Hello, I have what I think to be an AC CDI with no means of powering it. There are only one out of 10 wires the power to the CDI could be on. It's red and goes to a 4 pin connector (2x W/G, 1xR, 1xW/R). These 4 wires all go to the CDI. On the mating connector, there is only 2 wires which I believe is the pickup coil (Blue and Black). My problem is, is there a missing exciter coil to power the CDI or am I doing something wrong? I can't find much information on the CDI so am unable to see if it is AC or DC. Let me know if you need any more information i can provide to help you in this diagnosis. The quad is a 2010 Hisun HS400ATV I think it is the HS400ATV-2. Thanks!


4 pin 2 wire from stator

4 pin 2 wire from stator

4 pin 4 wire to harness

4 pin 4 wire to harness

CDI connector

It seemed weird to me that the quad would be missing an exciter coil yet use an AC CDI. The seal into where the stator is looks to have not been touched, so I don't think it has been accessed before. Strange that there are possibly two missing wires though. Help would be appreciated! Thanks

 

I would be deeply suspicious if that plug in pics 3 and 4 should plug into the stator plug at all. Once had a Yamaha with deep electrical problems, owner had removed the plastics and, after a couple of hours head scratching, I found he had needed to unplug some connectors when taking the plastics off and plugged two sets of identical wrong plugs together afterwards. How many wires are there on the other stator plug? It is quite common to feed both 3 phase (3 yellow) wires and the exciter wires through that plug. Also possible for only one wire from pickup and one wire from exciter to be needed, if other side of them is earthed.

 

Hi! Thanks for the response. By "other stator plug" I assume you mean the connector carrying 3 phases to the rectifier, that connector has 3 white wires going to the rectifier, with 5 in total coming out of the stator cover. I never thought about those 2 wires being different coils, though when I measured resistance between them there was a connection, can not remember off the top of my head what the resistance was. These 2 wires are blue and black. Would that prove the statement wrong? I currently do not have the rectifier hooked up, but the 2 wires coming out of the rectifier (Red and Black) only then go on to join with the other red wires that go to the battery and main switch with the black of course going to ground. This has really stumped me as the CDI seems to have no power source, neither DC nor AC input is going to that red wire, simply a terminated wire at the connector. I have the loom out of the bike so if you need me to test anything for more information I can do that, also reverse-engineering the wiring is easy as I have the loom on the table spread out. Thanks!

 

Like I wrote in the first post, be absolutely positive there isn't another set of identical four pin plugs that you have connected wrongly. That one with the two wires in it has two blanking plugs in the spare terminal holes, so must have been like that from new. Get a service manual if you can, I see there are lots "on-line" though they may not be for a 2010. I also note that Googling Hisun HS400 comes up with a UTV rather than an ATV. Which is it?

 

There is no identical connectors I checked, also I do have an ATV not a UTV but yes that's what shows up now. The bike is a pretty similar clone of a raptor 350 and in that diagram there is a red wire going into the 4 pin plug I posted. The wiring diagram is pretty much identical with the shapes of connectors and everything. I just don't understand why there would be no source/exciter coil but use an AC CDI. Thanks again.

 

Hello, I've made a discovery. Turns out I missed over an important wire to the CDI, the red was in fact not connected, nor was an exciter coil supposed to be there, but the power comes into a red/black wire through the kill switch. I got too used to conventional colours and missed out on this wire. I'm reasonably sure it's a DC CDI now and will continue to work on it now. I will return to this thread if more help is needed. Thanks, merryman for the help!

 

Hondas use that power coming through the kill switch idea, logical when you think about it, for DC CDI systems. Still seems odd to run those extra wires to the trigger coil plug, then not use them. I guess they must have designed the loom for AC, then changed their minds.

 

Yeah, that's what I'm going with for now. Possible it's a mass manufactured universal-ish loom

 

Happy to report that there was indeed a damaged wire between the kill switch and the CDI. I now have more functions working in the dash namely reverse indicator light. We are now powering the CDI and it is also sending a signal to the starter relay, though i broke it by accident. This has been a real learning curve but have learned some great stuff.