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Understanding Electronic Test Equipment

1. 73 YAMAHA DVA and RESISTANCE CHARTS HP YEAR Cyl STK MDL STATOR TRIGGER CDI IGNITION COIL SPK PLG OHMS DVA CHECK POINTS OHMS CHECK DNA POINTS Out OHMS 10 CAP Spd HSpd LS HS HS LS Ohms DVA Primary Sec 200 2000 2004 12 2 HPDI CDI OUTPUT 140 Blk Org Blk Yel Blk Blue Blk Grn BIK Wht to Red Yel Wht Red Wht Grn Wht Bik 5 Wht Blue Wht Yel Wht Brn to Blk 140 0 5 4 6 220 1984 1986 900 1100 2127 75 14 Bm Blue to Red Blk Red 280 460 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 1 6 58 0 5 2 5K 5K 225 1984 1989 900 1100 21 27 75 14 to Red Blue to Blk Red 280 460 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 1 6 58 0 5 2 5K 5K 225 1990 1995 L HP 660 820 62 79 145 40 to Red Blue to Blk Red 280 460 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 105 0 5 3 8K 5K 225 1996 1997 L HP 660 820 62 79 145 40 to Red Blue to Blk Red 280 460 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 130 0 5 4 1K 5K 225 1994 1995 U HP 224 224 336 336 90 90 Brn to Red Blue to Blk Red 294
2. S Engine Ground E General 1 Clean all battery connections and engine grounds 2 Disconnect the mercury tilt switch and retest If the ignition works properly replace the mercury switch 3 Connect a spark gap tester to the spark plug wires and check for fire on all cylinders If some cylinders fire and not others the problem is likely in the distributor cap rotor button or spark plug wires 4 Perform a voltage drop test after the engine is repaired to see if there is a problem with the voltage going to the CD module NO SPARK ON ANY CYLINDER 1 4 9 Engine Wiring Connection for Testing Ignition Module 3 8 to 7 16 n Air Gap 3 Cylinder Battery Ignition WIO Points Disconnect Trigger Before Test Tap Jumper Wire Against Engine Ground Ignition Module Should Fire Each Time Ignition Coil Jumper Wire Jumper Wire Red Wire must Still be Connected Jumper Wire At cranking and while the engine is running use a DC voltmeter and put the black meter lead on the battery POS post and the red meter lead on the positive battery cable at the starter solenoid Keep the black lead on the battery post and shift the red meter lead to the positive post of the rectifier then to the red and white terminals on the switch box If you find a reading above 0 6V there is a problem at the point where the voltage jumped up For example if the meter reads 0 4V until you get to the white terminal and then jumps to
3. NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS l 2 HIGH SPEED MISS 1 2 3 If the cylinders are only misfiring above an idle connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders Using a set of piercing probes check the trigger DVA output as shown below Wire Color Check to Wire Color Resistance DVA Reading Purple wire Engine GND Open or more White wire Engine GND Open or more Brown wire Engine GND Open or more NOTE These triggers have the bias circuitry internally built in therefore you cannot measure the resistance like you can measure on the older engines If 1 CDM module is not sparking disconnect the 72 CDM module and see if the 1 CDM module starts sparking If it does the module you just unplugged is bad If it does not reconnect 2 then disconnect the 3 CDM module and see if the 1 module starts sparking If it does the module you just unplugged is bad If there is no spark ire on either 2 or 3 swap locations with 1 and see if the problem moves If it does the module is bad A continued no spark on the same cylinder indicates a bad trigger Connect an inductive Tachometer to all cylinders and try to isolate the problem A high variance in RPM on one cylinder indicates a problem usually in the trigger or CDM module Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high sp
4. Temperature sender to gauge Pink Pk Fuel Gauge Fuel sender to gauge Green White Stripe Tilt Trim down or in Tilt and Trim circuits Blue White Stripe Tilt Trim up or out Tilt and Trim circuits os 10 40 Mercury Battery CD Ignitions with Points SERVICE NOTE Check the battery voltage at approximately 3500 RPM MAXIMUM reading allowable is 16 volts Over 16 volts will damage the ignition Check for loose connections or a bad battery Maintenance free batteries are NOT recommended for this application A CD Tester CDI Electronics P N 511 9701 can be used to test the CD module distributor cap rotor button and spark plug wires on the engine Engine Wiring Connection for Testing Ignition Module Engine Ground Brown Points Wire Tap against engine ground with the keyswitch on and pack should fire each timo geen black coil spark gap 1 4 3 8 Ignition Coil Mercury Battery Ignition with Points Clean all battery connections and engine grounds Disconnect the mercury tilt switch and retest If the ignition works properly replace the mercury switch Connect a spark gap tester to the spark plug wires and check for fire on all cylinders If some cylinders fire and not others the problem is likely in the distributor cap rotor button or spark plug wires Connect a spark gap tester to the high tension lead coming from the ignition coil and set it to app
5. 04996142 332 7778 58007000 135 20V Blue to Eng Gnd ee eae 800 een 1992 oc221999 114 7778 am Red to Eng Gnd 1400 Eins 0 1100 OW 1989 0 222000 18495 3250 3650 75 90 20V Blue to Eng Gnd 8085 Oe 800 1996 06437099 114 4953 500 00 28 32 Red to Eng Gnd 1400 0 1100 NOTE 3 Purple 90 1995 0 141089 18495 3250 3650 75 90 50 20V Blue to Eng Gnd 800 a 0 2 800 Sport Jet 1997 OE315900 114 4953 500 700 28 32 Red to Eng Gnd 1400 P 0 1100 E 1988 209468 332 5772 3250 3650 75 90 je 20V Blueto BIWht 800 y PUO WWBk Q2 goo 1996 06437999 114 5772 500 700 28 32 Red to Red Wht 1400 apie 0 1100 Blue to Gnd 105 1992 00082000 332 7778 3250 3650 75 90 20V BI Wht to Gnd 800 0 2 800 Jet 1996 06840500 114 7778 500 700 28 32 180 Red to Gnd 4400 4Y NOTE 0 1100 Red Wht to Gnd Blue to Gnd 115 1979 5314656 3327778 98207900 BE 20 BI Wht to Gnd 80 m 0 2 800 6 Cyl 1989 0 09999 114 7778 As a Red to Gnd 1400 0 1100 E Red Wht to Gnd 115 125 1989 0 10000 332 5772 3250 3650 75 90 20V Blueto gs A E ee 800 4Cyl 1996 06437999 114 5772 500 700 28 32 Red to Red Wht 1400 miei 0 1100 120 1995 080400 3250 3650 75 90 je 20V Blueto BUWht 80 ee ce 0 2 800 Sport Jet OE141088 526806 500 700 28 32 Red to Red Wht 1400 pl 0 110
6. o Green White White Green Stator Stator Three Cylinder Engines 1996 2006 Engines Using CDM Modules NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wires from the harness and retest If the engine s ignition now sparks the stop circuit has a fault check the key switch harness and shift switch Disconnect one CDM module at a time and see if the other modules start sparking If they do the module you just unplugged is bad If the bottom two CDM modules are not sparking swap the connection between the top and middle cylinder If the middle cylinder starts sparking replace the top CDM Disconnect the yellow wires from the stator to the rectifier and retest If the engine now has spark replace the rectifier Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to spark properly Check the stator resistance and DVA output as given below WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more Check the resistance of the CDM as follows Red Meter Lead Black Meter Lead Reading CDM Pin A C 7700 1300 Ohms CDM Pin D A DIODE CDM Pin A D DIODE CDM Pin D B DIODE CDM Pin B D DIODE CDM Pin A B DIODE CDM Pin B A DIODE High Tension Lead A 700 1300 Ohms Diode readings are to be read one way then reverse the leads and read again You should get a low reading in one direction and a higher reading in the other
7. 398 Wht Red Wht Grn Wht BIk 3 Wht Blue Wht Yel Wht Brn to Blk 100 0 5 2 7K 5K 225 2002 2004 CDI OUTPUT 252 Blk Org to Red Yel BIk Yel to Red Yel BIK Wht to Red Yel 459 561 Wht Red to Blk Wht Grn to Blk Wht BIk to Blk 5 3 252 19 6 1 5 1 9 35 4 None 225 1996 2002 S X U L LX SX 224 336 115 Brn to Red Blue to Blk Red 294 398 Wht Red Wht Grn Wht BIk 3 Wht Blue Wht Yel Wht Brn to Blk 100 0 5 2 7K 5K 225 1998 2004 VX 224 336 115 Brn Blue to Red Blk Red 294 398 Wht Red Wht Grn Wht Bik 3 Wht Blue Wht Yel Wht Brn to Blk 100 0 5 2 7K 5K 225 2003 2004 VZ HPDI 224 336 160 Red to BIk Wht 294 398 Wht Red Wht Grn Wht Bik 3 5 Wht Blue Wht Yel Wht Brn to Blk 160 8 93 187 4208 2 53 None 250 1990 1996 224 336 90 Bm Blue to Red Blk Red 294 398 Wht Red Wht Grn Wht BIk 3 Wht Blue Wht Yel Wht Brn to Blk 100 0 5 2 7K 5K 250 1997 2002 224 336 115 Brn to Red Blue to Blk Red 294 398 Wht Red Wht Grn Wht BIk 3 Wht Blue Wht Yel Wht Brn to Blk 100 0 5 2 7K 5K 74 YAMAHA DVA and RESISTANCE CHARTS STATOR TRIGGER IGNITION COIL S
8. NO SPARK OR INTERMITTENT ON ONE CYLINDER l 2 Connect a spark gap tester to the high tension leads coming from the distributor cap and set the gap to approximately 7 16 Use of a CD Tester is highly recommended Align the rotor with 1 spark plug wire Disconnect the trigger wires and connect a jumper wire from the white black trigger terminal to the black trigger terminal on the switch box Connect another jumper wire to the blue trigger terminal turn the ignition switch on Strike the jumper wire from the blue terminal against engine ground DO NOT HOLD THE JUMPER AGAINST ENGINE GROUND Only the 1 spark plug wire should fire If any other spark plug wire now has fire there is a problem in the distributor cap Repeat the test for the other cylinders 41 HIGH SPEED MISS Check the battery voltage on the red and white terminals of the switch box at high speed the voltage should be between 12 5V and 16V DC A reading outside this range will damage the CD module If the readings are abnormal perform the voltage drop test described above Four and Six Cylinder Engines with 332 2986 393 3736 Battery Type Ignitions Note CD Tester like the one by CDI Electronics or Merc o Tronics can be used to test the CD module distributor cap rotor button and spark plug wires on the engine while the Trigger Tester by CDI can be used to test the distributor trigger SERVICE NOTE Check the battery voltage at approximately 3500 RPM MAXIMUM
9. OMC Sea Drive and Yamaha engines Other ignitions can be tested using test results given by the manufacturer of the equipment or by comparing a known good system to a suspect one Please forward any additional readings you would like to have included in future printings Big enough to do the job small enough to care e Tech Support 866 423 4832 e Fax 256 772 5701 e www rapair com 61 DVA Peak Reading Voltage and Resistance Chart Please note that all DVA readings are minimum voltages measured at cranking speed not while the engine is running Model Ignition Stator Trigger Ignition Coil HP Year Serial Part Ohms DVA Reading DVA Reading Primary Output Number Low Spd Hi Sp Low Hi Colors Ohms Out Colors Ohms 1972 3296137 Green to Points 800 4 E 336 4516 3600 5500 450 550 180 cis N A wu Or oe Brn to Brn 1976 9075839 339 6222 1600 1800 Orange to 800 4 1980 5595531 114 6222 800 900 per coil 190Vt Eng Gna i 140160 linen lh ite 1980 5595532 Green to Points 800 414 5 n 0599932 336 4516 3600 5500 450 550 180 Suis pur N A NA Browna 0210 100 332 7452 Bik Yel LS 1986 A197112 3327452 3200 3800 120 180 180 750 Brn Yel to 800 DOO 1996 OG289100 1 2200 2600 225 300 v 20V BIWWRHHS 4400 05 0
10. Purple Wht Blue Green Orange Overheat Tan b White Blk c Pink Orange Tan Green Yel a Ignition Driver systems only all others were battery driven systems b The stripe color on the Tan wire indicates the temperature at which the sensor trips c The White Black wire is the cold engine temp indicator and shorts to Gnd at approx 105 deg F Blk Black Yel Yellow Wht White Blk Black Gry Gray Recommended Boat Wiring Color Codes Color Function Comments Yellow Red Stripe YR Engine Start Circuit Brown Yellow Stripe BY Bilge Blower Alternate color is Yellow Y Yellow Stripe Y Bilge Blower If used for DC negative blower MUST be Brown Yellow Stripe Dark Gray Gy Navigation Lights Fuse or Switch to lights Dark Gray Gy Tachometer Brown Br Generator Alternator Charge Indicator Lights Fuse or switch to pumps Ammeter to alternator output and accessory Orange O Accessory Power fuse or switches Distribution Panel accessory switch Ignition switch to coil and electrical Purple Pu Ignition Instrument power instruments Distribution Panel to electric instruments Dark Blue Cabin and instrument lights Fuse or switch to lights Light Blue Lt Bl Oil Pressure Oil sender to gauge Tan Water Pressure
11. Wht BIk to Bik Wht Blue to BIk Wht Yel to Blk Wht Brn to 100 0 5 2 72 3 68 None 150 1994 1995 660 820 62 79 145 40 Brn Red Blue to Blk Red 280 460 2 5 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 65 0 5 3 8K None 150 2000 2004 ZILZNZ CDI OUTPUT 140 BI B Org k Yel Blk Blue Blk Grn BIK Wht to Red Yel Wht Red Wht Grn Wht Bik Wht Blue Wht Yel Wht Brn to BIk 140 4 6 150 2004 OUTPUT 260 Blk Org to BIK Wht to 459 561 3 5 White Red to BIk White BIk to 260 1 53 2 07 12 5 16 91 None 72 YAMAHA DVA and RESISTANCE CHARTS STATOR TRIGGER IGNITION COIL SPK CDI PLG HP YEAR STK MDL CHECK Gut y OHMS DVA CHECK POINTS OHMS DVA Fonts OHMS 10 L Spd HSpd LS HS HS LS Ohms DVA Primary Sec Wht Red to Bm Wht Grn 1996 660 Blue to 280 Wht BIk to 4 1 175 2000 6 2 820 62 79 140 40 2 Bleed 150 2 5 Wivenes 130 0 5 5 Wht Yel to Wht Brn Wht Red Blk Org Wht Grn BIk Yel 2001 BIK BI 175 6 2 ZNZ CDIOUTPUT 140 Her 5 WhwBlue 140 4 6 2004 Blk Grn Wht Yel BIk Wht to Red Yel Wht Brn to Blk Wht Red to Bm Wht Grn 1984 900
