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Outboardparts.com: your source for Outboard Motor Parts! |
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Troubleshooting Force Outboard Motor / U.S. Marine |
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Alternator Driven ignitions |
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******** This information is supplied as a service guide only and Outboardparts.com is not liable for any misunderstandings, errors or omissions regarding this information. The information has been obtained from actual Unit analysis, parts manuals, and other sources. ******** |
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| Recommended Tools: | ||||
| for DVA: | Fluke Multimeter with CDI #511-9773 Peak Adapter, (or CD-77) | |||
| CDI #511-9770 Piercing Probes | ||||
| CDI #511-9710 Trigger Tester | ||||
| CDI #511-9766 Spark Gap Tester | ||||
| Jumper Wire | ||||
| A Reliable Volt/Ohm Meter (if the CD-77 is used for the DVA). | ||||
| for P/Ns: | 116-3301, 116-5301, 116-8301, 475301-1 (300-F475301-1) | |||
| 653301 (300-F817974A1), 658301-2, 658301-2, 685301-1 (300-F658301-2) | ||||
| DVA readings should always be taken with everything hooked up | ||||
| 1. Check for broken wires and terminals, especially inside the plastic plug-in connectors. We recommend that you remove the pins from the connectors using the CDI 554-9706 Pin Removal Tool and visually inspect them. | ||||
| 2. Check the flywheel for broken or loose magnets. | ||||
| 3. Disconnect the kill wires from the CD and connect a DC voltmeter between the kill wires and engine ground, turn the Ignition switch on and off several times. If, at any time, you see voltage appearing on the meter, there is a problem in the Harness or Ignition switch. At No TIME SHOULD YOU See Battery Voltage on A Kill CIRCUIT. | ||||
| 4. Visually inspect Stator for burned or discolored areas. If found, replace the Stator. If the areas are on the battery charge windings, this indicates a possible problem with the rectifier. | ||||
| 5. Trigger Wire sets read approximately 50 ohms between the Wire sets(DVA-5V or more), OEM Stator reads 680-900 ohms CDI=250-300 ohms (DVA 180v or more) from blue to yellow. Neither Trigger or Stator should show any resistance reading to ground.. | ||||
| if No fire on ANY Cylinder: | ||||
| Disconnect kill Wire AT the Pack. Check for broken or bare wires on the Unit, Stator or Trigger. Using the Fluke meter with the CDI 511-9773 Peak Reading Adapter, or CD-77 and CDI 511-9770 piercing probes, measure DVA voltage of the Stator between the output Wire sets. with everything connected, reading should be approximately 180 volts or more. Resistance readings between the Stator Wire sets is (OEM 980-900 ohms/CDI=250-300 ohms). Disconnect the rectifier. If the engine fires, replace the rectifier. | ||||
| No fire or INTERMITTENT on one Cylinder: | ||||
| Check Stator and Trigger resistance. If readings are good, disconnect kill Wire from all packs. If the dead cylinder starts firing, the problem is likely the blocking diode in one of the other packs. | ||||
| No fire on Two Cylinders: | ||||
| If the two cylinders from the same CD Unit will not fire, the problem is usually in the Stator. Test per above. | ||||
| Engine WILL NOT Kill: | ||||
| Check kill circuit in the pack by using a jumper Wire connected to the kill Wire coming out of the pack and shorting it to the ground. If this kills the pack, the kill circuit in the Harness or on the boat is bad, possibly the Ignition switch. | ||||
| Coils Only fire with the Spark plugs Out: | ||||
| Check for dragging starter or low battery causing slow cranking speed. DVA test Stator and Trigger. | ||||
| High SPEED Miss | ||||
| Using fluke meter with the CDI 511-9773 peak reading adapter, (or CD-77) and CDI 511-9770 piercing probes, DVA check Stator voltage to each pack at high speed. If it exceeds 400 volts, replace the pack. If the voltage drops below 200V, the Stator is likely bad. Disconnect the rectifier and retest. If the miss is gone replace the rectifier. | ||||
| 5 Cylinder with Single Switch Box: | ||||
| NOTE: This Engine uses a battery powered inverter module to supply the high voltage for the switch box. The Inverter is in a 332-4797 switch box case. The Unit is easily identifiable by the fact of it only having 4 terminals instead of the usual 7. The Stator is for battery charging only. | ||||
