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Another Headlight Rattle Fix!

23K views 55 replies 20 participants last post by  reb2005 
#1 · (Edited)
As most of you know, our little rebs seems to have an issue with a rattle originating from the headlight. I purchased a rebel a week ago and have been trying to figure out what the heck the buzzing noise was at speed. If you reach forward while riding and hold the headlight and the buzzing stops, your problem is the infamous headlight rattle. No worries, you can fix that in about 10 minutes.

What you will need:

  • 8mm wrench or ratchet to remove outside bolts
  • #2 phillips head screwdriver
  • Closed cell foam tape (see picture below)

Start by removing the two bolts on the bottom of the headlight. Grab the now loose headlight, pull it out slightly, then down to unclip the top tab. It should hang freely like this..

Brass instrument Musical instrument Wind instrument Auto part Cornet


Now we must remove the ring that is around the headlight which is now dangling. Remove these two screws..

Electrical wiring Wire Auto part Tire Wheel


Once you have the two screws removed, you must remove the headlight aiming screw and spring. One of the screws is attached to the ring around the headlight, the other aiming screw is not. Remove the one that is attached to the ring around the headlight.

Now, get foam..

Auto part Tire Automotive wheel system Wire Subcompact car


I bought two sizes of foam. One thicker than the other.

Where to place thick foam:

  • Around inside of ring that is around headlight
  • On surfaces where the screws you removed touch when put together
  • In the can, running from front to back and connecting all the peices

Where to place thin foam:

  • Around the outer edge of the can (must be thinner in width, so cut a normal piece in half and place all the way around except for where the tab is on top)
  • In the slots on the tab
Place foam in these places..

Wire


Auto part Wheel Tire Automotive lighting Automotive tire


I hope this makes sense to everyone. I took her out for a ride after I put everything back together and heard NO NOISE. I actually like the sound of the bike now...
 
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#3 ·
Excellent pics! It should be noted that this headlight bucket is for the '01 and later years. I hope you don't mind that I made it a "sticky" since this is such a common problem.

TIP: measure the length of threads sticking out of the adjuster before you remove it. It will save you a lot of headlight aiming/adjusting later on. Picture shown has the screw removed already.



http://www.hondarebelforum.com/attachment.php?attachmentid=11703
 
#4 ·
Lacking the ambition to measure the threads, compress the string and blacken the threads on the front side of the threaded teflon adjuster nut with a sharpie. If you blacken the back side, you are permitted to be provoked but not surprised if it rubs off when you remove the screw.
 
#5 ·
I'm so glad I found this thread. I was wondering if anyone else had this annoying rattle. Mine rattles even when idling. I tried tightening up the screws & nuts, but that did not help. Off to Lowes for some foam tape today!
 
#7 ·
The foam tape seems to have done the trick. I only stuck it round the rim, the tabs where you screw the rim into the can and on the little tab at the top.

Now I will probably have to readjust the headlight beam as I screwed the adjuster screws in tight, thinking they were part of the fastening assembly. Any suggestions how to adjust the beam?
 
#9 ·
This one may or may not be a new issue in the Rebel rattle. I knew that my headlight was the source of the rattle. However, I didn't know what was causing it. Opening up the headlight I found that one of the adjusting screws had snapped where the screw post mounts to the bracket that sits over the back of the headlight.

Either the rattling broke this mounting point or the point breaking is the source of the rattle (I'm not sure which). Regardless, I'm in need of a new headlight since the aim constantly drifts to the left during rides and the "soundproofing" technique on here wouldn't solve the problem of the broken alignment screw mounting plate. I don't think I'll be able to repair the break. Looking around online I can't order just the metal bracket which that plate is welded onto. It's the one part in the parts diagram that has no number and is not able to be ordered (of course). Does anybody have any suggestions? I'd rather not pay $115 for an entire bulb assembly when all I need is that one part.
 
#11 ·
I don't like the design of the 2nd gen headlights, having adjustment screws like a car headlight is ridiculous when a simple bottom mount headlight can be adjusted at the mount much easier. I would ditch it for a simpler better made headlight.
 
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#15 ·
Also, with all the headlight rattle discussion, has anyone ever found a way to put pads or grommets between the frame and the headlight assembly? Everyone talks about wrapping the bucket. What about padding the points where the metal mounts to the metal on the forks?
 
