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General Category => Maintenance => Topic started by: Old Rider on August 31, 2020, 06:47:14 AM



Title: Headlight Lens
Post by: Old Rider on August 31, 2020, 06:47:14 AM
Does anybody know if its possible to separate the headlight glass from reflector and also if its possible to do it without remowing the hole fairing?
I see 3 clips holding the glasslens but is it also glued ? and does the clips fall off when they are released ?
Many questions here =)  i want to separate the lens so i can clean the reflector because its dirty and someone used a 100w bulb in the lamp so its
brown dirt in top of the reflector.


Title: Re: Headlight Lens
Post by: Ted Schefelbein on August 31, 2020, 07:30:44 PM
I tried getting two of mine apart, I quit before breaking either. Not sure if it is glued or welded from use.

Ted


Title: Re: Headlight Lens
Post by: ribbert on August 31, 2020, 11:39:02 PM

Does anybody know if its possible to separate the headlight glass from reflector and also if its possible to do it without remowing the hole fairing?


Yes, it is glued and no, if you take the clips off it won’t fall apart. In fact, you could take to it with a jack hammer and it wouldn’t fall apart!

I have heard of it being done but the benefit of doing so doesn’t warrant the trouble or the risk and certainly not in situ. I don’t know whether the heat from the headlight cures the adhesive over time or what, but I’ll venture more lenses have been broken trying to get them apart than have been successfully separated.

I’m sure if one persevered they could be separated, but why? The only reason for doing so would be to clean inside and the headlight is still going to be terrible anyway.

My suggestion would be to pour a detergent solution in there and swish it around vigorously, rinse and let dry for a couple of days or make a little articulated arm with a sponge on the end to mechanically clean it through the globe opening.

On my own bike, the solution was to ignore it and fit auxiliary lights.

Noel


Title: Re: Headlight Lens
Post by: Bones on September 01, 2020, 12:17:44 AM
I’m pretty sure it was on here where I read that someone had done it successfully, they put the headlight in an oven on low heat so as to soften the adhesive holding the glass and it pulled apart. I think he put a projector lens inside the housing and then sealed it back up again.


Title: Re: Headlight Lens
Post by: Bones on September 01, 2020, 12:31:22 AM
Found it, he used a heat gun to get the lens off.
http://www.fjowners.com/index.php?topic=10268.msg113294#msg113294 (http://www.fjowners.com/index.php?topic=10268.msg113294#msg113294)


Title: Re: Headlight Lens
Post by: Old Rider on September 01, 2020, 07:12:25 AM

My suggestion would be to pour a detergent solution in there and swish it around vigorously, rinse and let dry for a couple of days or make a little articulated arm with a sponge on the end to mechanically clean it through the globe opening.

On my own bike, the solution was to ignore it and fit auxiliary lights.

Noel

[/quote]

I followed your suggestion used  steel wire wrapped with pieces of microfiberclots taped at the tip and hot soap water.worked very nice.I was sitting in front of bike with arms up in the fairing (remowed the horn) same as when replacing the bulb. The lamp
does not have the bulb or the bulbholder for the parkinglight so i think some of the dirt was sucked in .The brown spot over the mainbulb was easy to wash clean.Now the reflector and inside of glass is clean .I have replaced the bulb that was osram nightbreaker with a phillips racing vision
Now its just waiting  patiently  for the darkness to test it  :i_am_so_happy:

Rolf


Title: Re: Headlight Lens
Post by: Old Rider on September 01, 2020, 07:16:04 AM
Found it, he used a heat gun to get the lens off.
[url]http://www.fjowners.com/index.php?topic=10268.msg113294#msg113294[/url] ([url]http://www.fjowners.com/index.php?topic=10268.msg113294#msg113294[/url])


Thanks for the link Bones.


Title: Re: Headlight Lens
Post by: ribbert on September 01, 2020, 07:21:07 AM

My suggestion would be to pour a detergent solution in there and swish it around vigorously, rinse and let dry for a couple of days or make a little articulated arm with a sponge on the end to mechanically clean it through the globe opening.

On my own bike, the solution was to ignore it and fit auxiliary lights.

