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BATTERY NOT CHARGING:
1.
Clean and service the battery cable connections (both on the engine and on the battery). Stainless hex nuts and lock washers are
recommended to connect the cables to the battery.
2.
Charge and load test the battery.
3.
Check the voltage on the Purple wire while the engine is running, you should see the same voltage as the battery.
4.
Verify that the Red wire is connected to 12 VDC from the battery.
5.
Remove the flywheel and inspect the heavy battery charge windings for discoloration. If the windings are a dark color, replace the
stator. Typical resistance readings of the Stator's battery charging circuit should measure less than 2 Ω.
TACHOMETER TESTS
1.
Measure the DVA across the Stator's Yellow battery charge wires, while connected to the Voltage Regulator. At idle the DVA will
normally be between 8-25 DVA. If not, disconnect the Yellow wires from the Voltage Regulator and retest. DVA will normally be 17-50
DVA at idle. If the voltage is now within specification, the Voltage Regulator is likely defective.
Check the resistance between the Gray wire from the Voltage Regulator and engine ground. You should read about 10K Ω. Gray to
2.
Red, and Gray to the Yellow wires should be a high reading, usually in the M Ω range.
3.
Disconnect the Voltage Regulator's Gray wire. At 800-1,000 RPM, check the DVA on the Gray wire FROM THE VOLTAGE
REGULATOR measured to engine ground. The reading should be 8 DVA or more. If not, replace the Voltage Regulator.
4.
If at least 8 DVA, run a jumper wire from the Gray wire out of the harness to one of the Stator's Yellow wires.
5.
If still no tachometer signal, try a known good tachometer.
6.
If still no tachometer signal, replace the Stator.
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 Purple 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 Purple 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 digital voltmeter 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.
BENCH TEST:
1.
Test the Voltage Regulator as follows:
Black Meter Lead
Yellow Stator Leads (each)
Red
Yellow Stator Leads (each)
Red
Gray
Red
Gray
Web Support:
All rights reserved. Reproduction or use of content, in any manner, without express written permission by CDI Electronics, LLC., is prohibited.
Rev E • 6/20/2023
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.
Red Meter Lead
Red
Yellow Stator Leads (each)
Case
Case
Case
Gray
Yellow
CDI Electronics, LLC • 353 James Record Road SW • Huntsville, AL 35824 USA
www.cdielectronics.com
Ohms
No Reading (Diode test)
Reading (Diode test)
MΩ
MΩ
10K Ω
MΩ
MΩ
• Tech Support: 1-866-423-4832 • Order Parts: 1-800-467-3371
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QF-358
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