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CDI burned at idle.

H

H Henry

New member
I have an S200TXRV '97 model year that hasn't been used for a year or more. I got it running after cleaning the fuel system and rebuilding the carburetors.

It was running fine for fifteen minutes or so at idle, 700 rpms +/-, using a hose and muff's for cooling water. The engine just stopped on it own and I saw smoke coming from the CDI, or ignition pack and smelled that electrical plastic burning smell. The engine wasn't overheated it was only about 150 degrees on the heads.

I removed the cover and there is small hole burned through it near the center. What might be some of the causes of this. It is obviously the original CDI, so my first suspicion is old age.

Given the cost of a new unit at more than $1,000.00 I am reluctant to just put another one on and try starting it. I will greatly appreciate your advice.
 
Sh1t just sometimes happens. Parts fail internally and smoke gets out.

There is little external that I can think of that will cause an internal failure of a CDI.

You can find them used on Ebay for much less than the price of a new one.

Would not hurt to inspect all electrical connections to make sure every thing is clean and tight.
 
Thanks Boscoe. I was wondering along the lines if something could have caused a power surge unbeknownst to me. And yes, I will go the used route.
 
Also watch out for frayed insulation on the wires-short circuit after vibration of the motor and fraying of the wires would instantly toast the cdi. also have a look at the cdi electronics manual and check the resistances on the wires so as to be sure that you don't fry the next cdi. it is not necessary to check the frequencies and etc with a fancy meter, just the resistances with a regular meter. just a good quick check.
 
vroomZoom, Good point; I will look into it. I have just a rudimentary grasp of electronic principles so I want to be cautious in my approach. When the motor stopped, I tried to restart it several times before I turned the key off. It then follows that something supplied power to the CDI to let it get hot enough to burn a small whole through the housing, no? The energy had to come from the battery and not the pulser or charge coils to make that much heat for that long. What could cause an internal short in the CDI?

I tried to insert a photo, it uploaded but I don't see it here or know where it went.
 
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