Headlight frustration

[Draketh]

So I decided to take a look at my headlight today to see if I could maybe replace the bulb to something brighter, but it seems the whole glass housing has to be replaced if the bulb burns out, and if this isn't the case, I sure as hell can't figure out how to get that dang bulb out.

What is really frustrating be is the glass lens has these three little metal clips that hold it into the metal housing and for the life of me I can't get these damn things back on. It's driving me crazy, I've been sitting here for hours in front of the TV holding the headlamp trying for awhile, getting frustrated and stopping, and trying again.

Has anyone dealt with these? Is there some special trick to make them go back on easily?

[chef1366]

What bike?

[Draketh]

1982 GS450GAZ. I got one back on a few hours ago, the other two are impossible, I've been trying since I got the first one on. aaaaaaaaaaaaaaaaaaaaagh

[bwringer]

What sort of bike are you talking about?

Do you have a way to post a photo of what you're dealing with? Perhaps it is not stock or something. Your description doesn't sound familiar to me, but maybe it's a model I haven't worked on yet.

[Draketh]

http://www.bikebandit.com/houseofmotorcycles/suzuki-motorcycle-gs450gaz-1982-headlamp/o/m6034sch275129

Part number 4 fits into part number 3 which is like a metal housing. Assembled 3+4 fits into part number 2 and then mounts onto the bike. Part number 4 is held into part number 3 by part number 7, and stupid little retaining clip. I swear to god this is the worst design EVER. Hold on and I'll get a real picture up.

[Draketh]

Clip:


Headlight overall:


Clip Installed:

[Draketh]

Its messed up, you have to like, stick one side of the clip into the holder, and then try to muscle the other side of the clip into the other holder. I've tried every pliers and vice grip I have and they all slip because the force needed to get the final side in is so great. Amazing I got the first clip in by hand but my thumb now has a large dent.

[Draketh]

Alright, all three are on, I folded up a thick square of construction paper and put it in between the clip and my thumbs so I could apply more pressure without having to stop because it hurt my thumbs too bad.

I swear to god I will sell this bike before I ever replace a burnt out headlamp. This is so retarded, why would they make the head lamp all one big peice? Why not just make it so you only have to replace the bulb instead of a $40 glass lamp with a non removable bulb? Someone must have been hitting the Sake too hard when they designed my bike.

[chef1366]

I rebuilt a 450 and had to put in a new headlight. I don't seem to remember it being that hard.
I do have a selected memory though.

[robinm]

not the clearest photos

But it looks like you have put the clips on upside down. They will fit backwards but it is bl##dy hard work, as you have found. Its a bit hard to describe, but the clip centre curve sort of wraps around the lip of the lamp unit. Done that way they are still quite tight to get on, but nowhere as hard as they are when they are upside down.

[KamakaziDude]

Get yourself one of these. Then if it goes out again all you need to do is replace the bulb which cost around $10 and can be found at your local Walmart. Beats paying a dealer $41 for a glass lamp. I took one of those clips off once and I had a devil of a time getting it back on.

http://www.jcwhitney.com/autoparts/ItemBrowse/c-10101/s-10101/p-100000165788/mediaCode-ZX/appId-100000165788/Pr-p_CATENTRY_ID:100000165788