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 - 4 of 4 QF-358
ENGINE WILL NOT ACCELERATE BEYOND 2500 RPM (Runs smooth below that RPM):
1. Verify the engine is not actually over heating by using a digital pyrometer.
2. Check the routing of the Tan temperature wires, an example of a bad location is shown below. The Tan wires have to be located as
far away as possible from the spark plug wires.
Unacceptable routing for the temp wire (V6 engine shown).
3. Verify the engine is not overheating and disconnect the Tan temperature sensor wire. If the engine performs normally, check both
temperature sensors and replace the defective one.
4. If there is not any indication of a problem at this point, replace the Power Pack.
ENGINE STAYS IN QUICK-START:
1. Check the Yellow/Red wire for DC voltage while the engine is running. You should only see voltage on this wire while the starter
solenoid is engaged. A voltage reading of 5-7 VDC will not engage the starter solenoid but will engage Quick Start. Check the
starter solenoid, harness, and ignition switch.
2. Short the White/Black temperature switch wire from the Power Pack to engine ground. Start the engine, if the Quick Start drops out
after approximately 5 seconds, replace the White/Black temperature switch.
3. Disconnect the Black/White wire from the Power Pack. If the Quick Start feature is not now working, replace the Power Pack.
ENGINE DIES WHEN QUICK-START DROPS OUT:
1. Check ignition timing at idle with the White/Black temperature wire disconnected. Remember to allow for the drop in ignition timing
when Quick Start disengages. Verify ignition timing after engine has warmed up, according to the service manual.
QUICKSTART DOES NOT WORK:
1. Check DVA from the Orange to the Orange/Black Power coil wires while connected to the Power Pack. The reading should be 8-24
DVA. A reading above 24 V indicates a problem in the Power Pack while a reading below 8 DVA usually indicates a problem in the
Stator.
WILL NOT RUN WHEN HOT:
1. Check the Stator resistance and DVA as given below:
Read from
Read to
Ohms DVA (Connected) DVA (Disconnected)
Brown (Stator)
Brown/ White (or Brown/Yellow) Stator 900-1200
Ω
150-400 V 150-400 V
Orange (Power Coil)
Orange/Black (Power Coil)
50-60
Ω
11-22 V 45-120 V
2. Test the Optical sensor while hot (CDI P/N 511-4017 Optical Sensor Tester) or by using another Optical sensor for testing.
