R1200GS - Headlight/Instrument Assembly Removal

[Mick-B]

Can anyone assist please? I am endeavouring to remove the entire headlight / instrument assembly and have removed the 2 bolts and the 2 multi-plug wiring connectors. However, on withdrawing the assembly I find it is still tethered at the bottom by a pair of wires (feeding the parking light?) entering the back of the bottom of the headlight housing at right-angles through what might be a rubber grommet or could be a plug connector... I've tried pulling at the rubber groomet thing but it isn't giving way. It stretches but I don't want to break it, or the wires.

The next b*stards are the 4 torx bolts retaining the windscreen support bracket - 2 have already rounded out and I have to assume the remaining 2 will do exactly the same as there is minimal depth to the torx inserts... Still, the bolts are so soft I could use a toy plastic drill-bit...

Anyway, an early response on the wires would be really appreciated

 

[Mick-B]

Can anyone assist please? I am endeavouring to remove the entire headlight / instrument assembly and have removed the 2 bolts and the 2 multi-plug wiring connectors. However, on withdrawing the assembly I find it is still tethered at the bottom by a pair of wires (feeding the parking light?) entering the back of the bottom of the headlight housing at right-angles through what might be a rubber grommet or could be a plug connector... I've tried pulling at the rubber groomet thing but it isn't giving way. It stretches but I don't want to break it, or the wires.

The next b*stards are the 4 torx bolts retaining the windscreen support bracket - 2 have already rounded out and I have to assume the remaining 2 will do exactly the same as there is minimal depth to the torx inserts... Still, the bolts are so soft I could use a toy plastic drill-bit...

Anyway, an early response on the wires would be really appreciated

Sorry - being very stupid!!! The offending plug IS the parking light carrier. Simply needs to be FIRMLY pulled out. Entire assembly now removed.

So, angle grinder to remove the torx bolts on the windscreen lower support mount - deep joy situation.

 

[davegs]

Torx bolts

Make sure you have the correct size bit, the next size down will often be a slack fit and sometimes works correct size is a tight fit. Just a thought having had mine apart several times without a prob the wires are the pilot light and require a firm tug.

 

[Mick-B]

Make sure you have the correct size bit, the next size down will often be a slack fit and sometimes works correct size is a tight fit. Just a thought having had mine apart several times without a prob the wires are the pilot light and require a firm tug.

All of the torx heads stripped - even having knocked the bit fully home with a light hammer so as to ensure a snug fit.

I have now ground the heads off and, the support bar being separated from the side brackets, have successfully removed 3 of the remaining 4 "studs". However, the 4th has proved to be a total sh*tbag and, due to the grips not doing as their name would suggest, now resembles a somewhat chewed, pointed bit of metal which the grips simply slide off

Any useful suggestions as to how to remove the remains of the totally f*cked bolt will be appreciated - not starting the job would have been a useful suggestion 5 hours ago... like every job that ought to be straightforward this one is proving to be a complete and utter pain in the arse.

 

[Mick-B]

All of the torx heads stripped - even having knocked the bit fully home with a light hammer so as to ensure a snug fit.

I have now ground the heads off and, the support bar being separated from the side brackets, have successfully removed 3 of the remaining 4 "studs". However, the 4th has proved to be a total sh*tbag and, due to the grips not doing as their name would suggest, now resembles a somewhat chewed, pointed bit of metal which the grips simply slide off

Any useful suggestions as to how to remove the remains of the totally f*cked bolt will be appreciated - not starting the job would have been a useful suggestion 5 hours ago... like every job that ought to be straightforward this one is proving to be a complete and utter pain in the arse.

And so to complete - the 4th bolt never did come out. As a final and perhaps forlorn hope I flatted off the remains of the bolt and attempted to drill it with the idea of deploying a stud-extractor... yes, telegraphed hours in advance, the drill had ideas other than following the centre-punch and followed the path of least resistance, straight into the aluminium... B@STARD!

Finally, does anyone have a spare RHS screen / headlamp support they don't need or, do I: a) buy a new sub-assembly (nice, bright, shiny, all its paint intact but pricey); b) buy a second-hand sub-assembly from a breaker(somewhat cheaper), or; c) keep calm and carry on ignoring the fact the windscreen lower support is held by only 3 bolts, not 4.