2009 FYM AGM F450R
Engine: Subaru 450

I did not have spark and assumed it was the CDI, ordered a CDI and plugged it in today






old CDI
, the entire wiring harness started smoking!
I assume there is a short (no smoke with previous CDI) but I'm not certain, I would like to chase down every individual wire on the machine, but I just don't have the knowledge of exactly what everything does.
Of note: I just picked this machine up, seller sold due to no spark. The bike doesn't have head lights only a tail/brake light. I've searched the net high and low for a wiring diagram for this machine.
I'll try and add a few photos.
Any help is greatly appreciated!!!

New CDI

 

Lots of wires not wrapped, as they would be in the original loom. Several cut and joined, evidenced by the insulation tape, and a CDI made for an LTZ400. You need to be good at wiring to tackle it. Get the LTZ400 wiring diagram and try to trace how the CDI works from that. I expect the colours are totally different, Suz use black/white for earths and I suspect this one uses green, which makes life more difficult, but knowing what each wire does is vital in order to do any diagnostics.

 

When searching for an exact match for the CDI the LTZ was the only thing that populated. After the new CDI was plugged in and it started smoking I started unwrapping the harness to check for damage and also try and follow each wire (there was no loom just the cheap chinese electrical tape). For the joints it only appears that there are 2 (green & black) wires that have been cut, the other joints are typical of a Chinese harness with several wires crimped together in different locations. I'm a great mechanical guy but I may have gotten over my head with this electrical problem. Youre correct on wire colors, it appears greens are ground and from what I can tell blacks are positive. I'm currently searching methods to test the CDI, Rectifier, Coil, and Stator in hopes that I havent damaged anything.

 

You can't test the CDI. Stator tests are written up in the "help diagnose stator" sticky on here, but resistances and voltages vary from make to make, so are a guide, open circuit or no resistance where there should be some is bad, some resistance, probably good. Rectifier doesn't affect spark directly so forget it for now.

 

For the life of me I just cant figure this things out, I was able to chase the wires and determine the cause of the smoking harness, there was a blk/white strip wire connected to a ground, I'm assuming this was a mistake on the previous owners part. I was however concerned as to why it didnt smoke with the old cdi. I did a quick voltage test on this wire with each CDI, the old CDI only had 4.5 volts but the new CDI was sending 12.3 to this wire. Does this sound like a bad CDI or is the new CDI pushing to many volts ??

Is there any rime or reason to the wire colors on these bikes?

 

Honda use green for earth, black/red for power from stator for AC CDIs, blue/white for trigger coil, blue/yellow or black/yellow for CDI to ignition coil and black/white for kill wire. Chinese makers tend to use the same. I can't understand the fascination with voltage on the kill wire, on most AC CDIs it is open circuit until you switch the ignition off, then it is earthed. On DC CDIs Honda used it as the pos wire to the CDI, so engine stops when this pos is switched off, other makers have different ideas.

 

Update:
I went back over the harness mutiple times and checked every joint, connection, and pin. I didnt find anything that appeared to contribute to the no fire issue. I pulled the cover and inspected the stator and pickup coil. both appeared to be in good shape, I removed both from the case tom inspect the connects on the underside. All connections appeared to be good. I wiped everything down and reinstalled and BOOM I now have spark. I'm not certain what was preventing spark but I now have it. Unfortunately I now have a host of other issues with the carb and oil coming out of the crank case vent. Seems to be never ending