CDI Electronics Outboard Ignition Troubleshooting Guide

21 Chrysler/Force Troubleshooting Chrysler/Force Force Mercury Designed Ignitions 1991-1996 Two Cylinder Engines using a Separate Switch Box and Two Ignition Coils NO SPARK ON ANY CYLINDER: 1. Disconnect the Black/Yellow stop wire AT THE POWER PACK and retest. If the engine’s ignition sparks, 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 now has spark, replace the rectifier. 3. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be caused by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine. 4. Inspect and clean all engine and ignition ground connections. 5. Check the stator resistance and DVA output as follows: Black Stator WIRE READ TO OEM RESISTANCE CDI RESISTANCE DVA (Connected) DVA (Disconnected) Blue Blue/White 3250-3650 488-662 180-400 V 180-400 V (*) Red Red/White 75-90 28-32 25-100 V 25-100 V (*) Red Stator Kit WIRE READ TO OEM RESISTANCE CDI RESISTANCE DVA (Connected) DVA (Disconnected) White/Green Green/White 500-700 400-550 180-400 V 180-400 V (*) Blue Engine GND OPEN OPEN 180-400 V 180-400 V (*) (*) This reading can be used to determine if a stator or pack has a problem. For instance, if you have no spark on any cylinder and the stator’s DVA reading is low – disconnect the stator wires and recheck the DVA output. If the reading stays low – the stator is bad. If the reading is now within spec – the pack is bad.