ZX Mark2 - Triple w/points

The Starfire ZX Mark2 -3 CDI fitted with the Points Interface Unit gives the following advantages:

1) Easy fitting with the very small size , will convert the S series to either points driven CDI or with simple mechanical modifications, to the better KH400 system using pick up coils.

2) Retained points last almost indefinitely with timing adjustments remaining fixed for longer

3) Electrical load on battery/charging circuit reduced dramatically, allowing brighter and modern lighting to be fitted... approx 48 watts with the old system to 12 watts with the new.

4) Brings the complete ignition system up to modern standards, and a performance advantage to match

A small additional box is to interface the points to the CDI. This will incorporate the necessary circuitry plus the three LED timing lights. This makes the initial setup of the engine very easy.

For road racing and drag racing applications.

1) The new CDI will run as a simple minimal equipment, stand alone system.

2) Will run 1.5 hours on a small set of AA nicads or similar... total loss system for weight reduction.

3) Small and light weight.

4) Potentially allows the rotor, and ALL rotating mass to be completely or partially removed from the crankshaft.

5) Increased CDI limit of 12000 RPMs

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Experimentation is required after fitting this unit to any non CDI equipped bike. Best timing will not be "as per the book", and spark gaps can be opened considerably. Sometimes the mixtures can also be leaned because of the higher intensity spark at high speeds. The ignition dwell angle is now decided electronically, so the points or contact breaker gap can be reduced considerably to help prevent bounce at high RPMs. The
condensers that are normally fitted across the points can be retained, but some bikes could benefit at higher RPM's by their removal. It is VITAL that care is taken when fitting and using the Starfire CDI. The ignition coil primary terminals have over 300 volts DC on the exposed terminals at all times when the ignition key is on. This will at the very least give a very nasty bite... far worse than a spark plug can, and is potentially lethal. DISCONNECT AND REMOVE battery before fitting these units to be safe, and take care when servicing the bike.

------------STARFIRE ZX Mark2 -3 CDI INSTALLATION INSTRUCTIONS FOR S1B/C, S3/A, KH250------------

This installation requires the additional Points Interface Unit with the RED, ORANGE and GREEN timing lights.

1) Mount CDI unit to bike

2) Remove the YELLOW wires from the coil (+) terminals, and route these back toward the CDI unit.

3) Remove the GREEN, BLUE, and BLACK wires from the other coil (-) terminals, and route these back toward the CDI unit.

4) Connect the CDI ORANGE, BLUE and DARK GREEN wires to the three ignition coil (-). These are coil left, center and right, respectively.

5) Connect three RED wires to each ignition coil (+) terminal.

6) Connect the BROWN CDI wire to one YELLOW female connector from step 2

7) Connect the CDI BLACK wire to a firm ground.

8) Mount the Points Interface Unit (PIU) in an accessible place where the timing lights can be easily seen when setting up the timing.

9) Connect the PIU YELLOW, PURPLE and LIGHT GREEN to the GREEN, BLUE and BLACK wires removed in step 3. These are the harness wires to the three point (contact breaker) assemblies, left, center and right cylinders respectively.

10) Connect the PIU BLACK wire to a firm ground, as in step 7

11) Connect the PIU RED wire to the YELLOW from step 2, (female from kill sw).

The bike will now run with the new CDI. The three "traffic light" LED's will make setting of timing a breeze. These lights will be on when the points open and off when they close. The spark occurs as each one opens.

Click for Wiring Diagram

---------STARFIRE ZX Mark2 -3 CDI INSTALLATION INSTRUCTIONS FOR S1/A, S2/A---------

This installation requires the additional Points Interface Unit with the RED, ORANGE and GREEN timing lights.

1) Mount CDI unit to bike

2) Remove the RED wires from the coil (+) terminals, and route these back toward the CDI unit.

3) Remove the GREEN, BLUE, and BLACK wires from the other coil (-) terminals, and route these back toward the CDI unit.

4) Connect the CDI ORANGE, BLUE and DARK GREEN wires to ignition coil (-). These are coil left, center and right, respectively.

5) Connect three RED wires, one to each ignition coil (+) terminal.

6) Connect the BROWN CDI wire to the RED connector from step 2

7) Connect the CDI BLACK wire to a firm ground.

8) Mount the Points Interface Unit (PIU) in a accessible place where the timing lights can be easily seen when setting up the timing.

10) Connect the PIU BLACK wire to a firm ground, as in step 7

11) Connect the PIU RED wire to the RED from step 2, (from main harness).

---------STARFIRE ZX Mark2 -3 CDI INSTALLATION INSTRUCTIONS FOR H1B---------

This installation requires the additional Points Interface Unit with the RED, ORANGE and GREEN timing lights.

1) Mount CDI unit to bike

2) Remove the three BROWN wires from the coil (+) terminals, and route these back toward the CDI unit.

3) Remove the GREEN, RED/WHITE, and BLACK wires from the other coil (-) terminals, and route these back toward the CDI unit.

4) Connect the CDI ORANGE, BLUE and DARK GREEN wires to ignition coil (-). These are coil left, center and right, respectively.

5) Connect three RED wires , one to each ignition coil (+) terminal.

6) Connect the BROWN CDI wire to a BROWN connector from step 2

7) Connect the CDI BLACK wire to a firm ground.

8) Mount the Points Interface Unit (PIU) in a accessible place where the timing lights can be easily seen when setting up the timing.

10) Connect the PIU BLACK wire to a firm ground, as in step 7

11) Connect the PIU RED wire to the BROWN from step 2, (from main harness).