| Page 7 - Index - Page 9 |
Force
Three and Four Cylinder Engines Using Separate Switch Boxes and Ignition Coils (Continued)
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NO FIRE OR INTERMITTENT ON ONE CYLINDER:
- Check stator and trigger resistance, trigger wire sets read approximately 50 ohms between the wire sets (DVA-4V or more), stator reads 680-800 ohms (factory) and 200- 300 (CDI/RAPAIR) DVA 180V or more from blue to yellow.
- If readings are good, disconnect kill wire from one pack. If the dead cylinder starts firing, the problem is likely the blocking diode in the other pack.
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NO FIRE ON TWO CYLINDERS:
- If two cylinders from the same CD unit will not fire, the problem is usually in the stator. Test per above.
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ENGINE WILL NOT KILL:
- Check kill circuit in the pack by using a jumper wire connected to the kill wire coming out of the pack and shorting it to ground. If this kills the pack, the kill circuit in the harness or on the boat is bad, possibly the ignition switch.
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COILS ONLY FIRE WiTH THE SPARK PLUGS OUT:
- Check for dragging starter or low battery causing slow cranking speed. DVA test stator and trigger.
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HIGH SPEED MISS:
- DVA check stator voltage to each pack at high speed. If it exceeds 400 volts, replace the pack.
- Disconnect the rectifier. If the engine fires, replace the recfifier.
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5 Cylinder with Single Switch Box
(1991-1992)
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Note:
- This engine uses a battery powered inverter box to provide 250V power to the switch box. The inverter is in a 332-4797 CD case. This unit is easily identified by the fact that the inverter only has four terminals instead of the seven used on the 3324797 CD. The stator's only function is to charge the battery.
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No Fire on Any Cylinder:
- Check the red wire from the battery at cranking, minimum voltage is 9.5V.
- Check DVA voltage on the purple/white terminal at cranking. A minimum of 0.3V is needed to trigger the switch box. If the voltage is low, check the DVA voltage from the white/black trigger to the yellow, black, brown, white and purple trigger wires. If you read 4V or more, the switch box is likely bad.
- Check the DVA voltage on the blue terminal at cranking, reading should be approximately 250V.
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No Fire on One Cylinder:
- Check the DVA voltage from the white/black trigger to the yellow, black, brown, white and purple trigger wires. If you read 4V or more, the trigger is likely good.
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Fires All Cylinders But Will Not Run:
- Disconnect the white/black wire from the switch box and check the resistance from the switch box's white/black wire to engine ground. The reading should be approximately 8400 ohms. A low reading indicates a bad bias circuit and the switch box needs replacing.
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| Connections - 2 & 3 cylinder
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Pack #1 - fires #1 and #2 cylinder
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Trigger: |
Orange
Green
Orange
Green |
To Pack #1: |
White/Orange Stripe
White/Yellow Stripe
White/Red Stripe
White/Green Stripe
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Stator: |
Yellow
Blue (Both)
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To Pack #1: |
Brown/Yellow Stripe
Brown/Blue Stripe
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Coil #1
Coil #2 |
White
White
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To Pack #1:
To Pack #1: |
Orange/Blue Stripe
Blue/Red Stripe
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Pack #2 - fires #3 cylinder
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Trigger: |
Red
White/Green stripe
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To Pack #2: |
White/Red Stripe
White/Green Stripe
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Stator: |
Yellow
Blue
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To Pack #2: |
Brown/Blue Stripe
Blue & Brown/Blue stripe pack #1
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Coil #3 |
White
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To Pack #2: |
Blue/Red Stripe
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| Page 7 - Index - Page 9 |
