125-200cc CR Ignition swap - dummy questions

[rockdancer]

I am finally doing this swap ( about 2 1/2 years late) . Thanks for Darin (Dartyppt) for the ignition setup - great to deal with and exellent packaging
I had a bit of trouble with removing the flywheel - even with a puller but getting serious with a rubber mallet was the trick
Ive lined up the sator with the same markings that penned on by Darin
Just having trouble working out what to do with the wiring -
There are three wires from the CDI which i am not sure about
There is an White/ Orange ( Brown?) one which has a flat connector - I assume this goes to the flat connection on the coil ??
The wiring diagram I have shows an earth connection at the same side of the coil as where the spark lead comes from - is an earth required here ?

The other two wires - Yellow/black and white /black
are something to do with the kill switch and an earth ?
If I get a kill switch how is it wired up ?

Do any of these go to the coil ?
(On the WR there were two other connections to the square ends of the coil )

Any one have any pictures of their wiring ?


I assume I cant use the wiring from the WR ? Not that I want this as a long term solution.

Thanks guys

 

[rockdancer]

CR 125 CDI wiring help please - anyone? Pics?
I believe the orange and white goes to the coil - flat connection
On the opposite side of the coil there is an earth required
Not sure how the kill switch will connect to these wires

 

[dartyppyt]

Orange/ White with female flat connector goes to flat male connector on coil.

Black and White with connector that has hole thru it gets grounded to one of coil bolts. Make sure where coil mounts is paint free, metal to metal.

Yellow wire. This is where your single wire kill switch wire plugs in from up by grip.

 

[dartyppyt]

CR 125 CDI wiring help please - anyone? Pics?
I believe the orange and white goes to the coil - flat connection
On the opposite side of the coil there is an earth required
Not sure how the kill switch will connect to these wires

I sent you an email

 

[rockdancer]

I sent you an email

I getting 26 ohms resistance across the red/white and red/black wires from stator
106 ohms between red and green wires - this seems to tally with what others have posted


Coil - I get .8 ohms resistance reading for primary winding from flat spade connector to earth
11600 ohms from square end to plug cap - so that seems to be ok


Not sure how to check the CDI

cheers

 

[rockdancer]

This thread is useful for anyone who needs help
http://www.cafehusky.com/threads/humiliating-loss-of-spark-08-cr125.3781/


Still no spark
I know this ignition was in great shape - 2011 10 hrs use but Im not sure if ive done some damage to CDI

There is good voltage going into the CDI - 12 v roughly . The black yellow wire from the CDI is reading 5v . This goes to kill switch. The White / Brown wire is the wire that I believe connects to Coil doesnt have any voltage reading but has .20 Direct Current Amperage
any of this sound ok

 

[rockdancer]

Getting some assistance from pms - Thanks Troy and Darin

I cant pull the flywheel off again - need a cr puller now

Coil : Secondary 11600 ohm. Primary .6 ohm
White with Brown/orange stripe from CDI ( connects to Coil) = -.1V kicking with everything connected - result same with not kicking
I dont believe that coil is the issue as the wire going to the coil isnt carrying charge

Yellow/Black wire from CDI - 3 volts


Red and Green wires measure at connector to CDI with CDI disconnected - 101.4 ohms - no voltage
Red/Black Red/ W - 25.9 ohms Over 12 volts



Looking at attached pic of flywheel I am wondering if the flywheel is far enough back - the rectuangular tag on the flywheel may not be getting picked up by sensor
Bolt doesnt fully go on crankshaft . It could be a simple as this ? Tightened the flywheel using rope in sparkplug method.
Is the wooddruf key different on CR to WR ? maybe stopping flywheel from moving back another few millimetres

 

[Troy F Collins]

There is a square slug on the outside of the reluctor that lines up and passes through the path of the pick up. Take a look ...I must be lined up fully or the woody key is trapped behind. ?? Take a quick peek behind the cover

 

[rockdancer]

I remove the silver bracket - I could see that the metal pickup inside that black part looks about 3mm out of wack with the plate on outside of flywheel put a washer behind to push it out further ( 2mm)
tested wire again and no difference - no charge recorded
Thought stuff it - give it another try with spark plug and .....we have spark !!!

Not sure if i dare try to start it now but really want to


Attached is a pic of the cranskhaft before I put the CR stator on showing the woodruff key (I believe) on the top of the shaft
I am quite sure I line the key up with the slot in the flywheel so I am not sure why the flywheel doesnt seem to be going back far enough

Thanks you Troy and Darin so much for your help
Merry Christmas

 

[Troy F Collins]

I would not shim up the pick up...somethings going on there.......the stator retainer nut seems to have too many threads showing ......I think the key may have slipped back and got caught...hence your clearance issues....

the good news at least youve confirmed your wiring is OK

 

[wallybean]

I would not shim up the pick up...somethings going on there.......the stator retainer nut seems to have too many threads showing ......I think the key may have slipped back and got caught...hence your clearance issues....

the good news at least youve confirmed your wiring is OK

+1

 

[rockdancer]

Yes it looks pretty obvious now. I will be getting the flywheel off when the CR puller arrives to try to work out whats happened

 

[dartyppyt]

Yes, your key way was not rotated forward in install and probably got jammed. You might want to get new keyway, just in case it got damaged. Make sure nothing is keeping flywheel from seating.

Glad some old worn out Husky guys could help!

Getdatthingfixedandride!

 

[Troy F Collins]

Yes it looks pretty obvious now. I will be getting the flywheel off when the CR puller arrives to try to work out whats happened

when you reinstall the flywheel...a slight turning action will help you feel out the keyway position then use a light tapping with plastic mallet or the like to fully seat the taper.....you'll know its fully home when the threads are more or less flush with surface of the nut.....

I always find the best way to tighten things on spinning shafts is to hold it with a rag and use a light blast or two with a air impact.....but it all depends on what tools you have on hand

 

[Troy F Collins]

Yes, your key way was not rotated forward in install and probably got jammed. You might want to get new keyway, just in case it got damaged. Make sure nothing is keeping flywheel from seating.

Glad some old worn out Husky guys could help!

Getdatthingfixedandride!

Hey I'm still 5 yrs younger than Norm