Installation and Troubleshooting Guide
Contents
1. H T Installation and Troubleshooting Guide Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited CDI P N 114 7509 NOTE This unit replaces all 827509A1 A3 A7 A9 A10 AND T4 series CDM Modules This product is designed for installation by a professional marine mechanic CDI cannot be held liable for injury or damage resulting from improper installation abuse neglect or misuse of this product INSTALLATION 1 Disconnect and clean all engine and battery ground wires 2 Disconnect the old CDM Module and remove the high tension coil wire from the spark plug 3 Unbolt and remove the old CDM Module Note the direction of the spark plug wire 4 Check for DC voltage on the kill stop wires usually Black Yellow with the key switch in the on and off position At no time should you see over 2 volts DC on this wire as severe damage to the power pack can occur 5 Apply a light amount of dielectric grease i e CDI 991 9705 to the seal area of the wire connector from the engine harness 6 Apply a light amount of dielectric grease to the outside of the new spark plug wire and thread the spark plug wire into the new CDM Module 7 Bolt the new CDM Module onto the engine orient the new CDM Module so that the spark plug wire is pointed in the same direction as the original 8 Plug in the connector from the wire harness into the new CDM Mod2. a WIRE Read To STATOR RESISTANCE DVA White Green Green White 500 700 2 3 4 Cyl 180V or more White Green Green White 380 430 6 Cyl 2 5L 180V or more White Green Green White 800 1200 6 Cyl 3 0L 180V or more 6 Check the resistance of the CDM as follows Red Meter Lead Black Meter Lead Reading CDM Pin A C CDI 2200 2400 Ohms OEM 1200 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 High Tension Lead A OEM 700 1300 Ohms CDI 2200 2400 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 INTERMITTANT SPARK OR NO SPARK ON ONE OR MORE CYLINDERS 1 Check the resistance of the Black wire in the 4 pin connector to the CDM referenced to engine ground It should show a short less than 0 5 ohms A high reading or an open reading indicates a break in the Black wire Check the wire at the ground terminal 2 Ifthe cylinders are only acting up above an idle connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders SERICE NOTE As these triggers have the Bias circuit built into them you cannot meter them Using a set of piercing probes check the trigger DVA output as given below 2 CYLINDER Check From Check to Resistance DVA Reading Connected Disconnected Purple wire Engine GND Open 0 5V to 1 5V 5V or more White wire En
3. module is likely bad If still no fire on 1 CDM reconnect 2 CDM and disconnect 3 CDM module and see if the 1 module starts firing If it does the 3 module is likely bad If no change at this point swap the 3 and 1 CDM modules If the problem moves to another cylinder replace the CDM that was on 1 cylinder If no change swap the Green White and White Green wires If fire changes replace the stator When moving CDM modules around on the engine pay attention to the stator wire colors going to the CDMs You must have a Green White and White Green wire connected or you will lose fire on all CDMs Follow these guidelines for whichever CDM is not firing Stop Circuit Stop Circuit Black Yellow Black Yellow Purple Trigger White Trigger Brown Trigger Purple Trigger White Trigger Brown Trigger TOO TOG TEC TST TEC a val White Green vol White Gree L Green White val White Green vol AONE h Green White Stator Stator Stator Stator Stator Stator 4 CYLINDER Check From Check to Resistance DVA Readin Brown wire Engine GND Open 0 5V or more White wire Engine GND Open 0 5V or more Purple wire Engine GND Open 0 5V or more Blue wire Engine GND Open 0 5V or more When moving CDM modules around on the engine pay attention to the stator wire colors going to the CDMs You must have a Green White and White Green wire connected or you will lose fire on all CDMs Whichever CDM is not firing disconnect it and one of the other CDMs on the opposite side
4. e stator one bolt hole in either direction and re test If the miss is gone leave the engine as is if you applied a thread locker to the stator Screws os 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 5 14 13 Page 3of3 QF 319
