CDI Electronics Outboard Ignition Troubleshooting Guide

175 Four Stroke NO SPARK ON BOTH CYLINDERS: 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 OEM RESISTANCE DVA (Connected) Brown (Chg Coil) Blue 270-410 150 V-325V Green/Wht (Crank Position Sensor) Black 230-350 2.5 V or more Orange Black 0.16-0.24 150 V or more High Tension Lead #1 High Tension Lead #2 3.9-5.9K without boots ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 3000 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 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. 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. 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: 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 2005-2012 8-9.9 HP by Tohatsu 835401T02 (3AA060600M) NO SPARK ON ONE CYLINDER: Replace the ignition coil. NO SPARK ON BOTH CYLINDERS: 1. Disconnect the kill wire (Brown on pack – may be 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 OEM RESISTANCE DVA (Connected) Black/Red (Chg Coil) Blue 236-354 110 V or more Red/Wht (Trigger) Black 148-222 2 V or more Orange Black 0.248-0.372 90 V or more High Tension Lead #1 High Tension Lead #2 6.8-10.2K ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 3000 RPM: 1. Verify the engine is not overheating and causing the power pack to limit the RPM. 2. Disconnect the Light Green Overheat wire from the power pack and retest. If the engine now performs correctly, check the overheat sensor