Installation and Troubleshooting Guide
Contents
1. IN a gt isi Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited STITUTE The thin area between the crank position and the cylinder position is the most common breakout location 12 Check the sensor eyes for dirt grease etc If you have to clean it use denatured alcohol and a Q tip Do not use any other cleaning agent because damage to the optical lens will occur 13 Check the stator resistance and DVA voltage as given below WIRE READ TO RESISTANCE DVA Connected _ DVA Disconnected Brown Brown White Brown Yellow 900 1200 150 400 V 150 400 V Orange Orange Black 50 60 11 22 V 45 120 V This reading can be used to determine if a stator or pack has a problem For instance if you have no spark on any cylinder and the stator s DVA reading is out of spec disconnect the stator wires and recheck the DVA output If the reading is still out of spec the stator is bad If the reading is now within spec the pack is bad NOTE Low readings on all checks indicate a possible problem with the flywheel magnets that require checking SERVICE NOTE It is recommended that liquid neoprene be applied to the areas where piercing probes were used 14 Check the DVA output from the power pack to the primary coil wires as follows WIRE READ TO DVA Connected Orange Blue Engine Ground 150 V Orange Green2. HI T Installation and Troubleshooting Guide Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited TUTE Be CDI P N 113 6292 This unit replaces the following P N s 586015 586098 and 586292 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 SERVICE NOTE This unit requires the Factory Recommended Champion QL78YC 0 30 Gap Spark Plugs and the Gray spark plug wires DO NOT OPERATE ENGINE WITH PLASTIC ENCODER COVER OFF OF THE ENGINE INSTALLATION Disconnect the battery cables Remove timing wheel cover power pack cover and regulator rectifier cover Between the timing cover and the power pack Disconnect the stator wire connector from the power pack Disconnect the harness wire connector from the power pack Disconnect the timing wire connector from the sensor Disconnect the spark plug wires from the spark plugs Unbolt and remove the ignition coils and old power pack Look for burned areas between the coil mounting holes on the stainless steel RF shield If a discoloration is found replace that coil 8 Check for DC voltage on the kill stop wires usually Black Yellow with the key switch in the on and off position At no time should you see over 2 vo
3. 4 QF 319
4. DVA output See Step 13 on NO FIRE ON ANY CYLINDER above If the power pack has no fire on one bank and the readings are good replace the power pack 2 Disconnect the 4 pin connector on the port side of the power pack and see if the fire returns If it does check resistance to see if the Black Yellow wire is shorted to engine ground or is intermittently shorting to ground 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 C e 3 13 13 Page 2 of 4 QF 319 a gt isi Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited Installation and Troubleshooting Guide miez UTE INSTIT Port 4 Pin Connector Starboard 4 Pin Connector a Black Yellow Brown b Tan Orange Black C White Black Orange d Yellow Red Brown Yellow POWER PACK REPEATEDLY BLOWS ON SAME CYLINDER Replace the ignition coil on the cylinder dropping spark ENGINE WILL NOT SHUT OFF Disconnect the stop wire at the power pack Connect a jumper wire to the stop wire from the pack and short it to engine ground If this stops the pack from sparking the stop circuit has a fault Check the key switch
5. QF 319 H Tr Installation and Troubleshooting Guide Hectronics All rights reserved Reproduction or use of content in any manner without express written permission by CDI Electronics Inc is prohibited 2 Check the routing of the tan temperature wires an example of a bad location is shown below The tan wires have to be located as far away as possible from the spark plug wires _ Z p Wa Unacceptable routing for the temp wire V6 engine shown 3 Verify the engine is not overheating and disconnect the Tan temperature sensor wire If the engine performs normally check both temperature sensors and replace the defective one 4 If there is not any indication of a problem at this point replace the power pack ENGINE STAYS IN QUICK START 1 Check the Yellow Red wire for DC volts while the engine is running You should only see voltage on this wire while the starter solenoid is engaged A DC voltage of 5 7 volts will not engage the starter solenoid but will engage Quick Start Check the starter solenoid harness and ignition switch 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 from the power pack If the Quick Start feature is not now working replace the power pack ENGINE DIES WHEN QUICK START DROPS OUT Check igniti
