Replacing the 08+ CDI with an 88-94 unit

g21-30 · August 12th, 2009, 05:44 PM

After watching eBay for the last few weeks, I finally located a relatively cheap '89 Ninja 250 CDI and a used '90 wiring harness from another seller. For roughly $55, I can now start my experiment with replacing my '09 CDI (igniter), which appears to be breaking down when it gets hot.

Racer x did this same procedure prior to buying one of the TIS units and installing it.

The following picture details what I purchased. After taking the picture this afternoon, I spent the next hour or so, removing the tape wrap from the wiring harness. This allowed me to see the real colors (not faded) of the wires from the two connectors (yellow circle), which connect to the CDI.

Racer x installed by disconnecting the '08 harness from the CDI and using taps to connect the wires from the '88 harness to the '08 harness.

I may purchase a pin removal tool and transfer the '09 wires/pins to the '90 connectors or build a short connector harness which adapts the '09 connector to the '90 connector. The second method would be ideal, as that would make it simple to go back to the factory CDI, should Kawasaki every admit there is a problem.

After reviewing both factory schematics ('08 and '88), the wire colors are a one to one swap with 2 exceptions. The '08 Red wire must connect with the '88 Brown/Black and the '08 Gray is left disconnected (per Racer x). The schematics indicated the Gray is an additional feed from the ignition switch.

Stay tuned.

g21-30 · August 12th, 2009, 06:03 PM

The '08+ CDI has a total timing advance of 37 degrees or so I have read, while the '88-94 has 42 degrees. According to the '88 spec, Kawasaki made 2 versions (CA and eveyone else) of the CDI. I don't know which one I have, but since it came from a bike in CO, I can hope it's not CA.

Timing specs: 10 degrees BTDC @ 1300 RPM / 42 degrees BTDC @ 4500 RPM
CA: 5 degrees/42 degrees @ same RPM

Between 7000-8000 RPM, the timing drops back to roughly 35 degrees and remains there to 13000 RPM (graph ends here) on both '88-94 models.

Of course, the rpm limiter shutoff is higher with the '88-94 model, so I will need to watch and not go over 13000 RPM or so.

randomwalk101 · August 13th, 2009, 06:48 AM

Interesting to see...
although if it was me, I would just swap out the 08 cdi with another 08 cdi (and I did and that rpm fluctuation is now a thing of the past...so far).... or just go with an Sportisi/ztrack's aftermarket cdi where you can actually adjust the timing to get a little more out of the 250.

g21-30 · August 13th, 2009, 02:05 PM

After more research, I now know that I have the non-CA, i.e. US version of the '88-04 CDI. The relevant part numbers are: 21119-1229 (US) and 21119-1233 (CA). Per the attached picture from the '88 Service Manual, it looks like the timing can vary roughly 5 degrees thru-out the power curve!

g21-30 · August 13th, 2009, 02:13 PM

Quote:

Originally Posted by randomwalk101

Interesting to see...
although if it was me, I would just swap out the 08 cdi with another 08 cdi (and I did and that rpm fluctuation is now a thing of the past...so far).... or just go with an Sportisi/ztrack's aftermarket cdi where you can actually adjust the timing to get a little more out of the 250.

I finally stopped by my dealer yesterday and they said "we haven't had any issues with the '08+ igniters and nothing has been reported by Kawasaki!"

I don't want to leave my bike with them; therefore, my experimenting on the cheap.

August 12th, 2009, 05:44 PM	#1
g21-30 ninjette.org certified postwhore Name: Sam Location: Northern Virginia Join Date: Nov 2008 Motorcycle(s): Ninja 250R 2009 Posts: A lot.	Replacing the 08+ CDI with an 88-94 unit After watching eBay for the last few weeks, I finally located a relatively cheap '89 Ninja 250 CDI and a used '90 wiring harness from another seller. For roughly $55, I can now start my experiment with replacing my '09 CDI (igniter), which appears to be breaking down when it gets hot. Racer x did this same procedure prior to buying one of the TIS units and installing it. The following picture details what I purchased. After taking the picture this afternoon, I spent the next hour or so, removing the tape wrap from the wiring harness. This allowed me to see the real colors (not faded) of the wires from the two connectors (yellow circle), which connect to the CDI. Racer x installed by disconnecting the '08 harness from the CDI and using taps to connect the wires from the '88 harness to the '08 harness. I may purchase a pin removal tool and transfer the '09 wires/pins to the '90 connectors or build a short connector harness which adapts the '09 connector to the '90 connector. The second method would be ideal, as that would make it simple to go back to the factory CDI, should Kawasaki every admit there is a problem. After reviewing both factory schematics ('08 and '88), the wire colors are a one to one swap with 2 exceptions. The '08 Red wire must connect with the '88 Brown/Black and the '08 Gray is left disconnected (per Racer x). The schematics indicated the Gray is an additional feed from the ignition switch. Stay tuned.

August 12th, 2009, 06:03 PM	#2
g21-30 ninjette.org certified postwhore Name: Sam Location: Northern Virginia Join Date: Nov 2008 Motorcycle(s): Ninja 250R 2009 Posts: A lot.	Other Considerations with this mod The '08+ CDI has a total timing advance of 37 degrees or so I have read, while the '88-94 has 42 degrees. According to the '88 spec, Kawasaki made 2 versions (CA and eveyone else) of the CDI. I don't know which one I have, but since it came from a bike in CO, I can hope it's not CA. Timing specs: 10 degrees BTDC @ 1300 RPM / 42 degrees BTDC @ 4500 RPM CA: 5 degrees/42 degrees @ same RPM Between 7000-8000 RPM, the timing drops back to roughly 35 degrees and remains there to 13000 RPM (graph ends here) on both '88-94 models. Of course, the rpm limiter shutoff is higher with the '88-94 model, so I will need to watch and not go over 13000 RPM or so.

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
DIY - Replace the '08+ CDI (Ignitor) with the '88-94 CDI	g21-30	2008 - 2012 Ninja 250R Tech Talk	177	April 11th, 2022 05:19 PM
CDI replacing BRT i-DTIS with Programmable or Non-Programmable?	wyciwug	2008 - 2012 Ninja 250R Tech Talk	44	September 2nd, 2014 02:35 PM
Best Value for GPS Unit?	SmithSwede	General Motorcycling Discussion	14	November 5th, 2013 07:26 PM
New JettingPRO CDI	samw	Motorcycle-related	11	June 15th, 2013 05:51 AM

August 13th, 2009, 06:48 AM	#3
randomwalk101 self wrencher Name: john Location: houston Join Date: Dec 2008 Motorcycle(s): 08 250r and 07 600r Posts: A lot.	Interesting to see... although if it was me, I would just swap out the 08 cdi with another 08 cdi (and I did and that rpm fluctuation is now a thing of the past...so far).... or just go with an Sportisi/ztrack's aftermarket cdi where you can actually adjust the timing to get a little more out of the 250.

August 13th, 2009, 02:05 PM	#4
g21-30 ninjette.org certified postwhore Name: Sam Location: Northern Virginia Join Date: Nov 2008 Motorcycle(s): Ninja 250R 2009 Posts: A lot.	After more research, I now know that I have the non-CA, i.e. US version of the '88-04 CDI. The relevant part numbers are: 21119-1229 (US) and 21119-1233 (CA). Per the attached picture from the '88 Service Manual, it looks like the timing can vary roughly 5 degrees thru-out the power curve!