CDI Electronics Outboard Ignition Troubleshooting Guide

186 TROUBLESHOOTING GUIDE - Four Stroke 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. If the engine now performs correctly, check the overheat sensor, oil level sensor 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 the ignition timing; it should be between approximately 2-8 degrees BTDC at idle to 32-38 degrees BTDC at about 3000. If the timing does not advance with RPM, replace the ignition pack. HAS SPARK BUT WILL NOT RUN: 1. Make sure the engine is getting fuel to the combustion chamber (make sure there is no water or residue in the carburetor). 2. Check flywheel shear key to make sure it has not sheared due to backfiring or impact on the propeller. 3. Check flywheel magnet to make sure it has broken loose and moved, causing a timing shift. 4. Check spark plug for presence of water, indicating a possible cracked block or blown head gasket. 5. Check compression, carburetor, reeds and do a cylinder leak down test. 6. Check the fuel in the carburetor. Check to see if a very high ethanol content is present. . If so, purge the fuel system with fresh fuel and see if the engine will start. 7. Check the fuel pressure AT THE CARBURETOR. You should see over 2 PSI. Check fuel lines for inner wall breakdown and wall collapse. 8. Check the Triggers as follows as a defective trigger can cause timing variance: Check From: Check To: Ohms Reading: DVA Reading: White/Red Black 172-212 (1984-1990) 2.5V Minimum White/Red Black 168-252 (1991-2004) 2.5V Minimum WILL NOT STOP (KILL): 1. Disconnect the White wire from the CD Module. 2. Short the White wire from the CD Module to engine ground. If the engines stops, the problem is in the stop circuit. If the engine continues to run with the White wire shorted to engine ground, replace the defective CD Module. F9.9, T9.9 HP 2005-2006 2 Cylinder 4 Stroke 66R/66N Series 66M-85540-01-00 NO SPARK ON BOTH CYLINDERS: 1. Disconnect the White kill wire. If fire returns, the kill circuit is shorted. Possibly the Stop switch or harness. 1. Inspect and clean all engine and ignition ground connections. 2. Verify the correct sparks plugs are installed. OEM recommends NGK DPR6EA-9, gapped at 0.040 in. 3. Check the stator resistance and DVA output as given below: WIRE READ TO OEM RESISTANCE DVA (Connected) Brown (Chg Coil) Blue 272-408 135 V Minimum White/Green Black 234-348 3.5 V Minimum Orange Black 0.16-0.24 115 V Minimum High Tension Lead #1 High Tension Lead #2 3.93-5.89K -- 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. Disconnect the Pink wire from the power pack and retest. If the engine now performs correctly, check the overheat sensor, oil level sensor in the oil tank mounted on the engine and the wiring harness. 3. Check the ignition timing, it should be between approximately 2-8 degrees BTDC at idle to 27-33 degrees BTDC at WOT. If the timing does not advance with RPM, replace the ignition pack. HAS SPARK BUT WILL NOT RUN : 1. Make sure the engine is getting fuel to the combustion chamber (make sure there is no water or residue in the carburetor). 2. Check flywheel shear key to make sure it has not sheared due to backfiring or impact on the propeller. 3. Check flywheel magnet to make sure it has broken loose and moved, causing a timing shift.