Many people have asked about the differences between 01 and 02+ CDI wiring. Some have had issues with wrong/mismatched CDI/wiring harness years. I have been trying to resolve this issue and with help from others here, I believe that I finally have an answer. I originally posted part of this today as an answer to BigDaddy's thread. However, it's come up so often that I felt I should start a new thread about it also.
After quite a while trying to get the other schematic (the one NOT in the PDF manual), finally with help from ROCKO, who has done the conversion and sent me pictures and drawings of it, I think we may finally have the definitive answer to the 01 vs 02 CDI wiring debacle. Please comment or tell me if any of you see any errors!
ADDED 4/11/2012 - FYI, you can identify which year (01 or 02+) CDI you have by a simple feature- if your CDI has a step on the front face, it's 02+, if it's flat, it's 01. Here's a link to a forum discussion on this topic: https://www.raptorforum.com/forums/sh...2&postcount=13
ADDED 12/9/2012 - Member jbennett posted at the current end of this thread: "You might want to update the first post and add that for 2005, there is no green/yellow wire in the 4 pin plug. There are only 3 wires."
He is correct - so if you have a 2005 ONLY, because there no parking brake switch on the newly designed parking brake lever for the 05, there is no green/yellow wire in the harness going to the CDI. Thanks for the correction, jbennett!
As has been said before, the harness at the motor is no different, there are no new wires. THe only change between 01 and 02+ is in the WAY the wires connect to the CDI. Yamaha changed the specific pin placement used for many of the wires at the CDI between 01 and 02. So, with the drawings below, one can simply pull the wires out of the connectors, and replace them in the correct positions in order to use a mis-matched year wiring harness and CDI.
IMPORTANT: You only need to change the connections if you use an 01 CDI with an 02+ harness or you use an 02+ CDI with an 01 harness. Again, the year of the engine has no import.
Here's the original pinouts from the manual (looking into the connectors at the wiring harness end) This is the 01 version, according to BigDaddy
and here's the pinouts required for the 02+ according to ROCKO. He sent pictures of the wires in place, so I have confidence that this is correct:
One minor discrepancy: The manual's schematic shows that the 8 pin connector has a Green/blue wire to drive the reverse light, and the info I got from Rocko shows no Green/blue wire but does have Green wire in the 6 pin connector. Carefully looking at ROCKO's pictures shows a hint of blue on the green wire, so i do not believe there is a problem here. I've included the pictures of ROCKO's conversion below.
PLEASE, if anyone sees an error here let me know so I can fix it and eliminate any confusion and problems.
Hope this helps.
Below are two images from ROCKO showing views of his modified harness. Notice that the drawings above are looking INTO the harness connectors from the pin end and so are flipped horizontally from what you see in the pictures. Imagine that you have unplugged the connector and the drawings show you what you would see if you were looking into the harness' connector. For example, the light blue wire at bottom right of the 4 pin connector in the picture below will be at bottom LEFT of the 4 pin in the drawing above. Left and right are just swapped between the pictures and the drawings, in order to match what was already published in the manual. Hope it's not too confusing.