Noel


I followed your suggestion used  steel wire wrapped with pieces of microfiberclots taped at the tip and hot soap water.worked very nice.I was sitting in front of bike with arms up in the fairing (remowed the horn) same as when replacing the bulb. The lamp
does not have the bulb or the bulbholder for the parkinglight so i think some of the dirt was sucked in .The brown spot over the mainbulb was easy to wash clean.Now the reflector and inside of glass is clean .I have replaced the bulb that was osram nightbreaker with a phillips racing vision
Now its just waiting  patiently  for the darkness to test it  :i_am_so_happy:

Rolf

[/quote]

Excellent.  :good2:

Noel


Title: Re: Headlight Lens
Post by: Old Rider on September 03, 2020, 12:50:06 AM
Yesterday i was riding in the dark the light was a lot  better but nothing to write home about.I adjusted the beam angles, but that did not help much.
I still have the old 100w/90w bulb that was there when i bought the bike ,but unsure if i can use it because the bulb connector was meltled i replaced the connector with a ceramic when i replaced the bulb (60w 55w )back then.
I heard that the wires and lightswitch can melt  or catch fire with a 100w bulb.
Next step is to try to do the headlight mod i found here at the forum ,but i really suck when it comes to electrical stuff
Or maybe i should try to put a LED bulb in ? is it possible to use a LED bulb without having to mess with relays and resistors ?


Title: Re: Headlight Lens
Post by: ribbert on September 03, 2020, 03:41:07 AM
Yesterday i was riding in the dark the light was a lot  better but nothing to write home about.I adjusted the beam angles, but that did not help much.
I still have the old 100w/90w bulb that was there when i bought the bike ,but unsure if i can use it because the bulb connector was meltled i replaced the connector with a ceramic when i replaced the bulb (60w 55w )back then.
I heard that the wires and lightswitch can melt  or catch fire with a 100w bulb.
Next step is to try to do the headlight mod i found here at the forum ,but i really suck when it comes to electrical stuff
Or maybe i should try to put a LED bulb in ? is it possible to use a LED bulb without having to mess with relays and resistors ?

Rolf, there are only 3 choices, Halogen, HID, LED. It costs 100's of dollars to try all three, as I and many others have done. Not surprisingly, everyone got the same result and the conclusion was that while you can make the light brighter, a better colour and easier to be seen, it will never throw a decent beam down the road.

Halogen globes benefit from a relay to deliver full voltage but the LED is not so voltage sensitive and doesn't need one. I have one because it makes the bike much more visible to oncoming traffic in the daytime, not only because it's brighter but also the white/blue colour (about 6000k from memory) is more striking.

To actually see where I'm going at night, I have fitted additional lights.

(https://live.staticflickr.com/7413/27619488585_97a2021ed6_b.jpg)

(https://live.staticflickr.com/578/31439996990_b4f63a426e_b.jpg)

It's like riding in the daylight (...at night) with these.

Noel


Title: Re: Headlight Lens
Post by: FJ Flyer on September 03, 2020, 05:43:30 AM
One of the easiest and best mods most folks do is install relays for the headlight.  Instructions are on the site.  Gives full power to the bulb and bypasses the weak-ass factory wiring.


Title: Re: Headlight Lens
Post by: Old Rider on September 03, 2020, 08:26:09 AM
One of the easiest and best mods most folks do is install relays for the headlight.  Instructions are on the site.  Gives full power to the bulb and bypasses the weak-ass factory wiring.

Yes thanks for sharing that instructions i downloaded the PDF some weeks ago but I'm not sure i able to get the right size wiring and relays.I'm a little afraid starting a electrical fire because i done that before twice :flag_of_truce: I got 10 thumbs when i comes to electrical stuff.
Not sure i understand the drawing at the old headlight connector .Is it supposed to use spade connectors into the old headlight connector and keep it ?. and the 3 wires from the old connector at the right side on the PDF picture are they supposed to be cut i guess not but not 100% sure.
And what about the thinner wires going from the old connector to the relays do they have to be thinner ?

Now i will first use a voltmeter in the headlight connector and see how much volt it is if it reads 12 volt there is no use to do the relay mod right  ??


Title: Re: Headlight Lens
Post by: Old Rider on September 03, 2020, 08:35:15 AM


Rolf, there are only 3 choices, Halogen, HID, LED. It costs 100's of dollars to try all three, as I and many others have done. Not surprisingly, everyone got the same result and the conclusion was that while you can make the light brighter, a better colour and easier to be seen, it will never throw a decent beam down the road.

Halogen globes benefit from a relay to deliver full voltage but the LED is not so voltage sensitive and doesn't need one. I have one because it makes the bike much more visible to oncoming traffic in the daytime, not only because it's brighter but also the white/blue colour (about 6000k from memory) is more striking.

To actually see where I'm going at night, I have fitted additional lights.


It's like riding in the daylight (...at night) with these.

