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Headlight cracks
#1
Hello from the Northwoods of Wisconsin. The weather here is not great for riding so until it warms up, the only way to spend quality time with my RS is in the garage.

Somewhere along the line, one of my headlights became cracked (see photos below). Years ago I had been experimenting with brighter bulbs (some xenon) and it may have been the heat associated with those. To what degree do you think the cracks affect the beam? I don’t want to compromise the output, throw, or annoy oncoming vehicles.

Has anyone else had this happen and replaced it themselves?


   


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#2
I don't know if the cracks will affect the light output.

If it was a rock strike your comprehension insurance would cover it. A new light costs $574

Comprehensive claims usually don't affect your rates. I had comprehensive pay for a car windshield replacement once. It had a lot of sand pitting causing some glare at night and my insurance agent considered it a safety problem.



I had the part of the fairing that holds the light off.

I think that fairing part has to be removed to remove the light.

You also need to remove the small internal cover and mirror.



   



   



   



Internal cover

   
Lee
Iowa, USA
2022 R1250RS White Sport

Past BMWs: 2016 R1200RS x 2,  2011 K1300S x 2,  2003 K1200RS x 2,  1991 K75S x 2,  1987 K75T x 2, 1984 R100RT
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#3
A friend with a 2016 model with over 100,000 miles has what I consider "crazing" on both headlight lenses. Not as bad as what you have shown. I believe there is no fix except replacement. The front fairing has to pretty much come off the bike to access the headlights.
Frank
'23 R1250RS, 9000 mi. 1 yr., '03 R1100S BCR #6/200, '85 K100/1100RS- 38 yrs. 331,000 mi., '17R1200RS- 51,054 mi. (gone), '16 R1200RS- 28,322 mi. (gone), '11 R1200RT-30,000 mi. (gone), '05 R1200ST-58,000 mi. (gone), '96 Ducati 900SS/SP-89,000 mi. (gone), 560K+ BMW miles
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#4
(01-26-2024, 08:43 AM)Eleven Wrote: ...
Somewhere along the line, one of my headlights became cracked (see photos below). Years ago I had been experimenting with brighter bulbs (some xenon) and it may have been the heat associated with those. To what degree do you think the cracks affect the beam? I don’t want to compromise the output, throw, or annoy oncoming vehicles.

You second photo is the best for illustrating the problem, which in my opinion, was caused by excessive heat. The through-thickness cracks seen in the photograph are new refractive surfaces in front of the light source, whatever it is, and will absolutely affect the projected beam. I suspect that it will become more scattered / less focused and will likely increase the glare to oncoming drivers. This is a worse scenario than slight pitting of the outer surface of the lamp over time.

There is no fix other than replacement of the assembly. You may want to look for a good condition second-hand lamp assembly, e.g from a salvage yard or on eBay. New is expensive, as you may have already found out.
Regards,
Grumpy Goat
2016 BMW R1200RS
2023 Triumph Tiger 900 Rally Pro
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#5
I had that happen to me on my FJR. Both lenses. Yamaha put a whole new front cowl on under warranty. Don't know what that cost, didn't care. Yamaha felt it was a defect in manufacturing. Ran stock bulbs the whole time, so it wasn't from an external source. The new cowl/lenses have not had an issue.
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#6
If insurance will not replace it, MAX BMW has a New Old Stock low beam light for $159 less than list price.

https://www.ebay.com/itm/404516573778?ch...vkQAvD_BwE
Lee
Iowa, USA
2022 R1250RS White Sport

Past BMWs: 2016 R1200RS x 2,  2011 K1300S x 2,  2003 K1200RS x 2,  1991 K75S x 2,  1987 K75T x 2, 1984 R100RT
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#7
Thank you all, gentlemen for the thorough, detailed responses. I think I'll jump on the NOS headlight from MAX and install it myself. I get a healthy check every year to remain claim-free and don't want to mess that up. Besides, it's my damn fault for trying a xenon bulb.
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#8
(01-26-2024, 11:31 AM)saread Wrote: Ran stock bulbs the whole time, so it wasn't from an external source.  The new cowl/lenses have not had an issue.

There is likely the difference. With mods you take chances.
Regards,
Grumpy Goat
2016 BMW R1200RS
2023 Triumph Tiger 900 Rally Pro
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#9
(01-26-2024, 11:38 AM)Lee Wrote: If insurance will not replace it, MAX BMW has a New Old Stock low beam light for $159 less than list price.

https://www.ebay.com/itm/404516573778?ch...vkQAvD_BwE

The assembly in that link is sold ... no longer available. I too saw it earlier before I made my first post above.
Regards,
Grumpy Goat
2016 BMW R1200RS
2023 Triumph Tiger 900 Rally Pro
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#10
(01-26-2024, 04:45 PM)Grumpy Goat Wrote:
(01-26-2024, 11:38 AM)Lee Wrote: If insurance will not replace it, MAX BMW has a New Old Stock low beam light for $159 less than list price.

https://www.ebay.com/itm/404516573778?ch...vkQAvD_BwE

The assembly in that link is sold ... no longer available. I too saw it earlier before I made my first post above.

That was probably me. I jumped on it early this afternoon and it looks like the sale went through.
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#11
(01-26-2024, 04:40 PM)Grumpy Goat Wrote:
(01-26-2024, 11:31 AM)saread Wrote: Ran stock bulbs the whole time, so it wasn't from an external source.  The new cowl/lenses have not had an issue.

There is likely the difference. With mods you take chances.

