[tw200sgp]

I was in traffic in Singapore and with no warning - no cough - fortunately at a low speed the engine cut. I switched to reserve but no luck. After I pushed it out of traffic I had a quick check and there's no spark. I had just changed the sprocket and chain an hour earlier (about 15 mins of run time) and I'm assuming I've disturbed something in the stator or wiring. I had a good dig around the exposed wiring - a small cut in the insulation of the red/white wire from the stator but the conductors appear undamaged. The plugs seem tight under the seat. I hot wired the kick stand (blue connector?) under the seat but no spark from that. Any ideas? I've got the dealer picking it up tonight anyways. I can't believe a CDI can go that quickly and I was careful with the stator cover but it did pull once when it slipped out of my hands so maybe I've damaged a wire

 

[mhomadness]

Ugh!! What a kick in the gut! Sadly, grounding out the right / wrong wire could take out your CDI, or perhaps pulsar, stator coil in a split second! My first thought was the side stand switch too, but that pinched wire, not good. As far as pulling a wire loose by letting the side cover slip, I think unlikely, as those wires run under a wire protector on the inside, shielding them from the stator, & are held in there very well.



Don't beat yourself up on this one. Those wires are hard to get into the right spot. We've all pinched wires, broken off bolts, you get the picture. Feces occurs.



Let us know what happens. m.

 

[tw200sgp]

I can't see it being a pinched wire (the wires look like the clear ok to me via the grommet but maybe others have opposite experiences). Anyways it's at the shop so I'll find out soon enough.

 

[tw200sgp]

Well the shop wanted a week to fix it so I pushed it home (500 yards). Within 30 minutes I had found that the stator wires had been misrouted when I replaced the chain/stator cover and had gotten crimped. I checked them for damage, wrapped a bit of tape around - put it all back together and it works. I don't think ground either a stator wire or pulse coil wire can damage anything but definitely cutting them randomly would. The time I spent working on the CDI and going through the wiring was well spent - I feel much more familiar with where things are now.

 

[mhomadness]

Pinched / crimped wires... If the wire insulation was compromised, & the wires were grounding to the case, this could kill the spark. If that was the case, and you didn’t damage anything, you are lucky! All that really matters, is that you didn’t have to pay the shop, & your bike is back to doing its most important job, putting a smile on your face.

m.

 

[mhomadness]

PS: Good job! m.

 

[Rainman]

Thats excellent to hear that your bike its up and running again!

 

[lizrdbrth]

...... The time I spent working on the CDI and going through the wiring was well spent - I feel much more familiar with where things are now.

+1.



That's the 'tude we're trying to cultivate around here.

 

[Hiway]

A big ol "whew" from me. Glad you got the problem diagnosed and if you have any more knowledge about the infamous CDI in the t-dub let us know.

 

[tw200sgp]

Stator tips I learnt;



With the stator disconnected no wire connected to the stator show a short to earth (only a drain resistance in the MOhm range). The R/W combination in the white connector from the pulsar coil showed an earth connection which gave me a hint that a crimp had occurred (none of the CDI stator coils are grounded - they are all isolated from the Chassis).



The wiring resistance on the pulsar coil is about 400k.



The wiring resistance on the AC coil for the CDI is about 400 ohm.



Both coils will generate a voltage spike when the engine is turned over.



CDI hints;



The connection coloured L/Y on the CDI connector should show a short to earth with the key on, side stand down and kill switch on 'run'.



I am seriously considering buying a second CDI and keeping it in storage.

 

[lizrdbrth]

Here's how I used to carry my backup. The bike has since been rewired and most of this space is empty now but you get the idea. It's now encased in a rubber sleeve which I pilfered from another brand of bike and piggybacked onto the existing unit. Plug and play:

Late model CDI's are nearly twice the size and could be a bit more challenging to find a home for, but there is plenty of room for those if you get creative.

 

[qwerty]

Glad you're up and running. Lesson to learn is it's impossible to be too careful with those wires when replacing the side cover. The potential for catastrophic damage is one reason I advocate for a complete sprocket and o-ring chain set, new gasket, and new countershaft and shifter shaft seals when the time comes to replace the chain. The work isn't difficult, but proper wire routing is critical and easily messed up.