Table of Contents I 221

CDI Electronics Outboard Ignition Troubleshooting Guide

General Troubleshooting 1
DVA Explained 3
Shop Test Equipment and Tools 4
Tricks to Testing 5
Voltage Drop Measurement 6
Battery Charging Issues 7
Wiring Cross Reference Chart 9
ABYC Wiring Color Codes 9
Chrysler/Force Troubleshooting 10
Battery CD Ignitions 10
Alternator Driven Ignitions (Prestolite) 1983-1992 11
Alternator Driven Ignitions (Mercury Designed Ignitions) 1991-1996 21
Alternator Driven Ignitions (Mercury CDM Modules) 1996-1999 108
Johnson/Evinrude Troubleshooting 29
Battery CD Ignitions 29
Alternator Driven Ignitions 1971-1978 (Screw Terminal Power Packs) 30
Flywheel Magnet Orientation 38
Alternator Driven Ignitions 1977-2006 39
60 Optical 3 Cylinder Engines 1996-2001 67
60 Optical 4 Cylinder Engines 1995-2006 69
60 Optical 6 Cylinder Engines 1991-2006 72
Mariner Troubleshooting 78
2 HP One Cylinder Engines 1977-1989 With Points Ignition 78
Mercury Troubleshooting 82
Battery Intro 82
Battery CD Ignitions with Points 83
Battery CD Ignitions without Points 89
Mercury Triggering Magnets 90
Alternator Driven Ignitions 91
Mercury/Force CDM Ignitions Troubleshooting 108
2, 3 and 4 Cylinder CDM Ignitions 1994-2006 108
6 Cylinder CDM Ignitions 1996-2005 2.5L 113
6 Cylinder CDM Ignitions 1994-2003 3.0L 116
Tohatsu/Nissan Troubleshooting 118
2 Stroke Carbureted Ignitions 118
TLDI 127
Yamaha Troubleshooting 129
2 Stroke Carbureted Ignitions 129
Four Stroke Troubleshooting 173
2 Stroke Carbureted Ignitions 173
Appendix 198
DVA (Peak Voltage) and Resistance Charts (Introduction) 198
Chrysler/Force DVA and Resistance Charts 199
Johnson/Evinrude DVA and Resistance Charts 201
OMC Sea Drive DVA and Resistance Charts 203
Yamaha DVA and Resistance Charts 204
Mercury DVA and Resistance Charts 211
OMC Stern Drive Electronic Shift Assist Applications and Wiring Diagrams 216
Ignition Checklist 219
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