CDI Electronics Outboard Ignition Troubleshooting Guide

39 Johnson/Evinrude Troubleshooting Johnson/Evinrude Johnson/Evinrude Alternator Driven CD Ignitions 1977-2006 Two Stroke Carbureted Engines Two Cylinder Two Stroke Engines 1978-2007 4-60 HP Models Service Note: Please use the Factory recommended spark plug (currently Champion QL77JC4) gapped at 0.030”. NO SPARK ON ANY CYLINDER: 1. Disconnect the Black/Yellow stop wire AT THE POWER PACK and retest. If the engine’s ignition has spark, the stop circuit has a fault. Check the key switch, harness and shift switch. 2. Disconnect the Yellow wires from the rectifier and retest. If the engine has spark, replace the rectifier. 3. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be caused by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine. 4. Inspect and clean all engine and ignition ground connections. 5. Check the stator and timer base resistance and DVA output as given below: Engines Without SLOW Function (Two Wire Trigger) WIRE READ TO OEM Ohms CDI Ohms DVA (Connected) DVA (Disconnected) Brown Brown/Yellow 500-650(1978-84) 500-650 150-400 V 150-400 V (*) Brown Brown/Yellow 550-600(1985-1988) 500-650 150-400 V 150-400 V (*) Brown Brown/Yellow 535-685(1989-1992) 500-650 150-400 V 150-400 V (*) Brown Brown/Yellow 800-1000(1993-2007) 500-650 150-400 V 150-400 V (*) Brown Engine GND Open Open 150-400 V < 2 V (c) Brown/Yellow Engine GND Open Open 150-400 V < 2 V (c) Black/White White/Black 30-50 45-55 0.6V or more 0.6V or more Black/White Engine GND Open Open 0.6V or more < 2 V (c) White/Black Engine GND Open Open 0.6V or more < 2 V (c) 1993-2001 40-55 HP 2 Cylinder Engines With SLOW Function (Three Wire Trigger) WIRE READ TO OEM Ohms CDI Ohms DVA (Connected) DVA (Disconnected) Brown Brown/Yellow 750-950 650-850 150-400 V 150-400 V (*) Orange Orange/Black 360-440 45-55 11-22 V 45-120 V (*) White Blue 22-32 25-30 100-400 V (a) 0.6 V + (#) White Green 22-32 25-30 100-400 V (a) 0.6 V + (#) White Engine GND Open Open SHORTED N/A Blue Engine GND Open Open 100-400 V (a) N/A Green Engine GND Open Open 100-400 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 out of spec – disconnect the stator wires and recheck the DVA output. If the reading is still out of spec – 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) Check stator DVA first. Then if timer base DVA is 0.6 - 2.5 V, the pack is faulty. If below 0.6 V, the timer base is faulty if craning RPM is over 250. (b) 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. (c) Some meters will pickup static/stray electricity up to 2 volts.

RkJQdWJsaXNoZXIy NTU1MzIx