[ST] Bulb Replacement tips

["STeve Duncan" <xhippy@xxxxxxxxxxx>]

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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