Author Topic: IT125 wiring changes  (Read 565 times)

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Offline mboddy

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IT125 wiring changes
« on: October 02, 2017, 09:19:23 AM »
This thread will document the changes I am making to my IT125 wiring.
The changes are to improve reliability and ease of working on the bike.

Problems with the existing setup:
. Connections from the stator are between the tank and countershaft sprocket and so are vulnerable to damage and reduce access to carby.
. Battery box needed to be removed so that shock canister that is attached to swing arm did not hit it.
. Battery box mounts needed to be removed to assist removal of inner mudguard for shock adjustments.
. Small battery was relocated to under the seat but it is not currently well located.
. Flasher unit wire has a break somewhere in the loom (the wire runs the full length of the loom).

Changes:
. Relocate CDI box from right rear side of inner mudguard 8cm forward and up and mount to top of right side inner mudguard.
. Remove the stator to CDI box brown, red, and white/red wires from the loom and discard.
. Create new ignition wire loom from CDI box to coil and kill switch with orange ignition wire, black/white double female connector for kill switch and main switch and new black earth wire with loop connector to coil mount.
. Remove orange and back/white ignition wires from the loom.
. Relocate wiring from the stator so that it goes under the air box boot and connects directly to the CDI box bypassing the loom. Fit IT175F wiring guide above sprocket cover.
. Relocate the small battery to area where the CDI box was. 
. Relocate the flasher unit to space below the trip knob on the speedo.
. Relocate the brown power wire to the flasher unit from rear to front of loom. Remove the brown/white flasher wire from the loom and fit new spade connector.


Here is the CDI box in it's original mounting position (side view):


Here it is in it's new position (top view):


From the side you can see that it will connect directly to the wires from the stator without any issues:


 
 
Vinduro Penrite Team
1980 IT125G, 1979 IT175F, 1984 IT200L, 1977 IT250D and IT400D

Offline mboddy

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Re: IT125 wiring changes
« Reply #1 on: October 07, 2017, 08:45:46 AM »
I found some space for the flasher unit. Not easy on a bike as compact as the IT125. But it will be protected and simplifies the loom.
Attached via a large cable tie around the speedo bracket leg and two tiny cable ties to join the rubber holder to the large cable tie.

Vinduro Penrite Team
1980 IT125G, 1979 IT175F, 1984 IT200L, 1977 IT250D and IT400D