SuzukiSavage.com - How to test the CDI

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How to test the CDI
07/05/19 at 13:02:28

I installed the carb kit I got from Lancer's Performance. Every thing went well and the bike started and ran. After looking at the install I decided to remove the airbox and during this task I unplugged all of the connectors under the seat and cleaned them and retaped some of the harness. I mounted the
CDI on the back of the battery box, plugged everything in. I put the tank on and tried to start it. It cranks but won't start. There is no spark at the plug. I removed the tank and checked all my work and inspected everything again. I see nothing that looks broken or burnt. My first thought is the CDI so I looked at some of the threads on this forum and I want to test some components like the CDI and coil. Can anyone instruct me on how to bench test the CDI? I have a lot of experience with Detroit Iron but not so much on motorcycles.

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pacoacevess

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Re: How to test the CDI
Reply #1 - 07/05/19 at 13:27:15

1997 Ignitor

1: Black/Yellow tracer -> ignition coil;
2: Black, no tracer -> starter relay
3: no wire
4: no wire
5: Orange/White tracer -> ignition coil & kill/start switch = + 12V
6: Green, no tracer -> magneto pickup coil
7: Orange, no tracer -> magneto pickup coil
8: Black/White tracer -> ground

Check pin number 1 with a lamp test, it shoud blink while you keep push starting buttom , also check 12 V on pin 5

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BrokeAss Junior Member Offline SuzukiSavage.com Rocks! Posts: 69	Re: How to test the CDI Reply #2 - 07/05/19 at 14:52:03 You can't really bench test a CDI, just test and rule out everything else until it's the only likely culprit.
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oldNslow Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2683 Rochester, NY Gender:	Re: How to test the CDI Reply #3 - 07/05/19 at 17:48:40 A weak battery will still crank the engine, but wont supply enough juice to the ignition module to fire the plug while the starter is running. Common problem.
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batman

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Re: How to test the CDI
Reply #4 - 07/05/19 at 18:22:14

Old slow is correct ,if the voltage drops bellow about 10 volts you have no spark, charge the battery fully and check your spark again, also test that the voltage at the battery while cranking doesn't drop below 10 ,the sign of a weak battery.
You removed the air filter ,if you haven't replaced it with anything ,that may increase problems in starting also.
You should recheck you wiring ,I would think you may have had to extend some of the wires?
You don't have a CDI ,it's a TDI and it can be destroyed by living the power (key switch on ) for an extended time without the bike running, it overheats
I believe the TDI can only be tested by replacement ,even by a dealer.

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« Last Edit: 07/08/19 at 11:46:01 by batman »

my old work mates called me MacGyver

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Yoshi Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 874 LongIsland, N.Y. Gender:	Re: How to test the CDI Reply #5 - 07/05/19 at 23:39:43 Theres 2 connections under the seat that can plug in vise versa, i think the connectors are green in color
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madmikesmech

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Re: How to test the CDI
Reply #6 - 07/06/19 at 10:26:16

oldNslow wrote on 07/05/19 at 17:48:40:

A weak battery will still crank the engine, but wont supply enough juice to the ignition module to fire the plug while the starter is running. Common problem.

OldNslow, you are as absolutely correct! Just this spring I had the low voltage blues! Starter rolled engine over fine, but no start, which ain't right, my '99 normally pops RIGHT off.
Pulled battery out charged it problem solved! FOR NOW! Bike sat for a few days... same issue. Load tested battery after I charged it, failed to keep a peak charge. So I went to Walmart, as it was Sunday, and my only option at the time.
The stock battery box in my opinion is a P.I.T.A! So while at Walmart I opted for a battery (standard acid type) I'm CHEAP! that was the same size just considerably shorter in height. Now the reason to this is so I can pull carb without removing battery box

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1999 Savage, basically stock, except drag bars, 4"risers,Jardine turn out muffler, Raptor petcock, Verslagen modified cam chain adjuster,4" forward controls

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: How to test the CDI Reply #7 - 07/06/19 at 12:25:25 Nice move ! now you have to tell us the battery you used? ( Yep, it's kiss and tell time )
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madmikesmech Full Member Offline SuzukiSavage.com Rocks! Posts: 227 Olean ny Gender:	Re: How to test the CDI Reply #8 - 07/06/19 at 16:35:19 Es9a2 atWalmart, 4 3/16" tall, but next time I'm going with an AGM ES-TZ10L 3 11/16" TALL. I did totally hack... in a decent way the stock battery box no top of battery box used, BUT I CAN use the tool box housing
Back to top	« Last Edit: 07/07/19 at 06:44:32 by madmikesmech » 1999 Savage, basically stock, except drag bars, 4"risers,Jardine turn out muffler, Raptor petcock, Verslagen modified cam chain adjuster,4" forward controls IP Logged

madmikesmech Full Member Offline SuzukiSavage.com Rocks! Posts: 227 Olean ny Gender:	Re: How to test the CDI Reply #9 - 07/06/19 at 18:15:05 I'm unable to post pics from Blogger like I always used too!! Gotta load them up to some other server... any recomendations
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2778	Re: How to test the CDI Reply #10 - 07/07/19 at 06:07:07 Just add them as an attachment to your post and they will uploaded and hosted by this site.
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2778	Re: How to test the CDI Reply #11 - 07/07/19 at 06:08:45 Once you have uploaded a file as an attachment, you can use it as an image in other posts if you like. (Probably should resize the image first!)
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madmikesmech

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Re: How to test the CDI
Reply #12 - 07/07/19 at 06:35:28

ohiomoto wrote on 07/07/19 at 06:08:45:

Once you have uploaded a file as an attachment, you can use it as an image in other posts if you like. (Probably should resize the image first!)

http://suzukisavage.com/yabb2.2/Attachments/IMG_20170322_215332147_001.jpg

Okiomoto what is a recomended size to resize them to?
Plus I use my android phone for EVERYTHING!
This forum wont accept photos DIRECTLY from my phones gallery, I first must use a "just to establish a jpg? As you all see, I'm not real computer or tech SAVY!!!!
Thanks for all the help

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1999 Savage, basically stock, except drag bars, 4"risers,Jardine turn out muffler, Raptor petcock, Verslagen modified cam chain adjuster,4" forward controls

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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2778	Re: How to test the CDI Reply #13 - 07/08/19 at 06:28:54 I think under 2MB. I took this shot, cropped it (to get under the size limit) and then posted on my Android phone.
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Shanghai Smith YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 2	Re: How to test the CDI Reply #14 - 07/08/19 at 09:33:39 Thanks for all the info guys. I have spark now. I'm almost sure it was nothing more than a low battery. Thanks again.
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