kenq
Junior Dawg
Posts: 11
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Post by kenq on Feb 27, 2010 10:36:26 GMT -5
I recently purchased an used Aprilia Leonardo 250 cc-engine (Yamaha-built) together with all required electrical components. Except for the wire harness... I will use the engine to build a rather funny winch-system for towing wakeboarders and snowboarders but before the build can begin, I need to figure out how the cables shall be connected to the CDI. The problem is that there's no numbers on the pins of the CDI so I can't figure out what cable from the wiring diagram that goes where. I'm really puzzled at the moment and any help is appreciated. Does anyone have a scooter with an engine like this and can take a picture of the CDI-connector? Attachments:
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Post by JR on Feb 27, 2010 20:01:04 GMT -5
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 3, 2010 16:24:43 GMT -5
Thanks for the reply Ryan. Is it the exactly same engine in the Leonardo as on the YP250?
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Post by jalat on Mar 3, 2010 16:44:24 GMT -5
I can answer that. Same YP250 Yamaha Engine is used in the following scooters: aprilia leonardo 250 benelli velvet 250 italjet jupiter 250 malaguti madison S250 (newer versions without S-letter uses piaggio engine), password 250 mbk skyliner 250 yamaha majesty 250 - upto 2001 (or up to 2003) Engine parts, carburetor parts and variator parts fits for all of those scooter models. So it is kind of easy to find parts. And here is wiring diagram for Malaguti Madison S250 yp250-engine. david.alfa-romeo.eu/Motorcycle/Malaguti/Malaguti_Madison_250_Service_Manual.pdfSee page: 131 and 132 Number 19 in page 131 is CDI I think.
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 3, 2010 17:33:17 GMT -5
Thanks for the info Jalat. So basically it should be the same in/out-pinning on the CDI's on the models above or can they have different CDIs even though the heavy parts of the engines are the same? The CDI that I got along with this engine have a Mitsubishi-logo on it and it says "Exterior >PBT<" Interior >PUR<" on it. Also, when I use the YP250-pinning info and try to map it against my Aprilia wiring diagram, the pins have this order (if we go from left to right in the wiring diagram I attached):
7|6|4|1 - |5|2|3
Shouldn't they be in a consecutive order? Or is the order of the CDI-connections in the Aprilia diagram not related to the order of the pins?
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 3, 2010 17:55:56 GMT -5
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Post by jalat on Mar 4, 2010 0:42:20 GMT -5
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 4, 2010 14:24:24 GMT -5
Hmm, yeah they look awfully similar. I can't help thinking that it would suck if the pinning was different between the models and I'd ruin the CDI by putting input on an output pin. I wonder why they would manufacture different boxes for similar engines though. To make sure users and workshops buy "genuine" parts? Do you know if people have been running Malaguti Bikes with Yamaha CDIs for example? Or would it be possible for me to measure the resistance between certain pins to figure out if the pin order is correct? Gah, this turned out to be more puzzling than anticipated. If the scrap company could have just sent the connector, this would not be a problem...
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Post by jalat on Mar 5, 2010 1:22:17 GMT -5
I can't say for sure. I also wonder why they would manufacture different cdi boxes for similar engines Maybe they wouldn't. Ebay showed that even starter relay is same for these different models.
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 5, 2010 17:36:33 GMT -5
I can't say for sure. I also wonder why they would manufacture different cdi boxes for similar engines Maybe they wouldn't. Ebay showed that even starter relay is same for these different models. I guess I'll just have to cross my fingers and give it a try. Hopefully I can find a new CDI online if I burn this one. But is nobody out there driving a Leo 250 and can take a pic of the CDI-connector?
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Post by jalat on Mar 5, 2010 17:55:24 GMT -5
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 21, 2010 11:46:32 GMT -5
Hello again! I did not get as far as I had hoped. We connected the electrical system yesterday to check that the start motor worked - and it did. But after just a 1/4 rev the actual engine stopped and got completely jammed. Now it is impossible turn the flywheel in any direction. It is completely jammed. As it actually turned 1/4 of a rev before meltdown, I have come to the conclusion that the engine was not jammed when we bought it.
Now - What might have happened? What could cause an engine to be blocked like that?
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Post by jalat on Mar 21, 2010 12:47:52 GMT -5
Broken piston ring maybe? I think it can stuck the piston. But first open the variator cover and check that everything is in order there.
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Post by torque on Mar 21, 2010 13:22:25 GMT -5
I can answer that. Same YP250 Yamaha Engine is used in the following scooters: aprilia leonardo 250 benelli velvet 250 italjet jupiter 250 malaguti madison S250 (newer versions without S-letter uses piaggio engine), password 250 mbk skyliner 250 yamaha majesty 250 - upto 2001 (or up to 2003) Engine parts, carburetor parts and variator parts fits for all of those scooter models. So it is kind of easy to find parts. And here is wiring diagram for Malaguti Madison S250 yp250-engine. david.alfa-romeo.eu/Motorcycle/Malaguti/Malaguti_Madison_250_Service_Manual.pdfSee page: 131 and 132 Number 19 in page 131 is CDI I think. Same CDI is also used in the Linhai Mainstreet 300 (basically a YP250 clone with different body work.)
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 22, 2010 9:05:52 GMT -5
Hello there helpful people. I removed the front variator wheel (which I accidently called "flywheel" above) and there was no problem there. I'm gonna remove the cylinder this week to hopefully locate and solve the problem. In case the cylinder has been badly scratched - is there any not so expensive big bore/standard bore kit to buy instead of fiddling with the old cylinder and piston?
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 22, 2010 9:06:36 GMT -5
Thanks Torque, I have located a dealer who sells Linhai-CDIs in case I mess mine up.
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 22, 2010 15:39:52 GMT -5
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Post by jalat on Mar 22, 2010 16:35:09 GMT -5
Wow!!!! Looks bad. Is that rust in cylinder?
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kenq
Junior Dawg
Posts: 11
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Post by kenq on Mar 22, 2010 16:38:50 GMT -5
Yeah... It seems like the piston had busted the cylinder wall at some point before it was sold to me so I guess that the cooling fluid has been flowing into the cylinder. And.. umm... yeah that's pretty much it. Look at the shattered lower part of the piston.
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Post by jalat on Mar 23, 2010 1:55:42 GMT -5
There is no piston oil ring at all
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