CDI Electronics Outboard Ignition Troubleshooting Guide

161 Yamaha Troubleshooting Yamaha 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, keyswitch or emergency stop switch is bad. C115 (4 Cyl) 2000 P115 (4 Cyl) 1993-1996 B115 (4 Cyl) 1998-1999 S115 (4 Cyl) 1996-1999 115 (4 Cyl) 1990-2010 130 (4 Cyl) 1990-2004 6N7-85540-01-00 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 - 2.5 V Minimum White/Black Trigger wire White/Green Trigger wire 256-384 ohms - 2.5 V Minimum Brown Stator wire Red Stator wire 592-888 ohms - 160 V Minimum Blue Stator wire Black/Red Stator wire 55-83 ohms 10-20 ohms 45 V Minimum 4. Check the cranking RPM. A cranking speed of less than 250-RPM may 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 DVA (connected) White/Red Trigger wire White/Yellow Trigger wire 256-384 ohms 2.5 V Minimum White/Black Trigger wire White/Green Trigger wire 256-384 ohms 2.5 V Minimum Brown Stator wire Red Stator wire 592-888 ohms 160 V Minimum Blue Stator wire Black/Red Stator wire 55-83 ohms 45 V Minimum Black/White Coil Leads Engine Ground 125 V Minimum 2. Remove the resistive sparkplug caps from the sparkplug leads and check the resistance of the sparkplug caps 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 resistance of the ignition coil’s secondary resistance. You should read between 3.04 K to 4.58 K ohms from the sparkplug lead to the Black ground wire with the resistive sparkplug cap removed. 4. 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.