TCI & CDI Electronic Ignition / Stators & Charging …

1 Ignition FAQ. TCI & CDI Electronic Ignition / Stators & Charging Systems This guide was started for the "YAMAHA VISION" motorcycle group ( ). However, much of this info applies to any Ignition /. Charging / electrical system. Specifically, how this stuff works, how to trace problems, and ultimately how the driveway mechanic might fix an electric, Ignition -or- Charging problem . If you have comments or PLEASE email. I will update this when I can. 1999 Dave "Leather". Draper . My Vision Info Site Here. "Yamaha Vision" Motorcycle Electronics / Ignition FAQ. Version (July 2005). Designed for 1024x768 screens Photos & Diagrams Download This Entire Guide As PDF. Main Links How Does Electronic Ignition Work?

2 (NEW page) The basics & big picture view of typical Ignition systems Motorcycle Charging Systems and Vision stator problems (NEW page) Basics of motorcycle Charging How Vision TCI Works (jump on this same page) Disassemble & Repair A Vision TCI (NEW page). Electricity Guide (new page) Battery Guide (new page). Top Vision Links Yamaha Vision Riders Group Vision Resources Page file:///E|/_WebPages_Posted/JetAv8rNew/ (1 of 43)8/6/2005 7:13:08 AM. Ignition FAQ. Top Ignition Links Yamaha XZ550RJ/RK Ignition FAQ Table Of Contents 1. Intro 7. Electronic Ignition System Overview 11. "Wasted Spark". 2. Trouble shooting Overview Symptoms Common Coil Spark Common sense approach What is TCI Vision Wasted Spark What ARE the symptoms TCI is not CDI Symptom Quick Checklist TCI vs.

3 CDI How It Works Troubleshooting Chart How it works 12. TCI Power-On Tests 3. First Things to Check How Coil spark works Test at SparkPlug Fuses How TCI works to fire coil Test at TCI. Replacing Fuse Box Good news about TCI 13. COILS. Connections Bad News about TCI Symptoms Cleaning connectors Replacement cost of TCI Spark Test Battery What's inside and goes bad Ohm Test Battery Voltage test How To Tell TCI Module bad Swap coil test Battery Charging Circuit 8. Pickup Sensors Plug Wire Check Test Tach Importance 14. Ignition Cares Moisture Symptoms Ignition Burnout Spark Plugs! Sensor ohm test Coil Care 4. Side Stand Relay Bad news about this test Symptoms TCI pin to sensor check === A P P E N D I X ====.

4 How it works Pickup Crosstalk / Short Disconnecting Crosstalk check A1. TCI Pin/Plug Diagram 5. Engine Stop Switch Short check A2. Spark Test 6. Rev Limiter + Tachometer Swap Pickup Test A3. Multi meter Use Symptoms Calibrate ohm Scale TCI manual triggering Disconnecting Volts vs Amps Replacing pickups How Tach + Limiter work To Measure A. Pickup kills TCI. Inside the TACH Good 12 Volt Connection 9. Checking TCI module (Power Checks). Pin / Plug Checks Testing Current Draw Voltage dropout test Voltage Drop Test while running "Near Ground". file:///E|/_WebPages_Posted/JetAv8rNew/ (2 of 43)8/6/2005 7:13:08 AM. Ignition FAQ. 10. TCI Disassembling + Inspection A4. Battery Theory and Care Why?

5 (=Moisture problem!) A5. Removing TCI Wires Getting Inside "The Black Box". From Plugs (to be added). What You Will See A6. Electrical Theory / Formulas Moisture Solution A7. Rebuilding A TCI module B1. The Author B2. Credits & Contributors B3. Revisions & Corrections top > INTRO. The document you're reading here (and below) is primarily about the Vision Electronics with emphasis on solving Ignition problems. If you want to read about how most all ignitions work then open the new page on Ignition basics listed above. If you want to understand basic motorcycle Charging systems or have problems specifically with the Vision open the new Charging page listed above.

6 If you're already convinced your Vision TCI is bad and are motivated enough to try a fix it, open the new page above on fixing a TCI. We have not had anyone document in detail fixing a TCI but clearly know that it has been done. Would be great to hear from someone who has done it. There are also 2 other pages dealing with basic Electronic theory and batteries. The 82/`83 VISION has a "Transistor Controlled Ignition " system ("TCI"). This type of Ignition is used on many older non-automotive motors (look at a ) and is closely related to modern Capacitive Discharge Ignition ("CDI") systems. While technology advances bring us to the computerized Ignition systems of today, the principles of Ignition have remained fairly the same.

7 The 2-cyclinder Vision motorcycle TCI system consists of : file:///E|/_WebPages_Posted/JetAv8rNew/ (3 of 43)8/6/2005 7:13:08 AM. Ignition FAQ. - 2 sensor pickups under the crankshaft cover - magnet on outside edge of flywheel (triggers sensor pickups). - 2 spark coils (1 for each cyclinder). - a solid state module box ("ignitor") that controls the spark Solid state ( Electronic ) ignitions were introduced in the early 70's (my '72 Outboard has one), became widely used in autos in the mid 80's and are now common on ALL motors. The Vision Ignition has the typical problems associated with older (and poorly built) solid state Ignition systems. The sensors or control module will fail completely.

8 -OR- .. (more frustratingly) the Ignition becomes erratic and usually increasingly worse when hot. Electronic Ignitions fail usually due to: - Electronic components (switching transistors) in the system breaking down with heat (older transistors were not as good as today). - material defects (bad or broken solder joints). - corrosion and bad connections to the module or inside the module - normal life span ("MTF" mean time between failure rate) of older electronics (diodes, transistors, etc). Lets face it, electronics don't last forever and I'll bet you don't have your first stereo anymore either (or do you ?!?!! you cheapskate). A Vision TCI cost about $400 new and about $50 used.

9 If you have Ignition problems you know your ride is not worth too much more than that. Still it's a great ride!! If you want to fix it affordably here's your best chance. Eliminate Ignition problems in an organized progression and you will minimize the chance of buying a expensive parts you really didn't need. (.. example: "put the coil back, you really don't need a new coil" ..). top => TROUBLE SHOOTING OVERVIEW. [COMMON SENSE APPROACH]. You want to narrow down ALL the possibilities before you replace a TCI, PICKUP, or COIL. If you can get (beg, borrow, steal ..) a good spare Ignition then DO IT. Bottom You have 2 coils and 2 pickups. So you can eventually tell if one is BAD by using the other in its place.

10 BUT there is no "SURE". test of the TCI. You can prove it's bad, but you can't prove it's good. Eliminate every other possibility and then you know it's a TCI module. REMEMBER Some Comon Sense Stuff Plugs really do foul bad enough not to work (check spark with plug removed). Don't confuse Ignition symptoms for carb problems (again, check for spark). Bad connections (voltage dropout) and fuses can produce all the same symptoms of bad TCI/Pickups Dude .. Is Your Battery Good ???? file:///E|/_WebPages_Posted/JetAv8rNew/ (4 of 43)8/6/2005 7:13:08 AM. Ignition FAQ. [WHAT **ARE** THE SYMPTOMS]. Exactly "WHAT IS GOING ON" ?? Take your time and write it down. Try to pin down your symptoms: -Is just ONE cylinder misfiring?