CD-77 Instructions - Stevens Instrument
Contents
1. Using one of the Stevens adaptors precludes the need for jumpers on most engines Remember that switch positions on SA 77 SA 5 and SA 6 adaptors ON or OFF are critical to obtaining proper test results The CD 77 may be used to read peak voltage on any engine for which peak voltage or DVA specifications are available In addition the following instructions cover all basic types of OMC CD systems from early battery CD to early 90 s SENSOR NOTE All original peak voltmeters were made with a Sensor position SEN This position is more sensitive on the CD 77 than on other brands so you may expect unusually high readings on some engines This is okay as long as readings meet the minimum spec Some manuals call for testing sensors on the POS position This is only to accommodate testers which lack a sensor position continue to use the SEN position on the CD 77 for all sensor tests SYSTEM TYPE PAGE Battery CD 2 Pack Terminal Systems Magneto CD with screw terminals on pack 2 CONNECTOR SYSTEMS 4 11 2 amp 4 cylinder through 1988 Except 1988 Loop V 4 3 amp 6 cylinder through 1988 Except 1988 Loop V 5 V 8 through 1987 7 1987 90 2 5 Ultra 4 Excel 4 Mag CD single pins on pack external magnets 8 1989 90 2 cylinder CD2 UL Mag CD pack under flywheel 8 1989 90 3 cylinder 9 1988 90 Cross V 9 1988 90 Loop V 11 Heads Up When using a spark checker be sure it is an open gap tester and not one w2. SPARK TEST Remove high tension leads from spark plugs and connect to spark checker Spark checker remains connected for all other tests Set gap to inch Crank engine If spark jumps each gap alternately ignition system is okay Check spark plugs and other engine systems If no spark go to key switch or stop button elimination test in service manual If spark at only one gap go to resistance tests for charge coils and sensor coils in service manuals CHARGE COIL OUTPUT TEST Set Meter NEG 500 Disconnect connector between armature plate and pack Insert probes in connector from armature plate 2 cylinder pre 1985 4 wire Red to A Black to D 2 cylinder 1985 and later 5 wire Red to A Black to D V 4 2 wire Red to A Black to B Crank engine Meter should read minimum 2 cylinder 230 V 4 pre 1985 160 V 4 1985 and later dual pack 150 single pack 175 Cross V 1988 150 If reading okay check for short to ground If no reading replace charge coil If low reading check resistance of charge coil If resistance low replace charge coil If resistance okay replace flywheel CHARGE COIL SHORT TO GROUND TEST Set Meter NEG 500 Use same connectors as for Output Tests above Connect black probe to stator base Connect red probe to 2 cylinder A then repeat to D V 4 A then repeat to B Crank engine If there is any reading charge coil is shorting to ground If there is no reading go to Sensor Tests SENSOR OUTPUT TEST Set Mete
3. ignition system is okay For high speed or intermittent problem see service manual If there is no spark or poor spark go to stop button elimination test in manual SENSOR COIL GROUND TEST Set Meter SEN 5 Disconnect sensor leads from pack Connect meter black probe to engine ground Connect red probe to one of the sensor leads and crank engine Repeat with red probe connected to other sensor lead Any reading on either test indicates a grounded sensor coil or lead Locate and repair ground or replace sensor coil as required SENSOR COIL OUTPUT TEST Set Meter SEN 5 Connect meter red probe to one sensor lead and black probe to other sensor lead Crank engine Reverse leads and repeat test Meter should read 4 volts or higher on both tests If not check condition of wiring and connectors If okay make sensor coil resistance test See manual POWER PACK OUTPUT TEST Set Meter NEG 500 Remove primary leads from ignition coils Install TS 77 terminal extenders and connect primary leads to extenders Connect meter black probe to engine ground Connect red probe to metal part of extender on 1 ignition coil Crank engine and read meter Repeat with red probe connected to extender on 2 ignition coil Reading should be 125 volts or higher on both tests If reading is low remove primary lead s from extender Connect red probe to spring clip in boot of primary leads Crank engine and take a reading If reading is 125 volts or higher check ignition c
