CDI Electronics Outboard Ignition Troubleshooting Guide

168 TROUBLESHOOTING GUIDE - Yamaha Troubleshooting Yamaha Troubleshooting 150 HP (6 Cyl) 1996-2009 V150 (6 Cyl) 2000-2009 L150 HP (6 Cyl) 1996-2009 P150 HP (6 Cyl) 1996-2009 S150 HP (6 Cyl) 1996-2009 P175 (6 Cyl) 1996-2009 S175 (6 Cyl) 1996-2009 200 (6 Cyl) 1996-2009 L200 (6 Cyl) 1996-2009 P200 (6 Cyl) 1996-2009 S200 (6 Cyl) 1996-2009 64D-85540-01-00/64D-85540-10-00/64E-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/ Green Trigger wire 256-384 ohms - 2 V Minimum White/ Yellow Trigger wire White/Brown Trigger wire 256-384 ohms - 2 V Minimum Brown Stator wire Red Stator wire 592-888 ohms - 145 V Minimum Blue Stator wire Black/Red Stator wire 55-88 ohms - 40 V Minimum Green (Crank Position Sensor)Green (Crank Position Sensor) 158-255 ohms 2 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: NOTE: Cylinders 2 & 5 are fired by the CDI Unit Assembly. A sensor problem can cause these cylinders not to fire. All cylinders should have spark over 1800 RPM IN GEAR. 1. Check the resistance and DVA output of the Stator, Trigger and CD Unit: Read from Read to OEM Reading CDI Reading DVA (connected) White/Red Trigger wire White/ Green Trigger wire 256-384 ohms - 2 V Minimum White/ Yellow Trigger wire White/Brown Trigger wire 256-384 ohms - 2 V Minimum Brown Stator wire Red Stator wire 592-888 ohms - 140 V Minimum Blue Stator wire Black/Red Stator wire 55-88 ohms - 55 V Minimum Black/White Black - - 130 V Minimum Green/White Green/Blue 179-242 ohms 2 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 130 V 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). 3. Check the ignition coil resistance and the spark plug cap. With the spark plug cap removed from the coil, you should read between 4 and 6 K ohms through the cap. The ignition coil should read between 3.78K to 4.92K ohms from the high tension lead to the primary Black lead. ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM: 1. Verify the engine is not overheating and causing the control module to limit the RPM. 2. Verify the correct sparkplugs are installed and gapped correctly.