled and money refunded.

I think I'll order the ones in my previous post even though they do look like the ones at half the cost from China.

alans1100 · « **Reply #9 on:** January 27, 2018, 04:21:08 PM »

Quote from: alans1100 on January 25, 2018, 10:29:11 PM

Quote from: alans1100 on January 22, 2018, 07:21:48 PM
Found a couple of plugs on eBay for $8.50
A seniors moment occurred and I ordered male instead of female plugs so contacted seller and the order was cancelled and money refunded.

I think I'll order the ones in my previous post even though they do look like the ones at half the cost from China.

After investigating various eBay sellers selling the same plug at varying prices with only the colour as a variable I bought a couple for the huge sum of $1.94

While the bike is in a state of undress the gauge lights might get a makeover as well for about $42 delivered.

https://www.ebay.com.au/itm/BLUE-HONDA-ST1100-PAN-EUROPEAN-ABS-led-dash-clock-kit-lightenUPgrade/152004653643?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

Blue by Alan , on Flickr

Shiney · « **Reply #10 on:** January 28, 2018, 08:07:57 AM »

AWESOME

alans1100 · « **Reply #11 on:** January 29, 2018, 06:40:56 PM »

I started working on the bike today and I forgot to take my camera over to Tammies and had to use the phone for the few that I did take.

One for the log book - 445km since last fill - fuel warning light came on at 407km.

20180129_165834 by Alan, on Flickr

Screen Off - need to get at least one new bolt so I'll order a set and have a few spares.

20180129_161816 by Alan, on Flickr

Black panel below screen removed.

20180129_162250 by Alan Williams, on Flickr

Grey panel moved and dash shelf off

20180129_164409 by Alan, on Flickr

and can now access the back of the gauges and I can look through the gaps and see the broken plug but not visible in picture.

The red wire to the lower RH of the picture is the 12volt power supply and I need to remove that before the top fairing and grey panel can be removed.

20180129_164439 by Alan, on Flickr

Next were the mirrors, indicators and driving lights

20180129_165239 by Alan, on Flickr

20180129_165757 by Alan, on Flickr

I took note of the driving light wiring because I had to turn the plugs around for the lights to work and hold them together with electrical tape when I installed them.

20180129_165434 by Alan, on Flickr

Even a place to put the parts

20180129_165247 by Alan Williams, on Flickr

That's all for today.

If all goes well I can order the gauge lights next week though the colour is up for discussion between the blue and the pink below. Since the coolant is also getting done I've had a look at prices for that as well and going with the red Nulon again. The Territory needs doing as well but I have no idea how much it needs yet.

Pink by Alan, on Flickr

Brock · « **Reply #12 on:** January 29, 2018, 06:46:04 PM »

Allan,

If you find some, I think 5mm is the size. I used Stainless with allen hexhead for mine. looks good.

If you like I can get some of the correct size and send to you.

alans1100 · « **Reply #13 on:** January 29, 2018, 07:16:18 PM »

Quote from: Brock on January 29, 2018, 06:46:04 PM

Allan,

If you find some, I think 5mm is the size. I used Stainless with allen hexhead for mine. looks good.

If you like I can get some of the correct size and send to you.

Thanks but I have these in my screen and getting some more - https://www.ebay.com.au/itm/5-BOLT-BLUE-ALUMINIUM-SCREEN-KIT-HONDA-ST-1100-PAN-EUROPEAN-ST-1989-2002/110964261595?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

Brock · « **Reply #14 on:** January 29, 2018, 07:34:40 PM »

alans1100 · « **Reply #15 on:** February 03, 2018, 07:02:22 PM »

Got the rest of the bike stripped down this afternoon.Almost a total strip down just so I could fix a plug and a few other neglected items.

Disconnected the TomTom and 12volt power wiring and took it out with the grey panel that covers the back of the gauges. Power supply fuse holder had to be cut off as there wasn't enough space to pull it through - My slack solder job lasted from when it installed so I'll have to some how repeat the process. While this is visible I'll see if I can tidy up the driving light wiring a little.

DSC_1398 by Alan, on Flickr

The RH filler panel is getting replaced - you can just see the crack just below the lighter area on the panel. It is repairable so I'll keep it as a spare.

DSC_1401 by Alan, on Flickr

And this little beast. One plug which has seen better days. The electrical tape was there to prevent a possible short in the wiring. With everything all together I caught a hint of a bare wire and thought the feed wire to driving light relay might have been the one. That wire has been in 9 years and no trouble and as it turns out is one of two wires still connected. Can't fault the RH plug. Going re route the feed wire along the globe cable and solder it in with the new wiring.

