- Joined
- Mar 1, 2000
- RO Number
- 6
- Messages
- 231
TROUBLESHOOTING FORCE/U.S. MARINE ALTERNATOR DRIVEN IGNITIONS
For P/Ns: 116-3301, 116-5301, 116-8301, 475301-1 (300-F475301-1),
653301(300 -F817974Al), 658301-2, 685301-1 (300-F658301-2)
(NOTICE: Maintenance-free batteries are not recommended for use with these systems!)
NOTE: DVA stands for Digital Voltage Adaptor, I.E. Peak Reading Voltmeter
1. Check for broken wires and terminals, especially inside the plastic plug-in connectors. We recommend that you remove the pins from the connectors using the Rapair R554-9706 Pin Removal Tool and visually inspect them.
2. Check the flywheel for broken or loose magnets.
3. Disconnect the kill wires from the CD and connect a DC voltmeter between the kill wires and engine ground, turn the ignition switch on and off several times. If, at any time, you see voltage appearing on the meter, there is a problem in the harness or ignition switch. At NO TIME SHOULD YOU SEE BATTERY VOLTAGE ON A KILL CIRCUIT.
4. Visually inspect stator for burned or discolored areas. If found, replace the stator, If the areas are on the battery charge windings, it indicates a possible problem with the rectifier,
5. IF NO FIRE ON ANY CYLINDER: Disconnect kill wire AT THE PACK. Check for broken or bare wires on the unit, stator and trigger. Using the Fluke meter with the CDI 511-9773 Peak Reading Adapter, or CD-77 and CDI 511-9770 Piercing Probes, measure DVA voltage of the stator between the output wire sets. With everything connected, readings should be approximately 180 volts or more. The OEM stator resistance between the blue and yellow wires is 700-900 ohms. CDI/Rapair stator should read 300-500 ohms. Disconnect the rectifier. If the engine fires, replace the rectifier,
6. NO FIRE OR INTERMITTENT ON ONE CYLINDER: Check stator and trigger resistance. Trigger vare sets read approximately 50 ohms between the wire sets (DVA-5V or more), OEM stator read 700-900 ohms (DVA 180V or more) from blue to yellow, while CDI/Rapair stator read 300-500 ohms. If readings are good, disconnect kill wire from one pack. If the dead cylinder starts firing, the problem is likely the blocking diode in the other pack.
7. NO FIRE ON TWO CYLINDERS: If two cylinders from the same CD unit will not tire, the problem is usually in the stator. Test per 5 above.
8. ENGINE WILL NOT KILL: Check kill circuit in the pack by using a jumper wire connected to the kill wire coming out of the pack and shorting ft to ground. If this kills the pack, the kill circuit in the harness or on the boat is bad, possibly the ignition switch.
9. COILS ONLY FIRE WITH THE SPARK PLUGS OUT: Check for dragging starter or low battery causing slow cranking speed. DVA test stator and trigger.
10. HIGH SPEED MISS: Using the Fluke meter with the CD[ 511-9773 peak reading adapter, (or CD-77) and CDI 511-9770 piercing probes, DVA check stator voltage to each pack at high speed. If it exceeds 400 vofts, replace the pack. Disconnect the rectifier and retest, If the miss is gone replace the rectifier.
Connections: 2 and 3 cylinder with 116-5301 and 116-8301 power packs
Pack #1 (Firing #1 and #2 cylinders)
Trigger: Orange ---- Pack: White/orange stripe
Green White/yellow stripe
Red White/red stripe
White/green stripe White/green stripe
Stator: Yellow ---- Pack: Brown/yellow stripe
Blue (both) Brown/blue stripe
Coil #l: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Coil #2: White ---- Pack: Blue/red stripe
Pack #2 (Firing #3 cylinder)
Trigger: Orange ---- Pack: White/orange stripe or Blue/orange stripe
Green White/yellow stripe
Stator: Yellow ---- Pack: Brown/blue stripe
Blue (must be connected to the blue and brown/blue stripe on pack 1)
Coil #3: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Connections: 4 and 5 cylinder with 116-5301 and 116-8301 power packs
Pack #1 (Firing #1 and #2 cylinders)
Trigger: Orange ---- Pack: White/orange stripe
Green White/yellow stripe
Red White/red stripe
White/green stripe White/green stripe
Stator: Yellow ---- Pack: Brown/yellow stripe
Blue Brown/blue stripe
Coil #l: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Coil #2: White ---- Pack: Blue/red stripe
Pack #2 (Firing #3 & #4 cylinders)
Trigger: Orange ---- Pack: White/orange stripe or Blue/orange stripe
Green White/yellow stripe
Red White/red stripe
White/green stripe White/green stripe
Stator: Yellow ---- Pack: Brown/yellow stripe
Blue Brown/blue stripe
Coil #3: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Coil #4: White ---- Pack: Blue/red stripe
Pack #3 (Firing #5 cylinder)
Trigger: Orange ---- Pack: White/orange stripe
Green White/yellow stripe
Stator: Yellow ---- Pack: Brown/blue stripe
Blue (must be connected to the blue and brown/blue stripe on packs 1 or 2)
Coil #5: White ---- Pack: Orange/blue stripe or Blue/orange stripe
NOTICE: The color codes listed above may appear on the packs, stators or triggers. Some packs have solid colors and some triggers have striped wires.
