CDI Electronics Outboard Ignition Troubleshooting Guide

60 TROUBLESHOOTING GUIDE - Johnson/Evinrude Troubleshooting Johnson/Evinrude Troubleshooting 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. Disconnect the tan warning system wire from the pack and retest. If the engine now performs properly, the temperature switch, VRO or harness may be bad. Reconnect the Tan wire to the pack and disconnect the Tan wire from the temperature switch in each cylinder head in turn. If the engine now performs normally, the temperature switch is defective. If it does not perform correctly, there is likely a problem in the engine harness, VRO (if equipped) or the boat harness. 3. Make sure the tan temperature switch wire is not located next to a spark plug wire. 4. Disconnect the VRO sensor from the engine harness and retest. If the engine performs correctly, replace the VRO or sensor. ENGINE DIES WHEN QUICK-START DROPS OUT: Check ignition timing at idle with the White/Black temperature wire disconnected. Remember to allow for the 12- 15 degree drop in ignition timing when Quick-Start disengages. Verify ignition timing after engine has warmed up, according to the service manual. ENGINE STAYS IN QUICK-START: 1. With the engine idling, check the Yellow/Red wire for DC voltage. If there is DC voltage over 2 volts on this wire while the engine is running, the Quick-Start will not disengage. A voltage of 5 to 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 5-10 seconds; replace the White/Black temperature switch. 3. Disconnect the Black/White wire from the power pack to the timerbase. If the Quick-Start feature is not now working, replace the power pack. ENGINE WILL NOT ENGAGE QUICK-START: 1. Disconnect the White/Black wire from the temperature sensor. 2. With the engine idling, check the Black/White timer base wire for DVA voltage. There should be about 6 to 10 volts DVA voltage on this wire while the engine is running for the Quick-Start to engage. If the voltage is not present at cranking, check the Orange to Orange/Black power coil wires for the 10-22V DVA. If the DVA on the Orange to Orange/Black power coil wires is correct, replace the power pack. 3. Short the White/Black temperature switch wire FROM the power pack to engine ground. If the voltage on the Black/White wire drops out after approximately 5 seconds but the engine timing does not change, replace the timer base. If the voltage remains present, disconnect the Yellow/Red wire to the pack and repeat the test. If the voltage still remains, replace the pack. ENGINE TIMING TOO HIGH: 1. Check the flywheel center hub magnet to make sure it’s tight. Look for signs of cracks and bulges in the Brown ferret magnet material. 2. Short the White/Black temp wire to engine ground and see if the timing drops back to normal. 3. Check the DVA voltage on the Black/White wire going to the timer base. With the White/Black temp wire disconnected, the voltage should be 6 to 10 volts. When the White/Black temp wire is shorted to engine ground, the voltage should drop out. If the voltage on the Black/White wire stays in the 6-10 volt range, disconnect the Yellow/Red wire from the power pack. The voltage should drop out on the Black/White wire. If it does, the harness or starter solenoid is likely defective. If the voltage on the Black/White wire stays in the 6-10 volt range with the Yellow/Red wire disconnected and the White/Black wire shorted to engine ground, the power pack is defective. ENGINE IDLING TOO HIGH: 1. Index the flywheel for ALL cylinders. Check ignition timing on all cylinders. If one or more cylinders have advanced timing, replace the timerbase. 2. If the ignition timing on all cylinders is too high, check the flywheel center hub magnet to make sure it’s tight. Look for signs of cracks and bulges in the Brown ferrete magnet.