CDI hotbox wiring (93-00 XR600R CDI on 83 XR500R)

Printed from: 4Strokes.com Forums
Topic URL: http://www.4strokes.com/forums/topic.asp?TOPIC_ID=26476
Printed on: 09/08/2010

Topic:

Topic author: Greasser
Subject: CDI hotbox wiring (93-00 XR600R CDI on 83 XR500R)
Posted on: 04/07/2007 06:16:40 AM
Message:


Wire and pin connections for 93-00 XR600R CDI onto 83 XR500R

Hey guys, if anyone is interested i have wire color codes for installing newer XR CDI boxes and hot boxes onto older XRs because finding performance cdi boxes for older machines is almost impossible and newer boxes have the latest timing advance curves anyway. And a easy way to hook them up without any wire cutting or splicing new plugs on or anything, not even new pin connectors. Using a fine pick or a jewelers screwdriver carefully push the wires "with the female pin connectors still attached" out the back side of the wiring harness plug for the cdi. Then using the proper wire color chart slide the wires onto the correct cdi box pins. Using some kind of powder or spray lube lightly mist the inside of the wiring plug socket on the cdi box. Now simply fill the plug socket to the top with some type of RV silicon rubber covering all the wire to pin connections. that's it, it's water proof and holds all the wires together and tightly in the cdi box. And without much hassel it will unplug as 1 unit if need be. I'll see if the admin can help with putting up a wire color to pin picture.

Replies:

Reply author: gdavis2265
Replied on: 04/16/2007 09:49:43 AM
Message:

Greasser,

I find this very interesting!

I have been looking hi and low for a CDI for my 1986 xr600-- all I can find are the 93-00.

I am building my harness from ground up, coil, reg, cdi, kill switch, etc.. - This motor is going into a CR roller chassis.

So you are telling me I have no problem using the 90-00 CDI on the '86 motor?

Thanks for the info.

Glenn

Reply author: suicide
Replied on: 04/17/2007 02:15:07 AM
Message:

since the 600R CDI's have a better curve how would they work on say a 650L?

Reply author: Greasser
Replied on: 04/17/2007 05:52:34 AM
Message:

gdavis2265, that is correct. After looking at the 85-87 XR600R cdi wiring diagram it appears to be the same as in the picture shown above. The 93-00 performance cdi box is currently working perfectly on my 83 XR500R. The bike pulls harder through the gears, starts easier usually with 1 kick, hot or cold, and even idles smoother. The only negative I've noticed is the motor runs alittle warmer, so I switched the spark plug 1 size colder(NGK DPR9EA-9). I'd also suggest using atleast 91 octane or better, if you don't use it already, just to prevent any pre-ignition or pinging, pre-ignition starts occuring well before you can hear it, just something to keep in mind.

Suicide, I do not know about it working on the XL's as they take a battery and use a DC charging system but I'm unsure if the ignition system is AC like the XR's. sorry I can't help but I have no doubt that there are mod wizzards on this site that will have your anwser. Good Luck

Reply author: gdavis2265
Replied on: 04/17/2007 09:13:23 AM
Message:

Thanks Greasser!

I did a very extensive search this weekend on CDI's-

I found a place in Minnesota called Pat's Small Engine Plus. Ordered a new 93-00 CDI drop-shipped to my door for $50.00

I have the phone number at home if needed.

Thought I would pass it on.

Glenn

Reply author: sel86xr600r
Replied on: 05/20/2007 4:06:06 PM
Message:

gdavis - Did you install that cdi & is it working? Anybody else tried this. I want to on my 86xr600.
Scott

Reply author: gdavis2265
Replied on: 05/21/2007 8:19:15 PM
Message:

oh yea guys, the CDI works perfect! I can start it most times on the first kick! And it pulls hard- I finally got the jetting right I think (It's a harley D. carb)

I actaully cut down standard female blade type crip terminals, slid them over each contact and then siliconed the whole mess to be water tight.

Thanks Greasser for the tip.

Glenn

Reply author: sel86xr600r
Replied on: 05/21/2007 9:01:25 PM
Message:

I'm going to give it a try. I've adjusted my valves and that helped a lot. It could use a new cdi after 21 years. Let you know how it works out.
Scott

Reply author: tikigod65
Replied on: 05/22/2007 12:11:27 AM
Message:

Would the newer cdi work on a XL600 of the same mid 80s vintage as the XR? Or is it like the 650l with the battery concerns?

Reply author: Greasser
Replied on: 05/22/2007 8:42:03 PM
Message:

Tiki, I'm not absolutely sure but I believe it will work. To the best of my knoledge the ignition side is seperate from the light and charging side of the stator. If that is the case the ignition systems should be the same meaning it will work. Unless I'm missing something. The Plug for the cdi on the 1985 XL600 looks the be exactly the same as the cdi plug on my 83 XR500. You might want to do a little more research to be sure but if it were mine I think I'd try it. But that's me. LOL Hopefully someone else here can say for sure. Good luck

Reply author: waverunner
Replied on: 04/23/2008 7:41:54 PM
Message:

OK, so to those who said they were going to try this swap, how did it work, I'd like to know if it will work with my old gal as well, 82 XL500R, I'm thinnking it might , since the 83 CR500 seems a lot similar to my power plant, probably the same one.. any ideas,, thanks

© 2010 4Strokes.com