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The black wire with the yellow stripe goes from the CDI unit to the coil. It will have a minimum 150 volt pulse each time the pulse generator tells the CDI to fire the spark plug. The pulse is milliseconds in length and has to be checked with an oscilloscope or a peak voltage tester.
What you are trying to do is fix something without having the right tools. It's like trying to to catch a mosquito with a fish net.
There's only 5 parts to the ignition system; alternator, pulse generator, CDI box. coil and wiring. Forget about the switches and concentrate on the basics.
You said you got a new coil and a new CDI - the coil is just a transformer and easily tested - where did you get the CDI box?
There are no tests for the CDI box other than replacing with a known good one. With an o-scope or a peak voltage tester you can measure and observe the inputs and outputs at the CDI box.
Precautions listed in the service manual: 1) Never disconnect any electrical connections when the engine is running 2) Apply Dielectric grease to all electrical connectors prior to reconnecting them to help seal out moisture 3) Make sure all electrical connectors are free of corrosion and are completely coupled to each other 4) Do not substitute another type of ignition coil 5) The DC-CDI unit is mounted within a rubber vibration isolator. Always be sure that the isolator is in place when installing the unit.
NOTE: Honda does not provide any service specifications for testing the DC-CDI unit. They provide only test procedures for the components within the ignition system.
First there should be 6 wires going to the CDI unit (4 wires in one plug and 2 wires in another plug.
You need 12 vdc on the blue wire with the white stripe (or black wire with a white stripe) at the CDI box (the wiring diagrams in the service manual indicate a black wire with a white stripe in one drawing and the b/w wire changing to a blue/white wire in another drawing) - if you have this, you have just eliminated the kill switches, fuses and battery as a problem.
You should have 12 vdc on the gray wire at the CDI box - if you do not have voltage on the gray wire, check the clutch diode in the wiring harness
There should be 18-45 vac on the yellow wire with the white stripe when the engine is cranking or running
There should be a pulse from the pulse generator on the blue wire with the yellow stripe
Dark green should have continuity to ground
The black wire with the yellow stripe goes to the coil
If the coil is new and the CDI is new that only leaves the pulse generator, alternator stator and the wiring
A friend of mine was troubleshooting a no spark issue on his 86 XR200-RFVCC many years ago. He used my meters and the Honda service manual - the only part that tested good was the stator, so he replaced the pulse generator; still no spark - he then replaced the coil; no spark - he replaced the CDI unit; no spark - he replaced the stator; SPARK!. He put the old parts back on one at a time, still had spark - it turned out the only part that tested good was the bad one.
Good luck, I think I have detailed the entire procedure to help you get your ignition system fixed. NOTE: all testing should be done with a new spark plug.
PS - in my previous post I mis-identified a the gray wire as a green wire
Last edited by Here 2 help; 06-09-2018 at 05:20 PM.