CDI Electronics Outboard Ignition Troubleshooting Guide

124 TROUBLESHOOTING GUIDE - Tohatsu/Nissan Troubleshooting Tohatsu/Nissan Troubleshooting SPwith the coil (replace if it does). Replace the sparkplug if NC. 3. If the miss is gone, re-connect the Black/Yellow wires. 4. Disconnect the Light Blue warning wire going into the CDI unit. If the engine performs normally, re-connect the Light Blue wire to the CDI unit. A) Disconnect the Light Blue wire to the oil sensor. Retest engine. If the engine performs normally, replace the oil sensor. If the miss is still present, re-connect the Light Blue wire to the oil sensor. B) Disconnect the Light Blue wire to the water pressure sensor. Retest engine If the engine performs normally, replace the water pressure sensor. C) Disconnect the Light Blue wire to the overheat temperature sensor. Retest engine. If the engine performs normally, replace the overheat temperature sensor. HIGH SPEED MISS: 1. Disconnect the regulator/rectifier. If the miss is gone, replace the regulator/rectifier 2. Perform a high speed shutdown and read the spark plugs. If one sparkplug is black and the others are a tan color, swap the ignition coil to another cylinder. Repeat the test. If the black sparkplug reading follows the coil, replace the coil. 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. 80A, 90A (3 Cylinder) 1992-2000 (3B7061602M) NO SPARK ON ANY CYLINDER: 1. Disconnect the Black and Brown stop wires and retest. If you now have spark, the stop circuit has a fault. 2. Disconnect the Yellow and White wires from the Rectifier/Regulator. If spark returns to all cylinders, replace the Rectifier/Regulator. 3. Test the stator (exciter) and trigger (pulsar) stator coils as follows: Red Lead Black Lead Resistance DVA Connected White Wht/Yel 175-241 135 V Minimum Wht/Red Black 166-230 4.75 V Minimum Wht/Blk Black 166-230 4.75 V Minimum Wht/Blue Black 166-230 4.75 V Minimum Blk/Wht Black 190 V Minimum CDI Output to coil Blk/Red Black 190 V Minimum CDI Output to coil Blk/Grn Black 190 V Minimum CDI Output to coil ENGINE HAS A MID-RANGE MISS OR WILL NOT GO OVER 3000 RPM : 1. Verify the warning horn is working properly by grounding the water temperature sensor in the cylinder head (if present). 2. Disconnect the Black/Yellow RPM jumper (connected together with bullet connectors) looping out of and back into the CDI unit. If the miss is still present. A) Disconnect the rectifier/regulator. If the miss is gone, replace the rectifier/regulator. B) Monitor the stator and trigger coils DVA voltage. It should not drop significantly right before the miss becomes apparent. C) Check the output DVA voltage from the CDI unit. If one cylinder has a drop in DVA and the other cylinders do not, replace the CDI unit. D) Perform a high speed shutdown (hold the RPM at the point where the miss is apparent) and shut the engine down using the keyswitch or emergency kill lanyard. Check the spark plugs. If water is present, you may have a crack in the engine block or a leaking head gasket. If there is no water present and one of the sparkplugs is black, swap the ignition coil for that cylinder with another cylinder and see if the problem stays with the coil (replace if it does). Replace the sparkplug if NC. 3. If the miss is gone, re-connect the Black/Yellow wires. 4. Disconnect the Light Blue warning wire going into the CDI unit. If the engine performs normally, re-connect the Light Blue wire to the CDI unit. A) Disconnect the Light Blue wire to the oil sensor. Retest engine. If the engine performs normally, replace the oil sensor. If the miss is still present, re-connect the Light Blue wire to the oil sensor. B) Disconnect the Light Blue wire to the water pressure sensor. Retest engine. If the engine performs normally,