Headlight replacement issues

I have a 1980 KZ440 LTD (chain) in need of a new headlight. I see a lot of people claiming the H6024 is a direct replacement, but it doesn't seem to have the bolt holes for mounting within the headlight bucket. How do these type of headlights mount up? If they aren't a direct replacement, what is involved with replacing the headlight unit?

If your 440 has a seven-inch, round headlight (I am pretty sure it does), then the 6024 should be plug and play.

www.z1enterprises.com/headlight-sealed-b...60w-12v-halogen.html

I just replaced the 7" headlight on my KZ1000 with an H6024. There's a 2 piece mount that goes around the headlight bulb and it has the hardware to mount it to the main chrome ring. I see by the partzilla schematic that your unit is quite different www.partzilla.com/catalog/kawasaki/motor...0-a1/headlight-80-a1 . Unfortunately, it's OS with them. The part # is 23007-059

First thing is to verify the size. I would think a 440 headlight would be smaller than 7". .??? .Then I would look into swapping the headlight with something that accepts a standard sealed beam or can be converted to an H4 bulb. Candlepower may have something, but some of the 6-3/8 lens units are NLA as the mfg plant apparently was affected by the Fukushima Tsunami nuclear disaster.



...

martin_csr is on the right track. Check the size and type of your current headlight. There were a couple different types used depending on the year of the KZ440. I suspect you might find the stock headlight is different than a "normal" 7 inch unit, so you may need to adapt a different shell to the bike if you want to use a 7" unit. Ed

I measured the headlight and the glass lens at the front is about 6 inches across. There are also mounting brackets welded/soldered onto it (two bolt holes at the top and bottom for the horizontal aim adjustment pivot, and one on the side for the adjustment screw.

So it looks like I'll need to replace the bucket. Anyone have any ideas as we what bucket works well and looks mostly stock?

No eBay APP ID and/or Cert ID defined in Kunena configurationDoes your old sealed beam lens unit have any information on it? either in the glass or stamped in ink on the back? If so & this may be a long shot, but I would try looking into a Honda headlight. I'm thinking maybe Honda used the same sealed beam on some of their models, but of course the part number is different. So if you can find Hondas that use the same lens unit, then you can search for something affordable. Or maybe try Suzuki or Yamaha, but I didn't look at any of those.

.... Just an example. It appears to be similar to the KZ440 & is listed as 6-1/2".

DimeCityCycles lists a couple of 6-1/4" headlights. The description for the black one says it's 6-1/2" between the fork ears.

dimecitycycles.com --- 6-1/4" Chrome H4 Headlight Assembly --- H4 Bulb --- SKU: 66-64312 --- $49.95

....

No eBay APP ID and/or Cert ID defined in Kunena configuration

martin_csr wrote: Does your old sealed beam lens unit have any information on it? either in the glass or stamped in ink on the back? If so & this may be a long shot, but I would try looking into a Honda headlight. I'm thinking maybe Honda used the same sealed beam on some of their models, but of course the part number is different. So if you can find Hondas that use the same lens unit, then you can search for something affordable. Or maybe try Suzuki or Yamaha, but I didn't look at any of those.

.... Just an example. It appears to be similar to the KZ440 & is listed as 6-1/2".

That does look really close. The clincher is that it has the mounting/pivot bolt holes and the adjuster screw bracket. $50 though... ow.

If you can figure out if the Honda part fits, then you can search by price. If your lens unit doesn't have any info stamped on the back for comparison or it's faded & unreadable, try checking eb photos to see if any other KZ440 headlights have some info.

Here's another Honda headlight. see video in the pics on the left.
common-motor.com --- Honda CB350 / CB450 K1-K4 Headlight Lens & H4 Bulb Kit --- 6.25" lens unit