1976 R90/6 Headlight bulb replacement.

[gr8ridn2]

OK, a silly question, but I am new the these airheads.

I am trying to open the headlight to access the wiring and replace the bulb. I have a copy of the owner manual and it simply states to pry from the bottom with a flat screw driver. This doesn't sound right as this would most certainly scratch the black paint of the housing. I also notice a small slot at the bottom of the chrome ring but don't know if that is used to pop off the bottom. In searching my Clymer Repair manual it isn't much help on this procedure basically saying the same as the owner manual.

Any advice or pointers would be appreciated. I don't want to mess up a very clean bike.

 

[20774]

I believe what you need to do is to push a screwdriver up into that slot. It will push on a sprung tab which will release the chrome ring. Be sure to have your hand around the headlight as you're doing this so it doesn't pop off suddenly.

 

[james.a]

I usually put the corner of a rag over the flat end of the screwdriver to cushion against getting a chip of paint knocked loose. Re-installing involves getting the bezel lined up and applying a sharp blow at the bottom of the headlight ring with the heel of your palm.

 

[gr8ridn2]

Thanks for the responses. I will give these tips a try.

 

[gr8ridn2]

Thanks for the tips.

I was able to remove the headlight from the shell. In my case it was a matter of pushing up on the shell opening at the bottom just behind the chrome ring opening with a small flat blade screwdriver. I then saw slight movement if the chrome ring from the shell. I used a plastic tool used to remove interior trim in the separation and that released the headlight. No damage inflicted.

On re-assembly I simply gave a good hit to the bottom of the headlight with my palm after insuring the locking clip was aligned with the shell cutout and the top was in place with the shell.

Good to know should I need to replace a headlight bulb on the road.

 

[20774]

When it came to the /7s, they included a screw there to more securely hold chrome ring and lens into place. In fact, the /2s also had a screw mechanism as part of the installation. But for some reason they omitted that on the /5/6...maybe trying to reduce weight!

You might want to consider adding a black zip tie to further hold the lower clip in place. Unfortunately, that might mean drilling a hole. But take a look and see if there's something that can be added.

 

[JoeDabbs]

Add a piece of blue painters tape along the bottom where the chrome ring meets the shell. If u hit a large pothole at speed, the assembly will pop out and bounce off the metal bolts fastening the front fender.

 

[dpmonk]

small zip tie

I have been using a small zip tie to secure the ring for years. If the headlight ever pops off you will be out bunch of money and lots of work replacing and re-wiring.

 

[gr8ridn2]

Great tips. I will try the tie wrap idea between the housing and chrome ring. Like mentioned I have always encountered the screw fastening method on this style of headlight.

Thanks for the helpful tips.

 

[DRRAOULDUKE]

Sometimes it is tough to keep these closed

after opening. I resorted to a zip tie - kind of belt and suspenders reaction to it repeated popping off.

 

[r2frame]

potholes??

I had my R90/6 up in Monteverde Costa Rica when I lived there for three years. Had to install Pirelli enduro tires and add a skid plate under the engine.
Costa Rica is well known for terrible roads, and Monteverde is famous there as being among the worst and most dangerous (wet clay on narrow mountain roads)

I hit potholes and rocks so hard that my front rim bent several times (I replaced it) but the headlight never popped off....although I sometimes felt I had lost parts off my body