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  1. #1
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    Help! 1981 Cr80 Lost Spark Again!

    Any suggestions or advice?





    I have a 1981 CR80 that I had acquired for my son.
    When we got it it had no spark and found that the Stator was bad. After months of searching (****, Bike Graveyards and other websites)with no luck for a stator I tried taking the stator from a 1985 CR80 assemble and replacing the stator only by soldering it on to the 1981 Stator assemble. It got us a spark and the bike was running great after rebuilding the carberator.
    My son was having a blast riding around in the yard and finally got a chance to take it out somewhere else and let her rip. He was riding it in 4th gear and it suddenly stopped. It lost its spark again!
    We checked the plug and replaced it even though it looks fine.
    I am afraid after researching this that the stator repair may have damaged the CDI Igniter or something. Any suggestions where I should go from here? The 1981 CR80 stator assemble is discontinued and I cannot find one anywhere. Any one know where I might get one or have mine rebuilt? I have the original but it had gotten torn up when a bolt backed out inside behind the rotor.
    The bike runs great and is in great shape otherwise.
    Any info would be much appreciated




  2. #2
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    try dirt cycle salvage-1-508-478-5700- if cdi is bad
    dennis kirk has them listed- cr80- 80/81 staters-part number-20-1730-and are
    $ 59.95 new!!! 1-800-969-7601
    you could have had a local electric shop re wire it /auto starter repair shop-
    i would get it from dennis kirk
    happy riding




  3. #3
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    Jason33, Thanks for the reply, I will check contact Dennis Kirk.




  4. #4
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    If the newer stator that you installed isn't bad, you could try mating it up with the newer CDI box from the bike the stator coil came out of. That sounded confusing huh! I guess what I am saying is, if you can't find the correct components for your bike, try using the complete system from a newer bike and install the stator coil on your stator plate as you have already done. Might be worth a try.
    BTW I have been down this road too, my son's first bike was a 1983 CR60, and everything seemed to be obsoleted.




  5. #5
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    Check and see if get any voltage out of the stator with voltmeter it should be less then 1volt.




  6. #6
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    Thanks guys for the responses. I contacted denniskirk.com and they have new stators available but they state that the one they sell works for 1980 thru 2002 CR80R's.
    So I guess the used stator that I soldered on from a 1985 CR80 should be okay to use. I have located a used cgi box and coil to try replacing them one at a time to see which if either is bad. I did check to see if I got any voltage coming out of the stator assemble when I kicked the kick starter and I did get a reading.
    Could it just be coincedence that the CGI box went bad after I replaced the stator? I'd hate to change out the CGI box and burn another one out. Even used ones are not cheap (if you can find one). Don't really know what else to do at this point though. I'll have the used parts in a few days and will try it and see what happens i guess.




  7. #7
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    i have heard different stories about them needing to be changed as a unit- but i dont think thats true-there all electrical devices,that work together mass produced,
    mabe it shorted out
    use a test light to see if theres power from the stater, then hook up the cdi box and check power from there ,then the coil
    its called a
    CDI- not cgi-- lol
    capasiter discharge ignition




  8. #8
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    Looks like I have power from the stator but nothing coming out of the CDI box once connected. I should have the replacement used CDI Monday. I'll see if thats the problem then.
    Thanks




  9. #9
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    Okay I finally got a chance to get back and test things on this bike. I have voltage coming from the stator assemble on up through the CDI box.
    When I checked the stator voltage it seems to be around 1.4 volts coming out. Is this to much?
    I checked the voltage from the lead on the CDI box that connects to the ignition coil and I get 1.3 to 1.8 volts there. Does this sound right?
    When I connect the lead to the ignition coil I get nothing. I tried another used coil that I had purchased and it doesn't produce a spark either.
    What can I do to find out if the ignition coil is bad or if 1.3 t0 1.8 volts going into it is correct. My manual doesn't seem to mention voltage it just mentions about measuring resistance and I have not had any luck getting consisitent resisitance readings.
    Any help/suggestions or ideas would be appreciated.




  10. #10
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    was the coil grounded? there is power from the cdi ,then i think its the coil,
    is the kill switch bad ? try disconnecting it
    the coil magnifies the power from the cdi box
    i dont know the voltage output sorry




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