True. But in my case it was a defect in the lenses. Mama Yamaha never batted an eyelash at covering them under warranty. They are built into the cowl so the entire cowl needed to be replaced.  Geez, the labor alone for that makes me cringe. The part had to be close to a grand, or more.  Previously, that bike had the famous FJR ground spider (basically an insufficient system ground that would burn out) and it got a new wiring harness under warranty.  That job really hurt Yamaha. But, to their credit, they stood behind it and did the job without hassle. Needless to say, it was a considered decision to move from Yamaha to BMW.

My experience makes me wonder if Eleven's issue wasn't from the Xenon bulb and was actually a manufacturing defect.  You would think that the issue would have affected both lenses if the Xenon's were the problem.
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#12
(01-26-2024, 04:50 PM)Eleven Wrote: That was probably me. I jumped on it early this afternoon and it looks like the sale went through.

If it was then good for you. You have a way ahead.
Regards,
Grumpy Goat
2016 BMW R1200RS
2023 Triumph Tiger 900 Rally Pro
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#13
(01-26-2024, 08:00 PM)saread Wrote: My experience makes me wonder if Eleven's issue wasn't from the Xenon bulb and was actually a manufacturing defect.  You would think that the issue would have affected both lenses if the Xenon's were the problem.

Probably not. The damaged lamp assembly was the low beam which is used far more than high beam for most people. At least, in my case, the low beam is always used and I hardly ever use the high beam. Between the low beam and my Denali D2 auxiliary lights, there’s plenty lighting for visibility and for nighttime riding.
Regards,
Grumpy Goat
2016 BMW R1200RS
2023 Triumph Tiger 900 Rally Pro
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#14
When I worked for Apple we had special training to identify types of damage to glass to determine if someone's phone that was brought in would be covered by warranty or not. Observed damage is consistent with excessive heat/cold stresses on the lens. You already have a set of Darlas on the bike -- or were they installed after the incident?

Regardless, glad to hear you picked up a relatively inexpensive replacement from Max BMW. Maybe treat yourself by upgrading your Darlas as well?
Craig
'20 R1250RS
Previous
: '21 R1250RS, 
'03 K1200RS, '01 R1100RS, '83 R800
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#15
(01-28-2024, 12:58 AM)Pyrrho Wrote: When I worked for Apple we had special training to identify types of damage to glass to determine if someone's phone that was brought in would be covered by warranty or not. Observed damage is consistent with excessive heat/cold stresses on the lens. You already have a set of Darlas on the bike -- or were they installed after the incident?

Regardless, glad to hear you picked up a relatively inexpensive replacement from Max BMW. Maybe treat yourself by upgrading your Darlas as well?

The Clearwater Lights had been installed by the previous owner and really help with seeing and being seen. I may upgrade someday, but any of my discretionary income is going into guitars these days.
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#16
(01-28-2024, 12:58 AM)Pyrrho Wrote: Maybe treat yourself by upgrading your Darlas as well?

Why
Lee
Iowa, USA
2022 R1250RS White Sport

Past BMWs: 2016 R1200RS x 2,  2011 K1300S x 2,  2003 K1200RS x 2,  1991 K75S x 2,  1987 K75T x 2, 1984 R100RT
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#17
(01-28-2024, 12:59 PM)Lee Wrote:
(01-28-2024, 12:58 AM)Pyrrho Wrote: Maybe treat yourself by upgrading your Darlas as well?

Why

He damaged his lenses by attempting to upgrade the LED mains, assumedly because he felt he wasn't getting enough light output. Darlas are the lowest-output Clearwaters @ 2400 lm ea, can easily go much brighter all the way up to Super Sevinas or Dixis at 10K+.
Craig
'20 R1250RS
Previous
: '21 R1250RS, 
'03 K1200RS, '01 R1100RS, '83 R800
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#18
(01-29-2024, 01:17 AM)Pyrrho Wrote:
(01-28-2024, 12:59 PM)Lee Wrote:
(01-28-2024, 12:58 AM)Pyrrho Wrote: Maybe treat yourself by upgrading your Darlas as well?

Why

He damaged his lenses by attempting to upgrade the LED mains, assumedly because he felt he wasn't getting enough light output. Darlas are the lowest-output Clearwaters @ 2400 lm ea, can easily go much brighter all the way up to Super Sevinas or Dixis at 10K+.
I like the Darlas - light weight enough to mount on the forks - where they don't light up parts of the bike like a car coming fast from behind.

I've found them plenty bright at nighttime, wildlife-friendly speeds. When aimed correctly, they light up a nice section of road and highlight all the surface irregularities. 

   
"A good man always knows his limitations...."
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#19
I've gone with Denali; a pair of D3s mounted to the frame, a pair of DMs with selective yellow lenses mounted to the forks, and some B6 brake lights on a license plate frame.
Craig
'20 R1250RS
Previous
: '21 R1250RS, 
'03 K1200RS, '01 R1100RS, '83 R800
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#20
(01-30-2024, 12:28 PM)Pyrrho Wrote: I've gone with Denali; a pair of D3s mounted to the frame, a pair of DMs with selective yellow lenses mounted to the forks, and some B6 brake lights on a license plate frame.

Most excellent set, IMO. The D3s are a nice size for the RS (there is such a thing as too big and ridiculous looking) and the DMs with selective yellow are perfect for conspicuity. Based on my D2s, well-aimed D3s would be plenty for night street riding.
Regards,
Grumpy Goat
2016 BMW R1200RS
2023 Triumph Tiger 900 Rally Pro
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