For P/Ns: 116-3301, 116-5301, 116-8301, 475301-1 (300-F475301-1),
653301(300 -F817974Al), 658301-2, 685301-1 (300-F658301-2)
(NOTICE: Maintenance-free batteries are not recommended for use with these systems!)
NOTE: DVA stands for Digital Voltage Adaptor, I.E. Peak Reading Voltmeter
1. Check for broken wires and terminals, especially inside the plastic plug-in connectors. We recommend that you remove the pins from the connectors using the Rapair R554-9706 Pin Removal Tool and visually inspect them.
2. Check the flywheel for broken or loose magnets.
3. Disconnect the kill wires from the CD and connect a DC voltmeter between the kill wires and engine ground, turn the ignition switch on and off several times. If, at any time, you see voltage appearing on the meter, there is a problem in the harness or ignition switch. At NO TIME SHOULD YOU SEE BATTERY VOLTAGE ON A KILL CIRCUIT.
4. Visually inspect stator for burned or discolored areas. If found, replace the stator, If the areas are on the battery charge windings, it indicates a possible problem with the rectifier,
5. IF NO FIRE ON ANY CYLINDER: Disconnect kill wire AT THE PACK. Check for broken or bare wires on the unit, stator and trigger. Using the Fluke meter with the CDI 511-9773 Peak Reading Adapter, or CD-77 and CDI 511-9770 Piercing Probes, measure DVA voltage of the stator between the output wire sets. With everything connected, readings should be approximately 180 volts or more. The OEM stator resistance between the blue and yellow wires is 700-900 ohms. CDI/Rapair stator should read 300-500 ohms. Disconnect the rectifier. If the engine fires, replace the rectifier,
6. NO FIRE OR INTERMITTENT ON ONE CYLINDER: Check stator and trigger resistance. Trigger vare sets read approximately 50 ohms between the wire sets (DVA-5V or more), OEM stator read 700-900 ohms (DVA 180V or more) from blue to yellow, while CDI/Rapair stator read 300-500 ohms. If readings are good, disconnect kill wire from one pack. If the dead cylinder starts firing, the problem is likely the blocking diode in the other pack.
7. NO FIRE ON TWO CYLINDERS: If two cylinders from the same CD unit will not tire, the problem is usually in the stator. Test per 5 above.
8. ENGINE WILL NOT KILL: Check kill circuit in the pack by using a jumper wire connected to the kill wire coming out of the pack and shorting ft to ground. If this kills the pack, the kill circuit in the harness or on the boat is bad, possibly the ignition switch.
9. COILS ONLY FIRE WITH THE SPARK PLUGS OUT: Check for dragging starter or low battery causing slow cranking speed. DVA test stator and trigger.
10. HIGH SPEED MISS: Using the Fluke meter with the CD[ 511-9773 peak reading adapter, (or CD-77) and CDI 511-9770 piercing probes, DVA check stator voltage to each pack at high speed. If it exceeds 400 vofts, replace the pack. Disconnect the rectifier and retest, If the miss is gone replace the rectifier.
Connections: 2 and 3 cylinder with 116-5301 and 116-8301 power packs
Pack #1 (Firing #1 and #2 cylinders)
Trigger: Orange ---- Pack: White/orange stripe
Green White/yellow stripe
Red White/red stripe
White/green stripe White/green stripe
Stator: Yellow ---- Pack: Brown/yellow stripe
Blue (both) Brown/blue stripe
Coil #l: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Coil #2: White ---- Pack: Blue/red stripe
Pack #2 (Firing #3 cylinder)
Trigger: Orange ---- Pack: White/orange stripe or Blue/orange stripe
Green White/yellow stripe
Stator: Yellow ---- Pack: Brown/blue stripe
Blue (must be connected to the blue and brown/blue stripe on pack 1)
Coil #3: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Connections: 4 and 5 cylinder with 116-5301 and 116-8301 power packs
Pack #1 (Firing #1 and #2 cylinders)
Trigger: Orange ---- Pack: White/orange stripe
Green White/yellow stripe
Red White/red stripe
White/green stripe White/green stripe
Stator: Yellow ---- Pack: Brown/yellow stripe
Blue Brown/blue stripe
Coil #l: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Coil #2: White ---- Pack: Blue/red stripe
Pack #2 (Firing #3 & #4 cylinders)
Trigger: Orange ---- Pack: White/orange stripe or Blue/orange stripe
Green White/yellow stripe
Red White/red stripe
White/green stripe White/green stripe
Stator: Yellow ---- Pack: Brown/yellow stripe
Blue Brown/blue stripe
Coil #3: White ---- Pack: Orange/blue stripe or Blue/orange stripe
Coil #4: White ---- Pack: Blue/red stripe
Pack #3 (Firing #5 cylinder)
Trigger: Orange ---- Pack: White/orange stripe
Green White/yellow stripe
Stator: Yellow ---- Pack: Brown/blue stripe
Blue (must be connected to the blue and brown/blue stripe on packs 1 or 2)
Coil #5: White ---- Pack: Orange/blue stripe or Blue/orange stripe
NOTICE: The color codes listed above may appear on the packs, stators or triggers. Some packs have solid colors and some triggers have striped wires.