[flitecontrol]

If it's only been hacked at the CDI, soldering the splices and shrink wrapping may be a viable option. But the question remains; why the CDI? Did a PO install a different CDI, and if so, why?

 

[titustc]

If it's only been hacked at the CDI, soldering the splices and shrink wrapping may be a viable option. But the question remains; why the CDI? Did a PO install a different CDI, and if so, why?

Good question. Hey guys. I'm sorry I didn't get back with you sooner. It seems its just around the CDI. Do you think maybe they already had this problem and were thinking of rewiring for a different box? maybe they just didn't put the rest of the effort in and decided to rig it back?

 

[gyrojunkie]

Hard to tell why people do things. Start by fixing the wiring then we can try to sort the rest out.

 

[wright33308]

who has a new or working cdi for a 86?

 

[gyrojunkie]

You can adapt a new second gen CDI to fit your 86 250. If it is a 450 you could get one from Jack.

I can test your existing one if you wish?

 

[SoakedKarma]

85-87 adapter To use '96 up CDI

Rather than hack into wiring harness to preform the above adaptation, I chose to order male and female CDI Connectors from Cycle Terminal, found at the very bottom of linked page..

Tested today to assure I was achieving full operation and electronic advance from new 2nd Generation CDI
Need to encapsulate wiring and connector ends with electronic potting epoxy before permanent install.

May get another 30 years use out of the ol' gal

 

[DesertRebel]

Do the wires HAVE to be encapsulated?? How about shrink tubing?

 

[SoakedKarma]

Do the wires HAVE to be encapsulated?? How about shrink tubing?

you could use heat shrink..
some types come with glue stick type adhesive on the inside known as Waterproof Heat Shrink Tubing which would work well I am sure..
I revised wiring with longer pigtail that worked out very well..

end encapsulated

 

[kryton]

Do the wires HAVE to be encapsulated?? How about shrink tubing?

Rain, wash-day, etc, you gotta do something to keep them electrical connection metal bits dry one way or another...
I wonder what else might work, Flex Seal? silicon caulk? plumber's epoxy putty? hot glue? varnish/lacquer/polyurethane for furniture?

 

[DesertRebel]

Rain, wash-day, etc, you gotta do something to keep them electrical connection metal bits dry one way or another...
I wonder what else might work, Flex Seal? silicon caulk? plumber's epoxy putty? hot glue? varnish/lacquer/polyurethane for furniture?

Thanks, yeah shorting out would be nasty. So many plastics, etc. to choose from hey? Looks like it would be about $50 to do the job. With used 1st gen CDI’s going high as 75 to 100 out there it makes sense.

 

[DesertRebel]

you could use heat shrink..
some types come with glue stick type adhesive on the inside known as Waterproof Heat Shrink Tubing which would work well I am sure..
I revised wiring with longer pigtail that worked out very well..

end encapsulated

The longer pigtail looks good. I went to the link and wasn’t sure about what you bought at the bottom of the page, just the male or female or both?? Also where did you get your wires? From a stash or do they come from someplace else. Thanks.

 

[SoakedKarma]

The pigtail came with CDI https://www.amazon.com/gp/product/B0081TGQ6Y/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 I bought.
I had ordered all 3 plugs from http://www.cycleterminal.com and had it soldered up prior to obtaining CDI in anticipation of conversion..

The pigtail didn't have the black rubber wire seals on the CDI end of plug so I used those that came from cycle terminal and slipped them on each wire so wasn't a total waste...
long pigtail made for easy connection to wire harness connector rather than stretching harness to connect to shorter first version.. Longer wire loop tucks up nicely under tank

2 Green CDI ground wires are soldered together to the single terminal Orange spark output wire terminal jumped to 2nd terminal using short wire..

I checked cheap Chinese CDI for advance using timing light..
full 30 degrees of advance was observed..

 

[DesertRebel]

The pigtail came with CDI https://www.amazon.com/gp/product/B0081TGQ6Y/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 I bought.
I had ordered all 3 plugs from http://www.cycleterminal.com and had it soldered up prior to obtaining CDI in anticipation of conversion..

The pigtail didn't have the black rubber wire seals on the CDI end of plug so I used those that came from cycle terminal and slipped them on each wire so wasn't a total waste...
long pigtail made for easy connection to wire harness connector rather than stretching harness to connect to shorter first version.. Longer wire loop tucks up nicely under tank

2 Green CDI ground wires are soldered together to the single terminal Orange spark output wire terminal jumped to 2nd terminal using short wire..

I checked cheap Chinese CDI for advance using timing light..
full 30 degrees of advance was observed..

Thank SK. I will keep this page bookmarked for the first of the year work Merry Christmas.

 

[mporciani]

Does anybody has the pin-out of the CDI for REBEL 1986, I mean to which function each of the pin is connected ?

 

[SoakedKarma]

Does anybody has the pin-out of the CDI for REBEL 1986, I mean to which function each of the pin is connected ?

1st generation 85-87 Rebel CDI pin out showing wiring harness modification used to connect 2nd generation CDI

 

[GryffTakeshi]

Would you like an explanation on how it works?

I would like an explanation as to how this works. I’ve been searching for a new CDI box to no avail.

 

[SoakedKarma]

I would like an explanation as to how this works. I’ve been searching for a new CDI box to no avail.

1st generation CDI has two outputs one to each coil
2nd gen has one coil output which Y's off to both coils
2nd gen CDi has safety interlock through grounding side stand switch.. 1st gen has no side stand switch or interlock..
What was coil output in 1st gen cdi was changed to provide safety interlock which must be grounded for it to function..

 

[Walkers85]

I know this thread is old but I recently found out that PO did an engine swap on my 85 rebel 250 with an 06 rebel 250. Prior to knowing the engine was swapped I replaced the wiring harness with a lightly used harness (assuming it was a 1st gen engine). That being said do I still need to do this CDI wiring modification to use the 2nd gen CDI? Are there other things I need to look out for?

 

[SoakedKarma]

do I still need to do this CDI wiring modification to use the 2nd gen CDI?
Are there other things I need to look out for?

Yes you would need to do the modification to use 2nd gen CDI with 1st gen wire harness..
Using Honda oem CDI will also require pulling Black/White and Black/Red wire harness connector pins and swapping location on 1st gen wire harness..
Aftermarket 2nd gen CDI i bought didn't have proper pin out to work on 2nd gen Rebel..
There were many review complaints on Amazon due to CDI exciter & kill switch pin out being wrong..

Honda oem 2nd gen CDI connection to 1st gen wire harness should be modified to look like this..

There isn't a reason you couldn't use 1st gen CDI with 2nd gen engine
This is how you should find 1st gen harness and CDI wiring

 

[Walkers85]

Yes you would need to do the modification to use 2nd gen CDI with 1st gen wire harness..
Using Honda oem CDI will also require pulling Black/White and Black/Red wire harness connector pins and swapping location on 1st gen wire harness..
Aftermarket 2nd gen CDI i bought didn't have proper pin out to work on 2nd gen Rebel..
There were many review complaints on Amazon due to CDI exciter & kill switch pin out being wrong..

Honda oem 2nd gen CDI connection to 1st gen wire harness should be modified to look like this..
View attachment 117640

There isn't a reason you couldn't use 1st gen CDI with 2nd gen engine
This is how you should find 1st gen harness and CDI wiring
View attachment 117641

Ok so it run fine with a 1st gen CDI and I won’t have to do any modifications to my wiring harness? If I’m understanding correctly. But if I buy a 2nd gen CDI I will have to change the wiring for it.