Kz1000 headlight inop after control restoration

I repainted both left and right controls on my 1977 KZ1000. After reassembly the only think not working is my headlight. Iv checked and rechecked everything and all wires and switches seem to be operating as normal. So far I’m convinced it must be the headlight switch that is not allowing power to the headlight. Any thoughts on a possible solution? Anyone had this issue before? Thanks!
 

Not sure where your other post has gone but the below should get you sorted

Could the bulb have burned out?

TexasKZ wrote:

Could the bulb have burned out?

it looks like he isn’t getting a feed to the light (I suspect it’s linked to the switch rebuild)

Your RH switchblock wiring is only half the circuit. RH just switches Brown + thru that white slider to the Blue/White when in ON position. That Blue/White, within wiring sheath (female) dumps out underneath the petrol tank and plugs into the Blue Main harness which routes back to the fusebox. From there goes back up main harness to again connect to the LH switchblock. You'll see that halfmoon wafer with 3 wires soldered to it. That wafer HAS to be seated correctly in the upper half or the sliding knob for HI/LO won't function. Also check your fuse terminal holders, they can get weak or rotted. And those glass fuses. Don't always trust eyesight, they can unsolder at the ends internally but appear fine.   

As explained with my diagram, three prods with a voltmeter/test lamp will confirm or disprove the switch as the location of the problem (should take about 5 minutes) you can discount the right switch and wiring as you know you have power at the fuse on the blue wire

Absolutely Wookie!! I was just adding some additional crap that follows the path of failure /success. Also "unseen" don't know what KZ1000 he has? An LTD1000 has individual connectors whereas the A model had connector 4&9 female non latching blocks..just don't know enough? But if he'd removed the stuff and it was working before, something is astray in reassembly. He never mentioned if he removed the internals on handlebar or completely removed/disconnected from main harness on both assy's?? Who knows, i'm just having FUN!

asphalt900 wrote:

Absolutely Wookie!! I was just adding some additional crap that follows the path of failure /success. Also "unseen" don't know what KZ1000 he has? An LTD1000 has individual connectors whereas the A model had connector 4&9 female non latching blocks..just don't know enough? But if he'd removed the stuff and it was working before, something is astray in reassembly. He never mentioned if he removed the internals on handlebar or completely removed/disconnected from main harness on both assy's?? Who knows, i'm just having FUN!

Indeed Clay, I just try and keep it simple for the non-electricians (bite size chunks) as even many dealership techs struggle when it comes to electrics 

Wookie that was it! Thanks for your help. 
Now the fun part. The reason im not getting power is because the half moon shaped plastic piece has broken. Tried to superglue the part back together and that sort of worked, atleast enough to get the headlight to turn on, however I dont trust this fix long term. Now I need to find a replacement part. Any suggestions on how to approach this?

This part is on the dimmer HI/Low Switch 

Yep. I have boxes of those. What's your soldering skill level?

I soldered the horn back together the other day and got it right on the first attempt. That was the 1st time. So very inexperienced, yet fairly confident.