Ignition Troubles

[FLGuy]

Hi everybody, I am Free Labor Guy and I am working on a pals bike, a 1982 XS 650 and have a bad Ignitor/CDI box, # 5V4-82305-10-00. Anyone know if a 80 or 81 box will work on a 82 or does anyone repair them?
When it failed it was noticeably hot, a component melted through the white plastic insulator sheet. It was running at a high idle, it started running rough then I shut it off. After letting it cool down, no spark. What could cause that failure? Thanks

 

[Wingedwheel]

https://www.xs650.com/pages/tech/
Welcome FL guy. You can probably find your answer in the tech section.

 

[jetmechmarty]

@rickthefix will fix it for you. If no response here, PM me. I have contact info for him. He has repaired many of these.

 

[jpdevol]

5V4-82305-10-00

'82-'83 share that p/n, the '80-'81 Igniter would work too if the extra white/black wire from the sidestand relay on later models have been dealt with (likely) and the connector @ harness aligned for earlier plug-in.

And...https://www.xs650.com/threads/gonzo-diy-tci-system.57694/ Note that more recent (maybe chinese) versions of the Suzuki Igniter have seen quality issues

 

[gggGary]

A bit of trimming of the plastic shield on the connector and it's "plug n play" either way 6 to 7 wire 80-84 TCI