6. harness and shift switch If this does not stop the pack from sparking replace the power pack ONLY FIRES 1 CYLINDER 1 Verify the engine is spinning in a clockwise direction 2 Check the optical sensor to encoder wheel mesh You may need to shim the optical sensor upwards 0 020 to 0 0285 to make it engage the encoder wheel HIGH SPEED MIS FIRE OR WEAK HOLE SHOT 1 Connect DVA meter to between the brown wires and do a running test AT NO TIME SHOULD THE VOLTAGE EXCEED 400v If it does the regulator circuit in the power pack is bad The voltage should show a smooth climb and stabilize gradually falling off at high RPM above 5000 If you see a sudden drop in voltage right before the miss becomes apparent the problem is likely in the stator 2 Disconnect the Yellow wires from the stator to the rectifier and retest If the miss clears replace the rectifier 3 Inthe water or on a Dynameters 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 DVA or more increasing with engine RPM until it reaches 300 400V DVA maximum A sharp drop in DVA right before the miss becomes apparent on all cylinders will normally be caused by a bad stator A sharp drop in DVA on less than all cylinders will normally be the power pack 4 Ifthe engine runs fine until you get above 4900 RPM and then starts missing check the Orange to Orange Black power coil wires wit
7. Black wires from the power pack and see if soark returns If it does spark check resistance to see if the Black Yellow wire is shorted to engine ground 9 If it loses spark after the key switch is disengaged check the DVA voltage on the stator s power coil Orange to Orange Black as given below in Step 13 Either the power coil or power pack is the fault 10 Check the battery voltage on the Yellow Red wire while cranking the engine If below 11 VDC charge the battery and check all battery cables A continued low battery reading could be from a dragging starter If still below 11 VDC disconnect the power pack s Yellow Red wire from the starter solenoid and apply a verified 12 VDC to the Yellow Red wire If the engine now runs good check the DVA voltage on the stator s power coil Orange to Orange Black as given below in Step 13 Either the power coil or power pack is the fault 11 Remove the sensor wheel and check for damage especially where the top slots are located Sometimes the wheels will break out where the windows overlap oo N Pe i i 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 C e 3 13 13 Page 1 of 4 QF 319 Installation and Troubleshooting Guide
8. Engine Ground 150 V NOTE If the DVA values are below these specifications the power pack or sensor is likely bad 15 Check the sensor DC voltage as follows WIRE READ TO DC voltage Connected Orange Red Engine Ground 10 5 12 VDC Black Orange Engine Ground 8 10 VDC WARNING The Black Orange wire should NEVER be shorted to engine ground as this will damage the sensor 16 Check the center hub triggering magnet in the flywheel A loose magnet can cause this problem 17 Check the triggering and charge coil flywheel magnets for cracked broken and loose magnets ONLY HAS FIRE AS LONG AS THE KEY SWITCH IS ENGAGED OR WILL NOT REV ABOVE IDLE SPEED Check the DVA voltage on the stator s power coil Orange to Orange Black as given above in Step 13 NOTE The readings should rapidly increase as the engine RPM increases and stabilize below 22 volts DVA voltage exceeding 22 V DVA indicates a bad power pack A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator winding A sharp drop in voltage when you disengage the key switch indicates a bad power coil on the stator ENGINE TRIES TO RUN BACKWARDS 1 Check the encoder wheel It must have 5 notches 2 Check the timing Before Quick Start it should be set to 4 BTDC After Quick Start it should be set to 6 ATDC 3 Try another sensor 4 Replace the power pack NO FIRE OR INTERMITTENT FIRE ON ONE BANK 1 Check the stator resistance and
9. h an oscilloscope if available or replace the pack A breakdown inside the pack could cause RFI noise to activate the rev limiter for no apparent reason 5 Connect an inductive tachometer to the spark plug wires one at a time and compare the readings If most of the cylinders show the same reading and one or two show different readings check the primary wires with the inductive pickup to see if the readings are the same from the power pack A difference in readings between the primary and secondary coil wires usually indicates a bad coil or bad ignition wires No difference indicates a bad power pack 6 Perform a high speed shutdown and read the spark plugs Check for water A crack in the block can cause a miss at high speed when the water pressure gets high but a normal shutdown will mask the problem 7 Check the triggering and charge coil flywheel magnets for cracked broken and loose magnets 8 Rotate the stator one bolt hole in either direction and retest ENGINE WILL NOT REV ABOVE 2500 RPM AND SHAKES HARD SLOW ACTIVATED 1 Verify the engine is not actually over heating by using a digital pyrometer 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 C e 3 13 13 Page 3 of 4
