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Hello All,

I was replacing the H4 headlight bulb in my '77 R100/7, and I noticed the reflector and the inside surface of the glass lense were dusty. I tried to pry the glass out with plastic tools for auto body trim, and ended up ripping the gasket. Seems like the gasket holds the glass really tight.

Now that I have to replace the gasket, can anyone tell me the best way to pop the lense in and out without bending the reflector, or breaking the glass?

Thanks

The reflector is glass, so it will be difficult to bend. There are several "V" shaped clips made of wire around the bezel, between the bezel and the reflector that press the reflector into the bezel. Depress one side of these clips to remove. Remove them all. The lens and reflector can then be removed from the bezel as a unit.

I have wrapped electrical tape around the joint bewteen the lens and reflector as a substitute for the gasket.

Hope this helps.

As Native says, use tape, it works better anyway. That also makes it easier to remove the glass.

Hey guys, thanks for the replies.

I'd still like to separate the glass lense from the reflector. Even after rinsing them with alcohol and installing a new halogen bulb, the headlight has a decidedly "dusty" quality. I was thinking of wiping the reflector surface with a microfiber cloth, and cleaning out the facet cuts on the inside of the glass lense. In addition, there is some kind of galvanized, two-pronged heat shield on the reflector that sits in close proximity the the end of the halogen bulb. I was going to buff it inside and out.

Have any of you guys actually separated the lense from the reflector? I read a while back where someone used feeler gauges to get between the reflector and the lense. Is it possible to do that without scratching the reflector? Is there any sealant used on the gasket? It seems like it won't give up without a fight.

Thanks for your help.

I did exactly this job on my 81 RS two weeks ago.
After removing all the spring clips that hold the chrome bezel in place, the bezel came away quite easily.
I then carefully pried around the lens bit by bit and it eventually came free from the reflector without damaging the rubber seal.
If you have broken the rubber seal, I would buy another one, they are still available.
A good seal is needed otherwise it will quickly fill with dust etc again.
While I had the lens and reflector apart I washed them both with soapy water and dried them. Nice and clean!
My reflector is steel I think with a super shiny coating on it.
I was careful not to drop or damage that reflector!
Getting the lens, reflector and bezel back together with the seal in its right place took a little work because the rubber seal contracted after it was removed. But I got back together ok.

I easily removed the shield that sits in front of the halogen globe, apparently it gives a fair bit more light although I haven't been out at night yet to see how much better it is.

Good luck!

No big deal, remove the glass and clean off the old rubber gasket. Then wrap it in tape and put it back together. If the reflector is dirty, clean it in water and a very mild soap. Pat it dry. Put it all back together. Just make sure that the notches fit together correctly.

Duane Ausherman wrote:No big deal, remove the glass and clean off the old rubber gasket. Then wrap it in tape and put it back together.

Duane, that sounds like an ME109 fix!

Well, what's good for you is good for me. next time.

I then carefully pried around the lens bit by bit and it eventually came free from the reflector without damaging the rubber seal.

Which tools did you use? I tried plastic automotive levers used for removing interior and exterior trim.I couldn't budge it at all. I'm somewhat hesitant to use screwdrivers or steel prying tools. I've already snapped off one of the tips of the plastic levers.

No big deal, remove the glass and clean off the old rubber gasket.

Did you simply use screwdrivers and "walk" them around the circumference of the glass? I was thinking of putting the assembly in a warm pan of water to expand the reflector somewhat, and make the seal more pliable. I'll be using a new seal for re-assembly.

After removing all the spring clips that hold the chrome bezel in place, the bezel came away quite easily.

Yep, this is on a Wixom frame-mounted fairing with an adapter kit for the OEM halogen headlight. Once I've removed five of the six Wixom-supplied clips, the bezel literally falls off. My problem is, I can't get the glass lense to separate from the reflector, without going Godzilla on it.

I did use a screwdriver (no point screwing around) but I picked an old one that didn't have sharp corners on its sides that could concentrate pressure on a very small area of the lens.
I found that applying x amount of pressure and maintaining it for a few seconds at various points around the lens eventually did the trick.
I'm assuming that your headlight is the same as my 81?

I too would consider soaking the headlight in hot water (as hot as your hands can bear) to soften the rubber seal.
It's a matter of applying pressure and waiting. Good things come to those who wait.
I've always been an impatient bastard tho'

It's a matter of applying pressure and waiting. Good things come to those who wait.

Thanks ME109, I'll give it a try.

And thanks to Duane and Native/5 for their help.