HELP '93 250 CDI on '95 500 problem. motor won't crank

[LAYNFRM]

i bought a 93 cr250 CDI off ebay (i was outbid on the rest, but ordering the rest from a 94 250) and it came in yesterday. i put it on the bike this morning, and now the bike won't start. i plugged the factory 500 CDI back in and the bike runs like it did before. as soon as i got back from the test ride, i put the 250 cdi back on and again, it wouldn't run. am i missing something? i read the entire 250 ignition thread multiple times, and saw where you can run the 250 CDI with the 500 flywheel and stator.

naturally, i figure that either the CDI is bad, or i read it wrong and it won't work without the stator and flywheel? if y'all say it sounds like the CDI, then i'll send it back ASAP while i can still return it.

[lewisclan]

Ive got a few hillclimbers with 250 cdi
I think you got a bad unit

[LAYNFRM]

well that stinks. i just put the 500 cdi back on for some trail riding this weekend. a buddy of mine at a local dealership said they can check the CDI unit for me. i guess i'll be dropping it by there soon. if it turns out to be bad, i'll just send it back to the guy and order another one.

the 92-96 cdi/stator/flywheel all work together, right? the stator/flywheel i am looking at are from a 94 250

[LAYNFRM]

found a complete '94 ignition on ebay. should be here in a week or so.

the guy on ebay i bought the 93 CDI from gave me a refund, and didn't want the part back.

[powermizer]

I bought a 94 cr250 complete set up, and I can run the engine with the 250 cdi and 500 flywheel but I cant run the 500 cdi with the 250 flywheel. Because of the length of the reluctor on the flywheel it would make the timing off for the 500 cdi. The reluctor on the 500 is shorter which would make the timing way far advanced with the 250 cdi. I believe that the 250 cdi makes up for this when used with 250 flywheel. I know mick can change cdi's back and forth, but we need to know year of engines and reluctor length. Please tell me your year of engine and your reluctor length so we can get to the bottom of this. Thanks

[LAYNFRM]

it's a 94 500 motor. i don't know what you're talking about when you say reluctor.

[powermizer]

it's a 94 500 motor. i don't know what you're talking about when you say reluctor.

on the flywheel outer edge you will see a small tab welded on, it's there for the pick up to sence when piston is near top dead center. Thanks for info, there is so much to learn about these ignitions. When you get your new stuff please first try your new 250 cdi with your 500 flwheel.

[MICK]

You're not the only one who's had this problem. It may not be a bad CDI? I did all my comparisons back to back...switching ignition components when the motor was still hot. Had I ridden one combination at a time I may very well have experienced the same problem. At any rate, I didn't like the 250 ignition in any combination other than when ran with the corresponding 250 components. I don't recommend mixing the 250/500 stuff up. Although I may have said in the 250 swap thread I didn't mind other combinations...do keep in mind those were initial impressions, based off as little as ten minutes of riding in one case. I've got hours and hours of riding with the full 250 setup. I can say this; 1) It kicks ass for MX! 2) I don't believe it makes as much difference on top as I initially thought. The motor's ability to build power and what is perceived as "top end" I think can be missleading. Now I wouldn't be surprised if the motor doesn't make one stinking more horsepower with the 250 ignition than it does with the 500! BUT...it pulls so much better above half throttle it reaches those peak numbers sooner. And I was never able to tune out the flat spot off an idle. So I have to also say this jurry finds the '94 model 250 ignition guilty of producing a softer hitting bottom end.

[lewisclan]

I have 3-4 hillclimber bikes with 96 250 cdi and they all run great .
I think they are 96 250s cdi and just the cdi all the rest is cr500 componints

[thestuz]

I have 3-4 hillclimber bikes with 96 250 cdi and they all run great .
I think they are 96 250s cdi and just the cdi all the rest is cr500 componints

when you cdi, you mean the black bos on the frame right?

[CR500R7]

That would be a yes.

[lewisclan]

10-4

[pstoffers]

Did you Copy that gostrider "staticcccccccccccccccccccccccc"

[CR500R7]

Breakerr 1 9 Whats your 20.

[powermizer]

Breakerr 1 9 Whats your 20.

That would be a 10 100

[CR500R7]

Breakerr 1 9 Whats your 20.

That would be a 10 100

OH man my memory is not that good.

[LAYNFRM]

just to update this thread. i bought a entire 94 cr250 ignition. i tried just the CDI and it wouldn't crank. i put the entire ignition on and it cranks easy now. 4-5 kicks when cold, and one kick when warm. it definitely feels more responsive too

[thestuz]

shit yeah, mine still starts like a dream now. starts first or second kick every time. try setting your air gap to.4mm.it helped mine. do you have a flat spot at low rpm?

[LAYNFRM]

shit yeah, mine still starts like a dream now. starts first or second kick every time. try setting your air gap to.4mm.it helped mine. do you have a flat spot at low rpm?

it doesn't have what i'd say is a flat spot. i couldn't really tell since at the same time i went from 15/40 gearing for street riding to 12/44 for dirt (didn't feel like buying a chain for one ride) and that changed the feel up a bit. that was robbing some of the power anyways. i'll throw the SUMO wheels and tall gearing on soon to see if i notice a difference.

the top bolt holding the stator plate on is slotted, i guess so the timing can be adjusted. it had marks where it was set on the CR250 it came off of, so i just set it in the same spot. it ran strong. i might get some feeler guages and pull it apart next week so i can see what setting the air gap is all about. there definitely isn't much room at all right now.