Another Headlight Rattle Fix! - Honda Rebel Forum
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post #1 of 55 Old 06-16-2013, 05:36 PM Thread Starter
 
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Join Date: May 2013
Location: Iowa City, IA
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Another Headlight Rattle Fix!

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..

20130616_143002.jpg

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

Step Screws.jpg

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..

20130616_152345.jpg

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..

Foams.jpg

foams2.jpg

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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post #2 of 55 Old 06-16-2013, 05:41 PM Thread Starter
 
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Here is a better picture of the adjuster screw and spring to remove...

Adjuster Screw.jpg
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post #3 of 55 Old 06-16-2013, 08:32 PM
 
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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.



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post #4 of 55 Old 06-16-2013, 10:48 PM
 
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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.

No Fool Like an Old Fool

86 Rebel 250 / basket case - impulse buy
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post #5 of 55 Old 03-11-2014, 09:09 AM
 
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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!

=========================
Newbie motorcyclist.
2006 Honda Rebel 250
2011 Triumph Bonneville T100
.............................................
.............................................
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post #6 of 55 Old 03-11-2014, 11:25 AM
 
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I just put some electrical tape around the edge of the bucket... rattle gone...


Hers 2001 Honda Rebel 250
His 1999 Honda ACE Deluxe 750

If you don't turn around to look at it when you walk away, you bought the wrong bike!
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post #7 of 55 Old 03-12-2014, 12:19 PM
 
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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?

=========================
Newbie motorcyclist.
2006 Honda Rebel 250
2011 Triumph Bonneville T100
.............................................
.............................................
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post #8 of 55 Old 03-12-2014, 02:40 PM
 
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???? Honda Rebel 250 (...still shopping!)
Road:
1996 Lemond Alpe d'Huez (Campagnolo Record upgrade)
1986 BiKyle criterion (needs restoration)

Mountain:
2002 Trek 4500 hardtail
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post #9 of 55 Old 05-03-2014, 11:44 PM
 
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Garage
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.

2012 Honda Rebel 250, "Pepe, my Little Mule"
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post #10 of 55 Old 05-03-2014, 11:49 PM
 
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You can try Jacks Rebel Warehouse, he sells used parts for cheaper. Give him a call.

Jack's Rebel Warehouse - Rebel Catalog, Honda Rebel parts and accessories

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