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NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER:
1.
Disconnect the Black/Yellow stop wire AT THE SWITCHBOX and retest. If the engine now has spark, the stop circuit has a fault. Check
the key switch and harness (if equipped).
2.
Check the Stator and Trigger DVA and Resistance (See NO SPARK ON EITHER CYLINDER).
3.
Check the DVA on the Green Primary wires from the Switchbox while connected to the Ignition coils. Check the reading on the
Switchbox terminal AND on the Ignition coil terminal. You should have a reading of at least 150 V minimum at both places. If the
reading is low on one cylinder, disconnect the Green Primary wire from the Ignition coil for that cylinder and connect it to a Pack Load
resistor. Retest. If the reading is now good, the Ignition coil is likely bad. A continued low reading indicates a bad Switchbox or low
Trigger DVA for that cylinder. Test Trigger DVA and Resistance (See NO SPARK ON EITHER CYLINDER).
Check the Ignition coil's primary resistance from the Positive (+) terminal to the Negative (-) terminal. You should read 0.02-0.04 Ω. If
4.
out of specification, replace the Ignition coil.
Check the Ignition coil's secondary resistance from the sparkplug wire to engine ground. You should read 0.8-1.1 KΩ. If out of this
5.
range, replace the Ignition coil.
6.
Connect an inductive tachometer to each cylinder and compare the RPM readings at the RPM where the problem is occurring. If only
one cylinder is dropping out, swap the Ignition coil locations and retest. If the problem follows a coil, replace the coil. If it stays on the
same spark plug, either the Switchbox or Trigger is faulty. Test Trigger DVA and Resistance (see NO SPARK ON EITHER
CYLINDER).
ENGINE WILL NOT STOP (KILL):
1.
Check the kill circuit in the Switchbox by using a jumper wire connected to the Black/Yellow wire coming out of the Switchbox and
shorting it to ground while the engine is running. If this kills the engine, the kill circuit in the harness or on the boat is defective. If not,
the Switchbox is defective.
HIGH SPEED MISS:
1.
Check the DVA of the Stator from the Red wire to the Black wire while running the engine. It should show a smooth rise in voltage as
the RPM rises. If there is a sudden or fast drop in voltage right before the miss becomes apparent, the Stator is usually at fault.
2.
Verify the correct spark plugs are installed. OEM calls for a BP8H-N-10 or BPZ8H-N-10. If the BP8H-N-10 spark plugs are installed, try
the BPZ8H-N-10 spark plugs.
3.
If there is no indication of the problem, it could be a small water leak in one or both cylinders. Perform a high speed shutdown and read
the sparkplugs.
BOTH CYLINDERS HAVE SPARK BUT THE ENGINE WILL NOT RUN:
1.
Check the flywheel shear key.
2.
Index the flywheel and check timing on both cylinders. If the timing is off, check the Trigger and flywheel.
If one of the Trigger wires is shorted, the timing may not advance on ONE cylinder, but the other cylinder will advance.
3.
Check the idle screw adjustment set point. If set too low, the engine will not run.
4.
Check the idle air/fuel mixture set point. If out of adjustment, the engine will not run.
5.
Check the fuel pump diaphragm for a pin hole. It could be leaking fuel into the intake and have too rich of an air/fuel mix.
ENGINE LOW ON POWER OR TIMING WILL NOT ADVANCE WITH ENGINE RPM:
1.
Verify the ignition timing is advancing from 3-5° BTDC at idle to approximately 28° BTDC at 3000 RPM.
The timing will retard slightly from 28° BTDC at 3000 RPM to 25° BTDC at 5500 RPM, dropping down to 15° Degrees BTDC
between 5800-6200 RPM.
2.
Index the flywheel and check timing on both cylinders. If the timing is off, check the Trigger and flywheel.
If one of the Trigger wires is shorted, the timing may not advance on ONE cylinder, but the other cylinder will advance.
SWITCHBOX OR TRIGGER REPEATEDLY BLOWS ON SAME CYLINDER:
1.
Check the Trigger wires for shorts to engine ground as a shorted Trigger wire can destroy a SCR inside the Switchbox.
2.
In contrast, a shorted SCR inside the Switchbox can destroy a Trigger. Check the Trigger resistance and DVA (see NO SPARK OR
INTERMITTENT SPARK ON ONE CYLINDER).
3.
Replace the Ignition coil on the cylinder dropping spark.
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Rev C • 6/19/2023
Installation and Troubleshooting Guide
This installation is to be completed by an Authorized Dealer or Professional Service
Technician. For questions regarding installation or warranty, call CDI Tech Support
at 866-423-4832. Do not return to the Dealer or Distributor where the part was purchased.
Contact CDI Electronics Directly for Return Material Authorization.
CDI Electronics, LLC • 353 James Record Road SW • Huntsville, AL 35824 USA
www.cdielectronics.com
• Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
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