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Thread: Broken headlight adjustment assembly

  1. #1
    dlmorgan
    Join Date
    Feb 2012
    Location
    Wellington, FL
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    3

    Broken headlight adjustment assembly

    While attempting to adjust the height on my k1200r sport, the whole assembly popped out. Now the light beams exremely high. Any experienced reply is appreciated. Thanks

  2. #2
    Registered User
    Join Date
    Jul 2005
    Location
    Colorado
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    51
    This happens when you turn the adjuster too far. I had that happen on an R1100Rt several years ago and was able to heat the caulk/glue and remove the glass front of the assembly to repair it. However, I suspect that you will not be able to do that with yours because the adhesive is a different type IIRC.

    You may be able to remove the headlight assembly and put it upside down on the workbench. Using the access provided by the hole for the parking light, insert a tool to lever the reflector back towards the adjuster. The headlight assembly is, of course, VERY expensive, and the reflector inside rather delicate plastic, so proceed with all possible caution. Another idea is to remove the adjuster and somehow reach inside the assembly to pull the threaded shaft to the rear. Then, block the forward movement of the plastic reflector (it is spring loaded) and thread the adjuster back onto the threaded shaft. Think: building a ship in a bottle.

    Good luck!

    Greg

  3. #3
    What, me worry? GILLY's Avatar
    Join Date
    Jul 2007
    Location
    Evansville, WI
    Posts
    1,918
    You could also try pulling back on the bulb or bulb base and trying to get the nut reconnected to the shaft that way. Or removing the main beam bulb and put your finger in to the bulb hole (I'd wear a cotton glove to avoid getting dirt or even skin oil on to the lens) and pulling back on the inner reflector that way. Not sure how much spring tension is on the reflector.
    87 K75S, bought new, now sold
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  4. #4
    dlmorgan
    Join Date
    Feb 2012
    Location
    Wellington, FL
    Posts
    3

    Thanks

    Quote Originally Posted by Evergreen View Post
    This happens when you turn the adjuster too far. I had that happen on an R1100Rt several years ago and was able to heat the caulk/glue and remove the glass front of the assembly to repair it. However, I suspect that you will not be able to do that with yours because the adhesive is a different type IIRC.

    You may be able to remove the headlight assembly and put it upside down on the workbench. Using the access provided by the hole for the parking light, insert a tool to lever the reflector back towards the adjuster. The headlight assembly is, of course, VERY expensive, and the reflector inside rather delicate plastic, so proceed with all possible caution. Another idea is to remove the adjuster and somehow reach inside the assembly to pull the threaded shaft to the rear. Then, block the forward movement of the plastic reflector (it is spring loaded) and thread the adjuster back onto the threaded shaft. Think: building a ship in a bottle.

    Good luck!

    Greg
    Thanks

  5. #5
    dlmorgan
    Join Date
    Feb 2012
    Location
    Wellington, FL
    Posts
    3

    Thanks

    Quote Originally Posted by Gilly View Post
    You could also try pulling back on the bulb or bulb base and trying to get the nut reconnected to the shaft that way. Or removing the main beam bulb and put your finger in to the bulb hole (I'd wear a cotton glove to avoid getting dirt or even skin oil on to the lens) and pulling back on the inner reflector that way. Not sure how much spring tension is on the reflector.
    Thanks

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