Busted Headlight Lens - BMW Luxury Touring Community
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post #1 of 12 Old Mar 2nd, 2016, 4:29 pm Thread Starter
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Busted Headlight Lens

All y'all...

My headlight lens on my '02 LT busted on a recent trip along the Rio Grande. There is a hole in the glass and I can no longer pass inspection. I am trying to figure out my options. Is it possible to simply replace the glass or do I need to grab an entire headlight unit?

I can figure out how to replace bulbs but I need to replace the lens, which I suspect is not possible, in which case, how do I remove the entire headlight unit and replace it. I've seen nothing posted about this anywhere. I've looked at a replacement headlight unit on Beemer Boneyard and it looks like there are two screws on the sides that must be impossible to access up under the nose cone of the bike. Does this mean I have to take off all of the engine cladding and trim just to replace the headlight unit?

Anybody have recommendations for the best course of action?

Jim Bob in Texas

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post #2 of 12 Old Mar 2nd, 2016, 5:03 pm
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Re: Busted Headlight Lens

Try Beemer Boneyard or a similar recycler. Also EBay has a good selection of used motorcycle parts.
2002 BMW K1200LT K 1200 Lt S584 Headlight Housing Assembly | eBay
http://www.ebay.com/itm/HEADLIGHT-BM...ZWumaJ&vxp=mtr


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post #3 of 12 Old Mar 2nd, 2016, 5:15 pm
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Re: Busted Headlight Lens

This one looks good;
BMW 63122305400 K1200LT Headlight | eBay
Darn things are $600 at the dealer.

Beech
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post #4 of 12 Old Mar 2nd, 2016, 6:57 pm Thread Starter
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Re: Busted Headlight Lens

Thanks. I've found plenty of headlight units. What I am baffled by is how do I remove the present one and put in the replacement without taking off all of the trim/cladding on the side. Is that actually necessary?
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post #5 of 12 Old Mar 2nd, 2016, 9:28 pm
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Re: Busted Headlight Lens

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Originally Posted by JamesRobertBob View Post
What I am baffled by is how do I remove the present one and put in the replacement without taking off all of the trim/cladding on the side. Is that actually necessary?
Unfortunately you will have to remove the left and right upper tupperware and nose cone to access the head light assembly. Its not a difficult job, but it can be a slightly time consuming. I can do it in an hour, but I've had practice with it over the past year installing HID lights. The only gotcha is the hidden screw at the top front of the nose cone. Otherwise, make a note on the electrical connections to the nose cone for reassembly. I forgot to reattached one the first time I had the nose cone off and thought I really screwed something up when I didn't get power to my headlights.

Rob, 2000LT
Navarre, FL
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post #6 of 12 Old Mar 2nd, 2016, 10:08 pm
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Re: Busted Headlight Lens

I have a headlight assembly for sale from my 03' in the classifieds section. I'd be happy to talk with you about a price if you're interested.
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post #7 of 12 Old Mar 3rd, 2016, 6:59 am Thread Starter
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Re: Busted Headlight Lens

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I have a headlight assembly for sale from my 03' in the classifieds section. I'd be happy to talk with you about a price if you're interested.
I will go to classifieds and check it out. Thanks....

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post #8 of 12 Old Mar 3rd, 2016, 7:01 am Thread Starter
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Re: Busted Headlight Lens

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Unfortunately you will have to remove the left and right upper tupperware and nose cone to access the head light assembly. Its not a difficult job, but it can be a slightly time consuming. I can do it in an hour, but I've had practice with it over the past year installing HID lights. The only gotcha is the hidden screw at the top front of the nose cone. Otherwise, make a note on the electrical connections to the nose cone for reassembly. I forgot to reattached one the first time I had the nose cone off and thought I really screwed something up when I didn't get power to my headlights.

Rob, 2000LT
Navarre, FL
Thanks very much for this. Exactly what I needed to know. I've taken off the tupperware on one side to repair quick release fuel lines so I know what I am up against. Have never messed with a headlight or a nose cone but I reckon I will figure it out. - Jim Bob
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post #9 of 12 Old Mar 6th, 2016, 12:16 pm Thread Starter
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Re: Busted Headlight Lens

I am still having a bit of a hard time believing that in order to replace my headlight assembly I have to remove, according to all of the advice I've received here, the tupperware on both sides of the bike, the windscreen, instrument panel cover, and finally that allows me to remove the nose cone to get at the headlight. Is this the storied BMW engineering I've heard about all my life?

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post #10 of 12 Old Mar 6th, 2016, 1:02 pm
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Re: Busted Headlight Lens

You saw the pictures of where the three screws are and the adjuster cable. If you think you can squat in front of the tire and lay back on the fender while you reach up in that cramped space, then you will not have to remove any tupperware. But it will be a heck of a lot easier if you do.

And yes BMW's storied engineering is strictly for performance and not maintenance.

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post #11 of 12 Old Mar 6th, 2016, 1:25 pm
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Re: Busted Headlight Lens

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Originally Posted by JamesRobertBob View Post
I am still having a bit of a hard time believing that in order to replace my headlight assembly I have to remove, according to all of the advice I've received here, the tupperware on both sides of the bike, the windscreen, instrument panel cover, and finally that allows me to remove the nose cone to get at the headlight. Is this the storied BMW engineering I've heard about all my life?
It seems like a lot, but it is not difficult. Get the Clymer manual and you'll see it's not that bad.
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post #12 of 12 Old Mar 9th, 2016, 5:26 pm
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Re: Busted Headlight Lens

If you look at the first picture above, you'll see that the windscreen and instrument panel cover do not need to be "removed". Once you get the side panels off, it's 4 screws from the base of the instrument panel cover (where the windscreen sits), that hidden screw behind the map light, that other hidden screw under the front of the instrument panel cover, 2 of the 3 mirror mounts on each side, and 3 other screws along the bottom of each side. Then it's just unplugging wires. On reassembly, note the tiny notches at the very top of the mirror surround that must be tucked in for alignment.

'15 GTLE


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Last edited by smahon; Mar 9th, 2016 at 5:40 pm.
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