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Discussion Starter · #1 ·
i have been working on putting a 4S 110cc in my FS509 cateye and have a question. i am wiring the magneto into the original 2 stroke wiring harness.

I just need to know what wires in this picture go where, please no more wiring diagrams. I can read diagrams with no problem but none of them are in depth enough or are "general" and don't have anywhere close to the same wiring as my bike. Some even show the wires going into the regulator/rectifier differently.

Also, is this even a rectifier to convert AC to DC or is it something else because the 2 grounds coming out of it are just confusing and the input of the voltage from the "starter" into something that the other diagrams say is an output is weird.

if anyone can help it would be much appreciated, thanks!
 

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Discussion Starter · #3 · (Edited)
i have seen these diagrams but the problem with the X18 diagram is that there is are no pin-outs so its impossible to tell where the wires go into the connectors, not really a true wiring diagram.

and the CDI diagram isn't for my engine, i do not have a Red\Black wire which is for an AC input into the CDI. I didn't realize this and purchased a 5 wire CDI when i should have bought a 4 wire CDI that is DC controlled (unless there is a conversion?)

Maybe I'll just purchase a Regulator that i know the pin-out to...no one has a diagram that shows the inner circuit of a cateye regulator and its pin-outs.

its always a pain when it seems not many people have done a swap or just haven't made threads about it, haha
 

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Discussion Starter · #4 ·
is the regulator for a cateye a rectifier too? the wires that come in and out of it make no sense compared to parts listed as rectifiers.

the pinout for the stock cateye wiring is...

Top Left...AC input from magneto/starter & signal to speedo
Top Right...Ground
Bottom Left...DC out?
Bottom Right...Ground

and all the ones i see online and in the wiring diagrams are...

Top Left...To battery +
Top Right...AC input from Stator
Bottom Left...AC input from Stator
Bottom Right...Ground

so this is where im getting confused. These are nowhere close to the same which means i need a diagram to see whats inside the cateye regulator to see how to wire it.
 

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You went from 2 stroke wiring to 4 stroke engine, you may have to make your own wiring bundle. TNCScooters has all the elect plugs for these bikes cheap. The CDI takes a 6 prong plug w/ 1 blank, you get a male & female plug with all the connector to make your own stuff. Or a $20 X bike 4 stroke wiring harness PB Parts in Florida.
Look at the second strip down wiring, it is easy to wire and will get the bike running till your can mod or find a wiring harness that will work. PB Parts has a phone on their website.
 

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Discussion Starter · #6 ·
i think im gonna just buy a CDI that i know the pins for...the one on the cateye has two grounds and only one pin for an ac voltage. i have 2 ac voltage wires. i just don't get why there are 2 grounds on the CDI, weird.

and i bought the 5 wire CDI no knowing that i only have 2 ac wires from the magneto and not a 3rd that the CDI needs for power. could i run a splice in one of the ac wires and feed it to the CDI? i believe it should work just fine
 

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I don't see why not on the splice. I would want a fuse off the battery or solinoid, & Volt Reg before runnig it to a CDI. I got a Blue finned racing CDI and hp orange coil $20 for the set, on eBay.
 

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Can someone post a video or complete turtorial on the cateye fs509 convertion to a 110cc 4s
Try utube for that info............everybody has their idea of how things should be done and mounted and youll find many different methods in order to get the same idea done ...........

IMO instead of making a 4 stroke cateye bike,,,fix-up the one you have,,sell it and buy yourself a 4 stroke engined pb already made......putting a 4 stroker in a cateye isnt gonna make it any faster just alot more unrideable and very sketchy which isnt very fun...In the end youll have a high dollar project that doesnt look too good and wont re-sell for even half of what you have in it..................4 stroke x7's are also called cateyes and theyre alot safer and cheaper to buy..........Find one of those............
 

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Cam I been waiting to talk to you. Is it crazy your pretty much famous on this forum. But I bought this. Cateye fs509 a few days ago from a shop. It was in terrible shape. I took eveeything apart rewired it thanks to your diagram. I'm 22 years old an. I'm addicted to pbs. I read that the muffler was not to good itself. So I'm buying a new muffler tomorrow and a carb with vstacks. But I clocked in at 21 mph using digihub. It takes a little while to accelerate. Btw this is my first.
 

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Try utube for that info............everybody has their idea of how things should be done and mounted and youll find many different methods in order to get the same idea done ...........

IMO instead of making a 4 stroke cateye bike,,,fix-up the one you have,,sell it and buy yourself a 4 stroke engined pb already made......putting a 4 stroker in a cateye isnt gonna make it any faster just alot more unrideable and very sketchy which isnt very fun...In the end youll have a high dollar project that doesnt look too good and wont re-sell for even half of what you have in it..................4 stroke x7's are also called cateyes and theyre alot safer and cheaper to buy..........Find one of those............


Ty for all the help. Any advice to get this to peek performance let me know.
 

