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Advice - Rusted Headlight
- Quartermaster35
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Advice - Rusted Headlight was created by Quartermaster35
I am trying to remove the headlight from the fork brackets , however the bolts just spin inside the case. Just wondering if anyone has experienced this that can share with me how they removed them?
1973 Yamaha CT3 175
Prior Bikes:
1973 Suzuki TS90
1977 Yamaha IT175
1978 Suzuki 390SP
1980 Yamaha 175 Tri-Moto
1969 Yamaha DT1 250
1981 Yamaha XS650 Special
1982 Suzuki GS550ES
1982 Honda 250R
1984 Honda Nighthawk "S"
2005 Kawasaki KLR650
Prior Bikes:
1973 Suzuki TS90
1977 Yamaha IT175
1978 Suzuki 390SP
1980 Yamaha 175 Tri-Moto
1969 Yamaha DT1 250
1981 Yamaha XS650 Special
1982 Suzuki GS550ES
1982 Honda 250R
1984 Honda Nighthawk "S"
2005 Kawasaki KLR650
27 Nov 2020 18:14
#1
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- MarkT
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Replied by MarkT on topic Advice - Rusted Headlight
Umm... remove the headlamp lens/reflector and hold the nut that's on the inside with a wrench.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
The following user(s) Liked this Post: bart.ives, JayB, HouseofEnduro, Pedalcrazy
27 Nov 2020 18:34
#2
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- Quartermaster35
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Replied by Quartermaster35 on topic Advice - Rusted Headlight
Yes agreed.....but I cannot remove that screw either......(of course)
I can grind the main head bolts off but was hoping that someone had advice for me before I went to that route.....
I can grind the main head bolts off but was hoping that someone had advice for me before I went to that route.....
1973 Yamaha CT3 175
Prior Bikes:
1973 Suzuki TS90
1977 Yamaha IT175
1978 Suzuki 390SP
1980 Yamaha 175 Tri-Moto
1969 Yamaha DT1 250
1981 Yamaha XS650 Special
1982 Suzuki GS550ES
1982 Honda 250R
1984 Honda Nighthawk "S"
2005 Kawasaki KLR650
Prior Bikes:
1973 Suzuki TS90
1977 Yamaha IT175
1978 Suzuki 390SP
1980 Yamaha 175 Tri-Moto
1969 Yamaha DT1 250
1981 Yamaha XS650 Special
1982 Suzuki GS550ES
1982 Honda 250R
1984 Honda Nighthawk "S"
2005 Kawasaki KLR650
28 Nov 2020 04:41
#3
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- DaveHunter
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Replied by DaveHunter on topic Advice - Rusted Headlight
I’d attack the screw first Quartermaster as once bolts cut off there would be a headlight bucket hanging by the wires. It’s the big screw, small one is only to adjust beam
If you have a mig welder one method is place a small nut over screw head and weld in center of nut. Then use wrench and the heat sometimes helps loosen things. No welder - you’d have to drill screw head off.
If you have a mig welder one method is place a small nut over screw head and weld in center of nut. Then use wrench and the heat sometimes helps loosen things. No welder - you’d have to drill screw head off.
The following user(s) Liked this Post: MarkT, Pedalcrazy
28 Nov 2020 05:16
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- Gr8uncleal
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Replied by Gr8uncleal on topic Advice - Rusted Headlight
Apologies if you've already tried, but any chance of being able to drill the retaining screw for the headlight rim? It will be pretty mild steel, and it's only the screw head that needs removing.
Alternatively, what screwdriver type have you been using and is there anything left in the screw head that you can get purchase on? The reason I ask is that Yamaha used JIS (Japanese Industrial Standards) screw heads, and Phillips screwdrivers can bugger these up. If there is some purchase left, buy a small set of JIS screwdrivers/socket heads and give these a go - you'd be surprised what a difference there is.
Alternatively, what screwdriver type have you been using and is there anything left in the screw head that you can get purchase on? The reason I ask is that Yamaha used JIS (Japanese Industrial Standards) screw heads, and Phillips screwdrivers can bugger these up. If there is some purchase left, buy a small set of JIS screwdrivers/socket heads and give these a go - you'd be surprised what a difference there is.
28 Nov 2020 05:21
#5
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- Quartermaster35
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Replied by Quartermaster35 on topic Advice - Rusted Headlight
Thank you for the advice guys........
I ended up getting the screw to break free by beating the handle of the phillips head with hammer while turning.
(Fortunately, it didn't break the lense)
I ended up getting the screw to break free by beating the handle of the phillips head with hammer while turning.
(Fortunately, it didn't break the lense)
1973 Yamaha CT3 175
Prior Bikes:
1973 Suzuki TS90
1977 Yamaha IT175
1978 Suzuki 390SP
1980 Yamaha 175 Tri-Moto
1969 Yamaha DT1 250
1981 Yamaha XS650 Special
1982 Suzuki GS550ES
1982 Honda 250R
1984 Honda Nighthawk "S"
2005 Kawasaki KLR650
Prior Bikes:
1973 Suzuki TS90
1977 Yamaha IT175
1978 Suzuki 390SP
1980 Yamaha 175 Tri-Moto
1969 Yamaha DT1 250
1981 Yamaha XS650 Special
1982 Suzuki GS550ES
1982 Honda 250R
1984 Honda Nighthawk "S"
2005 Kawasaki KLR650
The following user(s) Liked this Post: MarkT, bart.ives
28 Nov 2020 09:50
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- Mothersbaugh
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Replied by Mothersbaugh on topic Advice - Rusted Headlight
Ah...the old homemade impact wrench trick! (With apologies to Don Adams/Max Smart)
The following user(s) Liked this Post: Quartermaster35
28 Nov 2020 20:20
#7
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