who knows about CDI wiring? need help! - Kawasaki KLR 650 Forum
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post #1 of 19 Old 09-10-2017, 02:14 PM Thread Starter
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Unhappy who knows about CDI wiring? need help!

hello
im looking for some advise about wiring my '86 klr 250
hope you can help me out or point me to someone who knows about wiring a CDI

the wire colours dont match any diagram !!
the cdi unfortunatly doesnt have the original plug connector, just wires coming out of it...
im trying to build a new wire harness

CDI (its a denso 21119-1180)

Black -
Red - power from stator
Red/Green -
Blue/Green -
Black/White - Killswitch circuit?
White -
Red/Black – ground to have spark (sidestand switch etc kills it)

MAGNETO

Yellow - power to Rectifier
Yellow - power to Rectifier
Red - Power to CDI
White -

PICKUP COIL

Black/Yellow - to ??? on CI
Black - to ??? on CI

RECTIFIER
Yellow: power from Magneto
Yellow: power from Magneto
White: power to battery?
Brown: power from ignition switch?
hope sooo much that anyone is able to help me! thanks in advance!!

Last edited by Jakob; 09-10-2017 at 06:36 PM.
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post #2 of 19 Old 09-10-2017, 05:28 PM
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Posting wiring diagram.

KILL mechanism is GROUNDING stator power lead to CDI.





Since you say authentic wire color codes do not exist, you may have to do some detective work, chasing down wires for continuity with a multimeter.
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post #3 of 19 Old 09-10-2017, 06:10 PM Thread Starter
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thanks for the reply
im still not clear on what to do, theres just no wiring diagram out there that is similar to my cdi, thus not giving me any clear direction on where to go.
i wouldnt really know how to chase down the wires, maybe i need to learn how exactly a cdi works?

im considering ordering a replacement cdi, oem, in the hope that the colours on it will match any diagrams

this is what i got:
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post #4 of 19 Old 09-10-2017, 07:14 PM
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A modest proposal:

Contact the CDI manufacturer/vendor; ask them how to hook up the device to your specific motorcycle.

They might share a helpful wiring diagram of their own, showing connections, etc.

Also, you might engage a knowledgeable technician and/or shop experienced in the desired installation.
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post #5 of 19 Old 09-11-2017, 02:48 PM
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According to the Wiring Diagram I have for my Gen 1 KLR 650:

R/Gr = Changes to a B wire en-route to a B wire at the Pick-up Coil.
Bl/R = Changes to a B/R wire en-route to a B/Y wire at the Pick-up Coil.
R = R wire at the Stator
B = B/Y wire which is the General Ground Circuit
R/B = R/B wire to the Diode Unit
B/W = B/W wire to the Ignition Switch, Stator and Kill Switch
B/W = B wire to the Ignition Coil and Tachometer

While these color codes don't match up perfectly; by process of elimination a solution may be within reach?
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post #6 of 19 Old 09-11-2017, 05:34 PM
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Check the KLR250 wiring diagram for parity with your KLR650 wire colors, Bluehighways!

May be the same.

One apparent circuit difference: 250 powers ignition with one main stator coil, vs. two separate exciter coils on a Generation 1 KLR650.

Even after identifying connections to components on his bike, the OP must know which connections he should make to his aftermarket CDI. Here is where the manufacturer/vendor can make a valuable contribution. IMHO.

Last edited by Damocles; 09-11-2017 at 05:42 PM.
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post #7 of 19 Old 09-11-2017, 09:30 PM
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Quote:
Originally Posted by Damocles View Post
Check the KLR250 wiring diagram for parity with your KLR650 wire colors, Bluehighways!

May be the same.

One apparent circuit difference: 250 powers ignition with one main stator coil, vs. two separate exciter coils on a Generation 1 KLR650.

Even after identifying connections to components on his bike, the OP must know which connections he should make to his aftermarket CDI. Here is where the manufacturer/vendor can make a valuable contribution. IMHO.
21119-1180 is the genuine Kawasaki oem part # for the igniter on a KLR250.
But electricity is my biggest down-fall. So I will politely defer to Damocles, who does actually own and ride a KLR250 & understands electricity.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 19 Old 09-11-2017, 10:17 PM
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OK, Sword of . . . .

The challenge is that most wiring diagrams for the KLR250 show the Wiring Harness for the Bike plugging directly into the CDI Unit. In fact the Wiring Harness plugs into a set of two Pig Tails that are a part of the CDI Unit and these Pig Tail Wires are not color coded the same as the Bike's Wiring Harness that it attaches to. This is because Denso makes the CDI Unit for many customers and then each customer (Kawasaki in this case) hooks it up to their own Wiring Harness. It's luck of the draw that any of the color codes actually match up.

Anyhow . . . I've attached a diagram both as a *.jpg file and as a *.pdf file. This diagram shows three things: 1.) What the Wiring Diagrams, like the one you posted here show, 2.) What you have in your hands and 3.) The translation from one to the other. In other words; what you want.

Let us know how things go for you.

Cheers

Last edited by Bluehighways; 08-31-2018 at 01:20 AM.
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post #9 of 19 Old 09-12-2017, 04:22 PM
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EXCELLENT!

You have made the OP's life complete, Bluehighways!
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post #10 of 19 Old 09-17-2017, 05:50 PM Thread Starter
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wow thats the best, you're the best. thanks so much!!!
i'll be back from vacation in 10 days, first thing i do after i drop my bag is run to the garage and get this thing fired up.
cant wait! will post back once its running.


thanks everyone too!

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