12. 1000 AV or more Service Note You should get a high or open resistance reading to engine ground from each wire but you will get a DVA reading of approximately 1 2 Volts This reading can be used to determine if a pack has a problem in the triggering circuit For example if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad High Speed Miss T Connect an inductive RPM meter to all cylinders and try to isolate the problem A high variance in RPM on one cylinder usually indicates a problem in the switch box or ignition coil Occasionally a trigger will cause this same problem Check the trigger as described above under No fire or Intermittent on One or More Cylinders Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets 55 Two Cylinder Engines 1996 2006 Engines Using a Combination Switch Box and Ignition Coil CDM Modules NO SPARK ON ANY CYLINDER l 2 e Disconnect the black yellow stop wires from the harness and retest If the engine s ignition sparks the stop circuit has a fault check the key swit
13. 180v 20 gniton NotApplicable N A di 1976 4382057 332 7778 925039690 75 90 20V Blue to Eng Gnd 800 gy Wh BiKtoBm 02 800 1979 4571651 114 7778 Sus 28 32 Red to Eng Gnd 1400 Wht and Pur 0 1100 m 1994 00283222 18495 3250 3650 75 90 20V Blue to Eng Gnd 800 gy WhtBikto Brn 02 800 1996 06437999 114 4953 500 700 28 32 Red to Eng Gnd 1400 Wht and Pur 0 1100 1992 OE009500 18495 3250 3650 75 90 180V4 20V Blue to Eng Gnd 800 AV Wht BIk to Brn 0 2 800 65 Jet 1995 0 138599 114 4953 500 700 28 32 Red to Eng Gnd 1400 Wht and Pur 0 1100 1977 4571652 332 7778 5800 7000 De aov 20V Blue to Eng Gnd 80 T E N 0 2 800 1993 00283221 114 7778 dnd E Red to Eng Gnd 1400 EE 0 1100 5800 7000 135 Brn to WhUBIK 1984 643901 3329772 2200 165 T E a uet don B005 AVE Purple to TS Md 75 1988 0B279480 2400 30 90 White 5800 7000 135 Brn to WhUBIK 1978 4831999 3325712 2200 165 180v 20 Luv Evie ie AV Purple to Pe zn 80 1983 6432900 2400 30 90 ECERS White i d 1987 OA966142 332 7778 5800 7000 135 aov 20V Blue to Eng Gnd 800 gya ae 0 2 800 1988 08209468 114 7778 aes Red to Eng Gnd 1400 0 1100 Blue to Gnd 90 1979 5299506 332 7778 98007000 135 goys 20 Gnd 80 aed 0 2 800 Inline 6 1986 0 110053 114 7778 Cop Red to Gnd 1400 0 1100 Red Wht to Gnd pu 1987
14. 2 3V on the white terminal this indicates a problem in the key switch or harness Repeat the test for the negative battery post by putting the black meter lead on the battery NEG post and the red meter lead on the negative battery cable terminal then shifting to the engine block rectifier base and case ground of the CD module 3 o oO gt o o 5 ga Connect a spark gap tester to the high tension lead coming from the ignition coil and set it to approximately 7 16 When you crank the engine over if it fires while the spark gap tester is connected to the coil and does not fire through the spark plug wires there is a problem in the distributor cap rotor button or spark plug wires Check the DC voltage present on the white and red terminals while at cranking It MUST be at least 9 volts If not there is a problem in the harness key switch starter battery cables or battery Check the DC voltage on the white black trigger terminal while cranking there must be at least 9V available with the trigger wire connected Check DVA voltage between the blue and black trigger wires they must be connected to the switch box You should read at least 3V A low reading indicates a bad trigger Check DVA voltage on the green wire going to the coil it should be over 100 volts at cranking ONLY HAS SPARK AS LONG AS THE STARTER IS ENGAGED This symptom usually indicates a bad trigger or low voltage
15. 330 6 Blk 51 0 5 37K 4 6K 1995 White Red to 48 2000 2 4 81 99 Brown to 92 111 Blk 0 3 5 4 None White Red 1999 White BIk 50 2002 3 2 420 510 145 Brown to Blue 180 240 3 White Grn to 25 0 5 32K None Bik 1995 Red Wht to 3 8 5 7 50 2000 4 4 F 300 380 137 Brown to Blue 375 475 3 5 White Blk 50 0 5 44K K 1996 Red Wht to 3 8 5 7 50 2000 4 4 F 300 380 137 Brown to Blue 375 475 3 5 White BIk 50 0 5 4 1K K 2001 Red Wht to 0 078 3 5 3 8 5 7 50 2004 4 4 F 272 408 144 Brown to Blue 396 594 6 3 White Blk 26 0 106 47K K White Red 55 1985 2 2 200 260 135 Brown to Blue 70 98 2 White BIk 50 0 5 34K None 1994 23 29 Yel to White Red 55 1995 2 2 200 260 135 Brown to Blue 280 360 2 White BIk to 50 0 5 34K None Bik White Red 1991 White BIk 60 2000 3 2 145 190 140 Brown to Blue 110 150 2 5 White Grn to 00 0 5 32K None Bik 1992 White Red to 60 1999 2 2 P 150 190 120 Brown to Blue 270 330 2 5 White BIk 05 0 5 44K None 1996 White Red to 60 2002 2 2 150 190 120 Brown to Blue 270 330 2 5 White Blk 05 0 5 44K None 05 on 1 amp 3 at idle 2001 White Red to 0 60 2004 3 2 150 190 150 Brown to Blue 270 330 2 5 White Blk PA 0 5 44K None 45 on all at 1500 RPM 2002 Red Wht to 0 078 3 5 3 8 5 7 60 2004 4 4 F T 272 408 144 Brown to Blue 396 594 6 3 White Blk 26 0 106 47K K White Red 1984 White BIk 70 1991 3 2 145 190 140 Brown to Blue 110 150 2 5 White Grn to 00 0 5 32K Blk 05 on 1 amp 3 at idle 199
16. BROWN YELLOW 4 WHITE ORANGE BROWN BLUE 1 BROWN YELLOW 2 79 Modified Engine Wiring Diagrams for CDI Electronics Components 5 CYL FORCE TYPE IGNITION SYSTEM NOTICE This stator has been redesigned to enhance durability and reduce inventory stock s m m m s levels It replaces the original dual winding with a single winding with larger wire This design z allows ALL of the Yellow Brown Yellow wires to be connected together and ALL of the Blue z E Brown Blue wires to be connected together from stator permitting the stator to be used fo 2 the 2 3 4 and 5 cylinder applications z z 2 2 L L L 9 t t5 t c c carm TYTHNVMNO LYISNVNO agaaa WHITE GREEN WHITE GREEN 5 1 wHITEIORANGE E WHITE YELLOW gm WHITE RED WHITE ORANGE WHITE YELLOW H BROWN BLUE annoon DOOOQooQ DCQ 300 4002 YELLOW JUMPER 5 _ ty DVA 180V MINIMUM BROWN YELLOW 4 BROVWN Y QW BROWN BLUE dE
17. at the point where the voltage jumped up For example if the meter reads 0 4V until you get to the white terminal and then jumps to 2 3V on the white terminal this indicates a problem in the key switch or harness Repeat the test for the negative battery post by putting the black meter lead on the battery NEG post and the red meter lead on the negative battery cable terminal then shifting to the engine block rectifier base and case ground of the CD module NO SPARK ON ANY CYLINDER 1 Connect a spark gap tester to the high tension lead coming from the ignition coil and set it to approximately 7 16 When you crank the engine over if it fires while the spark gap tester is connected to the coil and does not fire through the spark plug wires there is a problem in the distributor cap rotor button or spark plug wires 2 Check the DC voltage present on the white and red terminals while at cranking It MUST be at least 9 volts If not there is a problem in the harness key switch starter battery cables or battery 3 Check the DC voltage on the brown trigger terminal while cranking there must be at least 9 V available with the trigger wire connected 4 Check DVA voltage between the white and black trigger wires they must be connected to the switch box You should read at least 3V A low reading indicates a bad trigger 5 Check DVA voltage on the green wire going to the coil it should be over 100 volts at cranking 42 H
18. da 0 5 None 1 7 6K White Red 2 5 6 1999 396 o Blk 4 1 wd A 1999 4 r 2 Sb 0 5 MD Rm o Blk K 4 72 Wht Red to 1989 900 105 Redto 290 White Yel 48 85 1996 2 C 10 140 95 59 370 25 wnyGmto 99 0 5 K None Wht Bik Brn Wht Red to 1984 765 105 Redto 290 White Yel 2 5 20 1989 2 935 135 99 4 do Blue 370 25 wnyGmto 99 0 5 K None Wht Bik Brn Wht Red to 1990 900 105 Redto 290 White Yel 48 90 1991 2 1100 140 99 4 370 25 wnyGmto 99 29 K None Wht Bik Brn White Red 90 oor e 2 220 70 90 100 nicht ccn 5 o 130 0 5 P None Red White Blk Bm Wht Red to 1984 625 Blueto 280 White Yel 3 8 115 acera 2 oq 6279 160 45 o grea 4e 25 wh Gmio 95 0 5 None WhUBIk Bm Wht Red to 1994 900 105 Blueto 320 White Yel 2 5 113 2000 4 2 C 4400 140 85 45 eios Bl Red 400 25 wnyGmto 99 0 5 K TEK Me WhUBIk White Red 2000 o Blk ns Zala 4 F 2 3 a 5 None o Bik 71 YAMAHA DVA and RESISTANCE CHARTS HP YEAR Cyl STK MDL STATOR TRIGGER CDI IGNITION COIL SPK PLG OHMS DVA CHECK POINTS OHMS DVA CHECK POINTS Out OHMS 10 HSpd LS HS LS Ohms DVA Primary Sec 130 1984 1989 900 105 1100 140 85 45 Red to Blue 2
19. ignition now has spark the stop circuit has a fault check the key switch harness and mercury tilt switch 2 Disconnect the yellow wires from the stator to the rectifier and retest If the engine now has spark replace the rectifier 3 Verify the correct flywheel is installed 4 Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly 3 5 Check the stator resistance and DVA output as shown below e Flywheel with Bolted in Magnets d WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA Blue White 5000 7000 2200 2400 180V or more 2 Red Red White 125 155 45 55 25V or more 5 Flywheel with Glued in Magnets c WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA 4 Blue Blue White 3250 3650 500 600 180V or more Red Red White 75 90 28 32 25V or more Red Stator dS WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more Blue Blue OPEN 180V or more Blue Each Ground OPEN 180V or more NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS 1 Ifthe cylinders are only misfiring above an idle connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders 2 Check the trigger resistance and DVA output as given below Wire Color Check to Wire Color Resistance DVA Reading Purple wire White wire 800 1400 4V or more Connected Brown wire White Black wire 800 1400 4V or more Connected Purple wire Engine GND Open 1V or
20. more White wire Engine GND Open 1V or more Brown wire Engine GND Open 1V or more White Black wire Engine GND Open 1V or more This reading can be used to determine if a pack has a problem in the triggering circuit For instance if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad Note If 1 and 2 or 3 and 4 are misfiring check the trigger as described above The trigger has two coils firing four cylinders 1 amp 2 share a trigger coil and 3 amp 4 share a trigger coil Also the switch box is divided into two parts The 1 and 2 cylinders are fired on one side and 3 and 4 are fired from the other side of the switch box If the trigger tests are okay according to the chart above but you have two cylinders not firing either 1 and 2 or 3 and 4 the switch box or stator is bad 53 3 Ifyou have two cylinders not firing either 1 and 2 or 3 and 4 switch the stator leads end to end on the switch box red with red white and blue with blue white If the problem moves to the other cylinders the stator is bad It the problem stayed on the same cylinders the switch box is likely bad 4 Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on
21. the problem A high variance in RPM on one cylinder usually indicates a problem in the switch box or ignition coil Occasionally a trigger will cause this same problem Check the trigger as described above under No spark or intermittent spark on any cylinder 2 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets 4 Use the wiring diagram below as an aid in locating areas where problems may occur Remember a short in either 1 or Z2 can cause either 3 and 4 not to have spark U Stop Circuit Black Yellow Purple Trigger i i Brown Trigger Blue Trigger White Green White Green Green White Green White 58 Six Cylinder Engines 1996 2005 2 0L and 2 5 L Engines Using CDM Modules NO SPARK ON ANY CYLINDER l 2 3 S Inspect the spark plug wires boots and spark plugs Check for chafing on the wiring and harnesses Clean and inspect CDM ground wire connection to engine ground Disconnect the Black Yellow stop wires from the harness and RPM Limiter Retest If the engine s ignition now has spark the stop circuit has a fault check the key switch harness and shift switch If there 1s still no spark disconnect the CDM s one at a time and see if you get spark