4. STEVENS INSTRUMENT GOMPANY Instructions Model CD 77 Peak Reading Voltmeter 111 W Greenwood Ave Waukegan IL 60087 phone 847 336 9375 fax 847 662 6808 email stevensinstrument tds net GENERAL INFORMATION The CD 77 is a peak reading voltmeter often referred to as DVA designed specifically for testing CD ignition systems The meter has three scales 0 5 0 50 and 0 500 corresponding to the settings of the right hand range selector switch The left hand switch selects sensor position for measuring trigger voltages and the other two positions select polarity of the voltage to be measured either positive or negative The test leads have pin type terminations which can be plugged directly into the connectors used with the OMC connector type systems A plug in clip is also furnished with the black test lead for use when it is necessary to clip to a ground Overload protection is provided by an internal protection circuit however if the needle swings hard against the right end of the scale or vibrates against the left end of the scale disconnect or stop cranking as quickly as possible and recheck switch settings and connections Jumper wires are furnished for tests on the connector type systems Three of the jumpers have single terminals for straight through connections between plugs The other two jumpers are piggy back types with an extra terminal so that the meter can be plugged in for readings with the system in operation
5. ack terminals POWER PACK OUTPUT TEST Set Meter NEG 500 Connect black meter lead to engine ground POWER PACK II POWER PACK III POWER PACK IV Connect red probe to power pack Connect red probe to power pack Connect red probe to power pack terminal 2 and crank engine Meter terminal 1 and crank engine Meter terminal 3 and crank engine Meter should read 180 or more Repeat with should read 170 or more Repeat with should read 170 or more Repeat with red probe at terminal 3 red probe at terminals 2 and 3 red probe at terminals 5 10 amp 11 Readings okay but still no spark check ignition coil s If pack readings low disconnect coil primary from pack one at a time and connect red probe to terminal Crank engine If reading low pack is defective If reading okay check ignition coil s If coil s okay pack is defective FINAL TEST Make a final spark test of the entire ignition system with all leads connected to the power pack CONNECTOR SYSTEMS 2 amp 4 cylinder through 1988 except 1988 Loop V The following is a systematic procedure for checking the CD II ignition system Whenever possible it is recommended that service manual procedures be followed An additional test in the V 4 manuals covers Rough Running Engines Readings used here are based on hand cranking through 1984 and on starter cranking thereafter VISUAL INSPECTION Check wiring for broken pinched or loose leads connector misalignment etc
6. amp D on both connectors Crank engine with red probe at each terminal Any reading indicates sensor coils or leads are grounded Locate and repair ground or replace timer base SENSOR COIL OUTPUT TEST Set Meter SEN 5 Using same connectors as above connect meter probes Reading V4 Black to E Red to A B C amp D 3 V6 9 Amp Black to timer base ground lead Red to A B C D E F 2 V6 35 Amp Black to port timer base connector D Red to A B C 2 Repeat for starboard Additional test for V6 35 Amp Connect jumpers between D terminals of port connector and between D terminals of starboard connector Connect black meter probe to engine ground Connect red probe to A B amp C of port and starboard connectors cranking each time Reading should be 1 2 If readings okay go to power pack test If low check wiring and connectors If wiring and connectors okay make sensor coil resistance test See manual POWER PACK TEST Set Meter POS 500 Remove primary leads from ignition coils Connect Stevens PL 88 load adaptor red clip to 1 primary lead and black clip to engine ground Connect meter red probe to adaptor red lead and black to engine ground Crank engine Repeat with PL 88 and meter connected to remaining primary leads Readings should be 150 for V4 and 175 for V6 If okay check ignition coils If one primary lead has no output replace power pack 10 1988 90 Loop V Note Cranking output tests musts must be performe
