TOPIC:

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?  

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.

wrote:

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.

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.

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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?

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? 

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. 

wrote:

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?

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. 

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

and set Multimeter to DC Volt not AC

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.