Overhaul
Headlight AssemblyDISASSEMBLY
1. LENS
CAUTION:
- Do not touch the bulb glass portion.
- Do not touch inside the lens (extension portion) or reflector portion.
- Replace the packing with a new part.
1. Remove the headlight assembly.
2. Disconnect the headlight bulb connector.
3. Remove the back cover and then remove the bulb.
4. Use a drier to warm up the area around the seal through the bulb installation hole.
CAUTION: Avoid heating one specific point of the seal portion and heating the headlight assembly to 120 °C (248 °F) or more.
5. Remove the hook, and then take the lens off the headlight assembly.
6. Remove the packing (A) from seal groove.
CAUTION: Completely remove the packing not to leave any residue behind.
2. HID HEADLIGHT BALLAST
CAUTION:
- Do not operate with wet hands.
- As the lightening circuit on the HID headlights uses high voltage, be sure to confirm that the power supply is turned off before working on it.
- Do not leave the headlight without a ballast for a long time. Dust, moisture, etc. entering the headlight may affect its performance.
1. Disconnect the ground cable from the battery.
2. Remove the headlight assembly.
3. Remove the back cover.
4. Disconnect the harness connector.
5. Loosen the screws to remove ballast.
6. Disconnect the connector from the headlight ballast.
CAUTION: Be careful because the notch is easily bent.
7. Turn the beam adjustment screw so that the beam is facing upward, then create space for the socket portion to pass through the inside of the light.
CAUTION: The reflector should not interfere with the extension case.
8. Place the socket portion toward the front side of the reflector bracket.
9. Turn the beam adjustment screw so that the beam is facing downward, then create space for the socket portion to pass under the reflector bracket.
CAUTION: The reflector should not interfere with the extension case.
10. Remove the socket from headlight from below the housing.
CAUTION: The socket should not get sandwiched between the reflector and the light housing.
ASSEMBLY
1. LENS
1. Cut the tip of packing (A) at an angle of 45°.
2. With the cut end facing upward, insert packing (A) into the seal groove.
CAUTION:
- If the packing protrudes, slowly take it off the groove.
- Do not stretch the packing. If the packing is stretched, seal fails.
3. After making a round of the seal, cut its tip at an angle of 45°, with its length 10 mm (0.39 in) longer than the circumference of seal so that the tip overlaps the other. Then, press it onto the seal, using a screwdriver.
4. Match the positions of the lens and headlight assembly, and then insert the lens into the headlight assembly.
5. Engage the hooks.
6. Put the seal portion of headlight assembly into the water and check that water does not enter inside the headlight.
CAUTION: Be sure that water does not enter inside the headlight through the bulb socket and ventilation hole.