Rae-San Stock Coil Kit CX_STK_CDI-S CDI-P2. X Stator type G47 rewind Engine Apart to replace Internal Pick Up coils

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Stuart Stevenson
5 years ago
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1 CX 500 CDI Ignitions Motivation The CX 500 CDI ignition is unusual in the motorbike world while not completely unique it is an uncommon arrangement share only with a few other bikes. It uses 3 sets of coils to generate the timing information and another pair of CDI charging coils on the stator to power the system separately from the battery. Of course being 30 years old and with so many coils they are starting to consistently fail in a variety of ways. There is a lot of information available on the www as to testing of the stator, having it rewound, and failure of the trigger coils. Unfortunately however the point has now been reached where there are no longer spares available for most of the parts the stators can be rewound but there are no CDI units available. There are some aftermarket CDI units available however these will only work if your trigger coils are still correctly functioning these are no longer available new and are becoming extremely rare in the used market and are all of course 30 years old and may fail shortly after installation. So in light of all of this I embarked upon a design to address the pickup issue by using a custom HALL EFFECT sensor. This provides the timing information necessary to run the engine and perform the advance without the need to use the existing coils in any way shape or form. I refer to this as the Rae-San CX Hall Effect CDI Ignition. I also as part of this developed an option that is able to work with the original pickup coils if these are still functional This replaces the CDI box, runs of 12V only and provides the advance electronically, and is referred to as the Rae-San Stock Coil Kit. The primary design considerations were Address the failing pickup /reliability issue Keep the cost as low as possible - Use readily available parts as much as possible Protect the electronics inside the engine Make the system 2 independent channels to provide redundancy and avoid common points of failure. WHICH ONE DO I NEED / WANT The table below shows the differences as to what coils on the bike are NEEDED for various systems. OEM CDI Ignitech DC- CDI-P2 Rae-San Stock Coil Kit CX_STK_CDI-S Rae-San Hall Effect Kit CX_HALL_CDI-S Comment Stator Charging coils X Stator type G47 rewind Engine Apart to replace Internal Pick Up coils X X X - No Longer Available Engine apart to replace Advance Coils X No longer Available - 12V power - X X X Use of 12V power means the G8 Stator can be used. CDI spark coils X X X X Needed to make spark aftermarket available Installation None Wiring only Wiring only Need to drop the engine but not open. 30y old New electronic but needs trigger coils. New - electronic needs trigger coils New uses new Hall effect trigger, making it possible to completely replace the entire ignition system.

WHAT ARE MY OPTIONS FOR XXXX FAULT With the number of coils involved in the stock CDI ignition there are a number of failure modes and a number of suitable solutions.

2 WHAT ARE MY OPTIONS FOR XXXX FAULT With the number of coils involved in the stock CDI ignition there are a number of failure modes and a number of suitable solutions. This table attempts to cover what WILL work with what fault. fault Faulty Stator Charging coils (blue or white wire) Faulty L or R trigger coils Faulty Advance Coils-(rear plate) OEM CDI Rae- San CDI PSU Ignitech DC-CDI- P2 Rae-San Stock Coil Kit CX_STK_CDI-S Rae-San Hall Effect Kit CX_HALL_CDI-S Comment X-(3) X X X Stator rewind would fix.rev problem rpm - - (1) - X Replace with Hall sensor X-(2) - X X X Lacking power stocks still runs but no advance. Notes : 1 An Ignitech can be used here but the Rae-San Hall effect sensor for Ignitech needs to be used to provide trigger information for the Ignitech module. 2 The OEM CDI will run without the advance coils but will exhibit poor power and fuel economy as there will be no timing advance feels a bit like riding a heavy 250cc. 3 This product provides only a replacement for the CDI charging coils on the stator. It is still available as it allows keeping the remainder of the ignition completely original and is a useful emergency spare if still running a stock system in case the charging coils start to fail. If not wishing to keep the ignition as stock as possible the other alternatives provide more flexibility and fault coverage. WHAT DOES IT LOOK LIKE / WHAT DO I GET This is the Hall Effect kit (CX_HALL_CDI-S) containing : Hall Effect Trigger Rotor Dual CDI (GY6) DC-CDI Spark Module Hall Effect Sensor with Advance computers sealed in Epoxy Stainless Mounting Screws. This is the Stock CDI kit (CX_STK_CDI-S) containing: Trigger Coil Interface Circuit Dual CDI (GY6) DC-CDI Spark Module

Note there is no case in most cases the electronics are encased in epoxy with the exception of the Stock Coil Interface board above this has been done to minimize cost and size.

