03/04 cdi is better than the 06


20 replies to this topic
  • Gunner354

Posted February 24, 2014 - 08:31 PM

#1

I have installed an 03 cdi on my 09 and my son inlaw installed an 04 cdi on his 09. We both first installed a Dr. D pipe, Rekluse Pro and then an 06 cdi. The 03/04 seems to hit harder than the 06 we had on our bikes and still maintains a good top end. It hits like a 450 should when you twist the throttle. The 03 cdi is my new favorite cdi on my 09.

  • RockerYZWR

Posted February 24, 2014 - 09:29 PM

#2

Any differences noted between the 03 and 04? Did you ride both? Any difference in starting? Where did you notice the biggest difference in power?

  • Gunner354

Posted February 25, 2014 - 11:27 AM

#3

The 03/04 just seems to be a little more of what the 06 did. Everyone's perspective is different so I encourage more people to give feedback. I mainly ride 2nd and 3rd gear single track and like more low end grunt. The 06 was an improvement over the stock cdi and the 03 was a little more than the 06. I now love the power of my 09 with a Dr D pipe and 03 cdi. Really good low end grunt but manageable. Although I have a friend that thinks the 06 cdi has to much power down low.

  • grayracer513

Posted February 25, 2014 - 01:38 PM

#4

It would be interesting to actually see the difference in the two maps.  A great deal of the "explosive power" impression one gets from an '03 is just that; an impression, partly created by the very intense low RPM response the engine has compared to, well, almost anything.  On a dyno, comparing an '03-'04 to an '06, what you see is around 47-48 peak on the '03, and right at 50 for the '06.  But the '06 doesn't "feel" as powerful down low.  However, running the two bikes side by side on asphalt (having owned one of each at the same time) would see the two running step for step right along with each other, dead even until the '06 begins to pull away in its 4th gear. 

 

Part of the difference in the two engines is the exhaust cam, and some of it is the black box.  It seems to me that using the higher rev-biased cams from the later engine (even more so on the '07, and more again in the '08) would be likely to mitigate some of the actually excessive low end that made the '03 famously difficult to manage, while still benefiting a lot from the more aggressive power curve. 

 

Probably not worth changing an '06 (mine runs so freaking perfect I'm just not interested in it) but if I had an '08-'09, or even an '07, I'd try an '04 CDI in it. 



  • Gunner354

Posted February 25, 2014 - 05:38 PM

#5

I found one for $22 and free shipping on eBay so trying one was a no brainer. I'm glad I did!

  • f150jokerstyle

Posted February 25, 2014 - 08:36 PM

#6

As I said in another topic when this was brought up i'm planing on trying my 09 CDI on my 03 and vice versa for grins and giggles. I'm just having trouble making time to put Humpty Dumpty(my 03) back together again to do the comparison. At the ripe old age of 27 LOL, who knew how busy one could be with work,wife,house,racing,club, and maintaining your primary bike. It will be sooner than later because I need to sell it to help get the front porch done that i'm now being reminded about daily haha.



  • Yzflier977

Posted February 28, 2014 - 07:46 PM

#7

What gearing are you running?

  • Gunner354

Posted March 01, 2014 - 07:16 AM

#8

What gearing are you running?

Stock



  • f150jokerstyle

Posted March 03, 2014 - 06:58 PM

#9

Well I swapped the 03 CDI into my 09 today. I think it may be the Rekluse but I could not really tell any difference between the two. If you had to nail me down on one or the other I think the 09 CDI was more punchy.

 

I still cannot find the time/motivation to get the 03 back in once piece to see how it would respond to the 09 CDI.



  • Gunner354

Posted March 04, 2014 - 06:32 AM

#10

Well I swapped the 03 CDI into my 09 today. I think it may be the Rekluse but I could not really tell any difference between the two. If you had to nail me down on one or the other I think the 09 CDI was more punchy.

I still cannot find the time/motivation to get the 03 back in once piece to see how it would respond to the 09 CDI.

What type of riding were you doing when you compared?
I also have a Rekluse on both bikes and I like the 03 over the 06 and 09.

Edited by Gunner354, March 04, 2014 - 06:42 PM.


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  • Yzflier977

Posted March 04, 2014 - 06:39 PM

#11

I'm running 13/50 and ride MX exclusively.  I just got my '03 box in today.  This weekend I plan on riding my 2009 with the 2006 CDI as I have been for the last year for a little while and then swapping to the '03.  Interested to see (and hopefully feel) what the back to back comparison is.  Will report back next week on what my personal experience is.



  • f150jokerstyle

Posted March 05, 2014 - 08:42 PM

#12

What type of riding were you doing when you compared?
I also have a Rekluse on both bikes and I like the 03 over the 06 and 09.

