CDI Electronics Outboard Ignition Troubleshooting Guide

126 TROUBLESHOOTING GUIDE - Tohatsu/Nissan Troubleshooting Tohatsu/Nissan Troubleshooting ENGINE WILL NOT GO OVER 1500 RPM : 1. Disconnect the regulator/rectifier. If the miss is gone, replace the regulator/rectifier. 1. Disconnect the Black/Yellow RPM jumper (connected together with bullet connectors) looping out of and back into the CDI unit. 2. If the miss is still present, verify the Red/Yellow wire is connected securely and has a good connection, both at the CDI unit and at the keyswtich (it must have switched 12 VDC at the red/yellow wire going into the CD). If the Red/Yellow wire connections are good, replace the CDI unit. 3. Replace the CDI unit. 4. If the miss is gone with the Black/Yellow wires disconnected, re-connect the Black/Yellow wires. 5. 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 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 Light Blue wire to the water pressure sensor. Retest engine. If the engine performs normally, replace the water pressure sensor. C) Disconnect Light Blue wire to the overheat temperature sensor. Retest engine. If the engine performs normally, replace the overheat temperature sensor. 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 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 Light Blue wire to the water pressure sensor. Retest engine If the engine performs normally, replace the water pressure sensor. C) Disconnect 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. NOTE: If the ignition coil tests as defective, check the resistor boot (you should read between 4 and 6 K ohms through the boot). 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.