7. ct red probe to timer base connector terminal A Crank engine Repeat with red probe connected to terminals B C amp D Any reading indicates sensor coils or leads are grounded Locate and repair ground or replace timer base SENSOR COIL OUTPUT TEST Set Meter SEN 5 Connect meter black probe to timer base connector terminal D Connect red probe to terminal A Crank engine Repeat with red probe connected to terminals B and C Reading 3 V or higher go to power pack test Reading below 3 check wiring and connectors If wiring and connectors okay make sensor coil resistance test See manual POWER PACK TEST Set Meter POS 500 Remove primary leads from ignition coils Connect Stevens PL 88 load adaptor red clip to 1 primary lead and black clip to engine ground Connect meter red probe to adaptor red lead and black probe to engine ground Crank engine Repeat with PL 88 and meter connected to numbers 2 amp 3 primary leads If reading is 230 or higher check ignition coils If one lead has no output replace power pack 1989 90 Cross V Note Cranking output tests must be performed with spark plugs installed and properly torqued SPARK TEST Remove high tension leads from spark plugs and connect to spark checker Set gaps V 4 1 2 V6 7 16 If equipped install emergency ignition cutoff switch clip and lanyard Crank engine If there is good spark on all cylinders ignition system is okay See note below If there is go
8. d and go to Charge Coil Test Spark on only one ignition coil one problem is in key switch or switch lead Repair problem and go to Sensor Test CHARGE COIL OUTPUT TEST Set Meter NEG 500 POWER PACK II POWER PACK III POWER PACK IV Remove brown lead from power pack Remove brown lead and brown orange Remove brown lead and brown yellow terminal 1 Connect red probe to brown stripe lead from terminals 4 amp 5 Connect stripe lead from terminals 7 amp 8 Connect lead Connect black probe to engine red probe to brown lead Connect black red probe to brown lead Connect black ground probe to brown orange probe to brown yellow Crank engine Meter should read 230 or higher If reading okay charge coils okay If reading low check resistance of charge coils If resistance out of spec replace charge coils If resistance okay replace flywheel POWER PACK II POWER PACKS III AND IV Reconnect brown lead to terminal 1 and Continue with charge coil short to go to Sensor Test ground test CHARGE COIL SHORT TO GROUND TEST Set Meter NEG 500 Connect black meter lead to ground and leave red meter lead connected to brown wire Crank engine Move red meter lead to other charge coil lead brown orange or brown yellow and repeat If no meter reading on both checks charge coils are okay Go to Sensor Test If there is any meter reading above zero charge coils are grounded Reconnect charge coil leads to power pack SENSOR COIL OUTPUT TEST Set Me
9. d with spark plugs installed and properly torqued SPARK TEST Remove high tension leads from spark plugs and connect to spark checker Set gap to 7 16 If equipped install emergency ignition cutoff switch cap and lanyard Crank engine If there is good spark on all cylinders ignition system is okay See note below If there is good output on at least one cylinder V4 go to Sensor Coil Test V6 amp V8 go to Charge Coil Test If there is no output on V6 cylinders 1 3 amp 5 or on V8 cylinders 5 thru 8 go to shift switch test in manual If there is no output at all go to stop circuit test in manual Note See service manual for running test if high speed or intermittent problem exists Also the ignition system may have good output and still have a problem See manual for other possible sources of ignition trouble CHARGE COIL GROUND TEST Set Meter POS 500 Separate 2 wire connector two connectors on V6 amp V8 Connect meter black probe to engine ground Connect red probe to A then B both connectors on V6 and V8 Crank engine with red probe at each connection Any reading indicates charge coil is grounded Locate and repair ground or replace stator assembly CHARGE COIL OUTPUT TEST Set Meter POS 500 Using same connectors as above connect black meter probe to A red to B both connectors on V6 amp V8 Crank engine Readings V4 175 V6 amp V8 130 If reading okay go to sensor coil test If low check wiring and c
10. eading 2 cylinder Pre 1985 BtoB CtoC Red to B repeat to C 180 85 and later N A Red to each output 200 V 4 pre 1985 AtoA BtoB Red to A repeat to B 160 1985 and later dual packs N A Red to each output 150 single pack N A Red to each output 175 black to ground on all engines Crank engine If reading okay but no spark check coils If reading low check with no load coils disconnected If reading still low pack is defective If reading okay check ignition coils If coils okay pack is defective 3 amp 6 cylinder through 1988 except 1988 Loop V VISUAL INSPECTION Check wiring for broken pinched or loose leads connector misalignment etc SPARK TEST Remove high tension spark plug leads at spark plugs and connect to spark checker Set gap on spark checker to 1 2 for 3 cylinder 7 16 for 6 cylinder Crank engine If spark jumps each gap alternately ignition system is okay Check spark plugs and other systems If no spark or poor spark see key switch test in service manual Spark checker remains connected for all other tests Prior to testing see Service Manual for Rough Running Engine test V 6 only CHARGE COIL OUTPUT TEST Set Meter NEG 500 Disconnect 2 wire connector 3 wire on 1985 and later 3 cylinders between stator and pack Insert meter red probe in cavity B and black probe in cavity A of connector from stator Crank engine Meter should read 3 cylinder pre 1985 220 If reading okay chec
