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The headlight bucket is a particular pos on these bikes.I was getting a rattle from my front end, primarily over bumps. I was adjusting the bucket one day after installing or removing a fly screen that utilized the bucket bolts when I realized there was play at the trim ring.I removed the ring and headlight and realized I couldn't just tighten the play away. I wound up applying a thin layer of silicone gasket material between the headlight and trim ring and then reinstalled the assembly and the rattle was gone.Might be worth a check.
The headlight bucket is crap. I tighten screws for a while, but eventually they vibrated and broke. I wound up drilling three small holes in the ring and headlamp shell, and wired it securely with baling wire. I have a small bikini fairing so you can’t see this repair.
I think I solved my rattling problem. I tighten up the single screw for the headlight and then put electrical tape and around the chrome retainer ring and headlight bucket in order to stop is slightly vibrating and keep moisture out. The retainer ring is now nice and tight and the tape doesn't look to bad at all and blends in well.
Bringing this one up from the dead.I've narrowed down a rattle/vibration at 3,000 rpm to my headlight. The chrome ring is loose and the screw on the left hand side is also loose. The whole thing feels like it's about to break.Did you apply silicone, let it try and then re-assemble the light housing? was it stuff in a tube or something that you could mold with your fingers? I might put electrical tape on mine for now as I'm worried about the headlamp falling out which wouldn't be very good at all.
Ohhhhhh sorry missed this earlier though I already saw you figured it out.But for the record, I applied something from a tube and reassembled before it set.
If I have problems going forward I'll try the same as you. For now, the electrical tape almost looks like a factory application and the headlight bezel feels very secure.