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When SD built the yellow 580 motors, someone thought it was a good idea to put a big yellow ignition/magneto housing on the front of the motor and install the CDI, and coil in it. Cheap, nice and compact was their aim, I'm sure.
If that was such a great idea, why did they start making grey plastic electrical boxes to house this stuff later?
I'll tell you why. A twin two stroke motor is a tuff bugger to balance. They viberate badly, especially at certain rpm ranges. The cdi and the coil are well built, solid state, and handle the viberations very well. But the little wire loom connecting the cdi to the coil has a tendency to sever from all of the viberations, usually at the connectors that go onto the coil. The result is an otherwise good running ski, that starts experencing ignition breakup and/or complete failure to spark the sparkplugs.
Many mechanics have spent countless hours testing the seperate parts to no avail when those parts test to be good. Even the wires will show continuity when they are not shaking.
But, the motor still won't run right, or not run at all.
Unfortunetly, SD does not sell the little two- wire loom seperately, it comes when you buy a new coil (expensive). You can take the wire loom out by unplugging each end and you can repair it with solder and a new connector.
You want to know what the scary part is ? They use a very similiar wire loom in the 580 series Rotax Ultralite engines, they just mount the coil on the side of the motor, not in a front cover !
It's a good thing Ultralites glide real well.
If that was such a great idea, why did they start making grey plastic electrical boxes to house this stuff later?
I'll tell you why. A twin two stroke motor is a tuff bugger to balance. They viberate badly, especially at certain rpm ranges. The cdi and the coil are well built, solid state, and handle the viberations very well. But the little wire loom connecting the cdi to the coil has a tendency to sever from all of the viberations, usually at the connectors that go onto the coil. The result is an otherwise good running ski, that starts experencing ignition breakup and/or complete failure to spark the sparkplugs.
Many mechanics have spent countless hours testing the seperate parts to no avail when those parts test to be good. Even the wires will show continuity when they are not shaking.
But, the motor still won't run right, or not run at all.
Unfortunetly, SD does not sell the little two- wire loom seperately, it comes when you buy a new coil (expensive). You can take the wire loom out by unplugging each end and you can repair it with solder and a new connector.
You want to know what the scary part is ? They use a very similiar wire loom in the 580 series Rotax Ultralite engines, they just mount the coil on the side of the motor, not in a front cover !
It's a good thing Ultralites glide real well.