| No Fire on any Cylinder: | ||||
| 1. Check the red Wire from the battery. You should have at least 9.5 volts while cranking the engine. | ||||
| 2.Check DVA voltage on the purple/white terminal. 0.2 volts or more is needed to Trigger the inverter box. If low or no voltage at all- Check the Trigger from the white/black to the yellow, black, brown, white and purple Trigger wires. You should have at least 4 volts on each. In the event you have Trigger voltage but no voltage on the purple/white, the switch box is likely bad. | ||||
| 3.Check the DVA voltage on the blue terminal of the inverter module. Should be approximately 200-300 volts at cranking. | ||||
| No Fire on One Cylinder | ||||
| Check the Trigger from the white/black to the yellow, black, brown, white and purple Trigger wires. You should have at least 4 volts on each. | ||||
| all cylinders fire but the engine will not crank and run: Disconnect white/black Wire and | ||||
| check the bias circuit (white/black terminals) resistance to engine ground. Readings should be approximately 8400W. If the readings are correct on the pack, index the flywheel and check timing on all individual cylinders. If the timing varies, replace the pack. | ||||
| Connections: 2 and 3 cylinder with 116-5301 and 116-8301 power packs | ||||
| Pack #1 (firing #1 and #2 cylinders) | ||||
| Trigger: | Orange | Pack: |
White/orange stripe | |
| Green | White/yellow stripe | |||
| Red | White/red stripe | |||
| White/green stripe | White/green stripe | |||
| Pack #2 (Firing #3 cylinder) | ||||
| Trigger: | Orange | Pack: |
White/orange stripe or Blue/orange stripe | |
| Green | White/yellow stripe | |||
| Stator: | Yellow | Pack: |
Brown/blue stripe | |
| Blue(must be connected to the blue and brown/blue stripe on pack 1) | ||||
| Coil #3: | White | Pack: |
Orange/blue stripe or Blue/orange stripe | |
| Connections: 4 cylinder with 116-5301 and 116--8301 power packs | ||||
| Pack #1 (Firing #1 and #2 cylinders) | ||||
| Trigger: | Orange | Pack: |
White/orange stripe | |
| Green | White/yellow stripe | |||
| Red | White/red stripe | |||
| White/green stripe | White/green stripe | |||
| Stator: | Yellow | Pack: |
Brown/yellow stripe | |
| Blue | Brown/blue stripe | |||
| Coil #1 | White | Pack: |
Orange/blue stripe or Blue/orange stripe | |
| Coil #2 | White | Pack: |
Blue/red stripe | |
| Pack #2 (firing #3 and #4 cylinders) | ||||
| Trigger: | Orange | Pack: |
White/orange stripe | |
| Green | White/yellow stripe | |||
| Red | White/red stripe | |||
| White/green stripe | White/green stripe | |||
| Stator: | Yellow | Pack: |
Brown/yellow stripe | |
| Blue | Brown/blue stripe | |||
| Coil #4 | White | Pack: |
Blue/red stripe | |
| Coil #5 | White | Pack: |
Orange/blue stripe or Blue/orange stripe | |
| Connections: 5 cylinder with 116-5301 and 116-8301 power packs | ||||
| Pack #1 (Firing #1 and #2 cylinders) | ||||
| Trigger: | Orange | Pack: |
White/orange stripe | |
| Green | White/yellow stripe | |||
| Red | White/red stripe | |||
| White/green stripe | White/green stripe | |||
| Stator: | Yellow | Pack: |
Brown/yellow stripe | |
| Blue | Brown/Blue stripe | |||
| Coil #1 | White | Pack: |
Orange/blue stripe or Blue/orange stripe | |
| Coil #2 | White | Blue/red stripe | ||
| Pack #2 (Firing #3 cylinder) | ||||
| Trigger: | Orange | Pack: |
White/orange or Blue/orange stripe | |
| Green | White/yellow stripe | |||
| Stator: | Yellow | Pack: |
Brown/yellow stripe | |
| Blue (must be connected to the blue stripe on packs 1 or 3) | ||||
| Coil #3 | White | Pack: |
Orange/blue stripe or Blue/orange stripe | |
| Pack#3 (firing #4 and #5 cylinders) | ||||
| Trigger: | Orange | Pack |
White/orange stripe | |
| Green | White/yellow stripe | |||
| Red | White/red stripe | |||
| White/green stripe | White/green stripe | |||
| Stator: | Yellow | Pack: |
Brown/blue stripe | |
| Blue | Brown/blue stripe | |||
| Coil#4 | White | Pack: |
Blue/red stripe | |
| Coil#5 | White | Pack: |
Orange/blue stripe or Blue/orange stripe | |
| NOTICE: The color codes listed above may appear on the packs, stators or triggers. Some packs have solid colors and some triggers have striped wires. Some of the newer items with striped wires may have an additional black stripe. | ||||