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, LLC
•
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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4/9/2021 Page - 2 of 3 QF-358
3. Disconnect the Yellow wires from the Stator to the Regulator/Rectifier and retest. If the engine now has spark, replace the
Regulator/Rectifier.
4. Check the cranking RPM. A cranking speed less than 250 RPM will not allow the system to fire properly. This can be caused by a weak
battery, dragging starter, bad battery cables, or a mechanical problem inside the engine.
5. Check the Stator and Trigger resistance and DVA for your engine in the lists below:
Check the 3 cylinder engine as follows:
Read from
Read to
Ohms
DVA (Connected) DVA (Disconnected)
Blue (Low speed Coil) Engine Gnd
2.0-2.4K
Ω 180 V Minimum
180 V Minimum
Red (High speed Coil) Engine Gnd
45-55
Ω 25 V Minimum
25 V Minimum
Brown (Trigger) White/Black (or Black) (Trigger) 0.8-1.4
K Ω
4 V Minimum 4 V Minimum
White (Trigger) White/Black (or Black) (Trigger) 0.8-
1.4K Ω
4 V Minimum 4 V Minimum
Purple (Trigger) White/Black (or Black) (Trigger) 0.8-
1.4K Ω
4 V Minimum 4 V Minimum
Brown (Trigger) Engine Gnd
Open
1 V Minimum -
White (Trigger) Engine Gnd
Open
1 V Minimum -
Purple (Trigger) Engine Gnd
Open 1 V Minimum -
NOTE: The 3 cylinder engines have several configurations to the firing order. Please refer to the Factory Service Manual to
make that determination. The pairing should always be as follows:
•
Green Coil Wire goes with the Brown Trigger Wire
•
Green/Red Coil Wire goes with the Purple Trigger Wire
•
Green/White Coil Wire goes with the White Trigger Wire
Check the 4 cylinder engine as follows:
Read from Read to
Ohms
DVA (Connected) DVA (Disconnected)
Blue (Low speed Coil) Blue/White (Low speed Coil) 2.0-2.4K
Ω
180 V Minimum
180 V Minimum
Red (High speed Coil) Red/White (High speed Coil)
45-55
Ω 25 V Minimum
25 V Minimum
Purple (#1 Trigger) White (#2 Trigger)
0.8-
1.4K Ω
4 V Minimum 4 V Minimum
Brown (#3 Trigger) White/Black or Black (#4 Trigger) 0.8-
1.4K Ω
4 V Minimum 4 V Minimum
Purple (#1 Trigger) Engine Gnd
Open
1 V Minimum -
White (#2 Trigger) Engine Gnd
Open
1 V Minimum -
Brown (#3 Trigger) Engine Gnd
Open
1 V Minimum
-
White/Black (#4 Trigger) Engine Gnd
Open
1 V Minimum
6. Inspect the flywheel Trigger and Stator magnets to see if they are loose or broken. Disconnect the Regulator/Rectifier and retest. If the
fire returns, replace the Regulator/Rectifier.
7. Disconnect Red and Red/White wires and retest. If the DVA tests above is withing specifications, the Switchbox is usually bad.
NO FIRE ON 2 CYLINDERS (4 CYLINDER ENGINE):
1. DVA test Stator (see
NO FIRE ON AN CYLINDER
).
2. Swap the Blue with the Blue/white Stator leads, and the Red with the Red/white Stator leads to see if the no fire problem changes. If it
does, the Stator is bad. If the problem remains on the same cylinder(s), the Switchbox or Trigger is probably at fault.
HIGH SPEED MISS-FIRE OR WEAK HOLE SHOT:
1. Connect DVA meter to the Blue and Blue/white wires and do a running test. The voltage should show a smooth climb and stabilize,
gradually falling off at higher RPM's (above 3,000). If you see a sudden drop in voltage right before the miss becomes apparent, the
Stator is likely at fault.
2. Connect DVA meter to the Red and Red/white wires. The voltage should show a smooth climb throughout the RPM range, a sudden
drop or decline in voltage indicates a problem usually found in the Stator, although a Regulator/Rectifier can cause the same symptom.
3. Disconnect Regulator/Rectifier and retest. If the problem disappears, replace the Regulator/Rectifier and retest.
4. Rotate the Stator one bolt hole in either direction and re-test. If the miss is gone, leave the Stator as is. If the miss is worse, rotate the
Stator back where it was.
ENGINE WILL NOT STOP (KILL):
1. Disconnect the Black/Yellow (or Orange) wire(s) at the Switchbox. Connect a jumper wire to the stop wire from the Switchbox and short
it to engine ground. If this stops the Switchbox from sparking, the stop circuit has a fault. Check the key switch, harness, and shift
switch (if present). If this does not stop the Switchbox from sparking, replace the Switchbox.
