headlight unit

[zippy500]

Is it possible to replace just the sealed lamp unit from within the housing, or does the whole unit need to be replaced

[Mike Self]

housings, so yes, you can do what you describe.

You have to remove the grille to access the three small screws that hold the headlight retainer--the chrome ring that keeps the headlight from falling out. Once the retainer is removed, you can pull the headlight out, unplug it from the wiring harness and install a new one.

Suggest replacing the three screws with stainless stee so they won't rust again...makes for easier replacement the next time.

cheers

mike

[SteveJ]

To add to what Mike said...

And as you remove the grille, remember there are four oval head philips screws (2 top, 2 bottom) AND the aluminum J-hook at the outside edge. Look down behind the headlight and you'll see a plastic knurled nut at the bottom edge. Unscrew it, don't drop it down the fender.

When you go to re-install the grille, aim the j-hook into the hole first as you put things back. There is supposed to be a plastic grommet that helps hold the hook in place.

Make sure you have contact with the screwdriver on the retainer ring screws. If the lamps have never been replaced, I'd maybe put a drop of oil on the screws before trying to remove them. You are dealing with some soft metal.