CDI Electronics Outboard Ignition Troubleshooting Guide

53 Johnson/Evinrude Troubleshooting Johnson/Evinrude ENGINE WILL NOT STAY IN QUICKSTART OVER 10 SECONDS: 1. Verify the engine temperature is below the trip point (89 degrees on some engines and 104 degrees on others) of the temperature switch. 2. Disconnect the White/Black Temperature Switch wire FROM the Port Temperature Switch. If the engine now stays in QuickStart, the Temperature Switch is likely defective. ENGINE STAYS IN QUICKSTART ON ALL CYLINDERS: 1. With the engine idling, check the Yellow/Red wire for DC voltage. If there is DC voltage on this wire while the engine is running, the Quick-Start will not disengage. A voltage over 1.5 volts but less than 7 volts will not engage the starter solenoid, yet will engage Quick-Start. 2. Short the White/Black Temperature Switch wire FROM the power pack to engine ground. Start the engine, if the Quick Start drops out after approximately 5 seconds, replace the White/Black Temperature Switch. 3. If the only way to disable QuickStart is to disconnect the 4pin connector with the Blue/White, Purple/White, Green/White and Pink/White wires between the power pack and the Timer Base, replace the power pack. ENGINE DROPS OUT AND BACK IN QUICKSTART AT IDLE: 1. Verify the spark plugs are the Champion QL77JC4 or QL78YC. These plugs are INDUCTIVE – NOT Resistive RF suppression. 2. Check the engine RPM, 3. With the engine idling, check the Yellow/Red wire for DC voltage. Intermittent DC voltage on this wire while the engine is running will re-engage Quick-Start. A voltage of less than 7 volts will not engage the starter solenoid, yet will engage Quick-Start. 4. With the engine idling, disconnect the Black/White wire from the power pack and short the White/Black Temperature Switch wire FROM the power pack to engine ground. If the Quick Start drops out and stays out after approximately 5 seconds, replace the White/Black Temperature Switch. If the problem is still present, replace the power pack. NO SPARK ON ONE BANK: 1. Swap pin location of the two Brown wires from the stator and retest. If the problem moves, the stator has a fault. 2. Disconnect the yellow wires from the stator to the rectifier and retest. If the engine fires, replace the rectifier. 3. Check the Timer Base resistance given below: Wire Color Check to Wire Color OEM Ohms CDI Ohms DVA Reading (Connected) Blue White 35-55 38-48 0.5V Purple White 35-55 38-48 0.5V Green White 35-55 38-48 0.5V Pink White 35-55 38-48 0.5V Blue/White White 100-160 100-160 1.2V Purple/WhiteWhite 100-160 100-160 1.2V Green/WhiteWhite 100-160 100-160 1.2V Pink/White White 100-160 100-160 1.2V 4. Check the spark plug wires for breaks and abrasions. 5. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to fire properly. This can be caused by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine. 6. 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 bank, disconnect the orange wires from the ignition coil for that bank and reconnect them to a load resistor. Retest. If the reading is now good, one or all of the ignition coils are likely bad. A continued low reading indicates a bad power pack. ENGINE WILL NOT ACCELERATE BEYOND 2500 RPM (Runs smooth below that RPM): 1. Use a temperature probe and verify that the engine is not overheating. 2. Verify the correct spark plugs are installed. 3. Make sure the tan temperature switch wire is not located next to a spark plug wire. 4. Disconnect the tan temperature wire from the pack and retest. If the engine now performs properly, the temperature switch, VRO switch or engine harness is likely defective. 5. Disconnect the VRO sensor from the engine harness and retest. If the engine performs correctly, replace the VRO or sensor.