11. ectors and proceed with Power Pack Test POWER PACK OUPUT TEST Set Meter NEG 500 Disconnect 4 wire connector or individual leads from pack to coils Connect piggy back jumpers from A to A Bto Band CtoC or reconnect individual leads with TS 77 terminal extenders Connect black probe to stator ground red probe to jumper at A or to terminal extender Crank engine Meter should read 3 cylinder 230 V 6 pre 1985 170 1985 175 1986 88 150 175 175 1986 amp 1987 200 225 100 Repeat test for remaining outputs terminals B amp C in 4 wire connectors If reading okay but still no spark check ignition coil s If reading low remove jumper or terminal extender and connect probe directly to connector or turn off switch on adaptor If reading still low pack is defective If reading okay check ignition coil s If coil s okay pack is defective V 8 through 1987 The V 8 ignition system has two identical power packs the port side for top cylinders 1 4 and the starboard side for cylinders 5 8 Both should be tested in the same way This test procedure is for engines which are hard to start or will not start See service manual for engines which have a high speed miss or run inconsistently above cranking speed VISUAL INSPECTION Check wiring for broken pinched or loose leads connector misalignment etc SPARK TEST Remove high tension leads from spark plugs and connect to spark checker Set gap to 7 16 Install emerg
12. ency ignition cutoff switch cap and lanyard Crank engine If spark jumps each gap alternately ignition system is okay Check spark plugs and other engine systems If no spark or poor spark on all cylinders see stop circuit test in service manual If no spark on cylinders 5 through 8 see shift switch elimination test in service manual CHARGE COIL SHORT TO GROUND TEST Set Meter Neg 500 Disconnect 2 wire connector between stator and pack Connect black meter probe to engine ground red probe to cavity A of stator connector Crank engine and observe meter Repeat with red probe to cavity B If there is any reading the charge coil or its leads are grounded Repair ground or replace stator assembly CHARGE COIL OUTPUT TEST Set Meter NEG 500 Connect black meter probe to cavity A red probe to cavity B of stator connector Crank engine If meter reads 130 or higher continue with sensor tests If reading is below 130 check component wiring and connectors Refer to service manual for charge coil resistance tests SENSOR COIL SHORT TO GROUND TEST Set Meter SEN 5 Disconnect 5 wire connector between armature plate and pack Connect black meter probe to engine ground red probe to cavity A of armature connector Crank engine and observe meter Repeat test with red probe to cavities B C D amp E Any reading means sensor coils or their leads are grounded Locate ground and repair or replace timer base assembly SENSOR COIL OUTPUT TEST Se
13. hich sparks across the surface of a board Sparks burn a carbon path on boards allowing a very weak spark to look good Gap settings on such a spark checker are meaningless BATTERY CD Following is a general test procedure for battery CD systems Refer to manuals or diagrams for specific engines if additional information is required Note Battery should be fully charged before proceeding with tests The CD 77 is not a DC voltmeter and will read slightly lower than actual voltage Take an initial reading directly across a fully charged battery to determine the exact CD 77 reading PACK INPUT TEST Set Meter POS 50 Connect black test lead to engine ground Connect red test lead to pack input wire with pack connected With ignition on reading should be same as battery voltage approximately 11 or more Crank engine Reading should not drop more than 2 volts If there is no voltage or low voltage at pack input trace back point to point with red test lead through connectors terminals wires ignition switch etc safety switch or voltage suppressor on some models to locate point of failure PACK OUTPUT TEST Set Meter POS 500 Connect black test lead to engine ground Connect red test lead to coil primary leaving coil connected Coils should remain connected to avoid damage to packs Crank engine Reading should be 250 volts or higher If no reading Sensor Substitute a test sensor and activate If reading is okay with test sens
