CDI 152-9209 Installation And Troubleshooting Manual

This unit replaces P/N's: 404470-1, 474470, 510450-1, 617450, 650450, 6PR2005A, 87-F650450, F404470, F404470-1, F475470,
F510450, F510450-1, F617450, F650450, F684450, F684458, FA617450, FA650450, and FK650450.
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.
DO NOT USE A MAINTENANCE FREE, AGM, OR DRY CELL BATTERIES AS THE USE OF THESE TYPE BATTERIES WILL VOID
THE WARRANTY AND CAUSE DAMAGE TO THE RECTIFIER/REGULATOR, ENGINE, AND/OR THE STATOR!
NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING AS THIS MAY DAMAGE THE REGULATOR/RECTIFIER.
If the boat is equipped with a battery switch, make sure that it is a make before break type.
1. Disconnect the Negative battery cable.
2. Disconnect the old Rectifier. Pay attention to the wiring colors.
3. Remove the old Rectifier, saving the original mounting screw.
4. Mount the new Rectifier, using the original screw. It is recommended you use a small amount of heat-sink compound on the backside of
the new Rectifier to aid in heat transfer to the metal mounting boss.
5. Connect the Black engine ground wire to the Engine Gnd terminal.
6. Connect the Red jumper wire from the starter solenoid to the + Bat terminal.
7. Connect the wires from the Stator to the AC 1 and AC 2 terminals.
8. Reconnect the Negative battery terminal.
BATTERY CHARGING ISSUES:
1. Regardless of whether the charging issue is overcharging or not charging at all, the #1 cause of all charging issues is the battery often
due to improper style and/or charging neglect. #2 is the battery's connections. #3 is the Rectifier. #4 is the Stator.
2. The recommended type of battery for outboards is a single (NOT more than one) 850+ CCA dual purpose or cranking/starting non-
maintenance-free battery.
Non-maintenance-free batteries (lead-acid flooded cell; has vent caps on its top) have heavy, thick plates. They're ideal for outboards,
3.
where batteries are commonly drained by accessories while fishing, etc. when there is no charge applied to a battery while the battery
is in use. Its heavy plates can withstand constant discharging and charging. These batteries have much more reserve time and are
much more suited for this behavior.
NOTE: Some Maintenance free batteries will have vented caps on top. When in doubt, change the battery to a non-
maintenance free type.
4. Maintenance-free batteries should NEVER be used in an Outboard application. A new, fully charged maintenance-free battery may
work fine at first but their life span is dramatically shortened due to the constant charging and discharging. This activity will cause the
cells to become weak, and/or the cells will become dead. When this happens, the battery is unable to accept a full charge, thus putting
the Rectifier at extreme risk of failure. Therefore, maintenance-free style batteries commonly cause charging issues shortly after
installation.
5. Check all battery connections, particularly at engine ground. Make sure that all connections are tight and free of corrosion. Do NOT use
wing nuts as they tend to loosen over a period of time from vibration. A loose connection WILL cause a premature battery and/or
Rectifier failure(s).
6. If there is no change, try a single (NOT more than one) known good fully charged battery that is 850+ CCA Dual Purpose, or a
cranking/starting battery that is non-maintenance free. Make sure the battery is a lead acid flooded cell battery (has vent caps on its
top).
Web Support:
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, LLC., is prohibited.
Rev D • 5/18/2023
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 P/N: 152-9209
TROUBLESHOOTING
CDI Electronics, LLC • 353 James Record Road SW • Huntsville, AL 35824 USA
www.cdielectronics.com
INSTALLATION
• Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
Page - 1 of 2 QF-358