CDI Electronics Outboard Ignition Troubleshooting Guide

11 Chrysler/Force Troubleshooting Chrysler/Force After repairing the engine, check the battery voltage at approximately 3500 RPM, The MAXIMUM allowable voltage reading is 15.5 volts and the minimum is 12V. Running below 12V or over 15.5 volts may damage the ignition. Check for loose connections or a bad battery. Chrysler/Force Two Cylinder Engines using Combination CD Module with Built-in Ignition Coils (1978-1988) NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER: 1. Check the Brown stop wires. They MUST be separated from each other. THIS SYSTEM SHORTS THE BROWN WIRES TOGETHER TO STOP THE ENGINE. The common practice of connecting the stop wires together and shorting them to ground in order to stop the engine will not work on this engine. Disconnect the Brown stop wires and retest. If you have spark, check the ignition switch’s “M” terminals if using remote start. You should have a White wire on one terminal and a Blue wire on the other terminal. If both the Blue and White wires are connected together, correct the wiring. If the engine has a tiller handle, check the push button stop switch. 2. Check the stator and trigger resistance and DVA voltage as follows: WIRE READ TO OEM Ohms CDI Ohms DVA Brown/Blue or Blue*Brown/Yellow or Blue* 680-900 250-350 180-400 V Connected Brown/Blue Engine GND Open Open < 2 V Disconnected Brown/Yellow Engine GND Open Open < 2 V Disconnected Orange Green 45-55 45-55 0.5 V + Connected Red White/Green 45-55 45-55 0.5 V + Connected NOTE: Some OEM stators had 2 Blue wires instead of the Blue and yellow wires more commonly used. 3. If readings are good and the #2 cylinder is the one not firing, swap the Red and White/Green trigger wires. If both cylinders now have spark, the trigger is not wired for this engine. However, you may leave the wires as they are and the engine will be run normally. 4. Disconnect the stop wire from one pack. If that cylinder starts firing, the stop circuit in the harness or on the boat is bad, possibly the ignition switch. 5. If readings are good, disconnect stop wire from one pack. If the dead cylinder starts sparking, the problem is likely the blocking diode in the opposite pack. ENGINE WILL NOT SHUT OFF: Disconnect the Brown stop wires. Connect a jumper wire to ONE of the stop wires from the pack and short it to engine ground. If this stops the pack from sparking, the stop circuit has a fault. Check the key switch, harness and shift switch. If this does not stop the pack from sparking, replace the pack.