I recently discovered lots of moisture build-up inside one of my RZR 900xp headlights. The moisture completely covered the inside of the lens and had a small amount pooled at the bottom (maybe a half teaspoon). I suspect that water leaked inside the housing when I recently pressure washed my RZR.

After reading various threads on this forum on how to disassemble and upgrade your RZR headlights (add extra LED lights), I decided to disassemble my headlight, re-seal it with fresh silicone and reassemble.

Here is how I did it.
First, I removed the headlight and cleaned it. I also removed the 2 screws on the back side of the metal housing. Then I placed the headlight in my oven (I don’t own a heat gun) at 170 degrees (the lowest setting on my oven) for 20 minutes. Wearing mechanic’s gloves, I carefully removed the headlight from the oven and placed it on some cardboard. Using a utility knife, I carefully traced the edges of the plastic headlight lens over and over. This slowly, but surely removed the silicone. After 10 minutes or so, the headlight cooled down, so I put it back in the over for another 20 minutes. Then I removed it and continued running the utility knife around the edges of the lens to remove more silicone material. Then I used a small flathead screwdriver to gently pry up against the edge of the lens…going around the lens as I did this to try to gently maneuver the lens away from the metal housing. Eventually, the lens broke free and I was able to pry back the 2 tabs on the plastic lens and remove the lens.

From that point, it was just a simple task of cleaning up the old silicone in the channel around the edges of the metal housing and wiping down the lens. I bought some black RTV silicone (which is heat resistant up to 500 degrees). I could have bought some red RTV which is rated for higher temps, but I didn’t want to use a red colored RTV as that may look ugly around the outside of the headlights. I wish I could have found some high temp CLEAR silicone, but my local store didn’t have any. That is why I chose the black RTV silicone. Hopefully, the black RTV will seal up good (haven’t tested it yet).

After I carefully wiped down the inside of the headlight housing and the black motherboard, I applied some black RTV to the 2 holes (inside and outside) where the screws are mounted on the back side. Then I inserted the 2 screws. Next, I applied black RTV to the channel around the edge of the metal housing and carefully re-installed the clean lens (making sure both tabs on the lens are installed all the way). Once it dried (in an hour), I remounted the headlight to the RZR. I hope to test it out this weekend at an upcoming XC race (which might be muddy). Hopefully, this repair holds up.

PICS:

FINISHED PRODUCT:

I hope this thread helps others thinking about doing the same repair.