headlight internal wiring

[skullduggery]

Hi guys,

I am new to the forum and in need of some advice regarding the completion of my Diana Mark 3. I am in the final assembly stages and getting to the part where I don't know squat! All the paint and mechanicals are completed and now down to wiring the bike. I am now looking at a birds nest of old wiring that I removed from the headlight shell. I know that all that old wiring, connectors, fiber boards, switches, etc. will be a source of future frustration if left as is. Can anyone recommend someone who is willing/able to rewire and repair or replace the parts inside the headlight shell as a unit?
I am also looking for a complete wiring harness kit for the bike because this is where my skill and understanding just come up short.
I am very pleased with what has been accomplished so far and don't want to spoil it with a shotty wiring job.
Thanks
Jim

[Rick]

At this point you probably know this, but just in case, lots of the corroded, brittle parts in the headlight are available as reproductions, here's one place:
http://www.guzzino.com/switcheskeys.html
The best wiring I've seen has been done by the aircraft guys- they've been through the soldering vs crimping battles, and know how to do reliable wiring- the local Air Guard base here is full of qualified guys who do work on the side.
I don't know of anyone making reproduction wiring harnesses for any of the old Italian motorcycles. There probably are some parts of the original wiring scheme that don't deserve being copied, tail light circuits are often a little strange.
Rick

[JimF]

Mach1 wiring.jpg

I used to make some harnesses to sell, but I don't have time anymore. This is a document I supplied with the harnesses. Maybe it will be of a little help.

Jim

[DewCatTea-Bob]

By: skullduggery...
" in need of some advice regarding the completion of my Diana Mark 3. "

____ You didn't mention which year-model your Mk3 is...
If it's a narrow-case model, then it's wiring is pretty-much as simple as it gets on most any road-going motorcycle ! _ And thus with some instructional-guidance from myself or another n-c Mk3-owner, YOU should then be able to do the re-wiring yourself, without much complication.
__ Do you now think that perhaps you (or a near-friend who's done such), could possibly handle the work-job ?


Duke-Cheers,
-Bob

[skullduggery]

Bob and Rick,
Thanks for replying.
I did forget to mention it is a 1965 n/c 250. I am sure I could manage to repair/restore the wiring myself. I am a little unsure because I have a Mach 1 style light with a key switch, dimmer switch, warning lights, and connector blocks. I was not sure how to wire those components to a magnito. I agree that the wiring is simple. But, I was looking to buy my way out this part of the resto...
Thanks for the schematic, this will prove to be helpful.
best regards,
Jim

[skullduggery]

Sorry,
I forgot to thank Jim F too!

[DewCatTea-Bob]

" I am a little unsure because I have a Mach 1 style light with a key switch, dimmer switch, warning lights, and connector blocks.
I was not sure how to wire those components to a magnito. "

____ First-off, there is no "magnito" (on any OHC-Ducati) ! ... However it is fair to say that your '65-Mk3 employs a magneto-LIKE ignition-setup.
__ Installing a Mach-I headlight on a Mark-III is not much of a problem... Most of the internal headlight-wiring will be excess & unneeded, and the headlight-switch & Hi/Lo-switch can work just as well on a Mark-III,, and while the key-switch is absent on stock Mk-III models, I believe it can still be wired-up to break the power-connection to the ign.coil whenever the key is not inserted.


" Thanks for the schematic, this will prove to be helpful. "

____ Not too much really, as the one posted (here in this thread) is the wrong scheme for ANY Mark-3 type model !
__ Are you completely positive that your Duke is mainly a "Mark III" ? ...
How many separate wires are within your engine's alt.cable -(of which it's black-conduit is seen exiting the motor-casing near the kick-lever), two or three ?


Duke-Cheers,
-Bob

[skullduggery]

Bob,
the bike has 3 wires coming out of the crankcase. the engine #'s are DM 250 M3. Also, the headlight was purchased separately from the bike.
Thanks,
Jim
BTW I thought "magnito" looked misspelled

[DewCatTea-Bob]

" the bike has 3 wires coming out of the crankcase. the engine #'s are DM 250 M3. "

____ Okay then, it seems your 'Duke' -("bike") must be a Mark-3 (or a Mark-III, depending on whether your model was actually made in 1965, [as many '64s were sold in '65!] ).
How about some pix of the parts you got with your n-c 250-Mk3 ? _ (If, for instance, it includes the toolbox-covers, then it's a 'Mark 3' ,, as the older 'Mark III' model didn't have those !)
Of course I-myself haven't had personal-contact with a very-great number of the Mk3-models, but it's been my experience that if the motor-case has 'M3' stamped onto it, then it was a Mk3-model that also included the side-box/covers as well.
__ Your Mk3-motor must have it's original alternator (often wrongly referred to as a "magneto"), as it has a 3-wire alt.cable. _ The three separate wires are Yellow (for ign.system); White (for brake-light); and, Red (for lights).
With my direction, it should be fairly easy for you to wire-up your Duke yourself with pretty-much standard Ducati-like wiring based on the Mk3's very simple wiring-scheme (while still making use of your M1-type headlight-wiring) ! _ However while it would be educational for you to experience the down-sides of the stock-type battery-less wiring-system, I ought now point-out that there are alternate ways to wire-up a Duke with the 3-wire n-c.alternator, which perhaps you may wish to consider, (more on such later, if you're interested).
__ While I'm certainly interested in moving-forth with the particular intended wiring-instructions for your somewhat unique combo.wiring project, (as I-myself have installed Monza-headlights on-to n-c.Motocross models before, [which is the very-same mod.work project, wiring-wise]),, you should first determine that your alt.wiring-circuits are good to go.
Do you have an ohm-meter or continuity-tester ? _ If so, you should find that the Yellow & White wires complete a closed-circuit to each-other, but not also to Ground ! _ While the Red-wire DOES complete a closed-circuit to Ground, (but not to either of the other wires) !
Can you let us know the results of your test-findings before deciding what to do next (with your wiring-project) ?


Duke-Cheers,
-Bob

[JimF]

I could probably take some photos of the headlight wiring - there are few enough wires that it's easy to see where they go.

I could talk you through it over a few emails regarding wire gauge, color, wire termination.

Jim