SX225TXRZ - Ignition troubles

[mesias_yam]

and you test red to brown and black/red to blue.

No, I didn't... what should I be looking for? I'll do it in the morning and report back.

myself I would test the CDI output and see, the CDI does not amplify anything it pretty much feeds the ign coil prmary what the charge coil fed it.

I tested the CDI output, I tapped the wire before the ignition coil. Is this what you are referring to?

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is this a 2.6l motor or a 3.1?

It is a 3.1L, SX225TXRZ

[rodbolt17]

that 3.1 system uses a bank to bank charge coil. it does NOT use a high and low speed. one coil controls one bank the other controls the opposite.
the SX uses CCS but during cranking it sparks all six.
retry the tests using the correct procedure and see what happens.

[mesias_yam]

were these tests done loaded or unloaded?
And what Peak voltage meter are you using?

Tests done unloaded while cranking,

Peak voltage taken with a Electronic Specialties 640 - DVA Adapter and a Klein MM100

that 3.1 system uses a bank to bank charge coil. it does NOT use a high and low speed. one coil controls one bank the other controls the opposite.
the SX uses CCS but during cranking it sparks all six.
retry the tests using the correct procedure and see what happens.

I tested resistance:

B/R to L - 299 | R to Br - 301
W/R - 344 | W/B - 342 | W/Y - 344 | W/G - 342 | W/L - 341 | W/Br - 344

I thought the dynamic test was better than checking resistance.

[mesias_yam]

Bump for some feedback...

[99yam40]

Rod will have to answer, I thought he was referring to a voltage test

[mesias_yam]

Bump for Rodbolt feedback...

Here are results again:

CDI Unit output:

Cyl 1 - 100v | Cyl 2 - 109v | Cyl 3 - 75v | Cyl 4 - 106v | Cyl 5 - 93v | Cyl 6 - 85v

Charge Coil:

Resistance:

B/R to L - 299 | R to Br - 301

Peak output:

First test: B/R - 171v | R - 187v | Br - 112v | L - 15v

Second test: B/R - 123v | R - 106v | Br - 112v | L - 15v

Pulser Coil

Resistance:

W/R - 344 | W/B - 342 | W/Y - 344 | W/G - 342 | W/L - 341 | W/Br - 344

Peak output:

First test: W/R - 10v | W/B - 9v | W/Y - 15v | W/G - 9v | W/L - 9v | W/Br - 6v

Second test: W/R - 5v | W/B - 7v | W/Y - 5v | W/G - 4v | W/L - 4v | W/Br - 4v

[rodbolt17]

something is wrong with your testing.
you simply cannot have voltage out of the CDI that is higher than into the CDI.
the CDI may drop a few volts but its output is about what the charge coils input to it.

[mesias_yam]

This is frustrating Rod...

Is there any chance I installed any component wrong? I mean, following the mounting holes and cable placements should be all it takes to get the stator and the pulser in place, right? There is a timing mark pointing the flywheel but there is only one way to install the flywheel.

I also used dielectric grease in many connections, specially those I found with a bit of rust. Could it affect anything?

I ran the tests again... some lower readings this time. I used a harness I build to tap the CDI output.

CDI: Cyl 1 - 82v | Cyl 2 - 84v | Cyl 3 - 90v | Cyl 4 - 103v | Cyl 5 - 85v | Cyl 6 - 85v

Stator: B/R - 123v | R - 110v | Br - 122v | L - 15v

The CDI output seems to be within spec but it makes no sense the blue wire from the stator to be so low. And it is consistently the same 15v in every test.

Every single of these parts are extremely expensive new... and it makes no sense throwing that much money to a motor this old. I could get some used parts for sure... but where do I start? The stator seems to be the number one suspect at this time. Would you agree? I'm also afraid of going to the ONE dealer near me with a certified Yamaha mechanic. The chances of them just start throwing new parts is high.

Any additional recommendation will be greatly appreciated.

[rodbolt17]

my suggestion.
test it correctly.
it looks like you are testing the charge coil outputs to ground. you test the output from wire to wire not from wire to ground.
you simply cannot have an 80V CDI output with a 15V input.

[mesias_yam]

You are totally right, I was testing the charge coil voltage output against ground. I totally misinterpreted the service manual and your advice.
I'll check it again later today once my helping hands arrive from school.
Thanks again for your patience and assistance.

[mesias_yam]

I tested the charge coil voltage output but got mixed readings based on the polarity... I hope Rodbolt can identify what's proper:

R(+) to Br(-) = 117v
R(-) to Br(+) = 130v

B/R(+) to L(-) = 124v
B/R(-) to L(+) = 14.7v

EDIT: measured while cranking.

[99yam40]

Was this measuring while just cranking or running


I though the service manual shows what wire and leads to hook up.

But I could very well be wrong

[mesias_yam]

It was measured while cranking. The manual doesn't specify...

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[mesias_yam]

Bump for Rodbolt feedback...

[99yam40]

Interesting, it shows 85V and 110 v
are the 2 readings for the 2 different charge coils?
or is the 85 - 110 a range

I thought they normally give a minimum peak voltage


3 of your readings are above the 110 and one is below 85
the manual says if below do this and if above do this other thing

very confusing

I would think the red lead would go to the red wires, but never seen it written