I rebuilt the motor on my trailboss and had to change the bottom end. This meant unhooking the wiring harness that goes up under the hood. Since then I ahve burne dout a couple cdi's. I put a voltmeter on the battery and started it and the voltage goes up to 30 volts when I rev it a little. Any ideas what could be hooked up wrong. I double checked my wiring, Changed my regulator/module box and things are no better. Any ideas. Thanks Tony

 

You may have inadvertently caused damage to your stator during your rebuild. If it is shorting out it could start throwing to much voltage rather than not enough as one would expect to see. It's not very common but can happen.

 

Got my voltage right, It was a bad meter and readings. Still if I rev the motor any the cdi wiull smoke and get hot. When I was rechecking voltage I saw smoke and turned off key. Moter would not turn off and I had to choke it to kill it. So voltage is ok but something is burning the cdi. Most of the connections are different enough to not confuse them, spade, bullet, plugs. Could anything else be causing this. Stator was in motor I got and I still have the original. HSould i change it. COuld it be sorting the cdi and not putting off bad voltage? Thanks Tony

 

If your voltage is right and your not seeing any voltage spikes I'd be tracing wires to see if any have bare spots and grounding against the frame or what-not. Not to mention check all your ground wires for good connections.

 

start checking grounds

 

either that or you got some pinched wires or hooked up wrong.