22. to Engine ground OEM RESISTANCE CDI RESISTANCE DVA Blue 5000 7000 2200 2400 180V or more Blue White 5000 7000 2200 2400 180V or more Red 90 200 30 90 25V or more Red White 90 200 30 90 25V or more 40 Amp Battery Charging Capacity WIRE Read to Engine ground RESISTANCE CDI RESISTANCE DVA Blue 3200 4200 2200 2400 150V or more Blue White 3200 4200 2200 2400 150V or more Red 90 140 90 110 20V or more Red White 90 140 90 110 20V or more 2 Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both terminals on all cylinders If the reading is low on one bank and the stator voltage is good the switch box is usually bad Note A final test to verify which component is bad is to swap the stator leads from one switch box to the other If the problem moves the stator is bad If the same bank still does not fire the switch box is usually bad 3 Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS 1 Connect a spark gap tester and verify which cylinders are misfiring If the cylinders only misfiring above an idle connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders 2 Check the trigger resistance and DVA output as
23. 0 114 6866 White Gnd to Wht BIk 900 120 1996 0 141089 827509 500 700 TN Green White to 5 4 5V AT Sport Jet 2000 OE384499 114 7509 400 600 White Green pen allie ML 2100 BmWht 2400 Blue to Gnd ben 1978 4868998 332 7778 99007000 19 ve 20 BI Wht to Gnd 80 Heres 0 2 800 1985 04904646 114 7778 Red to Gnd 1400 0 1100 9 15 2400 30 90 Red Wht to Gnd Blue to Gnd dud 1985 04904647 332 7778 99007000 4135 20V BI Wht to Gnd 80 METRE 0 2 800 01 2 1988 0 100860 114 7778 2 Red to Gnd 1400 0 1100 16 2400 30 90 Red Wht to Gnd 175 210 Blue Gnd 1997 398 9873 18495 1000 1600 75 90 jg 20V BI Wht to Gnd 80 0 2 800 port Je 2005 174 9873 16 114 4953 450 600 28 32 Red to Gnd 1400 0 1100 16 AMP Red Wht to Gnd 135 275 3200 4200 Blue to Gnd 20L 24L 1989 06100861 332 7778 32004200 90 140 20V BI Wht to Gnd 1100 0 2 800 2 5L 2005 06840500 114 7778 en 28 32 Red to Gnd 1400 0 1100 40 Red Wht to Gnd Gnd to WhUBIK Wht Yel 900 1996 OD280813 827509 Green White to 4 5V Blue Wht 1100 2004 06840500 114 7509 900 1100 White Green Open Brn Wht ns 2100 Red Wht 2400 Pur Wht Gnd Engine ground Black BIk Wht Black White Stripe Manufactured by CDI Electronics BI Wht Blue White 68 Wht BIk White Black Brn Yel Brown Yellow Stripe Red W
24. 0 1970 2858814 80 jen Not Does Does 50 1975 4357639 333 3213 380 420 91 v 20 Blue to Ignition Applicable not Aus White Driver N A Blue to Brn to z 1976 4357640 332 5772 5800 7000 135 165 80 soy BlueWht 800 ave 800 1985 6586624 114 5772 2200 2400 30 90 m Red to 1400 Purple to d 1100 Red Wht White Blue to Eng Wht BIk to 1985 6586625 332 7778 3250 3650 75 90 80 Gnd 800 Bm 800 50 1990 00000749 114 7778 2200 2400 28 32 v 20V Red to Eng 1400 V whtand 9219 1100 mpm 1991 00000750 19052 3250 3650 75 90 jy Blue toGnd soo 4 800 1996 06589999 114 9052 500 700 28 32 m Red to Gnd 1400 ns 1100 67 DVA Peak Reading Voltage and Resistance Chart Mercury Please note that all DVA readings are minimum voltages measured at cranking speed not while the engine is running Gnd to 900 50 60 1997 06590000 827509 660 710 T Green White to 5 4 5V Wht Blk wa 1100 65 Jet 2001 OG980600 114 7509 450 600 White Green pen Wht Yel 2100 Blue Wht 2400 2309311 20V Red to White Ignition 65 1968 333 3213 380 420 9 11
25. 2 Whie Redto 70 2004 3 2 150 190 150 Brown to Blue 270 330 2 5 White Blk Es 0 5 44K None 145 on all at 1500 RPM 70 YAMAHA DVA and RESISTANCE CHARTS 2 STATOR TRIGGER cp coi Rupe HP YEAR STK MDL Cyl CHECK CHECK Out OHMS DVA ONIS omms OHMS 10 L Spd HSpd LS HS HS LS Ohms DVA Primary Sec Brn Wht Red to 1994 900 105 Redto 290 Wht Yel t 1996 2 C 10 140 95 59 Blue 370 25 whtiGmto 95 0 5 4 9K WhtBIk 105 on 18 3 at idle Brn White Red 0 75 Pid 3 2 e pad 64 96 55 90 to js bs PA 7 to on 0 5 e None Red White BIK 2 145 on all at 1500 RPM Bm Wht Red to 1995 900 105 Redto 290 White Gm 75 an 2 E so 8 45 t E amn ea 05 48K None ue Wht Grn Brn Wht Red to 1996 900 105 Redto 290 White Yel 48 12 1999 3 b 1100 140 85 45 EIS Blue 370 5 wntyGmto 95 0 5 K None Wht BIk Bm Wht Red to 1997 480 Redto 290 White Gm 75 53 2 600 90 70 105 45 to Siue 55 05 41K None Wht Grn A 7 6K White Red 2 5 6 2003 396 to 44 K 75190 2003 4 4 F 2 212 2 2 So es emer 0 5 mum to Blk K 4 72 220 Blue to 241 White Red 4 1 80 1997 3 2 c 70 7090 100 60 t E d gl eee ee
26. 2 10 1100 7452 1 to Eng Gnd Green White 6 8 10 15 2 1995 06760299 855713 Brn Yel to 800 0 25 2006 1B000001 114 5713 3107445 1808 us 650 850 0 5 Bmwnt 02 10 1100 White Green 1972 3226958 Green to 800 9 8 20 Ha 2226958 336 4516 3600 5500 450 550 180 Brown amp 0240 jog Brn to Brn 1974 3795650 339 6222 1600 1800 Orange to 750 800 9 8 1985 5206549 114 6222 800 900 per coil 180 Eng Gnd 4400 95V pod 02 0 1100 1988 08238464 332 7452 3200 3800 120 180 80 sovs Se 750 ggy BmYdio 800 1993 06044365 2200 2600 225 300 m 1400 s 1100 7452K1 to Eng Gnd 45 2025 1994 99044027 18495430 3200 3800 120 180 80 sovs Blue 750 ggy 800 a 1996 m e n 2200 2600 225 300 m 1400 Br Wht 1100 1996 06438000 33227452 3200 3800 120 180 80 Bik Yel LS Brn Yel to 800 mE 1997 114 2200 2600 225 300 V 20V BIKWht HS 1400 Dot Brn Wht vee 1100 06760299 7452K1 to Eng Gnd m 332 BIk Yel LS 18 20 25 1979 5837437 7452A3 3200 3800 120 180 80 jov 799 osve BmYelto 0240 800 XD 1987 OB114230 114 2200 2600 225 300 m 1400 Br Wht 2 1 1100 to Eng Gnd 7452A3 Blue and 1973 3537531 332 4911 80 800 20 Eus 3500 5500 450 550 180 20v Red to N A BmtoWnt 02 10 8005 Engine Gnd 1980 5705532 3327452 3200 3800 120 1
27. 2002 390 t White Grn to Blk 1989 White Red to 35 30 oo 2 2 c 120 150 90 Brown to Bik 12 16 5 ER 210 0 5 None White Red to 30 T993 2 2 400 490 25 Brown to Blue m 4 White Bik 105 0 5 None 1996 390 K to Bik 310 White Red to 32 30 1997 2 2 340 420 25 Brown to Blue a 4 White BIk 105 0 5 None P to Bik K 69 YAMAHA DVA and RESISTANCE CHARTS SPK MD STATOR TRIGGER CDI IGNITION COIL PLG n TEAR Cyl SIK L CHECK CHECK Out 109 OHMS DVA POINTS OHMS DVA POINTS OHMS 10 CAP H LS HS LS S HS LS Ohms DVA Primary Sec 2001 Grn Wht to White Red to 30 2004 2 4 F 600 720 193 Wht Grn 270 330 6 Blk 51 0 5 44K None White Red 1984 White BIk 40 50 1988 3 2 180 250 175 Brown to Blue 310 390 4 White Grn to 35 0 5 6 3K Blk White Red 1989 White BIk 40 50 1994 3 2 280 330 200 Brown to Blue 180 220 4 White Grn to 75 0 5 32K None Bik White Red 1995 White BIk 40 50 2004 3 2 400 510 145 Brown to Blue 180 240 3 White Grn to 25 0 5 32K None Bik 40 oe 2 2 c 120 140 125 BrowntoBlue 1216 55 Wht Redto 115 05 35K None White Red 1998 White BIk 40 2002 3 2 400 510 145 Brown to Blue 180 220 4 White Grn to 25 0 5 3 2K None Bik 40 1999 4 4 F 300 380 140 Brown to Blue 375 475 7 Red Wht 05 0 5 44K 4 6 White BIk 2000 Grn Wht to Red Wht to 2 7 40 2004 3 4 F 600 710 193 Wht Grn 270
28. 4 FIFTI 280 White Red to 34 9 9 990 2 4 T 300 400 90 Brown to Blue 340 2 5 Blk 0 5 K None 1991 FIFTI 280 White Red to 9 9 2004 2 4 300 400 90 Brown to Blue 340 2 5 Blk 0 5 4 1 None 1984 White Red to 54 15 995 2 2 81 99 Brown to BLK 92 111 Blk 0 3 K None 1998 234 White Red to 491 15 2004 2 4 F 272 408 135 Brown to Blue 348 4 Blk 115 0 5 K None White Red to 20 1995 2 2 340 420 25 Brown toBlue 3 0 55 white BIK 105 0 5 32 None 997 390 hes K 1984 White Red to 35 25 2 2 120 150 90 BrowntoBlue 12 16 5 White BIk 210 0 5 None 987 K to Bik 1988 White Red to 35 25 9 2 2 200 275 90 BrowntoBLK 90 120 5 Bik White BIK 210 0 5 None 993 K to Bik White Red to 25 19965 2 2 340 420 25 Brown to Blue 310 55 Bik White Bik 105 0 5 Ps None 2004 390 MUR K White Red to Bik White BIk 25 1998 3 2 340 420 75 Brown to Blue 3107 4 to Bik 135 0 5 6 3 None 2002 390 K White Grn to Blk 1990 White Red to 35 25 brin 2 2 200 275 90 BrowntoBLK 90 120 5 e 210 0 5 None 1993 White Red to 54 25 ae 2 2 C 200 275 90 BrowntoBLK 90 120 5 2 210 0 5 None 1996 White Red to 85 25 ui 2 2 C 200 275 90 BrowntoBLK 90 120 5 2 210 0 5 E None 1998 Grn Wht to 300 44 25 2 4 F 660 710 90 A ae 6 RedtoWht 100 0 5 None 1984 White Red to 35 30 pel 2 2 120 150 90 BrowntoBlue 12 16 5 aa 210 0 5 None White Red to S ids Bik White BIk 30 3 2 280 330 75 Brown to Blue 4 to Bik 135 05 6 3K None
29. 80 B0 750 osy 800 1993 06044026 J 2200 2600 225 300 m HS 4409 Bm Wht 244 1100 7452K1 to Eng Gnd s 1984 6445653 332 7452 3200 3800 120 180 80 sovs BARS 750 ggy BmYdio 800 1989 OB393190 2200 2600 225 300 m 1400 l Bm Wht mE 1100 7452K1 to Eng Gnd 1970 2874704 332 4172 3200 3800 45 55 80 Blue and 750 800 40 1971 3336237 332 4172 2200 2600 45 55 v 207 White to 1400 O5V BrntoWht 0 2 1 0 1100 Engine Gnd 338 4733 Blue to Eng 1972 3336258 3324911 5000 7000 180 220 80 Gnd 750 Brn Wht to 800 i 1981 5823917 338 4733 2200 2500 45 55 v 20V Red to Eng 1400 99V Bm Yelow 92719 4100 114 4911 Gnd m 1982 5283918 3327152 3200 3800 150 200 80 sovs 750 ogy 800 1984 6999999 2200 2600 225 300 m HS 4409 Br Wht 24 1100 7452K1 to Eng Gnd 40 45 Blue to Brn to Pen 1989 159200 332 5772 3250 3650 75 90 80 soe BIWht 750 ave 800 NOTES 1996 06291031 114 5772 2200 2400 28 32 m Red to 1400 Purple to z 1100 Red Wht White 45 80 Blue to Eng Wht BIk to Bee 1989 C159200 18495 3250 3650 75 90 80 eee Gnd 750 25s Bm EPIS 800 1996 06291031 114 4953 500 700 28 32 m Red to Eng 1400 Wht and E 1100 NOTE 3 Gnd Purple Gnd to 900 1997 06531301 827509 660 710 hite Open osve WhUBIK NIA 1100 2001 ocasoses 114 7509 450 600 P Whi Yel 2100 Blue Wht 240
30. 90 370 2 5 Wht Red to White Yel Wht Grn to Wht BIK 95 0 5 48K None 130 1990 2003 625 820 62 79 160 45 Blue to Blk Red 280 460 2 5 Wht Red to White Yel Wht Grn to Wht BIK 125 0 5 3 8K 4 6 150 175 1984 1989 900 1100 2127 75 14 Blue to Blk Red 280 460 1 6 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 105 0 5 2 5K 4 6 150 175 1990 1995 660 820 62 79 145 40 Brn Red Blue to Blk Red 280 460 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 105 0 5 3 8K 4 6 150 1996 2004 D L P S 660 820 62 79 145 40 Brn to Red Blue to Blk Red 280 460 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 130 0 5 44K 5K 150 1996 1999 460 620 70 90 90 30 Brn Red Blue to Blk Red 280 460 2 5 Wht Red to Wht Grn Wht BIk to Wht Blue Wht Yel to Wht Brn 65 0 5 4 1K None 150 1999 2003 DX SX VX 224 336 110 Brn to Red Blue to Blk Red 294 398 Wht Red to BIk Wht Grn to Wht BIk to Bik Wht Blue to BIk Wht Yel to Bik Wht Brn to 100 0 5 2 72 3 68 None 150 1999 2002 LX PX 224 336 110 Brn Red Blue to Blk Red 294 398 Wht Red to BIk Wht Grn to BIk
31. AS SPARK AS LONG AS THE STARTER IS ENGAGED This symptom usually indicates a bad trigger or low voltage NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER 1 Connect a spark gap tester to the high tension leads coming from the distributor cap and set the gap to approximately 7 16 Use of a CD Tester is recommended 2 Align the rotor with 1 spark plug wire Disconnect the trigger wires and connect a jumper wire from the brown trigger terminal to the white trigger terminal 3 Connect another jumper wire to the black trigger terminal turn the ignition switch on Strike the jumper wire from the black terminal against engine ground DO NO HOLD THE JUMPER AGAINST ENGINE GROUND Only the 1 spark plug wire should fire If any other spark plug wire has fire there is a problem in the distributor cap 4 Repeat the test for the other cylinders HIGH SPEED MISS 1 Check the battery voltage on the red and white terminals of the switch box at high speed the voltage should be between 12 5V and 16V DC A reading outside this range will damage the CD module If the readings are abnormal perform the voltage drop test described above 2 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a high miss at high speed when the water pressure gets high but a normal shutdown will mask the problem Four Cylinder Engines 1970 1971 Engines with 337 4406 337 4411 Ignitions WARNING Check the batter
32. Blue to 280 WhUtBIk to 2 5 200 1989 2 1100 2127 75 14 mo BikRed 460 16 wntBle 105 0 3 K e Wht Yel to Wht Brn Wht Red to Brn Wht Grn 1990 660 Blue to 280 Wht BIk to 3 8 200 1095 6 2 820 6279 145 40 460 2 5 waue 105 0 5 K None e Wht Yel to Wht Brn Wht Red to Brn Wht Grn 1991 660 Blue to 280 Wht BIk to 3 8 200 1895 6 2 P 820 6279 145 40 ae eller 460 2 105 0 5 K None i Wht Yel to Wht Brn Wht Red to Brn Wht Grn 1996 660 Blue to 280 Wht BIk to 4 1 200 99d 6 2 UP S 35g 6279 140 40 G60 2 5 7130 0 5 5 Red Wht Yel to Wht Brn WhtRed Wht Grn Bm Blueto 294 WhUBlk 27 200 1998 6 2 V 224 336 115 to pied dos 3 WhwBlue 100 0 5 3 6 5 Red Wht Yel K Wht Brn to Blk Blk Org Whilhted to 19 6 2002 BIk Yel 459 PI vWhuGm 200 Xl 6 4 F CDI OUTPUT 252 TRHA Sol 5 3 to 252 1 5 1 9 a54 None Wht BIk to Red Yel K Blk Wht Red Blk Org Wht Gm BIk Yel 1999 BIK BI WhuB 200 6 2 LX CDI OUTPUT 140 ue 3 WhwBlue 140 4 6 2002 Blk Grn Wht Yel BIk Wht to Red Yel Wht Brn to Blk Wht Red Blk Org Wht Grn BIk Yel 1999 Bik Blue Wht Blk 200 6 2 SX CDI OUTPUT 100 3 WhwBlue 100 4 6 2004 Blk Grn Wht Yel BIk Wht to Red Yel Wht Brn to Blk WhtRed Wht Grn WhtBlk 2 7 200 ae 6 2 224 336 115 to edad ps 3 WhwBlue 100 0 5 3 6 5 Red Wht Yel k Wht Brn to Blk
