Remagnetized stators

I asked Gene M. about the remagnitized stators when considering building a fully stock motor and this is what I asked Gene:


If I go with a 6-pole stator/flywheel and have Barry Gwin at SF Scooter Center re-magnitise it -- do you think it would be very dependable with a freshly rebuilt motor or do you like the SIL set-up more?

Gene's response:

Does he have a flux tester -- to see which magnets are low?

If the recharge has worked?

Remagnetized stators are fine -I ran my tv200 with stock 6 pole DC system for years. Strong flywheel too. Ignition was fine. Charging was fine. What was poor was the headlight power..the elec kit I have now puts out a lot more wattage for lights...

Rewiring the junction box correctly

Recently I have been working more on my Bajaj Chetak and some body work on my wife's Chetak in an effort to be ready for a Rally ride in three weeks. To see what is happening with the Bajaj's click here. I need to add a post on the Bajaj site to share an interesting thing I found in the oil filter some time in this week.

For info on the rally see the flyer below:



Tonight I replaced the grommets around the junction box to the correct ones. Here's what it looked like first.
Note the incorrect grommets.

Here's what the wiring looks like complete inside the junction box:


To save myself time, I made a diagram to remind myself how to rewire it quickly:


I looked closely at the Technica photo and made sure this time I got it correct. Here's what it looks like:
Note: the only thing I am unhappy is about is the bottom grommet has two holes and I meant to run the wires from the PX HT Coil (mod) through the top hole closest to us so it would be less noticable, but I messed up. In the grand scheme of things, this isn't an issue in any way.

The anoraks may note that my screw for the junction box is also not stock.

Wiring

Currently my wiring is not adding up. The wires from the stator don't match the wire harness in colors. The "Blue" from the coil is THICK and I suspect that it is the one that carries the heavy load.
The "Red" wire from the stator goes to the HT Coil, but that's the end of the red wires there. Christopher Markley wired my stator and PX HT Coil, when he rebuilt/restored the engine. I will contact him to find out what is what as I am near ready to wire the junction box.

I called Christopher last night and he told me each manufacturer wires these differently so I emailed Scomo (Scoot Richmond), because they were closed and posted this question on BBS.
Here's my problem:

My SS180 is a 1967 USA released model and the wiring does NOT match the GS/SS diagrams I have found.

My model is:
- 6V
- non-batt
- non-indicator

I am using a PX125 HT Coil.

Christopher M. rewired the stator and copied exactly what was in the bike. Same color wires and gauge, etc.

Note that I only have FOUR wires coming from the stator:
- Red (hooked into the HT Coil and NOT available for the junction box)
- Blue (thicker than all the wires)
- Green
- Black

The wire harness I bought has FIVE wires:
- Red
- Blue
- Green
- Yellow
- Black

I have heard that some production runs will differ from the standard electrical schematics and that will NOT be noted in any electrical diagram I find. I know that Christopher M. copied exactly what wires came from my stator when he rewired it -- using the same colors. There were no signs that farmer John rewired the stator before the bike had its stroke and was put in the barn.

I am hoping I don't need to rewire the stator at this point, but I only have four wires coming from the stator . . . Red, Blue, Green and of course Black. I am short a wire or one wire needs to double up and do double the work.

Therefore, I wonder if I wonder if I need to add jumpers or what have you in order to properly wire my bike.

