cdi wiring xw

[medrider]

Hi there!
I am just finishing the general repair of my 1993 XW. It had not original cdi with wires coming from inside (no 4- and 6- pin connectors) with wires coloured different than original ones.
I have bought an original cdi and do not know how to connect wires. Althoug I have Haynes with wiring scheme, a picture of connectors connected to cdi with visible wire colors would be very helpful. Could someone post the picture.
Thanks in advance and greetings from Slovakia.

[movenon]

Hi there!
I am just finishing the general repair of my 1993 XW. It had not original cdi with wires coming from inside (no 4- and 6- pin connectors) with wires coloured different than original ones.
I have bought an original cdi and do not know how to connect wires. Althoug I have Haynes with wiring scheme, a picture of connectors connected to cdi with visible wire colors would be very helpful. Could someone post the picture.
Thanks in advance and greetings from Slovakia.

Sounds like a real problem. Is your bike an ABS model ? What year of engine is in it ?  Do you know what year of harness was installed in it ? More information. Pictures of what you have might help.
George

[medrider]

Thanks for quick response. Bike is a non-ABS model. It should be a 1991-1993 white-blue model (3XW).The harness is original one except the connector. I do not know whi the cdi was replaced. With cdi also the connector box was replaced, therefore it is not original one connected to the harness. I try to attach the picture of both connectors (6-pin and 4-pin) with cables connected. As one can see, the red-green and green-red cables are blinded and not connected. I also attach the picture of cdi I bought -it is downloaded from ebay as I am not in the garage now.

http://www.fjowners.com/index.php?action=gallery;sa=view;id=5889
http://www.fjowners.com/index.php?action=gallery;sa=view;id=5890

[medrider]

this is exactly the cdi i have: http://www.fjcatalogue.com/catalog/item/7309025/9049151.htm

[movenon]

As I understand it someone has cut the wiring harness and spliced in new / different connectors ?

When you got the bike was a CDI box installed in it ? Just a question to help me understand.

To check wiring you are probably going to have to go back to where the splices were made and work from there up to the cdi box.

I can take you a wire at at time I think. But it will have to wait until Monday as I am away from my bike at the moment.

George

[medrider]

Yes, you understand it correct. There was a cdi installed when I bought it, but apparently it was not original one. There were no connectors with pins outside, the cables came from inside of the cdi and were different coloured than described in the scheme in Haynes. The harness is original one, but I guess the wires are not connected to the connector box in order they are supposed to be. I just want to see the pic with cables to see how they are connected to the connector box and compare it with the scheme in Haynes (I am not professional, and in the scheme the cables are in line and I do not know what to connect in the upper and lower row in the connector. Thank you for your effort, I am not in hurry, I can wait until monday. I could ask an electrician - we could go cable by cable based on scheme, but it would take a long time. I think it is much quicker to have a picture of connector with correctly connected cables. As the connector on the harness is not original and does not fit to cdi, I am forced to remove it and connect the wires from harness directly to cdi.

[medrider]

To make everything clear I went to the garage and took some pics.
1. This is the cdi with wires and connectors present when I bought it (non-original): http://www.fjowners.com/index.php?action=gallery;sa=view;id=5901
2. This is the wiring diagram for my motorcycle from Haynes with cdi and wires marked green: http://www.fjowners.com/index.php?action=gallery;sa=view;id=5903
3. This is the picture of my new and original cdi I want to install. I numbered the pins and would like to know which wire, based on wiring diagram, connect to respective pins: http://www.fjowners.com/index.php?action=gallery;sa=view;id=5902

[movenon]

Good I will be back home this afternoon and will start on this in the morning. I see what they did with that old CDI box. Looks to be a non stock box ? Was there any marking or part numbers on the old box ? Was the bike running OK with that old box ? Just curious.

The photo's help and the last one with the connectors numbered will help a lot. Do you have the 4 and 6 prong connectors that plug into the stock box? More when I get back home.
George

[medrider]

Ther is nothing on it. I rode with the bike 200 km after I bought it. It was not OK, it was flooding 1. and 3. cylinder, but I do not know if it was because of cdi or carbs. I disassemled the whole bike, it got new paint, the engine has been overhauled, I replaced several parts and now I think it will look almost like a new one. I have bought it a yxear ago and would like to ride it at least one or two weeks until the winter starts. THe most of the work is already done - frame, wheels, engine, carbs (also the airbox with vent hose). I do not have prong connectors, I plan to take the wires out of their current connectors and plug them directly to cdi via insulated female receptacles.

