Headlight assembly lense removal

[4given]

Has anyone ever tried to remove the clear lense alongside the headlight? It is separate from the headlight in the assembly. It looks like there are tabs plus glue or sealer. I’m trying to make one good headlight assembly out of two. Pics below.

Notice the first one has a small piece out of the lense and the second has a crack on the other side. Thanks in advance for any and all advice

[MikeB]

I cannot say with 100% certainty for the headlight assembly but of the light assemblies I have disassembled on the GL1500, the lenses are held inplace with a hot glue. If the assembly is heated in an oven of about 200 degrees for less than 10 minutes, the glue should get soft enough to release.

I have taken apart saddlebag and trunk lights using an oven for my GL1500. Just don't leave the assemply in the heat for too long.

[4given]

Thanks Mike. That is what I was going to guess and that is what it looks like. I was thinking heat gun but your idea is probably the way to go. Easier to control and more even heat. I’m gonna give it a go. I’ll let you know how it turns out.

[MikeB]

I initially started with the heat gun too but the heat was too uneven. So the oven was the best way to go.

[offcenter]

I was thinking that warming the tail light in a pan of hot water
would work.
I will be doing this soon so I can convert to LED strips in
the tail lights.

[Erdeniz Umman]

I had to disassemble the lens 5 years ago. I had used a heat gun to heat up the lens and it came out easily after 5-10 minutes.
By the way, when heating the glass lens, heat spreads along the lens almost evenly.

The sealant is something like below in gray color. I had to replace the sealant, most probably you will have to replace it too.

[4given]

Thanks Erdeniz. Do you remember what you used to clean the sealant off the lens before reassembling?

[Erdeniz Umman]

If I remember correctly, after cleaning roughly with a knife, I used thinner to clean the residue.
Also, I used the black sealant since I couldn't find the gray one, and had no cosmetic issues.

[offcenter]

Why not reassemble it using GE clear Silicone seal?

[MikeB]

Silicone Seal is pretty messy for assembly work. After assembly it goes on pretty good but if you ever want to take the lens off again, it can be a real pain.

[4given]

Getting back to you on this project. I removed the lens using a heat gun. It would have worked better if I would’ve had a helper. If you were doing it alone, as Mike said an oven would work better. Controlled heat plus having both hands to maneuver the lens. Thanks to Erdeniz for his suggestion to use paint thinner to clean it up. I tried not to get carried away with the thinner. I then pressed the good lens back in place and used what is pictured below to seal it because that was the best I had on hand. If Mike is correct I hope I never have to remove it again. Pics below. As you can see without the lights on the new lens looks a little dull compared to the original one. Again thanks to everyone who help me with good advice on this project.

I use this stuff on my boats

[MikeB]

Nice job. Happy it worked out for you.

[FM-USA]

BUFF & POLISH that other lens.
I use Turtlewax polishing compound then McGuire's. Comes out almost like new.

If you have a Dremel kit you should have (red?) polishing clay block.
I used it dry on a plastic lens & came out even better AND FASTER than the polishing compounds.