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Three Cylinder Engines 1976-1996 Three Cylinder Engines Using a Single Switch Box and Three Ignition Coils

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, the stop circuit has a fault-check the key switch, harness and shift switch.

  • 2.

    Disconnect the yellow wires from the stator to the rectifier and retest. If the engine has spark, replace the rectifier.

  • 3.

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

  • 4.

    Check the stator resistance and DVA output as given below:

WIRE

Read To

Blue Engine

GND

Red

Engine GND

WIRE

Read To

Blue Engine

GND

Red

Engine GND

OEM RESISTANCE

CDI RESISTANCE

DVA

5800-7000

2200-2400

180V or more

135-165

45-55

25V or more

OEM RESISTANCE

CDI RESISTANCE

DVA

3250-3650

500-600

180V or more

75-90

28-32

25V or more

Flywheel with Bolted-in Magnets

Flywheel with Glued-in Magnets

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

White/Green Green/White

500-700

500-600

Blue

Engine GND

OPEN

Red Stator Kit

DVA 180V or more 180V or more

NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:

1.

2.

If the cylinders are only misfiring above an idle, connect a inductive Tachometer to all cylinders and try to isolate the problem cylinders. Check the trigger resistance and DVA output as given below:

Wire Color Brown wire White wire Purple wire Brown wire White wire Purple wire

Resistance

DVA Reading

800-1400 4V or more Connected 800-1400 4V or more Connected 800-1400 4V or more Connected

Open Open Open

1V or more (*) 1V or more (*) 1V or more (*)

Check to Wir White/Black White/Black White/Black Engine GND Engine GND Engine GND

e Color

(*) 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.

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 terminals. 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 symptom indicates a bad power pack.

ENGINE WILL NOT ACCELERATE BEYOND 3000-4000 RPM:

  • 1.

    Connect an inductive Tachometer to all cylinders 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 to the stator’s blue wire and engine ground and do 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. (blue to engine ground if the engine has a red stator kit installed).

  • 3.

    Connect a DVA meter to the stator’s red wire and engine ground and do a running test. 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.

HIGH SPEED MISS:

  • 1.

    Connect an inductive Tachometer to all cylinders and try to isolate the problem. A high variance in RPM on one cylinder indicates a problem usually in the switch box or ignition coil. Occasionally a trigger will cause this same problem. Check the trigger as described above under “No spark or Intermittent on One or More Cylinders”.

  • 2.

    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.

  • 3.

    Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets.

  • 4.

    Rotate the stator 1 bolt hole in either direction and retest.

WILL NOT IDLE BELOW 1500 RPM:

  • 1.

    Check the Bias resistance from the Black/White terminal to engine ground. Reading should be 14-15,000 ohms.

  • 2.

    Check for air leaks.

52

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