Noel

I like the extra lights you have fitted i think i will do the same if they dont cost a million. are they foglights or high beam lights? I also have to check if they are legal here in Norway so i dont have to take them off again .

Rolf


Title: Re: Headlight Lens
Post by: Old Rider on September 03, 2020, 09:35:10 AM
I found some connectors and wire in the shelf can this be used ?  is the wire thick enough ? the 1 into 2 connection is that okay to use or will it reduse power ?


Title: Re: Headlight Lens
Post by: Pat Conlon on September 03, 2020, 11:52:06 AM
That wire looks small to me.....possibly a 14 gauge?
For a headlight relay circuit I would use *no less* than a 12 gauge (AWG) or the equivalent 2.0mm wire.
To give me some headroom in case I wanted to use a high wattage halogen bulb, I used a 10 gauge (2.6mm) wire on my dedicated circuit.
The 2 relays I used were rated for 30 amps.

Hope this helps.


Title: Re: Headlight Lens
Post by: Old Rider on September 03, 2020, 12:19:08 PM
That wire looks small to me.....possibly a 14 gauge?
For a headlight relay circuit I would use *no less* than a 12 gauge (AWG) or the equivalent 2.0mm wire.
To give me some headroom in case I wanted to use a high wattage halogen bulb, I used a 10 gauge (2.6mm) wire on my dedicated circuit.
The 2 relays I used were rated for 30 amps.

Hope this helps.


Thanks Pat you are definitely right that the cables is to small ,because i went out to buy the stuff i needed but then i found a premade light enhancement cable set and the cables
is much thicker. The price was only 20 usd .But not sure if i can use it because it is made for cars sitting here scratching my head .It is intended for bulbs up to 160w
the relays is 40A and had 30w fuses.


Title: Re: Headlight Lens
Post by: FJ_Hooligan on September 03, 2020, 01:00:33 PM
A stock 55/60W bulb pulls approximately 4.6 amps on low beam and 5 amps on high beam.  If you move the FJ headlight switch slowly, it's possible to light up both filaments which would be about 10 amps total.

If you use higher wattage bulbs then the current draw goes up proportionally. 

A 14 gauge wire will safely carry 15 amps, which is why I used 12 gauge wire for my relay setup.  :-)

Your main concern is the size of the wire from the battery that supplies power to the 2 relays.  This is the wire that needs to be protected with an appropriate size fuse,

The wires from the relays to the headlight connector can safely be 14 or 16 gauge, assuming you're using bulbs of less than 100w.  Keep in mind if you use a higher wattage bulb it will produce more heat (watts is heat) and typically have a shorter bulb life.  I used to run 100/80w bulbs but after blowing several I went back to 55/60w after installing the relays.

I would avoid using those blue "vampire" connectors.  They can compromise the wire and make the connection unreliable. 



Title: Re: Headlight Lens
Post by: Old Rider on September 03, 2020, 11:35:06 PM
A stock 55/60W bulb pulls approximately 4.6 amps on low beam and 5 amps on high beam.  If you move the FJ headlight switch slowly, it's possible to light up both filaments which would be about 10 amps total.

If you use higher wattage bulbs then the current draw goes up proportionally.  

A 14 gauge wire will safely carry 15 amps, which is why I used 12 gauge wire for my relay setup.  :-)

Your main concern is the size of the wire from the battery that supplies power to the 2 relays.  This is the wire that needs to be protected with an appropriate size fuse,

Thanks David for informing me about that i checked the cable set and there is a 30A fuse on the wire from the battery to the relays
By the way did you notice any increase in the brightness of the headlight ?
The wires from the relays to the headlight connector can safely be 14 or 16 gauge, assuming you're using bulbs of less than 100w.  Keep in mind if you use a higher wattage bulb it will produce more heat (watts is heat) and typically have a shorter bulb life.  I used to run 100/80w bulbs but after blowing several I went back to 55/60w after installing the relays.

I would avoid using those blue "vampire" connectors.  They can compromise the wire and make the connection unreliable.  

I will not be using those since i bought the cable set .
Now after some head scratching about if i can use the cable set that is made for cars i think it just so simple that i can connect one part of the set going to one headlight and just leave the other part unconnected .


Rolf


Title: Re: Headlight Lens
Post by: ribbert on September 04, 2020, 04:03:21 AM

I like the extra lights you have fitted i think i will do the same if they dont cost a million. are they foglights or high beam lights? I also have to check if they are legal here in Norway so i dont have to take them off again .

Rolf

It would be strange if they weren't but a fairly standard requirement is that they are switched separately and through high beam. That is, they turn on an off with high beam or can turned off entirely with a separate switch.

