RE: [ST] Bulb Replacement tips

["David Pullen" <dpullen@xxxxxxxxxxx>]

I just finished putting the new Sylvania bulbs in (man, oh man, are they
bright!) and I have a few additional tips:

I found that turning the handlebars toward the side I'm working gave me more
clearance.  (Turn the wheel to the left when working on the left bulb, etc.)
When I turned in the opposite direction, I found the fork to be too close to
the bulb for me to move things around.

Not only should you not touch the bulbs with your fingers, you shouldn't
touch the bulbs to anything else.  This is a LOT harder than it sounds,
since as STeve notes, you will not be able to see what you are doing.

Put the gloves on only when handling the bulb; they will get plenty dirty
when you remove the boot, etc, and the gloves need to be clean.  I was able
to perform the operation while only holding the base, and didn't need the
gloves.

On my '03 ST, the cables for the instrument cluster on the right side had
the boot pinned in pretty good.  I had to yank quite forcefully to get it
out, and it took a good 10 minutes to get it back on and seated.

STeve is right about the metal retaining clip keeps wanting to swing back
over the opening while you put the new bulb in; make sure you secure it out
of the way.

Also, when putting the new bulb in, I had a tough time guiding it in and
getting it seated.  Since visibility is limited, I found it easiest to look
through the front of the headlight cover and watch for bulb alignment.
Admittedly, it was like looking through a kaleidoscope, but it worked.
While in this position, I could reach under the fairing and hold the
retaining clip aside.

You'll have to wiggle the bulb a bit to get it seated because of the hinge
of the clip.  When it is properly seated, you won't be able to rotate it at
all; if you can rotate it, then it isn't seated.  It should feel like you're
about to push the bulb all the way through and drop it inside the lens.

  - Dave

- -----Original Message-----
From: owner-st@xxxxxxxxxx [mailto:owner-st@xxxxxxxxxx] On Behalf Of STeve
Duncan
Sent: Thursday, October 21, 2004 10:49 AM
To: ST@xxxxxxxxxxxxxx
Subject: [ST] Bulb Replacement tips


This is a bit long and drawn out.  If it can be of some help to you, read
on, otherwise just hit delete.  :)

I received my new headlight bulbs from Tricktape last night.  These are the
H4 Xenon 100w / 90w bulbs.  They ARE bright, and have a distinct bluish tint
when looking at them, but the light seems bright white in color to the
rider.  They seem much brighter with a "cleaner" light than the PIAA "Super
White" bulbs they replaced.

The main reason for this note is to outline the process of installation.  I
have done this at least four times over the last 5 years, but between each
time was just long enough that I had to figure it out all over again.  It's
really a pretty simple process, once you know the "gotcha's".  So, here is
how I got the job done.  If anyone else has additional tips, or shortcuts,
please share with the collective.  This is just how one dumb guy got the job
done.

First, you will notice on the package that it is strongly recommended that
you NOT touch the bulbs.  This is very important, as even the slightest
fingerprint will shorten the life of the bulb considerably.  And you can't
really wipe off the oil either, you just spread it around.  So, I employed a
pair of industrial nitrile gloves.  They are very thin and form fitting.  
You could also use surgical gloves or the like.

So to the job at hand.  Put the bike on the centerstand.  Get a good
flashlight.  You will be doing most of the work by "feel", so looking under/
into the work area in between steps is a good thing.  Do the headlights one
at a time.  I started with the left side, as I am left-handed.  First turn
the handlebars in the opposite direction as far as possible.  This will give
you the maximum amount of area to work with.  You will need it.  Shine the
flashlight in there and you will see the rubber boot cover on the back of
the light and the connector.  Remove the connector, and pay attention to its
orientation to the bulb contacts.  Next, reach in there and remove the
rubber boot by pulling a little bit all around the edge.  Note the
orientation of the drain holes.

Now the tricky parts start.  Get your flashlight back out and shine it in
there taking note of just where everything is and what is holding what.  The
bulb is held in place by a spring wire, it goes across the top of the bulb
base as well as the bottom.  It is hinged on one side and fits into a catch
clip on the other side.  To "unhook" this thing you must push "in" slightly
on the top and at the same time push upwards, and it will swing free.  This
is a delicate little sucker, so be careful with it.  Next, reach your hand
in there and pull the bulb out.  Make note of the orientation of the
connector tabs.  It's a tight fit in there, if you have gorilla hands, you
may be better served to just remove the entire faring, nosepiece and
cockpit.

OK, so halfway there, or so you may think.  Reassembly is a bit trickier
than yanking things out of there.  Put on those gloves, but first I
recommend downing a cold beer, it will steady your hands and calm the mind.

Getting the bulb back in the headlight assembly is a bit tricky.  That
little clip that holds the bulb in place will be in you way, they tend to
want to close up in front of the bulb.  I found that taking a long rubber
band and looping it over the top end of the clip helped me keep it at bay.  
Using my left hand (left hand side of the bike) to hold the bulb and my
right hand to hold on to the rubber band, I was able to snake that little
sucker into its proper place.  It is very important to have the bulb
orientated properly when putting it into place as there is very little
wiggle room once your hand is buried in there.  The LARGE tab on the bulb
base should be at about 10 o'clock.  This will mean that one of the smaller
tabs will be a 6 o'clock, the other small tab will be at about 2 o'clock.  
The spring clip will NOT snap into place unless all the tabs are lined up
and in their respective slots.  DON'T FORCE THE SPRING CLIP.  If the bulb is
in properly, you should be able to push the clip against the bulb base to
the point of resistance, and then DOWN slightly and it will clip into place.

  If you paid attention earlier when you shined your flashlight in there you
will remember about where the little silver catch was and will be able to
get the clip into place by feel, cause you sure won't be able to see any of
what you are doing.

Once you have the bulb and clip in place, reinstall the rubber boot.  Make
sure the drain holes a pointing down.  Lastly reattach the plug, make sure
it seats all the way down.  The large slot should be on top.

There, you are DONE !!!   Oh, wait a minute; you still have to do the other 
side.  Repeat steps above.  If my experience is any indication, you will
have the other side done in half the time.

Good Luck.

STeveDuncan
'00 - ST  mostly RED
Tejas



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