Mocking and Wiring

Well aren't you lookin pretty today?

Here is the bike at the beginning of the mock up, before I dropped the 150cc engine in. The rear-side of the engine where the motor is supposed to drop partially into the frame was a bit thicker then my 125. Used a dead blow hammer to open up the frame just enough for the bigger engine to slide it. Didn't take too much work, just 10 hard hits to both sides of the frame.

Frame with engine mounted

From there I began re-wiring. The stock wiring harness was a disaster. I tossed it. Not to mention the wiring plug for the new engine was a bit different then the original 125cc engine.

Green = AC Ground, Black/Red = AC Power for CDI/Ignition Coil,
Blue=CDI Magneto Timing, Yellow/Pink = Power to 6vdc Rectifier/Regulator

I ordered a cdi/ignition coil combo kit online that was meant for a 150cc gy6 buggy. Doesn't have a rev limiter on it either, adjustable as well. Wired that all up and in. Currently sitting on the top side of the frame where the old cdi/ignition coil used to sit. For now its zip-tied on there, but I will be drilling into the frame later to seat it properly.

CDI/Magneto Timing sitting above Stator/Alternator

Gotta love CDI. Way better then having to time the bike with points. Not to mention you get a bit more horsepower out of CDI.