1974 army MZ TS250 restoration project

[Blurredman]

That's interesting. Is the replacement loom a pretty much identical match colour wise?



With those (red in your case) blocks are concerned, the connections inside are a staggered join. So.. you have 8 connections per side. If you're looking at it from any one side (it's the same both sides) the outer two spade connections and the inner two are conjoined making the possibility of 4 total spades that can be plugged into that section of the block. There are two single 1-1 connections in the box both sides of the middle 2-2 connections.

I have never messed around with a TS250 so I am unsure,
This manual is for the TS125 i believe, but the wiring setup is very similar I should think. Unfortunately my internet at home is gone boom so I cannot access my FTP server to see if I have a 250 diagramme. Can someone else post it please?






But, from what we can gleam from that diagramme, green and black is right indicator, white and black is left indicator. The Blue and black is the only wire that directly connects to the indicator relay (via the switch), other than the plain black which is ignition.

If you were close to me i'd come up and see.. Where do you live?

[NVA250]

Thanks for the reply and advice.

The colours of the new loom do seem to match the original (hard to tell due to the poor state of it) and the wiring diagram. The one in your reply is the same one that I've been using.

I was under the impression that the connector block was just straight through contacts, i.e. the input on one side matches the output on the other with no other internal connections. I have a battery for the bike now, so when I get a chance I will hook it up and see which of the auxiliaries I can get to work!

Thanks for the offer of potential assistance, I'm in Crystal Palace, South London if that's close to you?

On the plus side I've managed to find a set of original handlebar switches which should arrive soon!

[Guesi]

There are several different connector blocks available. Some have connections between the connections.

So you need to know which one the TS 250 has.

[NVA250]

There are several different connector blocks available. Some have connections between the connections.

So you need to know which one the TS 250 has.

Great... I'll have a look at the old on the old wiring

[NVA250]

Right, I've had a look at the bike's original connector block and there is no internal cross links between the terminals. Each connection just runs straight through to the other side.

When I get a moment I'll fill and fit the battery and see what I can get to work

[Blurredman]

Aha.. Well, that might be a problem then ....
Does the replacement have the cross links?


And, sorry, I'm in South Wales

By the way, would you want to be selling the master cylinder? I'm in need of one

[NVA250]

Aha.. Well, that might be a problem then ....
Does the replacement have the cross links?


And, sorry, I'm in South Wales

By the way, would you want to be selling the master cylinder? I'm in need of one

Dunno! I'll have a look when I get the chance. I'm waiting for some switches to arrive so I'll wait until after they arrive.

Did you mean the ETZ master cylinder from the front brake? If so I'd be happy to sell it. I'll have to find it first though! I'll drop you a PM when I've dug it out.

[Blurredman]

Yey!

Also, I might be tempted to just ride to you one day in the weekend in order to pick it up (and perhaps you want to sell other things too???? I am after a few items)


I can help you as best I can if you so wished.

[NVA250]

Leg finally healed enough for me to make another trip up to Bedford to finish the engine rebuild. As usual, nothing went according to plan…

Last time we tried to split the crankcase we found out that the bike has the clutch fitted from a supa 5 which meant the clutch puller I had bought didn’t fit. I bought another puller for the supa 5 clutch and this time it actually fitted! The downside was that no amount of leverage or heat would get the clutch to budge!

In the end we got fed up with trying and went for plan B...





…washing the whole lump down with petrol and hoping for the best!

I know, far from the best solution, but we’ve tried every trick we can to get the clutch off without any success. As far as I can feel the gears are engaging and the crank is spinning freely. Yes, it’s all dirty but plenty of petrol flushes and it’s cleaned up quite nicely. Plan B is to put it back together and fill it with oil and see what happens when it starts.


You can still see the tide mark from sitting in years of dirty oil. No amount of scrubbing would get ride of this.


On the plus side, at least it looks a lot cleaner now!


Finally, I know that this is the neutral light switch. All the wires were disconnected when I got the bike so I’m not sure how it’s supposed to connect. Should there be a spade connector attached to this?

[DAVID THOMPSON]

bikes and ham radio have something in common LOTS OF COMPLAINTS from the rest of the family

even though it keeps you out of trouble and the pub
dave

[Blurredman]

I find the only way to get the clutch off my MZ's, is to tighten up on the puller as much as possible, then wack the end bolt with a hammer sharply.
Then tighten up again if need be, then shock it again with the hammer. In my experience, it's the shock of the hammer that brings it off, not the pulling/tightening on the puller.

[NVA250]

Yup, tried all that but no use. In fact we gave up because we'd used so much force that we were concerned about sheering the puller bolt or knackering the crank shaft thread. That would have left us in a worse position that would have been exceptional expensive to fix. I felt ihad nothing to lose by rebuilding the engine to see what happens. Worst comes to the worst I'll be needing a whole new engine!

[Warner20]

This is a great post!
I've just read through it all with anticipation of seeing the final product but looks like ill have to wait to see the out come! how about an update on any progress to keep me going for now?
i'll be starting my own TS150 project in the next couple of weeks so this is giving me lots of inspiration, so thank you!

[NVA250]

This is a great post!
I've just read through it all with anticipation of seeing the final product but looks like ill have to wait to see the out come! how about an update on any progress to keep me going for now?
i'll be starting my own TS150 project in the next couple of weeks so this is giving me lots of inspiration, so thank you!

Thanks! Unfortunately there's not been a huge amount of progress...

I have had a fair few other things to do recently. I got married recently and have only just got back from the honeymoon, to East Germany! Another excuse is that I don't have a garage and the weather has been so poor that I've been unable to much as it's a bit cramped in the living room.

Here are a couple of pics just to update on what little I've done...


I finally managed to get hold of a front mudguard from Germany, I think it cost me about £25 including postage which I didn't think was too bad. It was covered in both thick black paint and dents. Rather than make the dents worse with some metal bashing I sanded the whole thing down and filled the worst of them.


Another part that I was struggling to find was the 5 litre fuel can that goes on one of the rear racks. You can get them from German ebay for about £20, but it rockets to about £35 with the postage. I bought this for about £8 from the really bizarre "Harzer bike forge" (http://www.harzer-bike-schmiede.de/) in Zilly.

Now the weather is getting better I'll hopefully make some progress over the coming months.

[breakwellmz]

Be honest, did you buy them on your honeymoon?