X hits on this document

130 views

0 shares

0 downloads

0 comments

23 / 41

Two Cylinder Engines 1996-2006 Engines Using a Combination Switch Box and Ignition Coil (CDM Modules)

NO SPARK ON ANY CYLINDER:

  • 1.

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

  • 2.

    Swap the White/Green and Green White stator wire and retest. If the problem moves to the other cylinder, the stator is likely bad.

  • 3.

    Disconnect one CDM module at a time and using a set of piercing probes and jumper wires- short the stator and trigger wire in the CDM connector to engine ground. Retest. If the other module starts sparking, the CDM you unplugged is bad.

  • 4.

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

  • 5.

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

  • 6.

    Check the stator resistance and DVA output as follows:

WIRE White/G

reen

Read to OEM RESISTANCE

CDI RESISTANCE

Green/White

500-700

500-600

DVA

180V or more

3.

If # 1 is not sparking, swap the White/Green and Green White stator wire and retest. If the problem moves to the #2 cylinder, the stator is likely bad. If no change, swap locations with #2 and see if the problem moves. If it does, the module is

bad. A continued no spark condition on the same cylinder indicates a bad trigger.

4.

Check the resistance of the CDM as follows:

High Speed Miss:

  • 1.

    Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem. A high variance in RPM on one cylinder usually indicates a problem in the trigger or CDM module.

  • 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 cracked or broken magnets.

NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER:

CDM Pin #

A

C

700-1300 Ohms

CDM Pin #

D

A

DIODE*

CDM Pin #

A

D

DIODE*

CDM Pin #

D

B

DIODE*

CDM Pin #

B

D

DIODE*

CDM Pin #

A

B

DIODE*

CDM Pin #

B

A

DIODE*

CDM Pin #

A

C

700-1300 Ohms

CDM Pin #

D

A

DIODE*

CDM Pin #

D

B

DIODE*

CDM Pin #

A

B

DIODE*

High Tension Lead

A

700-1300 Ohms

  • *

    Diode readings are to be read one way, then reverse the leads and read again. You should get a low reading in one direction and

a higher reading in the other.

High Tension Lead

A

700-1300 Ohms

  • *

    Diode readings are to be read one way, then reverse the leads and read again. You should get a low reading in one

direction and a higher reading in the other.

Red Meter Lead

Black Meter Lead

Reading

1.

2.

If the cylinders are only misfiring up above an idle, connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders. U s i n g a s e t o f p i e r c i n g p r o b e s , c h e c k t h e t r i g g e r D V A o u t p u t a s s h o w n b e l o w :

Reading

Wire Color

Check To (Wire Color)

Resistance

DVA Reading

White wire

Engine GND

Open

1V or more

Brown wire

Engine GND

Open

1V or more

Black Meter Lead

7.

Check the resistance of the CDM as follows: Red Meter Lead

56

Document info
Document views130
Page views130
Page last viewedSun Dec 11 02:18:14 UTC 2016
Pages41
Paragraphs4126
Words20178

Comments