DSC_1402 by Alan, on Flickr

Now all I have to do is wait for new plugs to get here, find the new clock globe and remove that gauge cluster I
in readiness for the new coloured globes.

alans1100 · « **Reply #16 on:** February 07, 2018, 01:10:13 PM »

Ordered the coolant today for $51 delivered. https://automotivesuperstore.com.au/nulon-rll5

The car needs doing as well so I should get 15 litres total out of this. The bought premix is 1/3 coolant to water and I still have some from the time I did the timing belt.

richo · « **Reply #17 on:** February 07, 2018, 04:16:26 PM »

Good luck with the rebuild. Hopefully you will not have any "spare parts" left over when she is all back together

alans1100 · « **Reply #18 on:** February 09, 2018, 05:18:03 PM »

Success!! Found the new clock globe - not very big either 15mm long and 4mm wide.

DSC_1411 by Alan, on Flickr

Also I found the solder iron and Heather found the solder - just waiting on plugs and heat shrink to arrive from China

Quote from: alans1100 on February 07, 2018, 01:10:13 PM

Ordered the coolant today for $51 delivered. https://automotivesuperstore.com.au/nulon-rll5

Coolant should get here Monday and was in Adelaide at midday today.

Biggles · « **Reply #19 on:** February 09, 2018, 06:30:05 PM »

Quote from: alans1100 on February 09, 2018, 05:18:03 PM

Also I found the solder iron and Heather found the solder - just waiting on plugs and heat shrink to arrive from China

Don't forget Brock's advice regarding soldering as a fix.

alans1100 · « **Reply #20 on:** February 09, 2018, 07:28:49 PM »

Quote from: richo on February 07, 2018, 04:16:26 PM

Good luck with the rebuild. Hopefully you will not have any "spare parts" left over when she is all back together

I didn't the last time. This time I only removed enough to take the top fairing off. Not so many to leave out.

alans1100 · « **Reply #21 on:** February 15, 2018, 08:17:02 PM »

Plugs arrived today - nice white ceramic around the terminals which are totally enclosed.

Just waiting on the heat shrink to arrive and I can get it fixed.

DSC_1458 by Alan, on Flickr

DSC_1459 by Alan, on Flickr

DSC_1460 by Alan, on Flickr

alans1100 · « **Reply #22 on:** February 17, 2018, 03:07:10 PM »

Need to order a few parts and one I need to get sooner rather than later. The rubber covers for the headlight globes need replacing though not urgent. The LH cover is the worst

Item 4 in the list. but doing both.

https://www.partzilla.com/catalog/honda/motorcycle/1999/st1100a-ac-abs-ii/headlight

This one is more important as it protects the electrics behind the gauges - from excessive water maybe. It should have been replaced when I did the timing belt but I just got some packing tape and stuck it back on - gone to far for that now but after 18 years who's complaining?

- Item 2 in the parts list

https://www.partzilla.com/product/honda/37104-MAJ-G00

alans1100 · « **Reply #23 on:** February 21, 2018, 05:37:33 PM »

Ordered the protector part that covers the back of the gauges plus the three nuts that secure it.

$US21.59 or $AUD28.02 (unless the exchange rate changes at my bank). $12 cheaper than quoted from a local dealer including delivery.

Will add a photo when the parts arrive in 4 to 8 days;

alans1100 · « **Reply #24 on:** March 01, 2018, 12:08:50 AM »

Still waiting for the items from Partzilla to be shipped - email from them saying they were waiting on them with an expected ship date of the 28th Feb or 1st Mar. Still the 28th in the US so I'll check again later today. This can be fitted anytime as it only means removing the screen and it attaches to the grey panel covering the back of the gauges.

Heat shrink for the wiring is still on it's way but if not here by Friday then I'll just have to work with old fashioned electrical tape and put it all back together over the weekend and only replace the broken plug for now.

Question for the electrical wizards amongst us.

Since I have my 1100 in pieces I'm considering relocating the wiring for the GPS. Until I had to disconnect everything I just fed the wire to the battery and the mount was live 24/7 though not using power until the GPS was placed on the mount.

I think it more wise to use a switched source fairly close to behind the gauges. Looking at the wiring diagram I can see the wiring for the actual gauge lights as maybe the only option as they are on as soon as the key is turned. Accessing one of the positive wires to the globes with the positive side of the GPS wire (thinner than OEM wiring ) I think should be ok; do you agree or not? Or another option maybe?

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Author Topic: LH Headlight Connection (Read 10607 times)