CDI compatibility

BLUDGEONER · Oct 15, 2015

Evening all - well it is here anyway...
I've just got a 550 engine slotted into my chassis which was recently occupied by a 650 - just got to the stage where I can fire it up. Both engines are 04 on kokusan ignition, but I can't be exact on the year (both race engines - no numbers). The 550 has been tuned, but I don't know exactly what was done - only that it came out of a race bike which had ALOT of money thrown at it! I've got the carb from the same bike, so that's a bonus, but not the CDI. Question is, is there any harm to be done trying it out with the CDI from the 650?
Sorry about the vagueness! Cheers.

canolman · Oct 15, 2015

Now there's a question!
I'm running '04 and '06 650 engines in my track bike. The CDI I have is an '04 550 according to the part number...
I have a theory that they differ in the advance/****** mapping that effects starting,
No one can tell me what the differences are but they do have different part numbers....

zaga · Oct 16, 2015

Hi

Bludgeoner, I don't think that you will have any problem with the 650 CDI, the only thing is, if your engine is a very race tuned one, with that CDI you might not get every single drop of hp of it.

Canolman, I agree with that the difference between them is the advance curve, but I don't think that will affect the starting. The curve will only be different in higher revs than the starting point ... I think

ZAGA

BLUDGEONER · Oct 16, 2015

There's a lesson to be learned here - always check your facts before asking questions on a forum! Checked the part number of my CDI......and it turns out to be for an 05 FS550

Started it - sounds sweet! Bit of fine tuning needed as it didn't want to tick over, but in my experience tha's not uncommon with a cold engine (didn't run it very long and can't road test it yet). One thing I noticed - it takes a hefty kick to start it. I've had 3 650's and I'm sure they were all a doddle to kick compared to this beast! High comp piston?

canolman · Oct 16, 2015

Hi Bludgeoner, sounds like your sorted. Part number 80039031100R? The 650 ends with 200.
If anyone's got a 650 CDI going spare part number 80039031200 I'm your man, been looking for a long time, they're a bit salty brand new!

BLUDGEONER · Oct 16, 2015

Mine is 81539031000

canolman · Feb 2, 2016

Bump!:spin:

Could these both be 650 CDIs? The one on the right is brand new, out of the box. The one on the left could be off the 550 but now I'm not sure:unsure: The bottom white sticker on the left unit was hanging off but had it's part number worn away anyway. Top numbers look the same, anyway to tell if they are the same? Sparks?

sparks · Feb 3, 2016

canolman said:
Bump!:spin:

Could these both be 650 CDIs? The one on the right is brand new, out of the box. The one on the left could be off the 550 but now I'm not sure:unsure: The bottom white sticker on the left unit was hanging off but had it's part number worn away anyway. Top numbers look the same, anyway to tell if they are the same? Sparks?

Hi Canolman,

These are the part numbers for following models depending on year, to the best of my knowledge anyway.
The difference being slight alteration to the advance curve, but spark up they are all the same.

2004
450 800.39.031.000
501/550 800.39.031.100
650 800.39.031.200

2005
450 810.39.031.100
550 815.39.031.100
650 820.39.031.100

If you were to send me your stator and pulse coil connections plus the 2 cdi's I can run them up on the test rig to see what curves they have.

Regards

Sparks.

canolman · Feb 3, 2016

Many thanks Sparks,
I was told that the CDIs pre and post 2004 were exactly the same despite having different part numbers, I was also told that the later ones had a better map!:unsure:
When you say they are all the same spark up do you mean they all have the same ****** to allow starting?

sparks · Feb 4, 2016

canolman said:
Many thanks Sparks,
I was told that the CDIs pre and post 2004 were exactly the same despite having different part numbers, I was also told that the later ones had a better map!:unsure:
When you say they are all the same spark up do you mean they all have the same ****** to allow starting?

2004 was the first year of using the Kokasan system, I know modifications were made in later years but I don't know exactly what, I would have to run them all back to back to find that out.

Yes they all have the same spark up ****** for starting, just the advance rpm time differs for each model, they will all run each other just not as good as the correct one.

Regards

Sparks.

canolman · Feb 5, 2016

Many thanks Sparks for your offer, can't spare both at the moment as the one on the right isn't mine (yet) I'll probably try them back to back at a track day. As I've always had trouble with overheating while waiting to go out on track, would this be as much to do with ******** ignition at tickover as the carb jetting? I found raising the tickover would bring the temp down.
Would there be any differences between the FE and the FC flywheels and stators regarding the power curve?:unsure:

sparks · Feb 7, 2016

Regarding ignition curves I would think they will both be the same, but I have never run an FC system on the rig, the FC system is pure ignition only and has a smaller flywheel, this system is very much like the Suzuki RM125 from back in 2000.

Regarding your overheating thing, might be that the rise in rpm circulates the coolant more efficiently.

Regards

Sparks

Sgtx · Jul 15, 2016

Same problem but different year a 1995 501 cdi # 14-05 101 890 00 and trouble finding another. Is there another one i can put on it.

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