DT/IT/MX/YZ 250, 360 & 400 B&C Ignition System

Applies to all machines that have generator rotor p/n FOT02173 & stator p/n FOT021 1973-75 The ignition tted to these machines is a capacitor discharge system and has positive advantages over points. Just like a magneto it is self generating and needs no battery to run. Another advantage is CDi will re a fouled spark plug when points ignition will not. However it was one of the rst CDi systems Yamaha used and is not without its faults. The major problem is it was made adjustable but with no timing marks on the ywheel. This makes it very difcult to check the ignition timing, we have never found a bike with the timing set correctly. Simply lining up the pick up is nowhere near accurate enough. We have noted bikes with the ignition set several degrees advanced do run better then those with less advance. Rexs Speed Shop stock CDi units, HT coils and offer a pulser-less CDi for failed pick up coils. We also carry out generator rewinds.

Common Faults
Incorrectly set timing Failed pick up (pulser) Failed CDi unit Failed source winding Incorrectly connected CDi leads Failed HT Coil

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+44(0)1580 880 768

Incorrect Ignition Timing This wont stop your bike running but can cause it to kick back viciously through the kick start or run off colour. The way we set up the timing is with the generator assembled to the bike, attach a simple wire pointer to the engine case. Then use a DTi in the spark plug hole to determine TDC, mark the rotor at the pointer with a ne black marker pen, rotate the crank clockwise 2.9mm from the DTi reading then mark this point at the pointer. This second point is the re mark. You need to be completely accurate marking and your pointer should be solid (gas or TIG welding wire is strong enough). It is then a simple case of tting a strobe light to the HT lead and checking the timing with the engine running at a slow idle. Adjust the timing by moving pulser or stator until the F mark lines up with your pointer. Some strobes wont work at rst, try turning the clamp the other way on the HT lead. Failed Pick up Coil The pick up coil is a very common failure on these machines. There is only a slight difference in readings between a good one and a failed one, so you will need a good multimeter. From experience any readings 90 Ohms or below indicates a failed pulser coil. The Yamaha specications may say 90 ohms is in limits, but in practise weve found the coil has failed with readings as low as this. If your machine has a low reading pick up and kicks back or wont rev past 3,000 RPM this is a sure sign the pick up winding is failing. We offer a replacement CDi box that runs without the pick up so all is not lost if a replacement part cant be sourced. Other Faults The remaining faults should be picked up by carrying out resistance checks, the source coil seems very reliable. The readings you should get are on the table on the next page. One fault that has caught us out is the CDi leads can be incorrectly connected. Its a basic mistake but one weve done and seen done by others. Check that the CDi lead with the white/red & white/green wires is connected to the bike side lead with the same colours! The other lead has mismatched colours on each side of the connector on some models. Failed CDi Unit This is the only item that cant be tested at home. At Rexs Speed Shop we do have the equipment needed and can properly test these units. Some manufacturers publish a table of resistance values for the CDi box, but this will only show a catastrophic failure and not the more common minor failures that stop the unit sparking. Therefore we strongly recommend checking all the other ignition components and if no fault is found with these the CDi unit should be replaced.

Timing Pulser Coil

2.9mm BTDC +/-0.15mm 100 Ohms (+/-10 Ohms) 127 Ohms Measure between the white/green & white/red Measure between the brown and black Secondary 6K Ohms

Source Coil

HT Coil 250cc Machines Charging Coil

Primary 1.02 Ohm

Yellow 0.23Ohms

Measure between the wire colour and black Measure between the wire colour and black Measure between the wire colour and black

Green 1.73 Ohms

Red/Green 0.54 Ohm 400cc Machines Charging Coil Yellow 0.21Ohms

Measure between the wire colour and black Measure between the wire colour and black

Green/Red 0.3 Ohms

www.rexs-speedshop.com

+44(0)1580 880 768