Having a relay up front is a great idea, the lights, horn and coils all benefit from full voltage but don't expect miracles from the headlight, the improvement is only relative and still inadequate. Depending on your riding, it might be enough but if you ride beyond street lighting or highways, even at modest speeds, the standard light is woeful.

Noel


Title: Re: Headlight Lens
Post by: Waiex191 on September 04, 2020, 06:57:13 AM
Ride a 1981 Suzuki GN400 with a 6 volt system for a while.  Then the stock FJ headlight will seem awesome.


Title: Re: Headlight Lens
Post by: Old Rider on September 04, 2020, 12:15:01 PM

Rolf

It would be strange if they weren't but a fairly standard requirement is that they are switched separately and through high beam. That is, they turn on an off with high beam or can turned off entirely with a separate switch.

Having a relay up front is a great idea, the lights, horn and coils all benefit from full voltage but don't expect miracles from the headlight, the improvement is only relative and still inadequate. Depending on your riding, it might be enough but if you ride beyond street lighting or highways, even at modest speeds, the standard light is woeful.

Noel

I checked and in March 2020 it became legal to add 2 extra highbeam lights placed like you have done  on your bike so maybe i will get some. Did the relay mod today and it was
a noticeable improvement see my next post.

Rolf


Title: Re: Headlight Lens
Post by: Old Rider on September 04, 2020, 12:16:36 PM
Ride a 1981 Suzuki GN400 with a 6 volt system for a while.  Then the stock FJ headlight will seem awesome.

I believe you ! :biggrin:


Title: Re: Headlight Lens
Post by: Old Rider on September 04, 2020, 12:21:11 PM
Today i installed the cablekit first i thought it will be a fast 20 minutes job but ending up using 2 hours because i had to modify the wires because the relays
ended up right at the cylinders and they don't like heat written in the instructions. The kit is made for cars so i cut off one of the wires going to the unused
headlight that was stupid and had to splice cables also cut one of the wires from battery and that was also stupid because then only low beam worked.
Everything works now, but one thing i think is wrong and need to be confirmed is that i earthed the black wire to the bracket for the horn.The lower triple clamp
is made of aluminium so don't know if that is good enough ??.
I measured the voltage at the bulbconnector before and after i started the work and before it was 11.5V  and after it was 12.6v .
it is still daylight but i could see the light was better and did a before and after test in a parking house see pics .Will take more compare pics and try the
100w /90w bulb later


Title: Re: Headlight Lens
Post by: Pat Conlon on September 04, 2020, 03:22:12 PM
.....Will take more compare pics and try the 100w /90w bulb later
Be sure to use a ceramic plug with that hot bulb....


Title: Re: Headlight Lens
Post by: X-Ray on September 04, 2020, 05:56:41 PM
That is actually a nice difference with standard bulb and relay. I still have to do this, although I rarely do any night riding, (too many things that want to jump out in front of you where I live).  :good2:


Title: Re: Headlight Lens
Post by: Old Rider on September 05, 2020, 02:15:05 AM
.....Will take more compare pics and try the 100w /90w bulb later
Be sure to use a ceramic plug with that hot bulb....

I replaced the bulbholder to ceramic when i got the bike and find the plastic bulbconnector had melted because of the 100w bulb that was in there.Now that connector was used
to connect the cablekit .The plastic bulb connectors in the kit looks low quality but they claim they can be used with up to 160w bulbs  :shok:.
I will replace with a ceramic anyway

Rolf



Title: Re: Headlight Lens
Post by: Old Rider on September 05, 2020, 02:30:34 AM
That is actually a nice difference with standard bulb and relay. I still have to do this, although I rarely do any night riding, (too many things that want to jump out in front of you where I live).  :good2:

Yes it was a good upgrade i think but  have not done a night test yet.It also was a good upgrade when i cleaned the inside of the lamp first.  Here in Norway there is also some animals to watch out for. My neighbor riding a BMW f800gs hit a moose in the middle of the highway doing 90 mph lucky to survive, but hospitalised for 8 weeks.He is about 65yrs and said he newer will ride again.All he remember is a shadow came from side and he looked right into the eyeball of the moose.I had some almost moments my self with deer's.

Rolf


Title: Re: Headlight Lens
Post by: Old Rider on September 05, 2020, 02:37:31 AM
So now i wonder if i did ground the earthcable good enough ??
the cable was only a few inches long so i grounded it in the bracket for braklinesplitter and horn because i was in a hurry and had not time to splice it and attach it another place in the frame.


