What would cause a CDI to pop - Yamaha ATV Forum
 
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post #1 of 12 Old 04-13-2012, 11:54 AM Thread Starter
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What would cause a CDI to pop

I tried putting this in another thread but it wasn't getting any hits. I bought a 96 Warrior as a project. I was told it had a bad CDI. I went through the carb and got a new CDI. I hooked it all up and got to crank it over a few times. I then heard a buzzing sound like electronics burning up. I went to shut it off and before I could the CDI popped and cracked the insulating cover for the box. Now everything is totally dead. I am getting a new box but I don't want to fry the new one. I checked the stator and pickup and they all check good. I talked with RMstator and they said they had only seen this one other time but I know one of the members on this board had the exact same problem. I don't have enough posts to send a pm to see if he found out what caused his problem. Rmstator said to look at the harness I will look at it closer but I didn't see any obvious rubs on it. I don't want to start throwing parts at it and if I can't get it running I am just going to part it out. It would be a shame because the engine is in great shape. Thanks in advance for any help.
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post #2 of 12 Old 04-13-2012, 09:22 PM Thread Starter
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Well I went out and looked at it a little bit this afternoon. I pulled all the wire wrap off the harness and didn't see any shorts but I will look it over closer another day. Does anyone know if there is a test for the voltage regulator and ignition coil. I ohmed the primary of the coil it had about 100 on it. I didn't check the secondary yet. Anyone have any ideas?
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post #3 of 12 Old 04-14-2012, 08:06 AM
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I would think you have a problem somewhere in the wiring harness, but you said you already looked it over. Perhaps you should see how much voltage your battery is putting out? I think you can look at the manual and see where the power comes into the CDI, and make sure your getting 12v there as well. Also make sure your ground connections are tight and clean. If all else fails, I would replace the regulator/rectifier. Good luck. I'm having spark issues with mine right now :(
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post #4 of 12 Old 04-14-2012, 02:38 PM Thread Starter
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I am going to go over each wire and look for rubs. I have a new battery. I am just trying to think of what would pull enough amps to blow the cap or transistor in the box. I got a wiring diagram. There are only a few wires that would pull any amps that could hurt the CDI. I will keep plugging away at it. Thanks,
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post #5 of 12 Old 04-17-2012, 07:28 PM Thread Starter
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150 views and only one comment?
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post #6 of 12 Old 04-17-2012, 10:44 PM
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yeah shit some of the same problems here, mine the battery was taking a shit, so i was jump starting it, stator was charging at 13.8-14.2, i jumped it maybe 4-5 times. then went out oneday and it took like 10min of cranking before it started, was running fine i rode it for like 2 hrs then put it up, 2 days latter wont spark at all. im wanting a wire diagram for the stator, coil, cdi, and rectifier and what readings for what wires on each. i know from having blasters is that no spark is a bad stator/pulsar. my stator was keeping the bike running but dont know if having a bad battery and a spurattic voltage spike might have burned my cdi, also 99.9% of the time its not the coil. never heard any rectifier issues though
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post #7 of 12 Old 04-17-2012, 10:48 PM
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i know sometimes its hard troubleshooting electronics, im a mobile electronics installer/automotive specialist, really it would be simple if you had a voltmeter and knew what wires to test and what readings you are looking for. but that would be to easy.
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post #8 of 12 Old 04-18-2012, 12:09 PM
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bad regulator? check the regulator.
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post #9 of 12 Old 04-18-2012, 08:01 PM Thread Starter
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I will check the rectifier. From the diagrams I have seen the CDI actually acts as the regulator. I could see that being a problem if I got the thing running but I never got it to fire off before the box crapped the bed. I talked to the company and they were going to look into returns of the boxes. I wish I could have broke into the CDI and see what blew. I am going to ask the the company to look at the box when they get it. It just has me stumped because most everything going to the CDI are just signals. There is not anything really carrying any amps. That and the box blew when I just had the ignition on, nothing else was going on. I got a manual on order so I will just have to go through every part. I am beginning to wonder if the box was faulty. The other member that had the same problem bought his box from the same people and it had the same date code stamped on it. I will just have to work it out.
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post #10 of 12 Old 04-26-2012, 10:49 AM Thread Starter
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Just figured I would give an update. Got the blown cdi sent off to RMStator (never should have ordered something from Canada) I got the manual in. I just need to burn off the sheets I need and go test everything. Never did find anything in the harness.
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post #11 of 12 Old 04-27-2012, 10:36 AM Thread Starter
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Went out last night with the manual and went through the steps. Only problem found was in the coil and cap. Nothing totally bad but resistance was out of spec. Have a new one on order.
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post #12 of 12 Old 05-12-2012, 11:48 PM Thread Starter
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Turned out to be a faulty CDI. I bought one from another vendor and it fired right up.
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