CDI Electronics Outboard Ignition Troubleshooting Guide

129 Yamaha Troubleshooting Yamaha Yamaha 2 Stroke Ignitions One and Two Cylinder Engines 1984-2005 2 HP 1995-2002 NO SPARK: 1. Connect a spark tester (gapped at about 3/8”) to the spark plug wire and check to spark. If the engine has spark on a spark tester but does not appear to have spark on the spark plug, replace the spark plug and retest. 2. Disconnect the White stop wire and retest. If the ignition system now has spark, the stop circuit has a problem. 3. Inspect and clean all engine and ignition ground connections. 4. Check the charge coil resistance and DVA voltage: Check From: Check To: Ohms Reading: DVA Connected Brown Black 281 to 422 150 V 5. Check the ignition packs output voltage, resistance of the ignition coil’s primary and secondary windings. Check From: Check To: Ohms Reading: DVA Connected Orange Black - 130 V Orange Black 0.08 to 0.12 Spark Plug Cap Black 2.56K (2080) to 3.84K (3840) HAS SPARK BUT WILL NOT RUN: 1. Make sure the engine is getting fuel to the combustion camber (make sure there is no water or residue in the carburetor). 2. Check flywheel shear key to make sure it has not sheared due to backfiring or impact on the propeller. 3. Check flywheel magnet to make sure it has broken loose and moved, causing a timing shift. 4. Check spark plug for presence of water, indicating a possible cracked block or blown head gasket. 5. Check compression, carburetor, reeds and do a cylinder leak down test. WILL NOT STOP (KILL): 1. Disconnect the White wire from the CD Module. 2. Short the White wire from the CD Module to engine ground. If the engine stops, the problem is in the stop circuit. If the engine continues to run with the White wire shorted to engine ground, replace the defective CD Module. 3 HP 1988-2002 NO SPARK: 1. Connect a spark tester (gapped at about 3/8” ) to the spark plug wire and check to spark. If the engine has spark on a spark tester but does not appear to have spark on the spark plug, replace the spark plug and retest. 2. Disconnect the White stop wire and retest. If the ignition system now has spark, the stop circuit has a problem. 3. Check the resistance of the ignition coil’s primary winding. You should read between 0.08 to 0.12 ohms from the Orange wire to the Black wire from the ignition coil. 4. Inspect and clean all engine and ignition ground connections. 5. Check the resistance and DVA voltage of the charge coil, trigger coils and ignition coil. Function Check From: Check To:Ohms Reading: DVA Connected Charge Coil Brown Black 250-300 150 V Minimum High Speed Trigger Red/White (88-92) Black 30-36 2 V Minimum High Speed Trigger White/Red (93-02 Black 30-36 2 V Minimum Low Speed Trigger Green/White (88-92) Black 279-341 1 V Minimum Low Speed Trigger White/Black (93-02) Black 279-341 1 V Minimum Pack Output Orange Black 0.08 to 0.12 150 V Minimum Ignition Coil Spark Plug Cap Black 2.08K (2080) to 3.12K (3120) HAS SPARK BUT WILL NOT RUN: 1. Make sure the engine is getting fuel to the combustion camber (make sure there is no water or residue in the carburetor). 2. Check flywheel shear key to make sure it has not sheared due to backfiring or impact on the propeller. 3. Check flywheel magnet to make sure it has not broken loose and moved, causing a timing shift.