CDI and wiring

asteroid500 · Post by **asteroid500** » December 22nd, 2009, 5:58 pm

Hi all,
i need to wire my motor up to the 99- CR250 CDI while retaining the factory look.

1) should i splice the motor wires to the 250 loom (if so what color goes were)
2) fit the whole 250 alt/backing plate/stator to the 500 (what mods are required)

please advise- i'd like to keep it simple and reliable with a simple parts # replacement for parts for future maintanance.

motor loom

250 loom ends

complete 99-250 wiring

robertg · Post by **robertg** » December 22nd, 2009, 6:32 pm

I'm pretty sure you have to change the stator with the CDI box. A 99 ignition is digital, and the 500 wasn't. If you search the 250 CDI swap thread here or on the other site, you will see pictures of what you have to modify. Just look at the back of your old stator and the new one and it's obvious.

asteroid500 · Post by **asteroid500** » December 22nd, 2009, 11:47 pm

excelent

asteroid500 · Post by **asteroid500** » December 22nd, 2009, 11:56 pm

NOT so excellent,
you serch 250 CDI and get 200 threads on every thing.

any one got a step by step run down on placing the 99-CR250 complete staror and wiring into a 500 motor. pics are easy to follow as well

Wheelie-Gene · Post by **Wheelie-Gene** » December 24th, 2009, 1:59 pm

The 250 has digital ignition???
My 125 stator looks exactly like yours.

The engine core I purchased didn't come w/a CDI box.
I wired in the (2001) 125's CDI into the 500's harness...had the same color scheme as in your picture.
I spliced the like-colored wires together...had spark...it fired up and runs (runs really good). I didn't think anything of it.

DitchWitch · Post by **DitchWitch** » December 24th, 2009, 3:42 pm

I hope this is OK Bob, feel free to delete if its not cool. www.cr500riders.com/cgi/yabb/YaBB.pl?num=1231982461/60 look on from post #65.

asteroid500 · Post by **asteroid500** » December 25th, 2009, 6:20 pm

ok, i read all 280-somthing pages of this thread.
http://bannedcr500riders.com/board/viewtopic.php?t=2264

ive worked out that my 99 donor bikes stator and CDI are more or less a strait forward replacement on to my 500 motor.

althoug not stated the CR250-97 to 99 & CR125-98 to curent are a digital pulse system as are the 2000 and onwards.

im going to replace the standard 500 stator and fly wheel with the 250 gear.

i'll post pics in a step by step format so future inquireis will be alot easier and quicker to do.

asteroid500 · Post by **asteroid500** » December 25th, 2009, 6:35 pm

it would seem i need to do some machining

BannedCR500Riders.com

CDI and wiring

CDI and wiring