Installation and Troubleshooting Guide
Contents
1. ead Installation and Troubleshooting Guide Electronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited CDI P N 113 4985 This unit replaces the following P N s 584910 584985 and 584990 WARNING This product is designed to be installed by a professional marine mechanic CDI Electronics cannot be held liable for injury or damage resulting from improper installation abuse neglect or misuse of this product ANALL INSTITUTE SERVICE NOTE This unit requires special inductive spark plug wires and spark plugs Please use the Factory Recommended Champion QL78YC 0 30 Gap Spark Plugs and the inductive Gray spark plug wires Order CDI P N 931 4921 for a set of 6 wires DO NOT OPERATE ENGINE WITH PLASTIC ENCODER COVER OFF OF THE ENGINE AS THIS CAN AFFECT THE IGNITION DO NOT OPERATE WITH A BLACK SLEEVED STATOR FROM A 1991 92 MODEL ENGINE INSTALLATION Disconnect the battery cables Remove timing wheel cover power pack cover and regulator rectifier cover Between the timing cover and the power pack Disconnect the stator wire connector and the harness connector from the power pack Disconnect the timing wire connector from the sensor Disconnect the spark plug wires from the spark plugs Unbolt and remove the ignition coils and old power pack Check for DC voltage on the kill stop wires usually Black Yellow with the key switch in the on a2. 11 volts at cranking verify the starter is not dragging 8 Remove the sensor wheel and check for damage especially where the top slots are located Sometimes the wheels will break out where the windows overlap 9 Check the sensor eyes for dirt grease etc If you have to clean it use denatured alcohol and a Q tip Do not use any other cleaning agent because damage to the optical lens will occur 10 Disconnect the voltage regulator rectifier and retest If the engine now has spark replace the regulator rectifier Using the Piercing Probes check the resistance then check the DVA voltage on the 6 pin stator connector while connected as follows Oe O Na D Red Lead Black Lead Resistance DVA Reading Orange Orange Black 50 60 ohms 12 V or more Brown Brown Yellow 450 600 ohms 150V or more Brown White Brown Black 450 600 ohms 150V or more Note Low readings on all checks indicate a possible problem with the flywheel magnets that require checking or low cranking speed Service note It is recommended that liquid neoprene be applied to the areas where the piercing probes were used The OEM power pack may fire with a bad stator power coil while the CDI power pack will not This is caused by the increased load on the coil in order to power the digital circuits in the new power pack If the stator is not replaced in this situation the stator will fail within a short time while running and result in an on the water breakdown If all the tests
3. SHAKES HARD WHEN OVER 2400 RPM SLOW Activated 1 Verify the engine is not actually over heating by using a digital pyrometer 2 Check the routing of the tan temperature wires an example of a bad location is shown below The tan wires have to be located as far away as possible from the spark plug wires 3 Disconnect the temperature sensors and see if the engine performs normally If it does check both temperature sensors and replace the defective one 4 If there is not any indication of a problem at this point replace the power pack Note Low readings on all checks indicate a possible problem with the flywheel magnets that require checking or low cranking speed Service note It is recommended that liquid neoprene be applied to the areas where the piercing probes were used The OEM power pack may fire with a bad stator power coil while the CDI power pack will not This is caused by the increased load on the coil in order to power the digital circuits in the new power pack If the stator is not replaced in this situation the stator will fail within a short time while running and result in an on the water breakdown CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com Tech Support 1 866 423 4832 Order Parts 1 800 467 3371 All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Rev C e 3 13 13 Pag
4. so far show good readings check the DVA output from the power pack on the primary coil wires as follows Red Lead Black Lead DVA Reading Orange Blue Engine Ground 130 V or more Orange Engine Ground 130 V or more Orange Green Engine Ground 130 V or more Note If the DVA values are below these specifications the power pack or sensor is likely bad 11 Check the DVA voltage on the Black Orange and Orange Red sensors leads as follows Red Lead Black Lead DVA Reading Orange Red Engine Ground 12 V or more Black Orange Engine Ground 12 V or more WARNING The Black Orange wire should NEVER be shorted to engine ground as this will damage the sensor 12 If an oscilloscope is available check the white blue crank position signal and white green cylinder position signal sensor wires while connected to the sensor With the engine cranking over you should see a square toothed pattern on both wires The white blue wire should show 1 pulse per revolution and the white green should show 7 pulses per revolution of the engine Led Power Black Orange Power Orange Red Ground Black Sync White Blue Stripe Cyl White Green eoao0p NO FIRE ON ONE BANK 1 Using the Piercing Probes and DVA adapter check the resistance and DVA voltage for the bank without spark on the 6 pin stator connector while connected as follows CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com Tech Suppo
