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Not a video (yet) - quad wiring loom

This is one of those random things I found on eBay.  It's the wiring loom for a quad bike.

The loom includes a keyswitch, handlebar mount control, magneto with high and low voltage windings and timing detector, Capacitive discharge ignition module, spark coil, spark plug, rectifier/regulator, starter relay and battery terminals.

It was interesting to explore and trace out all the wires and their functions.

The rectifier/regulator and CDI (Capacitive Discharge Ignition) modules are potted in resin.

Should I make a video about it?

Not a video (yet) - quad wiring loom

Comments

Some do still seem to shunt the AC output of the alternator. There are some very odd schematics online. Some stuff is very "retro".

Big Clive

It would be a wonderful thing to fully reverse engineer a modern permanent magnet 3-phase rectifier/regulator. Too many mechanics and amateurs alike believe that the excess power is shunted to ground once the battery is fully charged. Like as if technology hasn't progressed in 60 years. One of my previous motorcycles fed a DC current through a separate coil on the stater, which shut it down by saturating it. Modern ones have SCR's which may do similar through the main coils. Maybe they are doing a PWM type moderation. Yours looks like a single phase coil, so not sure if that makes a big difference.

Paul Malloy

I'm not sure he'd be too impressed.

Big Clive

Some of the electricians I work with could't wire a doorbell let alone follow a MC or cars diagram. IDK Clive, maybe sit this one out. (imo only, please don't hate me)

Aaron Nadler

Yep, all for it if you're game. I'm wholly unfamiliar with capacitive discharge ignition, other than what's indicated via the name.

I would be interested to see if and how different wire diameters are being used to accommodate for the expected current.

Frank

As usual ;)

Frank

If you have to ask, then yes make a video.

Yes please. Also, tell Eric O. about it, too. He may benefit

Chuck Kirchner

Should be quite a good tear down and reverse engineering project. πŸ‘πŸ‘πŸ‘Œ

I have done similar work, but not to those specifications. I kinda dig it. But only when they work the first time. :o

Michael Thompson

I beg to differ! You very well BETTER be igniting something with that spark plug! lol

Michael Thompson

If you don't it will make me sad.

Michael Thompson

I would expect the alternator to supply 3 phase, normaly a 2 wire connection with the 3rd wire switched in by the headlight switch.

I'm currently using the Moto G7 Power.

Big Clive

Their choice will be weighted accordingly to the final decision.

Big Clive

I wired up, then individually idented and point to point checked, then hand braided the looms on 5 drawer racks, each containing 4 massively heavy PSU's for an Indian Navy Sonar contract. Talk about a spaghetti of coloured wires, and if one wire was cut too short to reach a particular Cannon Connector, then you weren't permitted to extend it, instead you had to start all over again.... Yes please, I'd certainly welcome your video.

Andrew Donaldson

πŸ‘ ...just don't be igniting something with that spark plug πŸ’₯

Phil in the kitchen

What would happen if someone says No, don't do that video?

Peter Stimpel

As a motorcycle enthusiast I say absolutely! It would be nice to see how everything works.

Nathan Musick

Yes! I've got a scooter with very similar components so it would be great to see a breakdown of everything. Thanks!

l think its a good idea to include this as Astromanian said he is one of the many people who run a mile if auto electrics go wrong ,,,your way of doing teardowns would be a great reassurance and answer a lot of questions ......if you read this ,,,,,my phone has gone west and l wondered what you use to make the videos on here ...l have heard you mention the Moto G7 but cant find the video where you said what was your prefered choice of camera smartphone

John Catterall

Yes, but please turn it into a set of fairy lights at the end.

I would be interested. Anything that involves finding out how and why is a draw for me- ever since I can remember, I was curious as to how things worked, and would take all my toys to bits and put them back together again. I am still the same, but the toys are bigger and better now.

Mike Hughes

that's one pile of spaghetti LOL reminds me when my farther replace the wiring on his old BSA motorbike and yes would love to see a video of it to BIG thanks as all ways

Mort

Yes, please! Always fun to investigate different things! The plastic, snap-in ignition switch is... amusing. Compare this to mid-70s Chevy truck, dash-mounted ignition switch. Most essential circuits were grounded when switched off to fend off hot wiring attempts. None of this added security is shown in the wiring diagram! I only discovered it after gutting a failed switch, having wondered why the thing had a ground wire going to it.

Mike Cowen

If you would please. Also interesting to see your take on the quality of wire/connectors/components, I have found these things to vary massively!

Yes, please.! Could you talk a bit about how the rectifier works? I've always wanted to know how much my little motorcycle could generate for small electronics and additional lighting. I imagine its quite noisy? Is it electronics safe? Rectifiers just seem like diodes to me but there must be more to them. I'm going to rewire my Honda Grom this winter and this gets me all excited.

35 years as a technician in another field, Auto-Electrics... Scares me so much! Please run with this!

Of course!

Michael Horton

Yes!. Echo...

Wim

Definetly! I have a schematic when you’re interested :)

Mike Weijmans

Same here πŸ˜πŸ‘

Cerity

I'd definitely be interested in seeing more auto 12/24v stuff. Im in hgv build, repair and maintenance πŸ‘

Cool Yes!

I've found a generic wiring diagram that seems to tally up with most of the colours. Including the black positive, but not the sudden random colour transition from one side of the connectors to the other.

Big Clive

Yes of course. You may be able to get a wiring diagram, but they are fun to work on.

Yes, you should. Been wondering what makes these things tick.

NightshadeLenar

This could make for some quick and easy prop or set dressing for someone who didn't have bunches of random techno baubles sitting around in bins already.

Jason Brinkerhoff

I'd watch it! Though I might be procrastinating from repairing the wiring loom for one of my trucks when I do ;)

I would definitely watch, even though I deal with wire harnesses all the time. Normally on the machine, sometimes taken off to completely repair/replace with a hand made one. With a schematic its easy for me. Without one its still pretty easy, just way way more time consuming. Its always interesting to see how different manufacturers do things, sometimes you will see shortcuts that work. Sometimes they over build them like using multiple ground wires going out the same locations in the harness when current nor interference would be an issue.

Yes!

Of course you should, what a silly question Clive! :D

Roy Eltham

Absolutely. But then I'd watch anything you made.

Earl Plotner

Absolutely. I would love to walk through the loom.

Witold Witkowski


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