CDI problems on Suzuki TS 125 X

[daytona55]

Hi People,
Being king of the impulse buy, I have recently bought a "play bike" for messing around on in fields, when I can't be bothered getting geared up for a "real" ride out. It is a 1984 TS125X with a drum brake on the front - scary! It was bought proper cheap as a non runner.
"What fun" I thought, spending long summer evenings in the garden with it, midly tinkering with nuts and bolts and hardly even getting dirty!
Of course the reality is its a complete bag of nails, and I'm already miffed off with getting soaked and filthy, and losing all my free time.
The main problem is that, as always, there's no spark. I have a manual, but as I'm also king of the cheapskates, its only a CD copy and I can't tell what wire is meant to power 12 volts to my CDI unit.
So my long-winded question is, what wires am I meant to have going to the CDI? I'm guessing it will be some/all of the following:
Perm Live, Perm earth, ignition coil, timing coil and 2 others. Also some ideas of colours would be good, although most of my wires look all black as they are covered in either oil or black insulation tape residue.
I have bought a 2nd hand RM80 CDI from fleabay incase my CDI is faulty - will this be compatible?
Thanks in advance,
(oooh, nice icon!)

[stirlinggaz]

hi,
this is done from memory, but as i spent ages re-building a couple these (i actually detroyed them 1st) when i was younger, apologies if this is wrong, but i think i have a cdi, from that very bike.
(gaz goes off to look in big tub of random electrical bits & pieces)
RIGHT,

its black,definately a cdi,most likely a suzuki & either of an rg or a ts 125.
wires are as follows :
red/green tracer
bule/red tracer
black/white tracer
white/blue tracer
& black/red tracer x 2.

hold on, wouldnt it be simpler to get the wiring diagram?
& i know what you mean by drum brakes, my mtx200 (when it runs, which isnt often) has drums front & rear!
i find you have to brake a lot earlier or take more risks, lol
cheers,
GAZ

[daytona55]

Thanks for the reply Stirling - I really need to know which of those coloured wires go where. Mainly the one for the 12volt feed - would this be from the kill switch?
Thanks
PS - was in your neck of the woods last week on holiday - it was very nice - I mean very nice when it stopped raining!!

[Blue_SV650S]

Ok daytona sent me a wiring diagram (really blurry, so i couldn't make out the colour lables on it!) and this is what I can glean:-

From the wiring diagram, there are 6 wires to the CDI.

I'm squinting a bit to see the colours, so just working left to right on the CDI/Diagram we have:-

Wire 1 = To Coil
Wire 2 = Ignition pickup/trigger side 1
Wire 3 = Ignition pickup/trigger side 2
Wire 4 = Magneto (your input power)
Wire 5 = Ignition switch/kill switch - open means on, closed/earthed means off
Wire 6 = Earth at magneto


So in summery it is a magneto ignition, there is no permanent power feed, it is generated when the motor is turning and your power in is Wire 4. Wire 3, which goes to the kill switch (and ignition) is a way of shorting out the ignition to stop the spark. i.e. if you simply wanted to get the bike to spark/run, then you don't need to connect wire 3 to anything (you can then just stall it).

Hope that helps!
____________________
The purpose of life is to fight maturity.

[daytona55]

[baldy]

Wire 1 = To Coil = black and red
Wire 2 = Ignition pickup/trigger side 1 = green or blue and white
Wire 3 = Ignition pickup/trigger side 2 = blue and white
Wire 4 = Magneto (your input power) = yellow or white
Wire 5 = Ignition switch/kill switch - open means on, closed/earthed means off = white and black
Wire 6 = Earth at magneto = green or black

These are normal wire colours, yours could be the same.

[daytona55]

Thanks a lot guys
As soon as the misses gets back and I'm relieved of kid duties, I'm gonna make another start on it as its not raining for once!!

[daytona55]

Right guys - still no joy!
I'm getting good resistance readings of each coil according to the manual, so that must point directly to the CDI - yes?
I've got a CDI from an RM80 which I was going to try - however this is a 5 wire version. I presume this means that it has just one wire from the pulse coil, and not 2 like the TSX. theoretically maybe this is because the RM CDI uses a common ground for the magneto and pulse coil.
If this is right, could I link one wire from the pulse coil to the magneto earth and fit the RM CDI to my TSX to try and get a spark?
Sounds reasonable, doesn't it - just need to find what wire to link with wire 6.
its amazing really, it sounds so easy when ipost it here - I am sooo surprised when it doesn't work!!

[Blue_SV650S]

[daytona55]

Taken pics, but havcing crises or computer on main pc so relegated to rcap laptop - photos on main pc, so will post when up and running - (unlike the TS!)

[daytona55]

here it is - can we read my writing?
[/img]

What a shed!!

[daytona55]

Ok - had a couple of hours on it this morning, and i've got the following information

My CDI is as follows:
1) white/blue - ignition coil
2) Black/White - goes to front of bike in that wiring mess behind the light
3) Black/red - as above
4) Red/green - flywheel (trigger coil?)
5) Blue/red - flywheel (trigger coil?) on same connector as above
6) Red/black (again) - flywheel (poss magneto?)

Wires from my flywheel are as follows:
3 X yellow wires - rectifier
Red/green - cdi
Blue/red - cdi - these 2 are on the same connector block
Black/red - cdi
black/white
black - this is definately the magneto earth as it is on a spade where you connect the trigger coil to the housing. This black wire is on the same connector as the black/white wire - the black wire then changes to blue and both wires go to the front of the bike.

I have also found broken insulation on the black wire which I have covered with insulation tape, but still no spark.

I have also taken out the black/red and black/white wire from the cdi individually - no spark.
Also connected the black magneto earth wire to the black/red wire and the black/white wire of the cdi - still no joy.

If i was to kick the bike over, should I get a voltage on the magneto wire yes?, would I need to meter to battery earth or magneto earth (should be the same?) Is there any other tests I can do to check magneto operation. All coils have good resistance readings well within spec from manual.
Thanks.

[daytona55]

some more
carp under front light - just chocced these wires as they were just hanging - have no idea if they sould be joined or switched!

as you can tell - i've downloaded these twice

[Blue_SV650S]

The wires are not the correct colours ... does that mean you are still trying to use the RM CDI then? I think you are wasting your time!!
____________________
The purpose of life is to fight maturity.

[st3v3]

I can't knock the drum brakes on TS's, once a car pulled a sudden right without indicating (where there was no right turn, it was a dead end alley) and I ended up pulling a rolling stoppy scratching right down the drivers side of his car...... He had a go, I reasoned my case and rode off covering my plate.
____________________
Roger wrote: Women don't get damp for clingy puppies. Get some better happy pills, hit the gym & buy a medallion the size of a dinner plate. Job done

[daytona55]

[Blue_SV650S]

[daytona55]

I think it might be - this looks like mine

https://cgi.ebay.co.uk/Suzuki-TS125-X-CDI-TS-125-X-180401_W0QQitemZ190302938070QQcmdZViewItemQQptZUK_Motorcycle_Parts?hash=item2c4ef063d6&_trksid=p3286.c0.m14

..it is weired that its got 2 black/red wires though...

Thanks for your continued help btw

[Blue_SV650S]

[daytona55]

Ah - Ha, you're right!
That'll be it then!
Thanks