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1.

Disconnect the black/yellow stop wires from the harness and RPM Limiter. Retest. If the engine’s ignition has spark, the stop circuit has a fault-check the key switch, harness and shift switch. Disconnect the yellow wires from the rectifier and retest. If the engine has spark, replace the rectifier. Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.

2. 3.

4.

Check the stator resistance and DVA output as given below:

Four Cylinder Engines 1996-2006 Engines Using CDM Modules

NO SPARK ON ANY CYLINDER:

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

DVA

White/Green

Green/White

500-700

500-600

180V or more

1.

If the cylinders are only misfiring above an idle, connect an inductive RPM meter to all cylinders and try to isolate the problem cylinders. Disconnect the CDM’s one at a time and see if you get spark back on the problem cylinders.

2.

3.

Using a set of piercing probes, check the trigger DVA output as given below:

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*

High Tension Lead

A

700-1300 Ohms

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 spark or intermittent spark on any cylinder”.

  • 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.

    Use the wiring diagram below as an aid in locating areas where problems may occur. Remember a short in either #1 or #2 can cause either # 3 and #4 not to have spark.

Note: 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.

NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:

4.

Reading

Disconnect one of the CDM modules that are firing one at a time and see if the dead CDM starts firing. If it does, the CDM you just unplugged is bad.

Black Meter Lead

NOTE: These triggers have the bias circuitry internally built-in, therefore you cannot measure the resistance like you can measure on the older engines. In addition, these engines use four triggering coils versus the two triggering coils used on the older engines.

5.

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

Wire Color

Check to Wire Color

Resistance

DVA Reading

Purple wire

Engine GND

Open

3V or more

White wire

Engine GND

Open

3V or more

Brown wire

Engine GND

Open

3V or more

White/Black wire

Engine GND

Open

3V or more

58

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