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Discussion Starter #1
Any one got any idea how to change the bulbs in a 400?
Don't tell me I have to pull off all the plastic!
So far, they're working fine, but you know what'l happen some dark night!
 

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it's different on the 400

No tools required...at least for the headlight bulbs.

Simple reach up above the front fender and remove the plug going to the headlight you want to replace. Next, remove the rubber "boot" that surrounds the plug. Then, press in on the clip holding the bulb in place and swing it aside (if you look through the headlight lens, you can see if you are doing this correctly). Now you can remove and replace the bulb.

I followed this procedure myself a couple of days ago. I hope these $80 bulbs are not going to be burning out frequently! My scooter's practically brand new, and the bulbs aren't covered under warranty. :(

BTW, I used a $9 H4 bulb as a replacement. It works with a slight modification. The lens assembly doesn't seem to be overheating with the higher-wattage bulb.
 

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daveman, or others -
You said the H4 bulb worked with a 'slight modificaton'. Can you expand?
Is the H4 bulb better than the stock bulbs?
THanks!
Tom
2003 Burgman 400
 

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If I recall he had to bend one or more of the little tabs down since they didn't line up with the headlight sockets on the 400 -- but the spring-loaded clamping system keeps good pressure and stops them from turning (which is the intent of the tabs, apparently).
 

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I purchased a pair of the Sylvania Silver Star H4 headlamps and installed them this morning. Having removed the front leg shield from the scooter before, I am familiar with how the headlights are wired in so I was able to just reach up around the front fork to behind the headlights and feel my way through it. Took 5 minutes total to disconnect the existing lamps, remove the two protective rubber boots, undo the spring tensioner behind each headlight, remove the old headlight, and repeat the process in reverse to install the new headlamps. Be sure to take care not to touch the glass headlamp when inserting, is reported to shorten the life of the bulbs as the oil from your finger skin boils on the hot bulb.

The only thing I had to do that wasn't stock -- on each of the new H4 bulbs there are two little metal prongs/tabs which project out around a rectangular opening at the bottom part of the metal bulb housing -- the Sylvania's don't have the same sized hole as the stock bulbs, so they don't really fit that well out of the packaging - I had to bend the two little prongs flat on each of the bulbs before installing them, and then they fit like a glove. There are three ears/tabs around the edge which do a great job of "keying" the bulbs into the sockets and the spring tensioner clip which clips in behind each bulb does a great job of holding them in place.

The difference is awesome. The light is whiter and way brighter. Can't wait to try them tonight to see how much more light is thrown at the street and surroundings. Easy upgrade, appears to be a lot more light for the money.

For a better idea of what I'm talking about when I noted having to bend down the two little metal tabs on the new headlamps to make them fit, check out my photo gallery:

http://burgmanusa.com/gallery/Nakes-Burgman-400
 

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The headlight are easy enough to change, but that is one more job the table lift makes so easy by having the bike at waist level :D
 

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Daveman, you said bulbs aren't covered by warrenty? A buddy of mine had several replaced last year by his dealer under the first year warrenty, and recently had one replaced again under the 3 year extended warrenty. I have a low beam out on one of mine and will take it to my dealer soon to see what they say about it. I'd just as soon spend the $8 or so rather than hang around waiting at a dealer's shop.
 

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Hi all, I've had my pre owned 400 now for a couple of days and I want to fit a brighter headlamp. I see in the manual how to remove the plastic shroud under the windscreen and reach the bulb that way. I just cant get a good grip on the socket at the rear of the bulb. I used the search engine here and see that it's possible to get to the bulb by going up behind. Again I can get my hand up the the socket but don't have suffucient room to get a good hold on the socket. Now I don't have the biggest hands in the world but I can't see how either way is possible unless you have a hand the size of a toddler's with the strength of a gorilla. Any more ideas?
 

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I decided tp have another fiddle with the lights while waiting for you guys to get out of bed. I did manage the job but only by removing the cover at the front and also attacking from below. It took me about 15 mins to change the bulb.

The K2 over here came with a 55/60 watt H4 bulb and I've changed it for a newer type with 50% more output. I'm out in the sticks as we say and some of the roads are only 10 feet wide with 6 foot hedges on the sides with no lighting.

The doc says the skin grafts on the backs of my hands should heal nicely. Scuffed them up changing the bulbs. The Japanese must have little tiny hands.

Bob.
 

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Discussion Starter #11
Little tiny hands..

Actually, they start the production proceedure on the assembly line at the factory with the 2 headlight bulbs held in a jig. Then, they build the rest of the scooter around the bulbs!

LOL
 

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Treb me old mate - you need more practice!! :D

I have the bulb changing down to less than a minute now, (practise makes perfect). LOL Front lamps seem to blow for a passtime on the K4, I have now changed mine 3-4 times now. Glad they ain't expensive.

The front lamps are a piece of cake, the rear - still an unknown quantity.
 

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In trying to change the headlight bulb on a 2007 400, I can easily reach up under the front and feel where the plug goes into the headlight assembly. But when I try to pull the plug out, it seems fixed, like it might be locked in. I don't want to pull too hard and break something. Anybody familiar with the 2007 models? Do I just need to go ahead and use more force?
 

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In trying to change the headlight bulb on a 2007 400, I can easily reach up under the front and feel where the plug goes into the headlight assembly. But when I try to pull the plug out, it seems fixed, like it might be locked in. I don't want to pull too hard and break something. Anybody familiar with the 2007 models? Do I just need to go ahead and use more force?
You'll need to remove the rubber boot from around the reflector
assembly, unplug the wire power plug, & then unclip the wire retainer
that holds the headlight bulb in place.
 

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It happened to me after work a couple of days ago...poof, no lights.
so I have to drop the front cover? really? dang.
 

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It happened to me after work a couple of days ago...poof, no lights.
so I have to drop the front cover? really? dang.
Not necessarily. Could be your starter switch. It cuts the light when you start the bike. I had the sme thing happen to me just last week. I just toggled the start switch a few times and the headlight came right back on. If that doesn't work, you may try taking the switch apart and cleaning it.

If that doesn't work, then perhaps it is the bulb. But to date in eight years of ownership, I've only had one bulb go out. Good luck.

Btw, Waspie's post was from nine years ago. I wouldn't count on a response.
 

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Wooo Hooo

You do NOT have to take off anything, as long as you have small to medium hands.

I am a larger woman. After watching several youtube videos on how to....where they dropped the whole front off....I went into the parking lot on my break at work and reached up under the back of the headlight and felt all the things I had been looking at.

Order of action:

unplug bulb
remove boot
release clip (see youtub videos)
remove bulb

Being careful not to get your fingers on the glass, do it all in reverse.
The only tricky part is getting the boot to not get hung up on the prongs and making sure it is securely seated like the top of a tupperware dish.

TaDa!!!
 
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