My new TRX

[Homer]

Electrics NOT sorted. When I push the horn button, the headlight fuse blows. Its no wonder I drink.

[Mincehead]

Again Homer, another feed either going to earth or an ACTUAL bad earth that`s common to both the lights and the horn. It might be inside the handlebar switch, does the horn button live next to the light switch?.
If in doubt about earth issues run seperate earths all the way back to the battery negative terminal or make an earth post of a good fixing devoid of paint, make it an earthing point that all systems are wired to. It`s then easier to ascertain earthing faults as they`ll only be one point to check.

[Homer]

Hurray, I have a horn!!!! And I owe it all to you Mincehead.
Rewired the horn circuit from the switch to the horn and no more blown fuses.
Thanks mate.

[Mincehead]

I reckon that original loom has suffered some crushing damage somewhere, the wires plastic sheething being exposed and allowing some to short out with others.
You`ve got the horn now (oooer) JOB DONE!

[fung]

Homer is HORNY again !!
WOO HOO ! ! !

[Homer]

Heres how she looks with the exhaust and new muffler fitted.
Bloody painter hasn't done the cowl yet so tomorrow I'll just be sitting on the bike going broom broom, instead of taking it for a spin.

003.JPG

[Mincehead]

I must admit I really like that high level exhaust system, if you ever take it off for painting / repair see if anyone can jig it up Homer.
You could sell copies of the headers to folk like me.

[Homer]

Update;
Bloody painter hasn't started on the headlight cowl yet. Knob. On a positive note, picked up a DR250 speedo drive and cable today at the wreckers which will fit. Also picked up the collar out of the oil filter cover that went missing. Set me back all of 8 bucks. Supposed to pour down here for the next 3 days, so I'll probably get it going tomorrow, and won't be able to ride cos of the weather.
If its not raining, I'll be at cricket all day so won't get to work on it anyway.

[Homer]

Well finally picked up the tank and headlight cowl from the painters. Had to reshape the instrument bracket to fit the cowl. but its looking pretty good I think. Still got to paint a few bits and pieces and fix a few electrics.

Almost finished - Copy.JPG

[Mincehead]

Looking really nice Homer.

[davamb]

Yep, agree with Mince - looks the goods, though I reckon it could do with a sump bashplate to make it complete. Top job there Homer, well done.

[Homer]

Thanks guys. Got a bashplate painted and ready to go on, once I've fitted the new oil filter. Just can't bend down after playing cricket yesterday.

[SDN]

What a resto - I can hardly believe what you have done from a really unpromising start. I take my imaginary hat off to you

[Homer]

After filling her up with 4 litres of Motul 5100 and a new filter, I fired her up this arvo, (note to self, remember to turn the fuel on!). Had to relocate the choke to the handlebars first. Started and ran well. I was a bit paranoid about the oil flow to the head, so loosened the check bolt, and engine oil is dribbling out slowly. I would have thought the oil pump would have pushed the oil out under a bit more pressure. Oil level checks out OK.
Then after a while, the engine seemed to become a bit noisier. In particular the starter motor. Now I know oil pressure problems won't effect the starter motor, but is there an easy way to check that the head is receiving plenty of oil? The last thing I want to do is stuff the engine.

[Mincehead]

Those oil galleries have been calculated (by their diameters) to carry the oil at the correct pressure. That oil gallery bolt only opens up a 6 mm hole so a `dribble` is literally exactly what you would expect to see.
Of course the starter motor might need to be checked out, easy to remove just two bolts up into the bottom of the crankcases and an o-ring that seals it where it goes into the back of the alternator housing. It`s possibly just some wear on the spindle or pinion, easily checked and if another starter motor is deemed necessary they are pretty Yamaha `generic`, the one on my Skorpion (XTZ660 motor) is identicle to my TRX one as far as I can see.