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Post by alibev on Oct 5, 2023 9:52:36 GMT
I am trying to work out how to isolate the run/off switch and in doing so have examined all of the various wiring looms and connectors. When looking inside the headlight I found three wires not connected to anything. One black and two green all going to separate connectors. Unfortunately I can't seem to add a picture to this post so my question at this stage (until I can identify them) is, is it normal to have spare wires and if so why? Many thanks.
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Post by johnfcbn44dx on Oct 5, 2023 11:02:27 GMT
The run off switch can be isolated by taking the black/white wire from the CDI out of its bullet connector, as the switch in STOP position put that CDI wire to earth. In run position the switch is just ornamental, There are a few spare bullet connectors about on the loom, just to cater for different regional / country set ups.
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Post by alibev on Oct 5, 2023 15:39:35 GMT
Thank you that is very useful. My wiring seems to be a little different. The wiring from the cdi splits into three connectors. The first has white, green and red wires. The second, three yellows and the last a white wire and a blue one. I don't suppose that is much help but I live in hope.
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Post by johnfcbn44dx on Oct 5, 2023 17:10:26 GMT
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Post by alibev on Oct 6, 2023 11:32:09 GMT
I am embarrassed to say I am not sure I have identified where the CDI unit is. My bike has nothing in the position of your above example. I thought it was the unit on the outside of the alternator as my Haynes manual refers to it as such. However, I now think there must be another part to it.
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Post by buster on Oct 6, 2023 12:54:05 GMT
the CDI mounts to the frame top tube, under the petrol tank on the alternator side (black box, bit smaller than a fag packet) three wires on one connector (brown, green and pink from memory, they can fade) white and blue on a separate connector and finally the charging wires, three yellow, on another connector. the only link between the ignition stuff (cdi, coils, pick up etc) and the rest of the wiring loom is the black and white wire for the engine kill
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Post by johnjones on Oct 6, 2023 13:33:49 GMT
There seems to be some confusion creeping in on this subject, the stator, CDI unit, HT coil and ignition kill connection to the bikes loom.
The whole ignition system is stand alone, not dependant on the bikes battery to work, other than the electric starter method of whizzing the engine over.
Yes the CDI black/white wire is earthed via ignition switch/handle bar kill switch to kill ignition. It has been known for the handle bar kill switch to "leak" to earth, and to a much lesser extent , the ignition switch to do the same.
Loss of HT spark, disconnect the CDI black/white wire, is the first "test". Be warned, the ignition system must be considered to be "fragile", so use those red neon plug caps that fit "in line" between oe plug cap and fitted to spark plugs. A real world HT test which is quick and revealing, but you will have to make an "adapter" so they fit in line.alternatively, weld/screw in two working old spark plugs to a steel strip that has a " flying earth lead" with a crock clip to earth, to view HT spark in atmosphere. Just because you see HT spark in atmosphere does not mean a HT spark will jump the gap when inside engine and under compression, hence the red neons being a better test.
The stator has the bikes charging system ( 3 yellow wires ) and ignition system wound onto the stator, but the charging system is completely independabtly of the ignition system. The outer can sensor is part of the ignition system.
There are two ignition connections from the stator to the CDI unit. The CDI unit has the connection to the ignition HT coil and the single bullet ignition kill connection.
The oe CDI "steel can " is bolted to below the frame head stock slightly rearward, on the alternator side, via two bolts, the rearmost one having the loom eyelet earth connection.
May I ask, will your bike start and run ?
If not, does it produce a HT spark ?
Note, the cam cover is insulated !
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Post by johnjones on Oct 6, 2023 13:49:47 GMT
Ps, you have a manual and wiring diagram ?
You know of CMSNL.com for the exploded views, part number listed and actual pictures of parts of interest as well as other data/ info ?
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Post by alibev on Oct 6, 2023 15:57:50 GMT
Ps, you have a manual and wiring diagram ? You know of CMSNL.com for the exploded views, part number listed and actual pictures of parts of interest as well as other data/ info ? Thank you for the information. I am on a steep learning curve but getting there very slowly. I shall have a closer look at the various components and wiring tomorrow. It did start quite well until recently and now won't start at all. The battery gives up before any sign of life. I can see a strong looking spark from both plugs.
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Post by alibev on Oct 6, 2023 15:58:09 GMT
Ps, you have a manual and wiring diagram ? You know of CMSNL.com for the exploded views, part number listed and actual pictures of parts of interest as well as other data/ info ? Thank you for the information. I am on a steep learning curve but getting there very slowly. I shall have a closer look at the various components and wiring tomorrow. It did start quite well until recently and now won't start at all. The battery gives up before any sign of life. I can see a strong looking spark from both plugs.
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Post by alibev on Oct 6, 2023 15:59:25 GMT
Thank you for the information. I am on a steep learning curve but getting there very slowly. I shall have a closer look at the various components and wiring tomorrow. It did start quite well until recently and now won't start at all. The battery gives up before any sign of life. I can see a strong looking spark from both plugs. I have not heard of CMSL but I do have a wiring diagram. I find it difficult to follow but I will get there.
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