Everything is right thats the confusing part, bike has been in water many times, once even to such an extent water entered intake and bike kept misfiring alot, and even then the horns were fine. A deeper investigation is needed....hmmmm... Operation Initiated

1- what did you expect to gain from it ? Did the kiney accept the battery?
2 - How come ? Have you checked the voltage of the ZMA battery recently ?
Not much difference..!!!! Only 2 amps difference - and that translates into 24 W difference in a 12V battery !! And 5 amps charges quicker.....and drains quicker when the requirement is atleast 7 amps .!
Suspect your wiring , not the battery ... is what I think .
Windtones are unreliable than normal horns . But the leftover windtones from my sold RX still has some life in it after @ 50k kms of usage . I wouldn't risk using it now .
1 - Q?- How does it feel
A= - Like hitting the head against a wall !

2 - It's still clicking , but could it be the culprit ?

3 - the one thing that prevents me from using air horn is that it hurts my ears more than it does to others .
Quality issues for three set of horns continuously ?

Maybe problem in wiring or excess use . Cause with use carbon is deposited on point contacts creating less/no sound & i don't think 3/4 sets to be faulty . BTW windtones are easy to repair . I think even windtones are against law ( not sure about skoda ) 1) Well said charge quick drain quick on extra need . 2) Well they are easy to rebuild , ojust 15/20 minits job at home . Got couple of pairs from junkyard & rebuilded them . ( pics posted before , if you forgot ) 3) 4) What if they are some cheap one's ?

I only go for Roots windtones, they're said to be the best ones locally available.

Stock is 6amp, I lowered it to 5amp. Didnt check old battery, but just a few days before while I was photoshooting with HL on the battery had drained flat, midst a G2G trip.

In fear of blowing them out again I had added a seperate fuse box's to both car and bike, even with that bike one blew.

Anyways I have a 700~800Kms G2G tomorrow starting at 3am tomorrow morning and will end on 5am day after tomorrow morning. So will be opening everything up in the evening. @Acs sir, If you're present for the G2G, we can meet up.

Long term report of the Shell Rimula R3x..

Changed it last week only but did a 1800km ride after that through all sorts of terrain imaginable from beautiful four lane highways to off roads up a hill! One word to sum it up; BRILLIANT!! One of the best oils I have ever used. Costs just Rs260 per litre. Engine was very responsive and smooth. The best part of it was how relaxed and responsive the engine was in constant high speed rides. Oil still looks good. Will be changing it though. To the same oil of course!

1 - Maybe probs in wiring or relay . The horn relay ,I think, will be rated from 20 to 30 amps . That's more than enough to honk continuously .
2 - I think wind tones are legit . Air horns use high volume expulsion of air to create sound . Come to Kannur , here all private buses and even some KSRTC buses have air horns which give out bollywood type music . It'll blast your ears off .
3 - Ashwinprakas has replied to it .
OK I forgot , the later ones has 6ah battery as standard . And what load did they lessen ? The full time running instrument panel lights ?
If the bike's fuse is blowing , check your wiring - especially your relay .
I don't check the thread daily now so I must've missed the G2G . Where is it ? Am quite busy now-a-days . Normally dont have time to even boot the computer . And the latest avatar of xbhp takes an eternity to load on my mob .
Guess I'll be busy for may be one more week .

Here is a funny one! on my 05 zma, when i rev out the bike in any gear and then suddenly get off the throttle, i hear a loud khusss sound from the exhaust! It doesnt sound like a misfire or unburnt fuel combusting in the end car. It sounds like...well.. the bike farting!! She doesn't drink oil and the performance is good!! Now who could tell me why the gastric problem!?!

Thanks for the update....this oil is especially more specific for your use ,since you had recently done an engine job.....Try the Rimula R4 it has more additives ,apart from the ZDDP, to protect against acid and dispersants to keep engine running better,cleaner..

psr What about Diesel engine which does not contain Molybdenum disulphide. I don't remember which company but somebody mention the engine run smooth and even it flush the garbage type think the only issue with gear it work little bit hard.

Did you mean Diesel Engine oil ? without Molybdenum Di-sulfide ? The Shell Rimula R3X and Rimula R4 are such oils...apart from me others have tried and shared their experience here and in the Engine oil thread...
Most diesel oils contain Detergents which clean out the internals of the engine and keep it free of sludge,and varnish formation.

I could find the R4 only in a 5L can. Will try sourcing a 1L can and try it out sir.

Symptoms:

Knocking in lower rpms when bike pulled hard.
Engine over heating (a bit)
Whitish base of electrode of Spark Plug even with 3.5 full turns of AFR.
Piston noise/piston slap
Sharp metallic noise from piston area when engine is hot.
Decrease performance.

Odo: 65000 kms. New piston rings at 51000 kms. No decrease in oil level, no smoke from exhaust; no deposits at exhaust tip. Oil color starts to change color after 500 kms. Engine oil in air filter chamber.

Engine opened today keeping in mind reboring. Thanks to inputs from PSR, I had gone for reboring instead of new bore kit. I choose to rebore basically to learn. Hope my experiment will not fail.

Photos of the engine when opened.

Cam shaft:





Condition of the valves; the small one is exhaust and the big one is inlet.






Condition of cam chain guide




Crank and transmission assembly




Worn out Primary Drive




Dents on teeth of Second Gear




Dents on third gear too




Excessive lateral play of the connecting rod. Replaced the conrod big end bearing to correct it.




Prescription: Reboring of cylinder; check valve guides and do valve lapping again; replace conrod big end bearing; replace both crank bearings; replace all chamber bearings; new oil seals; new o rings; new packing kit. New cam chain guides. Still doubtful about camshaft though it appears fine without any scratches. Need to decide whether to change it or not.

Today, reboring, valve lapping, and conrod work done.

Reboring the cylinder, size 0.5mm





New piston:







Honing machine.








Bored cylinder, before honing the surface





Will update tomorrow about the progress.

Process of Honing the Cylinder

Thanks for detailed explaination , me too did a engine overhaul at 62k, just got back the ride yesterday, i went in for a new piston block, as i was skeptical on re-boring, din't know where to get the job done and how to inspect it as i had no experience. Guess we all need to learn and take chances.

Hope the build goes well , wishing you many more happy miles...!!

Cheers
Ride Safe
Krishna

Beautiful & Clear pics
Would be better if you have gone up with new Bore kit.
All the Best, Hope your bike does Best.