2 Stroke Carbureted Ignitions (Screw Terminal Power Packs)

2 Stroke Carbureted Ignitions (Screw Terminal Power Packs)
YAMAHA
2 Stroke Carbureted Engines - Screw Terminal Power Packs
Three Cylinder Engines
NO SPARK ON ANY CYLINDER:
1. Disconnect the White stop wire and retest. If the engine’s ignition now has spark, the stop circuit has a fault. Check the key switch,
harness and shift switch.
2. Check the resistance and DVA output of the Stator and Trigger:
Read from
Read to
OEM Reading CDI Reading
DVA (connected)
White/Red Trigger wire
White/Yellow Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/Black Trigger wire White/Green Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
Brown Stator wire
Blue Stator wire
840-1260 ohms 600-800 ohms 85 Volts Minimum
Blue Stator wire
Red Stator wire
110-130 ohms 10-20 ohms
25 Volts Minimum
3. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be caused
by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine properly.
NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:
1. Check the resistance and DVA output of the Stator and Trigger:
Read from
Read to
OEM Reading
White/Red Trigger wire
White/Yellow Trigger wire 280-430 ohms
White/Black Trigger wire White/Green Trigger wire 280-430 ohms
White/Red Trigger wire
Eng Ground
Open
White/Black Trigger wire Eng Ground
Open
White/Yellow Trigger wire Eng Ground
Open
White/Green Trigger wire Eng Ground
Open
Brown Stator wire
Blue Stator wire
840-1260 ohms
Brown Stator wire
Eng Ground
Open
Blue Stator wire
Eng Ground
Open
Blue Stator wire
Red Stator wire
65-130 ohms
Red Stator wire
Eng Ground
Open
CDI Reading 280-430 ohms 280-430 ohms Open
Open
Open
Open
600-800 ohms Open
Open
10-20 ohms
Open
DVA (connected)
2.5 Volts Minimum
2.5 Volts Minimum
2.5 Volts Minimum
2.5 Volts Minimum
2.5 Volts Minimum
2.5 Volts Minimum
85 Volts Minimum
85 Volts Minimum
16 Volts Minimum
16 Volts Minimum
30 Volts Minimum
2. Check the DVA output on the Black/White wires from the power pack while connected to the ignition coils. You should have a
reading of at least 125V or more. If the reading is low on one cylinder, disconnect the wire from the ignition coil for that cylinder and
reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a
bad power pack or trigger (test per above).
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM:
1. Verify the engine is not overheating and causing the power pack to limit the RPM.
2. Disconnect the Pink wire from the power pack and retest. If the engine now performs correctly, check the overheat sensor, oil level
in the oil tank mounted on the engine and the wiring harness.
3. Check the position of the Pink wire and make sure it is not next to a spark plug wire.
TECH SUPPORT 1.866.423.4832
CUSTOMER SERVICE 1.800.467.3371
www.cdielectronics.com
97
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2500 RPM:
1. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be
caused by a bad coil, power pack or spark plug.
2. If all cylinders show the same RPM and the engine will only rev to approximately 2500 RPM, check the running stator DVA output
from idle thru WOT. You should show a steady increase in voltage on the Blue to the Black/Red stator wires throughout the
RPM range. A drop in voltage can be the result of a bad stator coil or a bad regulator/rectifier (disconnect the Green wires to the
regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad).
MISS AT ANY RPM:
1. Verify the engine is not overheating and causing the problem.
2. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be
caused by a bad coil, power pack or spark plug.
3. Disconnect the Green wires to the regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad.
S.A.F.E. WILL NOT ENGAGE:
Disconnect the Pink warning wire from the power pack. Connect a jumper wire to engine ground and connect it to the terminal where
the Pink wire goes. If the engine now limits at approximately 2000 RPM, check the wiring from the temperature sensor and oil tank to
the power pack. If it still fails to engage, the power pack is likely bad.
ENGINE WILL NOT STOP:
Disconnect the White stop wire and connect a jumper wire to engine ground. If you still have spark, the power pack is likely bad. If the
engine has no spark with the jumper connected, either the wiring harness, key switch or emergency stop switch is bad.
