02 cr250 cdi. Can you use a 04

rbigair40
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1/24/2011
Location
Lebanon Junction, KY, USA

Found a nos cdi for a 04 can it be adapted to my 02 using my 02  harness. Thks 

|
4/14/2023 6:21pm

No, wiring harness would need to be modified, 2002 wiring...

image-20230415111523-1

2004 wiring...

image-20230415111621-2

rbigair40
Posts
235
Joined
1/24/2011
Location
Lebanon Junction, KY, USA
4/14/2023 7:15pm
No, wiring harness would need to be modified, 2002 wiring... 2004 wiring...

No, wiring harness would need to be modified, 2002 wiring...

image-20230415111523-1

2004 wiring...

image-20230415111621-2

Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground that's in that spot for the pick up ? 

4/14/2023 7:55pm

It looks like the ignition pulse generator ground connects to the ignition ground, and the alternator's white wire connects to a different pin on the 4 pin plug to the ECU.

rbigair40
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235
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Location
Lebanon Junction, KY, USA
4/28/2023 6:57pm

Darn I need help still

The Shop

Sandusky26
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7/28/2021
Location
Eastern, NC, USA
4/29/2023 2:08am
rbigair40 wrote:

Darn I need help still

I seen a complete wiring harness and CDI for an 02 for sale on MXlocker.com

Mr Happy
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10/9/2015
Location
GB
4/29/2023 8:38am Edited Date/Time 4/29/2023 8:41am
No, wiring harness would need to be modified, 2002 wiring... 2004 wiring...

No, wiring harness would need to be modified, 2002 wiring...

image-20230415111523-1

2004 wiring...

image-20230415111621-2

rbigair40 wrote:
Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground...

Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground that's in that spot for the pick up ? 

You can pop the pins out of the plug with the correct tool and you should be able to buy new pins, as they'll be standard Sumitomo plugs.

It looks like you need to switch the AC pin to the one occupied by the TPS pin. Pop the pulse generator ground pin out of the other plug and make a new wire and pin that connects to the chassis for the ground. Put a ring connector on it and put it behind a bolt. Edit: Scratch that, just swap the AC and TPS pins, the pulse pickup will be fine. You would only need to modify the pulse ground if you were fitting an 04 CDI to an 02.

Tools. https://www.ebay.co.uk/itm/223449805628?var=0&mkevt=1&mkcid=1&mkrid=710…

rbigair40
Posts
235
Joined
1/24/2011
Location
Lebanon Junction, KY, USA
4/29/2023 6:33pm
No, wiring harness would need to be modified, 2002 wiring... 2004 wiring...

No, wiring harness would need to be modified, 2002 wiring...

image-20230415111523-1

2004 wiring...

image-20230415111621-2

rbigair40 wrote:
Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground...

Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground that's in that spot for the pick up ? 

Mr Happy wrote:
You can pop the pins out of the plug with the correct tool and you should be able to buy new pins, as they'll be standard...

You can pop the pins out of the plug with the correct tool and you should be able to buy new pins, as they'll be standard Sumitomo plugs.

It looks like you need to switch the AC pin to the one occupied by the TPS pin. Pop the pulse generator ground pin out of the other plug and make a new wire and pin that connects to the chassis for the ground. Put a ring connector on it and put it behind a bolt. Edit: Scratch that, just swap the AC and TPS pins, the pulse pickup will be fine. You would only need to modify the pulse ground if you were fitting an 04 CDI to an 02.

Tools. https://www.ebay.co.uk/itm/223449805628?var=0&mkevt=1&mkcid=1&mkrid=710…

Will give that a shot.  Thks 

 

rbigair40
Posts
235
Joined
1/24/2011
Location
Lebanon Junction, KY, USA
4/29/2023 6:36pm
No, wiring harness would need to be modified, 2002 wiring... 2004 wiring...

No, wiring harness would need to be modified, 2002 wiring...

image-20230415111523-1

2004 wiring...

image-20230415111621-2

rbigair40 wrote:
Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground...

Do you know what needs to be done. Big plug colors match and are in same spots. Little plug 04 has tps wire.  02 has ground that's in that spot for the pick up ? 

Mr Happy wrote:
You can pop the pins out of the plug with the correct tool and you should be able to buy new pins, as they'll be standard...

You can pop the pins out of the plug with the correct tool and you should be able to buy new pins, as they'll be standard Sumitomo plugs.

It looks like you need to switch the AC pin to the one occupied by the TPS pin. Pop the pulse generator ground pin out of the other plug and make a new wire and pin that connects to the chassis for the ground. Put a ring connector on it and put it behind a bolt. Edit: Scratch that, just swap the AC and TPS pins, the pulse pickup will be fine. You would only need to modify the pulse ground if you were fitting an 04 CDI to an 02.

Tools. https://www.ebay.co.uk/itm/223449805628?var=0&mkevt=1&mkcid=1&mkrid=710…

I have tried removing pulse ground and grounded it with no luck . I will swap the ac to the tps spot on the box and give that a try.

rbigair40
Posts
235
Joined
1/24/2011
Location
Lebanon Junction, KY, USA
5/2/2023 12:58pm

Still no luck 

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