CDI Electronics Outboard Ignition Troubleshooting Guide

28 TROUBLESHOOTING GUIDE - Johnson/Evinrude Troubleshooting Johnson/Evinrude Troubleshooting Johnson/Evinrude Battery CD Ignitions with Points 1968-1972 55, 60, 65, 85 and 100 HP Battery-Powered Models (With Points Ignition) DUE TO THE CONSTRUCTION OF THE BATTERIES, DO NOT USE AUTOMOTIVE, MAINTAINENCE FREE OR LOW MAINTAINENCE BATTERIES FOR THIS APPLICATION! OVERCHARGING CAN CAUSE SEVERE DAMAGE TO THE IGNITION MODULE. (NOTE) All clipper modules, surge suppressors and safety circuits should be removed. After removing, the ignition wire (Red or Purple) must be connected directly to the ignition switch terminal (providing 12V from ignition switch). BATTERY VOLTAGE TO THE POWER PACK MUST BE CONTROLLED TO A MAXIMUM OF 16 VOLTS!!! THE REGULATED RECTIFIER LIKE THE 193-0705 OR 193-3408 IS RECOMMENDED. 1. Clean all battery connections and engine grounds. 2. Check wiring as follows: Pack Wire Color Function Red or Purple 12V from key switch Blue Positive to ignition coil Black/White To points Black Engine Ground Not Used Gray Tach Wire (Connect with one of the Yellow stator wires) Engine Wiring Connections for Testing Ignition Module 3. Connect a spark gap tester to the high tension lead coming from the ignition coil and set it to approximately ½”. 4. Crank the engine over, if it sparks while the spark gap tester is connected to the coil and does not spark through the spark plug wires – there is a problem in the distributor cap, rotor button or spark plug wires. 5. Check DC voltage present on the Purple wire at cranking. It MUST be at least 9.5 volts. If not, there is a problem in the harness, key switch, starter or battery. 6. Check DVA voltage on the Blue wire going to the coil while connected, it should be approximately 200 volts at cranking. 7. Disconnect the White/Black points wire. Turn the ignition switch on and strike the White/Black points wire against engine ground. The unit should spark each time. If it does, this usually means the CD module is good. Check the points, points plate and grounding wire for the points. 8. Check the Anti-reverse spring around the crankshaft. Make sure it is not shorting out the points set. 9. Connect a spark gap tester to the high-tension leads coming from the distributor cap and set the gap to approximately 7/16”. Align the rotor with #1 spark plug wire. Turn the ignition switch on and strike the White/ Black points wire against engine ground. Only the #1 spark plug wire should spark. If another spark plug wire has spark, there is a problem in the distributor cap. Repeat the test for the other cylinders. 10. Check the battery voltage at approximately 3500-RPM, MAXIMUM reading allowable is 15.5 volts measured at the power pack. Over 15.5 volts will damage the ignition. Check for loose connections or a bad battery. (NOTE) The CDI Electronics power pack may have a high pitched whine coming from it when the key switch is in the on position. This is normal and does not indicate a problem.