Four Cylinder Engines
NO SPARK ON ANY CYLINDER:
1. Disconnect the White stop wire and retest. If the engine’s ignition now has spark, the stop circuit has a fault. Check the key switch,
harness and shift switch.
2. Check the resistance and DVA output of the Stator and Trigger:
Read from
Read to
OEM Reading CDI Reading
DVA (connected)
White/Red Trigger wire
White/Yellow Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/Black Trigger wire White/Green Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
Brown Stator wire
Red Stator wire
840-1260 ohms 600-800 ohms 85 Volts Minimum
Blue Stator wire
Black/Red Stator wire
65-130 ohms
10-20 ohms
16 Volts Minimum
3. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be caused
by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine properly.
98
TROUBLESHOOTING GUIDE
KEEPING YOUR BOAT ON THE WATER
NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:
1. Check the resistance and DVA output of the Stator and Trigger:
Read from
Read to
OEM Reading CDI Reading
DVA (connected)
White/Red Trigger wire
White/Yellow Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/Black Trigger wire White/Green Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/Red Trigger wire
Eng Ground
Open
Open
2.5 Volts Minimum
White/Black Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
White/Yellow Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
White/Green Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
Brown Stator wire
Red Stator wire
840-1260 ohms 600-800 ohms 85 Volts Minimum
Brown Stator wire
Eng Ground
Open
Open
85 Volts Minimum
Red Stator wire
Eng Ground
Open
Open
85 Volts Minimum
Blue Stator wire
Black/Red Stator wire
65-130 ohms
10-20 ohms
16 Volts Minimum
Blue Stator wire
Eng Ground
Open
Open
16 Volts Minimum
Black/Red Stator wire
Eng Ground
Open
Open
16 Volts Minimum
2. Check the DVA output on the Black/White wires from the power pack while connected to the ignition coils. You should have a
reading of at least 125V or more. If the reading is low on one cylinder, disconnect the wire from the ignition coil for that cylinder and
reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a
bad power pack or trigger (test per above).
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM:
1. Verify the engine is not overheating and causing the power pack to limit the RPM.
2. Disconnect the Pink wire from the power pack and retest. If the engine now performs correctly, check the overheat sensor, oil level
in the oil tank mounted on the engine and the wiring harness.
3. Check the position of the Pink wire and make sure it is not next to a spark plug wire.
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2500 RPM:
1. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be
caused by a bad coil, power pack or spark plug.
2. If all cylinders show the same RPM and the engine will only rev to approximately 2500 RPM, check the running stator DVA output
from idle thru WOT. You should show a steady increase in voltage on the Blue to the Black/Red stator wires throughout the
RPM range. A drop in voltage can be the result of a bad stator coil or a bad regulator/rectifier (disconnect the Green wires to the
regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad).
MISS AT ANY RPM:
1. Verify the engine is not overheating and causing the problem.
2. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be
caused by a bad coil, power pack or spark plug.
3. Disconnect the Green wires to the regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad.
S.A.F.E. WILL NOT ENGAGE:
Disconnect the Pink warning wire from the power pack. Connect a jumper wire to engine ground and connect it to the terminal where
the Pink wire goes. If the engine now limits at approximately 2000 RPM, check the wiring from the temperature sensor and oil tank to
the power pack. If it still fails to engage, the power pack is likely bad.
ENGINE WILL NOT STOP:
Disconnect the White stop wire and connect a jumper wire to engine ground. If you still have spark, the power pack is likely bad. If the
engine has no spark with the jumper connected, either the wiring harness, keyswitch or emergency stop switch is bad.
TECH SUPPORT 1.866.423.4832
CUSTOMER SERVICE 1.800.467.3371
www.cdielectronics.com
99
Six Cylinder Engines
NO SPARK ON ANY CYLINDER:
1. Disconnect the White stop wire and retest. If the engine’s ignition now has spark, the stop circuit has a fault. Check the key switch,
harness and shift switch.
