I know this isn't the Honda Express Forum but-headlight info

[gspreesea]

The previous owner really had this thing messed up. I have got it running again after messing with a broken kickstart spindle, broken inlet pipe, and now headlight. As you know its a 6V system. I could order a replacement bulb from Beatrice Cycle, but I had a 12 volt halogen laying around, so the tiny cogs in my brain started squeakily turning.
I cut into the old sealed beam with my light saber(I found some threads on it in google) and JB-d that sucker in. Of course I tried it to see if it will work and low and behold it glows brightly! I used a 9005 HB-1 I believe high beam only. So the low position of the switch is "off" Always make sure you tape off hot wires, don't wanna burn down the house.
Now I know this is probably stupid to do with possible burning/shorting things out, but as long as I don't smell any wires cooking, Im leaving her in there! Its pretty much a jerry rig job, but Im cheap and like to tinker. It looks factory from the outside.
I found a cool mirror at a bike shop and clamped it on. Now all I have to do is get my awesome neighbor to weld me up a nut onto an old kickstart lever and I will pinch-nut the thing onto the shaft we welded onto the end of the broken spindle. I have been just starting it with a 3/4 wrench with the 2 nuts on the piece of threaded shaft.
I think the choke is stuck because when I cover the holes on the airbox it fires on the first, well, wrench turn!
This Express is very susceptible to weather changes but it goes just as fast as my Spree, possibly a bit faster, but you know how each bike is different. It hits 30-31 on a flat run, but has a little less low end that the Spree.

[mousewheels]

Good work, some of those old 6v bulbs are hard if not impossible to find. Some members here were looking to replace burnt out bulbs in their sealed beam headlights too. Aside from that light saber were there some tips you have for removing the old lamp and base?

I have been just starting it with a 3/4 wrench with the 2 nuts on the piece of threaded shaft

[gspreesea]

Good work, some of those old 6v bulbs are hard if not impossible to find. Some members here were looking to replace burnt out bulbs in their sealed beam headlights too. Aside from that light saber were there some tips you have for removing the old lamp and base?

I have been just starting it with a 3/4 wrench with the 2 nuts on the piece of threaded shaft

[/quote
Well I just used a hacksaw because it could get close enough to the reflector part and I don't have a dremel anymore.
But, safety glasses and a dremel is what a guy wants to do that with. Just break the bulb if you have to inside buy yanking it out by he base with some channel locks or reg. pliers pore out the glass and dispose of it safely.
On the Express bulb you can actually pry out the lens part of the sealed beam by bending the outer edge of the light all the way around it with a small screwdriver.
Looking back, Napa does carry a 1156 style 6 volt bulb with wattage similar to the orig. Express sealed beam.
I would use that instead of a 12V just because I don't really know if the 12V might cause harm to your wiring, or if it works ok. Mine seams to work great and is bright as can be. If time permits and you can do it, check out that Beatrice cycle and they have exactly what you need, but if you like to make your own, by all means it quite possible.

[Lunytune]

Some of the old cars, especially Chrysler/Dodge, had a stepdown resistor cutting 12v down to 6v for the ignition system. We're talking pre-HEI days. I wonder if that would work.