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6 1/4" non-sealed headlight mounting 19 May 2022 13:34 #867329

  • Sdaniels2010
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I picked up a new light housing but it doesn't come with anything to mount to the chrome ring...stock sealed unit has the two wings & left/right adjuster on it.  I'm not having any luck locating an adapter for this
1981 KZ440 A2 LTD
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6 1/4" non-sealed headlight mounting 19 May 2022 14:51 #867334

  • Scirocco
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No USA,Japan or Euro Model KZ or Z440 was ever sold with a H4 60/65 Watt bulb in a 6 1/4" headlight, only 30/35 Watt sealed beams.
You have to search for a lamp housing and mouting set for your headlight reflector, sorry.

You can try to bent the taps and bore out the dot welds and glue it to onto the new in the same position.

 
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6 1/4" non-sealed headlight mounting 19 May 2022 15:00 #867335

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edited bump 

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6 1/4" non-sealed headlight mounting 19 May 2022 15:15 #867336

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I thought about that but it's just simpler to pickup a new headlamp setup.  The light had the frame it was bolted into & that chrome ring you pointed out with the folding tabs that went around the glass that I thought  was going to be the part with those 2 mounting ears.  Was also hoping someone made an adapter for just this kind of thing but no luck yet.  No worries...thanks for the reply.
1981 KZ440 A2 LTD

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6 1/4" non-sealed headlight mounting 19 May 2022 18:05 #867347

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One thing I did think about was taking some 18 gauge sheet metal & cutting new pieces to use as those mounting ears.  I just don't know how I could attach it that would support the light without breaking loose.  I'm not 100% sure the new light backing is even metal so I wouldn't try welding or brazing.
1981 KZ440 A2 LTD

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6 1/4" non-sealed headlight mounting 19 May 2022 18:46 #867349

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One thing I did think about was taking some 18 gauge sheet metal & cutting new pieces to use as those mounting ears.  I just don't know how I could attach it that would support the light without breaking loose.  I'm not 100% sure the new light backing is even metal so I wouldn't try welding or brazing.
 

JB Weld or another form of epoxy?
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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6 1/4" non-sealed headlight mounting 20 May 2022 10:51 #867390

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One thing I did think about was taking some 18 gauge sheet metal & cutting new pieces to use as those mounting ears.  I just don't know how I could attach it that would support the light without breaking loose.  I'm not 100% sure the new light backing is even metal so I wouldn't try welding or brazing.


 

JB Weld or another form of epoxy?
I'm not sure I would trust anything other than a tack weld.  I've already got a new assembly on the way.
1981 KZ440 A2 LTD

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Last edit: by Sdaniels2010.
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