I needed to fix the headlight motor on my 1991 Formula. Motor was not going up very well..took it apart and bushings in motor were disintegrated.

Looking for a real low buck repair...I saw some 25 cent nylon spacers at Home Depot (see pics). The nylon spacers come 2 in a pack and are 50 cents for one pack. I found a nylon spacer that was just under 1/2" long by 1/2" Outside Diameter (OD)..the exact spec of the nylon spacer was 27/64" long by 29/64" OD. The nylon spacers are made by Crown Bolt Inc...they were available at Home Depot. These nylon 27/64" long by 29/64" OD spacers are pretty hard with little flex (even with the .324" ID hole)...

Note, I also bought a few 1/2" long by 1/2" OD nylon spacers...it appears the 1/2" OD is just a bit too big...so, did not use these.

Put in the nylon spacers (27/64" long by 29/64" OD) and headlight goes up and down nicely...so far no issues...if you are looking for a low buck headlighgt repair..this could be worth a look.

 

few more pics