CDI Electronics Outboard Ignition Troubleshooting Guide

22 TROUBLESHOOTING GUIDE - Chrysler/Force Troubleshooting Chrysler/Force Troubleshooting 6. Check the triggering and charge coil flywheel magnets for cracked, broken and loose magnets. NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER: 1. Check the trigger resistance and DVA output as shown below: WIRE READ TO RESISTANCE DVA (Connected) DVA (Disconnected) Purple White 800-1400 4 V + 4 V + (#) Purple Engine GND Open 1 V + N/A White Engine GND Open 1 V + N/A (#) This reading can be used to determine if a pack has a problem in the triggering circuit. For instance, if you have no spark on one cylinder and the trigger’s DVA reading for that cylinder is low – disconnect the trigger wires and recheck the DVA output. If the reading stays low – the trigger is bad. If the reading is now within spec – the pack is bad. 2. Check the DVA output on the Green wires from the switch box while connected to the ignition coils. Check the reading on the switch box terminal AND on the ignition coil terminal. You should have a reading of at least 150V or more (while connected) at both places. If the reading is low on one cylinder, disconnect the Green wire from the ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a bad power pack. 3. If the cylinders are only misfiring above an idle, connect an inductive tachometer to each cylinder in turn and try to isolate the problem cylinder. 4. Visually inspect the ignition coils for burned or discolored areas and cracks in the casing (indicating arcing inside the coil). 5. Swap the ignition coil with one that is sparking correctly. 6. Rare causes include a weak trigger magnet. If possible, try another flywheel. SWITCH BOX OR TRIGGER REPEATEDLY BLOWS ON SAME CYLINDER: 1. Check the trigger wires for shorts to engine ground as a shorted trigger wire can destroy a SCR inside the switch box. 2. In contrast, a shorted SCR inside the switch box can destroy a trigger coil. Check the trigger resistance and DVA output (see NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER above). 3. Replace the ignition coil on the cylinder dropping spark. ENGINE WILL NOT SHUT OFF: Disconnect the stop wire at the switch box. Connect a jumper wire to the stop wire from the switch box and short it to engine ground. If this stops the switch box from sparking, the stop circuit has a fault. Check the key switch, harness and shift switch. If this does not stop the switch box from sparking, replace the switch box. Repeat test as necessary for additional switch boxes. WILL NOT ACCELERATE BEYOND 3000-4000 RPM: 1. Disconnect the Yellow wires from the stator to the rectifier and retest. If the engine now has good spark, replace the rectifier. 2. Connect a DVA meter between the stator’s Blue and Blue/White wires. Run the engine up to the RPM where the problem is occurring. DVA voltage should increase with RPM. A sharp drop in DVA right before the problem occurs usually indicates a bad stator. (Read from Blue to engine ground if the engine has a Red stator kit installed). 3. Connect a DVA meter between the stator’s Red and Red/White wires. The DVA voltage should show a smooth climb in voltage and remain high through the RPM range. A reading lower than on the Blue wire reading indicates a bad stator. 4. Connect an inductive tachometer to each cylinder in turn and try to isolate the problem. A single cylinder dropping spark will likely be a bad switch box or ignition coil. All cylinders not sparking properly usually indicates a bad stator. 5. Perform a high-speed shutdown and read the spark plugs. Check for water. A crack in the block can cause a miss at high speed when the water pressure gets high, but a normal shutdown will mask the problem. 6. Check the triggering and charge coil flywheel magnets for cracked, broken and loose magnets. MISS AT ANY RPM: 1. Disconnect the Yellow wires from the stator to the rectifier and retest. If the miss clears, replace the rectifier.