CDI Electronics Outboard Ignition Troubleshooting Guide

195 Four Stroke 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. F50-T50 (4 Cyl) 2001-2004 64J-85540-01-00 F60 (4 Cyl) 2002-2004 T60 (4 Cyl) 2003-2004 64W-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 7.11 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 White/Red White/Black 396 to 594 3.5 V minimum 6.3 V minimum Brown Blue 272 to 408 137 V minimum 144 V minimum Black/Orange Black 0.078-0.106 150 V minimum 126 V minimum Black/White Black 0.078-0.106 150 V minimum 126 V minimum Spark Plug wire #1 Spark Plug wire # 4 3.5K (3500) to 4.7K (4700) Spark Plug wire #2 Spark Plug wire # 3 3.5K (3500) to 4.7K (4700) NO SPARK ON TWO CYLINDERS: 1. Swap the input wire ignition coil of the cylinders not firing with one that has fire. If the no fire problem stays on the same cylinders, replace the ignition coil. 2. If the problem moves to the other cylinders, replace the ECU. ENGINE KEEPS FOULING SPARK PLUGS: 1. Check the stator’s DVA output as follows: Check From: Check To: Idle 1500 RPM 3500 RPM Brown Blue 272 to 408 137 V minimum 144 V minimum 2. Check the resistance of the ignition coils. You should read between 3.5K (3500) to 4.7K (4700) ohms through each coil’s high tension leads. 3. Check the engine temperature. If the engine is not coming up to operating temperature, it will tend to foul the spark plugs. 4. Check the engine temperature sensor in a pan of water, as you warm it up. You should get the approximate readings below: Water Temp: @ 68 degrees @122 degrees @158 degrees 12.49K ohms 3.60 K ohms 1.75K ohms 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 7.11 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 ignition timing, it should be Engine Idle WOT (Wide Open Throttle) F50 3-7 degrees BTDC 30 degrees BTDC T50 BTDC 35 degrees BTDC NOTE: If he 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).