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Discussion Starter #1
are there any cdi savvy guys out there….

i have 4 cdi's that are faulty and would like to try to make them work if possible..i dont like to bodge stuff in general, this is just something id like to mess about with over the weekend before i buy 2 used for the bikes. i have a tw that has already had this done with a 2nd cdi being used rather than the black & white relays and both spliced together, but i dont know what the 2nd cdi if from, also a bike i sold had a honda cdi wired in..but my mechanic guy is away for a few days to ask for the info

the problem with the cdi's is that they dont allow the bike to rev properly, it coughs, splutters and back fires..at first i thought it was a carb issue as the bike runs but was missing at higher revs..(it was fine when i stripped it), but after 4 days swapping jets, carbs, lots of pointing and swearing, etc i discovered it was the cdi playing up..i am guessing that this is the orange wire not giving a strong or regular spark….i do think its strange that 4 are faulty all of a sudden so this is why id like to see if there is a way i can maybe add a live from somewhere else in the loom, or earth, join some wires, by pass something …..any ideas???



i think i know what most of the wires do from the cdi...

orange - spark
black/white- loom power from ignition
red- live
brown- live
blue/yel- safety relay switch?
green & white- pulse wire from engine?
black - earth

any info would be appreciated,

p.s i have the wiring diagram before thats suggested.

thanks
 

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I have a completely de-potted CDI that Im looking for help with as well. In the process of stripping all that silcone, rubber epoxy I lost some of the components on the board. What a pain in the butt!!
 

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Discussion Starter #3
i tried to cut 1 open to see what was inside….i soon gave up on that!!….the local mechanic told me that a yamaha mio or fino cdi will work so i will try one of those and see, if no go then i will buy 2 used TW ones from japan.
 

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i just baked mine in the oven tonight at 300 for just over 10 min. I put it on and its working so far. Will it last or is the bike up to its I work at random times trick again!?!?! We shall see.
 

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i just baked mine in the oven tonight at 300 for just over 10 min. I put it on and its working so far. Will it last or is the bike up to its I work at random times trick again!?!?! We shall see.
I've heard of folk successfully doing this in the past. Seemed like it was a temporary solution, but ultimately the cdi needed to be replaced. I do hope it lasts for you though, as these buggers can be expensive.
 

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I've heard of folk successfully doing this in the past. Seemed like it was a temporary solution, but ultimately the cdi needed to be replaced. I do hope it lasts for you though, as these buggers can be expensive.
I agree 100%. Yamaha showing these at $373, ouch!! I'll see how long it last, then I'll have to buy one.
 

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The best way to de-pot is to build yourself an oven out of foil-lined plywood or similar with a heat lamp in the top, controlled by a dimmer switch. The resulting radiant heat does a much better job of heating the potting material so it can be removed, while not overheating the components and board.

Bad capacitors will usually be obvious, sometimes before you even start digging. I recommend replacing all electrolytics on principle, since you have it open anyway.
 

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Discussion Starter #10
the TW guys in bangkok have used ones for $100-150, so i will try the mio scooter first for $30…much better option than $373!!
 

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I successfully fixed the CDI on my '87 TT225. It's very similar to the TW200 CDI. Over time, the solder joints end up breaking(cold solder joints). Touching the joints up with a soldering iron should fix the issue. There are numerous threads about fixing the CDI if you do a search.
 
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