CDI Electronics Outboard Ignition Troubleshooting Guide

174 TROUBLESHOOTING GUIDE - Four Stroke Mercury 4 Stroke Ignitions 2 Cylinder Engines 1997-2002 0G760300-0R042474 with PACK # 825667 (6G9-85540-21-00) 117-6921 8/9.9 HP Bondersee by Yamaha NO SPARK ON ONE CYLINDER: Replace the ignition coil. NO SPARK ON BOTH CYLINDERS: WARNING: BOTH SPARLKPLUG LEADS MUST BE CONNECTED TO A SPARK TESTER OR THE IGNITION COIL IS VERY LIKELY TO BE DAMAGED. 1. Disconnect the kill wire (White on pack – Black/Yellow in harness). If fire returns, the kill circuit is shorted. Possibly the Stop switch or harness. 2. Verify the correct sparks plugs are installed. OEM recommends NGK DPR6EA-9, gapped at 0.035 in. 3. Check the stator resistance and DVA output as given below: WIRE READ TO OHMS DVA (Minimum Connected) Brown (Chg Coil) Blue 280-420 90 V + at Idle, 205 V at 1500 RPM Green/Wht or White/Red (CPS)Black 230-350 2.5 V + at idle, 7.5V @ 1500 RPM Orange Black 0.16-0.24 85 V + at Idle, 195 V at 1500 RPM High Tension Lead #1 High Tension Lead #2 3.9-5.9K w/o -- 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 (Note: Some engines may have the Pink wire from the pack connected to a Brown/White wire in the harness). If the engine now performs correctly, check the overheat sensor, oil level in the engine, oil pressure 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. Check ignition timing, it should be between approximately 5 degrees at idle to 30 degrees BTDC at about 3000. If the timing does not advance with RPM, replace the ignition pack. ENGINE WILL NOT STOP RUNNING: Disconnect the Brown kill wire and short it to engine ground. If it stops running, replace the kill switch. If it continues to run, replace the ignition pack. NO WARNING LAMP: 1. Short the Pink wire from the warning lamp to engine ground and crank the engine over. The lamp should light up. 2. If the warning lamp lights up, check the oil pressure switch. It should be shorted below 2.5 PSI and open above that. 3. If the lamp does not light up with the Pink wire shorted to ground, check the voltage on the Yellow/Red wire going to it. It should be over 3 volts. If the voltage is OK, replace the warning lamp. WARNING LAMP DOES NOT GO OFF: 1. Check the engine oil level. 2. If the warning lamp does not go off, check the oil pressure switch. It should be shorted below 2.5 PSI and open above that Mercury 4 Stroke Ignitions Two Cylinder Engines 2000-2005 8, 9.9, 13.5, 15 HP by Yamaha 835401T 1 (66M-85540-01-00) NO SPARK ON ONE CYLINDER: Replace the ignition coil.