CDI Electronics Outboard Ignition Troubleshooting Guide

150 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting C70 HP (3 Cyl) 2001 6H2-85540-13-00 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. 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 White/Black wire260-360 2.5 V Minimum 4.5 V Minimum Brown Stator wire Blue Stator wire 136-204 150 V Minimum 120 V Minimum Blk//Org (#1) & Blk/Yel #3 Engine Ground - 105 V Minimum Black/White (#2) Engine Ground - 0 V Minimum (at idle) NOTE: The #2 Cylinder is triggered by the ignition pack, it is normal for it to have no fire under 1500 RPM. 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 White/Black wire 260-360 2.5 V Minimum 4.5 V Minimum Blue/Red (Crank Position Sensor) Blue/White 136-204 5 V Minimum Black/Orange Engine Ground - 125 V Minimum Black/White Engine Ground - 0 V (at idle) Black/Yellow Engine Ground - 125 V Minimum NOTE: The #2 Cylinder is triggered by the ignition pack, it is normal for it to have no fire at cranking or idling. All cylinders should fire by 1500 RPM. 2. 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. Verify the ignition timing is advancing to the WOT setting (24-28 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 an increase in voltage on the Blue to the Brown stator wires, stabilizing over 2000 RPM and showing a slight decrease over 5000 RPM. 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 STOP RUNNING: Disconnect the White kill wire and connect a jumper wire from the White wire to engine ground. If you still have spark, the power pack is likely bad. If the engine has no spark with the jumper connected, either the wiring harness, keyswitch or emergency stop switch is bad.