Author Topic: Removing headlight lens?  (Read 385 times)

Offline en0n

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Removing headlight lens?
« on: September 12, 2017, 08:03:53 am »
My LED pole light had unfortunately dislodged and fell into the headlight assembly.
Is there any way to open the headlight lens cover and get the bulb out?
See attached image

Offline ~TABASCO~

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Re: Removing headlight lens?
« Reply #1 on: September 12, 2017, 09:04:26 am »
Not that I know of.  You can try and fish it out from the back.  Or take the whole assembly out of the bike and turn it upside down and shake it out. 
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2012 Super Tenere - 1"bar riser - motoX grips - ECUnleashed flash - Barnett clutch pressure plate - UNI filter - Air box mod - Akrapovic custom muffler - Arrow headers - PCV&AT - Ohlins suspension front & rear - Trailtech Voyager - Steel braded lines on everything - Ride On skid plate - Carbon fork guards - rear disc gard - rear res guard - WC turn signals - WC headlight guard - ADV tires - WC/ride on graphics - sync TB - Baja Squadrons & S2 - custom dash LED's - Custom light harness - Ride On custom light switch - Keyless gas cap

Offline en0n

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Re: Removing headlight lens?
« Reply #2 on: September 12, 2017, 09:19:46 am »
I tried using a flexible magnetic pickup tool, the bulb does not have enough metal for it to get attached :(
I think I had no choice but to disconnect the harness and shake it out.

Is it easier to disconnect the sub harness from the headlight assembly ends or from the main harness end?

Offline holligl

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Re: Removing headlight lens?
« Reply #3 on: September 12, 2017, 09:49:41 am »
I tried using a flexible magnetic pickup tool, the bulb does not have enough metal for it to get attached :(
I think I had no choice but to disconnect the harness and shake it out.

Is it easier to disconnect the sub harness from the headlight assembly ends or from the main harness end?
The disconnect is high up under the right panel.  Not too hard to get to.
2014 BluES

Offline Don in Lodi

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Re: Removing headlight lens?
« Reply #4 on: September 12, 2017, 09:53:31 am »
There's a tool I call a 'reachy-grabby' tool. You press a plunger on one end and a small set of jaws open at the other to grab non-ferrous stuff out of deep dark holes.
Don in Lodi
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Online Dogdaze

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Re: Removing headlight lens?
« Reply #5 on: September 12, 2017, 10:36:31 am »
 
There's a tool I call a 'reachy-grabby' tool. You press a plunger on one end and a small set of jaws open at the other to grab non-ferrous stuff out of deep dark holes.

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Offline AVGeek

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Re: Removing headlight lens?
« Reply #6 on: September 12, 2017, 11:41:31 am »
There's a tool I call a 'reachy-grabby' tool. You press a plunger on one end and a small set of jaws open at the other to grab non-ferrous stuff out of deep dark holes.

Something like this?

https://www.amazon.com/Flexible-Claw-Automotive-Mechanic-Generic/dp/B000RB7AGY
IBA# 54462

Offline WJBertrand

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Re: Removing headlight lens?
« Reply #7 on: September 12, 2017, 11:44:25 am »
If you haven't done so already, take out one of the main bulbs to give you a larger hole to work through.


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Offline EricV

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Re: Removing headlight lens?
« Reply #8 on: September 12, 2017, 02:11:03 pm »
Remember the projector lens is sort of in the way of getting directly into the front of the headlight housing.

First things first, just remove the headlight assembly from the bike.  It's only four bolts and unplugging the harness.  Set the entire thing on a towel and remove the bulbs for the headlights and running lights and start looking at what access you have, or where you can roll the loose LED part to.

Worst case scenario, a heat gun will warm up the glue that bonds the lens to the base and it can be separated that way.  I don't have mine in front of me, but have done others in the past.  Some have retaining tabs too.
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Offline Xclimation

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Re: Removing headlight lens?
« Reply #9 on: September 12, 2017, 02:44:20 pm »
Or a shop-vac to suck it out. get a pvc elbow to fit in front of upper triple tree.
2015 Super Tenere Power Commander PCFC, Catless OEM headers, Delkevic slip-on, Uni-filters, Modified Airbox, Altrider Crash bars and skid plate, Flat seat mod. Dash in-fill, Nighteyes LED headlight bulbs, SW motech tank bag, Madstad windshield bracket, Parabellum/Give Airgflow windshield (Using stock windshield mostly) Touratech Headlight guard, Rox Risers, RideonAdv. extended brake/clutch lines

Offline WJBertrand

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Re: Removing headlight lens?
« Reply #10 on: September 12, 2017, 03:03:50 pm »
Remember the projector lens is sort of in the way of getting directly into the front of the headlight housing.

True, didn't think of that, this being my first projector lens equipped bike.
-Jeff-
Ventura, CA
2015 Yamaha Super Tenere ES
2005 Honda ST1300A

Offline en0n

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Re: Removing headlight lens?
« Reply #11 on: September 13, 2017, 08:00:18 am »
Yeah the convex projector lens is blocking access to the front. I had wriggle and squeeze the flexible magnetic pickup tool just to get near the bulb.

The claw of the 'reachy-grabby' tool is too big to squeeze into the lens :(

I will try the disconnect and shake the hell out of it ... keep you guys posted

Offline FM Rider

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Re: Removing headlight lens?
« Reply #12 on: September 13, 2017, 09:02:48 am »
While you are "shaking the hell" out of it, keep in mind that the headlight assembly is about $500!
2016 ES

Offline en0n

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Re: Removing headlight lens?
« Reply #13 on: September 21, 2017, 10:28:31 am »
Well, I managed to get the t10 bulb out.
A first I tried using a vacuum cleaner to suck that out, no luck.
Disconnect the headlight assembly, shake a little and the bulb just pop right out from the hole. Hole in one!

Offline Checkswrecks

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Re: Removing headlight lens?
« Reply #14 on: September 22, 2017, 09:31:47 am »
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