33. ENGINE WILL NOT ACCELERATE BEYOND 3000 4000 RPM 1 Connect an inductive Tachometer to all cylinders and try to isolate the problem A single cylinder dropping fire will likely be the switch box or ignition coil All cylinders misfiring usually indicate a bad stator 2 Connect a DVA meter to the stator s blue wire and engine ground and do a running test The DVA voltage should jump up to well over 200V and stabilize A drop in voltage right before the problem occurs indicates a bad stator blue to engine ground if the engine has a red stator kit installed 3 Connect a DVA meter to the stator s red wire and engine ground and do a running test The DVA voltage should show a smooth climb in voltage and remain high through the RPM range A reading lower than the reading on the blue wire indicates a bad stator HIGH SPEED MISS 1 Connect an inductive Tachometer to all cylinders and try to isolate the problem A high variance in RPM on one cylinder indicates a problem usually in the switch box or ignition coil Occasionally a trigger will cause this same problem Check the trigger as described above under No spark or Intermittent on One or More Cylinders 2 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem 3 Remove the flywheel and check the triggering and charge coil flywheel magnets for cra
34. Introduction The information contained in this Troubleshooting Guide has been compiled from various sources within the marine industry Any reference to a specific product or brand is not intended for commercial purposes References to test equipment and products are based upon the information available to the staff of CDI Electronics This information is designed for use as a reference guide by a professional marine technician CDI Electronics cannot be held liable for the misuse or abuse of the information contained herein The staff tries to make the information as accurate as possible However CDI Electronics cannot assume responsibility for either the data accuracy or the consequences of the data s application CDI Electronics 2004 Safety Issues Always remember to treat the outboard engine with respect The engine uses high voltage for ignition and contains several moving components Always be aware of moving mechanical parts the surrounding area and the position of your hands and body near the engine e Never touch electrical components with wet hands e Whenever the power source is not needed disconnect the cable from the negative terminal e Never reverse the battery leads when you connect the battery or disconnect the terminals while the engine is running e Never touch high tension leads spark plug leads with any ungrounded tools while the engine is running e Never install equipment with requirements exceeding the g
35. NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS 1 Ifthe cylinders only misfiring above an idle connect a inductive Tachometer to all cylinders and try to isolate the problem cylinders 2 Check the trigger resistance and DVA output as given below Wire Color Check to Wire Color Resistance DVA Reading Brown wire White Black 800 1400 4V or more Connected White wire White Black 800 1400 4V or more Connected Purple wire White Black 800 1400 4V or more Connected Brown wire Engine GND Open 1V or more White wire Engine GND Open 1V or more Purple wire Engine GND Open 1V or more This reading can be used to determine if a pack has a problem in the triggering circuit For instance if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad 3 Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both terminals If the reading is low on one cylinder disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading symptom indicates a bad power pack
36. PK PLG HP YEAR STK MDL o y OHMS DVA CHECK POINTS OHMS DVA CHECK POINTS OHMS 10 CAP L Spd HSpd LS HS HS LS Ohms DVA Primary Sec Wht Red to BI Wht Grn to Wht BIk to 8 93 250 2003 2004 6 2 HPDI CDI OUTPUT 160 Red to BIK Wht 294 398 3 5 Wht Blue to Blk 140 1 87 2 53 12 08 None Wht Yel to Blk Wht Brn to Blk Wht Red to BI Wht Grn to LZIVZIZ Wht BIk to Blk 7 31 300 2004 6 2 HPDI CDI OUTPUT 265 Red to BIK Wht 294 398 3 5 Wht Blue to Blk 265 1 36 1 84 9 89 K None Wht Yel to Blk Wht Brn to 75 Glossary of Terms ADI Alternator Driven Ignition consists of a flywheel stator trigger and ignition module ADTC After Top Dead Center Reference on ignition timing BTDC Before Top Dead Center Reference on ignition timing CD Ignition Capacitive Discharge Ignition The capacitor stores the power developed by a stator or inverter and uses a SCR to deliver the power to the ignition coil CDM Capacitive Discharge Module The CDM 1 a combination of the switch box and ignition coil Crank Refers to the engine being turned over with the starter not running Spark plug wires are usually connected to a spark gap tester DVA Direct Voltage Adapter Also known as Peak voltage The term refers to the peak voltage as read by a specialized meter or a multimeter using a adapter to convert the peak voltage in the ignition system to a DC value R
37. PM readings at the RPM where the problem is occurring If only one cylinder is dropping out swap the ignition coil locations and retest If the problem follows a coil replace the coil If it stays on the same spark plug replace the switch box If both cylinders become intermittent replace the switch box 5 lt n o oO gt o o 5 09 Two Cylinder Engines 1994 1996 With the 18495A4 5 A6 A8 A11 or A13 Switch Box NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wire AT THE PACK and retest If the engine s ignition now has spark now the stop circuit has a fault possibly the key switch harness or shift switch 2 Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly 3 Check the stator resistance and DVA output as given below Black Stator WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA Blue Blue White 3250 3650 500 600 180V or more Red Red White 75 90 28 32 25V or more Red Stator WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more Red Stator Adapter Not Available from CDI WIRE Read To OEM RESISTANCE DVA Blue Engine GND OPEN 180V or more 49 SPARK OR INTERMITTENT ON ONE CYLINDER 1 Ifthe cylinders are only misfiring above an idle connect an inductive an Tachometer to each cylinder in turn and try to isolate the problem cylinder 2 Check the trigger resistance
38. READING VOLTAGE AND RESISTANCE CHARTS NOTICE These charts were compiled using the CDI 511 9773 Peak Adapter with a shielded Digital Multimeter NOTE The resistance readings are given for a room temperature of 68 F Higher temperatures will cause a slightly higher resistance reading DVA readings should always be taken with everything hooked up with the exception of the kill circuit The CDI peak reading voltage adapter is specifically designed to work with shielded Digital Multimeters This adapter will simplify the testing of electronic ignition systems stators sensors and charging systems The DVA readings will be approximately the same as any other DVA meter and the specifications listed in the service manuals can be followed without problems Hopefully a little easier to you The CDI piercing probe set 511 9770 and the pack load resister 511 9775 are highly recommended for use with this adapter INSTRUCTIONS 1 Plug the adapter into the shielded Digital Multimeter with the rib side pin in the V Ohms jack and the other pin in the COM jack 2 Set the digital voltmeter to DC Volts the purpose of the adapter is to convert and store the voltage so that it can be read by a meter 3 Connect the probes to the component to be measured NOTE The adapter will automatically compensate for polarity and all readings will be peak voltage See the following pages for readings of Chrysler Force Mercury OMC Johnson Evinrude
39. and DVA output as shown below Wire Color Check To Wire Color Resistance DVA Reading Brown wire White wire 800 1400 4V or more Connected Brown wire Engine GND Open or more White wire Engine GND Open 1V or more This reading can be used to determine if a pack has a problem in the triggering circuit For instance if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad 3 Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both places If the reading is low on one cylinder disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading indicates a bad power pack WILL NOT ACCELERATE BEYOND 3000 4000 RPM 1 Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem A single cylinder dropping fire will likely be the switch box or ignition coil All cylinders misfiring usually indicate a bad stator 2 Connect a DVA meter between the stator s blue wire and blue white wires Perform a running test The DVA voltage should jum
40. back on the other cylinders A shorted stop circuit in one CDM will prevent ALL cylinders from sparking Disconnect the yellow wires from the rectifier and retest If the engine has spark replace the rectifier Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly Check the stator resistance and DVA output as given below WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more Check the resistance of each of the CDM s as follows Red Meter Lead Black Meter Lead Reading CDM Pin Z A C 700 1300 Ohms CDM Pin Z D A DIODE CDM Pin Z A D DIODE CDM Pin Z D B DIODE CDM Pin Z B D DIODE CDM Pin Z A B DIODE CDM Pin Z B A DIODE High Tension Lead A 700 1300 Ohms Note Diode readings are to be read one way then reverse the leads and read again You should get a low reading in one direction and a higher reading in the other NO SPARK OR INTERMITTENT SPARK ON ONE OR TWO CYLINDERS 1 Inspect the spark plug wires boots and spark plugs Check for chafing on the wiring and harnesses 2 Clean and inspect CDM ground wire connection to engine ground 3 Ifthe cylinders are only misfiring above idle connect an inductive RPM meter to all cylinders and try to isolate the problem cylinders 4 Using a set of piercing probes check the trigger Resistance and DVA output as given below Wire Color Check to Wire Color OEM Resistance CDI Resistance DVA Rea
41. ch harness and shift switch Swap the White Green and Green White stator wire and retest If the problem moves to the other cylinder the stator is likely bad Disconnect one CDM module at a time and using a set of piercing probes and jumper wires short the stator and trigger wire in the CDM connector to engine ground Retest If the other module starts sparking the CDM you unplugged is bad Disconnect the yellow wires from the stator to the rectifier and retest If the engine now has spark replace the rectifier Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to spark properly Check the stator resistance and DVA output as follows WIRE Read to OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more Check the resistance of the CDM as follows Red Meter Lead Black Meter Lead Reading CDM Pin A C 700 1300 Ohms CDM Pin D A DIODE CDM Pin A D DIODE CDM Pin D B DIODE CDM Pin B D DIODE CDM Pin A B DIODE CDM Pin B A DIODE High Tension Lead A 700 1300 Ohms Diode readings are to be read one way then reverse the leads and read again You should get a low reading in one direction and a higher reading in the other NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER l If the cylinders are only misfiring up above an idle connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders 2 Using a set of piercing probes
42. check the trigger DVA output as shown below Wire Color Check To Wire Color Resistance DVA Reading White wire Engine GND Open or more Brown wire Engine GND Open or more 3 If 1 isnot sparking swap the White Green and Green White stator wire and retest If the problem moves to the 2 cylinder the stator is likely bad If no change swap locations with 2 and see if the problem moves If it does the module is bad A continued no spark condition on the same cylinder indicates a bad trigger 4 Check the resistance of the CDM as follows Red Meter Lead Black Meter Lead Reading CDM Pin A 700 1300 Ohms CDM Pin D A DIODE CDM Pin D B DIODE CDM Pin A B DIODE High Tension Lead A 700 1300 Ohms Diode readings are to be read one way then reverse the leads and read again You should get a low reading in one direction and a higher reading in the other High Speed Miss 1 Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem A high variance in RPM on one cylinder usually indicates a problem in the trigger or CDM module 2 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem 3 Remove the flywheel and check the triggering and charge coil flywheel magnets for cracked or broken magnets 56 Stop Circuit Black Yellow Purple Trigger White Trigger
43. ck the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly 3 Check the stator resistance and DVA output as given below Stator WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA Blue Black 2900 3500 2200 2600 180V or more connected Red Black 100 180 200 250 25V or more connected Black Eng Gnd Open Open 2V or more connected NO SPARK OR INTERMITTENT ON ONE CYLINDER 1 Ifthe cylinders only misfiring above an idle connect an inductive an Tachometer to each cylinder in turn and try to isolate the problem cylinder 2 Check the trigger resistance and DVA output as shown below Wire Color Check To Wire Color Resistance DVA Reading Brown wire White wire 800 1400 4V or more Connected Brown wire Engine GND Open 1V or more White wire Engine GND Open 1V or more This reading can be used to determine if a pack has a problem in the triggering circuit For instance if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad 3 Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both places If the reading is low on one cylinder disconnect the gre
