Head light issues

[81xsproject]

Since I've had my xs the head light won't adjust down enough to really even hit the road. So, I took it apart last night and it was obviously put together wrong by a PO. When I tried to put it back together I saw why. For some reason, the hole between parts 3 and 5 won't line up? Am I missing something?

Sorry for the giant image, it was just too easy to copy the link from Bike Bandit.

[randy]

Is your part #4 the original or did the PO substitute an off-the-shelf sealed beam lamp?

[81xsproject]

because it is the replacable bulb type I assume it is stock...

[randy]

That's good, sounds like the stock lamp.

Now for the next scenario:

The jumble of connectors inside the headlight bucket can interfere with the fit of the lamp assembly. Try not to bunch them up directly behind the lamp, rather fan the wiring bundles out radially. Then try to fit the lamp.

[DiverRay]

You may also want to check the part #5. Did he put it in upside down? The headlights all have the locating tabs, but the frame must be installed correctly.
Just my guess.
Ray

[81xsproject]

it fits in the bucket fine it is just that the screw holes don't line up even close between 3 and 5. They hold the actual light. The slots on five are lined up with the ones on the back of the light.

[TopCatGr58]

Hey Jess,

Are you saying that the actual position around the curve of the Part #3 don't line up with the holes positioned on Part #5, or that the holes on part #3 don't get close enough to part #5 for the little screws to reach??

The PO may have put in an aftermarket bulb reflector housing?? I put in an aftermarket one, and the rim of the holder was a bit different, and thicker, and took a bit of tweeking to get the holding ring to fit and get close enough to fasten the retaining screws!?
T.C.

[81xsproject]

the holes would reach if they were lined up. So, your first guess.

[pathfinder]

Sounds to me like part # 3 is from a different model bike. Try getting a another ring. Could be all wrong, but PO's have done stranger things.

[Pat Kelly]

#3 may be in the wrong position. Thry removing it from the headlamp and installing it by itself. Rotate it to different positions.