butchered wiring harness By rangerdaver91 (Read 17,577 times)

[rangerdaver91]

Yee Haw , I just spoke to an actual person and the new CDI is ordered. The first one got lost on the internet lol. Ok so now I am wondering if you can recommend an intake/reed valve and carb to match my new 72cc BBK and expansion chamber. Or will rejetting my stock 17.5 Dellorto carb and stock intake and reeds be good enough ? There are so many sizes and choices that I am having trouble trying to figure out which ones will fit together and work correctly. Any advice on this will be greatly appreciated.

[alleyoop]

Do not need to mess with the intake or reed valve just up-jet the carb, try a #82 or #85 main jet.
Alleyoop

[rangerdaver91]

Oky Doky #85 main jet on its way.

[blitztek]

these minirelli 2 strokes never run right for me without the factory air box. bog bog bog. had one where the lid fell off. the filter was still in place but the lack of restriction made it bog out. it needed the 1/2" hole to restrict the air flow.

[rangerdaver91]

Well its here, the new 6 wire CDI , here is a pic .I don't want to burn it up or anything so I will wait for your instructions as to correct install.

[rangerdaver91]

I installed the new BBK and expansion chamber and fired her up just to hear it run. Sounds great can't wait to get the new CDI hooked up so I can actually take it for a ride. For the first time ever, I do not want to go to the lake for the weekend. I would rather stay home and get this scooter running. Hopefully I will have instructions for doing so when I return home Sunday. Thanks in advance for the help.

[justbuggin2]

Jr you are the guru lets get his bike going so he can have fun riding

[JR]

Hey Sorry Dave didn't see that it come in so it's probably pretty straight forward. The two plug on it looks like black/red and a green/white so that's apples for apples to the two plug on your stator.

So here is my thoughts.


2-plug


red/black to black/red on stator
white/green to green/white on stator

Single wires


black on CDI to black on coil
red/white from CDI to red/white from stator
orange on CDI to black/yellow on coil
black/white on CDI to red/white going to kill switch

So just pull the plug and test for spark, if you have none then reverse two wires.

orange on CDI to red/white going to kill switch
Black/white on CDI to black/yellow on coil.

I believe one of these combinations will do the trick!

JR

[rangerdaver91]

red/black to black/red on stator
white/green to green/white on stator
Single wires
black on CDI to black on coil
red/white from CDI to red/white from stator
orange on CDI to black/yellow on coil
black/white on CDI to red/white going to kill switch
This will produce a very weak spark, had to touch the plug it bit kinda hard and would spark between my finger and the head but not across the plug gap. I reduced the gap and could just barely see a spark with the lights turned off. I hooked up the 5 wire and it started, I was watching the green light on both CDI's. The 5 wire one flickers very brightly until it starts then kinda stays lit up. The new 6 wire just barely flickers when cranking. I thought maybe the factory 2 plug might not be getting good contact so I cut it out and hooked the wires directly to each other, no improvement. Switching the orange and black/white I had nothing. Damn it damn it damn it. I am so frustrated right now, Im ready to roll this thing into the river. Should I maybe be thinking about just getting a new Stator and CDI that match and will work together and that we are sure how to hook it up ? Man I was so sure that this would fix my problems. I am totally Bummed out. If I have to call the parts I have bought a lose and buy all new components so be it. I am prepared to do so at this point just to be done with this electrical stuff and move on.

[rangerdaver91]

Ok this thing is crazy. it will jump spark from the center electrode to ground, like my finger or a head bolt. But it will not jump spark across the center electrode to the side electrode. I have tried 3 spark plugs 2 NGK's and a champion with different gap settings. From nearly touching to .026 which is what it should be, and it does the same thing.

[JR]

Rangerdaver this is sounding like a grounding problem? First ot all where the coil bolts up make sure the frame is clean and no paint is on it and make sure the coil is bolted up good and tight.

Check each wire going to the coil and make sure they are making good connection.

Check the spark plug cap at the end of the wire that snaps on the spark plug, take it apart and make sure the center wire is making good contact with the pin in the cap.

The ground wire to the stator make absolutely sure it is getting a good ground.

I'm with you on the frustration and stators are cheap and if need be you can buy one to match either CDI but I just don't believe it's bad? Also just for kicks unhook the red/white kill wire the kill switch on the handle bars and see if the spark is any better. I made a phone call and that 6-wire CDI is apples for apples the same as your old one. Also I can look back but didn't you say you replaced the coil alreadty? Are you sure you got the right one?

Lastly where the negative battery cable hooks up to the frame makes sure it is clean and making good contact also.

JR

[rangerdaver91]

Ok I have checked and rechecked all grounds, I am certain they are good, no paint where they hook to frame. I stripped a small bit of insulation from the ground coming from stator and hooked a ground straight to the frame , no change. I even took the stator out and off the plate to see if there was anything wrong that I could see, there was not.There was no better spark with the kill wire unhooked.I even put the old coil on it and had the same results so I hooked the 5 wire CDI back up and she started on the first try. I bought the coil and 5 wire CDI as a set from Scrappydog, they had them on ebay as a matched set at a small discount price. Here are some pics of the coils.
the pink is the new performance coil.




this shows the bare metal on frame where the coil is mounted.

[rangerdaver91]

Well this just keeps going from bad to worse. Now the new CDI seems to have completely crapped out. It wont even tingle my finger now. JR, if you will tell me what and where to buy the new stuff to change this thing over to a standard configuration like most 1E40QMB's have. I have given up on this setup, and am ready to buy all new components to convert this thing over. 5 or 6 wire I don't care. 5 seems to be the more standard setup, but which ever you think best is what I will go with. hopefully it will be a plug and play operation then. I'm done trying to figure out how to make this one off bastard of a wiring nightmare run, which seems to be the issue. Lets just set it up like every other 2 stroke 1E40QMB powered scooter out there and then we know whats what. Or at least you will, I am having an information over load and am truly lost in the fog on this now. I wish this had done it and I know that you have put in hours researching this and I appreciate every thing you have done to help me. But I think we should now call this a dead horse and move on. Your thoughts ?

[JR]

I'm not going to disagree at all. I hate to buy stuff and just throw at something but this is NOT the case here.

You got this scooter with trouble and had someone else cause more, not your fault. We know our wiring has been right because point blank the scooter will run with the 5-wire CDI and there still seems to be a hitch?

We also know this scooter is a copy of Yamaha something but we are guessing what.

Rangerdave the hours of research doesn't bother me the least not only am I gl;ad to help but this also lets myself and others learn. Sometimes even the best football team has to punt and play defense then come back and score.

So what I now need from you is a good clear picture of the stator and some measurements. I'm trying to finish canning some tomatoes and had just a minute here and after while when it settles down I'll not only look for this stator but I'll give you a layout diagram of what I need plus we'll want to make sure we match the R/R.

I won't foget you so hang in there.

JR

[rangerdaver91]