CDI for Kawasaki ER-5 or GPZ500

ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

I need a replacement CDI for my Kawasaki ER-5 (2000). I was wondering if this part is the same as for the GPZ500. I read on Bike Chat Forums the following: "You would need to check the ER5 ignition system is compatable with the GPZ CDI. Some have one pickup, some have two (there is a GPZ CDI of each type, you'd just need the right one)." (It's an old post, so I don't want to resurrect it.) [https://www.bikechatforums.com/viewtopic.php?t=162231]

The part number for the ER5 is 21119-1494, and has two pickups (at least, I assume the two prongs out the bottom are pickups!). The GPZ500 one that looks exactly the same has part number 21119-1408.

The GPZ part is about 40% the cost of the ER5 part, so if they are the same part then that would save me money!

Thanks Smile

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

GPZ one has a different advance curve but I'd expect it to broadly work.

The wire colours and order will not be the same though. It wont be plug and play. So you'd need to know exactly which model it's off and have access to a wiring diagram for that model so you can wire it in.

This is no mean feat, I think there are up to 10 wires you'd need to re-order correctly. Given the level of knowledge you appear to have (the bits sticking out of the bottom of the CDI are mouldings for the wiring terminal blocks). I'd suggest you just get a replacement ER5 one and plug it in.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
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ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

Well it wouldn't actually be me fitting it, but rather the garage at which the bike currently is! Given the issues that you've outlined, I think I'll just go with the ER5 one. Thanks Smile

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

Definately. Wiring in a CDI off a different model is well beyond most motorcycle technicians. They are almost invariably utter crap at wiring/electrics.

It's unusual for a CDI to fail. I wouldn't be surprised if it turns out not to be your problem. The usual way motorcycle mechanics fault find is to randomly replace parts until it either starts working again or you run out of money.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

So he said that he didn't have the tools to test, but that someone comes in once a week with the testing kit. When this person came, they found power all the way up to the CDI, but then no power past the CDI...

Chris45 · Nitrous Nuisance Joined: 23 Oct 2016 Karma :

Chris45 · Nitrous Nuisance Joined: 23 Oct 2016 Karma :

Just checked the Haynes electrical diagrams and the guys are right. While the connector pins look similar by number, they are totally different in colour. I wouldn't even contemplate the idea of using one off a GPz.
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

The only reason a CDI would go on an ER5 and it is common is if the reg/rec went first. taking out the resistor on the ignition barrel as well.

The rev counter is probably gone as well.

ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

temeluchus · World Chat Champion Joined: 01 Oct 2008 Karma :

id generally suspect the coil/leads/plugs/wiring before id look at the ignitor.
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ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

stephen_o · Spanner Monkey Joined: 02 Aug 2011 Karma :

Have you checked your resistance wire from the ignition switch to the computer - mine failed twice and the computer was suspected before it was checked to find the wire had burnt out.
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stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

In fairness, it is a very overcomplicated system.

One thing that could also give you no CDI output is a faulty safety interlock. So a problem with the clutch/sidestand/neutral switch and associated wiring.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

So one other thing that I read was the following. (I don't remember exactly where.)

stephen_o · Spanner Monkey Joined: 02 Aug 2011 Karma :

ultimatechees... · L Plate Warrior Joined: 13 May 2018 Karma :

I've just found out the following additional information. When it was tried to be started, their positive crocodile clip from their van's battery touched against the frame when the negative was connected, and there was an almighty spark. Apparently that can destroy the CDI.

It does sound from what you people have been saying that it could just be the wiring though...