CDI Electronics Outboard Ignition Troubleshooting Guide

155 Yamaha Troubleshooting Yamaha emergency stop switch is bad. C75 (3 Cyl) 1998-1999 P75 (3 Cyl) 1996-1999 C80 (3 Cyl) 1997 C90 (3 Cyl) 1997-2001 90 (3 Cyl) 1992-2009 6H0-85540-07-00 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 wire 241-362 5 V Minimum 7 V Minimum Brown Stator wire Red Stator wire 191-288 100 V Minimum 90 V Minimum Blue Stator wire Red Stator wire 64-96 60 V Minimum 55 V Minimum Black//Orange (#1) Engine Ground - 130 V Minimum Black/White (#2) Engine Ground - 0 V (at idle) Black/Yellow (#3) Engine Ground - 130 V Minimum Blue/White (Crank Position) Blue/Red 158-236 5.5 V Minimum 5.5 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. 4. 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 White/Black wire 241-362 5 V Minimum 7 V Minimum Blue/Red Blue/White 158-236 5.5 V Minimum Black/Orange Engine Ground - 130 V Minimum Black/White Engine Ground - 0 V Minimum Black/Yellow Engine Ground - 130 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. 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 (19-21 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