TZR-V4 Electrics

Olivier Patrouix

For references, here are the wiring diagrams of the TZR250 and the RD500LC
TZR 250 wiring diagram and legend
RD500LC wiring diagram and legend

Decision not made yet but I think I'll order wiring components from Vehicle Wiring Products in the UK.

Rectifier

The rectifier unit is the same on both bikes RD500LC-TZR250 : 5 contacts (4 wires+case).

TZR250 / RD500LC (FZR400RR) Rectifier
Connector : 4 ways + case	Cable color	Yamaha color code
To batteries / main fuse / ignition switch	red	R
Magneto	white	W
Magneto	white	W
Magneto	white	W
Ground / Rectifier case	black	B

Stator

On the stator loom there is :

magneto,
pick-up coil
neutral switch

Here is a tab for comparison TZR250 / RD500LC

Connector	TZR250			RD500LC			Connector
	Cable color	Yamaha color code	signal	Cable color	Yamaha color code	signal	anti-clockwise
2 ways (2.8mm blade)	White/Green	W/G	Ignition coil	White/Green	W/G	Ignition coil	1 bullet
2 ways (2.8mm blade)	White/Red	W/R	Ignition coil	White/Red	W/R	Ignition coil	1 bullet
3 ways (6.3mm blade)	White	W	Magneto	White	W	Magneto	1/ 8 ways
	White	W	Magneto	White	W	Magneto	2/ 8 ways
	White	W	Magneto	White	W	Magneto	3/ 8 ways
1 bullet	Sky Blue	Sb	Neutral switch	Sky Blue	Sb	Neutral switch	4/ 8 ways
3 ways (round terminals)	Brown	Br	CDI magneto	Brown	Br	CDI magneto	5/ 8 ways
	Green	G	CDI magneto	Green	G	CDI magneto	6/ 8 ways
	Red/White	R/W	CDI magneto	Red/White	R/W	CDI magneto	7/ 8 ways
				Black	B	Ground	8/ 8 ways

CDI

I'll try sort this part of the wiring loom (left picture TZR CDI, right picture RD's CDI and loom).

Here is a tab to compare the CDI units from the TZR250 and the RD500LC.

Connector	TZR250			RD500LC			Connector
	Cable color	Yamaha color code	Signal	Cable color	Yamaha color code	Signal
4 ways	orange	O	Output to coil	orange (x2)	O	Output to coil (front and rear)	7 ways
	black	B	Ground	black	B	Ground
	black/white	B/W	kill switch ignition switch ignition control switch
	black/yellow	B/Y	To YPVS control box To tachometer	black/white		To YPVS control box To tachometer
3 ways	Green	G	CDI magneto	Green	G	CDI magneto
	Red	R	CDI magneto	Red	R	CDI magneto kill switch ignition switch
	Brown	Br	CDI magneto	Brown	Br	CDI magneto
1 bullet	White/Green	W/G	Pick_up coil	White/Green	W/G	Pick_up coil	1 bullet
1 bullet	White/Red	W/R	Pick_up coil	White/Red	W/R	Pick_up coil	1 bullet

Value table

Here is tab to compare the value of coil's resistor according to manuals. From this point I think I'll test the TZR250 CDI and stator before doing any modificatinos to the loom.

Designation	TZR250	RD500LC
pick-up coil (W/R-W/G)	94-140 Ohms	112 Ohms +-20%
Source coil 1 (G-Br)	128-193 Ohms	127 Ohms +-20%
Source coil 2 (Br-R)	3.6-5.4 Ohms	18 Ohms +-20%
Ignition coil primary	0.26-0.4 Ohms	0.67 Ohms +-20%
Ignition coil secondary	4.7-7.0 kOhms	12.0 kOhms +-20%
Spark cap	10 kOhms (x2 per coil)	5 kOhms (x2 per coil)

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