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Chapter 6 Electrical system
Fig. 6.8 Speedometer - early models (later models similar)
2
3 Speedometer assembly
4 Mounting bracket
5 Rubber ring - 2 off
6 Rubber washer - 2 off
7 Spacer -2 off
Speedometer cable complete
9 Inner cable
10
off
off
off
Spring washer - 2 off
A Seat
B Spacer
C Rubber ring
14 Horn push and horn: adjustment
1 The horn push button is incorporated in the handlebar
control and must be replaced if it malfunctions.
2 The horn is situated below the petrol tank at the front and
has an adjustment screw inset into the rear. This is a volume
screw which may need adjustment from time to time to com-
pensate for wear inside the horn.
3 To adjust the horn, depress the horn button (with the igni-
tion on) and screw the adjuster in or out to obtain maximum
horn volume. Turn off the ignition when adjustment is correct.
15 Fuse: location and replacement
1 The fuse is incorporated in the red lead wire from the
battery, enclosed in a nylon case. It is incorporated to protect
the wiring and electrical components from accidental damage
should a short circuit occur.
2 If the electrical system will not operate, a blown fuse should
be suspected, but before the fuse is replaced the electrical
system should be inspected to trace the reason for the failure of
the fuse. If this precaution is not observed the replacement will
almost certainly blow as well.
3 The fuse is rated at
amps and at least one spare should
be carried at all times. In an extreme emergency and only when
the cause of the failure has been rectified and no spare is avail-
able, a get-you-home repair can be made by wrapping silver
paper around the blown fuse and re-inserting it in the fuse
holder. It must be stressed that this is only an emergency
measure and the fuse should be replaced at the earliest possible
opportunity, as it affords no protection at all to the electrical
system when bridged in this fashion.
Ignition switch: location and replacement
1 On early models the ignition switch is secured to a bracket
rubber-mounted to the frame top tube, underneath the front
left-hand side of the petrol tank. If the switch is to be renewed
the tank must be removed so that the switch wires can be
disconnected; unscrew the plated retaining ring to release the
switch from its bracket. On refitting, use a hammer and a small
punch to tighten the ring without marking it.
2 On CG125-C and E models the switch is mounted in the
warning lamp cluster, next to the speedometer. Remove the
headlamp rim and reflector unit (see Section 6), then trace and
disconnect the switch wires. Remove the headlamp shell
mounting bolts and allow the shell to hang down on the wiring.
Remove the two screws which secure the cluster housing to its
bracket, unplug the warning lamps and withdraw the housing.
Use an electrical screwdriver or similar to disengage the clips
which secure the switch to the housing. On refitting align the
switch with the housing and press it into position from above
until the clips snap into place.
17 Resistor: function and testing
1 Except for early CG125 models, all models are fitted with a
resistor which is bolted to the front fork lower yoke. It's function
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