Monza Square headlight parts.

[averydad]

Wow...I`m finally really getting somewhere ! I recievd an email from Angela at Classic Ducati. She sent me an exploded parts diagram of a 1966 square headlight. Up till now all I had was a 1964 round headlight parts picture along with an early monza wire diagram. Both of these early references show a seperate "commutator" headlight switch. With Bob`s detailed info and generous help I had it mostly sorted but was still confused !
Now that I see what the original really looked like, the arrangement of the headlight componets is comming into focus.

I saw the `66 light 180904520287
on ebay last night and have contacted the seller to get a better description of it`s condition.
Thanks Dan

I also have looked at the listing, ebay 270790849851 which Eldert has found.
Thanks Eldert

Bob...do you think this NOS switch from Netherlands is correct for my Monza ?

[JimF]

Can you post the exploded diagram in this thread for future reference?

Jim

[averydad]

This is for a 1966 160 Monza Jr. Kindly sent to me by Angela at Classic Ducati in UK.

[DewCatTea-Bob]

" Now that I see what the original really looked like, the arrangement of the headlight componets is comming into focus. "

____ Actually, that really shouldn't be the case ! _ Cuz while the 1966/square-headlamp's internal-wiring/etc. for the 250-Monza, is pretty-much the same as the earlier 250-Monza's,, that of the 160-Monza Jr. is completely-different and nothing at all the same, (except for their high-beam indicator-lamp) !!


" Bob...do you think this NOS switch from Netherlands is correct for my Monza ? "

____ I'm really not sure of exactly what you're referring to. _ But if you're still in reference to that which you asked about before,, I then would've expected that my previous-response of: "I don't recognize that part,, although it could probably be somehow adapted to work for you, it couldn't be simply-done," , would've at least tipped you off that THAT particular part is certainly not of much use to you.
And it's most definitely NOT "correct" !
In fact, that's one (of many) such eBay-listings that's an out-&-out LIE ! _ As in no-way is that part ever been originally-intended for all the listed Duke-models claimed !


" This is for a 1966 160 Monza Jr. Kindly sent to me by Angela at Classic Ducati in UK.

____ Well that 160-info is going to lead you astray -(as in: way-off !) ! _ Cuz that of the 250/350 is TOTALLY different, (aside from the headlamp-shell itself) !


Dukaddy-DUKEs,
-Bob

[averydad]

Geez....just when I thought I was getting a grip on this thing !
Thanks for setting me straight Bob.
Does this ebay listing look like a 160 or 250 to you ?
ebay 180904520287
I know it looks a little rough but if you think it`s an original 250 set up it may be useful as a learning tool for me if nothing else.
If anyone has a Monza 250 square light parts diagram they can share it would be most apreciated.

[DewCatTea-Bob]

" just when I thought I was getting a grip on this thing !
Thanks for setting me straight Bob."

____ Haven't set you straight yet, it seems,, but have kept you from getting TOO mixed-up.


" Does this ebay listing look like a 160 or 250 to you ?
ebay 180904520287 "

____ From what I can see of it, (link: http://www.ebay.com/itm/180904520287?ru ... 26_rdc%3D1 ), it must be from a 160 because, it doesn't include a 250/350 type circuit-board -("switch-board" as Eldert has stated), and also the handlever-support appears to have a 160-type light-switch attached.
__ You could however make-use of such a switch !


" if you think it`s an original 250 set up it may be useful "

____ The eBay-listing (link: http://www.ebay.com/itm/270790849851?ru ... 26_rdc%3D1 ) which Eldert nicely found for you is THE circuit/switch-board that your 1966/250-Monza headlamp has missing !
Although it's probably the same unit which melts-apart at the fuse-mount location.


" If anyone has a Monza 250 square light parts diagram they can share it would be most apreciated. "

____ Have you not checked this w.site's tech-section for any listed parts-manuals which happen to include the later-model Monza-parts listings ?


Hopeful-Cheers,
-Bob

PS. Note that I've also finished-up my previous post.

[averydad]

OK....well I`ve heard from the ebay seller of the Monza headlight and he confirms what I alread learned from Bob that this is a 160 headlight. Therefore of no use to me.

The part from the Netherlands I was refering to was in fact the listing Eldert found for me. Sorry I wasn`t more clear.

My plan as of now is to order the correct switch/board as well as a new horn.
I`ll make sure the fuse is very tight, keep a close eye on it and hope for the best.

