FlatlandBusa
Registered
Ever since I bought my GEN 2 and converted the high and low beams to HID's, I have disliked the high beam aiming at the trees when the low beam is adjusted high enough to be useful. I also did not like the high beam cut off on the bottom of the high beam.
I finally got up the nerve to try and do something about it.
IF YOU TRY THIS AND DESTROY YOUR HEADLIGHT ITS ON YOU!
Here is how, start to finish including removing the nose from the bike took me about 6 hours, the worst part of the entire project is removing the non hardening sealer from the groove in the plastic head light housing.
Remove the upper from the bike, and remove the headlight from the upper.
Carefully pry the head light lens from the black plastic back of the head light, it is held in with a nonhardening sealer. Take your time, I used a combination of screw drivers and a stiff bladed putty to separate the pieces.
Before starting this step note how many threads the silver pivot screw protrudes through the nut in the reflector.
Loosen the 2 adjuster screws and 1 pivot screws 2 turns at a time until the reflector is separated from the housing.
Remove the high beam/adjuster assembly from the low beam reflector.
During reassemble you will add 3 #6 flat washers to the screws on both sides of the high beam, between the adjuster assembly and the low beam reflector. This will aim the high beam lower in relation to the low beam.
Remove the high beam reflector from the adjuster bracket.
Remove the high beam lens from the adjuster bracket.
Here is a pic of the part of the casting that makes the high beam be cut off on the bottom.
Carefully remove the cut off deflector, it is cast as part of the adjuster assemble.
I used a small drill and a dremel tool to cut it out.
View from the front with cut off deflector removed.
View from the back with the cut off deflector removed.
Before starting reassemble scrape all the non hardening sealer out of the groove in the black plastic headlight housing. Also carefully scrape the non hardening sealer from the head light lens its self.
Reassemble the high beam and adjuster assembly.
Reassemble the high beam/adjuster assembly to the low beam reflector with 3 #6 flat washers on both screws between the adjuster housing and low beam housing on either side of the high beam reflector.
Put both bulbs back in and hook them up to power to check the aim of the high beam in relation to the low beam on a distant wall, adding or removing flat washers as needed.
Reassemble everything else in reverse order.
I used ultrablack silicone to seal the headlight lens back to the headlight housing filling the groove in the headlight housing about 1/2 full then pressing the lens in place until the catches in the headlight housing were engaged.
Reassemble headlight to upper and upper to bike and adjust the headlight as needed.
-John
I finally got up the nerve to try and do something about it.
IF YOU TRY THIS AND DESTROY YOUR HEADLIGHT ITS ON YOU!
Here is how, start to finish including removing the nose from the bike took me about 6 hours, the worst part of the entire project is removing the non hardening sealer from the groove in the plastic head light housing.
Remove the upper from the bike, and remove the headlight from the upper.
Carefully pry the head light lens from the black plastic back of the head light, it is held in with a nonhardening sealer. Take your time, I used a combination of screw drivers and a stiff bladed putty to separate the pieces.
Before starting this step note how many threads the silver pivot screw protrudes through the nut in the reflector.
Loosen the 2 adjuster screws and 1 pivot screws 2 turns at a time until the reflector is separated from the housing.
Remove the high beam/adjuster assembly from the low beam reflector.
During reassemble you will add 3 #6 flat washers to the screws on both sides of the high beam, between the adjuster assembly and the low beam reflector. This will aim the high beam lower in relation to the low beam.
Remove the high beam reflector from the adjuster bracket.
Remove the high beam lens from the adjuster bracket.
Here is a pic of the part of the casting that makes the high beam be cut off on the bottom.
Carefully remove the cut off deflector, it is cast as part of the adjuster assemble.
I used a small drill and a dremel tool to cut it out.
View from the front with cut off deflector removed.
View from the back with the cut off deflector removed.
Before starting reassemble scrape all the non hardening sealer out of the groove in the black plastic headlight housing. Also carefully scrape the non hardening sealer from the head light lens its self.
Reassemble the high beam and adjuster assembly.
Reassemble the high beam/adjuster assembly to the low beam reflector with 3 #6 flat washers on both screws between the adjuster housing and low beam housing on either side of the high beam reflector.
Put both bulbs back in and hook them up to power to check the aim of the high beam in relation to the low beam on a distant wall, adding or removing flat washers as needed.
Reassemble everything else in reverse order.
I used ultrablack silicone to seal the headlight lens back to the headlight housing filling the groove in the headlight housing about 1/2 full then pressing the lens in place until the catches in the headlight housing were engaged.
Reassemble headlight to upper and upper to bike and adjust the headlight as needed.
-John
