TCI ignition box and rectifier relocation

MadeThatMyself

MadeThatMyself

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I am looking for some feedback on locations for my CDI ignition box and rectifier. I am building a kickstart only hardtail bobber and I am using a small electronics box that I got from Iron Heart Cycles to hide the electronics in the space where the starter used to be

Ebox

Ebox


This mini electonics box does not have room for the CDI unit. Along with the E box, Iron heart offers a rectifier relocation bracket, which I am planning to shamelessly copy and make myself. Would anyone be concerned with airflow in this location?

Regmount

Regmount


For the CDI box, I am wondering if it would be OK to leave it exposed to the elements like the rectifier? Does it get hot and need airflow? I was thinking about maybe mounting it underneath my battery box. PO cut off the original mounting tabs like an idiot, so I made up a little bracket to try and get some ideas. Would this work? Would I be better off fully enclosing it in some kind of box under the battery?

I also want to keep in mind that the CDI box/rectifier might die someday and I may need to move to an aftermarket ignition system, so I don't want to do anything that can't be removed from the bike in the future.

CDI 1

CDI 1


CDI 2

CDI 2


Battery Box Mounted

Battery Box Mounted

 
Last edited:
Originally, the TCI box was under the battery, so that should be fine. Not so sure about mounting the reg/rec to the side of your hot motor though. I'd consider putting it under the battery box too, next to the TCI.
 
MadeThatMyself said:
I am looking for some feedback on locations for my CDI ignition box and rectifier. I am building a kickstart only hardtail bobber and I am using a small electronics box that I got from Iron Heart Cycles to hide the electronics in the space where the starter used to be
Hi MadeThat,
as the TCI box lived out in the open under the battery box it won't mind being out in the weather.
But as the stock battery box was rubber mounted the TCI box should also be rubber mounted in it's new location lest it be shaken to death.
Click to expand...
Click to expand...
 
Just to be persnickety, If your using a stock electronic ignition CDI is the wrong term. There was never an XS650 that used a CDI. The electronic ignition used on the XS650 is a TCI.
There is a big difference. A CDI uses a big Capacitor that Discharges to cause Ignition. A TCI uses a Transistor to Control the Ignition.
A lot of people use CDI to mean any electronic ignition.
Now that's off my chest. The TCI box does not get warm. The rectifier portion of your combo reg/rec does get warm. Warm enough to need good air flow. IMHO it should not be put inside of a box.
Leo
 

That is REALLY good to know. Thank you. This is my first XS and it was already chopped when I bought it so I never got the chance to see the stock form up close and personal.

Paul Sutton said:
Is there enough room to mount the rec/reg on the end of the battery box?
Click to expand...

I think there might be. I'll have to measure. Seems like it would be better to have direct airflow over the fins though.

XSLeo said:
Just to be persnickety, If your using a stock electronic ignition CDI is the wrong term. There was never an XS650 that used a CDI. The electronic ignition used on the XS650 is a TCI.
There is a big difference. A CDI uses a big Capacitor that Discharges to cause Ignition. A TCI uses a Transistor to Control the Ignition.
A lot of people use CDI to mean any electronic ignition.
Now that's off my chest. The TCI box does not get warm. The rectifier portion of your combo reg/rec does get warm. Warm enough to need good air flow. IMHO it should not be put inside of a box.
Leo
Click to expand...

Thanks for the correction Leo. I updated the thread name so it is correct as well. I am running the stock ignition. I was referring to the TCI box when asking if it should be encased for weather reasons. It sounds like the TCI is ok to be either and the rectifier needs as much air flow as possible.

I guess I am surprised that iron heart would sell that bracket if it didnt get enough air. Has anyone run a rectifier in this position?
 
You know you can easily make a reg/rec from car parts that will fit inside your box. To see if there's enough ventilation check if any part gets too hot to keep your hand on. Also, does the TCI just barely not fit? You could use it removed from its box if you wanted to. Sorry, the usual car parts one might not fit, but there are other homebrews that would.
 
Last edited:
I believe the E box is made from 3 inch diameter steel. I'm not sure if that's OD or ID though. What does the TCI look like inside the box?
 
Thanks for that. Using the wrong nomenclature for things always bother me. My time in the Air Force further reinforced it.
Even with the home assembled reg and rec, the rec should still get good airflow. It does get warm.
Leo
 
MadeThatMyself said:
... What does the TCI look like inside the box?
Click to expand...

A coupla pics.
80TCI02.jpg 80TCI03.jpg
 
The easiest solution is get a larger electronics box if nothing will fit inside the one you have.
 
Just so you know, the rec/reg was originally mounted in a vertical position with the cooling fins pointing backwards so it did not get direct airflow over it. It does not get very hot, just feels nice and warm to the touch.
 

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