Installation and Troubleshooting Guide
Contents
1. 24V Connected over 45V Disconnected Blue White 35 55 0 5 Purple White 35 55 0 5 Green White 35 55 0 5 Pink White 35 55 0 5 Blue White White 100 160 1 2 Purple White White 100 160 1 2 Green White White 100 160 1 2 Pink White White 100 160 1 2 CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Tech support 1 866 423 4832 e Web support cdielectronics com Sales Support 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 B e 12 07 12 Page 1 of 3 QF 319 us asi Installation and Troubleshooting Guide klecir OnicsS All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited 4 Check the center hub triggering magnet in the flywheel A loose or broken magnet can cause this problem 5 Check the cranking RPM A cranking speed of less than 250 RPM will not allow the system to fire properly This can be caused by a weak battery dragging starter bad battery cables or a mechanical problem inside the engine NO SPARK ON ONE CYLINDER 1 Check the timer base s resistance and output see NO SPARK ON ANY CYLINDER above 2 Check the DVA output on the orange wires from the power pack while connected to the ignition coils You should have a reading of at least 130V or more If the reading is low on one cylinder disconnect the ora2. d retest If the engine fires replace the rectifier CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Tech support 1 866 423 4832 e Web support cdielectronics com Sales Support 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 B e 12 07 12 Page 2 of 3 QF 319 us asi Installation and Troubleshooting Guide Hecactronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited 4 Check the Timer Base resistance given below Wire Color Check to Wire Color Resistance DVA Readin Blue White 35 55 0 5 Purple White 35 55 0 5 Green White 35 55 0 5 Pink White 35 55 0 5 Blue White White 100 160 1 2 Purple White White 100 160 1 2 Green White White 100 160 1 2 Pink White White 100 160 1 2 5 Check the spark plug wires for breaks and abrasions 6 Check the cranking RPM A cranking speed of less than 250 RPM will not allow the system to fire properly This can be caused by a weak battery dragging starter bad battery cables or a mechanical problem inside the engine 7 Check the DVA output on the orange wires from the power pack while connected to the ignition coils You should have a reading of at least 150V or more If the reading is low on one bank disconnect the orange wires from the ignition coil for that bank and reconnect t
3. de available at most electronics stores CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Tech support 1 866 423 4832 e Web support cdielectronics com Sales Support 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 B e 12 07 12 Page 3 of 3 QF 319
4. hem to a load resistor Retest If the reading is now good one or all of the ignition coils are likely bad A continued low reading indicates a bad power pack ENGINE WILL NOT ACCELERATE BEYOND 2500 RPM Runs smooth below that RPM 1 Use a temperature probe and verify that the engine is not overheating 2 Verify the correct spark plugs are installed 3 Make sure the tan temperature switch wire is not located next to a spark plug wire 4 Disconnect the tan temperature wire from the pack and retest If the engine now performs properly the temperature switch VRO switch or engine harness is likely defective 5 Disconnect the VRO sensor from the engine harness and retest If the engine performs correctly replace the VRO or sensor ENGINE ENGAGES S L O W Limits at 2500 PM WHEN THE NO OIL LOW OIL OR FUEL VACUUM ALARM SOUNDS 1 Disconnect engine harness 2 Disconnect the Tan wires from the temperature sensors in both cylinder heads 3 Using an VOM Meter check the diode in the engine harness as follows Red Meter Lead Black Meter Lead Reading Tan pin in Engine Harness Connector Tan Lead From Port Cyl Head 0 500 approximately Tan pin in Engine Harness Connector Tan Lead From Stbd Cyl Head 0 500 approximately Tan Lead From Stbd Cyl Head Tan pin in Engine Harness Connector OL or over 1 0 Tan Lead From Port Cyl Head Tan pin in Engine Harness Connector OL or over 1 0 NOTE You can replace the diode in the harness with a 1N4007 dio
