lawmanbsi
Expert
I rolled my sled last winter and broke the rear mounting tabs on the headlight. I looked at it several times trying to figure out how I could build the tab back to mount it in the mounting holes 
. I've posted a couple times looking for a replacement headlight assy. I just couldn't justify spending a $100 to $200+ on an used or new one.
1. I drilled a 1/4" hole in the bottom of the remaining tab.
2. Cut a 2 1/2" piece of threaded rod
3. placed that in the hole to mark it on top of the mounting bracket.
4. Drilled the holes
5. put 4 nuts on the rod and set light assy in place. 1 under the mount and 1 on top of the mount. then 1 under the tab and 1 on top of the tab.
Cost about $1 for both side and took about 20 minutes from bright idea to done.
I took pictures and will post them later
. I've posted a couple times looking for a replacement headlight assy. I just couldn't justify spending a $100 to $200+ on an used or new one.1. I drilled a 1/4" hole in the bottom of the remaining tab.
2. Cut a 2 1/2" piece of threaded rod
3. placed that in the hole to mark it on top of the mounting bracket.
4. Drilled the holes
5. put 4 nuts on the rod and set light assy in place. 1 under the mount and 1 on top of the mount. then 1 under the tab and 1 on top of the tab.
Cost about $1 for both side and took about 20 minutes from bright idea to done.
I took pictures and will post them later
lawmanbsi
Expert
Simple fix, hope it works out.
headlight fix
I did something similar but used pieces of rubber hose as washers to help with vibration and such.
I did something similar but used pieces of rubber hose as washers to help with vibration and such.
lawmanbsi
Expert
I need to place some washers and dab of thread lock once I'm set on height. Didn't want to commit until I knew the aim was good. I made the hole elongated so I could adjust the side to side aim. Measured it from center to side and it straight but that doesn't mean its good.
ITHAPPENS
Expert
Glad to see common sense is alive and kicking. Well done! 
lawmanbsi
Expert
The beauty of it is that my insurance paid me $500 to fix or replace it.
THANK YOU VERY MUCH.
THANK YOU VERY MUCH.
NY AttakGT
TY 4 Stroke Guru
lawmanbsi said:
So you made an insurance claim because the headlight pod tabs were broken? Or was there an accident involved?
lawmanbsi
Expert
1st sentemce in the 1st post. I rolled my sled last year. so techniquely it was $250. Just if if it happens again I'll have to buy the light assy. Already got the new windshield and cowl pieces
hayastusa
Pro
That'll do for a couple of rides. They just keep breaking elsewhere until there is no more plastic tab left.
lawmanbsi
Expert
Didn't really want to here that. I'm going to have to ride it to make sure it's set right. I could fill in the support tabs with an epoxy resin that would increase the strength of the remaining tab. At least box in the tabs.
Actually with this setup I don't need the tabs. I should be able to weld or bond new tabs in. If anyone know what type of plastic the tabs are made of and what would works best for gluing or welding new tabs on let me know.
Worst case it makes for quick cheap repair idea for the next guy if they break while out on a trip. I know it cost me about 3hrs of riding on the first day of a four day trip.
Actually with this setup I don't need the tabs. I should be able to weld or bond new tabs in. If anyone know what type of plastic the tabs are made of and what would works best for gluing or welding new tabs on let me know.
Worst case it makes for quick cheap repair idea for the next guy if they break while out on a trip. I know it cost me about 3hrs of riding on the first day of a four day trip.
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