Question about 2004 Suzuki DR-Z 400 E

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BIKE IS NOT CHARGING,DOES THE CDI BOX HAVE ANYTHING TO DO WITH THE CHARGING SYSTEM ?WHAT SHOULD i CHECK?

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  • bradley_g756 Jul 14, 2009

    The wiring from the alternator plugs into the cdi box .There is definately no charge,all fuses ok tested at battery it does have a separate regulator I JUST REBUILT THE MOTOR WAS IN PIECES FOR A FEW MONTHS ALL PARTS WERE OILED NO RUST i DID JUMP IT FROM A CAR BATTERY,i ALSO HAVE AN EXTRA EARTH CABLE THAT i DONT KNOW WHERE IT GOES,BUT FRAME AND MOTOR ARE EARTHED,WHY DOES THE ALTERNATOR WIRING PLUG INTO THE CDI BOX?i UNDERSTAND ONE LOT WILL BE FOR SPARK DOES THE CHARGING POWER COME DIRECTLY OUT TO THE REGULATOR?

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Hi bradley
The CDI box is the Capacitor Discharge Ignition system for creating spark at the spark plug and does not charge the battery. When you say it is not charging, are you able to measure the voltage across the battery with the engine running at 2500 rpm. If it is charging it will run to at least 14.5 volts. The headlamp should also be nice and bright, and a noticeable increase in brightness when revs are lifted from idle.
If it does not, then you have a problem with the bikes alternator, or the regulator that controls the charge rate. Also check the fuses for failures, and general tightness of the battery connections and wiring about the battery and frame earth. If it appears to be charging, but the batt always seems to not be taking a charge and flat, then the battery itself may be the problem. They dont last forever and can often be the source of "no charging" issues.
Let me know how many volts you have at the batt terminals with the engine running.
regards robotek

Posted on Jul 14, 2009

  • Graeme Ross
    Graeme Ross Jul 14, 2009

    The wiring from the alternator area is for the CDI sensor/trigger off the alternator rotor . The CDI BOx, as I have already stated to you, has nothing to do with charging!! I suspect the "spare" earth that you have needs to be just that... taken to earth. Hope this helps you. Just need you to be asured that the CDI is just that! Many alternators have a regulator built in. I can try and find more info on your model for you. Look into the spare earth that you have and let me know how you go. Would be nice to get a better rating from you:) Creates an incentive to continue helping you! Cheers mate.


    regards
    robotek

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http://www.ghmould.com/share-book/b/bajaj-caliber-115-wiring-diagram.pdf


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