Headlight POD keeps breaking

[camoman]

I can't seem to repair my headlight pod and keep it from snapping the tabs off. I have tried reinforcing it with TECH Steel (hard putty like steel) but it sees when I hit some good moguls she breaks the tabs off! I ended up tie straping the thing down on the trail and they actually held pretty good. I'm thinking of a combo of fixing the tabs again and tie strapping it down??

Has anyone found a good fix for this? I can't be the only one with this issue.

 

[camoman]

Found this from another post.. think I will try it!

 

[sledneck22]

Both my tabs ended up breaking on their own so I drilled a 3/8" hole and put alluminum tape around it then used zip-ties to hold it back in place. I was never able to keep the tabs from breaking but now that I have it zip tied inplace I haven't had any problems. The only shitty thing is having to get new tie straps everytime you take the headlight off and only being able to use my low beams because my brights are shooting to the trees looking for coons!

 

[arcticace]

l used a block of plastic, I cut it so it fit inside the upper and lower flange part , used self tapping screws on the top, bottom and front, drilled a hole and used a wood screw to tighten pod to mount. l guess i should take a pic, because it seems hard to explain. but real easy and has lasted 3 yrs now with no problems.

 

[arcticace]

l used a block of plastic, I cut it so it fit inside the upper and lower flange part , used self tapping screws on the top, bottom and front, drilled a hole and used a wood screw to tighten pod to mount. l guess i should take a pic, because it seems hard to explain. but real easy and has lasted 3 yrs now with no problems.

 

[JFC]

One of mine broke. The Yamaha YES Warranty covered it no questions asked.

 

[arcticace]

headlight fix

pics, hopes this helps.

 

[favarcat]

Both my tabs ended up breaking on their own so I drilled a 3/8" hole and put alluminum tape around it then used zip-ties to hold it back in place. I was never able to keep the tabs from breaking but now that I have it zip tied inplace I haven't had any problems. The only shitty thing is having to get new tie straps everytime you take the headlight off and only being able to use my low beams because my brights are shooting to the trees looking for coons!

I also drilled holes and zip tied it. The best fix so far for me. When you have to remove the headlight pod, keep it zip tied and remove the whole bracket. Just 4 screws.

 

[arcticace]

hope the pics help, sry they got deleted earlier.

 

[mdkuni]

Careful with how tight you tighten the two bolts down. The headlight assembly moves quite a bit as the bracket it slides onto is flexible.

I have found that by making sure the bolts are just lightly tightened the tabs will last. Not sure if this allows a little more give or what, but I have not broken any tabs since.

 

[Sportfury]

headlight fix

I re-enforced mine with 1/8 in aluminum and used rivits and 2 stage epoxy worked great . wish i had pictures to show next time i take off I will post. both sides broke off fixed them both

 

[camoman]

Re: headlight fix

I re-enforced mine with 1/8 in aluminum and used rivits and 2 stage epoxy worked great . wish i had pictures to show next time i take off I will post. both sides broke off fixed them both

I ended up doing something very similar. I used 1/4" wall 1/2" steel flat bar , bent to fit , riveted it in and then used jbweld as well. I tapped the holes right into the steel bracket so I could bolt it back in. I also used two tie stainless tie straps to help secure it. Rode all weekend, hit lots of jumps etc and still strong!

 

[SnowBandit]

That first pic is what I did.... Not sure but that might even be my head light ad it looks the exact same...

 

[bashley]

I did the steel repair putty on mine too and also glued on some metal reinforcement plates (not pictured but they cover the flat area where the crack is and opposite side).
So far so good, but haven't taken good spills or roll overs yet.

 

[irondog rtx]

I wish someone would come up with a update kite for climers so they could drop there pods fast for high marking and hill climbing