A forum for owners of Yamaha TTR250 trail and enduro bikes!

I sold the TTR with the battery monitor installed and, after some battery/charging issues on my friend's TTR where I found the monitor to be a great check tool, I decided that I must fit one on my current TTR.

I already have a clock and heated grip switch on my bars so room was tight for another mount but recalled that there is an unused slot for another warning light in the warning light binnacle. 

I had a spare binnacle from a broken speedo so experimented with that first.

By taking off the black surround from the monitor LED, I was left with a 10mm LED bulb which only just fitted in the space available. 

The next job was to fashion a 10mm hole that was just tight enough to grip the bulb. I used a combination of drill bits and a countersink to achieve this without damaging the plastic lens. The bulb will be offset so mark the lens carefully to find the centre of the hole. Use the frame to do this.

You can see the amount of offset in the following photos:

This is the LED bulb fitted in the lens. I have put some heat shrink on the thin monitor wires to make them a better fit in the sealing grommet.

I test fitted the bulb/lens and it was fine so it was time to fit it properly to my TTR.

I had to remove the headlight to access the two screws at the bottom of the binnacle to allow the cover to be removed. Surprising how much dust gets in!

Remove the grommet from the bottom of the binnacle:

Then push out the lens from below with a screwdriver:

Put the led bulb in its lens frame in from the top and feed the wires down and through the grommet making sure the heat shrink is positioned correctly.

I protected the wires with some sheathing before attaching them to the coil and ignition connector:

Time to put the petrol tank back on and test the installation.

All worked - very pleased with a tidy installation 

Brian

Thanks Steve. I reckon the Monsoon 10 would be a good addition to the Totally TTRs shop.

It's like having an old-fashioned ignition light which will either be flashing when you switch the ignition on or showing green when the engine is running. Plus it gives an early warning of any charging problems.

I realised that the digital speedo binnacle is of a different design and have had one apart to see what the insides look like.

I reckon it would be easy to fit a Monsoon to it by drilling a 14mm hole in the top for the bezel (there is just enough room - I have checked!).

Before drilling, cover the area with masking tape as this will make it easier to mark where you want your hole to be, prevent any accidental scratches and help stop your drill bit from slipping.

If you do not have a sufficiently large drill bit, make the hole as large as you can by drilling then use a round file to open the hole out to necessary size. When you are approaching the correct dimension, frequently stop filing and check the fit. Remember, you can always take a bit more away from the hole, but you can’t put it back again – so please work carefully.

Then drill a hole at the bottom just big enough to feed the wires through. This could be sealed with a blob of silicone to prevent dust getting in.

Feed the Monsoon in from the top.

It isn't easy to get the coloured lenses off the top as it is glued on well so leave it on!

Brian