A forum for owners of Yamaha TTR250 trail and enduro bikes!

This is quite a common problem on TTRs and I have come across some ingenious repairs!

The blue headlight surrounds are hard to come by second hand so it is worth repairing them. 

I apologise in advance for the poor quality of the pics. I think I had the flash suppressed 

I carry a fairly heavy Slime compressor in a headlight bag on my TTR and, after a few spills, the brackets started to look a bit worse for the wear.

I made up a bracket from some aluminium scrap:

To help strengthen the repair I used some epoxy glue and then pop rivetted the plates into the headlight shell and temporarily bolted them up until the glue set.

A bit messy but I hope you get the idea.

The pop rivets don't look too bad - especially as the headlight plastic is in such bad condition. Cracked and crazed by sunlight. I am not going to get that many more rides out of it 

Whilst doing the work, I spotted another substantial crack indicated by the blue arrow which I have also plated in the same way.

The pink arrow indicates an earlier repair where I had used some Araldite to put a strip behind the top of the unit to stop it cracking any further.

I hope that maybe helps someone