44. cks or broken magnets 4 Rotate the stator 1 bolt hole in either direction and retest WILL NOT IDLE BELOW 1500 RPM 1 Check the Bias resistance from the Black White terminal to engine ground Reading should be 14 15 000 ohms 2 Check for air leaks 52 Four Cylinder Engines With Ignition Driver Distributors WARNING DO NOT CONNECT 12VDC TO THE IGNITION MODULE AS DC VOLTAGE WILL BURN OUT THE SWITCH BOX AND IGNITION DRIVER NO SPARK ON ANY CYLINDER 1 Disconnect the orange stop wire AT THE PACK and retest If the engine s ignition now has spark the stop circuit has a fault check the key switch harness and mercury tilt switch 2 Check the Ignition Driver resistance and DVA output Wire Color Read to Function Resistance DVA Reading Red White wire Cranking Winding 400 ohms 180V Blue White wire High Speed Winding 10 Ohms 20V Green Engine Gnd Pack output N A 150V White Common for Ignition Driver DOES NOT CONNECT TO ENGINE GND 3 Check the cranking RPM A cranking speed of less than 250 RPM will not allow the system to fire properly NO SPARK ON ONE OR MORE CYLINDERS If only one or two cylinders are not firing on this system the problem is going to be either in the distributor cap or spark plug wires Four Cylinder Engines 1978 1996 Four Cylinder Engines Using a Single Switch Box and Four Ignition Coils NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wires AT THE PACK and retest If the engine s
45. coil locations and retest If the problem follows a coil replace the coil If it stays on the same spark plug replace the switch box 3 Check the flywheel magnets to see if one has come loose and moved 48 Two Cylinder Engines 1979 1996 With the 332 7452 Switch NO SPARK ON ANY CYLINDER 1 Disconnect the Black Yellow stop wire and retest If the ignition system now has spark the stop circuit has a problem 2 Check the stator and trigger resistance and DVA output WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA Black Yellow Engine GND 3250 3650 2200 2400 180V or more Black White Engine GND 150 250 200 250 25V or more Brown Yellow Brown White 750 1400 925 1050 4V or more Brown Yellow Engine GND Open Open or more Brown White Engine GND Open Open or more NO SPARK OR INTERMITTENT ON ONE CYLINDER 1 Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both places If the reading is low on one cylinder disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading indicates a bad switch box 2 Check the trigger resistance and DVA output as shown below Wire Color Check To Wire Color Resista
46. connected is defective Remember that the coils must not be the Black or Blue coils these coils are not isolated ground 4 Test the 336 4516 module as follows 356 4516 REPAIR amp RETURN BLUE WIRE TEST UNIT WITH METER OHM SCALE SELLOWCWIER 1 CHECK STATOR COILS RED WIRE A BLUE YELLOW 170 1800 B RED YELLOW 4 6 4 7KQ ORANGE WIRE CHECK WITH METER 4516 MODULE USE THE FUNTION DIODE SCALE TO MEASURE UNIT FOLLOWING BLK STEP 2 STEP 3 SHORTED STEP S STEP 6 HIGH or OPEN mu CDI DIVISION OF RAPAIR ING FINISH Date Monday May 20 2002 Sheet 1 of T 46 1 2 Ifthe spark remains on the same coil when you swap the points wires and it is the coil where the green wire is coming from 3 Check the ignition coil You should have approximately 1 000 1 ohm of resistance from the spark plug wire to engine 4 Inspect the ignition coils You should have either a red orange or green coil with a bare braided ground wire coming out of Mercury Two Cylinder Engines 1974 1985 With the 336 3962 or 336 3996 Stator Switch Box WARNING DO NOT START AND RUN THIS ENGINE ON A FLUSHING ATTACHMENT OR EAR MUFFS AND ACTIVATE THE STOP CIRCUIT This system operates with the orange stop wire normally shorted to ground When you activate the stop circuit you open the orange s connection to ground The resulting backlash into the sta
47. d Reading CDM Pin Z A C 7700 1300 Ohms CDM Pin Z D A DIODE CDM Pin Z A D DIODE CDM Pin Z D B DIODE CDM Pin Z B D DIODE CDM Pin Z A B DIODE CDM Pin Z B A DIODE High Tension Lead A 700 1300 Ohms Note Diode readings are to be read one way then reverse the leads and read again You should get a low reading in one direction and a higher reading in the other NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS 1 Ifthe cylinders are only misfiring above an idle connect an inductive RPM meter to all cylinders and try to isolate the problem cylinders 2 Disconnect the CDM s one at a time and see if you get spark back on the problem cylinders 3 Using a set of piercing probes check the trigger DVA output as given below Wire Color Check to Wire Color Resistance DVA Reading Purple wire Engine GND Open 3V or more White wire Engine GND Open 3V or more Brown wire Engine GND Open 3V or more White Black wire Engine GND Open 3V or more NOTE These triggers have the bias circuitry internally built in therefore you cannot measure the resistance like you can measure on the older engines In addition these engines use four triggering coils versus the two triggering coils used on the older engines 4 Disconnect one of the CDM modules that are firing one at a time and see if the dead CDM starts firing If it does the CDM you just unplugged is bad High Speed Miss 1 Connect an inductive RPM meter to all cylinders and try to isolate
48. d on the meter to the ground connection of the ignition or battery charging system then working your way back to the battery negative post At no time should you see a reading above 1 V Johnson Evinrude Model to Year Identification for 1980 and newer Engines INTRODUCES I N T R O D U S 1 2 3 4 5 6 7 8 9 0 Example J150TTLCE would be 1989 150 HP Johnson and aE175STEU would bea 1997 175 HP Evinruide Engine Wiring Cross Reference Chart for Most Outboards m Mercury Mercury Force Force Circuit PRE 1978 1978 amp Yamaha PRE 1994 amp yp SUZUKI Power Red Red Red Red Red Red Purple White Ign Switch White Purple Purple Yellow Blue Red Blue Gray Eng Gnd Black Black Black Black Black Black Black Orange Green Kill Circuit Salmon Blk Yellow Blk Yellow White White BIK Yellow Red White Blue Brown Eng Start Yellow Yellow Red Yellow Red Brown Yellow Yellow Red Yellow Red Tach Brown Gray Gray Green Purple Gray Yellow Battery Yellow Yellow Yellow Charge 9 W Red Yellow Bik Yellow Gry Sree Yellow Yelowsik Yellow Red Blue Blue Red Blue White Brown Blue Blue Blue White Stator CDI White Red Brown Yel Brown Yellow Red Green Power Blue a Red White Brown BIk Red Brown Blue Red White Black Red Green Wht Brown Wht Blk Red Brown Yel Green Wht Wht Green Wht Green Choke EL Yellow BIk
49. different coil If it does you have a problem in the points points wire or insulator block for the cylinder not sparking the stator remove the green jumper wire Swap the green wire coming from the stator from one coil to the other coil If the spark moves to the other coil replace the green jumper wire connecting the two coils ground the backside of the coil This bare braided ground wire MUST be connected to a clean engine ground You cannot use a black or blue ignition coil c A lt m o o oO n gt o o 5 Us Orange or Salmon Wire Stop Wire Must be grounded thru the stop switch to run on two cylinder engine opens the ground path to stop engine Brown wire White wire from Points from points Engine ground Connect to engine ground for a one cylinder engine 47 Mercury Two Cylinder Engines 1974 1985 With the 339 5287 or 339 6222 Switch Box NO SPARK ON ANY CYLINDER 1 Disconnect the Orange stop wire and retest If the ignition system now has spark the stop circuit has a problem 2 Check the stator and trigger resistance and DVA output WIRE Read To RESISTANCE DVA Orange Engine GND 1600 1800 800 900 per coil 180V or more Brown White 140 160 0 5V or more Note Some units had used a trigger that has 2 Brown wires instead of a Brown and White 3 Inspect the ignition coils You should have either a red orange or green coil with a bare braided ground wire co
50. ding Purple wire Blue 1100 1400 850 1050 4V or more White wire Red 1100 1400 850 1050 4V or more Brown wire Yellow 1100 1400 850 1050 4V or more High Speed Miss 1 Connect an inductive RPM meter to all cylinders and try to isolate the problem A high variance in RPM on one cylinder usually indicates a problem in the CDM module 2 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem 3 Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets 4 Index the flywheel and check the timing on ALL cylinders On carbureted models the control module rev limi NO SPARK OR INTERMITTENT SPARK ON 1 2 and 3 OR 74 5 and 6 CYLINDERS 1 2 3 function starts to retard timing in sequence 2 3 4 5 6 1 at 5800 6000 RPM The control module will retard the timing each cylinder up to 30 degrees starting with 2 and then stop firing that cylinder if the RPM is still above the limit It will continue to retard then shut down each cylinder until the engine drops below the limit Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly Disconnect the CDM s one at a time and see if you get spark back on the problem cylinders Check the stator resistance and DVA output as given below Q 5 Z o e
51. e switch box if the stator tests good Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets 51 Three Cylinder Engines 1976 1996 Three Cylinder Engines Using a Single Switch Box and Three Ignition Coils NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wire AT THE PACK and retest If the engine s ignition now has spark the stop circuit has a fault check the key switch harness and shift switch 2 Disconnect the yellow wires from the stator to the rectifier and retest If the engine has spark replace the rectifier Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly 4 Check the stator resistance and DVA output as given below Flywheel with Bolted in Magnets e WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA BlueEngine GND 5800 7000 2200 2400 180V or more Red Engine GND 135 165 45 55 25V or more Flywheel with Glued in Magnets WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA BlueEngine GND 3250 3650 500 600 180V or more Red Engine GND 75 90 28 32 25V or more Red Stator Kit WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more Blue Engine GND OPEN 180V or more
52. eed when the water pressure gets high but a normal shutdown will mask the problem Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets Use the diagram below to help in locating the area where the problem may be Remember a short in 1 can cause either 2 and 3 not to have spark By the same reason a problem in either 2 or 3 can cause 1 not to have spark Stop Circuit Black Yellow Purple Trigger White Trigger Brown Trigger mo eag a White Green Green White Green White Stator Stator Stator lt x Q c o x Q J E 4 2 2 lt 2 o 5 oa 57 Four Cylinder Engines 1996 2006 Engines Using CDM Modules NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wires from the harness and RPM Limiter Retest If the engine s ignition has spark the stop circuit has a fault check the key switch harness and shift switch 2 Disconnect the yellow wires from the rectifier and retest If the engine has spark replace the rectifier 3 Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly 4 Check the stator resistance and DVA output as given below WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA White Green Green White 500 700 500 600 180V or more 5 Check the resistance of the CDM as follows Red Meter Lead Black Meter Lea
53. egular meters cannot read the voltages due to the frequency and duration of the pulses in the system Power Pack Term used by Johnson Evinrude for the ignition module RPM Revolutions per minute The number of times the engine rotates in one minute S L O W Speed Limiting Oil Warning system Limits the RPM of the engine to approximately 2500 RPM in order to reduce the damage to the engine caused by a no oil or overheat condition Spark Tester Device used to check for spark from the ignition coil to the spark plug Testers are normally available in 1 4 6 and 8 cylinder configurations Switch Box Term used for Force Mariner and Mercury ignition modules W O T Wide Open Throttle 76 Modified Engine Wiring Diagrams for CDI Electronics Components TOBATTERY GREEN YELLOW DVA 180V MINIMUM 2 94 PRESTOLITE I SS FORCE 2 CYL Ignition M sraron JE w FORK Terminals AN j TYPE Ill COIL m RA T ma GGNITION BLUERED 81 CYL PLUG 82 CYL PLUG NOTICE This stator has been redesigned to enhance the durability and reduce inventory stock levels It replaces the original multiple windings with a single winding using larger wire This design allows ALL of the Blue Brown Blue wires to be connected together and ALL of the Yellow Brown Yellow wires to be connected together from the stator This design allows the stator to be used for the 2 3 4and 5 cylinder applicatio
