CDI Electronics Outboard Ignition Troubleshooting Guide

176 TROUBLESHOOTING GUIDE - Four Stroke 3. If the engine still has a problem, disconnect Brown/White wire. If the engine now performs correctly, check the oil pressure switch and the wiring harness. The oil switch should open contact over 3 PSI. 4. Check ignition timing, it should be between approximately 5 degrees at idle to 30 degrees BTDC at about 3000. If he timing does not advance with RPM, replace the ignition pack. 5. 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 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. Mercury 4 Stroke Ignitions Two Cylinder Engines 1998-2006 F25 1998-2005/T25 2001-2006 878433A 1 (65W-85540-00-00) Service Notes: Please use the Factory recommended spark plug (currently NGK DPR6EA-9) gapped at 0.035”. NOTE: Oil Pressure Light Triggers When Oil Pressure Falls Below 2.13 PSI. NO SPARK OR WEAK SPARK: 1. Disconnect the White stop wire from the Ignition Module. Retest. If the engine’s ignition now has spark, the stop circuit has a fault. 2. Check the Stator, Trigger and ignition coil as follows: Check From: Check To: Ohms Reading: DVA Reading Connected Disconnected Red White 260 to 390 6 V minimum 6 V minimum Green/White Green/White 660 to 710 190 V minimum 190 V minimum Yellow/Black Yellow/Black 6.5 to 7.3 7 V minimum 10 V minimum Orange Black 100 V minimum Spark Plug wire #1Spark Plug wire #2 3.28K (3280) to 4.92K (4920) 3. Check the resistance of the ignition coil between the secondary (spark plug wire) and Black wires, you should read 3.28K (3280) to 4.92K (4920) ohms. NO SPARK ON ONE CYLINDER: Replace the ignition coil. 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. Verify the oil pressure is over the minimum 2.13 PSI. 3. Disconnect the Pink wire from the power pack and retest. If the engine now performs correctly, check the overheat sensor and oil pressure sensor mounted on the engine. 4. Check the position of the Pink wire and make sure it is not next to a spark plug wire. 5. Check ignition timing, it should be between approximately 4.5-10.5 degrees BTDC at idle to 27-33 degrees BTDC at about 3000. If he timing does not advance with RPM, replace the ignition pack. HAS SPARK BUT WILL NOT RUN: 1. Verify the sparkplug gap. The specifications may have changed. Gap should be 0.024-0.028. 2. Make sure the throttle plates are closed (the engine will not start if the warm-up lever is raised). 3. Make sure the engine is getting fuel to the combustion camber (make sure there is no water or residue in the carburetor). 4. Check flywheel shear key to make sure it has not sheared due to backfiring or impact on the propeller. 5. Check flywheel magnet to make sure it has broken loose and moved, causing a timing shift. 6. Check spark plug for presence of water, indicating a possible cracked block or blown head gasket. 7. Check compression, carburetor, reeds and do a cylinder leak down test. 8. Check the fuel in the carburetor. Check to see if a very high ethanol content is present. . If so, purge the fuel