ELECTRICAL
10.11
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
0No12 volt power or ground to CDI
0Spark plug gap incorrect
0Fouled spark plug
0Faulty spark plug cap or poor
connection to high tension lead
0Related wiring loose, disconnected,
shorted, or corroded
0Engine Stop switch or ignition switch
faulty
0ETC switch misadjusted or faulty
0Poor ignition coil ground (e.g. coil
mount loose or corroded)
0Faulty stator (measure resistance of
all ignition related windings)
0Incorrect wiring (inspect color coding
in connectors etc)
0Faulty ignition coil winding (measure
resistance of primary and
secondary)
0Worn magneto (RH) end Crankshaft
bearings
0Sheared flywheel key
0Flywheel loose or damaged
0Excessive crankshaft runout on
magneto (RH) end - should not
exceed .005²
0Faulty CDI module
CRANKING OUTPUT TEST
WITH PEAK
READING
VOL
TMETER
The following peak voltage tests will measure the
amount of output directly from each component.
A
peak reading voltmeter must be used to perform
the
tests
. A variety of peak reading adaptors are
commercially available for use with the FlukeZ 77
Digital Multimeter (PV--43568), which will allow peak
voltage tests to be performed accurately. Follow the
directions provided with the adaptor. All
measurements are indicated in DC Volts. Readings
obtained without a peak reading adaptor will be
significantly different.
Test output from the CDI and pulse (trigger) coil and
compare to the table. The following measurements
are obtained when cranking the engine with the
electric starter, spark plug installed. The starter
system must be in good condition and the battery fully
charged.
200 Watt 4 Stroke DC/CDI Ignition
Test
Connect
Meter Wires
To:
Reading
(Without Pea k
Reading V olt
meter)
CDI Output Yellow Blue
and Ground
20 DCV
Pulse (T rigger) Yellow/Red
and
Yellow
3.3 DCV
CDI OUTPUT TEST USING
PEAK READING ADAPT
OR
Re-connect all CDI wires to stator wires. Disconnect
CDI module wire from ignition coil primary terminal.
Connect one meter lead to engine ground and the
other to the ignition coil primary wire leading from the
CDI module. Set meter to read DC Volts. Crank
engine and check output of CDI wire to coil.
Reconnect CDI wire to coil.
Output w/ Peak output tester
130 DCV
Average Output w/ Digital Voltmeter
20 DCV
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