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Four Cylinder Engines (With Ignition Driver Distributors)

WARNING!! DO NOT CONNECT 12VDC TO THE IGNITION MODULE AS DC VOLTAGE WILL BURN OUT THE SWITCH BOX AND IGNITION DRIVER.

Read to

Function

Resistance

DVA Reading

White wire

Cranking Winding

400 ohms

180V+

White wire

High Speed Winding

10 Ohms

20V+

Engine Gnd

Pack output

N/A

150V+

NO SPARK ON ANY CYLINDER:

1.

2.

Disconnect the orange 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 mercury tilt switch. Check the Ignition Driver resistance and DVA output:

Common for Ignition Driver (DOES NOT CONNECT TO ENGINE GND)

Wire C Red Blue Green White

olor

3.

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

NO SPARK ON ONE OR MORE CYLINDERS: If only one or two cylinders are not firing on this system, the problem is going to be either in the distributor cap or spark plug wires.

Four Cylinder Engines 1978-1996 Four Cylinder Engines Using a Single Switch Box and Four Ignition Coils

NO SPARK ON ANY CYLINDER:

1.

2. 3. 4. 5 .

Disconnect the black/yellow stop wires 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 mercury tilt switch. Disconnect the yellow wires from the stator to the rectifier and retest. If the engine now has spark, replace the rectifier. Verify the correct flywheel is installed. Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly. Check the stator resistance and DVA output as shown below:

Flywheel with Bolted-in Magnets

OEM RESISTANCE

CDI RESISTANCE

5000-7000 125-155

2200-2400 45-55

WIRE

Read To

Blue

Blue/White

Red

Red/White

DVA 180V or more 25V or more

Flywheel with Glued-in Magnets

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

Blue

Blue/White

3250-3650

500-600

Red

Red/White

75-90

28-32

DVA 180V or more 25V or more

Red Stator

WIRE White/Green Blue Blue (Each)

Read To OEM RESISTANCE

Green/White

500-700

Blue

OPEN

Ground

OPEN

CDI RESISTANCE 500-600

DVA

180V or more 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 an inductive Tachometer to all cylinders and try to isolate the problem cylinders. Check the trigger resistance and DVA output as given below:

Wire Color Purple wire Brown wire Purple wire White wire Brown wire White/Black wire

Resistance

DVA Reading

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

Open Open Open Open

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

Check to Wire Co White wire White/Black wire Engine GND Engine GND Engine GND Engine GND

lor

(*) 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.

Note: If #1 and #2, or #3 and #4 are misfiring, check the trigger as described above. The trigger has two coils firing four cylinders. #1 & 2 share a trigger coil and #3 & 4 share a trigger coil. Also, the switch box is divided into two parts. The #1 and #2 cylinders are fired on one side and #3 and #4 are fired from the other side of the switch box. If the trigger tests are okay according to the chart above, but you have two cylinders not firing (either #1 and #2, or #3 and #4), the switch box or stator is bad.

53

Mercury Troubleshooting

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