OK guys, finally back in form, my net at home, and thus me too!
A loooooong update since Sunday (yesterday)-
Now I'd insisted on getting the horn alone working if the scoot were to run, for my own concerns of safety. For this, I had a hunch the existing (non-original, Li) headlight/horn switch had to be changed, for which I had a brand new original LD mk3 switch housing ready! This also has an ignition cut-off button (on right top corner)
Also the speedometer, in its present condition, wouldnt look presentable for the rally, and I couldnt afford an original speedo at present. So I had an original speedo blanking plate for the LD mk3, bought on ebay!
For both of these though, I was told that the wiring would have to be connected. For this, the headset handle cover and horncast would have to be removed, for which the headlight....one thing leading to another!
So yesterday noon, proceeded with undoing all the screws, which proved to be real time-consuming, as they were all jammed with ages of corrosion! Unfortunately, I forgot to take my trusty WD-40 can with me on Sunday, but the mech. seemed unperturbed, and insisted on using water instead even otherwise!
With what took an eternity, finally the headset and headlight came off....the speedo and horn body sure had some corrosion set in! Wiring seemed all messed up by previous hands. 'took us hours to figure out what wire was meant for what, a few of them having been blanked out as they didnt have connections with the new switch! At the end of the day by 3pm, figured out just the ignition cut-off wire!
I managed to get the speedo off and fit the blanking plate though, looks pretty neat! The cable however, will remain as it is, this being a temporary set-up.
Meanwhile the guy accidentally ended up locking the handlebar lock by trying to find a key that'd fit it....it was already in a bad state, cracked from previous attempts to move the handle when locked!
So when I left yesterday, he'd directed me to a key-maker nearby with his name as referral, on going to whom today I got a flat refusal because he didnt have the 'model' for the key to this lock!! Grrrrr......but to my luck, we happened to find a Bajaj key that fit just right in the handle-lock as well as the rear toolbox that I got to open for the first time ever- hoped to find some hidden spares, but nothing except discarded old spark plugs and bolts. And a little honeycomb as well!
Now the saga of the wiring resumed...the horncast was finally off too. Original wiring was intact, but difficult to source in the scoot, as it seemed to run through the chassis tube. 'finally found the little junction box under the engine (interesting spot to fit one!), still intact and working after 50+ years! from which the main wiring was supposed to originate, but only the ign. cut-off wire seemed to be connected to it.
According to my manual, 3 wires, the main, horn and headlamp wires should've been connected from this to the square junction boxes inside the horncast.
But as I needed just the horn working for now, it was decided to get 2 wires in, for the main and horn. So got 2 new wires with outer cable, took ages to insert them both in but finally was done!
More tomorrow...!