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how to remove headlight

This is a discussion on how to remove headlight within the Grizzly Electrical & Lighting forums, part of the Grizzly Forums category; so i get back from riding today to find both of my headlight bulbs laying loose, inside the lens housing. It doesn't look to be ...


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#1
07-02-2009, 09:52 PM
how to remove headlight

so i get back from riding today to find both of my headlight bulbs laying loose, inside the lens housing. It doesn't look to be a simple task, removing the headlight fixture. Can anyone give me direction? Do I have to remove the grill?
It's a '05 660.

thanks
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05-01-2010, 12:00 PM
How about a 450 lens?
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#3
05-01-2010, 01:34 PM
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Originally Posted by whaffner View Post
so i get back from riding today to find both of my headlight bulbs laying loose, inside the lens housing. It doesn't look to be a simple task, removing the headlight fixture. Can anyone give me direction? Do I have to remove the grill?
It's a '05 660.

thanks
PM "UpstateNYGrizz" he has an 02 660 that I know he has done headlight work on and can tell you how to handle your problem.
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#4
05-01-2010, 10:04 PM
Hey AZ08Grizz, the orginal post was back on 07-02-2009. I sure hope whaffner has figured it out by now.
The new post is for a 450 and I have no idea. maybe somebody with a 450 will chime in and help Cheeks. But, I don't know why Cheeks is asking about a 450 lense when his signature has a 700. Unless he is trying to answer whaffner 10 months later.
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#5
05-02-2010, 12:28 AM
Haha, nothin gets by you, UpstateNYGrizz!

Cheeks, the lens on the 450, like all grizzlies I believe, is a single-piece integrated lens/housing that is mounted from the back of the grill. If you have a broken lens, you will have to remove the grill to get it out. See here for explode view.
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#6
05-02-2010, 05:29 AM
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Originally Posted by UpstateNYGrizz View Post
Hey AZ08Grizz, the orginal post was back on 07-02-2009. I sure hope whaffner has figured it out by now.
The new post is for a 450 and I have no idea. maybe somebody with a 450 will chime in and help Cheeks. But, I don't know why Cheeks is asking about a 450 lense when his signature has a 700. Unless he is trying to answer whaffner 10 months later.
The wife rides the 450.

I was able to cut a small piece of the plastic shroud and bend down part of the gaurd then squeeze my arm in with a stubby screw driver and get the lens assembly out. Shoud be back together soon.
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#7
05-02-2010, 06:58 AM
geez.....after all this time, you guys thought I was riding in the dark! It was a pain in the arse, but I removed the bulbs, re-soldered the bases, and re-installed.
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#8
05-02-2010, 09:42 PM
Ye olde 600's are cake don't even need to pull the bumper just reach up and remove to phillips on each light and then it kist swingd our of the upper holding tab.
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05-02-2010, 09:59 PM

It seems we have now found the answer to a old question
I hope every one has learned a lesson about keeping the rest of us members in the DARK......
Remember then post up a reply, others may need your knowledge
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#10
05-03-2010, 09:24 AM
Quote:
Originally Posted by whaffner View Post
so i get back from riding today to find both of my headlight bulbs laying loose, inside the lens housing. It doesn't look to be a simple task, removing the headlight fixture. Can anyone give me direction? Do I have to remove the grill?
It's a '05 660.

thanks
next time, if there is a next time. Shut the fuel off, stand bike on the rear rack, take off the rubber cover on the back of the headlight assembly and then its easier to fish out the old bulbs. Glad to hear you got them out and fixed.
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#11
05-03-2010, 11:29 AM
Wow, all of these responses generated by Cheeks asking an unrelated question to a post that was 10 months old and never followed up on by the original poster. Just goes to show you have to pay attention to details like "dates". LOL
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05-03-2010, 01:16 PM
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Wow, all of these responses generated by Cheeks asking an unrelated question to a post that was 10 months old and never followed up on by the original poster. Just goes to show you have to pay attention to details like "dates". LOL
Wasn't unrelated...lol... I needed the same information, how to remove the headlight assembly on a 450 just not a 660. They have a lot of similarities so after a Google search led me back here I figured someone would have something by now.
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#13
09-21-2011, 04:58 PM
fishing out popped headlight bulbs in 660 Grizzly

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Originally Posted by whaffner View Post
so i get back from riding today to find both of my headlight bulbs laying loose, inside the lens housing. It doesn't look to be a simple task, removing the headlight fixture. Can anyone give me direction? Do I have to remove the grill?
It's a '05 660.

thanks
My sister-in-law crashed my new machine into my Griz 660, both bulbs broke at the soldered ring and poped out into the reflector. Don't dismantle everything. Remove the outer rubber boot, then twist and remove the inner bulb holder boot. create a small tight hook in the end of a wire, use it to make a loop the size of the bulb base. Bend this loop at right angle to wire. Insert through bulb hole, manipulate bulb until it is vertical with glass up and base drops through loop. carefully lift bulb and start glass through the hole. I had to jerk hard enough to break the glass, but got both bulbs out this way. Only a few shards of glass left in the reflector.
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#14
09-21-2011, 07:18 PM
I had mud in one headlite after a boot came loose and as i was trying to find away to clean the lense i stuffed a small piece of rag in and sprayed windex liberally in the hole where the bulb goes. Then got air hose and blew. It swirled the rag around and cleaned the lense nicely after 3 or 4 times
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