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How do I get inside the headlight assembly? (Fz8)

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NutsyUk
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Joined: 22 Jun 2016
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PostPosted: 15:13 - 02 Feb 2023    Post subject: How do I get inside the headlight assembly? (Fz8) Reply with quote
Ok some bad news on my new 11k mile bike...
The aim adjustment nut inside the assembly is certainly got a chewed thread. Its loose on that thing :/

But cant figure out a way to get inside to fix it...

It looks like its sealed with a heat rubber glue and has plastic tabs securing it in...

But ive tried with my heat gun to warm it up to pry it off... Just while exposed glue softens the stuff inside the bead seems to stay solid.

The outer plastic appears to show its PP. Which has a melting temp of 160c.

Family wont let me put this in the oven so thats out the question... any ideas?
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Yamaha FZ8/Fazer800 (split headlight one) 2014, gingerly getting used to the massive increase in HP and not killing myself in the process! That was easy to get used to.
Kawasaki ER6F 2007 650 Gonna sell as a project bike!
Lexmoto XTR S 125 Sold!
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NutsyUk
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PostPosted: 16:50 - 02 Feb 2023    Post subject: Reply with quote
got it in the oven... worked like a charm.
just under 100c 15 minutes...

And yes the 2 plastic nutes that aim the reflector are chewed through...
Why are these plastic!?

Anyway think im going to have to 3d print a metal nut retainer... I have some nuts that should fit these threads...
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Yamaha FZ8/Fazer800 (split headlight one) 2014, gingerly getting used to the massive increase in HP and not killing myself in the process! That was easy to get used to.
Kawasaki ER6F 2007 650 Gonna sell as a project bike!
Lexmoto XTR S 125 Sold!
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NutsyUk
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PostPosted: 17:24 - 02 Feb 2023    Post subject: Reply with quote
WTF! the bolt rails are M5 but have a nonstandard steeper thread. Not much but only just enough to not take M5 nuts D:


take it back it is M5... just that one bolt has a funky chewed top
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Yamaha FZ8/Fazer800 (split headlight one) 2014, gingerly getting used to the massive increase in HP and not killing myself in the process! That was easy to get used to.
Kawasaki ER6F 2007 650 Gonna sell as a project bike!
Lexmoto XTR S 125 Sold!
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Polarbear
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PostPosted: 21:22 - 02 Feb 2023    Post subject: Reply with quote
Do you always talk to yourself?
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NutsyUk
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PostPosted: 21:56 - 02 Feb 2023    Post subject: Reply with quote
Polarbear wrote:
Do you always talk to yourself?

Yep Very Happy
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Yamaha FZ8/Fazer800 (split headlight one) 2014, gingerly getting used to the massive increase in HP and not killing myself in the process! That was easy to get used to.
Kawasaki ER6F 2007 650 Gonna sell as a project bike!
Lexmoto XTR S 125 Sold!
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Zen Dog
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Joined: 11 Aug 2004
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PostPosted: 22:07 - 02 Feb 2023    Post subject: Reply with quote
NutsyUk wrote:
got it in the oven... worked like a charm.
just under 100c 15 minutes...

And yes the 2 plastic nutes that aim the reflector are chewed through...
Why are these plastic!?


That does seem particularly crap design, both the glue and the plastic nuts. I think Yamaha would much prefer it if you bought an entirely new light unit at vast expense when those plastic nuts wore through. Bad Yamaha. You've been naughty there.
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Current - '94 VFR750FR, '00 VFR800FI Previous - '10 Street Triple R, '92 MZ ETZ301, '05 TTR250, NSR125R, KMX125, "Honda" Win (chinese copy of an old Honda design with a C90 engine)
My bike trip around S.E. Asia 2010/2011
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A100man
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Joined: 19 Aug 2013
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PostPosted: 09:32 - 03 Feb 2023    Post subject: Reply with quote
NutsyUk wrote:
got it in the oven... worked like a charm.
just under 100c 15 minutes...


..a brave move - what 'Gas Mark' is that?
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Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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NutsyUk
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Joined: 22 Jun 2016
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PostPosted: 16:18 - 03 Feb 2023    Post subject: Reply with quote
A100man wrote:
NutsyUk wrote:
got it in the oven... worked like a charm.
just under 100c 15 minutes...


..a brave move - what 'Gas Mark' is that?

Gas mark tepid!

Youll need temperature control :p
The chassis is PP which has a melting point of 160C according to google. So just under 100c to melt the glue is safe.
____________________
Yamaha FZ8/Fazer800 (split headlight one) 2014, gingerly getting used to the massive increase in HP and not killing myself in the process! That was easy to get used to.
Kawasaki ER6F 2007 650 Gonna sell as a project bike!
Lexmoto XTR S 125 Sold!
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NutsyUk
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Joined: 22 Jun 2016
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PostPosted: 16:26 - 03 Feb 2023    Post subject: Reply with quote
Zen Dog wrote:
NutsyUk wrote:
got it in the oven... worked like a charm.
just under 100c 15 minutes...

And yes the 2 plastic nutes that aim the reflector are chewed through...
Why are these plastic!?


That does seem particularly crap design, both the glue and the plastic nuts. I think Yamaha would much prefer it if you bought an entirely new light unit at vast expense when those plastic nuts wore through. Bad Yamaha. You've been naughty there.


Even worse, the chrome is very very fragile D:
I had to try some chrome repair, turned into a can of worms Sad Damaged the chrome even more Sad

AAAND the bolts are also chewed up. struggling to get the new nuts back on now Sad
____________________
Yamaha FZ8/Fazer800 (split headlight one) 2014, gingerly getting used to the massive increase in HP and not killing myself in the process! That was easy to get used to.
Kawasaki ER6F 2007 650 Gonna sell as a project bike!
Lexmoto XTR S 125 Sold!
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