CDI Electronics Outboard Ignition Troubleshooting Guide

133 Yamaha Troubleshooting Yamaha 20 HP 1996-1997 (2 CYL) 25 HP 1996-2009 (2 CYL) 6L2-85540-23-00 NO SPARK: 1. Disconnect the White stop wire and retest. If the ignition system now has spark, the stop circuit has a problem. 2. Inspect and clean all engine and ignition ground connections. 3. Check the resistance of the ignition coil. Check From: Check To: Ohms Reading: Spark Plug Cap 1 Engine Ground 2.72K (2720) to 3.68K (3680) Spark Plug Cap 2 Engine Ground 2.72K (2720) to 3.68K (3680) 4. Check the Resistance and DVA Voltage of the CDI, Stator and Triggers as follows: Check From: Check To: Ohms Reading: DVA Reading : White/Red Black 277 to 415 5.5 V @ cranking/ 15 V @ 1500RPM White/Black Black 277 to 415 5.5 V @ cranking/ 15 V @ 1500RPM Brown (Charge Coil) Blue 304 to 456 125 V @ cranking/125 V @ 1500RPM Black/Orange (Top Cyl) Black (Eng Gnd) 0.18 to 0.24 105 V @ cranking/110 V @ 1500RPM Black/White (Bottom Cyl) Black (Eng Gnd) 0.18 to 0.24 105 V @ cranking/110 V @ 1500RPM HAS SPARK BUT WILL NOT RUN: 1. Make sure the engine is getting fuel to the combustion chamber (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. 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. 6. Check the Triggers as follows as a defective trigger can cause timing variance: Check From: Check To: Ohms Reading: DVA Reading White/Red Black 277 to 415 5.5 V @ cranking/15 V @ 1500RPM White/Black Black 277 to 415 5.5 V @ cranking/15 V @ 1500RPM NO SPARK ON ONE CYLINDER: Check the Resistance and DVA Voltage of the CDI, Stator and Triggers as follows: Check From: Check To: Ohms Reading: DVA Reading : White/Red Black 277 to 415 5.5 V @ cranking/ 15 V @ 1500RPM White/Black Black 277 to 415 5.5 V @ cranking/ 15 V @ 1500RPM Brown (Charge Coil) Blue 304 to 456 125 V @ cranking/125 V @ 1500RPM Black/Orange (Top Cyl) Black (Eng Gnd) 0.18 to 0.24 105 V @ cranking/110 V @ 1500RPM Black/White (Bottom Cyl) Black (Eng Gnd) 0.18 to 0.24 105 V @ cranking/110 V @ 1500RPM Ignition Coil Secondary Black (Eng Gnd) 2.56K – 3.84K 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. WILL NOT ACCELERATE OVER 2000 RPM: 1. Disconnect the Pink wire from the CDI and retest. If the engine now runs normally, check the head temperature sensor and the oil tank sensor. 2. Disconnect the White wire from the CD Module and retest. If the engine runs normally, the harness could have a intermittent short.