CDI Electronics Outboard Ignition Troubleshooting Guide

118 TROUBLESHOOTING GUIDE - Tohatsu/Nissan Troubleshooting Tohatsu/Nissan Troubleshooting Tohatsu/Nissan 2 STROKE Carbureted Engines MISS AT ANY RPM: 1. If the boat is equipped with a Hummingbird I.D. depth finder, disconnect the power to it and retest. If the miss is gone, switch to a different depth finder. See Tohatsu Service Bulletin # 1200, dated 9/14/1990. 2. Check fuel lines/tank for restrictions, leaks or loose connections. 3. Check fuel pump diaphragms for holes, allowing extra fuel at high RPM. 4. Verify correct spark plugs are installed and are not fouled. 5. Disconnect the stop switch and retest. If the engine performs properly, the stop circuit has a fault. 2.5A, 2.5A2, 3.5A, 3.5A2, 3.5B, 3.5B2 2005 and Older NO SPARK: 1. Disconnect the Black and Brown stop wires and retest. If you now have spark, the stop circuit has a fault. 2. Test the stator (exciter) stator coil as follows: Red Lead Black Lead Resistance DVA Connected White Component Gnd (Black) 280-420 110 V Minimum Orange (CD) Component Gnd (Black) - 110 V Minimum If the above readings are OK and there is no spark, the ignition coil is likely defective. ENGINE WILL NOT SHUT OFF: Short the Brown stop wire (from CD) to engine ground, if the engine shuts down, check the stop switch and harness. 4C, 5B, 5C 2005 and Older NO SPARK: 1. Disconnect the Black and Brown stop wires and retest. If you now have spark, the stop circuit has a fault. 2. Test the stator (exciter) and trigger (pulsar) stator coils as follows: Red Lead Black Lead Resistance DVA Connected White Red/Black 93-140 110 V Minimum* Red/Wht Component Gnd (Black) 80-117 3 V Minimum** Black/Yellow Component Gnd (Black) - 110 V Minimum If the above readings are OK and there is no spark, the ignition coil is likely defective. * A low resistance or DVA reading indicates the exciter coil is defective and needs to be rebuilt. ** A low resistance or DVA reading indicates the pulsar coil is defective and needs to be rebuilt. ENGINE WILL NOT SHUT OFF: Short the Brown stop wire (from CD) to engine ground, if the engine shuts down, check the stop switch and harness. 6B, 8B, 9.8B 2005 and Older NO SPARK: 1. Disconnect the Black and Brown stop wires and retest. If you now have spark, the stop circuit has a fault. 2. Test the stator (exciter) stator coil as follows: Red Lead Black Lead Resistance DVA Connected Green Black 224-336 110 V Minimum* If the above reading is OK and there is no spark, the CDI is likely defective. * A low resistance or DVA reading indicates the exciter coil is defective and needs to be rebuilt. ENGINE WILL NOT SHUT OFF: Short the Brown stop wire (from CD) to engine ground, if the engine shuts down, check the stop switch and harness. NO SPARK ON ONE CYLINDER: If only one spark plug has spark, the internal ignition coil is defective. The power pack will need to be replaced.