Installation and Troubleshooting Guide
Contents
1. 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 a gt isi Electronics CDI P N 133 3853 Note This unit replaces P Ns 583853 584363 763774 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 INSTALLATION UTE 1 Disconnect the Negative battery cable 2 Remove the power pack 3 Disconnect the old Timer Base 4 Remove the flywheel stator and old Timer Base 5 Lubricate the inside area of the new Timer Base where the White slip ring goes and the area where the inside of the new Timer Base contacts the upper bearing carrier 6 Install the White slip ring on the new Timer Base 7 Compress the White slip ring and seat the new Timer Base into the bearing carrier 8 Make sure the Timer Base is fully seated and secure the slip ring using the retainers removed during disassembly 9 Remove the bushing link kit from the old Timer Base link arm and install it in the new Timer Base arm 10 Connect the linkage to the new Timer Base 11 Re install the Stator and Flywheel according to the Service Manual 12 Start and run the engine adjusting the ignition timing according to the Service Manual Remember to allow the engine2. 104 degrees on others of the temperature switch 2 Disconnect the White Black Temperature Switch wire FROM the Port Temperature Switch If the engine now stays in QuickStart the Temperature Switch is likely defective ENGINE STAYS IN QUICKSTART ON ALL CYLINDERS 1 With the engine idling check the Yellow Red wire for DC voltage If there is DC voltage on this wire while the engine is running the Quick Start will not disengage A voltage over 1 5 volts but less than 7 volts will not engage the starter solenoid yet will engage Quick Start 2 Short the White Black Temperature Switch wire FROM the power pack to engine ground Start the engine if the Quick Start drops out after approximately 5 seconds replace the White Black Temperature Switch 3 Disconnect the Black White wire between the power pack and the Timer Base If the Quick Start feature is not now working replace the power pack ENGINE DROPS OUT AND BACK IN QUICKSTART AT IDLE 1 With the engine idling check the Yellow Red wire for DC voltage Intermittent DC voltage on this wire while the engine is running will re engage Quick Start A voltage of less than 7 volts will not engage the starter solenoid yet will engage Quick Start 2 With the engine idling disconnect the Black White wire from the power pack and short the White Black Temperature Switch wire FROM the power pack to engine ground If the Quick Start drops out and stays out after approximately 5 seconds replace the Wh
3. 6V or more Connected White Purple 2 connector a 0 6V or more Connected White Blue 2 connector a 0 6V or more Connected White Green 2 connector a 0 6V or more Connected White Black White 2 connector 215 225 6 10 V Connected cranking 6 10 V Running With engine temp below 90 degrees a Use a comparison reading as different brands of meters will give different readings The typical range is 1M to 5M ohms As long as you have approximately the same ohm reading on all six tests and the correct output with the DVA meter the Timer Base should be good Remember that temperature will affect the readings The exception would be if one of the scr s inside the Timer Base is breaking down while the engine is running This can be found indexing the flywheel and checking the timing on all cylinders If the readings are off reverse the meter leads and retest to see if the readings are corrected b Wires must be paired correctly If the wires are crossed between pairs the resulting feedback will destroy the power pack 4 Check the cranking RPM A cranking speed of 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 DVA output on the orange wires from the power pack while connected to the ignition coils You should have a reading of at least 150V or more If the reading is low on one bank disconnect the
4. fault possibly the key switch harness or shift switch 2 Disconnect the yellow wires from the stator to the rectifier and retest If the engine fires replace the rectifier 3 Check the stator and trigger resistance and DVA output as given below for each bank Wire Color Check to Wire Color Resistance DVA Reading CONNECTED DVA DISCONNECTED Brown Brown Yellow 1 Pair b 850 1100 150V 170V Brown Black Brown White 2nd Pair b 850 1100 150V 170V Orange Orange Black 93 103 12 24V 45V White Purple a 0 6V White Blue a 0 6V White Green a 0 6V White Purple 2 connector a 0 6V 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 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 UAL Welt onic All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Wire Color Check to Wire Color Resistance DVA Reading CONNECTED DVA DISCONNECTED White Blue 2 connector a 0 6V White Green 2 connector a 0 6V White Black White 2 connector 215 225 5 V Connected cranking 8 14V Running Use a comparison reading as different brands o
5. orange wires from the ignition coil for that bank and reconnect them to a load resistor Retest If the reading is now good one or all of the ignition coils are likely bad A continued low reading indicates a bad power pack ENGINE WILL NOT ACCELERATE BEYOND 2500 RPM Runs smooth below that RPM 1 Use a temperature probe and verify that the engine is not overheating 2 Make sure the tan temperature switch wire is not located next to a spark plug wire 3 Disconnect the tan temperature wire from the pack and retest If the engine now performs properly the temperature switch VRO switch or engine harness is likely defective 4 Disconnect the VRO sensor from the engine harness and retest If the engine performs correctly replace the VRO or sensor ENGINE ENGAGES S L O W Limits at 2500 PM WHEN THE NO OIL LOW OIL OR FUEL VACUUM ALARM SOUNDS 1 Disconnect engine harness 2 Disconnect the Tan wires from the temperature sensors in both cylinder heads 3 Using an VOM Meter check the diode in the engine harness as follows Red Meter Lead Black Meter Lead Reading Tan pin in Engine Harness Connector Tan Lead From Port Cyl Head 0 500 approximately Tan pin in Engine Harness Connector Tan Lead From Sibd Cyl Head 0 500 approximately Tan Lead From Stbd Cyl Head Tan pin in Engine Harness Connector OL or over 1 0 Tan Lead From Port Cyl Head Tan pin in Engine Harness Connector OL or over 1 0 NOTE You can replace the diode in the harness wi
