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MAXIMUM OUTPUT TEST:
1.
Install an ammeter capable of reading at least 10 Amps between the Red wire and the starter solenoid battery post.
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 4500 RPM in gear.
4.
Turn on the load bank switches to increase the battery load to equal 10 Amps.
5.
Check the ammeter.
6.
If the amperage is low,
a)
Check the Red 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 Red wire and recheck the ammeter. If the amperage is now correct,
there is a problem in the harness or key switch.
7.
If the amperage is correct, but the battery voltage remains low, replace the battery.
OVERCHARGING:
1.
Clean all battery terminals, cables, and mounting bosses.
2.
Check the voltage on the battery with a multi-meter and compare it to the dash meter.
3.
Compare the voltage at the Voltage Regulator with the voltage at the battery. If the voltage is ok at the Voltage Regulator and not good
at the battery, you have a bad connection somewhere. Clean the battery posts and terminals.
4.
Replace the battery with a known good Maintenance type flooded wet lead acid marine battery. If the battery voltage remains ok, install
a new Maintenance type flooded wet lead acid battery.
NO SPARK ON ANY CYLINDER:
1.
Disconnect the Black/Yellow stop wire from the Power Packs and retest. If the engine's ignition has spark, the stop circuit has a fault.
Check the key switch, harness, and shift switch (if present).
2.
Check the cranking RPM. A cranking speed of less than 250 RPM may 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.
3.
Disconnect the Yellow wires from the Regulator/Rectifier and retest. If the engine now sparks, replace the Regulator/Rectifier.
4.
Check Stator and Timer Base resistance and DVA as shown:
Read from
Brown (Stator)
White (Common)
White (Common)
White (Common)
White (Common)
White (Common)
White (Common)
5.
Rare causes include a weak or broken flywheel Charge coil or Timer Base magnets. If possible, try another flywheel.
NO SPARK ON ONE BANK:
1.
Disconnect the Black/Yellow stop wire from the Power Packs and retest. If the engine's ignition has spark, the stop circuit has a fault.
Check the key switch, harness, and shift switch (if present).
2.
Check the Stator and Timer Base DVA (see NO SPARK ON ANY CYLINDER).
3.
Swap the Stator wire pairs from one side of the engine to the other side and see if the problem moves. If it does, either the Stator is
faulty or there is a poor connection between the Stator and the Power Pack.
4.
Check the DVA on the Orange Primary wires from the Power Pack to the Ignition coils while connected to the Ignition coils. You should
have a reading of at least 150 V or more. If the reading is low on one cylinder, disconnect the Orange Primary wire from the Ignition coil
for that cylinder and reconnect it to a Pack Load resistor. Retest. If the reading is now good, the Ignition coil is likely bad. A continued
low reading usually indicates a bad Power Pack.
5.
Visually inspect the Ignition coils for burned or discolored areas or cracks in the casing (indicating arcing inside the Ignition coil).
ENGINE WILL NOT STOP (KILL):
1.
Disconnect the Black/Yellow wire at the Power Pack. Connect a jumper wire to the stop wire from the Power Pack and short it to engine
ground. If this stops the Power Pack from sparking, the stop circuit has a fault. Check the key switch, harness, and shift switch (if
present). If this does not stop the Power Pack from sparking, replace the Power Pack.
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Rev D • 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.
6 CYLINDER TROUBLESHOOTING
Read to
Brown/Yellow (Stator)
Blue (#1 Timer Base)
Green (#3 Timer Base)
Purple (#5 Timer Base)
Blue (#2 Timer Base)
Green (#4 Timer Base)
Purple (#6 Timer Base)
CDI Electronics • 353 James Record Road SW • Huntsville, AL 35824
www.cdielectronics.com
OEM Ohms
CDI Ohms
485-635 Ω
450-600 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
15-50 Ω
• Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
Page - 3 of 5
DVA (Connected)
DVA (Disconnected)
150-400 V
150-400 V
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
0.6 V Minimum
QF-358
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