CDI Electronics Outboard Ignition Troubleshooting Guide

13 Chrysler/Force Troubleshooting Chrysler/Force the # 2 pack. ENGINE WILL NOT SHUT OFF: Disconnect all stop wires at the power pack. Connect a jumper wire to the stop wire from the pack and short it to engine ground. If this stops the pack from sparking, the stop circuit has a fault. Check the key switch, harness and shift switch. If this does not stop the pack from sparking, replace the power pack. Repeat test as necessary for additional packs. COILS ONLY HAVE SPARK WITH SPARK PLUGS OUT: Check for dragging starter or low battery causing slow cranking speed. DVA test stator and trigger. MISS AT ANY RPM: 1. Disconnect the rectifier from the stator and retest. If the miss clears, replace the rectifier. 2. In the water or on a Dynameters, check the DVA output from the power pack outputs while connected to the ignition coils. You should have a reading of at least 150V DVA or more, increasing with engine RPM until it reaches 300-400V DVA maximum. A sharp drop in DVA right before the miss becomes apparent on all cylinders will normally be caused by a bad stator. A sharp drop in DVA on less than all cylinders will normally be the switch box or trigger. 3. Connect an inductive tachometer to each cylinder in turn and try to isolate the problem. A high variance in RPM on one cylinder usually indicates a problem in the switch box or ignition coil. Occasionally a trigger will cause this same problem. Check the trigger DVA voltage (see NO SPARK ON ANY CYLINDER above). 4. Perform a high-speed shutdown and read the spark plugs. Check for water. A crack in the block can cause a miss at high speed when the water pressure gets high, but a normal shutdown will mask the problem. 5. Check the triggering and charge coil flywheel magnets for cracked, broken and loose magnets. Chrysler/Force Prestolite ADI Ignitions 1984-1992 Two Cylinder Engines Using Separate Switch Boxes and Ignition Coils GENERAL: 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 the 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 all stop wires AT THE POWER PACK. 2. Disconnect the rectifier. If the engine sparks, replace the rectifier. 3. Check for broken or bare wires on the switch box, stator and trigger. 4. Check the stator and trigger resistance and DVA voltage as follows: WIRE READ TO OEM OHMS CDI OHMS DVA Brown/Blue (or Blue) Brown/Yellow (or Yellow) 680-900 250-350 180-400 V (Connected) Brown/Blue (or Blue) Engine GND Open Open < 2 V (Disconnected) Brown/Yellow (or Yellow) Engine GND Open Open < 2 V (Disconnected) White/Orange (or Orange) White/Yellow (or Green) 45-55 45-55 0.5 V + (Connected) White/Red (or Red) White/Green 45-55 45-55 0.5 V + (Connected) 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, swap the power pack output from the ignition coil that works to the one that does not. If the coil that had spark stops sparking, replace the power pack.