Testing a kick only HHB CDI

[icantwrench420]

I bought a late 70s xs650 chopper that was in boxes. The bike has a Hugh's handbuilt CDI installed. I finished grounding the system to the frame and when I go to kick it over I'm not seeing a spark.

I'm really new to wrenching so I'm not sure how I can troubleshoot why I'm not getting a spark when I kick.

Is there another way to test that the system works? I'd like to scratch the electrical system off the list before moving on to the engine.

I emailed Hughs handbuilt and he suggested hooking up a battery to it to test it. I can't seem to find a wiring diagram for the system to be used with a battery.

Any help is appreciated!!!!

 

[AUTOMAN]

https://www.hughshandbuilt.com/2012/03/01/install-hughs-handbuilt-pma-system-xs650/


not much of instruction as to how iggy works

PMA system

 

[gggGary]

I bought a late 70s xs650 chopper that was in boxes. The bike has a Hugh's handbuilt CDI installed. I finished grounding the system to the frame and when I go to kick it over I'm not seeing a spark.

I'm really new to wrenching so I'm not sure how I can troubleshoot why I'm not getting a spark when I kick.

Is there another way to test that the system works? I'd like to scratch the electrical system off the list before moving on to the engine.

I emailed Hughs handbuilt and he suggested hooking up a battery to it to test it. I can't seem to find a wiring diagram for the system to be used with a battery.

Any help is appreciated!!!!

Move the wires from the cap to a battery.

 

[icantwrench420]

Then I try to kick it over? If there's still no spark just follow connections back from the plug to the battery?

 

[gggGary]

Then I try to kick it over? If there's still no spark just follow connections back from the plug to the battery?

Don't know for sure which Hughes parts you have? He's offered several different set ups through the years.

 

[icantwrench420]

It's the hughs handbuilt complete CDI kit, I'll try to get a model #

 

[Its been a long time]

It's the hughs handbuilt complete CDI kit, I'll try to get a model #

Pictures of it will probably help.

 

[gggGary]

Pictures of it will probably help.

Beat me to it!

 

[icantwrench420]

I will post some pictures in a bit!

Thanks guys!

 

[Signal]

If checking for spark do it in a dark area, CDI sparks are very fine (needle point ) and hard to see not big fat blue sparks you may be expecting.
I was testing a CDI outside in the sun no spark, pushed it in a dark shed visible spark.

 

[icantwrench420]

Ok here's a few of what I got going on. Anything that is mounted is on on there temporarily and the location for the grounds are as well. My idea, was to just make sure I can get a spark so I can move onto checking the engine and carbs. Then add gas and oil, try to get her moving.

Im sorry if the pictures aren't great, If there's something you need a pic of just ask me and I'll do my best

Thank you!!

 

[gggGary]

sorry but not sure what all you have there. where's the ignition coil? the capacitor? That black plastic box looks like a stock TCI? but the sires aren't right for that. Box with fins prolly the voltage rectifier/regulator

 

[Its been a long time]

Yeah, I was about to say, I wouldn't really know where to start with that to be honest. Sorry.

 

[Signal]

It is a bit hard to piece it all together from the photos.
It looks to me the connections in the 3rd photo are your grounds. They need to be clean, no paint or rust under the terminals. And just to be extra sure run a wire from the crankcase to under one of your ground connection points.
The test result you should have almost no resistance, like when you touch the meter leads together.

Have a read of this thread.https://www.xs650.com/threads/hughs-hand-built-pma-wiring-diagram.64621/
Post #5 has a diagram also included are the kill switch relay connections

One other thing with CDI systems they have to spin quickly to excite the coils, kick it like you hate it or it won't spark.

 

[icantwrench420]

I'm going to install the system in a cleaner fashion and take pics of it.

I'll definitely clean up those ground connections and run an additional wire from the ground connections to the crank.

The rest you want me to preform, what points should I be testing the resistance from?

Also should I have a battery hooked up when testing the resistance, I am running a kick only with a capacitor, if I can test this and confirm without going out and find a battery that would great.

 

[Signal]

CDI systems are stand alone, no battery or capacitor required for basic operation (think early 2 stroke motocrosser ).

A battery is required to power the shut off relay that is used to connect the engine shut down switch and ignition switch to the CDI system. The relay interposes between the CDI system and the bikes 12V system.

With the ignition switches off the CDI shut down wire is connected to ground and the CDI stops sparking. Turning the switches on energises the relay and removes the earth from the CDI shut down wire.

If you have wired in the shut down relay as per the diagram linked in post #14 you will need a battery to energise the relay to enable spark.
A capacitor will not reliably power the relay.

If you have the relay wired in and no battery to check for spark remove the black white wire that comes from the CDI and goes to the relay pin 87a.
I did not see a relay in your photos though.

The check is to confirm you have a good clean ground, and that the motor crankcase is electrically connected to the ground connections. No battery required.
Test from the motor (use a cover screw hole) to your ground wire connection point.
I suggest you get the thing sparking, then move on to the charging system.

 

[Signal]

A moment later ....
Looking at your photo and try to decipher what you have connected to what. This is difficult as no overview and continuity of colours But it looks to me that you have connected the black white wire from the CDI to ground.
That is the shut down condition and the CDI will not spark.

 

[icantwrench420]

This is the wiring diagram I followed.

I see what you're saying with the white/black wire.

To wire in a kill switch, I would attached the white/black wire to the switch and the other end to a ground, when the switch is activated it would ground the CDI, disengaging the system?

 

[Signal]

To wire in a kill switch, I would attached the white/black wire to the switch and the other end to a ground, when the switch is activated it would ground the CDI, disengaging the system?

You are correct.

 

[icantwrench420]

Ok, I just checked that black/white wire on the connector, it's not the ground but there is no wire on the other side of the connector. I'm going to wire in a kill switch and send pics. Thank you for the help!