R1200ST Headlamp Vertical Beam Adjuster Broken

[k1w1_123]

Hi,

 

The adjusting knob off the headlamp vertical beam adjuster/compensator mechanism of my venerable R1200ST disappeared on a recent ride, which I found out when it got dark and the light was pointing at the treetops. On inspection, the knob had been simply pressed onto a knurled shaft which you rotate to raise and lower the headlamp. Without the knob the light flips up under spring tension to the maximum angle. I am wondering if anybody has had this problem and come up with a solution

The shaft is still there, It screws into a plastic housing inside the the headlamp and protrudes about 10 mm ouside the shell. I have some ideas how I might fix this and would like to know if anybody has unscrewed the adjusting shaft from inside the headlamp, and then been able to replace it? I am concerned that if I remove the shaft for repair I may displace spring loaded components which I won't be able to replace.

Any suggestions gratefully received

 

[dirtrider]

6 hours ago, k1w1_123 said:

Hi,

 

The adjusting knob off the headlamp vertical beam adjuster/compensator mechanism of my venerable R1200ST disappeared on a recent ride, which I found out when it got dark and the light was pointing at the treetops. On inspection, the knob had been simply pressed onto a knurled shaft which you rotate to raise and lower the headlamp. Without the knob the light flips up under spring tension to the maximum angle. I am wondering if anybody has had this problem and come up with a solution

The shaft is still there, It screws into a plastic housing inside the the headlamp and protrudes about 10 mm ouside the shell. I have some ideas how I might fix this and would like to know if anybody has unscrewed the adjusting shaft from inside the headlamp, and then been able to replace it? I am concerned that if I remove the shaft for repair I may displace spring loaded components which I won't be able to replace.

Any suggestions gratefully received

 

Morning   k1w1_123

 

I'm not even sure if that shaft will unscrew all the way. If by chance it could then there is most likely a pivoting barrel inside the light assembly that the shaft screws into. If so that would be a real pain to line back up to screw the knurled shaft back into. (that's assuming the spring stays in place with the shaft removed). 

 

Parts for the headlight assembly are not available (at least in my parts book) so you will probably need to make your own new knob from aluminum or brass with a side set screw to hold it on the knurled shaft. 

[Skywagon]

A long shot.  You might try McMasters hardware

 

McMaster-Carr

[9Mary7]

9 hours ago, k1w1_123 said:

Hi,

 

The adjusting knob off the headlamp vertical beam adjuster/compensator mechanism of my venerable R1200ST disappeared on a recent ride, which I found out when it got dark and the light was pointing at the treetops. On inspection, the knob had been simply pressed onto a knurled shaft which you rotate to raise and lower the headlamp. Without the knob the light flips up under spring tension to the maximum angle. I am wondering if anybody has had this problem and come up with a solution

The shaft is still there, It screws into a plastic housing inside the the headlamp and protrudes about 10 mm ouside the shell. I have some ideas how I might fix this and would like to know if anybody has unscrewed the adjusting shaft from inside the headlamp, and then been able to replace it? I am concerned that if I remove the shaft for repair I may displace spring loaded components which I won't be able to replace.

Any suggestions gratefully received

 

Mine did the same thing several years ago. I ended up using the available (at that time) adjuster from a GS..... I remember it wasn't an easy thing to install but I got it to fit and hold adjustment. I too was not about to try to take the light apart for fear of ruining an un-available part. I checked my records but was not able to find the part number for what I used...... 

 

[dirtrider]

36 minutes ago, 9Mary7 said:

Mine did the same thing several years ago. I ended up using the available (at that time) adjuster from a GS..... I remember it wasn't an easy thing to install but I got it to fit and hold adjustment. I too was not about to try to take the light apart for fear of ruining an un-available part. I checked my records but was not able to find the part number for what I used...... 

 

Afternoon 9Mary7 _ k1w1_123

 

BMW offers the entire adjuster for the GS (I think 05-09 is the same part)___P/N   63127723839  Hight Adjustment. 

 

That might be worth looking into (about $65.00).

 

 

[9Mary7]

On 10/29/2024 at 8:50 AM, dirtrider said:

Afternoon 9Mary7 _ k1w1_123

 

BMW offers the entire adjuster for the GS (I think 05-09 is the same part)___P/N   63127723839  Hight Adjustment. 

 

That might be worth looking into (about $65.00).

 

 

Yes, that is what I used. IIRC the hard part was getting the rest of the original adjuster out.....I probably made a notch or two in the plastic housing to do this. I remember adding a washer under the replacement due to the notches I cut. Still working fine according to my son.

[Dennis Andress]

On 10/28/2024 at 10:34 PM, k1w1_123 said:

Hi,

 

The adjusting knob off the headlamp vertical beam adjuster/compensator mechanism of my venerable R1200ST disappeared on a recent ride, which I found out when it got dark and the light was pointing at the treetops. On inspection, the knob had been simply pressed onto a knurled shaft which you rotate to raise and lower the headlamp. Without the knob the light flips up under spring tension to the maximum angle. I am wondering if anybody has had this problem and come up with a solution

The shaft is still there, It screws into a plastic housing inside the the headlamp and protrudes about 10 mm ouside the shell. I have some ideas how I might fix this and would like to know if anybody has unscrewed the adjusting shaft from inside the headlamp, and then been able to replace it? I am concerned that if I remove the shaft for repair I may displace spring loaded components which I won't be able to replace.

Any suggestions gratefully received

 

 

Years ago, I fixed this on my R1200ST by browsing through the 'lamp parts' bins at my local hardware store. I can't find a picture of the part I used, but something like this could work. I pulled the long screw out as far as I could with a pair of pliers and then held it there with a pair of needle nose vise grips. Stuff the knob with as much JB Weld as you can, push the knob onto the screw, tighten the set screw, and let everything sit until the epoxy is dry. Maybe dill a hole in the knob first so the screw can sick out the top a bit.

 

 

[k1w1_123]

Thanks everybody for your advice

 

From the wealth of information and suggestions I have now machined up a new knob from a short length of aluminium bar, knurled at the end to make it easy to turn, and fixed to the stub shaft with a couple of grub screws set opposite each other (I haven't had much luck in the past with epoxy resins like JB Weld). The appearance is somewhere between the original BMW GS part linked by mentioned by @9mary7 and linked by @diirtrider, and the knob pictured by @Dennis Andress. I would have had to order the GS part from overseas because I am in New Zealand so I chose to improvise. My original thought was to unscrew the entire adjuster rod and make a new one but the rod only came out part-way and then started to bind so I chickened out.

 

Here's the finished result.  The white twist tie through the hole in the knob is tied to a convenient anchor so if (when) the knob gets loose and slips off I can just retighten the grubscrews to secure it

[lkraus]

8 hours ago, k1w1_123 said:

The white twist tie through the hole in the knob is tied to a convenient anchor so if (when) the knob gets loose and slips off I can just retighten the grubscrews to secure it.

Belt and suspenders!

 

And if the knob is hard to grip, you can stick a nail through the hole for leverage.