AussieGlenn's Headlight Rattle Dilemma

Update 4/10/00 
   On-going fame for my tip, I love being able to give something back to this board!

   4000k's since the fix and it is still going strong with no problems. Got the film
   developed last week that shows the hooks (although anyone can see it if they
   pull their headlight apart). 

      Well I finally got sick of the headlight rattle last week because for me it is too
   noticeable at 100kmh in 5th gear which is cruising speed for me. It also rattles at
   a certain RPM in all other gears to which was annoying. At a guess I would say
   somewhere around the 1500 to 2000 rpm mark but I can't be sure. 

   I know some of you have had luck with wrapping the wires inside the headlight
   with various things but my wires are already enclosed in rubber, so this is what
   I did. 

   I have had the headlight apart once before and noticed the metal lips that
   protrude from the main housing and was thinking maybe I could get some
   rubber and stick it along those areas and deaden the sound. 

   I actually bought some rubber that had a back part that peeled off so it was self
   adhesive. I didn't want any problems getting the headlight back on so I got the
   thinnest I could find which was 1.6cm (about 1/2 an inch). 

   When I got home I wanted to see if I could get the headlight to rattle without
   actually having to ride the bike somewhere so I wasn't pulling it apart and
   putting it back together and saddling up continuously if it didn't work. 

   Sure enough if I stood beside the bike and very slowly applied the throttle I
   could get the headlight to rattle... Not only that I could get it to SHAKE RATTLE
   AND ROLL!! Geesh, have any of you guys done this? What happens at around
   the 1500 to 2000 rpm mark is the headlight starts whipping back and forth in
   it's mount like crazy! No wonder this bastard rattles! Under or over that mark
   and the headlight smoothes out, but you get it at that right point and the
   headlight becomes a blur! 


   So any ways I pulled the headlight apart and placed the self adhesive rubber on
   the metal bits that stick out from the main headlight housing and put it all back
   together. No good, DAMMIT! So I start trying to think logically about the problem
   (me logical, now THAT'S a laugh). 

   The headlight only has two bolts that hold the front headlight onto the actual
   housing. These bolts are at 4 and 8 o'clock. There is no bolt at 12 o'clock
   though. From the riding position the headlight whips up and done as if it was
   nodding. So I am thinking it has to be at the top of the headlight where there is
   no bolt. 

   After having another look at the housing I notice at the top there are two metal
   almost hook like things coming out from it that the headlight would hook over to
   go into position (have a look and you will see what I mean) Now these didn't
   look like they would fit all that snugly and I thought this could be where the
   rattle was coming from as the headlight does it's boogie. 

   I got some more of the rubber and squashed it down into the two metal lips
   and put the headlight back on. No more rattle for Glenn!! I have since done
   about 150 miles and it has not returned so this MAY have done it. No doubt the
   rubber will compress with time so I might look at something thicker at a later
   date but this will do for now. 

   My main concern now is that the headlight is still vibrating like crazy in that small
   window of RPMS. It concerns me because of the cruising speed, even though it
   doesn't rattle any more it is still shaking and that can't be good. What we need
   is someone to fabricate a bracket to strengthen it. 

   But anyway, there is what I did. 
                   Yup, Thas Right.  In Orstraylia, Mate
                 '99 Pearl and Olive Roadstar, ISRA# 1420
                 East Coast Australia Time GMT +10 Hours
                    Today for Me is Tomorrow for You

   From: Big Dan (REACHFORSTAR)

   There are several ways..I used cork. The 1/4 inch dot stick ons that you buy at
   the 5& 10 to put on the bottom of vases and stuff to protect furniture. Stick
   them on the rim they are adhesive and trim them even with the edge. I also put
   some bubble wrap around my wires. It worked.

                          "Big Dan" -'StarRider' 
                    Remember the Alamo, Never give Up 
            Visit my page: 
                          2000 Crimson/Cherry ISRA#1905