125-200cc 92- 96 CR-WR 250 conversion, wiring?

Hi,
I have a Husky 92 CR 250,
I have just purchased a 96 or so WR 250 engine,
The ignition wiring is different, and I was wondering which ones to hook to the coil, and kill switch.

The CR motor had a Motoplat ignition, with only 3 wires,
(2 had plugs to go to the coil, 1 for kill switch)
The WR has a larger flywheel,
and different wires,
(still only 3 with a plug that has 2 more small wires one with loop, one with bullet style connector)
can I still hook it up to my CR coil?
Cheers

Actually, my new WR motor may be later, up to 98.

I have found that the Motoplat cdi is built into the coil,
so I may be able to hook up straight to the coil.

Did this era 92-98 CR/WR 250 husky use the same coil?
As the WR flywheel is much larger, and the wires are other colours and a bit different.

Does anyone know which wire is the trigger for spark?
+ which is the other for the coil?
I will check timing with a light before firing it up as the built into coil CDI is new to me,
But once I know which colour wire is which should be all good.
Cheers

you will need the coil from the 96

Thanks,
You are most likely correct,
but why is that?
If the motoplat CDI is built into the coil, and I find which colour the trigger/ spark signal wire is, and the colour of the other wire to coil,
is it possible it may run fine?

I say this as there is usually only a little difference in a lot of CDI's, eg. a bit less timing down low etc. but within 5 deg. generally.

I was going to try using the dark blue, to dark blue, and light blue to replace the black (CR) as the other coil wire.
would the yellow then be for lights etc?
would this be correct?

(I am guessing for the 92 CR's Motoplat the dark blue is the power to coil and the Black is the spark signal wire?)

I have a pic of the ignitions plug and wires to show as I am unsure of exact year model of the WR 250 engine I just got,
It has the pipe in head exhaust style while my 92 head had the bolt in to head/ sleeve into pipe style.

As a side note the swingarm bolt holes in the engine were also different sizes and seems to be wider in the new one and had a bigger hole.

they quit using motoplat shortly after yours was made. i think motoplat actually went under about that time. after yours is the kokusan ignition so the two wont interchange

the Motoplat factory burned down
suspiciously to boot

I was going to try using the dark blue, to dark blue, and light blue to replace the black (CR) as the other coil wire.
would the yellow then be for lights etc?
would this be correct?

I'm talking 2001 WR here-

Yes yellow is for lighting.

Blue and L Blue for coil/CDI.

I would give what you suggest a try. For some reason the WR wiring from the Stator runs less wiring.

Ok,
Thanks a lot for that.
Any Idea if light blue is the spark signal wire?

Now I don't want to damage the coil after seeing the price of them!
But don't think It will do damage, as it just has the CDI built in to the coil on the Motoplat.
So will most likely try it.
Will have to check the timing first to see if it is reasonable, before starting it.

Otherwise I will be on the look out for the correct Year Model CDI and coil for the new motor,
any Idea what Year it is?

It has a 4pin plug, with an extra yellow wire coming from stator.
It has a big flywheel with: EP5328 JAPAN written on it.

Where would I find a CDI and Coil for this?

Is there a For Sale section on here?

My local Husky dealer suggested trying the Motoplat entire ignition, on the new motor,
But the old one had the sleeve into pipe style, which would make it a 92 wouldn't it?
and don't they have a shorter crank snout to suit the small flywheel and Motoplat?,
meaning I cannot swap them?

Thanks again

I tried,
No luck.
Can get a new CDI cheaper than a chipped used one in Oz,
so will do that.

Anyone know which coils fit?
I know some KTM's used Kokusan ignitions also,
and some of their CDI's are interchangable, (some with dual map switch)
So the Coil, should fit too?

I will Try and find the correct Husky one, anyone know which years and models they were the same?
It says 95 - 2010 WR 250 CDI's are the same,
so coil should be too.
Cheers

electrical fire?

Husk99, the only experience I've had with these is the wiring on my 2001 WR250 where I replaced the loom to wire in a reg/rec for 12V DC lighting using a unit from a Chinese pit bike!

Workshop manual for the WR250 1999. From page 240 on you have electrical dia
http://docs.wavenetworks.us/manuals//1999 WR-CR 250-360.pdf

I'd probably try to run with the system that's with the motor your using if you can source the coil/CDI your after if at reasonable cost. Parts from another make etc shouldn't be out of the question if wiring will allow. These things aren't that overly complicated. Check wiring dia's from similar year makes (ie KTM) from internet sourced manuals.

Sorry mate but it will probably take a day or two before you recieve this the way this runs!

Hi,
Thanks for that,
The CDI for the WR 250 is the same part from 95 - 2010
So Coil should be too.

