1986-93 Suzuki RM125 ESL450 Ignition/Lighting StatorFitting Instructions
Read these instructions completely
Step 1:Take the ignition cover off. Are The Replacement Parts Similar? Compare the replacement part to the original. The replacement part should match, including the mounting hole locations. If not: Double check the application listing with your bike.
Step 2: Remove the flywheel using a proper puller. Remove the baseplate with the original stator. Disconnect the wires from the wiring loom.
Step 3: Remove existing stator coil off the baseplate and cut the wires close to the coil. Replace it with the new unit and feed the new leads though the holes in the baseplate.
Step 4: Screw the unit tight in position, as shown in the diagram, and make sure you use locking compound on the screws. TIGHTEN THE SCREWS SECURELY! Ignition Connections Suzuki RM: Connect the new BLACK lead to the original RED/ WHITE wire. Connect the new BLUE lead to the original BLACK/ RED wire. Honda CR: Connect the new BLACK lead to the original WHITE wire. Connect the new BLUE lead to the original RED wire. Yamaha YZ: Connect the new BLACK lead to the original BROWN wire. Connect the new BLUE lead to the original RED wire.
Step 5: Make sure the connections you make are good ones. Preferably you should crimp the wires using a high quality crimps. Otherwise use solder, but be aware that solder doesn’t work very well on older wiring. Lighting Connection Single YELLOW lighting output can be connected up straight to the lighting circuit. However it is better to use a 12V-AC regulator (ERG-200) parallel in circuit. The ground tag for the lighting coil can be hooked up under the base plate fitting screw. Take a look at our universal instructions for lighting coils for wiring details.
Step 6: On all applications, ensure the wires CANNOT TOUCH THE FLYWHEEL.
Troubleshooting
Engine will not start: Sometimes the source coil wires are reversed. Swap the connections, resolder the wires and the engine should start. If the engine still does not start, and before calling technical support at ElectroSport, preform a few basic tests: 1) Re-check the connections. Make sure you carefully solder the connections. Twisting wires together or taping wires will cause engine inoperability. 2) Check the engine for spark and 3) Is fresh fuel in the gas tank? If you still cannot get the engine to start, have all your testing information ready for a technician prior to calling.
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