CDI Electronics Outboard Ignition Troubleshooting Guide

156 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting 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. E75 HP (3 Cyl) 1997-2000 688-85540-00-00 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 OEM Reading CDI Reading DVA (connected) White/Red Trigger wire White/Yellow Trigger wire 256-384 ohms 256-384 ohms 3 V Minimum White/Black Trigger wire White/Green Trigger wire 256-384 ohms 256-384 ohms 3 V Minimum Brown Stator wire Blue Stator wire 428-642 ohms 600-800 ohms 105 V Minimum Red Stator wire Blue Stator wire 48-72 ohms 10-20 ohms 45 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. 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 256-384 ohms 256-384 ohms 3 V Minimum White/Black Trigger wireWhite/Green Trigger wire 256-384 ohms 256-384 ohms 3 V Minimum Brown Stator wire Blue Stator wire 428-642 ohms 600-800 ohms 105 V Minimum Red Stator wire Blue Stator wire 48-72 ohms 10-20 ohms 45 V Minimum Black/White (All Cyl) Engine Ground - 105 V Minimum Spark plug Lead Engine ground 3.28K-4.92K ohms 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 125V 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.