CDI Electronics Outboard Ignition Troubleshooting Guide

188 TROUBLESHOOTING GUIDE - Four Stroke 10. Check the Trigger as follows as a defective trigger can cause timing variance: Check From: Check To: Ohms Reading: DVA Reading: White/Red Black 240-360 3.5 V 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 engine 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. F15 1998-2006 66M-85540-01-00 Service Notes: Please use the Factory recommended spark plug (currently NGK DPR6EA-9) gapped at 0.040”. NOTE: Oil Pressure Light Triggers When Oil Pressure Falls Below 7 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. Inspect and clean all engine and ignition ground connections. 3. Check the Stator, Trigger and ignition coil as follows: Check From: Check To: Ohms Reading: DVA Reading White/Red Black 234 to 348 3.5 V Connected Brown Black 272 to 408 135 V Connected Orange Black 0.16-0.24 15 V @ Cranking High Tension Lead #1 High Tension Lead #2 3.93-5.89K (caps removed) 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 and oil pressure sensor mounted on the engine. 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 272-33 degrees BTDC at about 3000. If the 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 system with fresh fuel and see if the engine will start. 9. Check the fuel pressure AT THE CARBURETOR. You should see over 2 PSI. Check fuel lines for inner wall breakdown and wall collapse. 10. Check the Triggers as follows as a defective trigger can cause timing variance: Check From: Check To: Ohms Reading: DVA Reading Connected Disconnected White/Red Black 234 to 348 3.5 V minimum 4 V 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 engine 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.