5. nge 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 3 Check the Timer Base resistance given below Wire Color Check to Wire Color Resistance DVA Reading Blue White 35 55 0 5 Purple White 35 55 0 5 Green White 35 55 0 5 Pink White 35 55 0 5 Blue White White 100 160 1 2 Purple White White 100 160 1 2 Green White White 100 160 1 2 Pink White White 100 160 1 2 4 Check the spark plug wires for breaks and abrasions ENGINE DIES WHEN QUICKSTART DROPS OUT Check ignition timing at idle with the White Black temperature wire disconnected Remember to allow for the 12 15 Degree drop in ignition timing when Quick Start disengages Verify ignition timing after engine has warmed up according to the service manual ENGINE WILL NOT STAY IN QUICKSTART OVER 10 SECONDS 1 Verify the engine temperature is below the trip point 89 degrees on some engines and 104 degrees on others of the temperature switch 2 Disconnect the White Black Temperature Switch wire FROM the Port Temperature Switch If the engine now stays in QuickStart the Temperature Switch is likely defective ENGINE STAYS IN QUICKSTART ON ALL CYLINDERS 1 With the engine idling check the Yellow Red wire for DC voltage If there is DC voltage on this wire while the engine is running the Quick Start will not disengage A voltage over 1 5 volts but less than 7 volts will not engage the
6. recommended that you check to make sure both the triggering and charge magnets are still secure in the flywheel before you service the engine A loose or broken magnet can be deadly to you or your pocketbook It is a recommended you index the flywheel and check the timing on all cylinders when servicing these engines Also check for static firing and intermittent spark ENGINE WILL NOT START OR MISFIRES Verify the wiring in the connectors as follows WIRE SIDE WIRE SIDE WIRE SIDE NO SPARK ON ANY CYLINDER NOTE These engines use a gear reduction starter which results in a lower cranking RPM than usual If you have one or more cylinders intermittent at cranking Try starting the engine and checking to see if ALL of the cylinders now fire correctly If so the engine s ignition should be good Make sure the battery is sized correctly as the cranking capacity can affect the cranking speed 1 Disconnect both of the black yellow kill wires FROM THE PACK and retest If the engine s ignition now has fire the kill circuit has a fault possibly the key switch harness or shift switch 2 Disconnect the yellow wires from the stator to the rectifier and retest If the engine fires replace the rectifier 3 Check the stator and trigger resistance and DVA output as given below for each bank Wire Color Check to Wire Color Resistance DVA Readin Brown Brown Yellow 430 650 150V Connected 175V Disconnected Orange Orange Black 93 103 12
7. starter solenoid yet will engage Quick Start 2 Short the White Black Temperature Switch wire FROM the power pack to engine ground Start the engine if the Quick Start drops out after approximately 5 seconds replace the White Black Temperature Switch 3 If the only way to disable QuickStart is to disconnect the 4pin connector with the Blue White Purple White Green White and Pink White wires between the power pack and the Timer Base replace the power pack ENGINE DROPS OUT AND BACK IN QUICKSTART AT IDLE 1 Verify the spark plugs are the Champion QL77JC4 or QL78YC These plugs are INDUCTIVE NOT Resistive RF suppression 2 Check the engine RPM 3 With the engine idling check the Yellow Red wire for DC voltage Intermittent DC voltage on this wire while the engine is running will re engage Quick Start A voltage of less than 7 volts will not engage the starter solenoid yet will engage Quick Start 4 With the engine idling disconnect the Black White wire from the power pack and short the White Black Temperature Switch wire FROM the power pack to engine ground If the Quick Start drops out and stays out after approximately 5 seconds replace the White Black Temperature Switch If the problem is still present replace the power pack NO SPARK ON ONE BANK 1 Swap pin location of the two Brown wires from the stator and retest If the problem moves the stator has a fault 2 Disconnect the yellow wires from the stator to the rectifier an
8. us asi Installation and Troubleshooting Guide klecir Omics as All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited v CDI P N s 113 4041 Note This unit replaces P N s 583489 584040 and 584041 WARNINGS 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 Disconnect the battery cables Remove power pack mounting bolts and disconnect all of the wires going to the old power pack Check for DC voltage on the kill stop wire 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 Connect the wires to the new power pack Use a small amount of dielectric silicone grease in the bullet connectors Mount the new power pack using the original bolts Connect the orange wires to the ignition coils remember that the blue striped wires go up and the green striped wires go down Reconnect the battery cables Sa ea SLO pis Troubleshooting Service Note Please use the Factory recommended spark plug currently Champion QL77JC4 gapped at 0 030 Note These engines usually have a 35 Amp battery charging capacity Due to the size and weight of the flywheel magnets it is highly
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