CDI Electronics Outboard Ignition Troubleshooting Guide

191 Four Stroke Connect a battery tester to the battery and start the engine. Increase the engine RPM to approximately 1500-2000 RPM and press the test button on the battery tester. The ammeter should show at least 3 amps of current flow. If not and the stator passes the test above, replace the regulator/rectifier. If the ammeter shows a charge, replace the battery. NOTE: If the problem only shows up at high RPM’s, repeat the test while connected to a Dyno or on the water.| F30 (3 Cyl) 2001-2006 F40 (3 Cyl) 2000-2006 67C-85540-01-00 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. Inspect and clean all engine and ignition ground connections. 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 Connected Disconnected Red/White Black 300 to 350 6 V minimum Green/White Green/White 528 to 792 193 V minimum Yellow/Black Yellow/Black 6.5 to 7.2 7 V minimum 10 V minimum Orange Black 151 V minimum Spark Plug wires Engine Ground 2.7K (2700) to 3.7K (3700) (cap removed) 4. Check the resistance of the ignition coil cap between the spark plug wire side and the spark plug side, you should read 4K-6K ohms. NO SPARK ON ONE CYLINDER: 1. Swap the ignition coil of the cylinder not firing with one that has fire. If the no fire problem follows the ignition coil, replace the ignition coil. 2. If the ignition coil is good, replace the ECU. ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM: 1. Verify the engine is not overheating or has low oil pressure 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 ignition timing; it should be between approximately 5 degrees BTDC at idle to 28 degrees BTDC at about 3000. If the timing does not advance with RPM, replace the ignition pack. HAS SPARK BUT WILL NOT RUN: 1. Check spark plug for presence of water, indicating a possible cracked block or blown head gasket. 2. Check compression, carburetor, reed blocks and do a cylinder leak down test (remember, a valve not seating properly, stuck rings, improper tappet clearance, damaged piston or a blown head gasket can cause a low reading for a leak down test). 3. Replace the sparkplugs. 4. Check the Timing Belt and verify the cam timing is correct. 5. Make sure the throttle plates are fully closed (the engine will not start if the warm-up lever is raised). 6. Make sure the engine is getting fuel to the combustion chamber (no water or residue in the carburetor). 7. Check flywheel shear key to make sure it has not sheared due to backfiring or impact on the propeller. 8. Check the fuel in the carburetor. Check to see if there is a high ethanol content 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 Red White 300 to 350 6 V minimum 6 V minimum WILL NOT STOP (KILL):