TCI Replacement 2020 It Works

@Jim: 80SG Direct TCI swap....................................Runs normally. (grounded trigger) Miles since install 100
@azman857 80SG Originally TCI/Pamco................ Runs normally. (grounded trigger) Miles since install 10
@YamadudeXS650C 83 Special. Direct TCI swap.. Runs normally. (grounded trigger) Miles since install 10
@2XSive 81 Bobber. Direct TCI swap...................... Runs normally. (grounded floating trigger) Miles since install 10
@Jim: 80SG Direct TCI swap....................................Runs normally. (grounded trigger) Miles since install 100
@azman857 80SG Originally TCI/Pamco................ Runs normally. (grounded trigger) Miles since install 10
@YamadudeXS650C 83 Special. Direct TCI swap.. Runs normally. (grounded trigger) Miles since install 125
@2XSive 81 Bobber. Direct TCI swap...................... Runs normally. (grounded floating trigger) Miles since install 10

http://www.xs650.com/threads/tci-replacement-2020-it-works.57388/page-33
#646
 
Dissected box surgery... :rolleyes:

box.jpg
 
Now you can return it. Right ?

Let's see how this new box works before worrying about the Start up thing.
The small magnets arrive tomorrow.
One thing both 2M and I noticed is the Floater is heaver.
 
After sleeping on it, I was convinced that my first box (floating trigger) is either defective... or different. The other day Jack suggested I pull the connector loose as his was easy to remove. In fact I think jacks came apart accidentally. I tried, but mine wouldn't budge. Did a partial dissection.... it's different. No wires on this connector... soldered directly to the board. And let me say... one of my students who never picked up a soldering iron could do a better solder job. It's absolutely pitiful.

View attachment 170470

View attachment 170471


Here's Jacks box that Steve dissected. On this one the gnd and trigger negative both go to the board ground.


View attachment 170472

My box doesn't. So... I'm asking again. Anyone who hasn't, would you please ohm as depicted below and let us know what you have. Here's the tally so far:
Jeff has -2- 3 boxes...both all are grounded.
Steve has 1 box (dissected).... grounded.
Jack has 1 box.........................grounded.
Jim has 1 box...........................grounded.
Jim has 1 box (dissected)... ....... floating.
Am I correct? Pleas copy this tally and update as you check.... thanks.

View attachment 170476


The problem with using this floating trigger box is that you have to reverse the trigger leads between boxes and that's not something I (personally) want to deal with. If the box puts me on the side of the road, I want the replacement to be plug and play.
The seller on Amazon has a 7 day free return policy. What I suggest we all do is check our boxes when we receive them and return the floaters so's we're all on the same page.
Unless of course, someone want to pursue making both boxes plug and play with each other... as I'm not interested in pursuing that goal.

Sorry Jim,
I'm playing catch up!\
2 boxes. Grounded
 
Are there differences from sellers? Have you guys been mainly purchasing thru Amazon?

I purchased mine thru this seller:

https://www.ebay.ca/itm/192770853628

gonna check it once it shows up at my door and report back. JC
I'm getting the same product from both Amazon and EBay.
See my posts above for the names of the sellers.
Yours seems to have white printing on it; havent seen that yet.
 
I hope these are not really the specs for the box. I had looked at this seller before and laughed about them including specs for what appears to be a 2 stroke CDI. Notice the 180V output. The Gonzo doesn't output anything. It grounds the coil.

Technical Requirements: (Modifier Reference)

1. low speed: ≤ 200r/min

2. start into the angle: 3000r/min

3. 2%d time: 3200r/min%p200r/min

4. 4%d time: 5100r/min%p200r/min

5. 10%d time: 6800r/min%p200r/min

6. Stop angle 13%d time: 9200r/min%p200r/min

7. 8000r/min: Output voltage: 180V



Pack
 
Testing, testing.....
So... it's taken me longer to organize my notes than it took to actually run some tests.
1. Grounded box. rev.0 pigtail: 1°advanced of F at idle. 32° at full advance. Smooth advance curve. (I'm calling this the gold standard. I'll elongate the hole in the trigger to get to 35° and put up a comment when I do.)

2. Same as #1 except with alternator disconnected: Same results as #1

(subsequent tests were with the floating trigger box)

3. Trigger polarity reversed from rev.0 drawing: Advance is wonky (+45-50°) on startup, settles down to 34° after 30-45sec.

4. Trigger polarity as per rev.0: Same results as #3 (that's correct. It's NOT polarity sensitive as I previously thought... works the same either way).

5. Polarity reversed and (TCI) advance trigger grounded to frame through a 10kΩ resistor: same results as #3

6. Advance trigger grounded to frame AND trigger negative through a 10kΩ resistor: No start.

7. Advance trigger grounded to idle trigger negative through a 10kΩ resistor: same results as #3

8. Trigger polarity reversed from rev.0 drawing and alt. disconnected: Went batsh*t crazy. Advance was all over the place and much popping and backfiring.

9. Trigger polarity as per rev.0 and alt disconnected: same result as #8

Conclusions: Almost certain now that the floating trigger box is fubar and all it's problems have nothing to do with advance trigger feedback. No way to verify that without another floating trigger box to try.

Conclusion #2: Floater is not polarity sensitive. I'll chock that one up to poor note-taking previously on my part but... rev.0 pigtail should work on both types of boxes.
 
Last edited:
Hey Jeff, when you get time... check my pin outs please? I think you're the only one who's done an 8 pin conversion.



8 pin rev 0.png
 
Last edited:
I was wondering why the floating timing existed. One reason I could think of because it was programed to do that to help the engine accelerate the to upper RPMs. Less "kickback to gain RPMs to a point and then advance as the RPMs gain. Maybe I'm out in left field with this train of thought.
 
Waiting for glue to cure on the TCI test stand. Have a floater ready to test in AM. If no startup anomalies on single coil pickup then we need to look at the signals coming off the dual coil pickup.
 
Discovered a few things today.
The RX135 pickup is 400 ohms and has a neo magnet on top off the coil
The little 3mm magnets are pretty strong.
Dual output CDI coils draw a lot of current at 12v (thought it was a Honda coil.

Have everything setup to test floater on single pickup and the 3mm neo magnet.
In the morning.
 
Update on boxes:

Jeff, 3 boxes........................... all are grounded.
Steve has 1 box (dissected)...... grounded.
Jack, 2 boxes............................ Floating
Jim has 1 box........................... grounded.
Jim has 1 box (dissected)... ....... floating.
Thuban, 2 boxes.........................grounded
Jake650 1 box............................floating
 
Back
Top