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shayne's Headlight Buzz fix
Headlight Buzz fix for Rebel
This is a mirror/reprint of a thread by shayne :
as found on the surfmaine REBEL FORUM message board ...
I fixed my headlight buzz through the rebel board here. But I had to piece together several posts, mix in a little guess work and trial and error. So I figured I'd share my experience with the board in hopes that is helps someone else fix this annoying problem.
Mine was a 56-62 mph buzz. The same range I usually ride in on the open road. I had the source down early on but the board provided the best pointer in obtaining a fix.
I used open cell foam cut from a piece of printer packaging. See below.
I thought about styrofoam, but it appears too crumbly and less apt to deal with the heat from the bulb.
Now for the removal. Being as I am an American, I used a 5/16" socket to take out the 2 metric hex screws at the 8 and 4 oclock positions on the bottom of the head light. Then I swung the bottom out towards me and unhooked the top of the light from the plastic chrome headlight dish. I laid in on top of a towel on the front fender. See below.
I then cut the foam blocked to fit in brackets around the edge at the 10, 2 and 6 oclock positions. Cut your blocks too thick, so when you try to fit it into the headlight dish there is not enough room to push it all the way in. Then trim the blocks equally to allow just a little pressure when reinstalling the headlamp. I had cut 3 sets of 3 blocks in anticipation of not having enough pressure on the light to stop the rattle. When I put the first set in, I had thought I cut off too much and that it would not help.
But as it turns out. You need very little pressure to stop the virbration. You can see in the picture below how much the foam block sticks out past the headlight rim.
So don't cut your foam blocks so thick on the first try that you can't stuff it all back in. It should take little to no pressure to reassemble. After hooking the top of the light I closed it back down to start the two hex screws with just one index finger. Tighten the two hex screws, a 5/16 will work. I hope this helps some people. I'll let you know in a few weeks how my modification has held up. Be safe and keep the shiny side up.
The Original Thread for this Discussion is located at ... surfmaine REBEL FORUM - Headlight Buzz Fix
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