1. Some members were not receiving emails sent from XJbikes.com. For example: "Forgot your password?" function to reset your password would not send email to some members. I believe this has been resolved now. Please use "Contact Us" form (see page footer link) if you still have email issues. SnoSheriff

    Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

Broken XJ900 headlight bezel?

Discussion in 'XJ Technical Chat' started by co.dirtbiker, Apr 8, 2025.

  1. co.dirtbiker

    co.dirtbiker Active Member

    Messages:
    180
    Likes Received:
    106
    Trophy Points:
    43
    Location:
    Colorado, USA
    Took the headlight out of my '83 XJ900 to see what was back there, and I think I found a problem. It appears the only thing holding the headlight in place are the two spring loaded adjustment screws. This allows the headlight to bounce around.

    It looks like there is some sort of 3rd mounting tab on the top of the headlight that is possibly supposed to latch it to some sort of corresponding tab on the bezel. But it appears the bezel side is broken off.

    What is it supposed to look like?

    upload_2025-4-8_19-10-58.png
     
  2. Franz

    Franz Well-Known Member

    Messages:
    4,096
    Likes Received:
    1,160
    Trophy Points:
    113
    Location:
    Scotland UK.
    You are right there is a recess in my 1991 900f fairing that tab fits into which stops it bouncing around. The screws and springs then allow for adjustment for headlamp aim.
     
  3. Franz

    Franz Well-Known Member

    Messages:
    4,096
    Likes Received:
    1,160
    Trophy Points:
    113
    Location:
    Scotland UK.
    20250409_105313.jpg
     
  4. co.dirtbiker

    co.dirtbiker Active Member

    Messages:
    180
    Likes Received:
    106
    Trophy Points:
    43
    Location:
    Colorado, USA
    Thanks @Franz. The tab that hooks into the fairing is ok. The part I am referring to is the one circled here. It looks like this the remnants of a tab spot welded in place, and the other side is completely missing. Can you get a photo of what the bracket is supposed to look like? Maybe I can manufacture something and rivet it in place.

    upload_2025-4-9_6-50-25.png
     
    Last edited: Apr 9, 2025
  5. Franz

    Franz Well-Known Member

    Messages:
    4,096
    Likes Received:
    1,160
    Trophy Points:
    113
    Location:
    Scotland UK.
  6. Franz

    Franz Well-Known Member

    Messages:
    4,096
    Likes Received:
    1,160
    Trophy Points:
    113
    Location:
    Scotland UK.
    There is no spring retaining bracket on the other side.

    Screenshot_20250409_144503_Samsung Internet.jpg

    Perhaps Chacal has one in stock?
     
  7. co.dirtbiker

    co.dirtbiker Active Member

    Messages:
    180
    Likes Received:
    106
    Trophy Points:
    43
    Location:
    Colorado, USA
    Yep. Looks like my bracket that the spring pushes the headlight into is broken/missing. Areas circled in red (and the spring) are missing on mine and the part circled in green is still there but broken.

    upload_2025-4-9_10-0-10.png

    Actually, found one on eBay that looks pretty good only costing an arm without the leg and includes the headlight. Guess it will be good to have a spare headlight too. Talked to seller and confirmed it's in good shape, and I can see the spring in their photos, so pulled the trigger. I have too much else to get done to sit there messing with trying to fabricate something, even though it would probably be a free fix. Maybe when I have more time I can try to rig something up.
     
    Franz likes this.

Share This Page