6. to warm up before adjusting the timing TROUBLESHOOTING Service Note Please use the Factory recommended spark plug currently Champion QL77JC4 gapped at 0 030 Note These engines usually have a 35 Amp battery charging capacity Due to the size and weight of the flywheel magnets it is highly recommended that you check to make sure both the triggering and charge magnets are still secure in the flywheel before you service the engine A loose or broken magnet can be deadly to you or your pocketbook It is a recommended you index the flywheel and check the timing on all cylinders when servicing these engines Also check for static firing and intermittent spark ENGINE WILL NOT START OR MISFIRES Verify the wiring in the connectors as follows Brn Blk Purple Yellow Purple Tan Red Black Yellow Black White Black WIRE SIDE MALE WIRE SIDE FEMALE WIRE SIDE MALE WIRE SIDE MALE NO SPARK ON ANY CYLINDER NOTE These engines use a gear reduction starter which results in a lower cranking RPM than usual If you have one or more cylinders intermittent at cranking Try starting the engine and checking to see if ALL of the cylinders now fire correctly If so the engine s ignition should be good Make sure the battery is sized correctly as the cranking capacity can affect the cranking speed 1 Disconnect both of the black yellow kill wires FROM THE PACK and retest If the engine s ignition now has fire the kill circuit has a
7. f meters will give different readings The typical range is 1M to 5M ohms As long as you have approximately the same ohm reading on all six tests and the correct output with the DVA meter the Timer Base should be good Remember that temperature will affect the readings The exception would be if one of the scr s inside the Timer Base is breaking down while the engine Is running This can be found indexing the flywheel and checking the timing on all cylinders If the readings are off reverse the meter leads and retest to see if the readings are corrected a Wires must be paired correctly If the wires are crossed between pairs the resulting feedback can damage the power pack 4 Check the center hub triggering magnet in the flywheel A loose or broken magnet can cause this problem 5 Check the cranking RPM A cranking speed of 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 NO SPARK ON ONE CYLINDER 1 Check the timer base s resistance and output see NO SPARK ON ANY CYLINDER above 2 Check the DVA output on the orange wires from the power pack while connected to the ignition coils You should have a reading of at least 130V or more If the reading is low on one cylinder disconnect the orange wire from the ignition coil for that cylinder and reconnect it to a load resistor Retest If the reading is now good the i
8. gnition coil is likely bad 3 Check the power pack resistance given below Wire Color CYL Check to Wire Color Resistance Orange Blue 1 Blue in male 4 pin connector with White wire 110 a Orange 3 Purple in male 4 pin connector with White wire 110 a Orange Green 5 Green in male 4 pin connector with White wire 110 a Orange Blue 2 Blue in female 4 pin connector with Black White wire 110 a Orange 4 Purple in female 4 pin connector with Black White wire 110 a Orange Green 6 Green in female 4 pin connector with Black White wire 110 a White Black Engine Ground Shorted Brown S ALL Black Engine Ground Open or M range a Use a comparison reading as different brands of meters will give different readings The typical range is 90 to 150 ohms You should have approximately the same ohm reading on all six tests If one of the SCR s inside the power pack is shorted or open the readings will be quite a bit different 4 Check the spark plug wires for breaks and abrasions ENGINE DIES WHEN QUICKSTART DROPS OUT Check ignition timing at idle with the White Black temperature wire disconnected Remember to allow for the 12 15 Degree drop in ignition timing when Quick Start disengages Verify ignition timing after engine has warmed up according to the service manual ENGINE WILL NOT STAY IN QUICKSTART OVER 10 SECONDS 1 Verify the engine temperature is below the trip point 89 degrees on some engines and
9. ite Black Temperature Switch If the problem is still present replace the power pack NO SPARK ON ONE BANK 1 Disconnect both of the black yellow kill wires FROM THE PACK and retest If the engine s ignition now has fire the kill circuit has a fault possibly the key switch harness or shift switch 2 Disconnect the yellow wires from the stator to the rectifier and retest If the engine fires replace the rectifier 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 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 H Tr Installation and Troubleshooting Guide ECHINICAT Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited TESS 3 Check the stator and trigger resistance and DVA output as given below for each bank Wire Color Check to Wire Color Resistance DVA Readin Brown Brown Yellow 1 Pair b 850 1100 150V Connected 170V Disconnected Brown Black Brown White 2nd Pair b 850 1100 150V Connected 170V Disconnected Orange Orange Black 93 103 12 24V Connected over 45V Disconnected White Purple a 0 6V or more Connected White Blue a 0 6V or more Connected White Green a 0
10. th a 1N4007 diode available at most electronics stores 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
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