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Headlight switch 06 Mar 2024 17:06 #896064

  • Slj029
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Forgive me if this has been posted before but I’m looking for the switch that actually controls the headlights. I have attached a picture to show what I’m looking for. As you can see the plastic piece is broke. I’ve searched for hours looking and thought I would ask here. 
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Headlight switch 06 Mar 2024 23:48 #896078

  • Wookie58
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Model and year of bike would be helpful
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Headlight switch 07 Mar 2024 02:22 #896081

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1979 KZ1000 LTD. Sorry about that. 
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Headlight switch 07 Mar 2024 03:26 #896082

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Do you have the piece that broke off? if so it may be repairable if you can't find one (I have done quite a bit with plastic on my current build so may be able to offer guidance if you choose to repair)

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Headlight switch 07 Mar 2024 03:26 #896083

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Check ebay. Unfortunately a common issue because of the brittle plastic used. That piece is used on multiple KZ's starting in 1976-1980. They are kinda pricey though, around 50bucks. Even a brand new one will crack at the hole when installed. You "could" put some superglue on it upon reassembly and it should be just fine.  

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Headlight switch 07 Mar 2024 03:30 #896084

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Check ebay. Unfortunately a common issue because of the brittle plastic used. That piece is used on multiple KZ's starting in 1976-1980. They are kinda pricey though, around 50bucks. Even a brand new one will crack at the hole when installed. You "could" put some superglue on it upon reassembly and it should be just fine.  
The "hot staples" I have been using on my project will reinforce the joint (like re-bar in concrete)  they are incredibly strong 
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Headlight switch 07 Mar 2024 03:49 #896086

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Hot staples, love it! I've got a bag of these that have that broken bit like the one shown Wookie. I've often considered fixing them, reason for saving them. I just wish they never changed the formula of black plastic used on the Z1's and triples, those never broke/shattered but they don't interchange unfortunately.  
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Headlight switch 07 Mar 2024 06:48 #896103

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You're fortunate you still have the handle & screw.

A way to prevent the plastic from cracking is to slightly enlarge the hole, just enough to clear the root of the threads but not so much as to keep the threads' crest from engaging., so the screw's root isn't constantly exerting pressure trying to split the plastic..  Slightly enlarging the hole relieves the stress.  A dab of black RTV in the slightly-enlarged hole will keep the screw in place & not stress the hole in the plastic tab as much. However, disturbing the screw on an original switch might further weaken it.

Mama Kaw used that basic switch slide design in many bikes of the era.  Many looked very similar but don't interchange because the dimensions differed slightly.  Even the very earliest '72 production Z1 switch slides differed from later Z1 and all Z1-A / Z1-B slides.

Mama Kaw offered a repair kit with handle, screw & slide, PN 99990-530.  A very brief search indicates NLA, but a deeper search might find one.

If only the slide is needed,  #46089-014 turns up a few slides on fleaBay.  Prices are steep, but if one wishes to keep correct OEM date coded switchgear, it might fill the bill.  We don't know if that one fits the 1979 KZ1000 LTD.

ASPHALT900 - there's a black slide from Germany on the 46089-014 number that might be what you're looking for.  Might be a 3D printed replica though.

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Headlight switch 07 Mar 2024 07:38 #896107

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Thanks for all the info. I did have the piece that broke and was supergluing but my son knocked the piece somewhere and I can not find it. 

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Headlight switch 07 Mar 2024 07:47 #896109

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Thanks for all the info. I did have the piece that broke and was supergluing but my son knocked the piece somewhere and I can not find it. 
If you go down the "hot staple" route you could attach a suitable piece of plastic then shape and drill it once the glue has set. Hot staple guns are approx $25 on Amazon and once you have used it you will wonder how you ever lived without one, can be used to repair pretty much anything made of plastic (side panels, car bumpers, household items etc)
PS: you can spend a lot more but as I was sceptical I bought one of these cheap guns which I have now installed hundreds of staples with on all the plastic fab for my project and it still works just fine 

 
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Headlight switch 07 Mar 2024 11:53 #896116

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You can buy a new replacement part from Z-Power in the UK...

www.z-power.co.uk/hilow-switch-repair-kit

H.
'81 GPz 550 D1 Click this link: www.kzrider.com/gallery/kz-550/1981-gpz550d1-9094#joomimg
'81 GPz 1100 B1 ELR "Tribute" www.kzrider.com/forum/11-projects/617040-1981-gpz1100-b1-rst
'82 Yamaha YB100 Fizzie
'79 Suzuki GT200 X5 TWO STROKE TWIN - SMOKER!
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Headlight switch 08 Mar 2024 06:49 #896142

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Thanks Howard, super handy to know!! Unfortunately they appear to out of them, figures, a popular item i'm sure. Something noteworthy though pertaining to the fitment in text. This one does NOT fit the 72-73 or 1974 Z's! Like mentioned, those were different and won't work or even fit. Note picture differences and what switch goes with what switchblock top housing.  You're so handy Howard you can probably make them!! But not cost effective i'm sure. Wookie, here's one little bag of those broken ones i ran across, ha.
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