Think I'll just replace the loom now, I've been struggling with burn head fuses for ages now so I'm just gonna replace the whole thing. Cheers.

Loom and Relay posted today. They should arrive at some point next week. I hope they help.

They will for sure. Thanks a lot. Cheers.

Loom and relay just got here (thanks smemly) along with some extra fuses lol. Will report back when I get a chance to spend some time in the garage. Cheers.

Turns out the only burned wire is from the 20A fuse to the frontlight, the rest of my loom is fully functional. Will replace the wire, fit it and see what happens. Could I have messed up anything in the magneto when checking my valves? I don't understand why it won't run without jumper cables when the battery puts out 12.75V.

maybe you earthed the light circiut and the fuse didn`t go allowing the wire and the battery to fry. So now the battery`s shagged out

Will fit a new battery today and take it from there. Also fitted new wire from the lights/horn controller to the 3x3 socket from the loom (which had melted a bit where the wires connect). Will see how it goes. Cheers.

IT LIVES ONCE AGAIN!!!!!!!

Fitted a new battery and it started right away. Still need to sort some things out but I'm happy to hear it again. Cheers everyone!!

After all this work, valve checking, carb balancing, new battery, filters and oil bike still wouldn't go past 9k rpm. Some of you may know that I bought the bike from a friend who 'modified' it with the back of a car that did a U-turn in front of him. I had to straighten a lot of things, one of which the headers. When he crashed the front wheel bent the headers and a new section had to be welded in place on one of the pipes. This took it's time and when I put the headers back on the bike, being the idiot that I sometimes insist on being, I managed to swap the exup cables. This means I had never eeeeeeeeever rode the bike properly. I always knew it could go harder but was never able to. Now after going through so many things on the bike I remembered to check the exup. Took it for a spin and saw it making 14000rpm for the very first time!! It obviously is a totally different bike now.

But, and there's always a but with my tj, it started getting louder towards the end of my test run. I'm guessing this could only be caused by a problem in the exhaust somewhere right? a crack, a nut that got loose, something like that right? It couldn't be anything in the engine could it? I was exhausted today so didn't get to check it, besides it was obviously hot. Will check tomorrow.

Anyway great progress has been made, I thought I'd never see the day it would run like the little evil rev crazy 400 it really is.

Cheers.

It sounds like either an exhaust stud / nut or one of the clamps of the link pipe.

Glad to hear the bike is running properly