While I wait I will follow Bob`s instructions to modify my harness with white and a blue wire added ground ect. This will be easy as my harness is not enclosed in a sheath but simply wrapped every eight or ten inches with electrical tape.

I have searched the motoscrubs tech section but have only found the pictures I already have. One reason I was so confused is that I (wrongly) figured the only difference from round to square headlights was the shape of the shell !
I had studdied the attached pictures and tried to mesh what I saw with what Bob was trying to teach me and some parts didn`t add up.

So, I`ll work on other parts of the Monza while await the switch. Then I`m sure to need more advise !
Cheers to all,
Rick

[DewCatTea-Bob]

" The part from the Netherlands I was refering to was in fact the listing Eldert found for me. Sorry I wasn`t more clear. "

____ At the time when I was unsure of what switch you were asking about, I had not yet bothered to search-out the given number at the eBay-site, (to confirm Eldert's belief).
BTW, Eldert's posted-info is pretty-much always quite trustworthy !
__ For the convenience of others, it's better to provide a link (direct to the listing), rather than merely providing eBay's 12-digit listing-number.


" My plan as of now is to order the correct switch/board
I`ll make sure the fuse is very tight, keep a close eye on it "

____ Once those boards are fully installed, it's then too difficult to see the melting-issue.
__ That board's plastic becomes melted because the copper-alloy fuse-holder doesn't hold it's connection to the fuse tightly enough, thus allowing very hot heat to build-up in-between and transfer through the fuse-holder's copper where it's directly attached to the board's plastic (which can't well handle the heat !).
Trying to bend/pinch the holder a little so that it then more securely grasps the fuse somewhat tighter, does indeed help decrease the heat build-up and thus prolong the life of the plastic (from melting out of shape). _ But that slight cure should not be expected to last forever with a headlight with any stronger than a 25w.bulb .
I've gone-through a number of those circuit-boards, (my first one was just 9-bucks in '69), and whether or not I tried to get the f.holders to press-against it's fuse more tightly, the board would still eventually get melted, when running a 35 or 45-watt 6v.sealed-beam !
The problem is directly blamable on the fuse-holder AND cheap fuse-type ! _ The situation should be totally bypassed, with the use of a good/modern Japanese or American fuse-holder & fuse !
__ So anyhow, if ya -(anyone) have a Monza/Sebring square-headlamp, then ya ought to check & see if your white-plastic type circuit-board has started melting & letting your fuses become rather loose !
It would be nice to get an idea of what percentage of us have actually developed the issue with THEIR boards ! _ And also, whether or not YOUR board is 'white' in color, or whatever, (as some are gray).


" my harness is not enclosed in a sheath but simply wrapped every eight or ten inches with electrical tape. "

____ That's really not too good. _ You ought consider getting some pieces of plastic conduit-sheath and slide them over your batch of wires, to become located at points such as where the wiring enters & exits from under the fuel-tank, etc.


" One reason I was so confused is that I (wrongly) figured the only difference from round to square headlights was the shape of the shell ! "

____ Well actually, the differences between the internals of the 250/350 round & square headlamps are only 'physical' ones, as their 'electrical' differences are nil.


" I`ll work on other parts of the Monza while await the switch. Then I`m sure to need more advise ! "

____ The stock circuit-board would be nice to have IF your wire-harness was also stock ! _ You're next now going to have additional work to accomplish when you then attempt to make your non-stock wiring all fit-up nicely with your new board.
__ Since your two added white and blue wires are more certain to be long enough to reach the circuit-board's terminals location, you can now go-ahead & connect the white-wire to the ign.coil,, and your blue-wire to the horn, as well as the brake-light switch. _ The existing black-wire going to the brake-switch shall be diverted to the horn's other terminal (for the horn-button).


" I asume only part of this applies to my square light 250 "

