Need wire connections dt85

[Yepblaze]

I have recently picked up a 1980-81 Suzuki DT85 3cyl 2 stroke and I need some help testing and getting it set up.

I need to know which color wire feeds the ignition, and some meter readings with connection points (wire colors) So I can look over the ignition system.

It was insinuated that it was in need of a trigger, but I'd like to know for sure for myself.

I have also seen online this morning that if in fact the trigger is bad they may be no longer available. Oh well, I better test it first. If I just have to rewire some pickup coil(s) I could do that.

If you can help but are leery about posting any scans here please email to me at
puddintane@frontiernet.net

 

[Yepblaze]

Re: Need wire connections dt85

I guess I can't delete threads....

So as I continue to work on this motor I was able to search these forums and find this info from RodBolt "right out of a book". Looks like I better print it out and head back out there to see if it makes sense. Brrrrr.

rodbolt
Supreme Mariner

Join Date: Sep 2003
Location: Kitty Hawk NC
Posts: 15,479
Default Re: Suzuki DT 85, 1982 electrical
hello sorry I was delayed. I have my manual on my lap now so let me see if I can help.condenser charge coil low speed wire colores black/red to red white should read 680-831 ohms. high speed wire colors red/white to black should be 114-140 ohms. I doubt this is a problem but check it. now pulser coil. the number 1 and 3 cyl share a single pulser the number 2 is a seperate pulser. they are located under the flywheel. to test use an ohm meter againgreen to yellow red is #1and3 cyl. should read 320 t0 391 ohms. the # 2 is pink to white red and should read 320 to 391 ohms on the ign coils the primary windings should read .21-.29 ohms and the seconday 2130-2880 ohms. I hope this helps good luck and keep posting ps if the #2 cdi output will spark #3 coil and the #3 CDI output wont spark #2 coil then I would suspect a faulty ign coil. or a bad ground. if you have a peak reading meter you can check this

 

[Yepblaze]

Re: Need wire connections dt85

That's not like mine.

Mine has three pickup coils, of which all three have similar resistance when checked for continuity.

I did find an open primary on coil one, and open secondary on the third.

I've looked over the harnessing but am still unclear as to the color wire for 12volts + to activate the CDI. I thought it might be the white one as it has an inline fuse at some point, yet for some reason I'm also looking at the black/white for some reason. I don't want to hook it up wrong.



Oh well I need to get the flywheel back on so I can see what the pickup coils can deliver.

I did find a youtube of generic troubleshooting.

http://www.youtube.com/watch?v=GP7ni_MEkH4

 

[Yepblaze]

Re: Need wire connections dt85

Wel,
I'm starting to make hide or hare out of it and have determined so far that I have 2 bad or suspect coils, my hi speed, low speed, and trigger coils appear to be operating within test parameters.

Now I still have to deal with the CDI itself. The manual says take it off, and take it to the dealer and let them test it or I can do a whole lot of connection combinations with a ohm meter and see if it matches their chart. About the second or third combination I get readings not good so now it looks as if the CDI might be faulty too.

I'm still not positive what wire color feeds the thing yet.

 

[Yepblaze]

Re: Need wire connections dt85

Well, I just found a used CDI and coils for less than they want for a coil at the dealer.

I hope it all works out.

I still need to know the color wire that is used to power the CDI

it's either the white, or the black with white stripe.

Anyone?

 

[Yepblaze]

Re: Need wire connections dt85

I still need the wire colors Suzuki uses to power and feed the ignition under the hood at the component so I don't burn out my new (used) parts I have on order. This motor has most of the harnessing in shambles. And when pieced together, the color code changes from one section to the next

I'm, sure someone has an 80's Suzuki 2 stroke they have worked with.

I suspect that the white wire with the inline fuse picks up the 12+ sends it through the switch and it comes back to the black/white stripe to power the CDI.

But by viewing the schematic it is unclear.

Gee if I'm wrong the CDI boxes are still available for $500+. Wonder if they even make a pop when hooked up wrong?

Sorry about the schematic clarity and size, by the time I whittled it down to the allowable 98k file size it gets pretty hard to view. I had though I had included the image earlier but it never made it through the upload process.

It almost looks like it is self powering ignition with the black/white grounded to stop the motor.

These are things I NEED to know.

I called a local Suzuki Dealer yesterday but was shunned.

 

[Yepblaze]

Re: Need wire connections dt85

In case anyone should in the future search for the answer....

Well it's been a while since I posted this message in desperation to get a second opinion as to the wiring arrangement of this motor and it's ignition components.

After receiving the motor with a no spark condition, then picking up a second non operational CDI switchbox, followed by a third box in operating condition I can now absolutely confirm...

This motor uses a ignition (flywheel) powered CDI ignition.
It requires no external power to operate and the black/white wire when run to ground stops the spark.

There are two charging coils, three trigger coils, three ignition coils, and the switchbox that make it work.

Do not try powering this unit.

 

[grid]

Re: Need wire connections dt85

At your ignition switch, BLACK is ground; ORANGE is choke; GREEN is the KILL SWITCH and OFF: GRAY is 12V ignition on; WHITE should be 12V to the switch. If you have the original control box, the safety kill button was always the main electrical problem. The kill lanyard was attached to a rubber button which, after a number of years, wouldn't push the kill button in and allow the engine to run. In a moment of desperation once I wadded up a piece of Kleenex and put it in the receptacle so the kill button could make full contact, and the engine ran fine for years. My nose ran, too, without the Kleenex. I've been servicing Suzukis since '79 and have never been faced with any ignition failure. Not to say yours weren't real, just that they're a rarity. Incidentally, if you have the opportunity to dyno your 85, you'll be interested in the horsepower reading...

 

[Yepblaze]

Re: Need wire connections dt85

I think the problems with the ignition were from previous owners or helpers there of trying to wire it up and applying voltages where they didn't belong. That was assumed by the jumble of harnessing connections, including at the one at the keyswitch end.

I'm past that now.

Thanks