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Author Topic: Removing the flat spot - CDI Wire cut walkthrough with photos  (Read 45793 times)

tommot6

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IF YOU HAVE A DIFFERENT CONFIGURATION PLEASE POST THE FOLLOWING DETAILS AND A PHOTO. year model, country, CDI unit model number. Please add to the knowledge on the forum. theres no point in posting "didnt work for me", "different configuration but worked" help others in the future.

www.youtube.com/watch?v=VyquFYqAmfs


The Bike:
Australian Delivered 2007 Hyosung GT250R
M815 CDI Unit (From Factory) Imprinted 32900 (on top of CDI Unit).

Other areas  that this cut has worked on.

2004 USA GT250 Blue wire instead of green (solution not yet found)

2004 AUS + NZ - Different wiring on the same CDI UNIT (NO solution posted yet)
2006 - AUSTRALIA - plagiarise - page 9
2008 model KM - series hyosung (toofat  page 1)from the Ukraine.
2008 model from Malaysia (gereralkiva page 2).
2008 Model from US  United Motors V2S-250R (thanks to RJstaten  :D)
2009 - See Tomcat98 on page 10 and Fernado_pt Page 12

2009 Onwards is apparently hardwired with a blue wire (DO NOT TRY) - Credit badboync (page 8 From South Africa)
2008 GT250R (Cameron B) same configuration


DOES NOT WORK ON:

EFI MODELS
2004 First Generation CDI UNITS
GT125R


Symptoms:
The bike was getting the well known flat spot in cold weather.

Tools:
Pointy nose pilers
8mm socket/ spanner/ Shifter
Insulators Shrink wrap, electrical tape, ect.

1)Remove Seats
2)Take bolt from the CDI mount

3)Cut/Remove Clip/Electrically insulate blue and green cable going to the brown plug in the CDI unit. DO NOT DISCONNECT OTHER CABLES. (HEAPS OF PEOPLE ARE COMPLAINING ABOUT THIS JUST THE ONE!)

4)Insulate the wires and secure them.

5)Put the CDI and the seats back in the bike

6)test ride

This took me about 5 minutes.

It should be noted that this mod is easily reversed with a Soldering iron and some shrink wrap. keep in mind that these cables are connected to the CDI and are important. If your confuration is different to what is in the pictures be very cautious with this.

Test ride gave a far smoother torque curve from 2500 all the way through to redline. The bike is far easier to ride at low revs.

I know this thread is nothing new to the forum bit there seems to be a lot of confusion as to the CDI Configurations.

FREQUENTLY ASKED QUESTIONS:
Does it work for EFI? - See the list of models this works for

Why does my fuel pump not work - Bike doesnt have a mechanical fuel pump

Bike doesnt start - PLUG BACK IN AND SHARE YOUR SOLUTION!

Wont start with sidestand down - Some have had issues bypass the switch on the sidestand (if you feel you can remember not to ride with it down :P)
« Last Edit: July 28, 2014, 12:24:02 PM by tommot6 »
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woody101088

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #1 on: July 02, 2010, 07:17:24 PM »

not sure if this is the same in the US as it is in AUS...i would love to get rid of that flat spot..since my friends t250 is pulling on me...
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09 GV650 - ZX6R master cyl, EBC pads, 4POT calipers
08 GT650 - parting out PM for parts. Runs great no issues


toofat

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #2 on: July 02, 2010, 09:00:32 PM »

not sure if this is the same in the US as it is in AUS...i would love to get rid of that flat spot..since my friends t250 is pulling on me...

in Ukraine, KM-series Hyosung 2008 GT - same thing done, flat spot - gone.
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woody101088

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #3 on: July 02, 2010, 11:08:10 PM »

holy hell....that makes a hell of a difference... even starting the bike is now easier....
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09 GV650 - ZX6R master cyl, EBC pads, 4POT calipers
08 GT650 - parting out PM for parts. Runs great no issues


ESP

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #4 on: July 03, 2010, 01:27:42 AM »

do I or dont I ....LMFAO
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tommot6

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #5 on: July 03, 2010, 05:27:43 AM »

Everyone Please:
If you do this mod list your model year and where you live. lets try to get a thread going as a one stop shop for this rather than the 50 odd others. If your setup is different maybe post a pick of your cdi wiring and let everyone know which one to choose.


For mine the main difference was in cold air (early mornings). Didnt really want to be louder than the noise cap here in aus but got sick of having a bike that was less than its potential.
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toofat

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #6 on: July 03, 2010, 08:31:24 AM »

holy hell....that makes a hell of a difference... even starting the bike is now easier....

You're cheating at yourself :))) As it was said to me: "This wire just cuts out the spark at specific rews, the mid one's.. Those, where "carbon" tests are provided to pass EURO-3..."

And thats all...

First feel when I've done this - Oh, I have a vibro-less mids :) Yes it goes up on rews smoother... and thats just because passing 4500- 5500 rpm is not a problem now, especially on low speed/high gear.

Like it was? Unstable engine work in "city mode" (5 gear/60-75 km/h)... It could start popping and flatting in some turn... Now it is gone.
« Last Edit: July 03, 2010, 08:35:36 AM by toofat »
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woody101088

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #7 on: July 03, 2010, 08:39:29 AM »

My mods probably also helped the bike quite a bit, prior to doing this..But i'm not joking about starting is easier now. No idea if it had to do with the wire or me changing gas stations.
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09 GV650 - ZX6R master cyl, EBC pads, 4POT calipers
08 GT650 - parting out PM for parts. Runs great no issues


Caligonetx

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #8 on: July 04, 2010, 12:51:22 AM »

Im a bit confused what this actually does; I looked on the eletrical diagram w little understanding.

Anyone care to elaborate? Thanks.


(fyi; I hadnt noticed a cold start issue or low ambient temp starting issue/flat spot w my mods.)
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tommot6

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Re: Removing the flat spot - CDI Wire cut walkthrough with photos
« Reply #9 on: July 05, 2010, 12:40:06 PM »

Im a bit confused what this actually does; I looked on the electrical diagram w little understanding.

Anyone care to elaborate? Thanks.


From what ive read on this forum and some others there are as many as 7 wiring setups for the hyos. depending upon place, year of manufacture ect.

The flat spot has only recently appear on my bike. Im not sure why its just 'appeared' my only guess is that after 25000 kays and a fairly tough life some of the electric sensors or the cdi unit may be suffering from a case of old age.

Caligonetx: if you have a different wiring configuration to mine and you do the mod post some pics to help get some more knowledge into the forum on the subject.
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