CDI Electronics Outboard Ignition Troubleshooting Guide

136 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting C25 HP (2 CYL) 1990-1997 695-85540-11-00 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 Spark Plug Cap 2 2.72K (2720) to 3.68K (3680) (1990-1992) Spark Plug Cap 1 Spark Plug Cap 2 4.52K (4520) to 6.28K (6280) (1993-1995) Spark Plug Cap 1 Spark Plug Cap 2 6.8K (6800) to 10.2K (10,200) (1996-1997)) 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 90 to 112 5 V @ cranking Brown (Charge Coil) Black 188 to 282 190 V @ cranking Black/Orange Black (Eng Gnd) 0.18 to 0.24 210 V @ cranking 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 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 90 to 112 5 V @ cranking NO SPARK ON ONE CYLINDER: If only one cylinder has spark, replace the ignition coil. WILL NOT STOP (KILL): 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. 25/30 HP (3 CYL) 1996-2002 6J8-85540-H1-00 NO SPARK ON ANY CYLINDER: 1. Disconnect the White stop wire and retest. If the engine’s ignition now has spark, the stop circuit has a fault- check the key switch, harness and shift switch. 2. Inspect and clean all engine and ignition ground connections. 3. Verify the correct spark plugs are installed. 4. Check the resistance and DVA output of the Stator and Trigger: Read from Read to Ohms Reading DVA (connected) DVA (Disconnected) White/Red Trigger wire Black wire 277-415 4 V Minimum 4 V Minimum White/Black Trigger wire Black wire 277-415 4 V Minimum 4 V Minimum White/Green Trigger wire Black wire 277-415 4 V Minimum 4 V Minimum Brown Stator wire Blue Stator wire 164-246 175 V Minimum 210 V Minimum