Hiya i have a Fzr6 3he bike which has a 1995 4jh engine fitted but the cdi boxes are different including connections.
With all the 3he wiring and cdi box the engine turns over sparks but back fires throw the carbs which ive been told is timing so have bought a 4jh cdi box and wiring loom so would like to be able to wire the 4jh cdi in to the 3he loom.
I have a haynes manual which has wiring diagram for both bikes but it dont cover all the wires that come from the 4jh cdi box and there is more connectiing to it then the 3he cdi
Was wondering if you knew best way to go about doing this
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Use a multimeter to test for continuity to ground on one of the crank sensors wires. Depending on the bike there should be 2~4 wires coming out of the crank sensor. At least one of these wires should have oscillating continuity (1/0, repetitively) when tested against ground (stick one lead to the frame). To get the oscillation, crank the engine while looking at the multimeter.
I'm not sure exactly how to test the cdi box. You'll still want to use the multimeter, but you will be testing for continuity and resistance on different wires. Check a workshop manual for the exact procedure.
Probably not, without some other modifications 10 years is a long time in the world of off road bikes.. For one that will fit check for the part number rather than the model number of your machine, you may find that the same CDI was used on other bikes from the same maker, but of a different size and type (scooter or chopper or even a bigger engine in the same range, (125 or 175) good luck.
Try following the wire from the stop button on the handle bar back to the CDI box. Simply unplug that wire. CDI is disabled by grounding. Does the KDX have a key switch or just the stop button. Try just connecting the pick up wire to the CDI and CDI to coil. You have to isolate ground to CDI to run. Check air gap at pick up. Use a matchbook for a gauge.(.018)
To my understanding, the problem is 'no spark' yet the engine cranks. Generally, to consider are:
pulser coil (least likely);
ignition coil (likely);
CDI (most likely).
Offhand, the CDI would be the main suspect. Since the CDI is sealed, it is not possible to do component level checks. The only way to check if the CDI is good is to check the external connections; if they are good and yet no spark, then the CDI is bad.
How to check the above:
to check the pulser coil, measure the low voltage coming from it using an analog/needle type AC voltmeter. While cranking, it should show a flickering low voltage;
to check the ignition coil, use a continuity tester. Primary should measure 3 ~ 5 ohms while primary to the high voltage end would measure 15 ~ 18 kilo ohms;
the ignition coil has 1 terminal connected to the IGN +12 while the other terminal is connected to the CDI. This should have a pulsating voltage when cranking.
all the interlocks could be checked with a continuity tester. Please note that most interlocks has a diode connected in series with their wires.
Before going to the CDI system go ahead and check the kill switches including the side stand switch, with an Ohmmeter. How good is the battery? Check the fuses. Check the wiring harness. Are all wires clean and with a solid connection? Any abraded wires? Check the operation of the ignition switch with a volt ohmmeter. Is the bike in neutral and the neutral light is lit up?
hi how did you know were 2 drill the cdi ? i have a 2008 rs i have fitted the powervale but its not working from reserch i think drilling the cdi activates the powervale but if you dont have one the light comes on on ur clock all i need 2 know is were 2 drill the cdi thanx