Last attempt at wiring or it goes to the shop. With video.

[oberonspacefr...]

Megelli 2009 125r

Ive rewired this bike, and now its worse.
no surprise really, electrics is deffo not my strong point.
Tried to do everything properly, bought all the correct components, but at the end of the day, I just dont understand how electrics function well enough to use a logical repair method.

the bike was running, but it was so butchered, i couldnt safely leave it so taped up and dangly.

I took all the tape off, and made a map of where everything went.

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0256_zpshjqimouv.jpg


I then re taped it, put new crimped connecters and fitted them in mostly new blocks.

I had a dry run on the table, and got all the lights and indicators working, as they were not attatched when i got the bike.

I put the loom back on the bike, and it immediately blew the fuse.

after a bit of cursing and head scratching, i worked out that the live feed form the battery went to to the kill swith on the right hand switchgear.

i unplugged the righthand switchgear, and it stips blowing the main fuse.

SO.......somthing from that point is blowing the fuse.

I dismantled the switchgear and the black and white wire that connects to the kill switch, has a green wire on the other side of the switch.
i disconnected the green wire from the main block, plugged the block back in, and it didnt blow the fuse.


so, to sumarise, turning the ign on, sends power via a black and white lead to the kill switch. at this point, none of the other spades inthe R/H switchgear are live. it hits the switch, and turns the green wire live. this then blows the fuse, if the green wire is in place in the multiblock.

if you turn the kill switch to run, it cancels the power to the green wire.
if you set it to kill, the green wire from the other side of the switch is made live.

from my diagram this green wire connects to a big lump of greens, which in turn got to pretty much everything.

nothing works, without this green wire out of its block, and i cant tell if anything works with it back in its block as it immediately burns the fuse when its in place.



I dont know what to do next other than take it to an electrician.

it must be somthing ive done, as it was running before, but I tried hard to keep to the diagram that i made when dismantling the loom.

The easy answer would be to buy a new loom, but they are not available.

[oberonspacefr...]

Im going to post avideo shortly, just uploading it.

[Vincent 2]

Hi wot u re-wiring

[oberonspacefr...]

heres the video.

https://youtu.be/BRgDKHfzYiM

[Vincent 2]

Hi again matey , from what I can see , the green wire which is the earth is live , and its lighting up the frame . Did you put a new kill switch on and wire it up , I know I`m sounding simple but maybe the wiring problem is at the kill switch itself or a connection problem with the live black and white wire to the kill switch

[oberonspacefr...]

[Vincent]

I take it you've tried to find a new loom?

Any use?

https://www.megelli-parts.com/acatalog/12_-_Electric_Parts_125R.html
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Space Is Deep

[oberonspacefr...]

[Vincent]

Did you see the link I added?
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Space Is Deep

[oberonspacefr...]

[Vincent]

Do you know if Migelli are still running?
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Space Is Deep

[oberonspacefr...]

They stopped production in 2013

[oberonspacefr...]

[oberonspacefr...]

On a normal kill switch, does it have just 2 wires, and what do they do?

is one live and one earth? it seems at the moment like the switch is just acting as a contact breaker taking bl/wh in and passing it on to the green....it seems too simple an objevct to cause so much trouble.

[Vincent]

Buggers... They should still have some support somewhere. Trying to patch up a bodged loom can be like welding something rusty, you fix one bit ...then it fails elsewhere.
I'd be isolating certain components first, ie, anything not required for running, inc the kill switch. Don't the kill switches usually work by grounding power that goes to the ignition?
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Space Is Deep

[oberonspacefr...]

if i knew how to bypass the kill switch, so it could be turned on/off at the key, id try that, but it would probably just complicate things.

[oberonspacefr...]

[oberonspacefr...]

Isolating stuff sounds good, if i was a bit more clued up about how to do it....the one live wire(b/w) that goes from the loom to the R/H switchgear is the only live wire in that whole switchgear.....so if i take that out, theres no power in that area at all, and therefore no lights but more importantly no electric starter..the button is mounted below the kill.

[Vincent]

Megelli have a new web site for the UK, did you see this and/or try some of the contact numbers?

https://www.megelli.com/#!distribution/c7hs

These bikes seem to be amongst those being ridden by rebels/terrorists in Syria.
They certainly get a bit of a slating online
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[oberonspacefr...]

ive just fired an email off to that adress but TBH i dont expect anything back....theres no listing for the uk that i could see.

megellis do get a slating everywhere i look. Im not bothered about that, i got it because its massive, i look like a circus bear on most 125's and i presumed that at worst case scenario id put a cg 125 engine or similar in it. im fine with fabrication and engineering, its just wiring that is a black art to me. It would be a shame to go down that route though, everything is fine apart from the loom.

[Vincent]

Aye...they're nice looking bikes....."All that glitters......." though
I've been fixing my own bikes for centuries and still hate doing anything electrical, it doesn't get much better.

The live wire...is it specifically for the kill switch part of the R'H switchgear or could it supply the lights?
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Space Is Deep

[Vincent 2]

Hi found this , although its not exactly the same , but the Chinese theme is , may help you with the structure of the loom although colours might be slightly different , as you can see with this one there is black/white wire and a white/black wire . Hope it helps
https://www.dropbox.com/s/agmh3use90qlbkq/125cc_Wiregram_AC%20%282%29.pdf?dl=0

[RhynoCZ]

At this point, I'd be tempted to break it into bits and sell it part by part and buy something a bit more popular and working.
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'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[Vincent 2]

Got a more basic view for you, hope this helps
https://i1172.photobucket.com/albums/r575/spagiratwink/WIRING-HARNESS-CDI-COIL-KILL-KEY-SWITCH-50cc-110cc-125cc-_zpsiqtzl5di.jpg

[oberonspacefr...]

mr spag that looks really handy.

in that diagram, the b/w wire goes from the ign, to the kill, then to the ground via green.
that it what my bike does!

so.........

the only conclusion i can make is that the B/W should not be live from the ignition?