bigmike1961 Posted April 5, 2009 Report Share Posted April 5, 2009 I'm planning to fit a Honda xl185 into my tl125 frame. Can the xl185 cdi ignition be wired without a battery? Which wires go where. The 185 engine came with a very tattly frame & running gear so I do have the old wiring loom to cannibalise. Thanks Mike Hammond Quote Link to comment Share on other sites More sharing options...
dond Posted April 5, 2009 Report Share Posted April 5, 2009 I put a 185 in a TL years ago and enjoyed the bike for years. Get a wiring diagram and just hook up the wires necessary for spark. You do not need a battery. The only modification I remember doing to make things fit was to move the rear brake pedal pivot back in the frame. You need to make a little space for the decompression release stuff that they used in the 185 and 200. I did not hook up the decompression cable and , in fact, left the arm off at the case. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted April 6, 2009 Author Report Share Posted April 6, 2009 Thanks DonD. That's what I was hoping to hear. What gearing did you run. Does the clutch & primary gear swap over from the TL or did you run with the standard 185 primary gear? How did you move the brake pivot? Was it just cut out and moved back onto the frame tube and re-welded? Cheers Mike Quote Link to comment Share on other sites More sharing options...
dond Posted April 7, 2009 Report Share Posted April 7, 2009 I did not change anything in the engine. I just switched to an appropriate countershaft sprocket. I can't remember which size now but it was probably the same size as the Tl usually comes with. The brake pivot has to be cut off the frame and welded in furthur to the back. Test fit the engine to see where it needs to go and allow enough room to attach the brake arm and rod. I remember putting mine too close and it was always hard to work on and get at. You may want to extend your brake lever if you put the pivot furthur back. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted April 7, 2009 Author Report Share Posted April 7, 2009 DonD, Thanks for the advice. I'll start the trial fitting sometime soon, Mike Quote Link to comment Share on other sites More sharing options...
ross brown Posted May 1, 2009 Report Share Posted May 1, 2009 DonD,Thanks for the advice. I'll start the trial fitting sometime soon, Mike As an exXL 185 owner, I'm keen to see how it works out. Do post some photos when you can. Quote Link to comment Share on other sites More sharing options...
brian r Posted May 3, 2009 Report Share Posted May 3, 2009 I think you'll want a 13 tooth primary sprocket. The TL came with a 15 and that's way too tall IMHO. I have a 12 on my TL but the TL motor has different gearing. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted May 3, 2009 Author Report Share Posted May 3, 2009 I was planning to use the 12 tooth sprocket in conjunction with the 60 tooth rear and see how that goes. Had one trial fitting, no photos. The rear of the frame needs a little grinding and the rear brake pivot does indeed need moving. I was planning to move it up the frame tube and lengthen the brake lever to compensate. I'll take some photos when the work finally gets underway. I've still got to sort the lack of spark in the direct wiring out yet. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted August 27, 2009 Author Report Share Posted August 27, 2009 After a minor diversion with my Scorpa cooling fan I found some time to look at the wiring for the CDI ignition wiring without a battery. Turned out to be pretty simple using the Clymer Manual and unpicking the old wiring loom. Turns out to be the same wiring as for the 1981 XR200. I found some 10mm OD tube with a 1mm wall thickness to sleeve the rear mounting holes in the cases to save re-drilling the holes in the frame. Quote Link to comment Share on other sites More sharing options...
hondanut Posted August 29, 2009 Report Share Posted August 29, 2009 i put an xl 185 engine in an ossa frame many years ago, this is when assembled and unpainted. i finnished it in lime green, so i could stand out when my wife watches me. the engine fitted quite well and despite a few teething troubles went quite well. it cost me approx Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted August 31, 2009 Author Report Share Posted August 31, 2009 (edited) The Ossa/Honda looks good. Made a bit of progress with my build - built a cradle the the engine can bolt into and be turned over on the kickstart. Wired up the ignition gave it a good kick and ... nothing, no spark. Second engine had some major timing issues - about 90 degrees out. re-timed it but no spark and not much compression either. sucks good through the inlet manifold and then blows equally hard through the inlet manifold! Major tear-down needed I think. Should I buy a new CDI unit or the pick-up coil unit that lives in the head? Which is the more likely to fail? I've a new ignition coil and used two different pick-up coil units one in each engine Ok got it running now - missed the earth from the CDI unit. XR wiring diagram shows it going just to the kill switch and the XL wiring diagram shows it connected to the frame earth. Tried it the latter way and it fired straight up in the test cradle. Edited September 1, 2009 by BigMike1961 Quote Link to comment Share on other sites More sharing options...
hondanut Posted September 1, 2009 Report Share Posted September 1, 2009 glad to hear you have a spark now. these honda electrics do not generaly go wrong, almost never, normaly just a bad earth or wire off. having a sper of each unit will make trouble shooting easier. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted September 4, 2009 Author Report Share Posted September 4, 2009 Yep I'm pleased, next step is modifying the rear of the frame & the rear brake pedal to get the engine in. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted January 4, 2010 Author Report Share Posted January 4, 2010 Frame finally all sorted, engine in, running gear all swapped over and it's running. Only tested in the driveway so far but it starts with a single prod so I'm happy. Quote Link to comment Share on other sites More sharing options...
bigmike1961 Posted January 30, 2010 Author Report Share Posted January 30, 2010 Now not so happy First and second gear don't always seem to engage when the engine is running,seems to engage but when the clutch is let out nothing - no drive? Any suggestions gratefully received. Quote Link to comment Share on other sites More sharing options...
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