CDI BOX Failure

[re5man]

Hi Guys,had an MOT booked today.Bike was running well but on the way there had the dreaded engine cut-out and no spark at the plug.The CDI box had gone.The wife brought out a spare and I hooked it up and returned home,had to cancel the test.I had a previous CDI box fail about seven years ago and now with this one gone I'm down to one left.This RE5 has been off the road about seven years so the two boxes have failed with not many miles between them.Is it just coincidence[because of the age of the units]or is there some component on the bike that's malfunctioning and causing the boxes to burn out?Anything I need to check?Thanks,Shaun.

[re5man]

Forgot to add the box that failed today had as far as I know 63,000 miles on it.The replacement has 21,000 and the one seven years ago had 22,000 miles,if that's relevant.Shaun.

[re5man]

Just read an article about an RE5M which had 2 CDI boxes fail.The reason given was a faulty speed relay not being replaced after the first box went down.Could this be my problem?Maybe I should check my vacuum switch/speed relay. Shaun.

[ziggystardust]

This might be of use.

re5rotary.proboards.com/index.cgi?board=wanted&action=display&thread=256

Lee.

[steveuk]

Hi Lee

do you happen to know if there is a new part no. for the boyer ignition can not find a KIT00069?

steve

[ziggystardust]

Steve,

Look here www.boyerbransden.com/instructions.html

Lee.

[re5man]

Good news fellas :)Passed MOT today.Running ok with the spare CDI Box.I have looked at the vacuum switch/speed relay and speed sensor to see any problems relating to my CDI Box failing.Only possible problem I could see was the vacuum switch behind the carb.The adjustable body of the switch was not in contact with the retractable plunger so was permanently on.Also the speed relay was in a bad state.I've adjusted the switch and replaced the relay.I've ordered some 1N4007 diodes and following the info by Gunnar Bakken on Tonny's RE5DK site will try to test and replace any faulty ones in my 2 dead CDI Boxes.Got nothing to lose .If I can repair them will be able to carry a spare around under the seat.Cheers,Shaun.

[raychappo]

I'm new to the board.
I owned an RE back in the 80's and am looking for one again.
I had a CDI unit fail and as I remember fixed it myself.
The ignition just went one day and the high pitched squeal stopped.
I took it apart and if I remember correct it was encased in epoxy so it took a bit of cutting to get in.
There was a diode that had gone open circuit and I just replaced it and everything was hunky dory for years after until I sold it.
Hope this helps.

[rx24u]

Hi Guys, I am down under about as far as you
can go and had a CDI s@#t itself, after much stress and research it was easy and cheap, I fitted an MSD street fire with a new coil and I have spark that is HUGE. The bike starts better than ever and runs great. The box is fitted where the original CDI goes and the coil also in the original place Need any details let me know, Leo

[supersaki]

Hi Leo,
Please let me have the details.
Kind regards,
Roy

[h2e Al In Aus]

this may help kawasaki tripple CDIs are failing now as well the general opinion is that they were designed to last 10 yrs or so, so were lucky that there doing this long, Automotive CDIs in cars fail after five yrs on a regular bases,

One of the guys on Kawasaki triple site makes new boxes for them , I wonder if there would fit the Re5 ?, yours Al

[gerryggg]

A big problem with all the early, pre-digital DC CDI ignition boxes was overheating. The Kawasaki ones would fail because people would store their jacket or sweatshirt under the seat and block the air flow. That said, under the seat wasn't a good place for air flow to begin with. Anything that can be done to improve the cooling of the box will extend its life.

[spottydog4477]

Hello chaps,,

I'd spent 6 months doing asst restore work on my bike. It ran before i started pulling bitz off it including a few wires too.....hmmm

Now its back together I dont have a spark

I has a MSD street fire unit. Which had a little red light on it. It blinks when I turn the bike on..but just blinks on for a moment. Should it stay on maybe?

I disconnect the wires going into the coil stuck a bulb across the terminals - cranked the bike over - looks like no power there

i put a bulb from the points cableto +ve battery, cranked it over - and the bulb goes on/off - so that look ok there..

Is there a fuse on the system?

Spent a few hrs and got fed up with it so I decided to watch Yulia Nova strip on the net.......that seemed to take my mind off the problem for a while....but now I'm thinking about it again.....!!

any thoughts

thanks everyone

john

UPDATE - WAIT - I found a PDF sheet on the unit with all the wiring info etc....looks simple enough......I'll have another go in the morning - must just be a wire issue I've introduced myself

Ok got to my missus said the banks on the phone.......something about an unauthorised funds transfer to Yulia in Romania......

[FC Zach]

I'm not sure which MSD unit you have so I'm just going to assume the wiring is similar to the 6ALs like the CDIs used on cars and based off that (I pretty much have the diagram memorized) I may be able to assist you somewhat. Is there a white wire on your MSD unit for connection to the points? If so, is it connected? The only thing I can think is that the unit is powering on but is not getting the command (signal from points) to send power to the coil.

"my missus said the banks on the phone.......something about an unauthorised funds transfer to Yulia in Romania......"

Too funny

[spottydog4477]

OK - its working - a spark!

I'd missed a black earth wire (not connected to the battery but the frame)

so, off to the shop for jets and fingers crossed - a run up over the weekend.

Got to go - Ive just received an important email...an upstanding christian man from Nigeria has a once in a lifetime financial opportunity for me..........I'm sure this will ease the missus money concerns what with the Yulia misunderstanding!

john