I like the Idea of using a cheap reg/rectifier for 12V DC as a headlight might be handy.

My local Husky dealer is very difficult on anything to do with older Husqvarna's,
They told me it was a 360 motor when it was a 250 and say they have no parts for something so old,
(except for piston and gaskets)
Funny that the CDI was used till 2010,
so if they don't have parts for a 4 year old bike available that"s a bit of a worry.

I can get the correct brand new CDI for half the cost of damaged but working ones here in Oz.

It's a shame as now my money will be going overseas.

I hope the stator itself is good after getting i get the other stuff,
but can get new ones as well.

Cheers

Husk99 I assume you are in Aus?

Have a chat to this bloke. He is just down the road from me and does plenty with bike stators/ignitions etc.

http://www.codrewinds.com.au/

Thanks for that Al H,
The more contacts that deal with the older bikes the better!

The stator should be sweet, it would have been a bit silly for them to do the re-plating,piston, etc, if the stator is no good,
But we'll see.
Aftermarket CDI's are available but, I am worried that they cover such a wide range of models,
that the timing curve may not be spot on, eg. aftermarket WR250 and 360 are the same, where the original part no is different.
I would have thought the 250 would run a more aggressive timing strategy, due to the higher revs.

I will check the stator with a multimeter soon to find out if it is OK.
Any probs and I will try the guy you recommended, I will check if he does the CDI I am after.

The same CDI no. is way cheaper through KTM US, than anywhere else I have found.
The coil is proving the most difficult thing to find at the moment.
Although they are generally a bit more universal.
Thanks again.

I provided the link to CDI rewinds so you can have a chat about your CDI/coil etc knowing your stator is fine. Usually when they deal with stators etc they are clued up with CDI's/coil's. He's only a phone call away. There was also some time back a fella in the Geelong (Vic) region who dealt with bike ignitions as there would be others. You could also try http://www.jaydeemotorcycles.com.au/ or http://www.jdk.com.au/ They may be of some assistance.

Ok,
Thanks a lot.
CDI part no is. 8000 75343 or CU 2197 for WR250 93-2010,
its $45 from KTM US who cannot deliver outside of US,
or $135 - $155 in Australia, with up to a 3 month wait!
Talk about a rip off!
Why is it 3 x the price in Australia?

I can get it from France delivered for $120 so may do that.
No where in Oz seems to have a coil, so may get it overseas too.

Funniest thing is people on ebay selling used CDI's etc. in Australia for double the price of a new one Scammers.

Thanks again,
I'll check out your links.
Pretty much everyone has been more helpful than my local, and not so local, Husky dealers, here in Oz.

Hi,
I finally have a CDI on its way!.
Also the Husky dealer said they had aftermarket coils for $50,
so that is good too.

Does anyone know how to test the stator?
I checked the resistance but what values is it supposed to have?
and voltages?

Cheers

Ring this bloke. http://www.codrewinds.com.au/

I rang him, the other day.
He was a very nice bloke. Rang me back and all. He can re-wind the stator, if it is no good, but didn't do CDI's for the kokusan's.
The resistance seems about right, so I think its fine,
I don't really want to waste his time asking him how to test it, when he is trying to run a business, and it may be fine.

basically the stator resistance was about 127.5 Ohms when I measured it (from memory), so is in spec. so far.
and I know things can change when it gets hot, but I can't check that untill my CDI arrives.
I do get a voltage out of each of the stator wires if I turn it over with the kick start also,
but am not sure how much they should be reading.
It all seems good though so far.

I found some specs on here for a 2000 WR 360 which had a very similar (eg. interchangable cdi, etc) ignition:
Yellow - Earth = Lighting coil = 0.7 Ohms
Dark Blue - Light Blue = Pulse Coil = 127.5 Ohms
White - Blue -Green (Earth) = Ignition Coil = 0.9 Ohms
Plug Cap = 5 Ohms

Any chance anyone knows which coil wire is which from the CDI to coil,
eg, which is power, and which is spark signal.
Cheers

I just double checked my readings and got:

Yellow- Earth = Lighting Coil= 0.7 Ohms
Dark Blue - Light Blue = Stator = 132.3 Ohms

On about a 40 deg. C day, with a bit of a dirty connector/ plug.

I read that others, on a wr 125 with about 129.7 Ohms,
So am still hoping it is in spec.
My CDI arrives tomorrow hopefully so should be easy after that.

Hopefully one of my spare coils from another bike will work till I can get the Husky one.
I have read abut a 5K Ohm resistor in the cap and without that CDI's or something else, get hot and cut out if riding hard.
Husky dealer has aftermarket Coils that should be OK,
Bu still is anyone sure?
Cheers.