Installation and Troubleshooting Guide

Installation and Troubleshooting Guide
Installation and Troubleshooting Guide
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, Inc., is prohibited.
CDI P/N 123-7567
This unit will replace P/N’s: 986999, 987403, 987567, and 987875
WARNING! This product is designed to be installed by a professional marine mechanic. CDI Electronics cannot be held
liable for injury or damage resulting from improper installation, abuse, neglect or misuse of this product.
WARNING! The 123-7567 may not work and could damage the unit if the ballast resistor is removed or a high
current aftermarket coil is used. The product warranty may be void. Contact CDI Technical support for help
selecting correct parts for aftermarket ignition systems.
NOTE: This install sheet covers the 123-7567 Electronic Shift Assist (ESA) module for boats equipped with the electronic
Prestolite BID (Breaker-less Ignition) distributor and a harness using a single 5 pin connector for the ESA. If your boat has
any other type of distributor than a Prestolite BID or a two plug ESA connection, please call CDI for a cross reference.
INSTALLATION
1. With the engine OFF, disconnect and remove the old ESA module.
2. Using the original bolts, mount the new ESA to the mounting bracket. Be careful not to pinch any wires.
3. Verify correct Ignition circuit resistance. (See Page 2)
A) Measure resistance of the coil (Step A). Normal coil resistance should be 1.5Ω, if less resistance is found
a higher resistance ballast resistor may be needed.
B) Reassemble all wiring, then, disconnect the 5 pin connector containing Violet and Gray/Black wires.
Measure the resistance between Violet and Gray/Black wire on the engine side (Step 2). Measurement
should be 3Ω.
C) If either reading in step A or B is not correct Perform engine stalls during shift Troubleshooting and then
select proper ballast resistor, or contact CDI Tech Support for further help.
4. Connect the wires as the original ESA was connected.
5. The following is a color code/function explanation:
A) Violet - Switched 12V power to the ESA module. This should NOT come from the positive side of the coil.
B) Gray/Black Stripe – Negative side of ignition coil for the ESA to monitor the engine RPM perform
interruption during shift. The BID distributor also connects to the coil’s negative terminal.
C) Gray - Tachometer output sent to the dash mounted Rpm gauge.
D) Black – Engine ground reference for the ESA module. The ESA must have a good ground connection.
E) Blue – Ground signal from the shift switch indicating a shift is occurring. This activates the ESA.
TROUBLESHOOTING
Engine stalls during shift:
This usually only occurs with performance coils and modified ballast resistance. The higher the current in the ESA the
more likely failure will occur. Typical ESA circuit current should not exceed 4-5 amps. With an aftermarket coil, ESA circuit
current can exceed 10 amps. A typical stock set up uses a 1.5Ω coil and a 1.5Ω ballast resistor (3Ω total).
Perform measurements per installation guide step 3. If the total circuit resistance between the gray/black and violet wires
is less than 3Ω, then calculate ballast resistance to be added. Example: If measurement is 0.8Ω, then 3.0 Ω - 0.8 Ω =
2.2Ω of ballast resistance needed. Rebalance the circuit by adding a ballast resistor per diagram on page 2.
Hard Shifting: ESA doesn’t appear to affect RPM
Verify all connections are correct. Inspect the connectors and make sure the wire colors and pin locations are the same
on both sides of the connector. Check for pins that may have pushed out of the connector shell.
Back probe the Blue wire (you may remove the wire from the connector if needed) and with the engine idling in neutral,
short the Blue wire (the end going to the ESA module) to engine ground. You should notice a slight drop in engine Rpm.
If the engine works correctly with this test, but does not work when the Blue wire is connected to the shift switch, check
the shift switch and wires to ensure it is providing the ESA with a ground when the switch is activated.
Note: If the engine is idling too fast, or too slow, the ESA will not engage. If the ESA does not work with the Blue wire
shorted to engine ground, recheck the engine RPM, ground wire connection and 12V power to the ESA.
Engine misses, erratic spark:
With the engine OFF, disconnect everything from the negative side of the coil except the distributor. If the condition
persists, the distributor or coil requires servicing. If the problem clears up, reconnect wires to the negative side of the coil
one at a time to isolate the problem. A defective tachometer gauge can affect ignition performance.
CDI Electronics • 353 James Record Road SW • Huntsville, AL 35824
Web Support: www.cdielectronics.com • Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, Inc., is prohibited.
Rev B • 1/08/13
Page - 1 of 2
QF-319
Installation and Troubleshooting Guide
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, Inc., is prohibited.
1.4 Ω
3.0 Ω
Set Meter
to Ohms - Ω
Set Meter
to Ohms - Ω
Ballast Resistor Required
3 Ohms – Step 2 reading =
(See Table for Selection)
T2
T1
See Diagram below
Step 2Measure circuit
resistance between
Gray and Violet wire
Step 1Disconnect all wires
from the coil and
measure it’s resistance.
Step 3Calculate how much
ballast resistance to
add.
Coil
Ohms
Ballast
Resistor
Required
Ballast
Resistor
Selection
CDI Part #
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.6
2.5
2.4
2.3
2.2
2.1
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
2.5
2.5
2.5
2.5
2.5
2
2
2
2
2
1.5
1.5
1.5
1.5
1.5
1.5
1.5
121-BR50-2.5
121-BR50-2.5
121-BR50-2.5
121-BR50-2.5
121-BR50-2.5
121-BR50-2
121-BR50-2
121-BR50-2
121-BR50-2
121-BR50-2
121-BR50-1.5
121-BR50-1.5
121-BR50-1.5
121-BR50-1.5
121-BR50-1.5
121-BR50-1.5
121-BR50-1.5
CDI Electronics • 353 James Record Road SW • Huntsville, AL 35824
Web Support: www.cdielectronics.com • Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, Inc., is prohibited.
Rev B • 1/08/13
Page - 2 of 2
QF-319
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