Jan

[fj11.5]

I use one of these ( ebay 151126346650 ) works great, and if you have a vaccume advance normaly it does away with it 

[movenon]

Ther is nothing on it. I rode with the bike 200 km after I bought it. It was not OK, it was flooding 1. and 3. cylinder, but I do not know if it was because of cdi or carbs. I disassemled the whole bike, it got new paint, the engine has been overhauled, I replaced several parts and now I think it will look almost like a new one. I have bought it a yxear ago and would like to ride it at least one or two weeks until the winter starts. The most of the work is already done - frame, wheels, engine, carbs (also the airbox with vent hose). I do not have prong connectors, I plan to take the wires out of their current connectors and plug them directly to cdi via insulated female receptacles.

Jan

I just got back home Jan. In the morning I will take a look at mine. Can you get back to where the aftermarket wires were spiced into the harness so you can read the colors of the original wires ?

When you say the carbs in cylinders 1 & 3 were flooding are you determining this by a plug reading, misfire or are you actually seeing fuel dripping from the vents on to the ground ? Just helps everyone visualize what you are saying. I wouldn't tear into the carbs until we get the wiring sorted out and running again.

George

[medrider]

I am sorry, I am not that familiar with  English and I am afraid I do not understand your first question. The original wires are coloured as described in Haynes. Normally they end in the 4- and 6-prong connectors which are connected directly to cdi. The cables from previous cdi (on the pics) were connected to a different connector, which were connected to connector in harness. These do not fit to original cdi. As it is visible on pics I posted, only some wires from harness were connected to connector.
To your second question: the fuel was dripping on the ground (I gues from the vent hoses). Initially it was only 3rd cylinder. Then I let the bike repair. I was told the fuel dropped only when the fuel pump was in use. I came home and I saw also the 1st cylinder was affected. Since then I did not ride it. I disassembled the bike totally, gave the engine, fairings to more reliable person. He replaced the piston rings and did what was necessary in the engine, painted it new and had a look on carbs. He said they were in a good condition with almost new needles and jets (replaced by previous mechanic who said he did nothing with floats), he played only a little bit with floats and set them on the same level. Now I am reassembling the bike - it is almost ready, I only have too put fuel, brake fluid, connect the electrics and put the fuel tank and fairing on.

Jan

[movenon]

I am sorry, I am not that familiar with  English and I am afraid I do not understand your first question. The original wires are coloured as described in Haynes. Normally they end in the 4- and 6-prong connectors which are connected directly to cdi. The cables from previous cdi (on the pics) were connected to a different connector, which were connected to connector in harness. These do not fit to original cdi. As it is visible on pics I posted, only some wires from harness were connected to connector.
To your second question: the fuel was dripping on the ground (I gues from the vent hoses). Initially it was only 3rd cylinder. Then I let the bike repair. I was told the fuel dropped only when the fuel pump was in use. I came home and I saw also the 1st cylinder was affected. Since then I did not ride it. I disassembled the bike totally, gave the engine, fairings to more reliable person. He replaced the piston rings and did what was necessary in the engine, painted it new and had a look on carbs. He said they were in a good condition with almost new needles and jets (replaced by previous mechanic who said he did nothing with floats), he played only a little bit with floats and set them on the same level. Now I am reassembling the bike - it is almost ready, I only have too put fuel, brake fluid, connect the electrics and put the fuel tank and fairing on.

Jan

Don't worry , your English is just fine. You have answered my question just fine. Tomorrow we will start to figure out the wires. Bike manufactures are not forthcoming about there CDI design / input - outputs or pin read outs. But we can work through it.

Usually when carburetors leak like that it is stuck floats, needle and seat "O" rings or the needle and seats themselves. All easy to fix. 
George

[movenon]

My bike is a 1990. Your colors might be different.

By your pin diagram:

Pin 1...........Grey
Pin 2.......... Black with Red stripe                This is the 4 pin "Ignition pick up connector". Pin 1 and 3 on mine are the pick up wires mine are black and grey.
Pin 3.......... Black                                     A 1991 diagram shows the pick up wires as White/Red and White Green.
Pin 4.......... Black with Yellow stripe


Pin 5..........Red with White Stripe                This is the 6 pin connector
Pin 6..........Black                                     
Pin 7..........Blue with Yellow Stripe
Pin 8.......... No connection
Pin 9..........Grey
Pin 10........Orange

Another approach would be to buy the cheapest 1993 wiring harness you can find and cut the CDI connector section out of it and splice it into your harness wire for wire. I will see whats on e bay over here.
George

[movenon]

Here is a UK FJ 1200 wiring diagram with pin layouts that might also help.

http://www.czd.org.uk/moto/fj1200/diagrams/wd1.html

This diagram is much like what I have with your pin numbers expect on the 4 prong terminal where I have black/yellow (pin 4) this shows red/green (going to reserve fuel switch)
and where I have black/red (pin 2) this shows red/green (going to a relay and fuel warning light).
George