CDI Electronics Outboard Ignition Troubleshooting Guide

142 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting 40-50 HP (3 CYL) 1989-1994 6H5-85540-02-00 / 117-6H5-02 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 Ohm Reading DVA (connected) DVA (Disconnected) White/Red Trigger wire Black wire 157-235 3 V Minimum 4 V Minimum White/Black Trigger wire Black wire 157-235 3 V Minimum 4 V Minimum White/Green Trigger wire Black wire 157-235 3 V Minimum 4 V Minimum Brown Stator wire Blue Stator wire 238-356 200 V Minimum 190 V Minimum 5. Check the cranking RPM. A cranking speed of less than 250-RPM may not allow the system to fire properly. 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) DVA (Disconnected) White/Red Trigger wire Black wire 157-235 3 V Minimum 4 V Minimum White/Black Trigger wire Black wire 157-235 3 V Minimum 4 V Minimum White/Green Trigger wire Black wire 157-235 3 V Minimum 4 V Minimum Black/ White (#1) Engine Ground - 125 V Minimum Black/White (#2) Engine Ground - 125 V Minimum Black/ White (#3) Engine Ground - 125 V Minimum 2. Swap the ignition coil for the problem cylinder with one that is firing correctly. Retest. If the problem stays with the coil, replace it. 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. 4. Verify the ignition timing is advancing to the WOT setting (24-26 Degrees BTDC). 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 a steady increase in voltage on the Blue to the Brown stator wires throughout the RPM range. A 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 STOP RUNNING: