HELP Continuing with CDI box (no spark) problem

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

Well I got the CDI box out. Looks brand new inside and tested fine according to Josh Connon's test on this forum.

Can someone verify that the voltage reading to the primary side of the coil (orange wire and red/white wire) should be 12 volts DC? This is with the key on kill switch on "ON" without the starter running.

Thanks. My bike is an 83 XJ Heritage Special.

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

I guess that there is nobody remaking the CDI Units?

Does anybody know of someone who will test run these things to verify they are good or bad?

Someone have an 83 XS and willing to put my CDI on to see if it works?

How about you Sundby? Laughing

weekendrider

If you want to send it to me I'll put on one of two running SK's

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

weekendrider wrote:

If you want to send it to me I'll put on one of two running SK's

I may do that. Laughing

See if I can find a cheap one first. I also asked another contact the same thing. I will let you know.

weekendrider

If you find a cheap one try to get two. I'll take the second if it's a 8 slot connecter.

xsjohn

Luckly these are early 80 technology....hopefully some one can check it out and fix it........John

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

I had a Tech at the TV station I work at tell me a secret. 90% of all electrical component failures (TV's VCR's Radios etc) are simply bad solder connections....

I found with mine that years of vibration have just cracked the solder joints on the circuit board. Some careful work with a low heat solder iron (not gun) and mine was like new again.

The TCI units are designed pretty well - they have a safety shut down in them to protect the circuits - so if they don't work - odds are it is just a solder joint.

Pull the boards and carefully resolder all of the conenctions - making sure to not use too much solder or heat. (don't fry the circuit components)

You'll love the results.

westcoastchi

Did you try pulling out the transistor and replacing it with the radio shack one yet? For a couple of bucks may be worth trying before you get to far into re-soldering things.

newxs650 · Full Member Joined: Jul 31, 2006 Posts: 62

phatdawg wrote:

Well I got the CDI box out. Looks brand new inside and tested fine according to Josh Connon's test on this forum.

Can someone verify that the voltage reading to the primary side of the coil (orange wire and red/white wire) should be 12 volts DC? This is with the key on kill switch on "ON" without the starter running.

Thanks. My bike is an 83 XJ Heritage Special.

I might be wrong with your but have you check your pick-up coil. the bike that i just pick-up has no spark, put in aother cdi from my running bike but still no spark. So I took off the pickup coil from the running bike and put into the new bike it start right up...... Laughing

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

Even if I changed out the tranisistor - while I had it on the bench I would touch up all the solder joints - only takes about 5 minutes. A lot less time then it takes to pull the unit out of the bike again.

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

I found a used one. The moment of truth will be here soon. My heart will sink if it does not spark after that.

I also purchased an aftermarked coil from MikesXS. Like I said, no spark after this and my hands go up in the air!

Confused

jimdi · 650Rider Supporter Joined: Oct 27, 2005 Posts: 512

The aftermarket coil from Mikes should work fine - I have one also.
FYI on the CDI box -

It has a safety circuit - that automatically shuts it down if it looses signal from the pickup sensor (timing) from the Rotor. Make sure those connections are clean.

THE TCI (CDI) box modulates the negative to the coil - the hot side should be hot once the key is on. Check that with a voltmeter.

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

Well. I put in a known working CDI on and still no spark (no voltage to the coil). Twisted Evil

Dang I am out of ideas now. Thinking of taking it down to the shop. I would like to be riding now!

newxs650 · Full Member Joined: Jul 31, 2006 Posts: 62

phatdawg wrote:

Well. I put in a known working CDI on and still no spark (no voltage to the coil). Twisted Evil

Dang I am out of ideas now. Thinking of taking it down to the shop. I would like to be riding now!

hey have you check the pick-up coil? that might be the problem....

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

I plead ignorant now. Have looked at the schematics and not sure what that is. Have seen it come up here on the forum.

I have replaced the original coils with Mikes HP coil. And the fuse box too.

School me.

newxs650 · Full Member Joined: Jul 31, 2006 Posts: 62

phatdawg wrote:

I plead ignorant now. Have looked at the schematics and not sure what that is. Have seen it come up here on the forum.

I have replaced the original coils with Mikes HP coil. And the fuse box too.

School me.

if you have the Clymer Manuals for the yamaha 650 tiwin, then it's on page 196-198. it will tell you about the pickup coil on the 1980 and up.

newxs650 · Full Member Joined: Jul 31, 2006 Posts: 62

phatdawg wrote:

I plead ignorant now. Have looked at the schematics and not sure what that is. Have seen it come up here on the forum.

I have replaced the original coils with Mikes HP coil. And the fuse box too.

School me.

hey phatdawg when you try to turn the motor over or start the bike do you get one small weak spark at the end or any?

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

I don't think that there is any spark. There is 0.0 volts at the 2 wires going into the coil.

I will try and get over to the library and look a the manual soon to look at this diagnosis. Unless someone has a link to it online. Laughing

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

Could this be a problem with not getting a good ground?

Wonder what would be the other indications?

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

Well I checked out the Pickup coil and the manual says it should be between 630-770 ohms. Both coils show infinite (Black to grey and black to orange). So I guess that I found my problem Very Happy

.

Now what?? Mikes has a kit for $300. Not sure I want to spend that kind of bread. Shocked

xsjohn · Last edited by xsjohn on May 22, 2008, 10:29 pm; edited 1 time in total

Again....settle down and snoop...........these seldom give out........try ebay and other salvage yards......they come off the stator by grinding the factory lock down screws off and the remaining stubs back out easily and the new pickup can be screwed on with regular screws.....then you can really fine tune the timing by swingning the pickup to good cruise....usually 2 degrees retarded....

xsjohn

Retiredgentleman

Pick-up coil might even be repairable if you know someone who is good with electrical things.

xsjohn

If the plug is not resolderable.....the winding is pretty much encased in epoxy and unrepairable..........tiny guitar pickup like wire.....xsjohn

phatdawg · Full Member Joined: Nov 19, 2007 Posts: 60

False Alarm! I had the ohm meter on the wrong setting. It appear that the pickup coil is OK.

Still no spark. Must be something else.

Arms are in the air again. Wish I had a twin bike that I could analize.

Anybody buy that XS electrical DVD that is for sale. Might help me find the problem?

Confused

What Happened to 650rider.com?

Yamaha xs650