Headlight throw adjuster problem

[bignosebry]

Hi

I've managed to disconnect the headlight throw adjuster inside the headlight unit - don't ask! So when I move the switch up and down, the reflector doesn't move and the headlight it permanently throwing too high and dazzling!

I've got the unit off and there appears to be a white plastic socket that needs to clip back onto a metal ball, right at the bottom. But I can't reach it. I presume the glass is sealed and cannot be taken off the unit?

If anybody knows how to solve this, your wisdom would be much appreciated.
My last option is to cut an access hole in the bottom of the unit and seal up afterwards.

Thanks

 

[Padge]

Had the same problem... And unfortunately it's a sealed unit so you need to be a part time gynecologist to get at them.


There are 2 of there Cup & Ball joints (one at the bottom for uppy-downy and another for the screw adjustment on the side) and the whole reflector assembly is suspended from the top.

Take the whole lot off and remove bulbs etc Very simple, 2 screws at the side and a multiplug for the light unit and another for the speedo.

On the bottom "cup" there is a bracket holding it with 2 phillips head screws.
You'll need to remove one of these screws and slightly loosen the other so you can swing the cup up and over the ball again.
Awkward bit is getting the screw back in as getting a good angle on the screwdriver is difficult.

Make sure the cup and ball at the side is seated properly too, as it seems to pop out when the bottom one comes off.

The cups seem to split easily and BM spares say you can't get them as spare parts (only replace the whole unit)

I'm waiting for word back from a more experneiced person in the bike dept who says I will be able to get them as spares.

If not, I'll just use a bit of Stainless securing wire to keep it in place.

PS. I've got fingers like sausages, so it is possible.

Hi

I've managed to disconnect the headlight throw adjuster inside the headlight unit - don't ask! So when I move the switch up and down, the reflector doesn't move and the headlight it permanently throwing too high and dazzling!

I've got the unit off and there appears to be a white plastic socket that needs to clip back onto a metal ball, right at the bottom. But I can't reach it. I presume the glass is sealed and cannot be taken off the unit?

If anybody knows how to solve this, your wisdom would be much appreciated.
My last option is to cut an access hole in the bottom of the unit and seal up afterwards.

Thanks

 

[bignosebry]

Excellent, thanks for that - I'll give it a go!

 

[bignosebry]

Tried to unscrew the screw, but failed! Didn't wish to persist as knew if I couldn't get it off that easily, I'd never get it back on!

Resorted to removing the silver sticker off the bottom of the unit, cutting an inch by half inch block out, popping the cup back on the ball, silicon sealing the square back in place, make nice and flat and putting sticker back in place to hide my crime. Perfect!

Thanks for your help though

 

[(RIP) Bin Ridin]

Who's a clever boy then!!!!!

 

[RickG]

Yeah, I did that too, just by trying to gently push in a new bulb! The darn thing popped out of it's socket and I spent an hour trying to figure out how to fix it.

My solution was to drill a 4mm hole in the base of the light unit right below the white plastic 'socket' into which the ball of the headlight carrier sits. Then I cut the pointy bit off a nail and pushed that through the hole until it pressed onto the white plastic so it bent it upwards allowing enough room to pop the ball back into the socket.

A bit of tape over the hole finished the job.

 

[WeeWillieWinkie]

As an alternative to serious drilling and major dismantling - make the following tool.

Take one metal coat-hanger cut off a straight length of wire about 14" long approx, at one end bend 1/2" approx to form a shallow V type hook (about 3/4" approx in width). Remove the cap from rear off the main beam. (Standing on the left side of the bike) Turn the hexagonal screw at the base of the lights until you see the ball move forward to meet the socket. They should be touching with just a slight pressure, so the reflector can no longer move. Insert the hooked end of the wire through the open 'main beam' cap hole and to the LHS of the socket. Place the hook end under the white plastic arm that connects to the socket. Then pull the wire up and towards the ball (at the same time), the socket should pop over the metal ball. This worked for me when I managed to disconnect the reflector from the bottom adjuster.

Note: a word of warning - you do this at your own risk. The white plastic part looks like it may be nylon, so too much force and it may snap or shear off.

WWW

 

[nedflanders]

Mine 'popped' out trying to put a HID bulb in, just stuck my finger through the bulb hole and pulled it back into place

 

[pt0310]

Had same problem when fitting hid bulbs. after reading this i thought fine i would cut a hole about the size of a 10p with a hole cutter and pop everything back together. didnt go to plan! cut hole too far back and in the proccess cut the ball out! many tears latter and after finding out a new unit was £225 i reverted to the industrial super glue. all seems fine now but i am not sure if it will adjust if needed so on the lookout for a cheap lamp! would have been fine if i had paid a bit more attention and cut hole further forward. you have been warned!!!

 

[IanC]

Thanks WeeWillieWinkee, I managed to do it as you suggested with a coathanger.

My bike's still under warranty, and the dealer said he would replace the whole unit if I was unable to fix it. So my question is, is the white nylon socket meant to have a split in it, or not?

 

[stevedude]

Note to self..... Look on this forum when you encounter the problem!!!

Did the same yesterday afternoon when changing a bulb. Spent hours last night taking the unit on and off trying to adjust and never seeing what the problem was. Gave up ay 10pm as a bad job.

Woke at 4am thinking about it (WTF???) Decided to get up and look on here. 5:30am, unit off, hole cut, popped back on, all done! I'd go back to be but I'm up at 6:30 anyway.

 

[Gremlin Serbia]

Had the same problem last year when replacing bulb with my sausage-shaped fingers ...so stupid made system

After few hours and good effort to crash to bits entire sealed box i went to local BMW dealer office here, and the mechanic fixed it in up to 3 minutes operation with "custom made tool"...the BMW office owner had the same problem with his own GSA, so mechanic exactly knew what to do...

 

[Bobbin-Man]

I had the same problem - BMW quality control must ensure the problem exists on all bikes I tried removing the glass to repair from the front but eventually decided drilling a hole in the back made more sense - managed to get the white ball joint back together ... but then it easily popped off again.
I repeated the fix but decided to look out for a good s/h light unit. Old one now sent to the scrapyard in the sky and replaced with an ebay sourced unit which actually functions better than the original - dip leaver does it's job properly and the headlight can be adjusted much better. Makes me wonder whether something was modified at some stage? Original was 2006 replacement I think is 2007, maybe later.
As an aside .... whilst the unit is off the bike wrap a bit of cloth round the end of a piece of dowel and accessing thorough the bulb holes, use something like "mr sheen" to clean the inside of the lens - it's surprising how dirty they get. Could easily give 100+% more light output.

Stu.