R1200GS Headlamp Assembly

[Beastie Boy]

I had to replace a blown low beam headlight bulb on my 2006 R1200GS. As I replaced the new bulb into the reflector housing I felt something give and found out that the up/down adjustment (a ball/hitch mechanism) had come off its track and the whole reflector was swinging loose in the headlamp assembly with the effect that the headlamp beam was pointing much higher than it should be. Trying to reset the ball/hitch mechanism was a nightmare and the only way I could do it was by drilling a small hole into the back of the headlight housing and taking out one the screws holding the up/down hitch, lifting it up and placing it back on the ball joint. I installed a new bulb and everything was fine but after a couple of weeks, the low beam bulb has blown again. Has anyone else had these problems and did you find a solution? I've thought about replacing the whole headlamp unit but the dealer has quoted £250! Can you get these any cheaper or s/hand?

 

[nedflanders]

Don't panic, do a search as it's a well known problem, some have drilled the headlight to get the ball back on, I used lockwire and pulled like buggery and it popped back on.

 

[Westy]

if its still under warranty you will be covered. Same thing happened on my 1200 GSA.

 

[admiral]

Happened to me and many others. I spent ages trying to get it back on, but failed. My local dealer (SSB) managed to do it for me (without charge)

Admiral

 

[Michaelk]

Headlamp Design Problem

I've had the same problem on my '06 GS12.

Had to drill out the back also. My bulbs kept blowing, but I later found out that it was the connector not being in properly.

Haven't had a problem since I made sure that it was in securely

I do think that this is a design issue with BMW and it should be fixed under warrantee! Anybody agree?

 

[Beastie Boy]

I guess that might be the problem with mine. I've switched the bulb from the main beam relector and tried to ensure that it's properly seated/connected. Trouble is you don't want to press too hard in case the same thing happens again.

Definitely agree with you that it's poor design and that it should be covered under warranty.

Thanks

BB

 

[Beastie Boy]

Thanks. I've got a 3rd year extended warranty but surprise, surprise, the policy doesn't cover the headlamp/lights.

BB

 

[Beastie Boy]

Don't panic, do a search as it's a well known problem, some have drilled the headlight to get the ball back on, I used lockwire and pulled like buggery and it popped back on.

Thanks. I've found the thread. As you say, a well known problem.

 

[Westy]

Thanks. I've got a 3rd year extended warranty but surprise, surprise, the policy doesn't cover the headlamp/lights.

BB

is that different to the normal warranty then ? because southport superbikes covered mine on the original 2 yr one !

 

[bike to work]

Headlamp adjuster undone

I was looking for a solution for the Headlamp no longer being adjustable but I was looking for more detail on how to reconnect the thingy, can't find another thread with the details. Could someone let me know some more details or what to search on to find the original thread with details please. I cannot believe a whole new headlamp is the only solution as my dealer suggested and if you have to replace the headlamp bulb 6 times in two years then it sounds like the thingy is more likely to become disconnected.

 

[gipsymagpie]

You could of course go to Mr Wassall of this parish for some HID...they never blow.

But anyway, I had the same problem and fixed it using a hook I borrowed from MOT centre. See here: Maplin. Done in 2 minutes flat....ok so I'll also mention in took 2 hours of fiddling before I gave up and asked the MOT centre for help. But with the right tool....

 

[bike to work]

Thank you Gypsymagpie, I have been wrestling with a knitting machine needle which wasn't man enough for the job, these look like just the thing.

 

[mark71]

Same happened to me

I had the same happen to me where the ball came out of the socket and the only way to get it back om was to drill a small 5mm hole in the back and once I had it fitted back on agin filled the hole with some hot glue.

4 years on and its still fine, just a bit of a fiddly job but you will get there.

Mark.

 

[Gremlin Serbia]

I just had same problem, and after spent hours trying to re-joint system, I was afraid that something will break inside, and I will then have to buy entire headlight for 200+ Euro.

Went to BMW service center here this morning, and they fixed it (I removed headlight from bike)

It was free of charge, even warranty expired. Plus we joked about Chinese parts in BMW headlight.

 

[gipsymagpie]

I had the same happen to me where the ball came out of the socket and the only way to get it back om was to drill a small 5mm hole in the back and once I had it fitted back on agin filled the hole with some hot glue.

4 years on and its still fine, just a bit of a fiddly job but you will get there.

Mark.

You can do it without drilling a hole. Just needs a bit of dexterity, patience and the hook tool in my last post. Happy to do if for anyone (have tools on my bike all the time so can pop round local to Bucks).

 

[Andy Hird]

It happened to mine.

I looped thick (about 4mm diameter) electrical sheathed cable looped through, to pull it back on to the ball socket.

Don't be shy with it, give it a firm strong pull, and it will pop back on.

Cheers

Andy

 

[vavhab]

Hi,

I really hope this forum is still alive.
I read your comments and was very helpful, however I do not understand what should I do.
I see two "balls" a white one and a black one. These should be connected?


Thanks,

 

[fatgser]

I have the same problem .
Cannot seem to pull back in .......its hard to do with out having an image of exactly where the ball is etc .
Anyone seen a diagram of how the light is assembled ?

 

[vavhab]

Damn!
I just did it. I have no idea how.

So, there is that white "ball", actually that is a hemisphere( I hope this is the correct world, I am not native English). When you look inside you should see this white hemisphere, front of it/against there is a black "ball", that black ball should be inside of the white hemisphere.
So you have to lift the white hemisphere and the black ball will fit into it.

Not easy to lift that white hemisphere, so bought a "pick and hook" tool , you can find it some reply earlier, and I use that hooked tool to lift that white hemisphere.
I am not sure I would able to do it once again.
I tired to shoot some pictures, but its impossible :S

I wish I could use AutoCAD, I would draw a picture.

Good luck!

 

[fatgser]

well done mate
did you take the headlight of the bike ?