#16 ·
The 450 and 2nd gen 250 headlights are different. The 450 has a sealed beam bulb and the 250 uses an H4 bulb. The 250 headlight doesn't rattle on the triple tree where it mounts, it rattles inside the bucket.
 
#17 ·
The 450 and 2nd gen 250 headlights are different. The 450 has a sealed beam bulb and the 250 uses an H4 bulb. The 250 headlight doesn't rattle on the triple tree where it mounts, it rattles inside the bucket.
I understand that the bulbs themselves are different. However, the ring that goes behind the lamp which the adjusting screws thread into appears to be the same in the '86 450 and the 2nd gen 250s.
 
#19 ·
Correction - I was wrong the 450 does use an H4 bulb. I don't know if the lights are the same diameter though, they might be.
I did some more digging and found that the part number is identified in the 2001 CMX250. I remember reading that '01 and up had the same headlight. I'm not sure why in '12 it isn't given a part number. However, it stands to reason that I can order the part for the '01 headlight and it should swap out one for one on the '12 headlight. The Headlight assembly part # for '01, '02, and '12 is the same.

It's part #12 in this diagram.

Part 33153-MM2-003
 
#21 ·
You may or may not agree but I would ditch the headlight and replace it with one that isn't as complicated with less parts to rattle/break. One that adjusts at the mount instead of adjusting screws and springs like a car.
 
#22 ·
You may or may not agree but I would ditch the headlight and replace it with one that isn't as complicated with less parts to rattle/break. One that adjusts at the mount instead of adjusting screws and springs like a car.
I probably should. I'll work with the stock light for now and if it gives me more trouble I'll look for a replacement. I guess I'll have to wrap the rim to make sure the vibrations don't give me any more trouble.

Do you happen to know if there's at least a better bulb that can swap in and use less power with more intensity? I'm not in need of the extra power right now. I'm just thinking ahead.
 
#23 ·
I really don't know. I don't think you will find one that uses less power with more intensity. You might find one that uses the same power with more intensity though. Maybe some of the 2001 and up owners can help you out with that.
 
#24 ·
This is great information, thank you. I'm interested to know if this has worked as a permanent solution to the headlight rattle problem. I found a solution somewhere online - perhaps on the forum here - that suggested cutting wedge-shaped foam blocks and putting them in all of the empty spaces around the brackets inside the bucket. That worked great for me for exactly one day. I put the foam shaped blocks in two days ago. Yesterday, I rode the whole morning with no vibration from the headlight, but took the bike out in the evening and found that my headlight vibration had returned with a vengeance.
 
#25 ·
I've been using one of Jack's headlights for several years. Great unit. Very simple mount, and two point adjustment. I had to replace the mountying bolt because the one that came with it was too short, but I haven't had to adjust it since I put it on. I posted pix of it somewhere. I'll look for them. As for the stock headlight buzz, I used gasket paper to silence it. It's very effective, but an ongoing process as the thing develops new buzzes as fast as you can fix them. I seriously considered foaming the thing with Greatstuff.
 
#26 ·
If I had a 2001-up Rebel I would do just what you did Fridg, ditch that noisy light for one that is solid. The Stock headlight is a terrible design for a motorcycle headlight.
 
#28 ·
I, too, am seriously considering foaming the inside of the headlight too. I would love to see what Jack's headlight looks like if you can find the pics. I plan to run a search on the forum for some pics myself as soon as I post this reply. I'm more than likely going to look into ordering one from Jack within the next couple weeks if I can't find a satisfactory solution relatively soon. The headlight vibration is the only bad thing I can nitpick about my otherwise fantastic 2013 Rebel. I really don't know why the vibrations in the headlight are so aggravating to me, but am relieved to know I'm not the only one. Honda must be aware of this problem, and I'm shocked they haven't fixed it in the headlights on the newer models.

Edit: Fridge, I posted my reply before I saw yours. Thanks so much for the pic!
 
#33 ·
I don't want to alarm you, but it appears as though a small child, or elf (or, perhaps an elfin child... :shrug: ) has wedged itself under your faring. I'm guessing you must've been going pretty fast (>120 mph) through that crosswalk by the school...

;)
 
#31 ·
FWIW, not all 2001 and up headlights rattle. The 2001, 2004, and 2009 I have don't rattle. That, or my hearing has gotten so bad I can't hear it over background noise!
 
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