54. en wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading indicates a bad power pack 50 Two Cylinder Engines 1994 1996 With the 1849549 A14 A16 A20 A21 or A30 Switch Box Continued WILL NOT ACCELERATE BEYOND 3000 4000 RPM 1 2 3 Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem A single cylinder dropping fire will likely be the switch box or ignition coil All cylinders misfiring usually indicate a bad stator Connect a timing light to 1 cylinder and verify that the timing is advancing Also check to make sure the timing is not retarding too early Connect a DVA meter between the stator s blue wire and black wires Perform a running test The DVA voltage should jump up to well over 200V and stabilize A drop in voltage right before the problem occurs indicates a bad stator read the blue wire to engine ground if the engine has a red stator kit installed Connect a DVA meter between the stator s red wire and black wires The DVA voltage should show a smooth climb in voltage and remain high through the RPM range A reading lower than the reading on the blue wire indicates a bad stator If both cylinders become intermittent replace the switch box Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high
55. enerating power of the engine Reference the service manual for values e Attempt to protect the electronic components from water e Insure fuel lines harnesses and oil lines are properly routed Failure to follow this rule could result in a fire hazard e Make sure all ground leads are clean and tight Recommended Marine Shop Electrical Test Equipment and Tools The following is a listing of tools available from CDI Electronics and recommended for testing late model engines Part Number Description Remarks Use 511 9764 Neon Spark Tester Sealed single cylinder has removable ground clamp can be used for running tests 511 9766 Sealed Spark Gap Tester Allows for testing up to 8 cylinder for cranking tests Sealed design reduces the chance of engine fire 511 9770 Piercing Probes Allows access to wires for testing without removing the connection Tiny hole usually reseals itself 511 9773 DVA Peak Voltage Adapter Unit automatically compensates for polarity Can be used with most quality Multimeters 511 9775 Load Resistor Used to load the output of ignition modules when testing ignition coils 518 33A CDI 33 Meter Meter has voltage amperage diode check and ohms Includes 511 9773 DVA Adapter DVA Adapter allows meter to read peak voltage 518 80TK Fluke Temperature Adapter Works with most digital Multimeters capable of reading millivolts 520 ST80 DC Inductive Timing Light DC Powered timing light
56. han one cylinder is not firing Replace BOTH switch boxes unless you can pin the problem down to the trigger Replacing just one switch box can result in damage to the engine if the remaining switch box on the engine has a problem in the bias circuit Always check the bias circuit Disconnect the White Black jumper between the switch boxes and check the resistance from the White Black terminal on each switch box to engine ground You should read 12 15 000 ohms on stock switch boxes and 9 000 9 800 ohms on racing switch boxes MAKE SURE THE READING IS THE SAME ON BOTH SWITCH BOXES Any problem with the bias circuit and BOTH switch boxes must be replaced as a set No Fire on 1 3 5 or 2 4 6 Swap the stator leads from one switch box to the other If the problem moves replace the stator If the problem remains on the same cylinders replace the switch box If the stator 1 replaced and the problem is still present try another flywheel No Fire on One Cylinder This can be caused by a defective blocking diode in the other switch box Disconnect the White Black jumper between the switch boxes and retest If all cylinders are now firing replace the switch box that was originally firing all three cylinders To verify this condition swap the trigger leads on the switch box that was originally firing all three cylinders If the misfire moves to another cylinder the switch box is bad Voltage Drop Measurement Start by using a good digital auto ranging
57. he black meter lead on the battery POS post and the red meter lead on the positive battery cable at the starter solenoid Keep the black lead on the battery post and shift the red meter lead to the positive post of the rectifier then to the red and white terminals on the switch box If you find a reading above 0 6V there is a problem at the point where the voltage jumped up For example if the meter reads 0 4V until you get to the white terminal and then jumps to 2 3V on the white terminal this indicates a problem in the key switch or harness Repeat the test for the negative battery post by putting the black meter lead on the battery NEG post and the red meter lead on the negative battery cable terminal then shifting to the engine block rectifier base and case ground of the CD module Battery CD Ignitions without Points Three Cylinder Engines with 332 4796 393 4797 Battery Type Ignitions Note CD Tester by CDI Electronics 511 9701 or Merc o Tronics can be used to test the CD module distributor cap rotor button and spark plug wires on the engine while the Trigger Tester by CDI can be used to test the distributor trigger SERVICE NOTE Check the battery voltage at approximately 3500 RPM MAXIMUM reading allowable is 16 volts and minimum is 12V Running below 12V or over 16 volts will damage the ignition Check for loose connections or a bad battery Maintenance free batteries are NOT recommended for this application
58. ht Red White BIk Yel Black Yellow Stripe YAMAHA DVA and RESISTANCE CHARTS sr STATOR TRIGGER cpi IGNITION COIL En HE NE OY ae CHECK DV CHECK Out OHMS DVA SONIS D Sonne OHMS 10 LIH DV LS us s S HS LS Ohms A Pri Sec 2 uU 1 2 320 390 Brown to Gnd N A N A 021 32K 11 6 2003 K 25 200 154 F 56 84 4 46K K 30 36 Red White to 1984 LS BLK 2 6 3 Per 1 2 250 300 100 Brown toBLK d 0 1 gt 340 HS BLK 30 36 White Red to 1984 LS BLK 3 1 4 1999 1 2 250 300 100 Brown to BLK 280 White Grn to 0 1 K None 340 HS BLK 11 6 1999 K 49 54 4 di 1 126 to Gnd 56 84 4 2 K 1984 2055 iy BLK 3 1 5 12 250 300 00 Brownto LS 280 03 None 2002 White Grn to K 340 HS BLK 1984 White Red to 35 6 bie 2 2 81 99 00 BrowntoBLK 92 111 A 0 1 None 2001 White Red to 78 6 8 oat 2 4 F 81 99 00 BrowntoBLK 92 111 ae 0 1 None 1986 White Red to 35 8 2 2 81 99 00 Brown 92 111 2 0 3 None 1984 White Red to 35 9 9 pan 2 2 81 99 00 BrowntoBLK 92 111 zi 0 3 E None 1993 White Red to 54 9 9 Dus 2 2 81 99 00 BrowntoBLK 92 111 Br 0 3 None 1996 396 White Red to 21 gos 1996 2 2 280 340 05 Brown to yu 0 6 A None 198
59. l z 4 x c 2 c 2 2 o 5 MS WIRE Read To OEM CDI DVA White Green Green White 500 700 ohms 500 600 ohms 180V or more connected White Green Engine Gnd Open Open 180V or more connected White Green Engine Gnd Open Open Less than 2 V disconnected Green White Engine Gnd Open Open 180V or more connected Green White Engine Gnd Open Open Less than 2 V disconnected 59 60 Using a set of piercing probes check the trigger Resistance and DVA output as given below Wire Color Check to Wire Color OEM Resistance CDI Resistance DVA Reading Purple wire Blue 1100 1400 850 1050 4V or more White wire Red 1100 1400 850 1050 AV or more Brown wire Yellow 1100 1400 850 1050 4V or more Using a set of piercing probes check the trigger voltage going to the CDM s Wire Color Check to Wire Color OEM Resistance CDI Resistance DVA Reading Purple wire Engine GND Open Open 3V or more White wire Engine GND Open Open 3V or more Brown wire Engine GND Open Open 3V or more Blue wire Engine GND Open Open 3V or more Red wire Engine GND Open Open 3V or more Yellow wire Engine GND Open Open 3V or more The connection guide below will assist you in locating areas where problems can occur Remember a short in either 1 2 or 3 can cause either 4 5 and 6 not to have spark Stop Circuit Black Yellow Blue White Red White Purple White White Black Brown White Green White White Green CDI ELECTRONICS DVA PEAK
60. likely shorted as well Any sign of rubbing on the outside of the stator indicates a problem in the upper or lower main bearings A cracked trigger or outer charging magnets can cause many problems ranging from misfiring to no fire at all Loose flywheel magnets can be dangerous check the tightness of the bonding adhesive Rectifier Regulators can cause problems ranging from a high speed miss to a total shutdown An easy check 1 to disconnect the stator leads to the rectifier Make sure to insulate them and retest If the problem is gone replace the rectifier regulator Johnson Evinrude Open Timer Bases When all cylinders fire with the spark plugs out but will not with them installed try re gapping the sensors using P N 553 9702 Gap Gauge See the section on OMC ADI Ignitions page 22 24 Engines with S L O W Features If the customer is complaining that the engine won t rev up and shakes real bad the S L O W function could be activating If the engine is NOT overheating a temperature sensor or VRO sensor failing early can cause this problem Disconnect the TAN wires at the power pack and retest If the engine performs normally reconnect the tan wires one at a time until the problem recurs then replace the last sensor you connected Make sure that all of the TAN wires are located as far as possible from the spark plug wires Also check the blocking diode in the engine harness Mercury 6 Cylinder Engines with ADI Ignitions If more t
61. lug replace the switch box 3 Check the flywheel magnets to see if one has come loose and moved Mercury Two Cylinder Engines 1974 1985 With the 332 4911 or 332 4733 Switch Box NO SPARK ON ANY CYLINDER 1 Disconnect the Orange or Black Yellow stop wire and retest If the ignition system now has spark the stop circuit has a problem 2 Check the stator and trigger resistance and DVA output WIRE Read To RESISTANCE CDI RESISTANCE DVA Blue Engine GND 3500 5500 180V or more Red Engine GND 450 550 20V or more Brown White 140 160 0 5V or more 3 Check the flywheel for broken magnets ENGINE HAS SPARK BUT WILL NOT RUN 1 Index the flywheel and check the timing If it is out by 180 degrees swap the trigger wires to the switch box 2 Ifthe timing is off by any other degree check the flywheel key NO SPARK OR INTERMITTENT ON ONE CYLINDER 1 Check the DVA output from the switch box on the Green wires while they are connected to the ignition coils You should have a reading of at least 150V or more If the reading is low on one cylinder disconnect the wires from the ignition coil for that cylinder and reconnect them to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading indicates a bad switch box 2 Connect an inductive tachometer to each cylinder and compare the RPM readings at the RPM where the problem is occurring If only one cylinder is dropping out swap the ignition
62. ming out of the backside of the coil This bare braided ground wire MUST be connected to a clean engine ground You cannot use a black or blue ignition coil 4 Check the ignition coils as follows Check resistance from to terminal reading should be 0 2 1 0 ohms and 800 1100 ohms from the high tension lead to engine ground There should be no connection from the terminal to engine ground 5 Check the flywheel for broken magnets ENGINE HAS SPARK BUT WILL NOT RUN Index the flywheel and check the timing If it is out by 180 degrees swap the trigger wires to the switch box If the timing is off by any other degree check the flywheel key NO SPARK OR INTERMITTENT ON ONE CYLINDER 1 Check the DVA output between the Green wire and Green Whites from the switch box also between the Blue and Blue White wires while they are connected to the ignition coils You should have a reading of at least 150V or more If the reading is low on one cylinder disconnect the wires from the ignition coil for that cylinder and reconnect them to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading indicates a bad switch box 2 Connect an inductive tachometer to each cylinder and compare the RPM readings at the RPM where the problem is occurring If only one cylinder is dropping out swap the ignition coil locations and retest If the problem follows a coil replace the coil If it stays on the same spark p
63. nce DVA Reading Brown wire White wire 800 1400 4V or more Connected Brown wire Engine GND Open 1V or more White wire Engine GND Open 1V or more This reading can be used to determine if a pack has a problem in the triggering circuit For instance if you have no fire on 8 p one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad 3 Connect a inductive tach to each cylinder and compare the RPM readings at the RPM where the problem is occurring If only one cylinder is dropping out swap the ignition coil locations and retest If the problem follows a coil replace the coil If it stays on the same spark plug replace the switch box 4 Check the flywheel magnets to see if one has come loose and moved WILL NOT ACCELERATE BEYOUND 3000 4000 RPM 1 Check the stator resistance and DVA output WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA Black Yellow Engine GND 3250 3650 2200 2400 180V or more Black White Engine GND 150 250 200 250 25V or more 2 Connecta DVA meter to the Black White wire terminal and while under load run the engine up to the RPM where the problem is occurring The stator high speed voltage should increase with RPM If the stator voltage falls off or if it does not increase with RPM replace the stator 3 Connect an inductive tach to each cylinder and compare the R
