CDI Electronics Outboard Ignition Troubleshooting Guide

36 TROUBLESHOOTING GUIDE - Johnson/Evinrude Troubleshooting Johnson/Evinrude Troubleshooting WIRE READ TO OEM Ohms CDI Ohms DVA (Connected) DVA (Disconnected) Brown Brown/Yellow (b) 220-330 650-850 150-400 V 50-400 V (*) White Blue (c) 11-17(1976-77) 35-55 0.6 V + 0.6 V + (#) White Blue (c) 13-23(1978) 35-55 0.6 V + 0.6 V + (#) White Purple (c) 11-17(1976-77) 35-55 0.6 V + 0.6 V + (#) White Purple (c) 13-23(1978) 35-55 0.6 V + 0.6 V + (#) White Green (c) 11-17(1976-77) 35-55 0.6 V + 0.6 V + (#) White Green (c) 13-23(1978) 35-55 0.6 V + 0.6 V + (#) White Engine GND Open Open 150-400 V (a) N/A Blue Engine GND Open Open 150-400 V (a) N/A Purple Engine GND Open Open 150-400 V (a) N/A Green Engine GND Open Open 150-400 V (a) N/A (*) This reading can be used to determine if a stator or pack has a problem. For instance, if you have no spark on any cylinder and the stator’s DVA reading is low – disconnect the stator wires and recheck the DVA output. If the reading stays low – the stator is bad. If the reading is now within spec – the pack is bad. (#) 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 timer base’s DVA reading for that cylinder is low – disconnect the timer base wires and recheck the DVA output. If the reading stays low – the timer base is bad. If the reading is now within spec – the pack is bad. (a) The trigger signal rides on top of the high voltage on these timer bases. Check stator DVA first. Then if timer base DVA is 0.6 - 2.5 V, the pack is faulty. (b) Check both pairs of stator charge coils. (c) Check both sides of the timer base. 6. Check the DVA voltage on the White wire to engine ground. You should have a reading of at least 150V or more (while connected to the pack). If the reading is low, disconnect the timer base wires from the pack and recheck the White terminal ON THE PACK. If the voltage jumps up to an acceptable reading, the timer base may have a problem in the internal wiring (possibly a thin spot in the insulation on one wire). 7. Check the triggering and charge coil flywheel magnets for cracked, broken and loose magnets. NO SPARK OR INTERMITTENT SPARK ON ONE BANK: 1. Disconnect the stop wires from both power packs and retest. If the spark comes back, swap the power packs from side to side and reconnect the stop circuit. If the no spark problem remains on the same bank, the stop circuit is bad. Check the key switch, harness and shift switch. If the problem moves, replace the power pack that was firing correctly due to a bad blocking diode in the pack. 2. Swap the stator wire pairs from one side of the engine to the other side and see if the problem moves. If it does, the stator is bad. 3. Check the stator and timer base resistance and DVA output on BOTH banks (see NO SPARK ON ANY CYLINDER above). NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS: 1. Disconnect the Yellow wires from the rectifier and retest. If the engine has good spark, replace the rectifier. 2. Check the timer base resistance and DVA output on BOTH banks (see NO SPARK ON ANY CYLINDER above). 3. Check the DVA output from the timer base. A reading of at least 0.6V or more from the White wire to the Blue, Green and Purple wires (while connected to the pack) is needed to spark the pack. 4. Disconnect the timer base from the pack and check the resistance in the pack as follows: Red meter lead Black meter lead Reading Black/White terminal Sensor 1 100-200 ohms Black/White terminal Sensor 2 100-200 ohms Black/White terminal Sensor 3 100-200 ohms All readings should be fairly even. If the sensor reading in the pack for the cylinder not firing shows over a 10% different reading compared to the other sensors, the pack needs replacing. 5. Check the DVA output on the Orange wires from the power pack while connected to the ignition coils. You should have a reading of at least 150V or more. If the reading is low on one cylinder, disconnect the Orange 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. 6. Visually inspect the ignition coils for burned or discolored areas and cracks in the casing (indicating arcing inside