No headlight

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No headlight

12 May 2022 18:35
#866985
I took everything out of the headlight bucket, disconnected the H4 plug, both handlebar switch plugs & several bullet connectors & the front brake light switch that connects underneath the gas tank.  Put everything back together but I don't have the headlight now...everything else works, speedo/tach lights, indicator lights, motor runs, brake/tail light, turn signals.  It's just the headlight.  What am I missing?  
1981 KZ440 A2 LTD

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Re: No headlight

12 May 2022 20:42
#866990
If it's affecting both high and low beams it may be either your ground is disconnected in the headlight bucket or your 12v wire feeding the high/lo switch is at fault.
Headlight could also be smoked.
81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
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LIC, NY

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Re: No headlight

13 May 2022 03:12
#866994
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If it's affecting both high and low beams it may be either your ground is disconnected in the headlight bucket or your 12v wire feeding the high/lo switch is at fault.
Headlight could also be smoked.
A spare H4 bulb doesn't light so don't think the headlight is bad.  I probably just missed something in the bucket but I remember the brake light switch bullets were under the tank & was wondering if there was some other connector outside the headlight bucket that would make the headlight inoperative.  I also cleaned up & painted the top triple...I'm guessing the black w/yellow tracer wire with a ring terminal going to one of the handlebar mounts is a ground wire.  Maybe that's my issue.
1981 KZ440 A2 LTD

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Re: No headlight

13 May 2022 06:11
#867002
Could be the headlight fuse.  I would check for power at the headlight connector & at both ends of the fuse. sometimes a fuse can look good, but the filament can be separated from an end cap or something.
1981 KZ650 Competition Sports and Road
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Re: No headlight

13 May 2022 15:22 - 13 May 2022 17:13
#867034
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Could be the headlight fuse.  I would check for power at the headlight connector & at both ends of the fuse. sometimes a fuse can look good, but the filament can be separated from an end cap or something.
Gotcha, I'll have a look again at the fuses...I did find a 3 post fitting near the front of the gas tank with nothing plugged into it.  Any idea what that is for?  Also, there are several ground wires with female bullets in the headlight bucket...does it matter which one I plug the wire running from the handlebar mount into?


1981 KZ440 A2 LTD
Last edit: 13 May 2022 17:13 by Sdaniels2010.

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Re: No headlight

13 May 2022 17:04 - 13 May 2022 17:14
#867038
So I checked the fuse, it's good.  All 3 wires to the H4 connector are good, at least to the bullet connectors.  Okay, bear with me here...how do I check for power at the headlight connector using a multimeter? 
1981 KZ440 A2 LTD
Last edit: 13 May 2022 17:14 by Sdaniels2010.

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Re: No headlight

13 May 2022 18:12
#867044
Most Kz’s have black with yellow stripe as a ground in the headlight bucket. Get the 3 terminal headlight connector, multi meter on DC, black from meter into the black/yellow female terminal. Then red to one of the others. (Sorry don’t know your actual colors) One wire is positive for low the other is positive for high. Ignition on stop/run/stop in the stop position. If you have a “lights” switch on the right hand control switch it to on. Left control on low for the headlight. Black/yellow to one should have power. Flip to high beam and check from black/yellow to the third wire. 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
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Re: No headlight

13 May 2022 18:31
#867045
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Most Kz’s have black with yellow stripe as a ground in the headlight bucket. Get the 3 terminal headlight connector, multi meter on DC, black from meter into the black/yellow female terminal. Then red to one of the others. (Sorry don’t know your actual colors) One wire is positive for low the other is positive for high. Ignition on stop/run/stop in the stop position. If you have a “lights” switch on the right hand control switch it to on. Left control on low for the headlight. Black/yellow to one should have power. Flip to high beam and check from black/yellow to the third wire. 
Think I understand...when I make those connections with the multimeter probes, what should I be looking for, a voltage reading of around 12 volts?
1981 KZ440 A2 LTD

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Re: No headlight

13 May 2022 18:56
#867047
Yes. Test the battery voltage. You should be close the that voltage.

If you don’t get 12v +- try moving the black from the meter to the engine ground. 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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Re: No headlight

13 May 2022 19:06
#867048
Maybe this will help. Looks like your looking for 12v +- between ground (black/yellow) and red/yellow is low. Ground to red/black is high beam. 
 


www.kzrider.com/modules/ServiceManuals/kz440.pdf
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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Re: No headlight

13 May 2022 19:21
#867049
and set Multimeter to DC Volt not AC
My 1975 Z 1 B 900 Project

www.kzrider.com/forum/11-projects/605133...ears-deep-sleep-mode

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Re: No headlight

14 May 2022 03:29 - 14 May 2022 04:23
#867062
I don't see an option for choosing between AC & DC on my multimeter but I'm pretty sure I got it right.  I checked the front turn signals because I know those were working & got right around 12 volts...I got nothing on either high beam or low beam when I tested the H4 plug.  Took apart the left switch hoping maybe the brass bits were corroded...they looked fine & still no light.
1981 KZ440 A2 LTD
Last edit: 14 May 2022 04:23 by Sdaniels2010.

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