64. nd Open 1V or more F mn lt lt 2 o oO un gt o o 5 ga This reading can be used to determine if a pack has a problem in the triggering circuit For instance if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both places If the reading is low on one cylinder disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading indicates a bad power pack WILL NOT ACCELERATE BEYOND 3000 4000 RPM 1 2 Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem A single cylinder dropping fire will likely be the switch box or ignition coil Connect a DVA meter between the stator s Green White wire and White Green wires Perform a running test The DVA voltage should jump up to well over 200V and stabilize A drop in voltage right before the problem occurs usually indicates a bad stator If both cylinders become intermittent replace th
65. nder engines with CDM Modules Single Ended Timer Unipolar Hub Magnet Base S E R Coil CDM Trigger Circuit Board Mercury Hub Magnet Design Push Pull Trigger Coil Design 1978 1996 on2 3 and 4 Cyl engines 1978 2005 L6 2 0L 2 4L and 2 5L engines 5 2 o 0 gt o o 5 ga The breaks in the magnets cannot be seen due to the Trigger out metal cover Trigger out Note that the design of the magnet for the push pull is the same for the 3 4 and 6 cylinder engines using standard ADI ignitions The trigger magnet for the CDM modules is completely different 45 Mercury Alternator Driven Ignitions Two Cylinder Engines 1971 1975 With Phase Maker Ignition NO SPARK ON ONE OR BOTH CYLINDERS 1 Disconnect the orange stop and retest If the engine now has spark the stop circuit has a fault 2 Check the Stator resistance and DVA output as given below Wire Color Check to Wire Color Resistance DVA Reading Red wire Yellow wire 320 550 Not Available Blue wire Yellow wire 3600 5500 Not Available Green wire Engine Ground 180V or more Connected 2 Disconnect the points wires Brown and White one at a time and retest If the spark comes back on the one still connected when you disconnect one of them the points or points wire is defective for the disconnected cylinder 3 Disconnect the Green wires one at a time and retest If the spark comes back on one cylinder the ignition coil not
66. ns TO BATTERY VHITE GREEN 300 4000 DVA 180V MINIMUM CYL FORCE TYPE Ill IGNITION SYSTEM NOTICE This stator has been redesigned to enhance the durability and reduce inventory stock levels It replaces the original multiple windings with a single winding using larger wire This design allows ALL of the Blue Brown Blue wires to be connected together and ALL of the Yellow Brown Yellow wires to be connected together from the stator This design allows the stator to be used for the 2 3 4and 5 cylinder applications 78 Modified Engine Wiring Diagrams for CDI Electronics Components TO BATTERY WHITE ORANGE DVA 180V MINIMUM 4 CYL FORCE TYPE III IGNITION SYSTEM LJ J N a t NOTICE This stator has been redesigned to enhance durability i and reduce inventory stock levels It replaces the original dual winding with a single winding with larger wire This design allows ALL of the Yellow Brown Yellow wires to be connected together and ALL of the Blue Brown Bluc wires to be connected together from the stator permitting the stator to be used for the 2 3 4 and 5 cylinder application IGNITION ORANGE BLUE BLUE RED 1 ORANGE BLUE BLACK VELLOW STOP SWITCH BLUE RED KH IGNITION BLACK BLACK COIL WHITE 2CYL BLACK es IGNITION BLACK COIL Lj MODULE 3 CYL 24 IGNITION BLACK COIL L 4 CYL N C WHITE ORANGE
67. ove 0 6V move the Black lead on the meter to the positive battery cable terminal on the battery and retest If the reading drops to below 0 6V the cable is bad or undersized Service Note A bad power connection to the ignition or battery charging system can be found by connecting the Black lead on the meter to the power connection of the ignition system or charging system then working your way back to the battery positive post At no time should you see a reading above 1V Testing the Negative Battery Cable to the Engine Select the DC Volts position on the meter Connect the Black Negative lead on the meter to the negative battery POST Connect the Red Positive lead on the meter to the engine block where the negative battery cable is connected Using a remote start switch activate the starter solenoid to spin the engine and observe the reading on the meter reading above 0 6V is an indicator of a bad cable or bad connection a Ifthe meter reads above 0 6V move the Red lead on the meter to the negative battery cable terminal on the engine block and retest If the reading drops to below 0 6V the cable connection 1 bad b If the meter still reads above 0 6V move the Red lead on the meter to the negative battery cable terminal on the battery and retest If the reading drops to below 0 6V the cable is bad or undersized Bes A bad ground connection to the ignition and battery charging system can be found by connecting the Red lea
68. p up to well over 200V and stabilize A drop in voltage right before the problem occurs indicates a bad stator read the blue wire to engine ground if the engine has a red stator kit installed 3 Connect a DVA meter between the stator s red wire and red white wires The DVA voltage should show a smooth climb in voltage and remain high through the RPM range A reading lower than the reading on the blue wire indicates a bad stator 4 If both cylinders become intermittent replace the switch box 5 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem 6 Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets Two Cylinder Engines 1994 1996 With the 18495A9 A14 A16 A20 A21 or A30 Switch Box NOTE This engine has a locked trigger arm Therefore the timing is controlled by the switch box and is adjusted according to the engine RPM RPM limiting is done by retarding the timing at high RPM s Where possible it is recommended that the ignition system be changed over to either the newer type ignition or the older type of ignition NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wire AT THE PACK and retest If the engine s ignition now has spark now the stop circuit has a fault possibly the key switch harness or shift switch 2 Che
69. reading allowable is 16 volts and minimum is 12V Running below 12V or over 16 volts will damage the ignition Check for loose connections or a bad battery Maintenance free batteries are NOT recommended for this application Engine Wiring Connection for Testing Ignition Module Engine Ground 4 or 6 Cylinder Battery Ignition Disconnect Trigger Wires Before Testing Jumper Wire Red wire has to Jumper Wire be connected to 12V Use a jumper wire and tap against engine ground Unit should fire each time Ignition Coil General 1 Clean all battery connections and engine grounds 2 Disconnect the mercury tilt switch and retest If the ignition works properly replace the mercury switch 3 Connect a spark gap tester to the spark plug wires and check for fire on all cylinders If some cylinders fire and not others the problem is likely in the distributor cap rotor button or spark plug wires 4 Perform a voltage drop test after the engine is repaired to see if there is a problem with the voltage going to the CD module At cranking and while the engine is running use a DC voltmeter and put the black meter lead on the battery POS post and the red meter lead on the positive battery cable at the starter solenoid Keep the black lead on the battery post and shift the red meter lead to the positive post of the rectifier then to the red and white terminals on the switch box If you find a reading above 0 6V there is a problem
70. roximately 7 16 When you crank the engine over if it fires while the spark gap tester is connected to the coil and does not fire through the spark plug wires there is a problem in the distributor cap rotor button or spark plug wires Check voltage present on the white and red terminals while at cranking It MUST be at least 9 volts If not there is a problem in the harness key switch starter battery cables or battery Check DVA voltage on the green wire going to the coil it should be over 100 volts at cranking Disconnect the brown points wires Turn the ignition switch on and strike one of the brown points wire against engine ground The unit should fire each time If the coil does fire this means the CD module is usually good and the points points plate and grounding wire for the points plate should be checked Connect a spark gap tester to the high tension leads coming from the distributor cap and set the gap to approximately 7 16 Align the rotor with 1 spark plug wire Turn the ignition switch and strike the brown points wire against engine ground Or use a CD Tester Only the 1 spark plug wire should fire If any other spark plug wire now has fire there is a problem in the distributor cap Repeat the test for the other cylinders Perform a voltage drop test after the engine is repaired to see if there is a problem with the voltage going to the CD module At cranking and while the engine is running use a DC voltmeter and put t
71. s a problem usually in the switch box or ignition coil Occasionally a trigger will cause this same problem Check the trigger as described above under No fire or Intermittent on One or More Cylinders 2 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem 3 Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets WILL NOT IDLE BELOW 1500 RPM 1 Index the flywheel and check the timing on all cylinders If the timing cannot be adjusted correctly or if the timing is off on one cylinder replace the trigger 2 Check for air leaks 3 Check synchronization of the carburetors Inline 6 and V6 Carbureted Engines Using Dual Switch Boxes and Six Ignition Coils NO SPARK ON ANY CYLINDER 1 Disconnect the black yellow stop wires AT THE PACK and retest If the engine s ignition has spark the stop circuit has fault check the key switch harness and shift switch 2 Disconnect the yellow wires from the rectifier and retest If the engine has spark replace the rectifier 3 Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly NO SPARK ON ONE BANK 3 OF 6 ON THE INLINE L 6 1 Check the stator resistance and DVA output as shown below 9 to 16 Amp Battery Charging Capacity WIRE Read
72. shown below 54 BLACK SLEEVE TO YELLOW SLEEVE Resistance DVA Reading Brown wire White wire 800 1400 4V or more Connected White wire Purple wire 800 1400 4V or more Connected Purple wire Brown wire 800 1400 4V or more Connected Service Note You should get a high or open resistance reading to engine ground from each wire but you will get a DVA reading of approximately 1 2 Volts This reading can be used to determine if a pack has a problem in the triggering circuit For example if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low disconnect the trigger wire and recheck the DVA output to ground from the trigger wire If the reading stays low the trigger is bad Check the DVA output on the green wires from the switch box while connected to the ignition coils Check the reading on the switch box terminal AND on the ignition coil terminal You should have a reading of at least 150V or more at both terminals If the reading is low on one cylinder disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading symptom indicates a bad power pack ENGINE WILL NOT ACCELERATE BEYOND 3000 4000 RPM 1 Connect an inductive RPM meter to all cylinders and try to isolate the problem If two or more cylinders on the same bank are dropping out the problem is likely going to be ei
73. speed when the water pressure gets high but a normal shutdown will mask the problem Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets Two Cylinder Engines 1994 2006 With the 855721A3 amp A4 Switch Box NO SPARK ON ANY CYLINDER 1 2 3 NO SPARK OR INTERMITTENT ON ONE CYLINDER l 2 Disconnect the black yellow stop wire AT THE PACK and retest If the engine s ignition now has spark now the stop circuit has a fault possibly the key switch harness or shift switch Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly Check the stator and trigger resistance and DVA output as given below WIRE Read To OEM Ohms CDI Ohms DVA Green White White Green 660 710 350 450 180V minimum connected Green White Eng Gnd Open Open None disconnected White Green Eng Gnd Open Open None disconnected Brown White Brown Yellow 850 1100 850 1100 4V minimum connected Brown White Eng Gnd Open Open None disconnected Brown Yellow Eng Gnd Open Open None disconnected If the cylinders are only misfiring above an idle connect an inductive an Tachometer to each cylinder in turn and try to isolate the problem cylinder Check the trigger resistance and DVA output as shown below Wire Color Check To Wire Color Resistance DVA Reading Brown White Brown Y ellow 850 1100 4V minimum connected Brown White Eng Gnd Open 1V or more Brown Yellow Eng G