General goon riding around my property, popping wheelies, little loose berm, and some logs in the back yard. I was really only interested in some extra torque right off the bottom so for me I figured this style of testing would suffice. I hit an obstacle about 5 times with the 09 CDI to get a good feeling for it then would swap in the 03 CDI and repeat then back to the 09 CDI and repeat and comapre for each obstacle.

 

My clubs race is this weekend and it's fairly sandy where were at, so i'm going to give it another go in some sand berms and what not this weekend.

 

Also my gearing in 13/47 120/90/19 rear tire.


Edited by f150jokerstyle, March 05, 2014 - 08:43 PM.


  • Yzflier977

Posted March 08, 2014 - 05:24 PM

#13

Well I put an hour and a half on the hour meter at the track today. The first half of that was with the '06 CDI and the other was with the '03 CDI. Track was a little muddy (a lot muddy in some spots) but pretty good traction overall. My verdict is I absolutely love the 2009 motor with the '03 ignition box. Hands down my new favorite for how I ride. Much improved low to mid torque feel. I was planning on swapping to the 2006 exhaust cam at some point, but probably won't now. This is the combo I was looking for. Supremely happy with my setup. I will say this though, it suited me just fine but I could see how it could be too much for some guys. The '06 is an improvement over the '09 box, but still makes it pretty manageable. I could see how the '03 could wear some guys out. I rode pretty hard and maybe it was fighting the muddy conditions or maybe just hanging onto the beast but I'm tired!! Probably gonna be sore tomorrow and I'm usually not. Anyway that's my verdict on my seat of the pants dyno. Great mod if you're looking for the low end hit.

  • RockerYZWR

Posted March 08, 2014 - 05:43 PM

#14

Thanks for reporting back on that.

  • Gunner354

Posted March 09, 2014 - 08:49 AM

#15

Well I put an hour and a half on the hour meter at the track today. The first half of that was with the '06 CDI and the other was with the '03 CDI. Track was a little muddy (a lot muddy in some spots) but pretty good traction overall. My verdict is I absolutely love the 2009 motor with the '03 ignition box. Hands down my new favorite for how I ride. Much improved low to mid torque feel. I was planning on swapping to the 2006 exhaust cam at some point, but probably won't now. This is the combo I was looking for. Supremely happy with my setup. I will say this though, it suited me just fine but I could see how it could be too much for some guys. The '06 is an improvement over the '09 box, but still makes it pretty manageable. I could see how the '03 could wear some guys out. I rode pretty hard and maybe it was fighting the muddy conditions or maybe just hanging onto the beast but I'm tired!! Probably gonna be sore tomorrow and I'm usually not. Anyway that's my verdict on my seat of the pants dyno. Great mod if you're looking for the low end hit.

Exactly how I feel. Great write up!

  • Yzflier977

Posted March 13, 2014 - 04:47 PM

#16

I bought another '03 box off eBay for $30 as a cheap backup, just in case mine goes out. I have a question though and I'm hoping Grayracer chimes in here. All these boxes from the various years look the same externally so how would you know for sure you have a 03 or an 09? Are the part numbers year specific?

  • grayracer513

Posted March 13, 2014 - 09:35 PM

#17

Usually, yes.  An '06 is 2S2-85540-00-00, an '03, 5TA-85540-00-00, '04 is 5XD-85540-00-00, so on.  Since all 85540's are CDI boxes, the part itself will usually only be stamped as 2S2-00, or 5TA-00. 

 

The two sets of zeros after the basic part number (85540) indicate significant revisions, alternate sizes and the like, and the second pair for less significant changes.  The '07 part number is 2S2-85540-70-00, so that CDI is stamped 2S2-70.



  • Yzflier977

Posted March 18, 2014 - 05:43 PM

#18

Thanks Gray!!! As always exactly what I was looking for.

  • vega_fe

Posted July 29, 2014 - 01:01 AM

#19

Usually, yes.  An '06 is 2S2-85540-00-00, an '03, 5TA-85540-00-00, '04 is 5XD-85540-00-00, so on.  Since all 85540's are CDI boxes, the part itself will usually only be stamped as 2S2-00, or 5TA-00. 

 

The two sets of zeros after the basic part number (85540) indicate significant revisions, alternate sizes and the like, and the second pair for less significant changes.  The '07 part number is 2S2-85540-70-00, so that CDI is stamped 2S2-70.

I have a cdi and be stamped 2S2-10. It is also 06'?? What is the difference 2S2-00 and 2S2-10?



  • grayracer513

Posted July 29, 2014 - 06:58 AM

#20

The 2S2-85540-10-00 was an early version of the '07.  Different map.  It was discontinued and replaced by the 2S2-70.







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