CDI Electronics Outboard Ignition Troubleshooting Guide

1 Introduction Introduction and Safety Notice ………………………………………………………………..…….. 2 General Troubleshooting Information DVA Explained …………………………………………………….……………………………. 3 Recommended Marine Shop Electrical Test Equipment and Tools ……………………..... 4 Tricks to Testing with Minimal Test Equipment ……………………………………………… 5 Voltage Drop Measurement ………..………….…….…….….………………….……………. 6 Johnson/Evinrude Model to Year Identification for 1980 and Up Engines ……………….. 6 Troubleshooting Battery Charging Issues, Regulator/Rectifiers and Tachometers ……… 7 Engine Wiring Cross Reference Chart………………………………………………………… 9 ABYC Recommended Boat Wiring Color Codes.……………………………………………. 9 . Chrysler/Force Troubleshooting Battery CD Ignitions…………………………………………………………………….…...….. 10 Alternator Driven Ignitions (Prestolite) 1983-1992 ………………………………………….. 11 Alternator Driven Ignitions (Mercury Designed Ignitions) 1991-1996 …………………….. 21-27 Alternator Driven Ignitions (Mercury CDM Modules) 1996-1999 ………………………….. 108-112 Johnson/Evinrude Troubleshooting Battery CD Ignitions …………………………………………………………………............... 29 Alternator Driven Ignitions 1971-1978 (Screw Terminal Power Packs) ……………......... 30 Flywheel Magnet Orientation ………………………………………………………………….. 38 Alternator Driven Ignitions 1977-2006 ……………………………………………………….. 39-67 60 Optical 3 Cylinder Engines 1996-2001 …………………………………………………… 67-68 60 Optical 4 Cylinder Engines 1995-2006 …………………………………………………… 69-72 60 Optical 6 Cylinder Engines 1991-2006 …………………………………………………… 72-77 Mariner Troubleshooting 2 HP One Cylinder Engines 1977-1989 With Points Ignition.............................................. 78-81 Mercury Troubleshooting Battery Intro……………………………………………………….................................…….. 82 Battery CD Ignitions with Points………………………………………………………... …….. 83-85 Battery CD Ignitions without Points……………………………………………………..…….. 89 Mercury Triggering Magnets …………………………………………………………………… 90 Alternator Driven Ignitions…………………………………………………………….............. 91 Mercury/Force CDM Ignitions Troubleshooting 2, 3 and 4 Cylinder CDM Ignitions 1994-2006 ……………………………...……………….. 108-112 6 Cylinder CDM Ignitions 1996-2005 2.5L ………………………………….………………… 113-115 6 Cylinder CDM Ignitions 1994-2003 3.0L ………………………………….………………… 116-117 Tohatsu/Nissan Troubleshooting 2 Stroke Carbureted Ignitions …………………………………….…………………………… 118-126 TLDI ……………………………………………………………………………………………… 127-128 Yamaha Troubleshooting 2 Stroke Carbureted Ignitions ………………………………….. ………………….…………. 129-172 Four Stroke Troubleshooting 2 Stroke Carbureted Ignitions ………………………………….. ………………….…………. 173-197 Appendix 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 Glossary of Terms …….…………………………………………………………………………. 213 OMC Stern Drive Electronic Shift Assist Applications and Wiring Diagrams …………….... 216 Ignition Checklist ……..………………………………………………………………………….. 219