5. gine GND Open 0 5V to 1 5V 5V or more A DVA voltage reading that is close to the same reading connected as disconnected may indicate a broken ground wire 1 If 1 is not firing disconnect 2 CDM module Check which stator wire feed 2 CDM and using a jumper wire short that side of the stator to engine ground If 1 starts firing replace the 2 CDM 2 For 2 CDM not firing short the stator wire that feeds the 1 CDM Again if the 2 CDM starts firing replace the 1 CDM 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 5 14 13 Page 1of3 QF 319 HT Installation and Troubleshooting Guide gL UTE All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Electronics Stop Circuit Black Yellow Purple Trigger White Trigger Green White White Green Stator Stator 3 CYLINDER Check From Check to Resistance DVA Readin Purple wire Engine GND Open 0 5V or more White wire Engine GND Open 0 5V or more Brown wire Engine GND Open 0 5V or more For example if 1 CDM is not firing If 1 is not firing disconnect 2 CDM module and see if the 1 module starts firing If it does the 2
6. of the stator Try to get two CDMs firing and swap connections on each side to isolate the problem CDM Remember a CDM on one side of the stator wire can stop the other CDMs on the opposite side of the stator For example if 1 is not firing disconnect 2 CDM module and see if the 1 module starts firing If it does the 2 module is likely bad If still no fire on 1 CDM reconnect 2 CDM and disconnect 3 CDM module and see if the 1 module starts firing If it does the 3 module is likely bad If no change at this point swap the 3 and 1 CDM modules If the problem moves to another cylinder replace the CDM that was on 1 cylinder If no change swap the Green White and White Green wires If fire changes replace the stator Stop Circuit Black Yellow Purple Trigger White Trigger Brown Trigger Blue Trigger 1 7 2 4 3 q4 reo e roy E White Green White Green Green White Green White CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com e 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 5 14 13 Page 2of3 QF 319 tT Installation and Troubleshooting Guide mez Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is p
7. rohibited i TITUTE 6 CYLINDER 1 Check the stator resistance as shown WIRE Read To STATOR RESISTANCE DVA White Green Green White 500 700 2 3 4 Cyl 180V or more White Green Green White 380 430 6 Cyl 2 5L 180V or more White Green Green White 800 1200 6 Cyl 3 0L 180V or more 2 Check the trigger resistance as shown Check From Check to OEM Resistance _ CDI Resistance DVA Readin Purple wire Blue 1100 1400 800 1050 0 5V or more White wire Red 1100 1400 800 1050 0 5V or more Brown wire Yellow 1100 1400 800 1050 0 5V 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 Purple White White Black Brown White Blue White iad Green White White Green 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 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 high speed miss 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 Disconnect the yellow wires from the stator to the rectifier and retest If the engine fires replace the rectifier Rotate th
8. ule and connect the spark plug wire to the spark plug TROUBLESHOOTING NO SPARK SERVICE NOTE A 511 5207A 1 CDM Test Harness is highly recommended for testing these parts 1 Disconnect the black yellow kill wires from the harness and retest If the engine s ignition fires now the kill circuit has a fault possibly the key switch harness or shift switch 2 Install a 511 5207A 1 test harness inline to one of the CDM Modules and unplug the Black Yellow wires in the harness This will isolate that CDM from all other connections If spark returns on that CDM with the Black Yellow wires unplugged test the remaining CDMs If you disconnect one CDM and all other CDMs start firing the one the test harness is connected to is defective Remember the fault could be in the CDM harness Disconnect one CDM module at a time and see if the other modules start firing If they do the module you just unplugged is defective Disconnect the yellow wires from the stator to the rectifier and retest If the engine fires replace the rectifier Check the resistance of the Black wire in the 4 pin connector to the CDM referenced to engine ground It should show a short less than 0 5 ohms A high reading or an open reading indicates a break in the Black wire Check the wire at the ground terminal 6 Check the cranking RPM A cranking speed less than 250 RPM will not allow the system to fire properly 7 Check the stator resistance and DVA output as given below A
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