CDI Electronics Outboard Ignition Troubleshooting Guide

154 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting Blue Stator wire Red Stator wire 96-144ohms 10-20 ohms 25 V Minimum 4. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be caused by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine properly. NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS: 1. Check the resistance and DVA output of the Stator and Trigger: Read from Read to OEM Reading CDI Reading DVA (connected) White/Red Trigger wire White/Yellow Trigger wire 280-430 ohms 280-430 ohms 2.5 V Minimum White/Black Trigger wire White/Green Trigger wire 280-430 ohms 280-430 ohms 2.5 V Minimum White/Red Trigger wire Eng Ground Open Open 2.5 V Minimum White/Black Trigger wire Eng Ground Open Open 2.5 V Minimum White/Yellow Trigger wire Eng Ground Open Open 2.5 V Minimum White/Green Trigger wire Eng Ground Open Open 2.5 V Minimum Brown Stator wire Blue Stator wire (1984-89) 680-1020 ohms 600-800 ohms 85 V Minimum Brown Stator wire Blue Stator wire (1990-96) 840-1260 ohms 600-800 ohms 85 V Minimum Brown Stator wire Eng Ground Open Open 85 V Minimum Blue Stator wire Eng Ground Open Open 16 V Minimum Blue Stator wire Red Stator wire 96-144 ohms 10-20 ohms 25 V Minimum Red Stator wire Eng Ground Open Open 30 V Minimum 2. Check the DVA output on the Black/White wires from the power pack while connected to the ignition coils. You should have a reading of at least 85V 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 a increase in voltage on the Blue to the Black/Red stator wires throughout the RPM range until it peaks out at approximately 300 Volts. A drop in voltage can be the result of a bad stator coil or a bad regulator/rectifier (disconnect the Green wires to the regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad). MISS AT ANY RPM: 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. 3. Disconnect the Green wires to the regulator/rectifier and retest – if the engine now performs OK, the regulator/ rectifier is likely bad. 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 terminal where the Pink wire goes. If the engine now limits at approximately 2000 RPM, check the wiring from the temperature sensor and oil tank to the power pack. If it still fails to engage, the power pack is likely bad. ENGINE WILL NOT STOP: Disconnect the White stop wire and connect a jumper 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, key switch or