Front headlight unit question

[NotAnotherHill]

I've got the headlight unit out but I'm struggling to separate the lens element from the main body to get behind to the cone. I assume these two bits come apart as there are clips. I've a feeling that the two parts have fused together at certain points so I'm trying to ease them apart with a flat bladed screw driver.


I'll attempt to upload the photos I've taken.

[NotAnotherHill]

[darrsi]

I tried that ages ago, it felt like a sealed unit to me, as if i was gonna have to muller it to get it apart, so i gave up.

[Dead Eye]

If you are trying to take the metal cone out, you don't have to abuse the headlights at all.

1. Remove left bulb and bend the cones legs to allow it to fall in to the headlight casing.

2. Remove right bulb

3. Use something to prod / pull the cone out through the gap on the right as it is large enough to get it out.

4. Refit bulbs, job done, have a brew


Took me literally 5 mins to do it yesterday. I have a handy torch which has a telescopic magnet in the centre which is damn useful for getting to bolts and things that I drop - this worked perfectly to grab hold of the metal cone and pull it out

[darrsi]

I have a horrible feeling he's not reading this and has a pneumatic drill or a pick axe on it by now  :lol

[Dead Eye]

I must admit, I had no idea how to remove it when I first looked and didn't even realise that the two compartments for the bulbs weren't actually individually sealed. I try to see how I could remove the cluster but figure it was far too much trouble and just left it

[NotAnotherHill]

Thankfully, after hacking at it for a while, I decided to refit the shock and exhaust to the Fireblade and await further advice. Thanks, Dead Eye, you have saved my headlight unit from certain death.


The cone is out. I shall fit it all back together on the bike tomorrow and check the beam adjusters work then rebook for it's test.


First ride on my RRV Blade today after buying it February: fast, fast, fast and..fast.

[riz]

The cone is out. I shall fit it all back together on the bike tomorrow and check the beam adjusters work then rebook for it's test.

Fingers crossed, but i do fear that now they have failed it for it being loose they will be looking at that part and they may not like just having it removed as the 'fix'.

[darrsi]

As long as there's a beam and it's down and to the left a bit then why should it not pass?


When i first got my bike the lighting was absolutely terrible, but probably the standard set up.
Just by upgrading to brighter bulbs, that are plastic lens friendly, makes a huge improvement so compared to the stock set up can only be a good thing and i see no reason why it should fail.


 

[NotAnotherHill]

Having put it all back together, I was trying the beam adjusters to check if they worked. The left side top corner one did (it moves the beam up and down). However the bottom one for the main beam didn't seem to do anything. It should have moved it left/right but I didn't see any beam movement despite turning the adjuster plenty. It appears to be working when you look at the bolt through the lens but I can't see the reflective lens backing move. Should the left/ right be noticeable?

[darrsi]

When i last adjusted mine i found that they didn't work as straightforward as they should, but if you persevere with it they will move eventually.
I found it easier to do aiming at a wall when it's dark so you can see what's going on a lot better too.

[john 087]

I have a 98 fazer removed the cone without taking out the headlamp unit. Went to a friends garage and the  checked the light pattern, was better than with the cone in and light has a higher intensity reading. Plus the annoying buzzing noise is gone.

[DanielT]

found this thread whilst searching for 'peeling reflector' - that problem seems to be a fazer one!

The headlight unit is glued together.  I bought angel eyes and to fit them the instructions were to put the headlight unit in the oven for 45 minutes.  Then using 2 screwdrivers (OK, two knives from the drawer - but don't tell the wife!) it opened up nicely.  another 30 minutes in the oven when you're done and it will reseal.  I used some black gutter sealant around it too.


The reason I looked for peeling reflector was that my bike failed its MOT due to the light beam.  The tester said to remove the angel eyes as they were likely the problem.  He said to turn the lights on and test it by holding a board in front.  The light should be a flat line which goes up to the left like this:

    \_____

Mine still looks fuzzy, a bit like this \__*_  which I thought may be down to the flaking reflector

[john 087]

I removed mine the last week, we don’t test bikes in Ireland, my friend has a garage and I put it on the beam sitter and it was giving a good pattern and better intensity reading. I did the headlamp mod; since I removed the cone the lights are a lot better.

[unfazed]

I've got the headlight unit out but I'm struggling to separate the lens element from the main body to get behind to the cone. I assume these two bits come apart as there are clips. I've a feeling that the two parts have fused together at certain points so I'm trying to ease them apart with a flat bladed screw driver.


I'll attempt to upload the photos I've taken.

You need to heat it with a heat gun, get it fairly hot without melting it to soften the glue and it pulls apart quite easily. Then heat it again to put it back together.
I have done it a few times over the years when I contverted the square lights on the 98 to 01 models to dual H4 bulbs. I managed to get completly shattered ones with the right side reflector from a breaker. Took them apart using a heat gun and removed right side reflectors from the broken ones and put it into the left side of the working ones. A little bit of fiddling to get it to fit then used Osram Nightbreakers and the result was well worth the effort

[DanielT]

You need to heat it with a heat gun, get it fairly hot without melting it to soften the glue and it pulls apart quite easily. Then heat it again to put it back together.

Ahh, but you miss getting to see a sight like this:

[unfazed]

What do you Baste it with, engine oil or brake fluid?