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TROUBLESHOOTING FOR SWITCHBOX IGNITION SYSTEMS
How to test the Engine Stop Circuit (Kill) for DC Voltage:
1.
DC voltage present on the kill circuit of the Switchbox due to a faulty key switch, boat harness, or engine harness will severely damage
the Switchbox's internal kill circuit. Connect a Digital Multi Meter to the Ignition Stop wire(s) AT THE SWITCHBOX while disconnected
from the Switchbox in reference to a known good engine ground. Turn the Ignition switch on and off several times. If, at any time, you
see over 2 VDC on the kill wire(s), there is a problem with one or both harnesses and/or the Ignition switch. The Ignition Stop wire
should not be connected back to the new Switchbox at any point until the problem is corrected OR DAMAGE TO THE SWITCHBOX
WILL OCCUR!
NO SPARK ON ANY CYLINDER:
1.
Perform a visual inspection of the Stator and Trigger wiring to the Switchbox. Check to make sure that the wiring is correct, clean, and
free of corrosion, and that all connections are tight.
Disconnect the Black/Yellow kill wire AT THE SWITCHBOX and retest. If the engine's Ignition now has spark, the stop circuit has a
2.
fault. Check the key switch, harness, and shift switch (if present).
3.
Disconnect the Yellow wires from the Stator to the Voltage Regulator and retest. If the engine now has spark, replace the Voltage
Regulator.
4.
Check the cranking RPM. A cranking speed less than 250 RPM will not allow the system to fire properly. This can be caused by a weak
battery, dragging starter, bad battery cables, or a mechanical problem inside the engine.
5.
Check the Stator and Trigger resistance and DVA for your engine in the lists below:
Check the 2 cylinder engine as follows:
Read from
White/Green (Stator)
Blue (Adapter Module)
Purple (#1 Trigger)
Purple (#1 Trigger)
White (#2 Trigger)
Check the 3 cylinder engine as follows:
Read from
White/Green (Stator)
Blue (Adapter Module)
Brown (Trigger)
White (Trigger)
Purple (Trigger)
Brown (Trigger)
White (Trigger)
Purple (Trigger)
NOTE: The 3 cylinder engines have several configurations to the firing order. Please refer to the Factory Service Manual to
make that determination. The pairing should always be as follows:
•
Green Coil Wire goes with the Brown Trigger Wire
•
Green/Red Coil Wire goes with the Purple Trigger Wire
•
Green/White Coil Wire goes with the White Trigger Wire
Check the 4 cylinder engine as follows:
Read from
White/Green (Stator)
Blue (Adapter Module)
Purple
(#1 Trigger)
Brown
(#3 Trigger)
Purple
(#1 Trigger)
White
(#2 Trigger)
Brown
(#3 Trigger)
White/Black (#4 Trigger)
Web Support:
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Rev F • 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.
Read to
Green/White (Stator)
Blue/White (Adapter Module)
White (#2 Trigger)
Engine Gnd
Engine Gnd
Read to
Green/White (Stator)
Engine Gnd
White/Black (or Black) (Trigger)
White/Black (or Black) (Trigger)
White/Black (or Black) (Trigger)
Engine Gnd
Engine Gnd
Engine Gnd
Read to
Green/White (Stator)
Blue/White (Adapter Module)
White (#2 Trigger)
White/Black or Black (#4 Trigger)
Engine Gnd
Engine Gnd
Engine Gnd
Engine Gnd
CDI Electronics, LLC • 353 James Record Road SW • Huntsville, AL 35824 USA
www.cdielectronics.com
Ohms
400-550 Ω
Open
0.8-1.4K Ω
Open
Open
Ohms
DVA (Connected)
400-550 Ω
Open
0.8-1.4K Ω
0.8-1.4K Ω
0.8-1.4K Ω
Open
Open
Open
Ohms
400-550 Ω
Open
0.8-1.4K Ω
0.8-1.4K Ω
Open
Open
Open
Open
• Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
Page - 4 of 6
DVA (Connected)
DVA (Disconnected)
180-400 V
200-400 V
180 V Minimum
180-400 V
4 V Minimum
4 V Minimum
1 V Minimum
1 V Minimum
DVA (Disconnected)
180-400 V
180 V Minimum
4 V Minimum
4 V Minimum
4 V Minimum
1 V Minimum
1 V Minimum
1 V Minimum
DVA (Connected)
DVA (Disconnected)
180-400 V
180 V Minimum
4 V Minimum
4 V Minimum
1 V Minimum
1 V Minimum
1 V Minimum
1 V Minimum
-
-
200-400 V
180-400 V
4 V Minimum
4 V Minimum
4 V Minimum
-
-
-
200-400 V
180-400 V
4 V Minimum
4 V Minimum
-
-
-
-
QF-358
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