74. t and the red meter lead on the positive battery cable at the starter solenoid Keep the black lead on the battery post and shift the red meter lead to the positive post of the rectifier then to the red and white terminals on the switch box If you find a reading above 0 6V there is a problem at the point where the voltage jumped up For instance if the meter reads 0 4V until you get to the white terminal and then jumps to 2 3V on the white terminal this indicates a problem in the key switch or harness Repeat the test for the negative battery post by putting the black meter lead on the battery NEG post and the red meter lead on the negative battery cable terminal then shifting to the engine block rectifier base and case ground of the CD module 43 NO SPARK ON ANY CYLINDER l 25 6 If a mercury switch is connected to the switch box disconnect it and retest If you now have spark replace the mercury switch Connect a spark gap tester to the high tension lead coming from the ignition coil and set it to approximately 7 16 When you crank the engine over if it fires while the spark gap tester is connected to the coil and does not fire through the spark plug wires there is a problem in the distributor cap rotor button or spark plug wires Check the DC voltage present on the white trigger wire and the red terminal of the switch box while cranking It MUST be at least 9 volts If not there is a problem in the harness key swi
75. tch starter battery cables or battery Check DVA voltage between the blue terminal and engine ground while cranking The trigger wire must be connected to the switch box You should read at least 9V Disconnect the wire from the blue terminal of the switch box and connect a jumper wire to the terminal Strike the other end of the jumper wire against engine ground The CD module should fire each time Failure to fire usually indicates a bad CD module Check DVA voltage on the green wire going to the coil it should be over 100 volts at cranking NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER l 2 3 Connect a spark gap tester to the spark plug wires coming from the distributor cap and set the air gap to approximately 7 16 Align the rotor with 1 spark plug wire Disconnect wire from the blue terminal of the switch box and connect a jumper wire to the terminal Strike the other end of the jumper wire against engine ground Only the 1 spark plug wire should fire If any other spark plug wire has fire there is a problem in the distributor cap Repeat the test for the other cylinders NOTICE The 4 cylinder engines using the 332 3213 ignition module and belt driven ignition driver DO NOT USE BATTERY VOLTAGE Connecting 12V to the Red terminal will destroy the module 44 Mercury Trigger Magnets THE FLYWHEELS WITH THESE MAGNET DESIGNS CANNOT BE INTERCHANGED Mercury CDM Hub Magnet Design 1996 to 2006 2 3 and 4 cyli
76. the ignition coil terminal You should have a reading of at least 150V or more at both terminals If the reading is low on one cylinder disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the ignition coil is likely bad A continued low reading symptom indicates a bad power pack ENGINE WILL NOT ACCELERATE BEYOND 3000 4000 RPM 1 Connect an inductive Tachometer to all cylinders and try to isolate the problem If two cylinders on the same end of the switch box are dropping out the problem is likely going to be either the switch box or trigger A single cylinder dropping fire will likely be the switch box or ignition coil All cylinders misfiring usually indicate a bad stator 2 Connect a DVA meter to the stator s blue wire and blue white wires and do a running test The DVA voltage should jump up to well over 200V and stabilize A drop in voltage right before the problem occurs indicates a bad stator Check from blue to blue if the engine has a red stator kit installed 3 Connect a DVA meter to the red wire and red white wires and do a running test The DVA voltage should show smooth climb in voltage and remain high through the RPM range A reading lower than the reading on the blue wires indicates a bad stator HIGH SPEED MISS 1 Connect an inductive Tachometer to all cylinders and try to isolate the problem A high variance in RPM on one cylinder indicate
77. ther the stator or the switch box A single cylinder dropping fire will likely mean the switch box or ignition coil is defective Check the stator resistance 9 to 16 Amp Battery Charging Capacity WIRE Read to Engine ground OEM RESISTANCE CDI RESISTANCE Blue 5000 7000 2200 2400 Blue White 5000 7000 2200 2400 Red 90 200 30 90 Red White 90 200 30 90 40 Amp Battery Charging Capacity WIRE Read to Engine ground OEM RESISTANCE CDI RESISTANCE Blue 3400 4200 2200 2400 Blue White 3400 4200 2200 2400 Red 90 140 90 110 Red White 90 140 90 110 Connect a DVA meter to the Blue wire and do a running test The DVA voltage should jump up to well over 200V and stabilize A drop in voltage right before the problem occurs indicates a bad stator Repeat for the blue white wire and compare the readings WIRE Read to Engine ground CRANKING 1000 RPM 3000 RPM Blue 100 265 195 265 255 345 Blue White 100 265 195 265 255 345 Red 25 50 120 160 230 320 Red White 25 50 120 160 230 320 White Black 1 6 3 15 10 30 Q yn 3 o m oO gt o o 5 09 This voltage is read with an analog DC volt meter Not a DVA meter 4 Check trigger as follows WIRE Read to OEM RESISTANCE CDI RESISTANCE DVA CRANKING Brown Black Sleeve White Yellow Sleeve 1100 1400 800 1000 4V or more White Black Sleeve Purple Yellow Sleeve 1100 1400 800 1000 4V or more Purple Black Sleeve Brown Yellow Sleeve 1100 1400 800
78. to load the battery when testing the battery charging output Optional Equipment 511 4017 OMC Optical Sensor Tester Unique handheld tester that will efficiently test the optical ignition sensor 511 0401 CDI 2 Cylinder Ignition Tester New hand held ignition tester generates high voltage stator and low voltage trigger signals to test a variety of 2 cylinder ignition systems Engine specific adapters are required Includes 511 0402 511 0403 and 511 0404 adapters 520 ST84 Ferret Ultra Bright Timing Light Ultra bright timing light is visible in bright sunlight Also has a built in tachometer for 2 and 4 stroke engines This feature is a valuable diagnostic tool when troubleshooting ignition system problems Tricks to Testing with Minimal Test Equipment All Engines Please keep detailed records when you repair an engine If an engine comes in with one cylinder not firing mark which one on the work order history Intermittent Firing This problem can be very hard to isolate A good inductive tachometer can be used to compare the RPM on all cylinders up through WOT wide open throttle A significant difference in the RPM readings can help pinpoint a problem quickly Visually Check the Stator Trigger Rectifier Regulator and Flywheel Cracks burned areas and bubbles in or on the components indicate a problem If the battery charge windings on the stator are dark brown black or burned on most or all of the posts the rectifier regulator is
79. tor may damage the electronics You must use the choke to stop the engine In the water the back pressure from the exhaust will slow the engine quickly enough to prevent damage to the stator Note The insulator blocks used with this stator are very important You are strongly advised to closely inspect the points wires and insulator blocks for cracking or arcing This system operates at a much higher voltage than the normal systems and what would be acceptable on other systems will cause arcing problems NO SPARK ON ANY CYLINDER 1 Disconnect the Orange stop wire and retest If the ignition system now has spark the stop circuit has a problem 2 Use a jumper wire and short the orange Salmon wire to ground If the engine now has spark replace the stop switch 3 Disconnect the points wires from the ignition coils and connect a jumper wire to the negative side of the coils Crank the engine and carefully tap the jumper to engine ground if the coil sparks check the points and points wires If it fails to spark inspect the ignition coil You should have either a red orange or green coil with a bare braided ground wire coming out of backside of the coil This bare braided ground wire MUST be connected to a clean engine ground You cannot use a black or blue ignition coil NO SPARK ON ONE CYLINDER Disconnect the points wires from the ignition coils and swap them for a cranking test Crank the engine over and see if the spark moves to a
80. voltmeter capable of reading 1 10 of a volt The use of an auto ranging meter will allow for more accurate testing without damaging the meter due to an incorrect range setting Remove the spark plug wires form the spark plugs and connect them to a spark gap tester and remove the emergency stop clip as well This prevents the engine from starting and also reduces the chance of getting shocked by the ignition system The use of an ohmmeter to test a conductor or switch contact for their condition is not the best tool to use In most cases it is preferable to use a volt drop test to make sure the conductor as well as the connection is in good condition Before testing remove and clean all battery cables and connection points Testing the Positive Battery Cable to the Engine Select DC Volts position on the meter 2 Connect the Red Positive lead on the meter to the positive battery POST 3 Connect the Black Negative lead on the meter to the starter solenoid terminal where the positive battery cable 15 connected 4 Using a remote start switch activate the starter solenoid to spin the engine and observe the reading on the meter A reading above 0 6V indicates a bad cable or bad connection a Ifthe meter reads above 0 6V move the Black lead on the meter to the positive battery cable terminal on the starter solenoid and retest If the reading drops to below 0 6V the cable connection is bad b If the meter still reads ab
81. with a very bright strobe light 551 33GF Gearcase Filler w Check Valve Universal design makes filling lower units easier Check valve assembly helps prevent oil spills and makes filling easier 551 34PV Pressure Vacuum Tester Repairable metal combination unit does both vacuum and pressure testing 551 5110 Flywheel Holder Longer handle helps during use 551 9765 Spark Plug Wire Puller Grounded design reduces the chances of shocking 553 2700 Amphenol Pin Tool Set Set contains 1 each of 553 2697 Insertion 553 2698 Pin Removal and 553 2699 Socket Removal 553 9702 Sensor Gap Gauge Tool Used to set the timer base air gap on 1973 1978 OMC 3 and 4 cylinder engines with screw terminal power packs 554 9706 Amp Pin Removal Tool Used to remove the connector pins in the ignition system on Chrysler Force engines using the Prestolite type ignitions Also used on the Mercury TPI sensor connectors 911 9783 Bullet Connector Kit Contains 10 pieces each of the male female and sleeves 912 9708 Marine Terminal Kit Contains 100 pieces of hard to find terminals and heat shrink 991 9705 Dielectric Grease Use to keep water and corrosion out of connectors 511 6996 Remote Starter For OMC Used to replace the boat side harness for engine testing Fits most OMC engines 1969 to 2000 511 7900 Remote Starter for Mercury Used to replace the boat side harness for engine testing Fits most Mercury engines 1979 to 2000 519 LB85 Load Bank Used
82. y voltage at approximately 3500 RPM MAXIMUM allowable reading is 16 volts and minimum is 12V Running below 12V or over 16 volts will damage the ignition Check for loose connections or a bad battery Maintenance free batteries are NOT recommended for this application SERVICE NOTE Due to problems associated with this system it is recommended that the system be converted over to a 332 2986 393 3736 type system CDI Electronics offers a conversion kit P N 114 2986K1 Engine Wiring Connection for Testing Ignition 337 4411 Module 4 Cylinder Battery Ignition Engine Ground 12V from Battery Trigger Use a Jumper and Tap against Engine Ground Should Fire the Ignition Coil Each Time Ignition Coil 3 o oO gt o o 5 ga 1 2 Air Gap General 1 2 3 4 Clean all battery connections and engine grounds Disconnect the mercury tilt switch and retest If the ignition works properly replace the mercury switch Connect a spark gap tester to the spark plug wires and check for fire on all cylinders If some cylinders fire and not others the problem is likely in the distributor cap rotor button or spark plug wires Perform a voltage drop test after the engine is repaired to see if there is a problem with the voltage going to the CD module At cranking and while the engine is running use a DC voltmeter and put the black meter lead on the battery POS pos

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