Monza Square headlight parts.

[averydad]

Thanks for the followup. I had mixed up my terminology on the warning lights. I knew of the high beam indicator as well as the park light (understood to be of limited use)
I mistated the "charge indicator" light and refered to it as an ignition warning light.....sorry. I do know the difference. However, I had become confused and thought the high beam was the light mounted to the board while the charge indicator was direct wired. Thanks for setting me straight once more.

I did find some fuses today. 16 amp purchased from a local shop that restores vintage Porsches. Still working on the bulbs. Would there be a problem to run with out bulbs for a while ?

[DewCatTea-Bob]

" Would there be a problem to run with out bulbs for a while ? "

____ No, those missing bulbs should be no cause for concern.


____ How about posting some pix showing your wiring-work !?
__ Also, I meant to ask before if you'd list the CORRECTED-order of the labeled-lettering (for the 8 slots), as it appears on your circuit-board,, so that others won't also have to further contend with that non-updated physical-layout of that old-style scheme-diagram. _ (Cuz otherwise I'd have to figure/deduce it all out.)


Hopeful-Cheers,
-Bob

[averydad]

Here are the correct circut board wire connections for the Square headlight Monza 250. These are illustrated in the right location and order for these later style bikes.
I`ll try to post some photos of the headlight wiring tomorrow.

[averydad]

Thanks for the full color switch lay out. Thats pretty cool !
I do plan to mount a 30 amp fuse between the battery and ground as instructed. The present ground is a lighter 16 gauge wire mounted to the underside of the frame near the battery, using a bolt for the regulator box.
I`ll again take your advise to use heavier wire and run the ground to the coil mounting bolt.

That`s about it for now, I also need to buy some sheathing for the handle bar switch wire as what I have is too small to fit the four wires. Busy week for me on the home front so it may be the weekend till I can get these final loose ends complete.

I believe (hope) I have all the knowledge I need to complete the job !
I`m going to check my valve tappet clearance before I reinstall the tank. Then I should be good to kick it over.
The previous owner told me there was a problem with the charging system. The bike would die after about a half hour and a fully charged battery would be flat. I only ran the Monza five miles or so and never verified what if any charging issues there are.
However, after seeing the rats nest inside the headlight I`m hoping that in fact the charging system is OK and the "problem" has been cured by our installation of a proper wiring system.

I`ll surly keep you posted on my progress.

.......the next Monza I re-wire will be a piece of cake !

[DewCatTea-Bob]

" I do plan to mount a 30 amp fuse between the battery and ground as instructed. "

____ That's good, as it will protect ALL the rest of the wiring that's not covered by the originally placed three fuses !


" The present ground is a lighter 16 gauge wire mounted to the underside of the frame near the battery, using a bolt for the regulator box. "

____ That's just as stock. _ Only issue with that is that the headlight can work it's best when less GROUND-connection circuits have to be depended on.


" I`ll again take your advise to use heavier wire and run the ground to the coil mounting bolt. "

____ That will be smart, as then your headlight will not have to depend on any ground-connection (since your headlight is also grounded at that very SAME point) !


" after seeing the rats nest inside the headlight I`m hoping that in fact the charging system is OK and the "problem" has been cured by our installation of a proper wiring system. "

____ It's fairly likely that who-ever did the previous wiring-job, failed to make sure that ALL loads were drawn off-from just the GRAY-wire ONLY !
Cuz if any load was getting it's power from between the Red-wire & ground, then the battery would not receive sufficient charging-juice.


____ I've combined a couple of your pix to make it easier for others to fully see how the newer-style Monza headlamp-wiring should be arranged.
It's now posted below.


Duke-Cheers,
-Bob

[averydad]

Here are some pics of my `67 Monza 250 wiring project. I still have to wire the handle bar switch along with the headlight socket.

Thanks to the Motoscrubs forum, I believe I have the parts and the knowledge to finish up by the weekend !

[averydad]

I finished wiring the handle bar switch today. This should complete the head light and circut board job !

Attached are pics of the completed job. I`ve got the fuses installed and fitted the board in the shell. The only problem is clearence between the circut board bullet conectors and the HL reflector.
I had to bend the bullets to 45 degrees and gently smoosh it all in when fitting the reflector and chrome ring all together.

Thanks one more time to Bob, I`m really enjoying this project and never could have done it alone. Working on these old machines gives me a sense of pride and accomlpishment that`s unmatched in my work a day world.
Any feed back or final advise before I button up the head light and connect the battery, would be apreciated.

Rick

[JimF]

Wow, you do nice work when it comes to wiring. It's clean, tight (but not too tight) and all your terminations look perfect.

Real quick, I noticed you do not have a crankcase breather hose on the engine as I look at past photos. You will add one before you fire it up, right?

Jim

[averydad]

Hi Jim,
Thanks for the compliment. I tried to work to the highest standard within my ability. It`s a nice luxury to have no time constraint. It`s great to know others have followed this thread.
It seemed mostly like a one on one instruction between Bob and my self. However, the thread really is a master class on sorting the wires on a square style Monza 250 and hopefully will be of great use to other owners in the future !
As for the breather tube, yes I have a new length ready to go. I plan to run it to the original terminus at the right side cover/ air filter box.
Cheers,
Rick

[DewCatTea-Bob]

" I`m really enjoying this project
Working on these old machines gives me a sense of pride and accomlpishment that`s unmatched in my work a day world. "

____ Yep, it seems you've acquired the rewarding-feeling of working-on & accomplishing (superior)- restoration-work on these old DUKEs.
Now you'll likely next discover the enjoyment of taking your Duke out for PLEASURE-rides.


" Any feed back or final advise before I button up the head light and connect the battery, would be apreciated. "

____ From what I can see, it all looks ready to go,, however you ought to first try-out everything -(all lights & horn) with the battery hooked-up, before you put the headlamp completely back together.


Duke-Cheers,
-Bob