SuzukiSavage.com - Headlight rattle

Starlifter

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Headlight rattle
08/02/07 at 16:04:18

I seem to have developed quite a headlight rattle. If I press the lens in at speed it quiets. Everything seems to be tight, and I'm not sure just what it is that's ratteling.
Checked the tech/fixes section and I don't seem to see anything about a fix.
I can get the light assembly apart with no trouble, so has anyone had this problem and successfully fixed it?
Thanks.

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Strafford_Guy

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Re: Headlight rattle
Reply #1 - 08/02/07 at 16:07:04

There is a headlight rattle -- take the two screws off on the bottom of the headlight and take the ring assembly off the hollow housing. First, make sure all your loose wires, guts and connectors are being held down correctly by the wire ties & such and are not kicking around loose. Tuck them in nicely and tighten those wire ties down over them to hold them properly in place.

Posted bt Oldfeller2 - Jul 5th, 2007

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toddlamp8 Full Member Offline I love YaBB 1G - SP1! Posts: 241 Gender:	Re: Headlight rattle Reply #2 - 08/02/07 at 16:10:09 My rattle is the outter ring. When I took it apart after buying it (to change the light bulb) I noticed there was electrical tape on the top, inside, of the ring. I took it off and now I get a bad rattle. I plan to put tape back on to fill the gap.
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Strafford_Guy

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Re: Headlight rattle
Reply #3 - 08/02/07 at 16:14:00

Heres another fix
Dr_Jim Jul 12th, 2007

Turns out that the lamp and glass are mounted in a flexible holder which secures them to the plastic headlight bucket. This holder may not seat properly against the blessed bucket - especially if the bucket has gotten hot - and then it works back & forth against the three small seating shoulders cast into the bucket.

My solution was crude, but effective, three narrow strips of double-sticky foam tape between the holder and the bucket's shoulders seem to have cured the buzz. I also taped the internal connectors to each other and stuck them firmly down to the holder too.
Dr_Jim Jul 12th, 2007

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Starlifter Serious Thumper Offline It only snows seven months of the year here. Posts: 3746 Eastern Michigan Gender:	Re: Headlight rattle Reply #4 - 08/02/07 at 18:46:30 Thanks for all the info, I'll start on the fix in the morning.
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skatnbnc Serious Thumper Offline Spinning Pink Posts: 1286 New Bern NC Gender:	Re: Headlight rattle Reply #5 - 08/02/07 at 18:52:44 You can try various thicknesses of the foam tape or rubber bumper tape used to draft seal windows and doors. They come in small rolls and you can use the remaining for any future rattling.
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Starlifter Serious Thumper Offline It only snows seven months of the year here. Posts: 3746 Eastern Michigan Gender:	Re: Headlight rattle Reply #6 - 08/02/07 at 20:41:34 Great idea! I have a roll of that in the garage now.
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Rogue_Cheddar

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Re: Headlight rattle
Reply #7 - 08/03/07 at 09:47:40

I just fixed my headlight rattle about a month ago. I had a strip or foam weather stripping laying around, so I used that. the strip was about 1 1/2" w x 1/2" thick about 15" long. I was able to cut up several pieces to fit arount the headlight bracket and another strip across the back of the bucket. From what I could see, it looked like the wiring harness was smacking the back of the plastic bucket, as there were a number of wear spots there. Put it all back together, not a peep. The rattle was so loud before, it drowned out the engine noise, and probably any noise coming from my drive pulley that now needs replacing. See my post on Got The Drive Pulley Blues.

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Headlight rattle Reply #8 - 08/03/07 at 10:05:09 I used clear silicon sealant as a rubber vibration insulator, especially since I have a visor installed. It vibrates badly otherwise.
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Starlifter Serious Thumper Offline It only snows seven months of the year here. Posts: 3746 Eastern Michigan Gender:	Re: Headlight rattle Reply #9 - 08/03/07 at 13:42:38 There are some very good and practical fixes here for the headlight rattle problem. I wonder if we can get these responses/fixes moved to the Tech/Ref section for future reference for others. Thanks to everyone for their input.
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Oldfeller2

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Re: Headlight rattle
Reply #10 - 08/03/07 at 16:36:38

Don't quote the boy half the fix, half of it won't always fix what he's got -- a loose hook fit up.

====================

There is a headlight rattle -- take the two screws off on the bottom of the headlight and take the ring assembly off the hollow housing. First, make sure all your loose wires, guts and connectors are being held down correctly by the wire ties & such and are not kicking around loose. Tuck them in nicely and tighten those wire ties down over them to hold them properly in place.

Any remaining headlight rattle most likely comes from the single steel hook on the top side of the ring assembly where it has made itself some vibratory clearance to the single ribbed boss on the top of the plastic hollow housing. Apply a dab of red silicone gasket sealant to the sheet metal hook so when you put it together it makes a silicone rubber buffered seal to the ribbed plastic boss. You will be able to take this apart later, just go gently when you go about doing it as that piece of plastic is worth WAY TOO MUCH MONEY -- so please don't force it and break it. The silicone will let go first, be patient.

====================

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Strafford_Guy Full Member Offline 96 in progress Posts: 238 Strafford, NH Gender:	Re: Headlight rattle Reply #11 - 08/04/07 at 10:38:04 "Don't quote the boy half the fix, half of it won't always fix what he's got -- a loose hook fit up" Sorry Oldfeller2, I am not sure why I did not offer the complete information. An oversite on my part. Could have been disctracted bt the rattle in the keyboard
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CalisOsin Senior Member Offline Rather die, than live down on my knees. Posts: 297 Orange County, Ca Gender:	Re: Headlight rattle Reply #12 - 06/17/10 at 07:06:35 Another great fix guys, thanks very much, that rattle was driving me crazy! Oldfeller you were right, the weather stripping didn't quite do it but some gasket sealant quickly eliminated the problem. You guys are awesome!
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MarkHB

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Re: Headlight rattle
Reply #13 - 05/22/14 at 12:05:26

I didn't have any foam tape or weatherstripping around, but I did have a package of those little self-adhesive felt pads you'd put on the inside surface of a cupboard door at the corners. I placed five of those roughly equidistant around the inside rim of the housing where the outer ring seats, and it seems to have done the job nicely.

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