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  • 3.

    If you have two cylinders not firing (either #1 and #2, or #3 and #4), switch the stator leads end to end on the switch box (red with red/white and blue with blue/white). If the problem moves to the other cylinders, the stator is bad. It the problem stayed on the same cylinders, the switch box is likely bad.

  • 4.

    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. If two cylinders on the same end of the switch box are dropping out, the problem is likely going to be either the switch box or trigger. 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 blue/white wires 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. (Check from blue to blue if the engine has a red stator kit installed).

  • 3.

    Connect a DVA meter to the red wire and red/white wires 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 wires 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 fire 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.

WILL NOT IDLE BELOW 1500 RPM:

1.

Index the flywheel and check the timing on all cylinders. one cylinder, replace the trigger.

If the timing cannot be adjusted correctly or if the timing is off on

  • 2.

    Check for air leaks.

  • 3.

    Check synchronization of the carburetors.

9 to 16 Amp Battery Charging Capacity

OEM RESISTANCE

CDI RESISTANCE

DVA

5000-7000

2200-2400

180V or more

5000-7000

2200-2400

180V or more

90-200

30-90

25V or more

90-200

30-90

25V or more

WIRE (Read to Engine ground) Blue Blue/White Red Red/White

Inline 6 and V6 Carbureted Engines Using Dual Switch Boxes and Six Ignition Coils

NO SPARK ON ONE BANK (3 OF 6 ON THE INLINE L-6):

NO SPARK ON ANY CYLINDER:

1.

Check the stator resistance and DVA output as shown below:

  • 2.

    Disconnect the yellow wires from 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.

1.

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

40 Amp Battery Charging Capacity

OEM RESISTANCE

CDI RESISTANCE

DVA

3200-4200

2200-2400

150V or more

3200-4200

2200-2400

150V or more

90-140

90-110

20V or more

90-140

90-110

20V or more

WIRE (Read to Engine ground) Blue Blue/White Red Red/White

  • 2.

    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 on all cylinders. If the reading is low on one bank and the stator voltage is good, the switch box is usually bad. (Note: A final test to verify which component is bad is to swap the stator leads from one switch box to the other. If the problem moves, the stator is bad. If the same bank still does not fire, the switch box is usually bad.)

  • 3.

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

NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:

1.

2.

Connect a spark gap tester and verify which cylinders are misfiring. 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 shown below:

54

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