Headlight bushings - ZR-1 Net Registry Forums

garyhugo · 05-10-2022

Does anyone have experience with using brass bushings in the plastic gear of the headlight motor? I have a set from many years ago and it is time to replace the bushings.

Jagdpanzer · 05-10-2022

The so called bushings are in fact not bushings in a true sense. They are more like cushions in the gear train to soften the sudden stop when headlight reaches either full open or closed position. The motor current sensor quickly opens the motor circuit when it sees the amps suddenly go up. The relatively soft "bushings" allows for the motor gear train to firmly hold the headlight doors in the open or closed position. Using rigid brass bushings will work for awhile but will probably cause accelerated wear on the actuator gears and not hold the headlight doors as firmly in the open or closed position as with the softer original "bushings".
When my original factory "bushings" turned to dust ten years back I replaced them with sections of silicon hose of equivalent diameter cut to the same length which have worked fine since.

Sent from my iPhone using ZR-1 Net Registry

Young1 · 05-14-2022

Gary there are a number YouTube videos on this subject. They give the how to and the part number for the Dorman nylon button bushings. Just lay out a towel and take your time.

garyhugo · 05-15-2022

Have the motor all apart and was surprised to find the gear for the second time cracked. Waiting on a new one from amazon. The plugs were fine.

05-10-2022	#1
garyhugo Join Date: Feb 2010 Location: Jacksonville,FL Posts: 240	Headlight bushings Does anyone have experience with using brass bushings in the plastic gear of the headlight motor? I have a set from many years ago and it is time to replace the bushings. __________________ Gary 90-1572

05-10-2022	#2
Jagdpanzer Join Date: Apr 2007 Location: Northern VA Posts: 2,650	Headlight bushings The so called bushings are in fact not bushings in a true sense. They are more like cushions in the gear train to soften the sudden stop when headlight reaches either full open or closed position. The motor current sensor quickly opens the motor circuit when it sees the amps suddenly go up. The relatively soft "bushings" allows for the motor gear train to firmly hold the headlight doors in the open or closed position. Using rigid brass bushings will work for awhile but will probably cause accelerated wear on the actuator gears and not hold the headlight doors as firmly in the open or closed position as with the softer original "bushings". When my original factory "bushings" turned to dust ten years back I replaced them with sections of silicon hose of equivalent diameter cut to the same length which have worked fine since. Sent from my iPhone using ZR-1 Net Registry __________________ Phil Wasinger 1994 Torch Red ZR-1 WAZOO Member George Braml Intake

05-14-2022	#3
Young1 Join Date: Sep 2016 Location: Ocala, FL Posts: 881	Re: Headlight bushings Gary there are a number YouTube videos on this subject. They give the how to and the part number for the Dorman nylon button bushings. Just lay out a towel and take your time. __________________ Steve Young 1991 ZR-1 Quasar Blue Metallic/Black #729 Second Owner 1991 ZR-1 Dark Red Metallic/Black #2040 SOLD 1990 ZR-1 Dark Red Metallic/Saddle #1670 SOLD Double your happiness.....complain half as much.

05-15-2022	#4
garyhugo Join Date: Feb 2010 Location: Jacksonville,FL Posts: 240	Re: Headlight bushings Have the motor all apart and was surprised to find the gear for the second time cracked. Waiting on a new one from amazon. The plugs were fine. __________________ Gary 90-1572