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Cam I been waiting to talk to you. Is it crazy your pretty much famous on this forum. But I bought this. Cateye fs509 a few days ago from a shop. It was in terrible shape. I took eveeything apart rewired it thanks to your diagram. I'm 22 years old an. I'm addicted to pbs. I read that the muffler was not to good itself. So I'm buying a new muffler tomorrow and a carb with vstacks. But I clocked in at 21 mph using digihub. It takes a little while to accelerate. Btw this is my first.
No need to wait...Im an ordinary guy like everyone else who doesnt mind helping out others..You can pm me anytime sometimes you gotta be a lil patient because I turned off my notifications as my emails and such were blowing up a dozen times or more a day............lol

Sounds like you need to work the bugs out..........To make sure its absolutely worth putting $$ and time into it you need to get compression #'s or do a visual insp on the cylinder/piston

remove carb,,,clean carb out

replace carb gasket and intake gaskets

get a new NGK BPM6A sparkplug gapped to .030"

get a v-stack w/built-in choke

get a hp airfilter

remove the coil,,,clean it up and the magnets on the flywheel and regap to .020"

remove the clutch arms,,,clean them up and de-glaze the pads and clutchbell with sandpaper,,de-rust the shoulder bolts and de-oxidize the pad mount holes.

lighten the clutch arms by crossdrilling them

get a rocket key

lighten the flywheel

With a good tune you should be able to get the cateye up to atleast 30mph...:thumbsup:

Grab a dremel set to do a lil port modifying and remove the basegasket to bump compression youll see 35-38mph............
 

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If you look into both the exh. and intake ports and make the piston go up and down, look at the cylinder walls. If everything is scratched up bad, probably better to rebuild at least the top end of the engine. $50 cyld piston ring & bearing set w/ gaskets. With it apart you do a bunch of small mods to increase your horsepower, takeoff and top speed.
The bikes pretty heavy for 49cc engine, and you add rider weight, and that dogs it down. They have to keep the gearing low to pull the bike, if you increase power you can gear it higher for more top speed. Light is the key word.
 

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Ty guys. ill inspect and clean the paerts mentioned today. I ordered a lot of different parts just yesterday. I say online an already ported header for the 49cc can I just throw that on tje list to buy. And my friend did a conversiom on his bike and he used a itailian conversion. Kit to make it 70cc. Any knowlage on that. Btw I onpy weigh 135
 

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Never heard of a 70cc kit for a Cag or Cateye P/P engine. The hole in the block for the cyld to fit in at the bottom is 50mm to 51mm ID. To get 70cc you would need a bore of 52mm or more w/ the 32mm or 34mm stroke. To fit a 52mm ID cyld, would need maybe a 58mm or 59mm OD hole bored in your cases to take the bigger cyld.
 

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Never heard of a 70cc kit for a Cag or Cateye P/P engine. The hole in the block for the cyld to fit in at the bottom is 50mm to 51mm ID. To get 70cc you would need a bore of 52mm or more w/ the 32mm or 34mm stroke. To fit a 52mm ID cyld, would need maybe a 58mm or 59mm OD hole bored in your cases to take the bigger cyld.
Most likely a 50cc Polini / Malossi or other italian brand sit down scooter engine with a big bore kit.................
 

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Most likely a 50cc Polini / Malossi or other italian brand sit down scooter engine with a big bore kit.................
Ill have to ask him he drives to nc everyday to work for some big motar company. But I followed your guys instrustions I tore the engine apart by bolt and cleaned everything. I haven't got the clutch lighten, the rocket keys, or exaughst but I clock it at 29mph. I was riding it done the road with my niece in her racing gear and the muffler snapped in half so I'm waiting for that before I ride it again. Plus the pisto. Head o. It had an 1/8 of an inch of burnt oil and gas at the top of it. I think that was the main problem
 

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Ill have to ask him he drives to nc everyday to work for some big motar company. But I followed your guys instrustions I tore the engine apart by bolt and cleaned everything. I haven't got the clutch lighten, the rocket keys, or exaughst but I clock it at 29mph. I was riding it done the road with my niece in her racing gear and the muffler snapped in half so I'm waiting for that before I ride it again. Plus the pisto. Head o. It had an 1/8 of an inch of burnt oil and gas at the top of it. I think that was the main problem
High carbon build-up does hinder performance and removing it is part of a 2 stroke service along with replacing the rings..................Good job getting it done.........:thumbsup:
 

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If you get an after market hp exhaust, the metal is twice as thick as the stock. On a 4 stroke you can buy just a hp rear glass pack muffler and put it on the end of your stock pipe. I got a $190 X12 HP racing side pipe for $69 onsale w/ alum glass pack and side head pipe.
 

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Update: thank you guys do all the help. I no longer will own the cateye tomorrow ill be selling it for $175 I broke the engine mount but I'm buying the x18 also tomorrow for 150. On a good note its in good condition only needs a clutch cable and master link and the fairing. Now when I get the new one you'll see me on the x18 threadn
 
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