where to find new aftermarket cdi box/ignition module??

[navy528]

hello,

does anyone know where i can find a new aftermarket cdi box/ignition module for a 1981 xs1100 special??

ive been looking everywhere and dont want to buy an old used one off of ebay. if they actually do work, then they might stop shortly after. after all, they are also 30 years old too. if you do know of a place, then do they sell new pick-up coils also? its terrible if there is no replacement other than old parts because every other part is replacable. so if i spend 1500.00 on everything else its all a loss of money these two parts are nowhere to be found new. ive rebuilt the entire bike and make it new but now im stuck.

thanks fellow xs'ers

[DiverRay]

The TCI box cannot be had new, unless you find someone with a NOS (new old stock) unit for sale. The '81 uses a different box than the earlier '78 to '80 bikes. Most of the older units have had NO PROBLEMS because they ARE solid state. Biggest problem is loose solder joints, and that is an easy fix. I think there have been a few boxes that have been fried, but PO abuse is usually the cause, NOT any "real" problem with the TCI.
One of the members here, Randy, used to rebuild the TCI's. You could try and get in touch with him to see if he is still in the rebuild business.

[crazy steve]

Well, there's this one...
http://cgi.ebay.com/ebaymotors/Ignit...Q5fAccessories
.... but everyone decided the price was a bit steep, and it's not correct for your '81. Finding a NOS unit like this if you want new is your only hope, and this may be a typical price...

'78E original owner

[DiverRay]

But Steve, that is for the older models, it won't even work properly on the '81! I'll bet if that seller has one, it's probably about $750!

[navy528]

thanks.....

my problem is that #2 and #3 are still not firing.

i have bought new, correct dyna coils, spark plugs, spark plug caps, spark plug wires. i know they are installed correctly because when i switch (mismatch) the connectors between the left and right ignition coils, the right does fire (spark) (ive been doing the ole screwdriver spark check test). so ive deducted that the problem is in the wires to the cdi box or the cdi box. before i take the cdi box apart, did i eliminate the pick-up coils from being the problem since the switching manuver with the ignition coil connectors worked?

thanks

[TopCatGr58]

Hey there Navy,

If you are truly wanting NEW ignition components, there are options. The 81 TCI...it's not a CDI btw, has the cent. adv. timing curve built into the electronics, and only uses a mechanical vacuum adv.. That's why the timing plate doesn't rotate on the 81, just the pickup coil plate due to the vac. adv. changes. Folks have done Fuel Injection conversions, along with the ignition module controls, but it ain't necessarily cheap!

If you were to swap out your 81 pickup/timing plate assembly with one from the earlier years, then you could utilize the techniques in the tech tips for making your OWN electronic ignition module from auto parts, since the earlier timing mechanical parts have the actual cent. adv. parts, so it's not needed to be programmed into the TCI. You still have the situation of the old pickup coils and wires...just checked bikebandit, and they don't show the pulsar coils assemblies as being available anymore...but I haven't checked other places to verify that, but I thought I read where someone posted that they weren't available anymore!?

But like Ray has stated in your other thread.....the TCI's are really quite ROBUST to use a rarely used word! They can get burned up by folks using the wrong type of ignition spark plug coils...CDI type that have only 0.7 ohms primary resistances instead of the proper 3.0 ohm type coils.

You did state that you used or put on new Dyna coils, I didn't see what model, don't think you stated which ones you got, but hopefully they were the ones with 3.0 ohm resistance!?

T.C.

[navy528]

actually, i just checked. i do have the 3ohm resistance ones. i thought i might have bought the 5ohm. but thank god i did something right so far. i got the J&P cycles part number 381-168. 3ohm 12v duals. you had me scared to death. thanks for that confirmation on coils.

[Axel]

I dont believe you have eliminated the pickups as a problem . You have checked the coils with the good circuit but may have a connector plug that needs cleaning in the other red white wire from the TCI . Take apart and clean all connectors to be sure .

[MindWebs]

here's a thought... just to throw it out here.

Are you running resistor spark plug caps?

Are you running resistor spark plugs?

don't run both. only one or the other.

does the resistor mounted to the frame need to be removed on your setup?
With the Mikesxs green coils the ballest resistor gets removed.
the wires just get plugged into each other.

that's the extent of my knowledge on the matter..
Good Luck!!

[FJ111200]

This any good to you?

http://www.elektronik-sachse.de/ZDG3/frset_zdg_en.htm

Been thinking along these lines and others myself.

[crazy steve]

http://www.elektronik-sachse.de/ZDG3/frset_zdg_en.htm

Still rather pricey at $329 (not including shipping), but the upside is they do offer one for the XS11. The biggest issue would be this unit as shown deletes both the mechanical and vacuum advances, limiting total timing to under 40 degrees; this would mean a pretty big wack to your cruising 'part throttle' fuel economy, probably dropping mileage into the low thirties or maybe even less.

Too bad somebody doesn't offer a 'switchable' unit like the Harleys use; these have two curves (well, most aftermarket units have multiple selectable curves) that are switched between by a vacuum switch. Pretty much the same setup the XJ uses, and would help with mileage.

'78E original owner

[TADracer]

Check this.

If you are using the 3 ohm Dyna coils, remove your balast resistor and plug the two wires into each oither. It will make a big difference in the spark.

Also, check the connection where the primary wires screw onto the coil to make sure it is not shorting out to a mounting angle or bolt head or something else. There is not much room for the wire connections screw heads, mounting bolts, etc. that all reside right there. Had that problem when I mounted mine several years ago. One of the primary wire screw heads was barely contacting a small mounting angle and you could hardly see it.

[andreashweiss]

have both 4ro units for you, sent you a pm, thanx andreas

[newc4]

It could be your pick up coil wires. Pull the 4 lead connector on the TCI and check the pairs on the connector (I think they were upper and lower but the manual will specify by wire) for continuity: 720ohms + or - 20 % I think.

Bad pickups would cause the coils not to fire. If you swap the coils and the problem remains, as you indicate, its probably a pick up problem.

Seems a number of folks are having the pulsars wires crap out, I guess we're pushing it at 30 years +. Just upgraded my bike to Dynacoils.

[Guy_b_g]

If you are using the 3 ohm Dyna coils, remove your balast resistor and plug the two wires into each oither. It will make a big difference in the spark.

81's don't have a ballast resistor, and use 3 ohm stock.