Installation and Troubleshooting Guide
Contents
1. 3371 All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Rev B e 1 08 13 Page 1 of 3 QF 319 H T Installation and Troubleshooting Guide Electronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited lt i TUTE 29 Connect the link rod to the vertical throttle lever Install the cowl mounting brackets 30 Connect the electrical connections and battery cables to the engine 31 Set the idle timing and wide open timing according to the service manual 1 Rotor Shaft CDI Replacement 994 4371 2 6 Cylinder Trigger Disk CDI Replacement 134 4313 S 3 4 Cylinder Trigger Disk CDI Replacement 134 3236 S 4 Original Spacer CDI Replacement 994 3538 5 Over size Spacer CDI Replacement 994 3538 10 6 Retainer Ring CDI Replacement 994 6406 7 Bearing Shim 8 Lower Bearing CDI Replacement 994 6379 9 Spark Advance Stop Plate 10 Spark Arresting Vent 11 Tension Spring 12 Distributor Housing CDI Replacement 134 3736 13 Plastic Shim 14 Washer Economizer Collar 15 Spacer Tube 16 34 Hex Nut 17 Upper Bearing CDI Replacement 994 0066 18 Economizer Collar 19 Adapter Housing 20 Wave Spring 21 Tab Lock Washer 22 Metal Shim Washer 23 Cap Nut2. Included with the new distributor housing x New distributor housing comes with these parts installed Distributor Service Kits 994 1111K1 Installation Kit 1 6 Cylinder Trigger Disk 134 4313 S 1 4 Cylinder Trigger Disk 134 3236 S 1 Retainer Ring 994 6406 1 Original Spacer 994 3538 1 Over size Spacer 994 3538 10 1 Lower Bearing 994 6379 1 Upper Bearing 994 0066 Rotor Shaft i PRA EEES Cap Nut Bearing Kit oe 1 Retainer Ring 994 6406 1 Lower Bearing 994 6379 1 Upper Bearing 994 0066 CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com Tech Support 1 866 423 4832 Order Parts 1 800 467 3371 All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Rev B e 1 08 13 Page 2of3 QF 319 n n n CDIEHECTOMES ve H T Installation and Troubleshooting Guide ECNO Heatroniacs All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited gt TE TROUBLESHOOTING NOTICE The trigger cannot be bench tested except with the CDI Electronics Trigger Tester P N 511 9710 the tester can also be used to test the trigger while on the engine Be sure to follow the instructions at the bottom when lining up the rotor and disk Dead or no spark until you
3. colElectronies I G4 I a gt isi Electronics CDI P N 134 3736 This unit replaces P N s 332 4177A 3 393 3736A 3 393 3736A23 393 3736A 77 and 393 3736A 79 NOTICE THIS TRIGGER REQUIRES THE STEEL DISK INCLUDED WITH IT T WILL NOT WORK WITH THE FACTORY DISK Warning This product is designed for installation by a professional marine mechanic CDI cannot be held liable for injury or damage resulting from improper installation abuse neglect or misuse of this product Refer to the Service Manual to set ignition timing DO NOT USE A MAINTAINENCE FREE OR LOW MAINTAINENCE BATTERY WITH THIS SYSTEM BATTERY VOLTAGE IN EXCESS OF 16 VOLTS MAY DAMAGE IGNITION PARTS NOT COVERED UNDER WARRANTY INSTALLATION Remove the electrical harness and the battery leads from the engine Disconnect the brown white and black trigger wires from the distributor body to the switch box Remove the distributor housing assembly from the engine according to the service manual Remove the distributor cap retainer clamp and screw and then lift the distributor cap from the distributor body Take care not to damage the carbon brush inside the distributor cap If the rotor is damaged and requires replacement the rotor and shaft must be replaced together THE ROTOR IS MADE ONTO THE SHAFT AND CANNOT BE REPLACED EXCEPT AS AN ASSEMBLY Remove the distributor vent tube or spark arresting vent Bend the tabs of the cap nut washer open Unscrew the cap n
4. arter mounting to the support plate Misses on one or more cylinders Connect spark gap checker to all cylinders align the rotor to each cylinder in turn and trigger the pack using the 511 9701 Battery CD Tester If a cylinder fails to fire or if another cylinder fires besides the one that the rotor is pointed to replace the distributor cap Watch for spark plug wires arcing to the engine block Disk assembly pos Note On 6 cylinder engines the tip of the rotor must split the right hand side of the opening in the disk Service Note On a double notched shaft the wide notch is for a 4 cylinder disk and the narrow notch is for the 6 cylinder engines CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com Tech Support 1 866 423 4832 Order Parts 1 800 467 3371 All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Rev B e 1 08 13 Page 3 of 3 QF 319