Title: Re: Headlight Lens
Post by: Old Rider on September 07, 2020, 06:01:08 AM
After Noel told me that it is not a good place to ground/earth into the lower
triple clamp because current will go thru the stearinghead bearings and can make a premature wear out of the bearings.  I decided to move it
Thank Noel!
So i  spliced the groundwire to make it longer and found a better place for it to be attached  to the frame see pick
I have now done a compare test of the old 100/90w bulb named world light that i kept since it was replaced because of a melted bulb connector some years ago.
   and the Phillips racing vision 60/55w i recently put in.
I think i just keep the Phillips bulb in since the light did not get any better with the old 100w. the test is 10 meters from the wall. last test was 5 meters from
wall. The low beam on the old 100w was also very diffuse see pick so it is maybe broken.


Title: Re: Headlight Lens
Post by: Old Rider on September 07, 2020, 06:07:57 AM
Later when it got dark outside i took a ride to test and i could instantly see that the light now is much better .Took a test in the parkinghouse again and now it was
total darkness in there also took some  picks in the dark at a deserted parkingplace .Did not test the 100/90w bulb in the dark only Philips racing vision 60/55w bulb is used in these picks


Title: Re: Headlight Lens
Post by: Old Rider on September 21, 2020, 07:52:31 AM
Update : since i just got my weekly paycheck from mummy i invested in a Osram super bright rally 100/80w bulb to see if it was brighter than the Philips racing vision 60/55w  that claims 150 % more light than original bulbs. The philips was good but the Osram was a lot better in the dark.The philips has a whiter sheen but not so strong light as the Osram 100w.Osram is more yellow but strong in the dark and i can also see strong reflections from roadsigns in full sun daylight.
In dark the reflections from roadsigns is very very bright.I have not replaced the bulb connector with a ceramic yet but so far there is no signs of melting.After all it is supposed to handle bulbs up too 160 watt
I don't know if a LED bulb will make better light than the Osram 100w it will be brighter but will it make same strong light at distance ?
here are a lot of compare picks ..
Thanks to FJ Flyer who triggered the idea to install a relay mod.


Title: Re: Headlight Lens
Post by: Charlie-brm on September 21, 2020, 09:28:11 PM
I really like the effort you went to recording accurate comparisons, keeping things consistent.
I can't locate those Osram bulbs online in Canada - not yet. Can you provide more information off the packaging please like OSRAM part numbers.
Or show fuller images of the box sides.
The numbers or names could be different for North America vs Norway/EU but it would be a start.


Title: Re: Headlight Lens
Post by: FJ Flyer on September 22, 2020, 05:39:26 AM
Old Rider, glad you found the sweet spot and thanks for documenting your results.  Good info for all of us.  The relay mod was my first foray into updating my FJ, and it was easy and definitely worth it, as I was commuting in the dark every morning.


Title: Re: Headlight Lens
Post by: Old Rider on September 22, 2020, 07:15:22 AM
Hi Charlie for a moment when doing the test pics i wonder if i was going nuts or maybe i have :biggrin: a little creepy in that garage at night to  :lol:
Anyway while i was searching about  the best H4 headlight bulbs on web i found this ultimate-headlight-upgrade-h4 150+ pages tread .I have just read some of it and found that the Osram super bright was one of the best bulbs. I then found a almost similar 100w bulb in a local store here in Oslo .It was on sale and price was about 7 USD.They had 4 in stock but i just bought 1 at first.Then after i tested it i wanted to buy the rest of them and traveled back to the store 3 days later ,but then all was sold out.Isn't that typical !
They are not listed on the stores web page any longer either.One thing i read in the ultimate headlight upgrade tread is that the bulb is produced both in Germany and China and the Germany made is the one to get.Here is some picks from the one i bought

FJ Flyer Chris Thanks again for posting the relay mod in Files section.


Here is some links from the tread:
https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/page-143 (https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/page-143)

https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/page-139 (https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/page-139)

https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/page-46#post-16837643 (https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/page-46#post-16837643)



Title: Re: Headlight Lens
Post by: ribbert on September 23, 2020, 02:25:00 AM
....who triggered the idea to install a relay mod.

 :biggrin:

Noel


Title: Re: Headlight Lens
Post by: FJ Flyer on September 23, 2020, 05:23:40 AM
Back when I had to worry more about H4 bulbs (the new FJRs LED headlights are pretty dang good), I was using Philips XtremeVision bulbs.  I found them to be a good compromise between more light and longer life.  I got them from a supplier in the UK cheaper than I could get them stateside.