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 - 3 of 4 QF-358
14. Check the Charge coil flywheel magnets for cracked, broken, or loose magnets.
ONLY HAS SPARK AS LONG AS THE KEY SWITCH IS ENGAGED OR WILL NOT REV ABOVE IDLE SPEED:
1. Check the DVA on the Stator’s Power coil.
2. As the engine RPM increases, the DVA should rapidly increase and stabilize up to 22 DVA (voltage exceeding 22 DVA indicates a
bad Power Pack). A sharp drop in voltage right before the miss becomes apparent usually indicates a bad Stator Charge coil
winding. A sharp drop in voltage when you disengage the key switch indicates a bad Power coil on the Stator.
ENGINE TRIES TO RUN BACKWARDS:
1. Check the encoder wheel. It must have 7 notches.
2. Check the ignition timing. Before Quick Start, it should be set to 2-6° BTDC. After Quick Start, it should be set to 4-6° ATDC.
3. If possible, try another Optical sensor.
4. If still no change, replace the Power Pack.
NO FIRE OR INTERMITTENT FIRE ON ONE BANK:
1. Check the Stator resistance and DVA (see
NO FIRE ON ANY CYLINDER
).
2. Disconnect the 4-pin connector on the port side of the Power Pack and see if the fire returns. If it does, check resistance to see if
the Black/Yellow wire is shorted to engine ground or is intermittently shorting to ground.
NO FIRE ON ONE CYLINDER:
1. Check the DVA on the Orange primary wire going to the Ignition coil not firing. You should have a reading of 150 DVA or more.
2. Check the resistance of the Ignition coil secondary circuit in reference to engine ground. A difference of over 25
Ω
indicates a
defective Ignition coil.
3. Check the resistance of the spark plug wire. Normally, you will read approximately 100
Ω
between the connectors on either end.
POWER PACK REPEATEDLY BLOWS ON SAME CYLINDER:
1. Replace the Ignition coil on the cylinder dropping spark.
ENGINE WILL NOT STOP (KILL):
1. Disconnect the stop wire at the Power Pack. Connect a jumper wire to the stop terminal in the Power Pack and short it to engine
ground. If this stops the Power Pack from sparking, the stop circuit has a fault. Check the key switch, harness, and shift switch.
ONLY FIRES #1 CYLINDER:
1. Verify the engine is spinning in a clockwise direction.
2. Check the Optical sensor to encoder wheel alignment. You may need to shim the Optical sensor upwards 0.020” to 0.0285” to
make it engage the encoder wheel.
HIGH SPEED MIS-FIRE OR WEAK HOLE SHOT:
1. Connect DVA meter to between the Brown wires and do a running test. At no time should the voltage exceed 400 DVA. If it does,
the Regulator circuit in the Power Pack is bad. The voltage should show a smooth climb and stabilize, gradually falling off above
5000 RPM. If you see a sudden drop in voltage right before the miss becomes apparent, the problem is likely in the Stator.
2. Disconnect the Yellow wires from the Stator to the Voltage Regulator and retest. If the miss clears, replace the Voltage Regulator.
3. Check the DVA on the Orange primary wires from the Power Pack while connected to the Ignition coils. You should have a reading
of at least 150 DVA or more, increasing with engine RPM until it reaches 300-400 DVA maximum. A sharp drop in DVA right before
the miss becomes apparent on all cylinders will normally be caused by a bad Stator. A sharp drop in DVA on less than all cylinders
will normally be the Power Pack.
4. Connect an inductive tachometer to the spark plug wires one at a time and compare the readings. If most of the cylinders show the
same reading and one or two show different readings, check the primary wires with the inductive pickup to see if the readings are
the same from the Power Pack. A difference in readings between the primary and secondary coil wires usually indicates a bad coil
or bad ignition wires. No difference indicates a bad Power Pack.
5. Perform a high speed shutdown and read the spark plugs. Check for a black porcelain insulator or one that looks brand new. A
crack in the block can cause a miss at high speed when the water pressure gets high and sprays water into the cylinder, but a
normal shutdown will mask the problem.
6. Check the Charge coil flywheel magnets for cracked, broken, or loose magnets.