3 Note there is no case in most cases the electronics are encased in epoxy with the exception of the Stock Coil Interface board above this has been done to minimize cost and size. Rather than put the assembly in a large and expensive case its left up to the user to mount the system how and where suits. In general the assembly can be placed inside a zip lock back, wrapped in plastic wrap, put in Tupperware or whatever suits the particular installation requirement. The boards are sprayed with a protective lacquer which is not evident in the photos above but which serves to prevent corrosion. HOW DO I INSTALL IT? Installation is simple, but please have a look at the installation manual. For the Rae-San Stock Coil Kit, the installation only involves some wiring changes to provide 12V power to the ignition. For the Rae-San Hall Effect Kit, the installation involves some wiring changes to provide 12V to the ignition and some access to the rear of the engine to remove the old advance coils and replace with the hall effect module. The actual engine does not need to be opened up just the small rear access cover to the advance coils. FEATURES HALL KIIT CX_HALL_CDI-S Operates of 12V only - works if the CDI power coils are dead. Provides electronically adjusted advance. Supports Driving an Ignitech Module. Default Advance Curve as for the TAI bike Improved drivability and torque. Provides Hall Sense and output fire indication LEDS. Provides 2 stage RPM limit - progressively retards timing over 2000 rpm - then stops firing >2000 rpm over selected limit. Fully electronic. Contains two completely independent circuits - one for each cylinder/pair to provide failsafe redundancy. Provides Higher spark energy than original CDI. Able to suit Coil On Plug (CDI Stick Coils).

4 Existing CDI kill switch functionality is retained. STOCK COIL KIT CX_STK_CDI-S Operates of 12V only - works if the CDI power coils are dead. Provides electronically adjusted advance. Provides Trigger Sense and output fire indication LEDS. Default Advance Curve as for the TAI bike Improved drivability and torque. Provides ability to choose from 4 standard advance profiles for the bike chosen. Provides 2 stage RPM limit - progressively retards timing over 2000 rpm - then stops firing >2000 rpm over selected limit. Fully electronic. Contains two completely independent circuits - one for each cylinder/pair to provide failsafe redundancy. Provides Higher spark energy than original. Able to suit Coil On Plug (CDI Stick Coils). Existing CDI kill switch functionality is retained. HOW DO I KNOW WHICH ONE I NEED? If your bike is CDI it will have a black or gold box located under the front of the seat that has an eight pin connector, a 2 pin connector and 3 flying bullet connectors that go to the ignition coils and the kill switch. In this case you can use either of the ignitions above - If your bike is a later model CX that is TAI it will have two igniter modules which with a 6 pin connector and they probably have NEC logos on them. The ignition cover on the very rear of the engine will also poke about 1.5 inches out from the main body of the engine. In this case you can go here to get the TAI Hall Effect version (CX_HALL_TAI-S). WHAT IF I HAVE AN IGNTECH If you already have an Ignitech DC-CDI-P2 but have failed pickup coils or just don t wish to be reliant upon the existing coils and want to convert to a HALL EFFECT setup then you don t need to purchase the full Hall Effect kit as the Ignitech can be used to provide the advance control and coils drive. A wire link is put on the normal Hall Effect sensor module to instruct it not to perform advance control but to rather output signals suitable to drive an Ignitech. The required settings for this are detailed in the installation manual. The wire link is exposed on the rear of the sensor so that the system can be changed to operating as a complete Hall Effect setup just by cutting two small wire loops. This would then need the addition of the CDI drive module which is available separately to allow conversion to the full Rae-San hall Effect Kit. The part number for the IgniTech configured Hall Sensor + rotor, without coil driver is CX_HALL_IGN-S WHAT about Warranty All Rae-San products come with a 12 month return to base warranty against manufacturing faults and product failure as a matter of course. You'll get the unit itself, a copy of the installation instructions for the variant you've chosen and support if needed to help you get installed and operational. User/Installation Manuals

5 Overview Variants Bikes Tested CX_CDI CX CX_TAI CX CX500ec 83 CX650ec 83 GL500 GL700

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