CDI Electronics Outboard Ignition Troubleshooting Guide

12 TROUBLESHOOTING GUIDE - Chrysler/Force Troubleshooting Chrysler/Force Troubleshooting Chrysler/Force Prestolite ADI Ignitions 1984-1992 General Troubleshooting 1. Disconnect the stop wires from the CD. Measure DC voltage from the stop wires (from the harness) to engine ground. Turn the ignition switch on and off several times. DC voltage should never exceed 2V. If it does, the stop circuit has a fault. Check the key switch, harness and shift switch. 2. Check the flywheel for a broken or loose magnet. 3. Check for broken wires and terminals, especially inside the plastic plug-in connectors. We recommend that you remove the pins from the connectors using the CDI 511-9706 pin removal tool and visually inspect them. 4. Visually inspect stator for burned or discolored areas. If found, replace the stator. If the areas are on the battery charge windings, it indicates a possible problem with the rectifier. NO SPARK ON ANY CYLINDER: 1. Disconnect the stop wire AT THE POWER PACK. 2. Disconnect the rectifier. If the engine sparks, replace the rectifier. 3. Check for broken or bare wires on the CD Module, stator and trigger. 4. Check the stator and trigger resistance and DVA voltage as follows: WIRE READ TO OEM OHMS CDI OHMS DVA Blue Yellow 680-900 250-350 180-400 V (Connected) Blue Engine GND Open Open < 2 V (Disconnected) 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) Remember that the stator may use Brown/Yellow or Brown/Black/Yellow for Yellow and Brown/Blue or Brown/Black/Blue for Blue. A. The DVA reading to engine ground is checking a circuit inside the power pack. If the readings are not fairly equal, swap the stator wires going to the power pack and recheck. If the low reading stays on the same wire from the stator, replace the stator. Otherwise, replace the power pack. B. Most meters will pick up a small amount of voltage due to inductive pick-up. As long as the voltage is very low, it will not indicate a problem. NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER: 1. Check the stator and trigger resistance and DVA voltage (see NO SPARK ON ANY CYLINDER above). 2. 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. POWER PACK OR TRIGGER REPEATEDLY BLOWS ON SAME CYLINDER: 1. Check the trigger wires for shorts to engine ground as a shorted trigger wire can destroy a SCR inside the power pack. 2. In contrast, a shorted SCR inside the power pack can destroy a trigger coil. Check the trigger resistance and DVA output (see NO SPARK ON ANY CYLINDER above). 3. Replace the ignition coil on the cylinder dropping spark. NO SPARK ON TWO CYLINDERS: 1. If two cylinders from the same CD unit will not spark, the problem is usually in the stator. Test per above. 2. If the engine has a CDI stator installed: A. If #1 and #3 are the ones not firing, disconnect the Yellow stator wire from the # 1 pack and see if the #3 cylinder starts firing. Is so, replace the #1 pack. If not, then reconnect the Yellow stator wire to the # 1 pack and disconnect the Yellow stator wire from the # 2 pack and see if the #1 cylinder starts firing. If so, replace the # 2 pack. B. If #2 and #4 are the ones not firing, disconnect the Blue stator wire from the # 1 pack and see if the #4 cylinder starts firing. Is so, replace the #1 pack. If not, then reconnect the Blue stator wire to the # 1 pack and disconnect the Blue stator wire from the # 2 pack and see if the #2 cylinder starts firing. If so, replace