Speed Triple 1200 Rs Headlight Removal

Richard Cheek · Jan 31, 2025

Hi all. I recently added the colour screen to my speed triple, but when reattaching the headlights I must have overtightened the two lower bolts and broken the plastic inside the actual headlight unit. So now the bolts spin around forever and I can't get the headlights off if needed. Any ideas??!

I'm hoping it's not a whole new headlight job but I suspect that may be the case. Even if it is, not sure how to remove the old headlights? Just destroy the existing ones to remove them??

TRIPLE X · Jan 31, 2025

Richard Cheek said: ↑

Hi all. I recently added the colour screen to my speed triple, but when reattaching the headlights I must have overtightened the two lower bolts and broken the plastic inside the actual headlight unit. So now the bolts spin around forever and I can't get the headlights off if needed. Any ideas??!

I'm hoping it's not a whole new headlight job but I suspect that may be the case. Even if it is, not sure how to remove the old headlights? Just destroy the existing ones to remove them??
Click to expand...

What size bolts are they?

joe mc donald · Feb 1, 2025

Richard Cheek said: ↑

Hi all. I recently added the colour screen to my speed triple, but when reattaching the headlights I must have overtightened the two lower bolts and broken the plastic inside the actual headlight unit. So now the bolts spin around forever and I can't get the headlights off if needed. Any ideas??!

I'm hoping it's not a whole new headlight job but I suspect that may be the case. Even if it is, not sure how to remove the old headlights? Just destroy the existing ones to remove them??
Click to expand...

@Richard Cheek Can you not remove the lens and get mould grips or something on the inside.

TRIPLE X · Feb 1, 2025

TRIPLE X said: ↑

What size bolts are they?
Click to expand...

Looks like they might be M5 button head screws? There will be a metal threaded insert embedded into the plastic headlight shell. The torque for these fasteners will be very low and overtightening has caused the insert to rotate. The insert is likely to have a shoulder on the inside so cannot be pulled out. The only way to remove the headlights will be to drill the head off the screw (assuming it does not spin). The remaining part of the screw can then be removed. You then need to figure out how to lock the insert in place to stop it from rotating. The headlight assembly is a sealed unit so there might not be any access to the inside? Might be better to leave well alone until you need to remove the headlights for whatever reason.