CDI Electronics Outboard Ignition Troubleshooting Guide

182 TROUBLESHOOTING GUIDE - Four Stroke F25A and F30A NO SPARK ON ANY CYLINDER: 1. Disconnect the Black and Brown stop wires and retest. If you now have spark, the stop circuit has a fault. 2. Check the 12 Volt power to the ignition pack from the rectifier. It should not drop below 10 volts at cranking. 3. If you do not show the correct voltage at the CD, test or replace the battery with a fully charged battery. If you still do not show the correct voltage at the CD, use a jumper wire and connect the CD directly to the battery post of the starter solenoid for 12V DC. If you get spark back, replace the rectifier/regulator. 4. Test the trigger (pulsar) and ignition pack output while connected as follows: Red Lead Black Lead Resistance DVA Connected White/Red Eng Gnd 168-252 2 V Minimum White/Black Eng Gnd 168-252 2 V Minimum White/Blue Eng Gnd 168-252 2 V Minimum Black/White Eng Gnd 110 V Minimum Black/Red Eng Gnd 110 V Minimum Black/Green Eng Gnd 110 V Minimum Plug Wire Eng Gnd 2.56-3.84K If the above readings are OK and there is no spark, the ignition coil is likely defective. NO SPARK ON ONE OR MORE CYLINDERS: 1. Swap the ignition coil from the cylinder not firing to one that does. If the no fire follows the coil, replace it. 2. Disconnect the Yellow and White wires from the Rectifier/Regulator. If the miss is gone, replace the regulator/ rectifier. 3. Test the CDI output as follows: Red Lead Black Lead DVA Connected Black/White Eng Gnd 110 V Minimum Black/Red Eng Gnd 110 V Minimum Black/Green Eng Gnd 110 V Minimum 4. Test the trigger (pulsar) stator coils as follows: Red Lead Black Lead Resistance DVA Connected White/Red Eng Gnd 168-252 2 V Minimum White/Black Eng Gnd 168-252 2 V Minimum White/Blue Eng Gnd 168-252 2 V Minimum ENGINE HAS A MID-RANGE MISS OR WILL NOT GO OVER 2800 RPM : 1. Verify the warning light and horn is working properly by grounding the overheat sensor in the cylinder head or the oil pressure sensor. 2. Check for blown fuses. NOTE: Sometimes a fuse will open up but appear to be OK, meter across it. 2. Check the 12 Volt power to the ignition pack from the rectifier. If you do not show the correct voltage at the CD, test or replace the battery with a fully charged battery. If you still do not show the correct voltage at the CD, use a jumper wire and connect the CD directly to the battery post of the starter solenoid for 12V DC. If you get spark back, replace the rectifier/regulator. 3. Monitor the stator and trigger coils DVA voltage. It should not drop significantly right before the miss becomes apparent. Red Lead Black Lead Resistance DVA Connected White/Red Eng Gnd 168-252 2 V Minimum White/Black Eng Gnd 168-252 2 V Minimum White/Blue Eng Gnd 168-252 2 V Minimum Black/White Eng Gnd 110 V Minimum Black/Red Eng Gnd 110 V Minimum Black/Green Eng Gnd 110 V Minimum 4. Disconnect the Light Blue warning wire going into the CDI unit. If the engine performs normally, re-connect the Light Blue wire to the CDI unit. A) Disconnect Light Blue wire to the oil sensor. Retest engine. If the engine performs normally, replace the oil sensor. If the miss is still present, re-connect the Light Blue wire to the oil sensor. B) Disconnect Light Blue wire to the water pressure sensor. Retest engine If the engine performs normally, replace the water pressure sensor. C) Disconnect Light Blue wire to the overheat temperature sensor. Retest engine. If the engine performs normally, replace the overheat temperature sensor.