Re: General 5-Star Build - Fast 50cc Single-speed

Mikey Antonakakis /
This single post is part of a larger thread. Start from the top or view this post in context.

Chapter 13 - Wiring, Part 1

Since the frame got stripped bare, and there was really no point in trying to hack up the stock General harness, and the KTM has only two wires (ground for the coil/TCI?/CDI? magic box, and power/trigger from the stator), I figured I would start from scratch and make exactly the harness I need. Goals here:

Practice with planning ahead, instead of slapping stuff together because it's a decent workout for the brain, and a good habit that mopeds have a way of making you want to avoid (for me, at least).

Ease of use because I don't plan to run the wideband or EGT all the time. Disconnecting and removing them should be quick and easy. And I expect the harness will see a few full removals and reinstalls for things like paint, more fabrication work, etc., so I want to be able to pull the whole thing out of the bike quickly without having to cut any wires.

No bullet or spade connectors, except where needed, like on the ignition box. I want weatherproof, easy to disconnect, durable. I chose Weatherpack here, because I had a kit on hand, and they're cheap and readily available. There's better stuff out there for sure, but for now this will work. Not a big deal to upgrade to better connectors later if needed.

Practice building a quality harness, one that either looks good or looks (mostly) invisible, or both. Added durability goes hand-in-hand with this. So I'll be using some sort of sleeving for it, which also forces me to plan ahead (see first goal).

First step, then, is to plan! Did the best I could here (using some electronics CAD here would have been a good idea, but whatever), including adding rough splice locations ahead of time. The electrics on this bike use two relays (one for gauges, one for lights), 5 switches (keyed ignition, kill button, lights, high beam, and gauges), and quite a few connectors, maybe 18 or so, to disconnect the various bits:

IMG_20190825_175920.jpg

Used that to start laying out the wire on the bike. This part took a ton of time, since I wasn't entirely sure where everything was going to live. This is also a good point to mention that this is set up to not rely on any power generation - this bike won't be used for hours of riding on end, and with something like a 5000mAh battery, the headlight (30W, supposedly, 45W high beam, LED all around) should last a couple hours. Taillight is the Treats vertical fixation, so not much power draw there. Wideband uses something like 3A since it has to heat the sensor, but that won't be used too often once the bike is tuned.

IMG_20190828_230511.jpg

Here's most of it layed out on the bench. A few of the splices got a little rearranged, but for the most part the initial sketch of the layout was pretty close to what I ended up with:

IMG_20190829_001627.jpg

(edited)

This single post is part of a larger thread. Start from the top or view this post in context.
Subject Written By Posted
  General 5-Star Build - Fast 50cc Single-speedTopic by: Mikey Antonakakis Mikey Antonakakis 09/03/19 03:20PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 03:32PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 04:14PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 04:21PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 04:46PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Overpriced Parts Overpriced Parts 09/03/19 05:10PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 05:19PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:08PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:22PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:32PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:41PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:49PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:55PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 06:59PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 07:05PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 07:13PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/03/19 07:43PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Aaron Blair Aaron Blair 09/03/19 09:23PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Johnnie Distefano Johnnie Distefano 09/04/19 12:39PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/04/19 03:44PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Chris Squid Chris Squid 09/04/19 08:25PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: ken gilbert ken gilbert 09/05/19 05:32AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 11:03AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 11:23AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 11:39AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 11:47AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 12:07PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 12:19PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 12:25PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 12:32PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 12:37PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 12:43PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Brandon Weiss (Detective brandon to you) Brandon Weiss (Detective brandon to you) 09/05/19 12:44PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 02:17PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: alex . alex . 09/05/19 02:03PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 02:20PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 02:26PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: ken gilbert ken gilbert 09/05/19 02:22PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 02:33PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 02:41PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 03:09PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 03:15PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/05/19 03:47PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/06/19 01:18AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/06/19 01:46AM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/12/19 11:03PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/14/19 10:21PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Born to be WillD Born to be WillD 09/18/19 07:33PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/18/19 07:49PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Alex Hedrick Alex Hedrick 09/21/19 02:30PM
  Re: General 5-Star Build - Fast 50cc Single-speedRe: Mikey Antonakakis Mikey Antonakakis 09/21/19 10:16PM

Want to post in this forum? We'd love to have you join the discussion, but first:

Login or Create Account