Lesson Learned:

Hi Jeremy,
our stator has the one doubled current power source for lighting generated by two lighting coils. I guess it would improve the load balance for the lighting (+ horn) circuit.
Or, Piaggio just want to cut the cost by eliminating the (Sky) Blue wire from the stator!? ;-)

Connections would be as following.
Cheers,
-Hiro

From the stator:
Red -> HT coil terminal 2 -> Red(add new wire) -> Junction box terminal #1
Blue -> Junction box terminal #2
Green -> Junction box terminal #3
Black -> HT coil terminal 1 (or motor case) -> Black(add new wire) -> Junction box terminal #4

At the junction box:
Red(from HT coil) -> Terminal #1 -> Red(from wiring harness)
Blue(from Stator) -> Terminal #2 -> Bule and Yellow(both from wiring harness)
Green(from Stator) -> Terminal #3 -> Green(from wiring harness)
Black(from Stator) -> Terminal #4 ->Black(from wiring harness)

At the switch box on the handle bar:
Terminal 1: Black (from wiring harness via Head light socket)
Terminal 2: N/A
Terminal 3: 2 Yellows (from wiring harness and Head light socket)
Terminal 4: White (from horn)
Terminal 5: N/A
Terminal 6: Brown (from Head light socket)
Terminal 7: Violet (from Head light socket)
Terminal 8: 2 Greens (from Horn and wiring harness)

At the Brake switch:
(Sky) Blue and Black (both from wiring harness)

At the Head light socket(terminal number unknown):
#1: (Sky) Blue(from Speedo) and Yellow(switch box)
#2: 2 Blacks(from wiring harness and switch box)
#3: Violet(from switch box)
#4: Brown(from switch box)

Color codes:
--Stator--
Red(stator): Ignition power source
(Sky) Blue(stator): lighting power source
Green: lighting power source
Yello(inside the stator): connection doubling the current from lighting coils
Black: ground line
--Wiring harness--
Red: Ignition kill circuit
(Sky) Blue(wiring harness): Stop light circuit
Yello(wiring harness): Speedo, Pilot and Tail light circuit
Green: Horn and Head light circuits
Black: ground line

Wiring (without battery)

Thanx to Palmog for both the instructions below and a spare junction box, which he shipped to me from Japan, as I believe my junction box is in bad shape as I remember it being taped up in painter's tape like my High Tension Coil (or there is a slim chance that is in good shape and just taped together for storage purposes -- not to loose screws. I can't remember). We did upgrade our stock HT Coil, which the case cracked and broke, to a PX125 HT Coil. The idea being better spark and brighter lights.

Emailed from Palmog:

Hi Jeremy,

ok, then you have an AC bike with original wiring harness. Assuming so, we can use the wiring diagram for GS160 non-battery model here as a basic,
http://www.scooterhelp.com/manuals/VSB1T.manual/24.jpg


We need four terminal on the junction box as the figure shows. (dots on the junction box in the figure show the terminals) What we need to care is one thing and it is the connection on the HT coil. The PX125 HT coil has only one terminal for the hot (not grounded) AC terminal and we need to connect the wires colored red both from the stator and the junction box to the only terminal (terminal #2 on the figure) on the HT coil. (the terminal at the end of the wire from the junction box would be grounded when you push the kill switch)

Then you would need to connect the ground wire (which colored as black) to the metal body of the HT coil or on the motor case. I'm using the fixing nut of the HT coil as a terminal and connect both black wire from the stator and the junction box to the nut. In other words, the terminal #1 on the figure (original HT coil) is not exist on the PX125 HT coil but the fixing nut can be recognized as the terminal.

To summarize this, first on the junction box,
connection #1: Yellow wires (for tail/speedo/head lighting system) from the stator and wiring harness
connection #2: Sky blue wires (for the stop lamp) form the stator and wiring harness
connection #3: Green wires (for the horn) from the stator and wiring harness
connection #4: Red wires (for the ignition) from the stator/HT coil and wiring harness.

Second on the PX125 HT coil,
connection #5: Red wires from the stator/junction box. (it's your choice that where you connect each two on the HT coil or the junction box but you need at least one connection on each terminal)

Third on the PX125 HT coil fixing nut or the motor case,
connection #6: black wires from the stator/junction box.

Special note: thanx to Palmog, Tom G., Christopher Markley, and all the others that consistently share information with me. Many of my blog readers benefit from your knowledge and expertise.