14. k for short to ground 3 cylinder 1985 and later 250 If no reading replace charge coil 6 cylinder pre 1985 160 If low reading check resistance of charge coil 6 cylinder 1985 and later 150 175 200 If resistance low replace charge coil If resistance okay replace flywheel 200 225 130 CHARGE COIL SHORT TO GROUND TEST Set Meter NEG 500 Using same connectors as above connect meter black probe to armature plate ground red probe to connector terminal B Crank engine If there is any meter reading charge coil is shorting to ground Repeat with red probe to terminal A Reconnect and proceed with Sensor Tests SENSOR OUTPUT TEST Set Meter SEN 5 NOTE Because of its sensitivity on Sensor setting the CD 77 will generally read considerably higher than the figures given in the service manuals particularly on smaller engines where cranking speeds are higher Disconnect 4 wire connector from stator to pack Connect red probe to terminal A of connector from stator Connect black probe to D Crank engine Repeat with red probe to B and again to C Meter should read 3 cylinder thru 1985 4 1986 1988 3 V 6 pre 1985 25 V 6 1985 amp later 150 175 2 200 225 3 If reading okay check for Short to Ground No reading defective sensor SENSOR SHORT TO GROUND TEST Set Meter SEN 5 Crank engine with black probe to stator ground and red probe to A B C then D Any meter reading means sensor is shorting to ground Reconnect 4 wire conn
15. nition coils Connect Stevens PL 88 load adaptor red clip to 1 primary lead and black clip to engine ground Connect meter red probe to adaptor red lead and black probe to engine ground Crank engine Repeat with PL 88 and meter connected to remaining primary leads Reading should be 150 for V4 and 100 for V6 amp V8 If reading okay check ignition coil s If one primary lead has no output replace pack 11
16. od output on at least one cylinder V4 go to Sensor Coil Test V6 go to Charge Coil Test If there is no spark go to stop circuit test in manual Note See service manual for running test if high speed or intermittent problem exists Note also that the ignition system may have good output and still have a problem See manual for other possible sources of ignition trouble CHARGE COIL GROUND TEST Set Meter POS 500 Separate connector between stator Connect meter black probe to engine and pack ground red probe to V4 2 wire A then B V6 9A 4 wire A then B C amp D V6 35A 6 wire A then B C amp D Crank engine with red probe at each connection Any reading indicates charge coil is grounded Locate and repair ground or replace stator assembly CHARGE COIL OUTPUT TEST Set Meter POS 500 Using same connectors as above connect meter black probe to terminal A red to B On V6 repeat with black to C red to D Crank engine Reading should be 150 on V4 200 on V6 If okay go to sensor coil test If low check wiring and connectors If wiring and connectors okay make charge coil resistance test See manual SENSOR COIL GROUND TEST Set Meter SEN 5 On V6 9 Amp disconnect timer base ground lead from powerhead and isolate Separate connector between timer Connect meter black probe to engine ground base and pack red to V4 5 wire A then B C D amp E V6 9 Amp 6 wire A then B C D E amp F V6 35 Amp two 4 wires A then B C
17. oil If reading is low check spring clip in boot and primary wire If these are okay replace pack 1989 90 2 cylinder CD2 UL Pack under flywheel Note Cranking output tests must be performed with spark plugs installed and properly torqued SPARK TEST Remove high tension leads from both spark plugs and connect to spark checker Set gap to 1 2 If equipped install emergency ignition cutoff switch clip and lanyard Crank engine If spark jumps each gap alternately ignition is okay See note below If there is no spark go to stop circuit test in manual If there is spark on one cylinder go to output test Note See service manual for running test if high speed or intermittent problem exists Also ignition system may have good output and still have a problem See manual for other possible sources of ignition trouble OUTPUT TEST Set Meter POS 500 Remove primary leads from ignition coils Connect PL 88 load adaptor red clip to 1 primary lead and black clip to engine ground Connect red meter probe to adaptor red lead and black probe to engine ground Crank engine Repeat with PL 88 and meter at 2 primary lead Readings should be 175 volts If both outputs are okay test ignition coils If one lead has no output replace ignition module If both leads have no output make charge coil resistance test See manual 1989 90 3 cylinder Note Cranking output tests must be performed with spark plugs installed and properl
