CDI Electronics Outboard Ignition Troubleshooting Guide

160 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting 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 288-432 ohms 2.5 V Minimum White/Black Trigger wire White/Green Trigger wire 288-432 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 Red Stator wire 840-1260 ohms 600-800 ohms 85 Volts Minimum Brown Stator wire Eng Ground Open Open 85 Volts Minimum Red Stator wire Eng Ground Open Open 85 Volts Minimum Blue Stator wire Black/Red Stator wire 62-79 ohms 10-20 ohms 20 Volts Minimum Blue Stator wire Eng Ground Open Open 20 Volts Minimum Black/Red Stator wire Eng Ground Open Open 20 Volts Minimum 2. Remove the resistive sparkplug caps from the sparkplug leads and check the resistance from the wire pin to the terminal that goes on the sparkplug. You should read between 4 K and 6 K ohms. If the reading is over the 6K ohms specification, replace the sparkplug cap. 3. 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. 4. Remove the resistive sparkplug caps from the sparkplug leads and check the resistance from the wire pin to the terminal that goes on the sparkplug. You should read between 4 K and 6 K ohms. If the reading is over the 6K ohms specification, replace the sparkplug cap. 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 Black/ Red stator wires throughout the RPM range. 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). 3. Remove the resistive sparkplug caps from the sparkplug leads and check the resistance from the wire pin to the terminal that goes on the sparkplug. You should read between 4 K and 6 K ohms. If the reading is over the 6K ohms specification, replace the sparkplug cap. 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 the SAFE Mode fails to engage, the power pack is likely bad.