CDI Electronics Outboard Ignition Troubleshooting Guide

9 General Troubleshooting General Checking Maximum Battery Output 1. Install an ammeter capable of reading the maximum output in line on the Red wire connected to the starter solenoid. 2. Connect a load bank to the battery. 3. In the water or on a Dynamometer, start the engine and bring the RPM up to approximately 3500. 4. Turn on the load bank switches to increase the battery load to match the rated output of the stator. 5. Check the ammeter. If the amperage is low: A. Check the Purple wire for voltage while the engine is running. You should see the same voltage as the battery. B. Connect a jumper wire from the Positive battery cable to the Purple wire and recheck the ammeter. If the amperage is now correct, there is a problem in the harness or key switch. 6. If the amperage is correct, but the battery voltage remains low, replace the battery. Engine Wiring Cross Reference Chart for Most Outboards Circuit Mercury PRE-1978 Mercury 1978 & UP OMC Yamaha Force PRE-1994 Force 1994 & UP Suzuki Tohatsu Power Red Red Red Red Red Red/Purple White Red Ign. Switch White Purple Purple Yellow Blue Red/Blue Gray Red Eng. Gnd. Black Black Black Black Black Black Black Black Stop Circuit Orange Salmon White Black/Yellow Black/Yellow White White Black/Yel Green Red Blue Brown Eng. Start Yellow Yellow/Red Yellow/Red Brown Yellow Yellow/Red Brown Yellow/ Red Green Tach Brown Gray Gray Green Purple Gray Yellow White Battery Charge Yellow/Red Yellow Yellow/ Black Yellow Yellow/ Black Green Yellow Yellow Yellow/Blk Yellow/ Red Yellow White Stator CDI Power Red White Blue(a) Blue Blue/White Red Red/White Green/White White/Green Brown Brown/ Yel Brown/ BlackBrown/ White Blue Brown Red Blk/ Red Blue Yellow Brown/Blue Brown/Yel Blue Blue/ White Red Red/White Green/ WhtWht/ Green Green Black/ Red Red Choke Gray Blue Yellow/Black Purple/White Blue Green Yellow/Blk Orange Blue Overheat Eng. Temp Tan Tan Tan (b) White/ Blk (c) Pink Orange Tan Green/ Yellow Light Blue (a) Ignition Driver Systems only, all others were battery driven systems. (b) The stripe color on the Tan wire indicates the temperature at which the sensor trips. (c) The White/Black wire is the cold engine temp indicator and shorts to GND. At approx. 105 deg. F. (Blk = Black) (Wht = White) (Gry=Gray) (Yel=Yellow) ABYC Recommended Boat Wiring Color Codes Color Function Comments Yellow/Red Strips (YR) Engine Start Circuit Brown/Yellow Stripe (BY) Bilge Blower Alternate color is Yellow(Y) Yellow Stripe (Y) Bilge Blower If used for DC negative, blower MUST be Brown/Yellow Stripe Dark Gray (Gy) Navigation Lights Fuse or Switch to lights Dark Gray (Gy) Tachometer Brown (Br) Generator/Alternator Charge Indicator Lights, Fuse or Switch to pumps Orange (O) Accessory Power Ammeter to alternator output and accessory fuse or switches. Distribution Panel accessory switch. Purple (Pu) Ignition Instrument Power Ignition switch to coil and electrical instruments. Distribution Panel to electric instruments. Dark Blue Cabin and instrument lights Fuse or switch to lights Light Blue (Lt Bl) Oil Pressure Oil sender to gauge Tan Water Pressure Temperature sender to gauge Pink (Pk) Fuel Gauge Fuel sender to gauge Green/White Stripe Tilt/Trim down or in Tilt and Trim Circuits Blue/White Strip Tilt/Trip up or out Tile and Trim Circuits