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6. engine idle speed 21 Reconnect the engine harness 22 Replace the timing wheel cover power pack cover and regulator rectifier covers 23 Connect the spark plug wires to the spark plugs 24 Disconnect the jumper wire from the Tan temp sensor wire 25 Connect Tan and White Black temp switch wire to the temp switch on the Port side of the engine 26 Using a motor flushing device or in the water start and run the engine until it reaches operating temperature 27 Verify the engine s Quick Start function is working by watching for the drop in engine RPM as the engine temperature goes above 105 Deg F and drops the timing back to running mode 28 Stop the engine and restart it You should have approximately a 5 10 second period of Quick Start timing advance before the engine settles down to a normal idle 29 Disconnect the Port temperature switch s Tan and White Black wires 30 Connect a jumper wire to the Tan wire and short it to engine ground 31 Using a motor flushing device or in the water start and run the engine Make sure the over temp alarm is working and try to rev the engine up You should not be able to exceed 2600 RPM as the engine should go into S L O W function CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com Tech Support 1 866 423 4832 Order Parts 1 800 467 3371 All rights reserved Reproduction or use of content in any manner without express written permi
7. nd off position At no time should you see over 2 volts DC on this wire as severe damage to the power pack can occur Disconnect the ignition coils from the old power pack and reconnect them to the new power pack Install the new power pack ignition coils and inductive spark plug wires Take care not to over torque the mounting bolts OEM specification calls for 50 95 in Ibs of torque Make sure the RF Noise Shield is between the ignition coils and the power pack 10 Connect the stator and harness connectors to the power pack Use a small amount of dielectric silicone grease on the connector seal Do not put any inside the sockets 11 Connect the harness wire connector to the power pack 12 Connect the timing wire connector to the sensor 13 Connect all spark plug wires to a spark gap tester 14 Disconnect the Port temperature switch s Tan and White Black wires 15 Connect a jumper wire to the Tan wire and short it to engine ground 16 Connect a timing light to the 1 spark plug wire 17 Connect the battery cables 18 Disconnect the engine harness from the boat harness 19 Using a piston stop tool or dial indicator verify the TDC timing pointer s accuracy Reset as needed to correct 20 Use a remote starter 511 6996 is recommended and verify the ignition timing as follows SLO Che N ENGINE IDLE Timing WOT Timing 150 4 6 Deg ATDC 20 Deg BTDC 175 4 6 Deg ATDC 17 Deg BTDC NOTE Adjust the idle timing to adjust the
8. rt 1 866 423 4832 Order Parts 1 800 467 3371 All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Rev C e 3 13 13 Page 2 of 3 QF 319 S459 installation and Troubleshooting Guide INSTITUTE Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Red Lead Black Lead Ohms Resistance DVA Bank Cyl Brown Brown Yellow 450 600 ohms 150V Stbd 1 3 5 Brown White Brown Black 450 600 ohms 150V Port 2 4 6 NOTE If the power pack has no spark on one bank and the readings are good replace the power pack 2 Disconnect the 5 pin connector on the port side of the power pack and see if the spark returns If it does use the Fluke meter set to Ohms and see if the Black Yellow or Black Orange wire is shorted to engine ground Check to see if the Shift Interrupter switch is located in the circuit where there is no spark HIGH SPEED MISS FIRE OR WEAK HOLE SHOT 1 If the engine runs fine until you get above 4900 RPM and then starts missing check the Orange to Orange Black power coil wires with an oscilloscope If available or replace the pack A breakdown inside the pack could cause RFI noise to activate the rev limiter for no apparent reason 2 Using the Piercing Probes and DVA adapter check the DVA voltage at the RPM where the problem is occ
9. ssion by CDI Electronics Inc is prohibited Rev C e 3 13 13 Page 1 of 3 QF 319 S459 installation and Troubleshooting Guide INSTITUTE Electronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited at 2500 RPM Turn the engine off and wait 10 seconds for the processor inside the power pack to reset before continuing 32 Disconnect the jumper wire from the Tan temp sensor wire 33 Connect Tan and White Black temp switch wire to the temp switch on the Port side of the engine TROUBLESHOOTING NO FIRE AT ALL Check the kill lanyard and key switch position Verify the engine rotation The engine needs to be turning in a clockwise direction Check the power pack and ignition coil ground wires for corrosion and tightness Connect a spark gap tester to all cylinders Disconnect the boat side harness and connect a remote starter unit Check for spark If the engine has spark check the boat side harness s Black Yellow wire for shorts to ground Disconnect the 5 pin connector on the port side of the power pack and see if the spark returns If it does use the Fluke meter set to Ohms and see if the Black Yellow wires are shorted to engine ground 7 Check the battery voltage on the Yellow Red striped wire while cranking the engine If below 11 volts charge the battery or check all battery cables If the battery continues to read below
10. urring while connected as follows Red Lead Black Lead DVA Bank Cylinder Brown Brown Yellow 150V Starboard 1 3 5 Brown White Brown Black 150V Port 2 4 6 NOTE The readings should rapidly increase as the engine RPM increases and stabilize below 400 volts voltage exceeding 400 V DVA indicates a bad pack A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator charge coil 3 Connect an inductive tachometer to the spark plug wires one at a time and compare the readings If most of the cylinders show the same reading and one or two show different readings check the primary wires with the inductive pickup to see if the readings are the same coming out of the power pack A difference in readings between the primary and secondary coil wires indicate bad ignition wires No difference indicates a bad power pack ONLY HAS FIRE AS LONG AS THE STARTER SOLENOID IS ENGAGED Using the Piercing Probes and DVA adapter check the DVA voltage while connected as follows Red Lead Black Lead DVA Orange Orange Black 11 24V NOTE The readings should rapidly increase as the engine RPM increases and stabilize below 24 volts voltage exceeding 24 V DVA indicates a bad pack A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator winding A sharp drop in voltage when you let off of the starter solenoid indicates a bad power coil on the stator ENGINE WILL NOT ACCELERATE OVER 2500 RPM AND
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