CDI Electronics Outboard Ignition Troubleshooting Guide

70 TROUBLESHOOTING GUIDE - Johnson/Evinrude Troubleshooting Johnson/Evinrude Troubleshooting 8. Disconnect the Port 4 pin connector (with the Yellow/Red, Black/Yellow, Tan and White/Black wires) from the power pack and see if spark returns. If it does spark, check resistance to see if the Black/Yellow wire is shorted to engine ground. 9. If it loses spark after the key switch is disengaged, check the DVA voltage on the stator’s power coil (Orange to Orange/Black) as given below in Step #13. Either the power coil or power pack is the fault. 10. Check the battery voltage on the Yellow/Red wire while cranking the engine. If below 11 VDC, charge the battery and check all battery cables. A continued low battery reading could be from a dragging starter. If still below 11 VDC, disconnect the power pack’s Yellow/Red wire from the starter solenoid and apply a verified 12 + VDC to the Yellow/Red wire. If the engine now runs good, check the DVA voltage on the stator’s power coil (Orange to Orange/Black) as given below in Step #13. Either the power coil or power pack is the fault. 11. Remove the sensor wheel and check for damage, especially where the top slots are located. Sometimes the wheels will break out where the windows overlap. 12. Check the sensor eyes for dirt, grease, etc. If you have to clean it, use denatured alcohol and a Q-tip. Do not use any other cleaning agent because damage to the optical lens will occur. 13. Check the stator resistance and DVA voltage as given below: WIRE READ TO RESISTANCE DVA (Connected) DVA (Disconnected) Brown Brown/Yellow (or Brown/White) 900-1200 150-400 V 150-400 V (*) Orange Orange/Black 45-65 11-22 V 45-120 V (*) (*) 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. (NOTE) Low readings on all checks indicate a possible problem with the flywheel magnets that require checking. (SERVICE NOTE) It is recommended that liquid neoprene be applied to the areas where piercing probes were used. 14. Check the DVA output from the power pack to the primary coil wires as follows: WIRE READ TO DVA (Connected) Orange/Blue Engine Ground 150 V + Orange/Green Engine Ground 150 V + (NOTE) If the DVA values are below these specifications, the power pack or sensor is likely bad. 15. Check the sensor DC voltage as follows: WIRE READ TO DC voltage (Connected) Orange/Red Engine Ground 10.5-12 VDC Black/Orange Engine Ground 8-10 VDC (WARNING!!) The Black/Orange wire should NEVER be shorted to engine ground as this will damage the sensor. 16. Check the charge coil flywheel magnets for cracked, broken and loose magnets. ONLY HAS SPARK AS LONG AS THE KEY SWITCH IS ENGAGED OR WILL NOT REV ABOVE IDLE SPEED: Check the DVA voltage on the stator’s power coil (Orange to Orange/Black) as given above in Step #13: (NOTE) The readings should rapidly increase as the engine RPM increases and stabilize below 22 volts DVA (voltage exceeding 22 V DVA indicates a bad power pack). A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator winding. A sharp drop in voltage when you disengage the key switch indicates a bad power coil on the stator. TRIES TO RUN BACKWARDS: 1. Check the encoder wheel. It must have 5 notches, not 7. Also, check for physical damage. 2. Check the timing. Before Quick-Start, it should be set to approximately 4° BTDC. After Quick-Start, it will be set to 6° ATDC. 3. Try another sensor.