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Help Zeal Headlight blowing up too often

Discussion in 'Yamaha 250cc In-Line 4's' started by Pyr0technicien, Jun 6, 2019.

  1. Pyr0technicien

    Pyr0technicien Active Member

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    Hi people,

    Just all new on this forum, wich looks really nice to improve my knoledge about bikes and more specifically my dear zeal.

    My headlight use to blow up really often, I would say every 3/6 month I need to change it i don't know if that's normal. I spend nearly 30$ everytime so I would like to know where that could come from.

    So i tought about de reg/rec being faulty but after testing it, everything seems alright, I didn't rev up all the way to 12k tough, would it make a difference ?

    All my dashboard lights are blown up too (only one left), and the size is so particular that I couldn't find a new bulb in any shop, so i'll have to order it online, didn't had the time yet.

    Backlights are never blowing and are working fine, so I don't see how this could be the reg/rec.

    Last details that might be important :

    - All dashboard bulbs are black (like burned, even the one still working)
    - Didn't had this problem for a while but when I rev up a lot (really stupid acceleration) I used to lose a cylinder for a while, usually untill the bike cool down for a while. I think this might be linked but i'm not sure.

    I'll buy new Bulb and maybe try to tight this the frame of the light, maybe it could come from the vibration if it's not tight enough ??

    Thanks for the help !
     
    Pyr0technicien, Jun 6, 2019
    #1
  2. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    My two cents, fit a Shindengen Rec-Rec anyway. Read about them here http://roadstercycle.com/index.htm. The OEM part is rubbish and if it allows the voltage to go too high you are going to blow your TCI unit.
     
    maelstrom, Jun 6, 2019
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  3. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Faulty regulator, overcharging
     
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    Linkin, Jun 6, 2019
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  4. Pyr0technicien

    Pyr0technicien Active Member

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    If I do have a weakness, it would be electicity ahah, I don't understand exactly what model to choose and those seems really hard to install.

    What's the difference between oem and these ones ? Unless the price wich is 3 times higher :D

    So does it make sense that it doesn't appear on the voltmeter ? Wouldn't it be a higher voltage all the time (and therefore burning all my bulbs) ?
     
    Pyr0technicien, Jun 6, 2019
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  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    I had a zeal that blew headlight globes. It blew backlights as well. It was overcharging up to 18 volts, higher rpm the worse it got. Left me stranded in total darkness 10pm at night on the M1 10k's out of Hornsby.

    Battery was boiled into a buckled mess, killed the tachometer, killed every bulb and fried every bulb housing on the bike.

    I would suggest checking with another meter as if the meters battery is old or weak your readings will differ.
     
    Linkin, Jun 6, 2019
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  6. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Jun 6, 2019
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  7. Amara

    Amara Active Member

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    I had a zeal as my first bike 3 years ago. It was the most reliable bike I've ever owned. I only ran my dad's spare Pajero headlight bulbs and never had a problem with them until about a week before I sold the bike. It blew 2 headlight bulbs in 4 days. The light I was running was for a '98 Mitsubishi Pajero
     
    Amara, Jun 6, 2019
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  8. Pyr0technicien

    Pyr0technicien Active Member

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    Hey thanks for all your replies.

    Well, as the voltmeter test doesn't show any problem with the reg (I tried different voltmeter) and that the headlight is the only one blowing up (3 on 4 dashboard bulbs blew up a while ago, the last one never failed), I would say the reg isn't faulty.

    The Headlight itself was really lose, so vibration might really be the issue here (the dashboard has a lot of vibration as well.

    I tied everything up, bought new headlight bulb and dashboard bulb for 17$, I'll see where it goes with this.
    As the reg is around 150$ I would rather wait before changing it.

    I think your post in here made me discover the forum earlier today (someone telling the same exact story).
    A reg problem would definitly blow up more than the headlight, and the rest of the bulb never had a single problem in 2 years and nearly 50k driven.

    I'll update the post if i get anymore informations, but I'll put that on the vibrations for now.
     
    Pyr0technicien, Jun 6, 2019
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  9. cornulio81

    cornulio81 Active Member

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    Did you Rev up while measuring? The Voltage is rising with the engine revolution, if the regulator doesn't restrict the voltage.

    I fixed on my FZRs the reglator with following:

    Funnily Yamaha has an OEM adapter cabel (for what ever): 3LD-82521-00 ( a few years ago it was about 7€)
    With this adapter cable you can connect any voltage regulator from FZR600 4jh (e.g. 4JH-81960-01), Thundercat, early R6 etc. with the old connector and you will never have any Problems anymore.
    The used regulator from an R6 costs me about 20€ in the past (They are more durable then the old types)
     
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    cornulio81, Jun 6, 2019
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  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    my67xr, Jun 6, 2019
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  11. cornulio81

    cornulio81 Active Member

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    That's quite cheaper, if able to crimp the cables. The Yamaha adaptor is PnP
     
    cornulio81, Jun 6, 2019
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  12. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    A second hand FH020AA would be better, but more expensive. I upgraded my R6 to one.

    Many modern sportsbikes use them, including triumph street/speed triples, bmw s1000's and r1200's

    You can try to find a wrecking listing on ebay or gumtree and ask if it is available... get the unit itself and the plugs from the harness if you can, they are good weatherproof plugs.
     
    Linkin, Jun 6, 2019
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  13. cornulio81

    cornulio81 Active Member

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    Any Regulator with a bigger housing and cooling fins is durable compared to the origin part
     
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    cornulio81, Jun 6, 2019
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  14. Pyr0technicien

    Pyr0technicien Active Member

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    Yeah I did but not much than 6000, I don't know if reving up more than that is really usefull.

    Thanks for the links guys, this is way cheaper, if it keeps blowing i'll change it !
     
    Pyr0technicien, Jun 8, 2019
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