18. onnectors If okay make charge coil resistance test in manual SENSOR COIL GROUND TEST Set Meter SEN 5 Separate connector between timer Connect meter black probe to engine ground red probe base and pack to each timer base terminal V4 5 and 4 wire 5 and 4 V6 2 4 wires Both 4 s V8 2 5 wires Both 5 s Crank engine with red probe at each connection Any reading indicates sensor coils or leads are grounded Locate and repair ground or replace timer base SENSOR COIL OUTPUT TEST Set Meter SEN 5 Using same connectors as above connect meter probes as follows for readings shown at right V4 Black to E of port connector red to A B C then D of both connectors 0 5 V6 Black to D of port connector red to A B then C of both connectors 0 2 V6 Additional test with jumper between D terminals of starboard connector and jumper between D terminals of port connector Black to engine ground red to A B C of both connectors 1 2 V8 Black to E of port connector red to A B C then D of both connectors 0 2 V8 Additional test with jumper between E terminals of starboard connector and jumper between D terminals of port connector Black to engine ground red to A B C then D of both connectors 1 2 Crank engine for all hookups If readings okay go to power pack test If low check wiring and connectors If okay make sensor coil resistance test in manual POWER PACK TEST SET METER POS 500 Remove primary leads from ig
19. or check engine sensor leads gap equipped cracks on sensor face etc engines If no reading with test sensor disconnect ignition coil and check with coil analyzer If coil is okay pack is bad Breaker Disconnect ignition coil and check on coil analyzer If coil is okay reconnect to pack Reconnect red test lead point to coil engines Disconnect wire between pack and points With key switch on touch amplifier connector to ground intermittently No reading pack is bad Reading okay trouble is in breaker point circuit PACK TERMINAL SYSTEMS NOTE V 6 engines are tested same as Power Pack III one side at a time When testing one side remove key switch lead black yellow stripe from pack on other side and insulate with tape Battery must be fully charged before testing SPARK TEST Remove high tension spark plug leads from spark plugs and connect to spark checker Set gap on spark checker according to service manual Crank engine If spark jumps each gap alternately ignition system is okay Check spark plugs and other engine systems If weak erratic or no spark from one coil go to sensor test If weak or erratic spark from ALL coils go to charge coil test If no spark from all coils go to key switch test KEY SWITCH TEST Remove black yellow stripe lead from power pack terminal Crank engine and observe spark Spark okay on all coils trouble is in key switch or key switch lead No spark from any coil leave key switch lead disconnecte
20. r SEN 5 NOTE Because of its sensitivity on Sensor setting the CD 77 will generally read considerably higher than the figures given in the service manuals particularly on smaller engines where cranking speeds are higher Disconnect between stator and Connect jumpers Connect meter leads to pack between terminals 2 cyl pre 1985 4 wire Ato A Dto D Black B Red C then reverse 1985 and later 5 wire AtoA Dto D Black B Red C then reverse V 4 dual pack 4 wire None Black A Red B Repeat with Red to C single pack 5 wire None Black E Red A Repeat with Red to B C amp D Crank engine Meter should read 3 or higher 2V for 1986 2 cylinder engine 1 5V for 1987 88 2 cylinder If reading okay check for short to ground If no reading defective sensor SENSOR SHORT TO GROUND TEST Set Meter SEN 5 Remove black probe from connector and clip to armature plate ground Connect red probe to 2 cylinder B then repeat to C V 4 dual pack A then repeat to B amp C single pack All 5 terminals Crank engine If any reading is present on meter sensor is shorted to ground If no short continue with pack test PACK TESTS Set Meter NEG 500 Disconnect between pack and amp coil Pre 1985 2 cylinder 3 wire connector V 4 2 wire connector 1985 and later 2 cylinder amp V 4 have direct connections Use TS 77 terminal extenders to connect pack to coils and provide a test point To Test Connect Jumpers Meter leads to R
