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Old 12-13-2009, 04:30 PM   #1
Ricky Rocket OP
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Pissed XR650L CDI...dead, or dying? Help!

My 2001 XR650L has a strange intermittent spark. When trying to start it, it fires once but won't run. Backfires like a freakin' cannon through the exhaust when it does fire. I pulled the plug and layed it against the cylinder head. When cranking the engine, the plug fires once when the start switch is engaged and does not spark while the engine spins over. When I let off the starter button, the plug fires once more. I swapped numerous plugs, no change. Unplugged CDI harness and checked connectors...clean and dry. Checked safety switches and kill switch, no problems there. Is this symtomatic of a bad CDI? Any ideas would be greatly appreciated....thanks!
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Old 12-13-2009, 08:28 PM   #2
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The first thing to want to do is unplug the pulse generator and check that, if that checks out than your cdi is the culprit.
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Old 12-14-2009, 12:16 AM   #3
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I just went through the same thing on a 650L. It would work and then it would quit. I was the ICM (cdi box). I would also check your pulse gen.
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Old 12-14-2009, 08:02 AM   #4
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Did the ohm-check on the ignition/kill switch, coil, plug wire, and pulse generator....all within spec (some a little off, but it's 31 degrees F outside and my meter is about 10 years old). I just ordered a CDI from Honda; no dealer in the area stocks one and the cheapest I could get was $148 tax included. I sure hope this does the trick!
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Old 12-14-2009, 08:08 AM   #5
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where did you order that from ? I think you can get them for less than 100 from cheapcycleparts.com
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Old 12-14-2009, 08:15 AM   #6
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Cdi

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30410-MN9-000 MODULE, IGN CONT $110.54 $
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Old 12-14-2009, 08:16 AM   #7
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I had my Honda dealer order it, cheapcycle wants $110.54 and another $9.70 for 7-10 day shipping. If you want it in 4-5 days, shipping goes up to $25.00. I figured I'd give my local dealer some business (they are pretty good to me) and they'll get it to me by this Friday for $140 out the door. I really want to go riding this weekend w/my buds...
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Old 12-14-2009, 11:30 PM   #8
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It sounds like you did the leg work and the ICM is the culprit. I also aprove of you trying to support your local shop.
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Old 12-15-2009, 07:34 AM   #9
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I had to replace the CDI in my XRL too. It worked fine if it was over 65 degrees or so out, but if it was cooler the bike wouldn't start. With the new CDI it starts without issue even if it's 5 degrees out.

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Old 12-18-2009, 05:23 PM   #10
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Help...need someone to run a test

Hey, I followed the troubleshooting procedure in the Shop Maual and ended up ordering a new CDI unit from Honda. It didn't work! Can somebody with an XR650L run a test for me? I need to verify that when you spin the motor over with the starter the plug fires consistantly. Mine is firing once when I initially hit the starter button....and again when I let OFF the starter button. When it spins over in between.....no sparking. Put in brand new plug (tried three others), NEW CDI, checked ohms on coil and Pulse Generator (all within spec). I could really use some good input here!! My next step is a new Pulse Generator, but I'd rather know for sure before sinking more money on this fishing expedition.

Ricky Rocket screwed with this post 12-18-2009 at 05:29 PM
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Old 12-18-2009, 05:50 PM   #11
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Quote:
Originally Posted by Ricky Rocket
Hey, I followed the troubleshooting procedure in the Shop Maual and ended up ordering a new CDI unit from Honda. It didn't work! Can somebody with an XR650L run a test for me? I need to verify that when you spin the motor over with the starter the plug fires consistantly. Mine is firing once when I initially hit the starter button....and again when I let OFF the starter button. When it spins over in between.....no sparking. Put in brand new plug (tried three others), NEW CDI, checked ohms on coil and Pulse Generator (all within spec). I could really use some good input here!! My next step is a new Pulse Generator, but I'd rather know for sure before sinking more money on this fishing expedition.
It sparks when you hit the starter button and again when you release the starter button. Sounds like the problem is in the starter button. Or your key switch.
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Old 12-18-2009, 06:07 PM   #12
Walterxr650l
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Quote:
Originally Posted by Ricky Rocket
Hey, I followed the troubleshooting procedure in the Shop Maual and ended up ordering a new CDI unit from Honda. It didn't work! Can somebody with an XR650L run a test for me? I need to verify that when you spin the motor over with the starter the plug fires consistantly. Mine is firing once when I initially hit the starter button....and again when I let OFF the starter button. When it spins over in between.....no sparking. Put in brand new plug (tried three others), NEW CDI, checked ohms on coil and Pulse Generator (all within spec). I could really use some good input here!! My next step is a new Pulse Generator, but I'd rather know for sure before sinking more money on this fishing expedition.
Make sure your sidestand switch is clean, or Bypass it. Do the same for the kill switch and clutch switch.

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Old 12-18-2009, 06:07 PM   #13
showtime45
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Mine sparks all the time. I thought I had a bad CDI & it turned out to be the pulse generator.
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Old 12-18-2009, 07:16 PM   #14
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Showtime, did you actually try it? I want to know that if I can troubleshoot, I'll look to get to the point it sparks continuously. Was yours in neutral with the clutch out and sidestand down? I tried it mine in neutral, clutch lever left alone, and sidestand down. Sparks when hitting the start button...no spark when turning over, and sometimes spark when releasing start button.
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Old 12-18-2009, 09:00 PM   #15
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OK, I finally got it to spark...it will only spark when the bike is in neutral and the kickstand is up. Anybody know which switch to look for as being at fault? It must be a ground switch...either clutch lever, neutral, or side stand.
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