CG125 Custom Wiring Diagram

[Wrighty1991]

I am currently in the process of building a CG125 the wiring is an absolute mess! So I am looking to build a completely new wiring loom.

I will be replacing the battery with a capacitor as it is a kick start only model and the bike will only be used occasionally. I have thrown together this quick wiring diagram in Microsoft paint (I apologise for the crudeness of it!) Can someone please have a look and see if they can see any problems?

Thanks in advance

[Wrighty1991]

It doesn't look like the above link has worked so here is a new one

https://photos.app.goo.gl/tSRbjv8q3yugNyVg7

[Tango]

Looks ok at first glance.....With the exception of the capacitor. The inrush current into the capacitor with no inline resistance on startup could quickly kill your reg/rec and stator.....

[Wrighty1991]

Thanks for the reply, would you recommend adding an inline resistor? If so where would you suggest this was added?

[fastbob]

Thanks for the reply, would you recommend adding an inline resistor? If so where would you suggest this was added?

 

Why does it have to have a custom wiring loom, why not just wire it exactly as it's supposed to be wired ? I don't understand.

Edited October 19, 2018 by fastbob

[Tango]

Thanks for the reply, would you recommend adding an inline resistor? If so where would you suggest this was added?

 

Personally I wouldn't mess around, and just stick a small battery in the capacitors place........but if you insist on using one, I'd take the red wire from the Reg / rec straight to the capacitor via a resistor, and then run the rest of the red circuit from the capacitor ......so that the circuit is fed from the smoothed voltage from the capacitor.....

[fastbob]

Just an idea https://m.ebay.co.uk/itm/Motorcycle-Ultima-Complete-System-Electrical-Main-Wiring-Harness-for-CG125/191661589200?epid=1843477789&_mwBanner=1&_rdt=1

[Wrighty1991]

Just an idea https://m.ebay.co.uk/itm/Motorcycle-Ultima-Complete-System-Electrical-Main-Wiring-Harness-for-CG125/191661589200?epid=1843477789&_mwBanner=1&_rdt=1

That's perfect, saves me a lot of messing around!

[Wrighty1991]

Thanks for the reply, would you recommend adding an inline resistor? If so where would you suggest this was added?

 

Personally I wouldn't mess around, and just stick a small battery in the capacitors place........but if you insist on using one, I'd take the red wire from the Reg / rec straight to the capacitor via a resistor, and then run the rest of the red circuit from the capacitor ......so that the circuit is fed from the smoothed voltage from the capacitor.....

 

I think I will just fabricate a small battery tray under the seat and use a small gel battery if it makes it easier

[fastbob]

Just an idea https://m.ebay.co.uk/itm/Motorcycle-Ultima-Complete-System-Electrical-Main-Wiring-Harness-for-CG125/191661589200?epid=1843477789&_mwBanner=1&_rdt=1

That's perfect, saves me a lot of messing around!

 

Here's another idea , how much of this is useable I don't know but its cheap as Chinese chips !https://m.ebay.co.uk/itm/UK-For-ATV-QUAD-CG125-250CC-Electric-CDI-Coil-Wire-Wiring-Harness-Stator-Kit/323502407619?_mwBanner=1&_rdt=1

[Guest]

I see a slight problem. Your diagram shows the routes but similar to the underground map it is drawn for clarity rather than correctness of cable length

I don't know if you have made a harness before and therefore have the experience to translate this into a real harness, but the way harness specialists work is with a large sheet of wood or mdf and on to that they draw lines to show the route of the loom to all the ancilliary parts to be connected. It makes sure that the wire lengths are correct and the harness will fit when offered up. To this wiring harness design they physically attach the wires fastening them to the diagram on the sheet.

To each wire end they add labels showing the part the harness connects to and the connector they will attach at that point.

This open layout makes it easy to wrap the harness so that job is complete before fitting to the bike.

I don't know how easy this would be to do but I hope this information will assist.

[Wrighty1991]

I see a slight problem. Your diagram shows the routes but similar to the underground map it is drawn for clarity rather than correctness of cable length

I don't know if you have made a harness before and therefore have the experience to translate this into a real harness, but the way harness specialists work is with a large sheet of wood or mdf and on to that they draw lines to show the route of the loom to all the ancilliary parts to be connected. It makes sure that the wire lengths are correct and the harness will fit when offered up. To this wiring harness design they physically attach the wires fastening them to the diagram on the sheet.

To each wire end they add labels showing the part the harness connects to and the connector they will attach at that point.

This open layout makes it easy to wrap the harness so that job is complete before fitting to the bike.

I don't know how easy this would be to do but I hope this information will assist.

 

That's great, thank you for the information. It seems a logical way to do it, this is my first attempt at motorcycle wiring so any advice/information is greatly appreciated.

[Grumpy Old Git]

Use MDF and panel pins to outline the cable loom - Once connectors are fitted, tie the loom (lace) wires together - remove from board and fit.

If using a capacitor - work out the charge current maximum for the reg/rect and then calculate the in-line resistor required for the correct capacitor (add 10% to the resistance value to ensure safety) - Work out the reactance at the frequency of the maximum input spikes and 'de-couple' with a large current diode (reversed) across the input to the capacitor (this also acts as a safe discharge path).

Not easy without some basic knowledge of electronics. Simpler to stick with a battery.