Post by re5man on May 15, 2010 13:00:20 GMT -5
CDI BOX REPAIR
Hi Guys,here’s my attempt at repairing my 2 CDI Boxes which have failed.No. 1 box has a very weak spark ,yellow in colour and is not strong enough to run the motor.No.2 box has no whine and no spark at all.Following Gunnar Bakken’s advice on Tonny’s RE5.DK website I purchased some 1N4007 Silicon Rectifier Diodes.Tools required are a soldering iron,solder for circuit board work and a phillips type screwdriver.,I used a crocodile clip as a heat sink to try and protect the board and some black insulating tape which I used to reinforce the cable entry point where it enters the box.I am no expert at soldering or camera shots so apologies for any out of focus shots or shoddy looking work.
All references to wires and cables etc.are made with the box in the position below .
.Open the back of the box removing the 4 screws,cover and rubber gasket.
1 Remove the screw at the bottom left-hand corner[under the entry cable]holding the black and orange
wire to circuit board.
2 Remove the screw at the bottom right-hand corner holding the black/white wire to circuit board.[this wire comes from the entry cable].
3 Remove small screw on the upper right-side of circuit board[adjacent to the screw hole for locating the back cover of CDI Box].
4 Remove the small screw directly opposite No.3 screw mentioned above,holding orange wire to circuit board.
5 At the bottom right of box,immediately left of the screw you have removed,there is a terminal with 2 wires on it..A black /yellow wire from the cable entering the box and a black wire coming from under the circuit board.Unsolder both of these wires.
6 To the left of these wires is another terminal with a black wire and a blue wire on it.You need to unsolder the blue wire which comes up from under the circuit board.
7 I removed the plastic cable-tie pictured above to allow some movement of the wires[some of them are very stiff].
8 At the extreme top of the picture [above] you can see 3 wires.1 black,1 green and 1 white.Unsolder the green wire.
9 The black and white wires come from the front of the CDI Box .You can see where they are attached in the picture (below). Unsolder both of these wires.
10 I also removed the black wire from under the circuit board which locates on Sanyo 2SF 1188, the component at the bottom left of box just above where the cable enters.
11 Remove the cable/grommet from the box and you should be able to gently ease the circuit board up from the right-hand side so you can see the underneath..
The 4 diodes which need to be replaced are immediately above to the right of the cable entry point . (as shown)
Position the new diodes with their marking band on the bodies on the left-hand side[as in picture].
Unsolder and pull out the old diodes .Some of their holes will block up with solder .I used the crocodile clip to help the circuit board with the heat.Bend the new diode legs and insert into their holes,using the soldering iron to heat the solder blocking any holes.I bent the legs of the new diodes and soldered them onto the board,cutting off the excess with wire snips
Lower the circuit board and resolder all the wires removed and replace screws etc.You should end up like the picture below.
I used insulating tape to strengthen the cable entry point.I connected both units to my RE5 with spark plug grounded and both produced a whine and a strong blue spark.I installed the plug and she fired up!!
I will have to run the boxes to see how long they last but at least I have 3 working CDI Boxes again.Cheers,Shaun
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Hi Guys,here’s my attempt at repairing my 2 CDI Boxes which have failed.No. 1 box has a very weak spark ,yellow in colour and is not strong enough to run the motor.No.2 box has no whine and no spark at all.Following Gunnar Bakken’s advice on Tonny’s RE5.DK website I purchased some 1N4007 Silicon Rectifier Diodes.Tools required are a soldering iron,solder for circuit board work and a phillips type screwdriver.,I used a crocodile clip as a heat sink to try and protect the board and some black insulating tape which I used to reinforce the cable entry point where it enters the box.I am no expert at soldering or camera shots so apologies for any out of focus shots or shoddy looking work.
All references to wires and cables etc.are made with the box in the position below .
.Open the back of the box removing the 4 screws,cover and rubber gasket.
1 Remove the screw at the bottom left-hand corner[under the entry cable]holding the black and orange
wire to circuit board.
2 Remove the screw at the bottom right-hand corner holding the black/white wire to circuit board.[this wire comes from the entry cable].
3 Remove small screw on the upper right-side of circuit board[adjacent to the screw hole for locating the back cover of CDI Box].
4 Remove the small screw directly opposite No.3 screw mentioned above,holding orange wire to circuit board.
5 At the bottom right of box,immediately left of the screw you have removed,there is a terminal with 2 wires on it..A black /yellow wire from the cable entering the box and a black wire coming from under the circuit board.Unsolder both of these wires.
6 To the left of these wires is another terminal with a black wire and a blue wire on it.You need to unsolder the blue wire which comes up from under the circuit board.
7 I removed the plastic cable-tie pictured above to allow some movement of the wires[some of them are very stiff].
8 At the extreme top of the picture [above] you can see 3 wires.1 black,1 green and 1 white.Unsolder the green wire.
9 The black and white wires come from the front of the CDI Box .You can see where they are attached in the picture (below). Unsolder both of these wires.
10 I also removed the black wire from under the circuit board which locates on Sanyo 2SF 1188, the component at the bottom left of box just above where the cable enters.
11 Remove the cable/grommet from the box and you should be able to gently ease the circuit board up from the right-hand side so you can see the underneath..
The 4 diodes which need to be replaced are immediately above to the right of the cable entry point . (as shown)
Position the new diodes with their marking band on the bodies on the left-hand side[as in picture].
Unsolder and pull out the old diodes .Some of their holes will block up with solder .I used the crocodile clip to help the circuit board with the heat.Bend the new diode legs and insert into their holes,using the soldering iron to heat the solder blocking any holes.I bent the legs of the new diodes and soldered them onto the board,cutting off the excess with wire snips
Lower the circuit board and resolder all the wires removed and replace screws etc.You should end up like the picture below.
I used insulating tape to strengthen the cable entry point.I connected both units to my RE5 with spark plug grounded and both produced a whine and a strong blue spark.I installed the plug and she fired up!!
I will have to run the boxes to see how long they last but at least I have 3 working CDI Boxes again.Cheers,Shaun
Uploaded with ImageShack.us
