Help Please Headlamp Problem

[Watty100]

My headlight (07 1200GS) has develpoed a mind of own as to whether it wants to work or not.
I've taken it off the bike, done some continuity and resistance tests on the wires and it seems theres a break in the live wires or dodgy connection at the connector block.
Probelm is, I can't get at the rear of the connector block, inside the headlamp unit, to fix it.
Can the headlamp unit be dismantled in any way? It looks like the glass might come off but I tried prising it and and broke a shard off. Fixing the glass in place last looks like the only way the factory could have assembled it
As a new light unit is so expensive, I'd much rather have go at a repair than replacement.
All help gratefully recieved

 

[Magwych]

Have a look here: What's-Inside-Your-Headlight

 

[socket086]

to remove the glass you will have to use heat but now you have a chip in it do not try and heat to remove as the glass will crack.
the problem can be fixed by using a small snips in through the back caps and cut the wires from the internal plug.
drill a hole next to the plug unit and bring the cables out and fit new connections, you will have to change the loom connection as well to match.
it is tight but I have done it that way on ones with cracked or chipped glass.
hope this makes sense and is of help to you.

 

[Watty100]

Thanks fellas,
I'll be off to Maplins for a new connector block of some description, I don't fancy risking breaking the glass when a simple re-wire is on the cards.

 

[Magwych]

If its just the connector block all you trally need ate 2spade terminsls to fit the blades on the bulb. You do not need the connector block. Neither of the terminals is connected to the body of the bulb, so you can connect it up any wsy round thst you like.

 

[Watty100]

Fixed it by cutting off the wires inside the headlamp, leaving them as long as possible. Drilled a hole in the underside of the unit and pulled the wires through. Sealed the hole with a blob of bathroom silicone.
Cut off the connector block on the bike, spade connectors attached to the 3 wires (earth, main beam and headlamp), all wrapped up tightly in Aldi's finest heatshrink tube and jobs a good 'un.

 

[Bendy toy]

There are new headlamp glasses on eBay. Shame they are not fully separate units.