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Page 20 - Index - Page 22
Two Cylinder Engines
1996-2000

Two Cylinder Engines Using a Combination Switch Box and Ignition Coil (CDM Modules)
No Fire At All:
  1. Disconnect the black/yellow kill wires from the harness and retest. If the engine’s ignition fires now, the kill circuit has a fault-possibly the keyswitch, harness or shift switch.
  2. Swap the White/Green and Green/White stator wire and retest. If the problem moves to the other cylinder, the stator is likely bad.
  3. Disconnect one CDM module at a time and using a set of piercing probes and jumper wires- short the stator and trigger wires to engine ground. Retest. If the other module start firing, the one you unplugged is bad.
  4. Disconnect the yellow wires from the stator to the rectifier and retest. If the engine fires, replace the rectifier.
  5. Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.
  6. Check the stator resistance and DVA output as given below:
  Wire Read To Resistance DVA  
  White/Green Green/White 500-700 180V or more  

No fire or Intermittent on One Cylinder:
  1. If the cylinders are only acting up above an idle, connect an inductive Tachometer to all cylinders and try to isolate the problem cylinders.
  2. Using a set of piercing probes, check the trigger DVA output as given below:
  Wire Read To Resistance DVA  
  Brown wire
White wire
Brown wire
White wire
Engine GND
Engine GND
800-1400
Open
Open
3V or more
1V or more
1V or more
 
  1. If # 1 is not firing, swap the White/Green and Green White stator wire and retest. If the problem moves to the #2 cylinder, the stator is likely bad. If no change, swap locations with #21 and see if the problem moves. If it does, the module is bad. A continued no fire on the same cylinder indicates a bad trigger.

High Speed Miss:
  1. Connect an inductive Tachometer to each cylinder in turn and try to isolate the problem. A high variance in RPM on one cylinder indicates a problem usually in the trigger or CDM module.
  2. Perform a high-speed shutdown and read the spark plugs. Check for water. A crack in the block can cause a high speed miss when the water pressure gets high, but a normal shutdown will mask the problem.
  3. Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets.
Three Cylinder Engines
1976-1997

Engines Using a Single Switch Box and Three Ignition Coils

No Fire At All:
  1. Disconnect the black/yellow kill wire AT THE PACK and retest. If the engine’s ignition fires now, the kill circuit has a fault-possibly the keyswitch, 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 cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.
  4. Check the stator resistance and DVA output as given below:
Motors with Flex-plate Flywheel
  Wire Read To Resistance DVA  
  Blue
Red
Engine Gnd
Engine Gnd
5800-7000
135-165
180V or more
25V or more
 

Motors with Cast, Vented Flywheel
  Wire Read To Resistance DVA  
  Blue
Red
Engine Gnd
Engine Gnd
3250-3650
75-90
180V or more
25V or more
 

Motors with Red Stator
  Wire Read To Resistance DVA  
  White/Green Green/White 500-700 180V or more  

Red Stator Adapter
  Wire Read To Resistance DVA  
  Blue Engine Ground Open 180V or more  

continued next page....
Page 20 - Index - Page 22