broken bulb clip- a fix

[Sancho Panza]

My HID dip light failed the other day, I think it was the ballast unit as the bulb looked Ok. I decided to revert to an ordinary bulb as I have been a bit uncomfortable that the HID light was dazzling other road users, and I rarely drive at night anyway, plus didn't fancy the cost of buying a new ballast unit. Anyway, to cut a long story a bit shorter, when I unclipped the bulb holder clip to fit a standard bulb, the clip pinged out and seemed to have broken the plastic groove in which it was held by a small grub screw.

Just to make life even more difficult, the b.....y clip disappeared off the face of the earth! After about half an hour it dropped to the floor having tried to hide somewhere in the innards of the bike. B.....d!

Anyway, the problem was to refix the clip to the headlight shell in a way which allowed it to swivel on its hinge without falling out due to the broken groove/nib in the back of the plastic headlight unit.

Afer trying various bent washers which wouldn't both hold the spring while still letting it swivel hingelike, and rapidly tearing out what little hair I have left, I had a brainwave.

Got a piece of copper wire from some old 2 plus earth electrical cable, cut a short length and wound it tightly round the hinge end of the spring clip, but leaving a small loop sticking out in the middle for the screw to go through.

Then screwed the clip back onto the headlight through the little loop. The spring clip was firmly fixed yet able to swivel perfectly. Light bulb in and firmly fixed.

I'm feeling slightly cocky about this wizard fix and needed to share it and hopefully win lots of praise.

The lesson from this is...as well as gaffer tape, always carry a length of copper wire around in your emergency repair kit!

 

[luckylucian]

Also stuffing a bit of foam behind the bulb and the black plastic cap works a treat in the dark!!

 

[Sancho Panza]

So am I not the only duffer to break the bulb clip then?

Lucky, your solution is also excellent especially on the road as it would make a very quick fix. If no sponge handy then a piece of paper or cloth screwed up would also work.

My solution would be longer term and save having to replace the whole light unit!

Wallace and Gromit still live!

 

[Dahoum]

Got a piece of copper wire from some old 2 plus earth electrical cable, cut a short length and wound it tightly round the hinge end of the spring clip, but leaving a small loop sticking out in the middle for the screw to go through.

pics would be useful - its difficult to visualise

 

[Sancho Panza]

Not sure how to attach photos, or if I am allowed to as I have not subscribed.

 

[Dahoum]

Subscribe and I'll tell you

 

[andyclift]

I managed to break a clip mounting on my last GS while changing a bulb in a car park, at night, and of course the clip disappeared.

A hunt around found a small self tapping screw, a large safety pin and a Coke can. With the assistance of a Leatherman a new clip was made and fitted in about 15 minutes.

For the clip the safety pin had the "head" cut off and was then bent to the shape needed to fit around the bulb and allow the open ends to slide under the "hooks" in the headlight. A piece of Coke can was cut to wrap around the closed side of the new clip (which was left straight for this purpose) to form a hinge. A small hole was made in the hinge to take the self tapping screw which was then screwed into an existing hole in the headlight housing which is in just the right place next to the headlight.

I intended to claim under warranty at the next service but as my DIY clip was a lot stronger than BMW's design I never bothered. It survived a number of bulb changes and was still in place four years later when I sold the bike - so no pictures.

 

[pathfinder]

Can you claim under warranty for this bulb clip?Yep I have broken as well.

 

[Glyno]

Mine broke as well but I just stretched the wire tenshioner thingy a bit and fastened it where the screw fits, if you know what I mean

 

[pathfinder]

Mine broke as well but I just stretched the wire tenshioner thingy a bit and fastened it where the screw fits, if you know what I mean

I did the same

 

[andyclift]

Can you claim under warranty for this bulb clip?Yep I have broken as well.

The fact that this clip breaks off so easily is, to me, a clear indication that the design is not fit for purpose. I stayed with my DIY fix as I was sure that if I had the housing replaced it would break the next time I changed a bulb

 

[Wapping]

The fact that this clip breaks off so easily is, to me, a clear indication that the design is not fit for my clumsy great fingers.

I stayed with my DIY fix as I was sure that if I had the housing replaced it would break the next time I changed a bulb

Is what you meant to say, possibly.

 

[pathfinder]

Is what you meant to say, possibly.

Possibly sir.