CDI Electronics Outboard Ignition Troubleshooting Guide

75 Johnson/Evinrude Troubleshooting Johnson/Evinrude 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 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 FIRE AS LONG AS THE KEY SWITCH IS ENGAGED OR WILL NOT REV ABOVE IDLE SPEED: Check the DVA voltage on the power coil (Orange to Orange/Black) as given in Step #13 on the previous page. (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 7 notches. 2. Check the timing. Before Quick-Start, it must be set to 2-6° BTDC. After Quick-Start, it must be set to 4-8° ATDC. 3. Try another sensor. 4. Replace the power pack. NO FIRE OR INTERMITTENT FIRE ON ONE BANK: 1. Disconnect BOTH of the Black/Yellow stop wires AT THE POWER PACK and retest. If the engine’s ignition has fire, the stop circuit has a fault. Check the key switch, harness and shift switch. 2. If possible, swap the stator wire pairs in the connector and see if the problem moves. If it does, the stator is bad. 3. Disconnect the Yellow wires from the stator to the rectifier and retest. If the engine now has fire, replace the rectifier. 4. 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. 5. Check the stator resistance and DVA output on BOTH banks (see Step #13 on NO FIRE ON ANY CYLINDER above). 6. Disconnect the 5-pin connector on the port side of the power pack and see if the fire returns. If it does fire, check resistance to see if the Black/Yellow or Black/Orange wire is shorted to engine ground. Check to see if the Shift Interrupter switch is located in the circuit where there is no fire.