Just an update regarding my spark no spark issues. Its been two weeks since I replaced the CDI and my pig has never ran better. No more stall, no more sputters, no more backfires, ...runs like it did the day I bought it. Something else to keep in mind. I found out the hard way about adjusting the intake & exhaust valves (Intake 0.004" / Exhaust 0.005" +/- 0.001"). In my case I had adjusted them to specification but would get a hesitation / sputter at high RPMs. I backed off the intake and exhaust by about 0.001" each and the sputter went away.  I can only assume the exhaust valves were too tight and not fully closing at the high RPMs. I still believe the XR650L is the best dual purpose bike produced if you plan on playing in the dirt. I'm currently saving up for a fully loaded BMW 1200 GS Adventure. I don't think it'll ever see the dirt but is good for thousands of miles on the pavement. I'd like to see Honda produce a knock off of the BMW 1200  

2004 XR650L, smog block off, baja design jet kit, FMF free flow exhaust, 48T rear sprocket, UNI free flow filter, and intake snorkle removed.

My CDI died a quick death luckily in my garage instead of out in the woods or miles form home.
A new one fixed the problem. No warning except it wound not start and farted at me when the CDI box was smacked.

Expensive little box that it is......

I wonder if the pg does the same too

Mine just would not start after a ride, no warning nothing, dead....

hmmm electrical crap, I hate it...I am happy it did this after a ride and not during...

man!

Just great, now that my Pig is running like new I get pulled over by a Texas State Trouper going down 377 towards Grandbury, TX. My Pig is a 2004 model with all the mods but it sure does go over 70.....i'm close to red lined at 65 with the 48T rear sprocket. We all know our Pigs are about low end power / not speed. Anyway this trouper was in the east bound lane and I was going west across the medium. Be dang if he did not come around, pull me over, and suggested I was going over 75. I politely explained its a single cylinder street legal dirt bike and red lines at 65...I'm sure I could push it to 75 but I don't like getting into those high RPMs. After showing proper insurance coverage he then wanted to inspect my backpack (fishing gear for my trip) as if I were a drug runner. I finally got fed up and told him to just write me a speeding ticket and we'd fight it out in court. He wrote me a warning....now that got my goat...but what the hell, cut your loses.

Proof read my post and it should be: "it sure does not go over 70..." Read some of the other posts and have to wonder if some of them could be the kick stand switch or the neutral switch for the lack of spark? I for one don't need big brother looking after my safety with the kickstand or weather or not I'm in neutral so I took them out....one less thing to worry about.

Hello,

Your input got my attention, I have an 05 XRL650. Just bought with 2700 miles, a real jewel.
I have noticed twice that i will be cruising along and the bike will just die like I turned off the key,
I let it roll in gear, fires up and I'm on my way. Does this sound like a CDI issue or maybe something
you have gone through???

Called the Honda shop, they tell me the CDI units either work or don't work period, I have heard other wise.
$165.00 for a new unit, like to get some input before I make the buy!!

Thanks

Steve

CDI`s are more noted for this than PG generators......read the CDI rebuild thread and resolder your CDI.......then you`ll know for sure and will not cost you anything if

you do it yourself........

B

solivas, on 05 February 2013 - 04:13 PM, said:

My CDI unit would fail when hot, usually after letting the bike sit.  So I would be unable to start it.

Eventually it also failed when cold and I had to buy a new one.

solivas, on 05 February 2013 - 04:13 PM, said:

Mine used to do this at full throttle, the po installed a 165 DJ main jet, went down to a 160 mj and it went away.  Take off the air cleaner side cover and go for a short ride, see if its better.

Edited by zx12r, 06 February 2013 - 10:16 AM.