CDI Electronics Outboard Ignition Troubleshooting Guide

74 TROUBLESHOOTING GUIDE - Johnson/Evinrude Troubleshooting Johnson/Evinrude Troubleshooting 3. 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. 4. Verify the engine is turning in a clockwise direction. If not, see TRIES TO RUN BACKWARDS below. 5. Check the power pack and ignition coil ground wires for corrosion and tightness. 6. Connect a spark gap tester to all cylinders. 7. Disconnect the boat side harness and connect a remote starter unit. Check for fire. If the engine has fire, check the boat side harness’s Black/Yellow wire for shorts to ground. 8. Disconnect the 5-pin connector on the port side of the power pack and see if fire returns. If it does fire, check resistance to see if the Black/Yellow wires are shorted to engine ground. 9. If it loses fire 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. The thin area between the crank position and the cylinder position is the most common breakout location. 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 for BOTH banks: WIRE READ TO RESISTANCE DVA (Connected) DVA (Disconnected) Brown Brown/Yellow 450-600 150-400 V 150-400 V (*) Brown/White Brown/Black 450-600 150-400 V 150-400 V (*) Orange Orange/Black 45-60 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.