Malossi CDI # M558133 Install instructions

[XPS1210]

okay, to start sorry this wasn't posted faster...

I can't post it in the moderator How To's yet... So this'll probably move in the near future!

Here goes...



Alright the relay that is needed is called a single pole double throw relay... It has terminals 30, 85, 86, 87, 87A

step 1, remove cover with headlights, there are 10mm bolts on the front of the scooter and 2 phillips screws on the black side above the ignition. Remove cover and unplug the 2 headlight wires.

Step 2, remove battery cover, seat, cover over cylinder, rear rack and the left side cover (all will come off with phillips screw driver, 10mm socket and a 5mm hex wrench).

Step 3, remove screw that holds stock cdi unit in place. Unplug the 4 wires from the stock cdi. plug wires into the new cdi unit (expect the black/white wire) , and mount on the screw where original cdi was.

Step 4, run a new wire from the black/white wire of the cdi to the ignition area. hook this wire to number 87A on the relay.

Step 5, splice wire into brown wire on ignition switch and connect to the number 86 on relay.

Step 6, unplug the black/white wire from the ignition switch and connect the switch wire to number 85 on relay.

Step 7, unscrew the the bolt that holds the horn on and hook a new wire to it as a ground wire, then tighten the bolt down. Run this wire to number 30 on the relay.

Step 8, start scooter to make sure it will run. Note, the new cdi will no longer all the thumb kill switch to work. The only way to kill the engine is by using the key!

Step 9, mount relay with a zip tie. Reinstall the headlight cover, remember to plug the headlights back in.

Step 10, reinstall the seat, cylinder cover, left side panel and rear rack.

It sounds more detailed than it really is... and I added a mile or so per hour on the top end (that's with changed gears, a stock one might be better off)... Also mine runs better with less bogging on the bottom end...

[vailitrev]

Is the relay something you had to purchase? Or did you use an existing one?
Great post. I've learned alot from this forum and saved a ton of money
Thanks EVERYONE!!!!

[XPS1210]

the relay is one that you need to go and buy... It took forever for me to figure out which one it needed...

basically there are 2 styles of 5 prong relays that look almost alike...

one has 2, 87's (both turn hot when the relay is powered, and not the right kind) the other has 1, 87 and 1, 87a (this turns 87 on when hot and 87a (on) when off...) allowing for the proper grounding to kill the scooters engine when the key is turned off..

[XPS1210]

here is what the pic on the relay needs to look like

[XPS1210]

here is a diagram of how the relay works... as you see when powered the relay switches to the 87 and powers that outlet...

When it is not powered it grounds the 87a outlet

[XPS1210]

This Is The Wrong Relay Don't Buy This One!

[XPS1210]

sorry that pic is to HUGE! oops... but you can see that the one I said not to get just has 2 87's taht are hot when it's powered... That is not what is needed for this application...

[Booya]

On step #5, You say to splice a wire into the brown wire. Does this mean to cut and interupt the circut to where the brown wire goes to, or jump a wire on the brown wire and leave it conected. Then use the new jumped wire and connect to # 86 on the relay?

[pinkymingeo]

This is only slightly off the topic. For the same bucks as the Malossi CDI you can get the TP retarding CDI. Requires the same relay, as does every CDI on the planet except the Yamaha stock. The TP shines on scooters that don't rev above the mid-10's, and most don't. You probably won't notice the Malossi switchover at all, but the TP gives a very noticeable acceleration increase.

[Booya]

Can you get one at provoscooter?

[XPS1210]

On step #5, You say to splice a wire into the brown wire. Does this mean to cut and interupt the circut to where the brown wire goes to, or jump a wire on the brown wire and leave it conected. Then use the new jumped wire and connect to # 86 on the relay?


do not cut the wire, simply use a in-line wire clamp and clip a new wire to it... or you can strip the plastic and then tape over the bare wires... but it needs to be left intact..

[Booya]

Thank you very much. Now to finish this last step.

[Flateric]

Where can we buy the "TP retarding CDI"? Does it work on a Yamaha Zuma 2005?

[XPS1210]

you will have to do internet searches for them...as links are not allowed in the forums... sorry

[D-Rocker]

I need help figuring out what the "single pole double throw relay... that has terminals 30, 85, 86, 87, 87A" is? I bought the Malossi TC Ignition Unit

[XPS1210]

thats the correct one... you need to wire it like the discripition says in the first couple posts...

the 30 is a ground wire and can go to a ground on the scooter frame.

86 goes to the brown ignition wire just splice into the line (don't cut it in half or anything)

85 you take the black/white ignition wire and put it into this spot (eliminating the stock b/w wire)

run a new wire from the 87A to the CDI's B/W wire and fire it up...

for some reason you can't use the stock b/W wire on the scooter to the CDI as it must have other connections in line that mess it up... you MUST run a new wire...


you are running this on a newer zuma right? For other scooters I'm not sure what needs to be done to make them work...as the yamaha CDI's are unique and backwards from everyone else... I think they are plug and play on most other models...

[D-Rocker]

Where do I buy a RELAY?

[XPS1210]

an auto parts store or radio shack...

[ScooterJim]

Relay---- NAPA.

[XPS1210]

as said in the original posts... make sure it's the 87 and 87a relay... if you get a double 87 87 relay you'll be fighting yourself for no reason....and it will never work...

[pinkymingeo]

I decided to get rid of my TP CDI after all. Somebody was looking. PM me.