AussieGlenn's Headlight Rattle Dilemma

Print
User Rating: / 40
PoorBest 
Written by Glenn Martin   
Friday, 11 June 2004

Reprinted by Permission from Mr Tidy's Tech Tips

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. 

AussieGlenn
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:http://members.delphi.com/reachforstar/ 
2000 Crimson/Cherry ISRA#1905



Questions should be asked in our forum (Use discuss link below). The forum is very active and you stand a good chance of getting your questions answered there. If you would like to leave feedback for the author, or have additional information you think will benefit others, please use the comment section at the bottom of this page.

Discuss this article on the forums. (0 posts)


DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.


Quote this article on your site | Views: 23529

  Comments (10)
gummy tire plugs
Written by appkrill, on 06-26-2015 17:31
I cut up some gummy tire plugs to wrap the headlight bezel and used bubble wrap on the wires and my rattles are gone. watch your fingers when cutting the plugs :-). i'll write back in a few weeks to comment on longevity of the fix but I have huge expectations... of corse.
Written by Stocked, on 10-20-2013 11:46
I'm getting a high pitched chirping at cursing speed that is driving me nuts, I've had the headlamp off four times now and have tried, bending the tabs a little, placing some foam around the tabs , tried a rubber strip up top as well. It's still there. I am actually suspecting the rattle/chirping to be coming from the headlight focusing springs at this point because I can't find anywhere else to look. I'm going crazy trying to find the thing.
Thanks for the help!!!
Written by ragation, on 06-16-2013 20:05
This solution worked perfectly. I used some adhesive felt pads on the hooks and used foam packing wrap in lieu of bubble wrap. Silence is golden! Thanks Glenn!!!
Headlight rattle
Written by Thumper1, on 04-26-2013 15:55
My headlight rattle was due to one of the spot welded brackets inside the headlamp bucket, the spot weld broke. Had to drill a small clearance hole for a sheet metal screw until i can can get it re-spot welded. One whole side of the headlight was completly loose. 1999 R*
head light rattle
Written by sundance, on 06-16-2011 15:24
I did the stuff around the housing etc and it took some of the rattle away, however my headlight lens also rattled. I took some of the double sided sticky rubber you get at the auto parts store and did the same as around the headlight housing. This fixed my problem. :)
Head light rattle on 05 Road Star
Written by jdmac, on 08-06-2010 11:58
I know it has been a while since the last comment on these rattles but i had a noise/rattle/vibration that was driving me nuts at certain RPM intervals. It really didn't even sound as though it was coming from the headlight but after researching everywhere and finally reading AussieGlenns comments and already filling the headlight "bowl" with cotton fabric, towels etc. i thought i would try the tape around the contact points between the lens and headlight bowl. 
 
I actually used electrical tape and ran a single strip all the way around where the metal touches and put it back together. To my complete amazement all the noises i was hearing are gone..... I am soooo happy, my only problem now is i had almost grown used to waiting on the rattle as a time to shift...HaHa!
Front lightbar rattle
Written by mike59, on 10-17-2009 10:06
Hello I am new to this board and I am looking for some help please. 
I am riding a 1999 Roadstar with Roadhouse Dooleys. I have a stock light bar which I have removed do to the amount of vibration on the bike. 
 
Has anyone run into this problem? I am looking at ways how to fix it or is it better to look at a different light bar which is smaller and lighter? 
 
Regards, 
Mike
FELT PADS
Written by BHD, on 10-29-2008 15:00
My 05 Roadstar had the same problem. My rattle started on return trip fom Nags Head NC to Harpers Ferry WV. Stopped at nearly every rest area trying to figure out where it was. It's been driving me crazy for months. I took off the windshield and grabbed the headlight visor and it stopped so I thought it was the visor. After much work on visor I checked out this site. I tried the felt pads on the bucket by the tabs and finally No Rattle. Thanks guys
thanks for the tip
Written by BlackHorse, on 09-03-2008 15:16
I have been trying to correct my more-than-a-little-frustrating headlight-bucket-rattle for two years now--without lasting success. I will give these solutions a try and get back to you.
This is another oissible soution.....
Written by jepaul2438, on 07-27-2008 14:48
I have an 00 RS recently purchased. A rattle at certain RPM regardless of gear was very obvious. I found this article and thought this would be my solution but what I discovered when I removed the headlight cover was that the rattle was still there. I tapped on the front forks and other items to determine the source and discovered that the plastic decorative cap on the turn signal bar was touching the quick release windshield plate. After removal of the cover, 90 percent of the rattle was gone. The remaining noise came from the headlight and I used this fix to remove most of that.

Only registered users can write comments.
Please login or register.

Powered by AkoComment Tweaked Special Edition v.1.4.6
AkoComment © Copyright 2004 by Arthur Konze - www.mamboportal.com
All right reserved

 
...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... -->



The Road Star Clinic is a collaborative community of riders who archive and publish user contributed technical data about Yamaha Road Star motorcycles.

We also sponsor the creation and support of other community websites similar to our own. Inquiries about availability of a website for your community can be submitted to us via any "Contact Us" option on the Clinic.

Copyright 2003-2007 Road Star Clinic and its respective authors. Road Star Clinic is sponsored by the folks at MLSHomeQuest.com.