Help needed rewiring a CDI UNIT By crazieness (Read 6,415 times)

[crazieness]

Brought a new performance CDI Unit for my Pulse Rage 125, the wiring connectors are different , just wondering if anyone can give me a clue as to wiring it in as the wiring seems to be different colours too??



Both the original and the replacement have a block of 4 and a block of 2 wires.

[Alleyoop]

Well this help.
Alleyoop

[Alleyoop]

Easiest is Follow the wire from your pick up coil and then the wire going to the COIL so that gets the two top on the 4 plug set. The two bottom ones on the 4 plug are ground. On the two plug the top is always the killwire and usually Black and White and it goes to the KILLSWITCH. So that just leaves the POWER WIRE it can be many colors but it will come from the stator(IF IT IS AC POWERED) if DC powered it will come from the IGNITION KEY. But that is easy to find out if with the KEY on it registers 12v then you know it is DC powered.
Alleyoop

[Alleyoop]

So did it help or not?
Alleyoop

[crazieness]

Hi Alleyoop, not had chance to try it yet been at work, will have a go tomorrow , your helps much appreciated (always is) , getting sick of it now

Its really weird whats its doing, sometimes starts every turn, then it just refuses to start other times, everything else has been replaced as you know so theres only the CDI unit left.

[crazieness]

Update..
With either CDI Unit on, not getting constant supply of electric to the red wire at the CDI unit

[Alleyoop]

BUMMER!! That wire if tested should be putting out 40-100VAC from the stator. So if not then the stator has gone south.
Alleyoop

[crazieness]

Not got the tools to get it off so looks like a job for the professionals

[Alleyoop]

If you have a volt meter TEST IT FIRST.
Alleyoop

[crazieness]

We have tried 2 plugs, 2 CDI Units , its a pretty new coil with lead and cap, it runs as and when it feels like it, the last two days, its started fine until tonight when i decided to actually use it , started, died and hasn't started since, it fires occasionally and sounds almost like its going to run and then nothing?
Tested all the wires to the CDI Unit, the 2 green wires are earthing properly, the kill switch wire appears to be altering the voltage so must be working, the wire from the trigger is showing a feed, the feed to the coil appears to be working and showing a feed, theres the only the red wire that has no sign of life .

[Alleyoop]

The RED WIRE is that the wire going into the BOTTOM on the TWO PLUG? In my CDI picture that would be the BLACK/RED wire that says POWER WIRE. Also is that wire coming from the STATOR? That is the wire IF COMING from the stator when you crank it, it should read anywhere from 40-100VAC. If the wire is coming from the IGNITION it should read 12V with the KEY ON.
Alleyoop

[crazieness]

Jan 18, 2014 16:41:19 GMT -6 Alleyoop said:

The RED WIRE is that the wire going into the BOTTOM on the TWO PLUG? In my CDI picture that would be the BLACK/RED wire that says POWER WIRE. Also is that wire coming from the STATOR? That is the wire IF COMING from the stator when you crank it, it should read anywhere from 40-100VAC. If the wire is coming from the IGNITION it should read 12V with the KEY ON.
Alleyoop

Its the black/red wire on your image, which is a direct feedfrom the stator, plugged a volt meter on to it, while cranking the engine over and reads nothing, all the other 5 wires , the 2 green earths, kill switch wire, coil feed and trigger are all doing what they are supposed to do, feeding or earthing accordingly.

[Alleyoop]

If it reads NOTHING then the stator is shot, that is why no spark. That feeds the CDI voltage then the CDI stores it and builds it up to around 400v then when the trigger sends the signal the CDI releases the 400v to the coil and the coil takes that and builds it up to 20000-40000 volts and sends it to the spark plug. So no power to the CDI no spark.
Alleyoop

[crazieness]

Jan 18, 2014 16:53:02 GMT -6 Alleyoop said:

If it reads NOTHING then the stator is shot, that is why no spark. That feeds the CDI voltage then the CDI stores it and builds it up to around 400v then when the trigger sends the signal the CDI releases the 400v to the coil and the coil takes that and builds it up to 20000-40000 volts and sends it to the spark plug. So no power to the CDI no spark.
Alleyoop

So can it still show something going to the coil and something to the trigger?

I thought the wire from the trigger is indirectly fed from the stator? if its feeding one it must surely feed all??

[Alleyoop]

The stator has a dedicated POLE just for the CDI FEED, and the TRIGGER, so the Trigger wire(PICK UP COIL) will show some VAC .05 the rest of the poles are for Charging and lights going to the Regulator Rectifier. But if nothing is feeding the CDI then maybe only some left over voltage is being generated. NOW on your meter there is a separate setting for DC voltage and AC voltage to test the stator you need to set it on AC Voltage. DC you would set that for like battery testing.
Alleyoop