:: Yamaha Virago XV Forums That Rock!!! General Help Broken headlight spring. (SOLVED)

#1:  Broken headlight spring. (SOLVED) Author: Itsnotme1988 Post Posted: Sat Mar 27, 2010 1:46 pm

A few weeks ago I pulled my headlight and wasn't really paying attention. I wound up unscrewing the adjusters and broke off the spring set that holds the ring on. I have no idea how it was attached so I can't figure out how to reinstall the new one I ordered. Any help?

Part is #10 here

Last edited by Itsnotme1988 on Sun Mar 28, 2010 6:21 pm; edited 1 time in total

#2:   Author: mark75 Post Posted: Sat Mar 27, 2010 2:51 pm

headlight has a rather odd spring attachment.
hope these help.

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#3:   Author: Itsnotme1988 Post Posted: Sat Mar 27, 2010 7:49 pm

That looks a little different than mine but I think it'll help.


#4:  Re: Broken headlight spring. (SOLVED) Author: viragoxv Post Posted: Thu Apr 22, 2010 11:47 am

Those pics certainly help show how the spring sets on top of that tang. I am guessing that it is there to stabelize the glass in the rim and restrict the headlight from vibrating the light glass and bulb beam beam.

I presume the procedure to remount would be, set the glass and trim ring in partially, then with the assist of a needlenose pliers try and reset the spring as shownin the pictures once the lamp is partially assembled and I can still get inside the lamp housing, is this correct?

My next question is, Obviously, during dissasembly I needed to turn out the only 2 screws holding th ring to the housing to remove fully the trim ring, glass and old bulb within and swap out for the new bulb.

I backed them both off fully, each of course releasing their spring loose into the lamp housing. The 2 small white nylon threaded blocks that the screws screwed into also fell into the housing as the screws backed off and withdrew on th outside of the housing into my hands. Once both screws (Also known as the adjusting screws were completely out, then the glass with bulb and ring were able to slide out of the assembly.

I put the glass on my lap, unscrewed the black protective cover holding the bulb, repleaced it with the new bulb, and then sat there trying to figure out how to reset the spring, which the photos are very helpful, and now trying to figure out how the hell I am going to keep the white nylon threaded keepers in their housing for as soon as I move the assembly, they want to drop back onto the floor of the assembly before I can get the screw shaft with spring started so I can tighten them down.

Who would have thought this procedure was so complex in such a tight space? No where in either Haynes or Clymer, or the owners manual do they show the proper procedure and what to expect with falling internal parts or I would have been prepared or maybe my dissasembly procedure was not correct?? Alll I could read in any of th 3 books was to ismply remove those 2 screw on the trim ring. Sounds simple enough, but here I sit. He He....OK what do I do next???


#5:   Author: mark75 Post Posted: Thu Apr 22, 2010 3:53 pm

To change the bulb:
1. first remove the Securing screws from the light unit assembly / headlight body
by removing the 2 large screws in the headlight bowl (see photo);

this allows the light unit assembly to come free from the body (bowl).

2. disconnect the lead wire and remove the light unit assembly

(the rubber thing should fit snugly to reflector - note where TOP is)

3. remove the rubber protector,

4. Rotate the bulb holder counter-clockwise,

5. Install new bulb. (avoid touching bulb as fingerprints/oil may shorten bulb life - can clean with alcohol or acetone)

Bulb gets very hot so don't touch it if it is on.

The 2 screws in the ring are for adjustment - up/down & right/left.

hope this helps.
Ride safe.

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#6:   Author: viragoxv Post Posted: Thu Apr 22, 2010 4:39 pm

Thanks Mark....

NOW I see what I did wrong. I removed the long adjusting screws, (Instead of the back screws holding the light assembly) not knowing that is what they were !

Your pictures show the screws in the bucket that I should have removed initially.. That explains why the adjusting screw springs and the nylon nuts that hold them all fell off into the bucket as I continued to screw them out fully, including the eventual drop of the spring clip that adds tension on the outer ring.

OK, so now I presume I proceed to remove the correct screws and inner ring I should have removed in the first place and try and put the glass and the outter ring, adjjusing screws and springs back in place BEFORE I attempt to reassemble the unit the way it should have been in the first place aye??

Eventually having to re-aim and re-adjust as whatever good adjustment was there is gone now.
Any tips on this reassembly procedure of adjusting screws and springs including the spring clip that bounced out from the upper tang on removal??

Virago XV

Last edited by viragoxv on Thu Apr 22, 2010 6:22 pm; edited 1 time in total

#7:   Author: mark75 Post Posted: Thu Apr 22, 2010 5:03 pm

first time taking the headlight apart is an education for us all. Laughing

don't loose the long adj screws, they are heck to replace. naughty

jmo: I would put the spring clip in last, that way the adjust screws can help hold the bulb while you wrestle with the clip.

#8:   Author: viragoxv Post Posted: Thu Apr 22, 2010 5:13 pm

Thanks for the tips Mark.

Now I have to remove my Memphis Fats Windshield plexiglass as it is in the way of being able to reach those screws on back of the lamp bucket...

You are correct this is an education and a mistake I will not make a second time for certain.

Virago XV

#9:   Author: viragoxv Post Posted: Thu Apr 22, 2010 7:18 pm

Got the back ring removed.

Put the front light assembly together the way it should have looked the first time!

Reinstalled the adjusting screws and the spring holding the assembly to the front ring.

Reconnected the wire to the back of the new bulb, and installed the unit back on the bike.

Now have to reinstall the windshield whch was blocking the bucket screws.

I have never tried to post a picture here , but if it will come out, I will post one with the "Light on" and consider this project complete, thanks to yall's help here on the forum!

Last thing is to re-aim LtoR Up to Down.

Virago XV

#10:   Author: packman Post Posted: Thu Apr 22, 2010 7:38 pm

I did the same thing first time too. It was the first thing I did on the bike & my wife was there observing, coaching, commenting, ordering.... She was afraid to ride the bike herself until I test rode it! I have not figured out how to post a picture either, but then I'm a lot older than you. General Help Broken headlight spring. (SOLVED)

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