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Anyone Made a Wiring Loom?

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johnsmith222
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Joined: 26 Dec 2008
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PostPosted: 21:23 - 21 May 2012    Post subject: Anyone Made a Wiring Loom? Reply with quote
Hi guys.

Has anyone made a wiring loom for a bike before? I have an electronic ignition CG125 which has a completely knackered engine. Both top end and bottom end knackered (don't ask).

I have a complete replacement engine but it's from around 1985 and it's on points ignition.

I was wanting to get the bike running, but the way things are looking, in order to use the new engine I'm going to have to make a wiring loom.

It's not something I have experience with, although I have experience wiring in lights to house wiring, soldering from modding old consoles like megadrives and guitars etc.

The thing is, I've not been able to find a wiring diagram for that 1985 CG125 and I also have no experience making a wiring loom.

I am just looking for general tips etc at the moment and I'm going to try and figure out exactly what I need to do.
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tomh
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Joined: 12 Nov 2011
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PostPosted: 22:09 - 21 May 2012    Post subject: Reply with quote
The old point engine's run 6v electrics so EVERYTHING electrical needs to be replaced. You will first need to remove your CDI, swap all your bulbs to 6V, new battery and change your ignition coil as well.

The easiest thing to do would be buy a complete a wiring loom which includes the regulator, resistors etc for that engine but then you come to the problem that even the light switch gear is different or at least wired different from the newer models.

I'll dig my Haynes manual out tomorrow morning and scan the wiring diagram for you and tell you what needs to be done.

It's not hard at all to make a wiring loom, especially for a simple bike like the CG if you work out and draw each circuit separately, so one for the spark, lighting circuit, horn etc.

The only tools you will need is a big box of bullet connects and some good wire crimper's, and wire cutters.
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jjdugen
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Joined: 03 Jun 2011
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PostPosted: 22:12 - 21 May 2012    Post subject: Reply with quote
Surely easier to swap the alternator and rig up an ignition pickup coil mount?
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Jamie S
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Joined: 28 Dec 2006
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PostPosted: 22:29 - 21 May 2012    Post subject: Reply with quote
TomH wrote:

The only tools you will need is a big box of bullet connects and some good wire crimper's, and wire cutters.


And spend twice aslong stuck at the side of the road, either solder and heatshrink the wires and do a proper job or don't even consider it IMO
Jamie
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tomh
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PostPosted: 22:32 - 21 May 2012    Post subject: Reply with quote
Do you know what model of the CG the engine is from? 1985 is the year the CG was upgraded to 12v which will make it a simple job if it is 12v.

You will then only have to slightly modify the current wiring loom by removing the CDI and possibly change the ignition coil. The lighting/power should be the same.
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johnsmith222
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PostPosted: 22:39 - 21 May 2012    Post subject: Reply with quote
TomH wrote:
Do you know what model of the CG the engine is from? 1985 is the year the CG was upgraded to 12v which will make it a simple job if it is 12v.

You will then only have to slightly modify the current wiring loom by removing the CDI and possibly change the ignition coil. The lighting/power should be the same.


It's the 12v one. I managed to find a Haynes manual online and compared it to the wiring diagram on that. The full diagram isn't that clear though.

if I could use my current loom then that would be ideal. My engine has 4 wires (black/white, green/red, yellow, white.) So it seems to be one of the first 12v CG engines.
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tomh
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PostPosted: 22:48 - 21 May 2012    Post subject: Reply with quote
That's good then Thumbs Up

What model CG do you have? I'll go scan both wiring diagrams now for you.

Looking at the wiring diagram

Yellow is the lighting circuit and can be connected up as normal.
White is main power and can also be connected as normal.
Green/Red is the neutral switch and can be connected as normal.
Black/White is for the spark plug so you will need to run a new wire to the ignition coil. This wire also goes to the ignition switch to kill the engine.

You can remove the redundant wires going to your CDI.
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johnsmith222
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PostPosted: 22:53 - 21 May 2012    Post subject: Reply with quote
TomH wrote:
That's good then Thumbs Up

What model CG do you have? I'll go scan both wiring diagrams now for you.

Looking at the wiring diagram

Yellow is the lighting circuit and can be connected up as normal.
White is main power and can also be connected as normal.
Green/Red is the neutral switch and can be connected as normal.
Black/White is for the spark plug so you will need to run a new wire to the ignition coil. This wire also goes to the ignition switch to kill the engine.

You can remove the redundant wires going to your CDI.


It's a W model CG125. It's from 1999. It's not the one with the electric start.

https://i14.photobucket.com/albums/a324/david_m213/cg1252.jpg?t=1317853796

Your help is much appreciated Tom. Thumbs Up
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tomh
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PostPosted: 23:28 - 21 May 2012    Post subject: Reply with quote
Wiring Diagrams:
https://www.sendspace.com/file/i7on4v

Modification's you need to do:

Connect black/white from the stator to the black/red coming from your bike.

Chop the plug of the wire going to your CDI.

Twist and solder/heatshrink these three wires together: Black/red, Black/white, Black/Yellow

At the alternator you will be left with Blue/Yellow and Green, this will be the same at the plug you've chopped. You can either solder these two together which will eliminate them or just blank off the end of each wire.

The only thing I'm unsure about is whether or not the ignition coil is different?
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johnsmith222
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Joined: 26 Dec 2008
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PostPosted: 23:35 - 21 May 2012    Post subject: Reply with quote
TomH wrote:
Wiring Diagrams:
https://www.sendspace.com/file/i7on4v

Modification's you need to do:

Connect black/white from the stator to the black/red coming from your bike.

Chop the plug of the wire going to your CDI.

Twist and solder/heatshrink these three wires together: Black/red, Black/white, Black/Yellow

At the alternator you will be left with Blue/Yellow and Green, this will be the same at the plug you've chopped. You can either solder these two together which will eliminate them or just blank off the end of each wire.

The only thing I'm unsure about is whether or not the ignition coil is different?


You're a total legend Tom!

Thanks. I'll be doing this over the next week or so and I'll let you know how I get on.

Thanks again. Thumbs Up

I'm not sure if the coil is different but if need be then I can always get one from ebay and switch it over. Is there any harm in trying the one that's on there at the moment though or can it damage anything?

Last edited by johnsmith222 on 23:38 - 21 May 2012; edited 1 time in total
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johnsmith222
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Joined: 26 Dec 2008
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PostPosted: 00:03 - 22 May 2012    Post subject: Reply with quote
Rob Fzs wrote:
didn't i sell you a loom for a points cg ?


Hi Rob.

I actually forgot that I got this from you. If I remember correctly it was off of a 6v points CG as at the time I believed the engine to be from a 6v CG.

As it was different I think I put it aside meaning to look at it and forgot about it (along with my CG).

I'll look it out and see if it's any use. Thumbs Up
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