KDXRIDER.NET

Ok, so here's the deal. I'm in the US. I picked up this 81 kdx 175 for next to nothing. It was thrown in on a trade deal. Tires have good meat on them, suspension seems good, clutch is good, brakes may need attention, but on the overall - it's in real good shape. However, that's where the dream ends and the nightmare begins. I will admit total noobness when it comes to these bikes. I've rebuilt a 1970 cb350, a 1974 cb550 four, a 1981 cb750, 1982 kz750, 1997 Vulcan 1500 classic and a 2001 Vstar without incident. But I know nothing about dirt bikes. In particular, I know nothing about the wiring, and what little I do know about these systems with no battery and no lights I have learned from scavenging these forums.

Here's the dilemma. The guy I picked up the bike from claimed that he believed the stator was shot. Well, in his infinite wisdom, he cut 3 of the wires down so far on the cdi box while trying to diagnose the problem he was having that I can barely make out what they are. I've pulled the grommet out in hopes of salvaging the unit, but most likely I'm going to have to replace it. What I'm failing to understand is that there are 4 wires coming out from the case for the stator/generator. Coming from the stator, I have a blue wire, white and red wire, a black wire and a yellow wire. The cdi has a matching blue wire, matching white and red wire, a green and white wire, a black wire with a white stripe and what looks like 2 black wires. Where I'm getting confused is the order in which to wire this all up. I would assume to tie the matching blue wires together, the matching white and red wires together, the black wire with the white stripe goes to the kill switch, one of the grounds should go to the ground of the stator, I'm unsure if the other one should go to a body or frame bolt or if it ties in elsewhere - and that's as far as I have guessed it. I'm unsure if the yellow wire should tie into the green and white wire or if it gets hooked up directly to something, and I have no idea what wire should be running to the contact point on the ignition coil. Diagrams online suggest the green and white wire should go to the ignition coil, but if that's the case, I still have no idea where the yellow wire from the stator should be ran.

I know it's going to take a miracle to solder into these wires in the cdi as far back as this guy cut them, but IF, somehow - I do manage that, I'm really hoping that you can give me some direction here. I really don't want to have to drop a couple hundred dollars into a used stator and cdi unless I absolutely have to. I'm including a few photos of the wiring in question, and I can add more of everything in general if needed and I cannot tell you how grateful I would be for some knowledge.

Thanks in advance,

Big James


http://i1206.photobucket.com/albums/bb4 ... 4n0tjh.jpg

http://i1206.photobucket.com/albums/bb4 ... ryixvv.jpg

http://i1206.photobucket.com/albums/bb4 ... vv1haz.jpg

<a href="http://s1206.photobucket.com/user/BigJa ... z.jpg.html" target="_blank"><img src="http://i1206.photobucket.com/albums/bb4 ... vv1haz.jpg" border="0" alt="Stator Wires photo 20160530_194012_zpsnivv1haz.jpg"/></a>

<a href="http://s1206.photobucket.com/user/BigJa ... v.jpg.html" target="_blank"><img src="http://i1206.photobucket.com/albums/bb4 ... ryixvv.jpg" border="0" alt="CDI box photo 20160530_193953_zpsd1ryixvv.jpg"/></a>

<a href="http://s1206.photobucket.com/user/BigJa ... h.jpg.html" target="_blank"><img src="http://i1206.photobucket.com/albums/bb4 ... 4n0tjh.jpg" border="0" alt="Mangled cdi photo 20160530_193951_zpsjh4n0tjh.jpg"/></a>

A wiring diagram is a good place to start



This is Australian and it has wiring for charging a battery and blinkers.



The yellow wire and the green wire are to run the lights and charge the battery in this picture.