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7

That process you're describing is VERY familiar to me - I do that for people from time to time. The difference is REALLY SIGNIFICANT... and at most it should take you five minutes of actual work per headlight - it's really pretty minimal, with diminishing returns VERY quickly. ALWAYS WET-SAND. Do NOT dry-sand. Start with nothing less than #600 sandpaper, ...


5

I recommend looking for a replacement side panel. Otherwise the standard panel beating approach is to try and hammer out the worst of the dents first. Car bog/filler/bondo is a last step to fill minor imperfections. This is harder than it sounds. Panels that have been creased or stretched seldom pop back to thier original position. Judging by your photo the ...


4

Do you have a Pulsar 220? If so, you probably don't want two full-blown headlights, if the electrical system on a 220 is anything like that of the 135LS. On my bike, the electricals can barely keep up with all the lights on, plus both signal lights blinking (unless I raise the idling speed). You should probably look into adding accessory lights, instead. ...


4

Bulbs - Swap the bulbs, like the comment suggested, with the ones on the other side. If works switch back and get replacement. Fuse - Swap the fuse with another in the fuse box with the same rating. If works switch back and get replacement. Connectors - Check for corrosion on connectors. Clean connectors with fine grade sand paper. Coat in something ...


3

I wouldn't even remove it until the replacement arrives. The only thing which is broke is the Lexan cover. There would be no more of a reflection (or chance of it flashing someone in the eyes) than would be seen normally. Another reason is that any road debris which comes up has the chance of damaging something which would normally be protected by the ...


3

I wouldn't bother covering it. First reason is the lamp gets hot enough to ignite or melt any type of clear tape that you'd use. Second is that there is no need to protect the lamp assembly from damage, the replacement is a complete unit. It contains the lens, reflector and the housing. I would remove the lamp and socket. Cover the socket in a plastic bag so ...


3

The bulb modules could actually be bad, despite both filaments coming on in high beam mode. Pull the connector at each bulb, there will be three wires: tan, green and black. The black is ground, tan is low and green is high. Make sure there is power on the tan wire when the headlights are on and the high/low switch is set to low. If the tan wire is hot, ...


3

I followed TDHofstetter's advice (partly) and I can now report that it is indeed quite effective. I wet-sanded with 600, 1200 and 2000 grit sandpaper (my local hardware store had nothing in between or finer). That removed the yellow discoloration and left the lenses smooth to the touch, but still a little cloudy. I then applied the Mother NuLens polish, ...


2

Early Xenon light conversions were totally unsuitable for vehicle use because they did not form a distinct beam or focused pattern. Later kits include lamp assemblies which very much correct these faults. Xenon are used on dipped beams because of the time lag from turning them on and thier reaching operating luminosity. European law requires main beams to ...


2

"Maintenance Free" doesn't have anything to do with charging rate or charging frequency. "Maintenance Free" means that the manufacturer didn't provide any means of maintaining the water/acid level in the battery, which means that if a battery boils dry you can only replace it instead of refilling it yourself with water or acid, whichever is appropriate ...


2

As I said previously, a set of Osram bulbs would help a lot. Further to that, your headlights may just need a nice polish. Some people try to get real fancy with products and methods, but what it really comes down to is that you need to use various grades of sandpaper (from rough to very fine) and finish off with rubbing compound and/or liquid polish (I use ...


2

It was the bulbs. I have read of the same phenomenon on other sites -- both low beams go at the same time. My theory is that either there is something about the electrical system that causes the second bulb to go once the first is gone, or... One headlight goes out but you don't notice because you still have one that works. The second one goes and you ...


2

Probably much cheaper solution to your problem could be more powerful light bulbs. I had same issue with Mitsubishi Galant EA0 and was considering xenons, but after some research I ended up changing bulbs to 100w "extra light" ones. These look like xenons, are much brighter and does not need any extra work or resources. Just to be more specific about the ...


1

If you just reach behind your headlight behind a rubber guard, there's a clip that holds your bulb inside, screwed in like a light bulb, as long as they are headlights and not fog lamps that you're talking about. It hooks and presses backwards, away from the headlight fixture, so you just press in and unhook it. With some cars there's things in the way. You ...


1

The Honda Shine does not have a high amperage output stator like a larger motorcycle, think goldwing. As Paulster2 so aptly put, less resistance in the wire the more amperage or 'flow' you get. Taking that into consideration. If you can increase the gauge of wire feeding your headlights you could go with your option number 2, which is to put a 60/55 ...


1

I would bet the problem lies in the relay, which should be located under the hood. It should look something like this: Each of the high beams and low beams will have their own relay. The switch which is only used to energize the relay. The relay provides the power for the head lights. The underhood fuse box should look like this: On the underside of ...


1

This thread on a motorbike forum suggests that an H4 bulb will fit in an HS1 holder, but that the bike in their question has a plastic lens that could melt - yours may be the same? Does the alternator have enough power to run the higher-wattage bulb and recharge the battery? I would always use a relay when upgrading or adding lamps, Halogens work much ...


1

Basically your headlamps are controlled by a computer. The Front Electronic Module (FEM) to be exact. The FEM grounds the headlamps when it wants to turn them on. This system was an early Multiplex design that reduced wire and total circuits where the modules communicate on a single serial line, now referred to as the CAN Bus (Controller Area Network). You ...


1

I think to pull a fuse is easy, as disconnect the battery. Anyway, I think some relay is broken. That will explain, why it flashing randomly. Turn the lights on and pull the relays under the dashboard one after another, until the light are off. Replace this relay ( shop or maybe you see the same one at another place).Hope, that will fix your issue.


1

I believe they are calling it the Outer Bumper Grill, Driver's Side .


1

I don't think I'd be very concerned about the "sealing wipe" not drying. As Juann pointed out, your conditions seem to be good for drying, so either it's as dry as it'll get or else something's interfering with it drying. For future reference, you can use ordinary car wax after wet-sanding with 2000-grit sandpaper. The car wax MUST be a "100% carnauba" ...


1

It is worth making sure that the bulbs are getting their full voltage - Halogen lamps drop off in brightness significantly as voltage drops. Many cars of that age didn't have relayed headlamps, and so as the wiring has aged, it's resistance has increased, and the performance of the headlamps will suffer - fitting relays close to the lamps with new, good ...


1

You're referring to recalls 07V452000 and 12V397000, right? If the recall has not expired, a dealer should perform the fix without charging you. The only way to know for sure is to contact a Suzuki Dealer or Suzuki and ask. The Dealer should be able to look the VIN up and give you a definitive answer as to whether the fix was applied to your vehicle. ...


1

This is what you can do ... The model of the headlight might be on the discharge tube itself. I had the problem with my vehicle where I ordered what I thought were the right replacement bulbs for the fog lamps (H7) and found them to be the wrong ones. I went and bought another set (H11) and they were wrong as well. I took the lamp out and discovered they ...


1

There is a relay in the fuse box under the hood on the driver's side. On a 2004, it's #46 and labeled 'HDM Relay'. YMMV. You can swap it with a known good relay (same type from the box for something you know is working). #45 should be the same (on a 2004 at least) and should be the engine fan clutch. If the headlights work after the swap, swap them back ...



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