News:

The simplest way to help GStwin is to use this Amazon link to shop

Main Menu

Opening a headlight assembly?

Started by lucky4034, September 28, 2011, 07:19:01 PM

Previous topic - Next topic

lucky4034

(I feel like such a noob)

I purchased an extra headlight assembly for a GS500F to tinker around with a new HID projector lens project. 

Located around the outside edge of the assembly there are 7 black snap ins that attach the front half (clear part) to the back half.  At first glance it seems that these 7 tabs are the only thing holding the halves together, but I'm trying to separate these snaps using a flat head screw driver and am getting virtually nowhere.  This leads me to believe that there must be additional points of attachment that don't seem obvious.  (screws perhaps?)

My question is... are these 7 black tabs the only thing stopping me from getting this thing cracked open? 

I also see two screws with hand turners on the back... and Ive tried to spin them to see if they loosen, but it doesn't appear that they are apart of the problem.

Any information would be helpful.  I don't really want to use brute force to pop this thing open if I don't have too.  (as I usually find brute force to be the wrong answer 9 times out of 10)

Thanks in advance,

-Mike
Own:
'09 Suzuki GS500F
'05 Kawasaki Ninja 250R

Hope to own one day:
'11 Honda CBR600RR
'87-'92  Yamaha YSR50
'90-'93 CBR 250RR
...and counting

4strings

The lens is sealed with silicone or something, all the way around.  The guy in this thread opens it up to do some crazy modding and has instructions as well.

http://gstwins.com/gsboard/index.php?topic=54836.0
'93 GS500E
-15T Front Sprocket
-Bar-end Mirrors
-ProGrip Gel Grips
-GSX600 Rear Shock
-CBR900RR Front Pegs
-Fenderectomy
-Custom Stealth Tail light
-Scorpion Battery
-Progressive Fork Springs
-WOLO Dual Tone Air Horn
-12V Accessory Outlet
-Ebay Carbon Look [lol]Levers
-CNC Aluminum Fork Brace

mitch79

I'll start with a disclamer, I've done this successfully with my car headlights, I have not had a need to try a GS500F headlight.

Put the headlight assembly in the oven. The black sealant around the edges softens with heat.

Preheat the oven to 200c/400f for 15min then turn the oven OFF!! (That's important)
Place the headlight in the oven and let it sit in the residual heat for 10min.
Be ready with gloves and a suitable prying instrument. I found a butter knife worked well.
If the headlight cools before you've finished separating it put it back in the oven rather than forcing it apart.

Use the same process when re-assembling to soften the sealant.

Worked for me.
2006 GS500F



lucky4034

That explains quite a lot actually  :thumb:

I knew something had to be holding it together... thanks for all the help gents.  In the oven she goes :D
Own:
'09 Suzuki GS500F
'05 Kawasaki Ninja 250R

Hope to own one day:
'11 Honda CBR600RR
'87-'92  Yamaha YSR50
'90-'93 CBR 250RR
...and counting

lucky4034

Quote from: 4strings on September 28, 2011, 07:48:22 PM
The lens is sealed with silicone or something, all the way around.  The guy in this thread opens it up to do some crazy modding and has instructions as well.

http://gstwins.com/gsboard/index.php?topic=54836.0

Actually this was the thread that inspired me to take on this project.  I haven't looked at the thread in so long and never took much note about the oven.

Cheers
Own:
'09 Suzuki GS500F
'05 Kawasaki Ninja 250R

Hope to own one day:
'11 Honda CBR600RR
'87-'92  Yamaha YSR50
'90-'93 CBR 250RR
...and counting

SMF spam blocked by CleanTalk