10-06-2014, 10:47 AM | #1 |
Join Date: Jun 2014
Posts: 13
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Wiring up a 200cc Chinese motor (163fml)
Hey all. I have a 82 XL 125 RC that I put a 200cc 163fml motor in. I have wired it up so that it run but cannot seem to be able to get the electronics working. I wired up the running circuit myself, then used a cg 125 loom hoping that I could just output the the power into the loom and that it would work... Sadly it does not. Would I be better off just buying a brand new loom or continuing with what I got. I really need to get it working soon though as it without my bike it means taking the bus to work which I hate!
Here is the bike, although I have now painted the wheels and it has lights (not that they work) Any input would be great! Just to add, although I could just put a cg 125 lump I have into it, I had to split the cases on this motor just to get it running and put lots of time into it! (first ever case split) So would REALLY like to use this motor, and not the cg lump |
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10-06-2014, 11:04 AM | #2 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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That's a project I've wanted to take on for some time; thanks for sharing it with us.
Since you got it running, you've conquered the hardest part. The CDI and regulator are connected properly. Where is the battery hiding? If you have a CG125 lump and a complete CG125 harness, the path of least resistance would be to use all CG125 stuff. If you remove the stator cover from the left side of the 125, you could remove the flywheel and stator, and transfer them to the CG200 motor. That would have your bike running on 100% CG125 electrics. If you prefer to use the China stator and flywheel, we'd need to know more about how you connected the stator to the CG125 harness.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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10-06-2014, 11:05 AM | #3 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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BTW, that exhaust header is lovely. Is it SS, or just bare steel?
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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10-06-2014, 11:21 AM | #4 |
Join Date: Jun 2014
Posts: 13
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I just have a capacitor in
place of the battery. But assumed this would not matter as for the last year my CG 125 has had no battery and the only thing that did not work was the horn - it fizzled instead of honked. I just placed a small capacitor there to run the horn for 3-4 seconds at a time. Also the CG loom is a points loom (not that im using its running circuit) the exhaust is a stainless steel micron thank you for taking an interest, Ed. I'll have to check the wiring tomorrow as I'm on the bus into work atm |
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10-06-2014, 02:34 PM | #5 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Where did you get that header pipe from?
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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10-06-2014, 06:03 PM | #6 |
Join Date: Jun 2014
Posts: 13
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I got it from eBay, think it was £100 for the whole exhaust including postage. Here is a guy in the UK selling just the silencer http://www.njmotorcycleservices.co.uk/parts.php but not too much help as you are in BC. just Google or check eBay for a xl125 or xl185 micron exhaust and you might have some pop up!
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10-07-2014, 01:41 AM | #7 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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No luck, but thanks for the info.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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10-07-2014, 10:28 AM | #8 |
Join Date: Jun 2014
Posts: 13
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No Problem. I stripped the bike of anything not needed such as ignition and horn, and I have lights! But only the rear light :/ The front light does come on dimly at about mid revs. I dont think this stator kicks out as much power as the one from my cg as I put a 55w bulb on my cg and it works just fine. Im going to try it again with a 35w bulb and also check the rear light bulb to see if I could maybe shave a few watts off of that too!
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10-07-2014, 10:49 AM | #9 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Perhaps there is a dedicated headlight wire on the CG200 stator that must be used.
You could switch the tail light to LED to save a few watts.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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10-07-2014, 11:17 AM | #10 |
Join Date: Sep 2014
Posts: 1,914
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Do you have the right regulator for the engine?
I don't know what the wiring system on your bike consists of but on my Lifan 200 all the lights including turnsignals will work without a battery in the system. Head, tail, brake light work on regulated AC. Turn signals work on regulated DC. The battery is not needed at all except for the electric starter. I can post a wiring diagram for the Lifan 200 if that would help. |
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10-07-2014, 12:05 PM | #11 |
Join Date: Jun 2014
Posts: 13
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The regulator I have looks exactly like my cg 125 one. It kicks out 12v. I looks like this one
This is the wiring diagram I have used for the engine. |
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10-07-2014, 12:28 PM | #12 |
Join Date: Sep 2014
Posts: 1,914
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Looks like everything is being run on DC in the diagram but the black wire from the regulator shows no connection. Very different than how the Lifan 163 FML is wired on my bike. The regulator is different too but may be the same internally.
I suspect that the DC output from the regulator is insufficient to power the lights and that going AC on the lights will solve the problem. Could the black wire from the regulator be regulated AC output? |
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10-07-2014, 12:41 PM | #13 |
Join Date: Sep 2014
Posts: 1,914
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Here's the diagram for the Lifan 200 GY5.
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10-07-2014, 10:43 PM | #14 |
Join Date: Jun 2009
Location: Brisbane, Queensland, Australia
Posts: 648
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if you want i can scan the diagram of the 1982 XL125S and post it? Not sure what the RC stands for, but it would help match the loom to the engine.
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1971 Garelli Gulp 50cc with open ports and 16 mm Bing Carbie + 1980 Honda XL 223 ZS + 2007 Zongshen LZX200G + DR400SM |
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10-08-2014, 07:43 PM | #15 | |
Join Date: Oct 2014
Location: Florida
Posts: 11
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Quote:
A unique feature of the Voltage sense input is the ability to "adjust" the Voltage on your bike. The regulator circuitry constantly analyzes Voltage on the Black wire, boosting or reducing output to maintain 13.8 Volts DC on the Black wire. For example, if you connect the Black wire at the ignition switch output, there is slightly less Volts there than at the headlight. The Voltage drop is due to switch, wire, and headlight resistance. If you tap into the wiring at the head light, overall Volts will be slightly higher. If you place a 22 Ohm resistor in the Black wire, Volts will climb further since the "sensed" Voltage is less. Have seen a few Black regulator outputs wired to power electric chokes. I looked and do not have the '82 XL125S RC diagram. I have a 1977 XL125S diagram. That scan would be interesting to see. Jon Last edited by InventorPardue; 10-08-2014 at 08:41 PM. Reason: Added note about scan |
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