5. haft Make sure the side marked ROTOR SIDE is facing the rotor Service Note On a double notched shaft the wide notch is for a 4 cylinder disk and the narrow notch is for the 6 cylinder engines 16 Using a plastic mallet VERY CAREFULLY tap the rotor shaft into the housing Continue work the rotor shaft into the housing until the collar on the shaft seats into the recess in the distributor the disk should not be loose 17 Slide the tube spacer onto the shaft and secure with the 3 nut BE VERY CAREFULL WHEN TIGHTENING THE NUT OR THE ROTOR MAY BE DAMAGED 18 Remove the distributor from the vise and gently tap the rotor shaft on the pulley end in order to seat the lower bearing against the snap ring Turn the housing over and check the clearance between the disk and the new distributor housing If the disk is touching the new distributor base you will need to dissemble the distributor housing and replace the old disk spacer with a new one 994 3538 10 spacer is 0 010 inches taller than the original 19 Replace the new distributor housing cap using the two screws removed earlier 20 Slide the upper bearing onto the rotor shaft and work it down until it contacts the 3 4 nut 21 Slide the large washer onto the new distributor housing and as you slide the adapter housing onto the new distributor housing connect the tension spring to the adapter housing pin 22 Install the small ring washer wave spring and cap washer Thread the cap
6. let off of the key switch 1 Clean ALL engine ground wires from the battery thru the engine cowling splash pan top cowl and support brackets 2 Verify that there is at least 9 1 2 volts on the White wire going to the switch box from the engine harness while cranking the engine 3 Verify that there is at least 9 volts on the Brown wire going to the trigger while cranking the engine If the voltage is low and the voltage on the White wire from the harness is above 9 1 2 volts disconnect the wires from the switchbox then check the resistance from the White terminal beside the Red terminal from the White Red wire on the CDI Electronics switchbox to the Brown terminal going to the trigger You should read 60 76 ohms A high reading indicates a possible bad switchbox 4 Check resistance between the White wire and engine ground It should read less than 1 ohm If it reads higher make sure the Black ground wire is connected to engine ground 5 Connect a secondary ground wire 12 gauge from the negative battery cable to the base or case of the switch box 6 Using the 511 9710 Trigger Tester check the output of the trigger according to the directions for the tester Only has spark as long as the starter is engaged Usually indicates a bad trigger Test per above Fires all cylinders but engine will not run 1 Recheck sensor wheel to make sure it is right side up See diagrams below for correct placement 2 Check the ground wire from the st
7. nut on and bend the tabs of the adapter cap washer to lock the adapter cap in place 23 Install the distributor vent tube or spark arresting vent 24 Place the distributor cap assembly onto the distributor housing BE CAREFULL not to bend the carbon brush sparing or damage the carbon brush Position and install the distributor clamp and retainer with the bolt and nut 25 Position the distributor and distributor adaptor assembly onto the powerhead mounting flange Check to be sure the driven pulley spacer and key are in place 26 Install the three screws securing the distributor to the powerhead block 27 Align the arrow on the pulley with the timing mark on the flywheel and install the timing belt timing belt cover and screw tighten to 60 inch pounds 28 Install the ground strap and connect the Black ground wire to the engine block Connect the Black Brown and White wires to the switch box matching wire colors to the terminals If the switchbox has stud terminals push in the ring adapter terminals into the female bullet connectors to convert the wire connections to a ring type Installation and Troubleshooting Guide All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited ae a o on CDI Electronics 353 James Record Road SW e Huntsville AL 35824 Web Support www cdielectronics com Tech Support 1 866 423 4832 e Order Parts 1 800 467
8. ut from the distributor housing Remove the tabbed washer and wave spring Work the tension spring off of the pin as you slide the distributor housing from the mounting adapter Do not lose the large washer or the smaller washer inside the adapter housing 7 CAREFULLY remove the upper bearing from the housing by working through the two holes in the sides of the housing Remove the 3 nut from the shaft while holding the rotor Use extreme care not to break the rotor tip or twist the rotor on the shaft If this happens the rotor and shaft assembly will have to be replaced 8 Using a plastic mallet GENTLY tap the rotor shaft free 9 Discard the old trigger disk saving the old disk spacer between the disk and bearing YOU MUST USE THE NEW STEEL DISK 10 Inspect the distributor cap and carbon brush for damage and wear Replace if needed 11 Using a punch knock out the tension spring pin Remove the tension spring and throttle stop plate 12 Install the tension spring pin using a good thread locker in the distributor housing tension spring and throttle stop plate Remember the spring must be free to rotate on the pin 13 Support the new distributor housing between two blocks of wood in a vise 14 Remove the two mounting screws from the new distributor housing cap and set the cap aside 15 Install the old disk spacer new trigger disk and rotor shaft into the distributor housing Align the tang in the disk with the notch in the rotor s
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