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BLACK SLEEVE TO

YELLOW SLEEVE

Resistance

DVA Reading

Brown wire

White wire

800-1400

4V or more Connected

White wire

Purple wire

800-1400

4V or more Connected

Purple wire

Brown wire

800-1400

4V or more Connected

Service Note: You should get a high or open resistance reading to engine ground from each wire, but you will get a DVA reading of approximately 1-2 Volts. This reading can be used to determine if a pack has a problem in the triggering circuit. For example, 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.

9 to 16 Amp Battery Charging Capacity

OEM RESISTANCE

CDI RESISTANCE

5000-7000

2200-2400

5000-7000

2200-2400

90-200

30-90

90-200

30-90

ENGINE WILL NOT ACCELERATE BEYOND 3000-4000 RPM:

  • 1.

    Connect an inductive RPM meter to all cylinders and try to isolate the problem. If two or more cylinders on the same bank are dropping out, the problem is likely going to be either the stator or the switch box. A single cylinder dropping fire will likely mean the switch box or ignition coil is defective.

  • 2.

    Check the stator resistance: WIRE (Read to Engine ground) Blue

Blue/White Red Red/White

WIRE (Read to Engine ground)

OEM RESISTANCE

Blue

3400-4200

Blue/White

3400-4200

Red

90-140

Red/White

90-140

40 Amp Battery Charging Capacity

CDI RESISTANCE

2200-2400 2200-2400 90-110 90-110

3.

blue/white wire and compare the readings.

WIRE (Read to Engine ground)

CRANKING

Blue Blue/White Red Red/White White/Black*

100-265 100-265 25-50 25-50 1-6

1000 RPM

3000 RPM

195-265

255-345

195-265

255-345

120-160

230-320

120-160

230-320

3-15

10-30

Connect a DVA meter to the Blue wire 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. Repeat for the

  • -

    This voltage is read with an analog DC volt meter – Not a DVA meter.

Brown (Black Sleeve)

White (Yellow Sleeve)

1100-1400

800-1000

4V or more

White (Black Sleeve)

Purple (Yellow Sleeve)

1100-1400

800-1000

4V or more

Purple (Black Sleeve)

Brown (Yellow Sleeve)

1100-1400

800-1000

4V or more

Service Note: You should get a high or open resistance reading to engine ground from each wire, but you will get a DVA reading of approximately 1-2 Volts. This reading can be used to determine if a pack has a problem in the triggering circuit. For example, 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.

4. Check the trigger as follows:

WIRE

Read to

OEM RESISTANCE CDI RESISTANCE DVA @ CRANKING

High Speed Miss:

  • 1.

    Connect an inductive RPM meter to all cylinders and try to isolate the problem. A high variance in RPM on one cylinder usually indicates a problem 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.

55

Mercury Troubleshooting

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