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NO SPARK OR INTERMITTENT ON ONE CYLINDER: 1. If the cylinders are only misfiring above an idle, connect an inductive an Tachometer to each cylinder in turn and try to

Wire Color

Check To (Wire Color)

Resistance

DVA Reading

Brown wire

White wire

800-1400 4V or more Connected

Brown wire

Engine GND

Open

1V or more (*)

White wire

Engine GND

Open

1V or more (*)

isolate the problem cylinder. 2. Check the trigger resistance and DVA output as shown below:

3.

(*) This reading can be used to determine if a pack has a problem in the triggering circuit. For instance, if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low – disconnect the trigger wire and recheck the DVA output to ground from the trigger wire. If the reading stays low – the trigger is bad. Check the DVA output on the green wires from the switch box while connected to the ignition coils. Check the reading on the switch box terminal AND on the ignition coil terminal. You should have a reading of at least 150V or more at both places. If the reading is low on one cylinder, disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a bad power pack.

WILL NOT ACCELERATE BEYOND 3000-4000 RPM:

  • 1.

    Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem. A single cylinder dropping fire will likely be the switch box or ignition coil. All cylinders misfiring usually indicate a bad stator.

  • 2.

    Connect a DVA meter between the stator’s blue wire and blue/white wires. Perform a running test. The DVA voltage should jump up to well over 200V and stabilize. A drop in voltage right before the problem occurs indicates a bad stator. (read the blue wire to engine ground if the engine has a red stator kit installed).

  • 3.

    Connect a DVA meter between the stator’s red wire and red/white wires. The DVA voltage should show a smooth climb in voltage and remain high through the RPM range. A reading lower than the reading on the blue wire indicates a bad stator.

  • 4.

    If both cylinders become intermittent, replace the switch box.

  • 5.

    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.

  • 6.

    Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets. Two Cylinder Engines 1994-1996 (With the 18495A9, A14, A16, A20, A21 or A30 Switch Box)

NOTE: This engine has a locked trigger arm. Therefore, the timing is controlled by the switch box and is adjusted according to the engine RPM. RPM limiting is done by retarding the timing at high RPM’s. Where possible, it is recommended that the ignition system be changed over to either the newer type ignition or the older type of ignition.

NO SPARK ON ANY CYLINDER:

1.

Disconnect the black/yellow stop wire AT THE PACK and retest. If the engine’s ignition now has spark now, the stop circuit has a fault-possibly the key switch, harness or shift switch.

  • 2.

    Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.

  • 3.

    Check the stator resistance and DVA output as given below:

Wire Color

Check To (Wire Color)

Resistance

DVA Reading

Brown wire

White wire

800-1400 4V or more Connected

Brown wire

Engine GND

Open

1V or more (*)

White wire

Engine GND

Open

1V or more (*)

DVA 180V or more connected 25V or more connected 2V or more connected

to each cylinder in turn and try to

(*) This reading can be used to determine if a pack has a problem in the triggering circuit. For instance, if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low – disconnect the trigger wire and recheck the DVA output to ground from the trigger wire. If the reading stays low – the trigger is bad.

NO SPARK OR INTERMITTENT ON ONE CYLINDER:

1.

If the cylinders are only misfiring above an idle, connect an inductive an Tachometer

2.

isolate the problem cylinder. Check the trigger resistance and DVA output as shown below:

3.

Check the DVA output on the green wires from the switch box while connected to the ignition coils. Check the reading on the switch box terminal AND on the ignition coil terminal. You should have a reading of at least 150V or more at both places. If the reading is low on one cylinder, disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a bad power pack.

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

Blue

Black

2900-3500

2200-2600

Red

Black

100-180

200-250

Black

Eng Gnd

Open

Open

Stator

50

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