____ More than just "part", as it's more-like MOST-everything is applicable ! ...
While the PHYSICAL-differences of many parts of the older round-headlamp & the newer square-headlamp are of-course obvious, your presented ELECTRICAL-setup is pretty-much completely the same for BOTH headlamp-types. _ However...
the reason I've stated "MOST-everything" & "pretty-much", is because I believe there's one minor difference as to exactly where the parking-light fuse actually gets it's power-juice from...
YOUR presented electrical-scheme/diagram indicates that that-fuse is connected to the (regulated-output) of the Gray-wire, and that is not correct for a PARKED/(& stopped)-engine. _ Rather, the parking-fuse ought to be connected to the Red-wire (directly from the battery).
This slight difference is likely due to the fact that the made-for-USA models used this (keyless)- circuit as a 'parking-light' function, whereas the otherwise identical, (except for headlamp sealed-beam/bulb version), models intended for other than N.America, (as I've been led to understand), used the circuit as a running-lights setting for ''city'' -(as the Italians put-it).
__ Note that I've included [below] another version of that which you had included within your-own post.
I got it from THIS w.site's tech-section,, and naturally I hate to put my-own knowledge up-AGAINST such supposedly credible sources but, IT -(THIS one, below) has a certain flaw ! ...
As IT shows that the White-wire to the ign.coil sources it's power-juice from the WRONG key-switch terminal ! _ (While YOUR posted scheme-diagram shows the CORRECT key-switch terminal-connection for that ign.power/white-wire !)
In this error-case, I have no explanation to offer for how such a (definite!) mistake ever got published. _ However I do KNOW for absolutely-sure that it is indeed a major mistake !! _ Cuz I've had to correct this wiring-error on both Monza & Sebring models (that had been rewired by others), which had been experiencing a battery-discharging issue...
The problem with that incorrect hookup-connection, is that the power-juice consumed by the ign.circuit DIRECTLY from the battery INSTEAD of that provided by the stock current-regulator's Gray-output, causes the regulator to provide insufficient charging-power !
So DO-NOT follow THIS wiring-connection scheme (below), in regards to where it indicates the White-wire should be connected to the key-switch !


Hopeful-Cheers,
DCT-Bob

[averydad]

Hello to all,
Well I`m back from a weeks vacation and have received the new switch/board ordered from the Netherlands. I`ve also purchased a handlebar switch and mounted a new horn.
The new white wire is run from the coil as well as the blue wire for the horn. I`ve also picked up some very nice woven wire loom casing that I`ll use as a final touch.
I still need some inline fuses and presume I`ll need a selection of bullet conectors for the switch/board. Any advise on the best type of fuse holders would be apreciated. Last thing I`ve yet to buy are the warning lights for the headlight shell.
The red ignition light seems important but I`m not sure of the second warning lamp function but believe it is for the parking lamp ?

I hope to do a nice neat job on the wiring. Make it safe and functional. However, I`m not really worried about a parking/town light nor even the low beam, especially if wiring these features will complicate my task.

Here are some pics of the items I have.
Once again I am in great debt for any help I can get.
Rick

[DewCatTea-Bob]

" have received the new switch/board ordered from the Netherlands. "

____ Well it's about time. _ (I had begun to lose interest in your project.)
What color is your new board ?


" The new white wire is run from the coil as well as the blue wire for the horn. "

____ They shall be plugged into your new circuit-board.
Your blue-wire (preferably with black-stripe) is supposed to go directly to the horn and then jump-over to the brake-light switch as well. _ Hopefully that wire is 14 or 16 gauge,, but if 18-gauge, then you ought to double-up that run of wire.


" I still need some inline fuses "

____ Your circuit-board is meant to handle the 3 fuses required but, replacing it's fuse-station meant for the lights would be a good idea.


" and presume I`ll need a selection of bullet conectors for the switch/board. "

____ You'll need about 8 of them which are all the same size.


" Any advise on the best type of fuse holders would be apreciated. "

____ If nobody-else responds, then just get a couple of whatever's stocked at your local auto-shop.


" I`ve yet to buy
the warning lights for the headlight shell.
The red ignition light seems important but I`m not sure of the second warning lamp function but believe it is for the parking lamp ? "

____ The only two are the red high-beam indicator, and, the charging-indicator (which is held by the circuit-board).
The other (opposite of the red-lamp location), is a dummy of which it's green-lens is intended to be lite-up by the (rather remotely located) parking-lamp.


" I hope to do a nice neat job on the wiring. Make it safe and functional. "

____ That's the only way I-myself have ever done such !


" I`m not really worried about a parking/town light nor even the low beam, especially if wiring these features will complicate my task. "

____ Well they would've added to the wiring-circuits to be completed, but, now that you've got a circuit-board, pretty-much all of the related wiring-tasks are already worked-out for you ! _ As they will automatically-occur when you plug-into the board.


" Here are some pics of the items I have. "

____ I'll comment on them later, (when I'm on another PC with a monitor that will show them much brighter to me).
UPDATE: ... I've now seen all your pix (posted above)...
All looks well except that your chosen handlebar-switch is not stock. _ However it IS the same electrically, (so it will work well enough) !


Duke-Cheers,
-Bob