<< Bat, Me again, I just went out and got my stock CDI and played with the connector and the Baja connector is the same kind, just not the same case. We could use the case off your stock one and put it on the Pami or RWR one and boom, your good to go. I could do it in about 5 min and it would be as good as from the factory. I was a copier repairman for 5 years so I deffinatly know how to fix and prepair plugs of all sorts for use. I would say order it. No worries what so ever. I would be glad to do it for you. Just trying to help. Let me know. >>



DemonDS,
The baja (cdi side)connector is molded to the cdi box,were you able to remove it some how?
You are right about the connector being the same style,different case though.
And your right about it being a 5 minute job,took me 10 min. I had to go get a beer

Here is my past post:
I put the RW cdi (off my other DS)on my Baja.I took my RW cdi to a automotive wiring shop,and found a female connector that matched up to the RW cdi(in a pile of old connectors)You could probably find one at a auto or motorcycle dismantler.The internal pins of connector are the same as the Baja's wiring harness connector,so it is a matter swapping out the connector(no splicing is needed)It's a 10 minute job,A paper clip works perfect for releasing the pins.
The wiring colors do not match up so here is the color to color conversion that worked for me.
RW cdi to Baja harness conn.

RW-cdi...to...Baja-wiring
red......to...red/violet
white....to...black/yellow
orange...to...white/green
black....to...black
blue.....to...black
green.........not used

I dont know if it matters wich black goes to blue,but mine worked the first time.
Hope this helps
Jeff

 

On the Carb:

I finally did my jetting last weekend and the impact driver (less than 15 bucks at Kregan) was a must have. I too stripped one of those butter screws on the top of the carb (I only have three screws there.) I used needle nose Vice Grips to get it off once I stripped it.

One of my buds brought over a set of screw drivers he got from Home Depot. We used for them for the bowl screw removal. They have black tips and rubber handles. I will be picking up a set and throwing my Craftsman ones in my wife's tool area (gotta keep here out of MY tools.)

The pipe is next on my DS. We put a ProCircuit Pipe on my buds 400EX last weekend and he was very happy with the performance.

I had been thinking of the Big Gun and talked with a guy at the Factory about their new system due out soon (removable quiet core). He was real cool and helpful. I have no doubt there have been some issues with their systems but it sounds like they have worked the bugs out. That being said, I like the idea of the ProCircuit slip on for two reasons: 1-less expensive and 2-easily removed so I could put the stock pipe on for trips to Oregon.

I wonder how much difference I will see between the pipe (ProCircuit) and the full system (Big Gun). (Knutz? What do you think?)

 

Jeff, When I was saying case, I was meaning the connector housing itself. I thought about that later, thinking I hope he didn't think I was going to remove the wireing from the CDI itself. I was just meaning, remove the pins from the connector housing and isntall them into the Stock connector housing so they will plug right in. Quite simple thing to do really. Thanks for the repost, I wrote it down for reference when we put it on his Baja. you wouldn't happen to know what kind of grease that is they use in those connectors do you? I think it is just di-electric grease but I have never seen it clear before.

 

DemonDS,
Not sure on the grease,I had an old tube of clear silicone di-electric grease but lost it(dont even remember where I got it)So I did go and buy some more di-electric grease the other day(didn't open it yet to see what color though).I have had my DS apart so many times,it was due to get the connectors lubed up again
Jeff

 

To remove those pesky carb screws, take the carb and lay it on a table, carefully take a hammer and whack the screwdriver a few times. That will loosen the screws.