Installation and Troubleshooting Guide
This installation is to be completed by an Authorized Dealer or Professional Service
Technician. For questions regarding installation or warranty, call CDI Tech Support
at 866-423-4832. Do not return to the Dealer or Distributor where the part was purchased.
Contact CDI Electronics Directly for Return Material Authorization.
CDI Electronics
•
353 James Record Road SW
•
Huntsville, AL 35824 USA
Web Support: www.
•
Tech Support: 1-866-423-4832
•
Order Parts: 1-800-467-3371
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Rev H
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8/3/2021 Page - 2 of 4 QF-358
TROUBLESHOOTING
NO SPARK ON ANY CYLINDER:
1. Disconnect the port 4 pin connector on the Power Pack that holds the Black/Yellow stop wire and retest. If the engine's ignition now
has spark, the stop circuit has a fault. Check the key switch, harness, and shift switch.
2. Disconnect the Yellow wires from the Stator to the Voltage Regulator and retest. If the engine sparks, replace the Voltage
Regulator.
3. Check the cranking RPM. A cranking speed of less than 250 RPM will not allow the system to spark properly. This can be caused
by a weak battery, dragging starter, bad battery cables, or a mechanical problem inside the engine.
4. Check the Stator resistance and DVA as given below:
Read from
Read to
Ohms DVA (Connected) DVA (Disconnected)
Brown (Stator)
Brown/Yellow (Stator)
450-600
Ω
150-400 V
150-400 V
Brown/White (Stator) Brown/Black (Stator)
450-600
Ω
150-400 V
150-400 V
Orange (Power coil) Orange/Black (Power coil) 50-60
Ω
11-22 V 45-120 V
5. Check the DVA on the Black/Yellow kill wire by back probing the connector of the Power Pack. You should have a reading of at
least 150 DVA or more. The Stator and Optical Sensor plugs should be connected to the Power Pack for this test. If you do not,
check the DVA on the Stator and the DC voltage on the Optical Sensor. If the DVA on the Stator and the DC voltage is good on the
Optical Sensor but the DVA on the Black/Yellow Kill wire coming out of the Power Pack is low, the Power Pack is likely faulty.
6. Verify the engine is turning in a clockwise direction. If not, see
TRIES TO RUN BACKWARDS
.
7. Check the Power Pack and Ignition coil ground wires for corrosion and tightness.
8. If the engine loses spark after the key switch is disengaged, check the DVA on the Stator’s Power Coil. If the DVA is low, the Stator
is likely defective.
9. Check the battery voltage on the Yellow/Red wire while cranking the engine. If below 11 VDC, charge the battery and check all
battery cables. A continued low battery reading could be caused by a dragging starter, a faulty starter solenoid, or a faulty key
switch.
10. Remove the Optical sensor wheel and check for damage, especially where the top slots are located. Sometimes the wheels will
break out where the windows overlap.
The thin area between the crank position and the cylinder position is the most common breakout location.
11. Check the Optical sensor eyes for dirt, grease, etc. If you have to clean it, use denatured alcohol and a Q-tip. Do not use any other
cleaning agent because damage to the Optical lens will occur.
12. Check the Power Pack DVA to the Primary coil wires as follows:
Read from
Read to
DVA (Connected)
Orange/Blue
Engine Gnd 150 V Minimum
Orange
Engine Gnd 150 V Minimum
Orange/Green Engine Gnd 150 V Minimum
NOTE: If the Orange Primary DVA reading is low on one cylinder, disconnect the wire from the Ignition coil for that
cylinder and reconnect it to a Pack Load resistor (CDI P/N 511-9775). Retest. If the reading is now within specification, the
Ignition coil is likely defective. If it still measures low, this indicates a defective Power Pack If the Optical sensor tests
within specification.
13. Check the Optical sensor DC voltage as follows:
Read from
Read to
OEM DC (Connected) CDI DC (Connected)
Orange/Red (Input from Power Pack)
Engine Gnd 11 V Minimum 9.5 V Minimum
Black/Orange (Return from Optical sensor) Engine Gnd
9 V Minimum 7.5 V Minimum
WARNING! The Black/Orange wire should NEVER be shorted to engine ground as this will damage the sensor.
NOTE: When checking the Optical sensor, there can be only a maximum voltage difference of 2 V DC between the input
voltage and the return voltage. If the voltage difference is more than 2 V, or if the input voltage and the return voltage are
equal (given that the input voltage is at an acceptable reading), replace the Optical sensor.