21. t Meter SEN 5 Connect black meter probe to cavity E of armature connector red probe to cavity A Crank engine Repeat with red probe to cavities B C amp D If meter reads 3 or higher on all tests continue with power pack output test If reading is below 3 check component wiring and connectors Refer to service manual for sensor coil resistance tests POWER PACK OUTPUT TEST Set Meter NEG 500 Remove primary leads from ignition coils Attach TS 77 terminal extenders and reconnect primary leads Connect meter black probe to engine ground Connect red probe to exposed part of terminal extender Crank engine Repeat with red probe to each output If reading is 100 or higher pack is okay If reading is below 100 remove primary lead from terminal extender and connect red probe directly to lead Crank engine Reading 100 or higher check ignition coil s Coil s okay pack is defective Reading below 100 check condition of primary wire and spring clip Wire and clip okay pack is defective Remove terminal extenders and reconnect primary leads to coils Make sure all connectors are firmly connected and wires and leads are properly routed 1987 90 2 5 Ultra 4 Excel 4 Note Cranking output tests must be performed with spark plugs installed and torqued to proper specs SPARK TEST Remove high tension leads from both spark plugs and connect to spark checker gapped at 3 8 Crank engine If spark jumps each gap alternately
22. ter SEN 5 Note If spark is present at spark checker during sensor tests replace power pack POWER PACK II POWER PACK III POWER PACK IV Remove both sensor leads from Remove sensor leads from terminals 8 9 Remove sensor leads from terminals 2 4 terminals 6 amp 7 Connect red probe to 10 and 11 Connect black probe to 9 and 12 Connect red probe to lead either lead and black probe to the other black white stripe lead removed from removed from terminal 2 Connect black terminal 11 Connect red probe to lead probe to lead removed from terminal 4 removed from terminal 8 Crank engine Meter should read 3 or higher POWER PACK II POWER PACK III POWER PACK IV Reverse meter leads and repeat test Move red probe to sensor lead from 9 Reverse probes and repeat test and repeat test then to lead from 10 and Then change probes to leads from 9 repeat and 12 and repeat above steps If reading okay continue with Short to Ground Test If reading low check sensor resistance If low resistance replace sensor If resistance okay problem can be too large sensor air gap weak sensor magnets in flywheel or too low cranking speed SENSOR SHORT TO GROUND TEST Set Meter SEN 5 Connect black probe to ground Connect red probe to each of the sensor leads one at a time and crank engine If no reading continue with Power Pack Output Test If any reading above zero sensors are grounded Repair or replace Reconnect sensor leads to proper power p
23. y torqued SPARK TEST Remove high tension leads from spark plugs and connect to spark checker Set gap to 1 2 If equipped install emergency ignition cutoff switch clip and lanyard Crank engine If spark jumps each gap ignition is okay See note below If there is good spark on at least one cylinder go to sensor coil test If there is no spark go to stop circuit test in manual Note See service manual for running test if high speed or intermittent problem exists Also ignition system may have good output and still have a problem See manual for other possible sources of ignition trouble CHARGE COIL GROUND TEST Set Meter Pos 500 Disconnect 5 wire connector between stator and pack Connect black meter probe to engine ground and red probe to terminal A of stator connector Crank engine Repeat with red probe connected to terminal B Any reading on either test indicates charge coil is shorted to ground Locate and repair ground or replace stator CHARGE COIL OUTPUT TEST Set Meter POS 500 Connect black meter probe to terminal A of stator connector red probe to terminal B Crank engine Reading should be 250 volts or higher If okay go to sensor coil test If below 250 check wiring and connectors If wiring and connectors are okay make charge coil resistance test See manual SENSOR COIL GROUND TEST Set Meter SEN 5 Disconnect 4 wire connector between timer base and pack Connect black meter probe to engine ground Conne
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