CDI and stator problems

[Jenik]

Or from Europe
https://ignitech.cz/en/vyrobky/dccdi/dccdi.htm
or
https://ignitech.cz/en/vyrobky/dccdip/dccdip.htm

[motorang]

Okay here we go (lunch break ... )

I checked Pick-Up wire colors from the original Yamaha Owners manual or Workshop manual digrams.
In the documentation, both 3AJ and 1VJ have the same color scheme.
Unfortunately, on the CDI side both pickup coil wires are said to have the same color code (white/green) which is not true.
See below.


1VJ electric diagram complete:


3AJ pick-ups and rpm range


3AJ CDI cable schematics


So I checked with my 1VJ spare stator and CDI. The connector is a three-bay with round plugs.



(if this Image does not last you also can find it here)

Black/yellow on stator = green on CDI = common ground for both Pick-Ups
Light blue/yellow on stator = white/red on CDI = high rpm pick-up coil
Green/White on stator = white/green on CDI = low rpm pickup coil

Hope that helps
Andy

[SOHC]

Sorry I must of missed the link, I had to find out ASAP as a friend is going to order me one.

[Mezo]

Sorry I must of missed the link, I had to find out ASAP as a friend is going to order me one.

He`s not the fastest, like i said he makes them to order (unless he has a canceled order on the shelf) so it could take a couple of weeks at the earliest, he`s well known how slow he is but it's worth the wait, it's a good product.

Mezo.

[SOHC]

Okay here we go (lunch break ... )

I checked Pick-Up wire colors from the original Yamaha Owners manual or Workshop manual digrams.
In the documentation, both 3AJ and 1VJ have the same color scheme.
Unfortunately, on the CDI side both pickup coil wires are said to have the same color code (white/green) which is not true.
See below.


1VJ electric diagram complete:


3AJ pick-ups and rpm range


3AJ CDI cable schematics


So I checked with my 1VJ spare stator and CDI. The connector is a three-bay with round plugs.



(if this Image does not last you also can find it here)

Black/yellow on stator = green on CDI = common ground for both Pick-Ups
Light blue/yellow on stator = white/red on CDI = high rpm pick-up coil
Green/White on stator = white/green on CDI = low rpm pickup coil

Hope that helps
Andy

Ah thank you that is very helpfull, do you know about my source coil wires? witch way to cdi would they go?

[motorang]

Hi
well as somebody swapped the original cables for other colors it is hard to tell from here :D
Possibly the source coil has been repaired (rewound).
You have the pickup coil colors sorted now, right?

The stator coil for ignition (charging the condenser in the CDI) originally has a red and brown wire. They attach to wires of the same color on the CDI, usually in a two-bay connector.

There are some aftermarket stators where this coil has been wound in the wrong direction, which will not produce a spark. Then you swap the wires: brown un CDI connects to red on Stator and vice versa and it works.

So this is my recommendation:

Check the expected resistance between the TWO stator wires you have left over, after sorting out the other stator wires. They should be the ones of the "ignition source coil", and 140-200 Ohm are to be expected. Also measure the resistance of each of those two wires to any other wire of the stator, it must be infinity or at least very high, in the Megaohm range.

If the resistance on the stator side is OK just connect the two wires to red and brown on the CDI and see if you can get a spark kicking. If not swap the wires.
No damage to be expected.

Only be aware that you can measure if the coil is bad (way outside its resistance specification). But it is hard to make sure it is good, as the real world load on that coil is much higher than your multimeter measuring current. So the resistance measurement may be OK but still the coil may shorten out internally. Alternator repair shops can check the coils properly, doing an insulation test under high voltage and temperature.

Andy

[SOHC]

Hi
well as somebody swapped the original cables for other colors it is hard to tell from here :D
Possibly the source coil has been repaired (rewound).
You have the pickup coil colors sorted now, right?

The stator coil for ignition (charging the condenser in the CDI) originally has a red and brown wire. They attach to wires of the same color on the CDI, usually in a two-bay connector.

There are some aftermarket stators where this coil has been wound in the wrong direction, which will not produce a spark. Then you swap the wires: brown un CDI connects to red on Stator and vice versa and it works.

So this is my recommendation:

Check the expected resistance between the TWO stator wires you have left over, after sorting out the other stator wires. They should be the ones of the "ignition source coil", and 140-200 Ohm are to be expected. Also measure the resistance of each of those two wires to any other wire of the stator, it must be infinity or at least very high, in the Megaohm range.

If the resistance on the stator side is OK just connect the two wires to red and brown on the CDI and see if you can get a spark kicking. If not swap the wires.
No damage to be expected.

Only be aware that you can measure if the coil is bad (way outside its resistance specification). But it is hard to make sure it is good, as the real world load on that coil is much higher than your multimeter measuring current. So the resistance measurement may be OK but still the coil may shorten out internally. Alternator repair shops can check the coils properly, doing an insulation test under high voltage and temperature.

Andy

Yes thank you, I have the pick up side sorted now, and I gess it it runs badly i can swap them over.

I once hand wound a low speed source coil for an old KX250 by hand, 300 meters of 0.03mm wire, I wound it the wrong way.

[Mezo]

Alternator repair shops can check the coils properly, doing an insulation test under high voltage and temperature.

My Megger tests up to 1KV



Mezo.

[motorang]

Oh boy
I have seen cheap ones online
but have no clue what to measure or to expect when checking stators or pickups.
My local guy takes 15,- plus shipping for a check. Puts the stuff in an oven, heats it up to 80 °C then measures insulation.

A 70,- unit from China would be paid for with three measurements if they are kind of reliable. What do you think?
Could you help me out with a dummy guide on how to check our XT600 stuff?

https://de.aliexpress.com/item/32808716 ... hweb201603_

Andy

[SOHC]

I use to have a home made peek meter witch was good for testing Motorcyle ignitions.

Well the guy sed he poasted the CDI box 2 weeks ago and it hasn’t arrived