Installation and Troubleshooting Guide
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QF-319
CDI P/N: 173-4560
This stator replaces P/N: 584560
WARNING! This product is designed to be installed by a professional marine mechanic. CDI Electronics cannot be held
liable for injury or damage resulting from improper installation, abuse, neglect or misuse of this product.
SERVICE NOTE: Discoloration of all the battery windings is an indication of a problem in the rectifier/regulator. Discoloration of only
one post of the battery windings indicates a problem in the stator.
INSTALLATION
1.
Remove the negative battery cable.
2.
Remove the flywheel.
3.
Disconnect the original stator wires.
4.
Using the appropriate pin tool (order P/N: 553-2700 for a pin tool set), remove the Black/Yellow Kill wire from the 5 pin
connector (in the center position) on the old stator.
5.
Remove the original stator, saving the original bolts.
6.
Install the new stator using the original bolts with a good thread-locker applied (CDI 989-3977 is recommended) to the
bolts and tightened to the factory torque specifications.
7.
Insert the Black/Yellow Kill wire into the 5 pin connector (in the center position) on the new stator.
8.
Connect the new stator to the
power pack
.
9.
Connect the new stator to the regulator/rectifier (ignore any stripes on the rectifier as the new stator does not require
the Yellow wires to be connected to a particular rectifier wire).
10.
Replace the flywheel according to the service manual.
11.
Replace the battery cable.
TROUBLESHOOTING
Service Note: Please use the Factory recommended spark plug (currently Champion QL77JC4) gapped at 0.030”.
Note: These engines usually have a 10 Amp battery charging capacity. Due to the size and weight of the flywheel magnets, it is highly recommended
that you check to make sure both the triggering and charge magnets are still secure in the flywheel before you service the engine. A loose or broken
magnet can be deadly to you or your pocketbook. It is a recommended you index the flywheel and check the timing on all cylinders when servicing these
engines. Also check for static firing and intermittent spark.
ENGINE WILL NOT START OR MISFIRES:
1.
Verify the wiring in the connectors as follows:
2. Check the flywheel center hub magnet to verify the triggering magnet has not come loose
NO SPARK ON ANY CYLINDER:
1.
Disconnect the black/yellow kill wires AT THE PACK and retest. If the engine's ignition now has fire, the kill circuit has
a fault-possibly the key switch, harness or shift switch.
2.
Disconnect the yellow wires from the stator to the rectifier and retest. If the engine fires, replace the rectifier.
3.
Check the stator and timer base resistance and DVA output as given below:
WIRE
READ TO
RESISTANCE (Disconnected) DVA (Connected) DVA (Disconnected)
Brown
Brown/Yellow 600-850
150 V +
150 V + (*)
Orange
Orange/Black 45-55
11-22 V
45-120 V (*)
White
Purple (3 Cyl Eng)
(^)
100 V + (a)
0.6 V + (#)
White
Blue (3 Cyl Eng)
(^)
100 V + (a)
0.6 V + (#)
White
Green (3 Cyl Eng)
(^)
100 V + (a)
0.6 V + (#)
White
Black/White (3 Cyl Eng) 400-500
6 to 12 V(b)
6 to 12 V (from pack)
White
Blue (2 Cyl Eng)
25-29
100 V + (a)
0.6 V + (#)
White
Green (2 Cyl Eng)
25-29
100 V + (a)
0.6 V + (#)