10. lts DC on this wire as severe damage to the power pack can occur Disconnect the ignition coils from the old power pack and reconnect them to the new power pack 10 Install the new power pack and ignition coils Take care not to over torque the mounting bolts OEM specification calls for 50 95 in Ibs of torque Make sure the RF Noise Shield is between the ignition coils and the power pack 11 Connect the stator and harness connectors to the power pack Use a small amount of dielectric silicone grease on the connector seal Do not put any inside the sockets 12 Connect the harness wire connector to the power pack 13 Connect the timing wire connector to the sensor 14 Replace the timing wheel cover power pack cover and regulator rectifier covers 15 Connect the spark plug wires to the spark plugs 16 Using a motor flushing device or in the water start and run the engine until it reaches operating temperature 17 Verify that the engine s QuickStart function is working by watching for the drop in engine RPM as the engine temperature goes above 105 Deg F and drops the timing back to running mode 18 Stop the engine and restart it You should have approximately a 5 10 second period of QuickStart timing advance before the engine settles down to a normal idle 19 Disconnect the Port temperature switch s Tan and White Black wires 20 Connect a jumper wire to the Tan wire and short it to engine ground 21 Using a motor flushing de
11. on timing at idle with the White Black temperature wire disconnected Remember to allow for the drop in ignition timing when Quick Start disengages Verify ignition timing after engine has warmed up according to the service manual QUICKSTART DOES NOT WORK 1 Check the stator resistance and DVA voltage as given below WIRE READ TO RESISTANCE DVA Connected DVA Disconnected Brown Brown White Brown Yellow 900 1200 150 400 V 150 400 V Orange Orange Black 50 60 11 22 V 45 120 V 2 Check DVA voltage from the Orange to the Orange Black wires while connected to the power pack The reading should be between 8 and 24V A reading above 24V indicates a problem in the power pack while a reading below 8 volts usually indicates a problem in the stator WILL NOT RUN WHEN HOT 1 Check the stator resistance and DVA voltage as given below WIRE READ TO RESISTANCE DVA Connected _ DVA Disconnected Brown Brown White Brown Yellow 900 1200 150 400 V 150 400 V Orange Orange Black 50 60 11 22 V 45 120 V 2 Test the Trigger sensor while hot using the 511 4017 Sensor Tester or substitute another sensor for testing 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 C e 3 13 13 Page 4 of
12. vice or in the water start and run the engine Make sure the over temp alarm is working and try to rev the engine up You should not be able to exceed 2600 RPM as the engine should go into S L O W function at 2500 RPM Turn the engine off and wait 10 seconds for the processor inside the power pack to reset before continuing 22 Disconnect the jumper wire from the Tan temperature sensor wire TROUBLESHOOTING oS oN NO FIRE ON ANY CYLINDER 1 Disconnect the Black Yellow stop wire AT THE POWER PACK and retest If the engine s ignition has spark the stop circuit has a fault Check the key switch harness and shift switch Disconnect the Yellow wires from the stator to the rectifier and retest If the engine sparks replace the rectifier Check the cranking RPM A cranking speed of less than 250 RPM will not allow the system to spark properly This can be caused by a weak battery dragging starter bad battery cables or a mechanical problem inside the engine Verify the engine is turning in a clockwise direction If not see TRIES TO RUN BACKWARDS below Check the power pack and ignition coil ground wires for corrosion and tightness Connect a spark gap tester to all cylinders Disconnect the boat side harness and connect a remote starter unit Check for spark If the engine has spark check the boat side harness s Black Yellow wire for shorts to ground Disconnect the Port 4 pin connector with the Yellow Red Black Yellow Tan and White
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