CDI Electronics Outboard Ignition Troubleshooting Guide

141 Yamaha Troubleshooting Yamaha NO SPARK OR INTERMITTENT ON ONE OR MORE CYLINDERS: 1. Check the resistance and DVA output of the Trigger: Read from Read to Ohm Reading DVA (connected to pack) DVA (Disconnected) White/Red Trigger wire Black wire 277-415 3 V Minimum 4 V Minimum White/Black Trigger wire Black wire 277-415 3 V Minimum 4 V Minimum White/Green Trigger wire Black wire 277-415 3 V Minimum 4 V Minimum 2. Check the DVA output on the Black/Orange, Black/White and Black/Yellow wires from the power pack while connected to the ignition coils. You should have a reading of at least 135V or more. If the reading is low on one cylinder, disconnect the wire from the ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a bad power pack or trigger (test per above). ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM: 1. Verify the engine is not overheating and causing the power pack to limit the RPM. 2. Disconnect the Pink wire from the power pack and retest. If the engine now performs correctly, check the overheat sensor, oil level in the oil tank mounted on the engine and the wiring harness. 3. Check the position of the Pink wire and make sure it is not next to a spark plug wire. ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2500 RPM: 1. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be caused by a bad coil, power pack or spark plug. 2. If all cylinders show the same RPM and the engine will only rev to approximately 2500 RPM, check the running stator DVA output from idle thru WOT. You should show an increase in voltage on the Blue to the Brown stator wires from idle to approximately 2000 RPM and remaining steady, dropping slightly over 4000 RPM range. A sharp drop in voltage can be the result of a bad stator coil or a bad pack. HIGH SPEED MISS: 1. Verify the engine is not overheating and causing the problem. 2. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be caused by a bad coil, power pack or spark plug. S.A.F.E. WILL NOT ENGAGE: Disconnect the Pink warning wire from the power pack. Connect a jumper wire to engine ground and connect it to the Pink wire from the power pack (If it still fails to engage, the power pack is likely bad). If the engine now limits at approximately 2000 RPM, check the wiring from the temperature sensor and oil tank to the power pack. ENGINE WILL NOT KILL (STOP) 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. WARNING LED WILL NOT WORK: 1. Disconnect the Pink wire from the temperature sensor and short it to ground. Start and run the engine, the warning LED and the horn should sound (if equipped with a horn). 2. Disconnect the Pink wire from the LED and short the Pink wire from the LED to engine ground. Start and run the engine, if the LED now works, check the wiring from the temperature sensor to the LED connection. 3. Disconnect the Pink wire from the LED and short the Pink wire from the LED to engine ground. Connect a DC voltmeter to the Yellow/Red wire coming from the CD module and check the voltage. You should have 0.5 – 1.5 volts.