Do you have the headlight assembly out and apart? If not, I would do that first, as the projector assemblies are held in place with four screws that pass through a steel plate. I am thinking the screws have backed out or stripped out of the zinc projector mounting plates allowing the whole shebang to flop around loose inside the headlight housing.
If so, this should be an easy fix. Just drill out the holes and pass a bolt though them, then snug them up with lock nuts or apply some red Loctite to the threads and be done with it. I had my headlight assembly completely apart a few weeks ago as I could feel the low beam projector was starting to loosen up. I just followed the headlight removal and disassembly instructions found in a few places on the net (probably here now that I think of it) and it came apart easily. I noticed that the infamous black dust problem was beginning in the low beam side. It looks like the zinc projector housing frets up against the steel plate and dust from the zinc particles gets spread around the whole headlight. My remedy was to make hard rubber backing pads out of 1/8" thick hard red rubber gasket material and tighten the screws back up tightly once it was all assembled. This should absorb the many wonderful buzzes which plague our bikes. I found putting two-sided rubber tape all along the outer edges of the windshield before I put it all back together again killed 95% of the buzzing, and my windshield doesn't vibrate madly up and down at low revs anymore. I removed the blockers while I was at it, and installed 9011, 9012 bulbs. There is a lot more light now, but the beam quality still sucks, and it seems to be all over the place. I have ordered a cheap HID upgrade kit to see if I can get the light I want out of this assembly. Naturally, I will probably have to take it all apart again and put the blockers back in...
Topic: Headlight assembly broken/2003 gsf1200s HELP!! (Read 5658 times)