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Ian Soady¹ said :-
I can't remember if it has been running at all Glyn. If so I would be suspecting the lead short issue. If it hasn't then could be any of Upt's suggestions. I find it useful to replace the fuse with a bulb and progressively disconnect things till the bulb goes out. But rereading your last point, it would be as well to check the alternator for a short. None of the 3 leads coming out of it should show a connection to earth.
15/03/2026 12:49:47 UTC
Glyn said :-
I don’t have any time today to check it out. However, if I remember rightly, the battery plus connects directly to the alternator without going through a fuse. I took a quick look at the wiring diagram which revealed that the horns, lights etc are switched through their earth return and not in the plus 12v feed. The old horns had 2 wire connectors whilst the new have a single with the earth being the body. This could hold the answer to the problem although, I suspect, the horns would have blasted loudly rather than the fuse rupture. It seems to me that switching the earths only permits the use of less fuses. When you have a fuse for everything, it’s much easier to trace a fault. The Triumph 30Amp fuse puts plus 12volts all around various electrical circuits not just one.
15/03/2026 14:46:23 UTC
Glyn said :-
Got it! It was the new horns. I’m afraid you folks didn’t have a chance to help me as it was on of those “man made faults” that, obviously, don’t comply with the usual rules of repair. I had (wrongly) assumed that the switch button on the handlebars was providing the plus 12v to the horns via the brown wires. I even checked it on the multimeter and found it switched on and off when the button was pressed. Therefore, I also assumed the black wires to the horn were the negatives and so earthed them to the frame. The truth is that the (earthed by me) black wires actually carried the plus 12v and the browns went off to the switch… pay attention young Glyn, assume nothing, Idiot boy!!
That “shunting the broken fuse with a 12v bulb” is a brilliant hack Ian, it saved the lives of several more 30Amp blade fuses.
15/03/2026 16:41:43 UTC
Upt'North ¹ said :-
I think the horns on my Strom are wired in the same way Glyn. I think what you are saying is that they are basically always live and operating the switch completes the circuit. Or some'at like that.
Upt.
15/03/2026 16:52:53 UTC
Glyn said :-
That is exactly it Up’t. In the Triumph this permanent feed comes through black wires. I’m very old school where black was usually negative. I remember that Vauxhall cars started using black wires for positive 12v feeds which blew up many after market radio cassettes players.
15/03/2026 17:03:22 UTC
Ian Soady¹ said :-
Most horns these days are switched on the earth path. I think the theory is that there's less current in it. However, I've wired the horns on the B'Zuki with the switch in the live side as that was convenient. If I'd been feeling posh I'd have added a relay but hopefully am not using the horns that much.
15/03/2026 17:06:26 UTC
Glyn said :-
I rarely use horns myself, usually because, when an incident occurs, I’m so glad to have survived or the incident has passed and what’s the point. I prefer to use the barrage of expletives that cant be heard by the perpetrator. This method has served me well enough for years.
15/03/2026 17:12:00 UTC
Flyn said :-
Unfortunately this will mean that the two metal bodies of the twin horns will be sat at plus 12 volts. If I simply isolate the mounting brackets it will work but if I drop a spanner below the headlamp and it ends up between the horn and the frame, I will have a zapped fuse.
15/03/2026 20:30:14 UTC
Ian Soady¹ said :-
Flyn? I assume a mistype!
The twin horns I use are plastic bodied from ali express and cost around a fiver the pair. They're copies of Fiamma type but seem very well made and are loud. I find that a short blast on them often gets the attention of the car driver wondering whether to pull out....
If you want to keep what you've got then I would use a relay to switch the live feed.
https://www.aliexpress.com/w/wholesale-twin-snail-horns.html?spm=a2g0o.productli...
16/03/2026 09:59:58 UTC
Ian Soady¹ said :-
I think it's looking pretty good although the test ride will have to wait as the knee's still a bit iffy....
19/03/2026 14:54:49 UTC
Ian Soady¹ said :-
and.....
19/03/2026 14:55:15 UTC
Ian Soady¹ said :-
and.....
19/03/2026 14:55:36 UTC
Ren - The Ed¹ said :-
The last picture actually made go "oooof!" out loud. Yeah, yeah I get it, that looks blummin' lovely that Ian.
19/03/2026 15:04:49 UTC
Upt'North ¹ said :-
Very nice Ian, can't wait to see Ed in the chair.
19/03/2026 16:19:14 UTC
nab301 said :-
That looks great Ian , I'm sure Ren could drop over and massage your knee for you , we need to know if the outfit performs as well as it looks!
Nigel
19/03/2026 17:56:23 UTC
Glyn said :-
That is superb Ian. How is the knee hampering your progress? My knee is making me look at Trikes again because I don’t fancy keeping a bike upright ( especially one weighing 210Kgs).
19/03/2026 21:22:28 UTC
Ian Soady¹ said :-
Thanks all. I don't know what I've done to my knee but I suspect it was actually getting on & off the outfit. What I have to do is: right foot on the pillion footrest (rider footrest is too far forward and also on a taper mount that I don't trust); stand up on that footrest and swing left leg over and navigate between the sidecar struts while holding the handlebars, then sit on the seat and bring right foot forward. Disembarking is the reverse. I think I may have twisted awkwardly doing this, but it's now been 3 weeks. It is recovering slowly with the help of an elasticated support but I'm very wary of damaging it further.
Your point re holding bikes up is one of the reasons for the outfit. I'm physically strong enough but once it crosses your mind that you may be vulnerable there's always that nagging feeling. A pity as I'm missing this good weather.....
20/03/2026 09:13:27 UTC
Glyn said :-
The good weather is definitely coming and so it’s time to sort out what stays and what goes. The Triumph, too big, too tall and too heavy will soon be on the market. It is complete and pretty much faultless. The Suzuki 600 Intruder is nice and ready to ride (on sorn at the moment), is easy to manoeuvre around the garage, nice and low and, in my book attractive but really uncomfortable on my back. The TZR is a peach and great for looking at and shows but not really a daily rider. I might keep it but the prices are starting to fall as that generation of rider grows older and less nostalgic. It reaches it’s 40 year birthday on May 1st and will be tax and mot free. My memory of outfits is that when I wasn’t on the wrong side ( offside) of the road, I was in the near-side ditch. It is certainly a dilemma. I secretly fancy a 250 Honda Superdream from the 70s.
21/03/2026 08:07:10 UTC
Ian Soady¹ said :-
I had a 250 superdream which I used for year-round commuting duties in the 1990s. It was OK once I'd fitted a 400 engine as the 250 was just too gutless. I found it quite a pleasant machine which handled well.
AS I understand it, the 400 had better performance than the much-loved 400/4 although that was far prettier with its swoopy exhausts.
21/03/2026 10:04:33 UTC
Glyn said :-
I think the majority of these bikes were daily commuters and so, more often than not, high mileage these days. I agree the 400 is probably a better bet.
22/03/2026 09:34:58 UTC
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