2. Check the resistance and DVA output of the Stator and Trigger:
Read from
Read to
OEM Reading CDI Reading
DVA (connected)
White/Red Trigger wire
White/ Green Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/Black Trigger wire White/Blue Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/ Yellow Trigger wire White/Brown Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
Brown Stator wire
Red Stator wire
840-1260 ohms 600-800 ohms 85 Volts Minimum
Blue Stator wire
Black/Red Stator wire
65-130 ohms
10-20 ohms
25 Volts Minimum
3. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be caused
by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine properly.
NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:
100
1. Check the resistance and DVA output of the Stator and Trigger:
Read from
Read to
OEM Reading CDI Reading
DVA (connected)
White/Red Trigger wire
White/ Green Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/Red Trigger wire
Eng Ground
Open
Open
2.5 Volts Minimum
White/ Green Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
White/Black Trigger wire White/Blue Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/ Black Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
White/ Blue Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
White/ Yellow Trigger wire White/Brown Trigger wire 280-430 ohms 280-430 ohms 2.5 Volts Minimum
White/ Yellow Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
White/Brown Trigger wire Eng Ground
Open
Open
2.5 Volts Minimum
Brown Stator wire
Red Stator wire
840-1260 ohms 600-800 ohms 85 Volts Minimum
Brown Stator wire
Eng Ground
Open
Open
85 Volts Minimum
Red Stator wire
Eng Ground
Open
Open
85 Volts Minimum
Blue Stator wire
Black/Red Stator wire
65-130 ohms
10-20 ohms
16 Volts Minimum
Blue Stator wire
Eng Ground
Open
Open
16 Volts Minimum
Black/Red Stator wire
Eng Ground
Open
Open
16 Volts Minimum
2. Check the DVA output on the Black/White wires from the power pack while connected to the ignition coils. You should have a
reading of at least 125V or more. If the reading is low on one cylinder, disconnect the wire from the ignition coil for that cylinder and
reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a
bad power pack or trigger (test per above).
TROUBLESHOOTING GUIDE
KEEPING YOUR BOAT ON THE WATER
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM:
1. Verify the engine is not overheating and causing the control module to limit the RPM.
2. Disconnect the White wire on the power pack coming from the control module and retest. If the engine now performs correctly,
check the overheat sensor, oil level in the oil tank mounted on the engine and the wiring harness. If everything test correctly, the
control module is likely defective.
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2500 RPM:
1. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be
caused by a bad coil, power pack or spark plug.
2. If all cylinders show the same RPM and the engine will only rev to approximately 2500 RPM, check the running stator DVA output
from idle thru WOT. You should show a steady increase in voltage on the Blue to the Black/Red stator wires throughout the
RPM range. A drop in voltage can be the result of a bad stator coil or a bad regulator/rectifier (disconnect the Green wires to the
regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad).
MISS AT ANY RPM:
1. Verify the engine is not overheating and causing the problem.
2. Using an inductive tachometer, check the RPM on all cylinders. A difference in readings between the individual cylinders can be
caused by a bad coil, power pack or spark plug.
3. Disconnect the Green wires to the regulator/rectifier and retest – if the engine now performs OK, the regulator/rectifier is likely bad.
S.A.F.E. WILL NOT ENGAGE OR ENGINES REVS ABOVE 6500 RPM:
1. Disconnect the Pink warning wire from the control module. Connect a jumper wire to engine ground and connect it to the terminal
where the Pink wire goes. If the engine now limits at approximately 2000 RPM, check the wiring from the temperature sensor and
oil tank to the power pack. If it still fails to engage, the power pack is likely bad.
2. Check the voltage on the Brown wire going to the control module. You should see approximately 35 volts when running at idle. Low
or high voltage is likely to be a shorted control module and a very low voltage is likely to be a defective power pack.
ENGINE WILL NOT STOP:
Disconnect the White stop wire and connect a jumper wire to engine ground. If you still have spark, the power pack is likely bad. If the
engine has no spark with the jumper connected, either the wiring harness, key switch or emergency stop switch is bad.
TECH SUPPORT 1.866.423.4832
CUSTOMER SERVICE 1.800.467.3371
www.cdielectronics.com
101
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