thesaint Posted July 3, 2019 Report Share Posted July 3, 2019 (edited) I am posting this in case any other here on the forum have the same problem I had 2 broken wires on the CDI connector on one of my bikes and off course the wires where broken almost down inside the CDI box connector (see the picture) I was not able to find identical "connector pins" that sit on each wire inside the CDI box connector but i found "connector pins" that can be used to repair this problem VAG or VW have the "connector pins" with the yellow wires and they can be used on the cdi box connector The picture below shows the CDI connector on my 2005 Gas Gas TXT Pro with 2 broken wires. The white wire with a blue stripe(see red arrow)goes to the coil The black wire with a white stripe(see blue arrow) goes to ground on the coil bracket The picture at the bottom with the yellow wire shows the "connector pins" that you can buy at VW. They are a little pricey but the alternative is to buy a new stator with harness i think.. Edited July 3, 2019 by thesaint Quote Link to comment Share on other sites More sharing options...
naichuff Posted July 3, 2019 Report Share Posted July 3, 2019 Check out a vehicle wiring and component supplier for the terminals and resolder or crimp the wires in place Quote Link to comment Share on other sites More sharing options...
thesaint Posted July 3, 2019 Author Report Share Posted July 3, 2019 (edited) There are no soldering needed after i replaced the wires. The new yellow wires with the "connector pins" on each end fit in the CDI box connector so you only have to pull out the 2 broken wires with "pins" in the end that sit inside the CDI box connector and replace them with the yellow ones from VW I have already replaced the broken wires. I pulled out the 2 "pins" that the 2 broken wires with the crimped on "pins" from the CDI box copnnector and replaced them with the new yellow wires fom VW After i replaced the brooken wires in the CDI box connector i have now a even spark on the spark plug for every stroke of the kick starter (done by hand just to check the spark) New yellow wire with the "pin" to the left and the old originak broken off wire with the "pin" to the right Edited July 3, 2019 by thesaint Quote Link to comment Share on other sites More sharing options...
thesaint Posted July 4, 2019 Author Report Share Posted July 4, 2019 (edited) The new yellow wires is much longer than the original white wire with a blue stripe and the black wire with a white stripe. The original wires wasonly about a 1,5 inch long so there was a lot of tension on these 2 wires So after you have put the CDI box on to the connector there will be no tension on the wires like it was on the original white wire with a blue stripe and the black wire with a white stripe The reason the white wire with a blue stripe and the black wire with a white stripe broke was because they was so short that when the CDI box was put on there was a lot of tension on the wires and if you are not careful they will break And the previous owner of my bike was not careful so that is why they broke Edited July 4, 2019 by thesaint Quote Link to comment Share on other sites More sharing options...
thesaint Posted July 8, 2019 Author Report Share Posted July 8, 2019 The Gas Gas importer here in my country could not get hold of the pins that sit on the end of the wires that goes to the stator harness CDI box connector but i had to get the pins with wires at VW Thats not a big plus in my book for the Gas Gas importer Quote Link to comment Share on other sites More sharing options...
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