Yamaha Troubleshooting BATTERY CHARGING ISSUES:
1. Check the condition of the cranking battery. Use a flooded wet lead acid battery Marine battery with a minimum MCA of 650. 2. Check the disconnected rectifier/regulator DC Voltage as shown: Read from Red
Read to Black
1,500 RPM 13 V
3,500 RPM 13 V
3. Check the Lighting coil DVA disconnected as shown: Read from Green (Lighting coil)
Read to Green (Lighting coil)
Cranking RPM 6 V Minimum
1,500 RPM 17 V Minimum
3,500 RPM 38 V Minimum
E40XMH, E40XW, 40XWH, 40XW 40 HP ENDURO ENGINES 2004-2011 (2 Cyl) (66T-85540-01-00,117-0010)
Service Notes:
1. Please refer to the General Troubleshooting section in the beginning of the Troubleshooting Guide for a better understanding of basic outboard principles, terminology, and repair techniques prior to attempting any troubleshooting or repairs. 2. All DVA tests are done at cranking speed unless otherwise noted. 3. All resistance tests are done disconnected from all other components. 4. Please use the Factory recommended spark plug specified and gapped at the correct setting. WARNING!!! NEVER DISCONNECT THE SPARK PLUG WIRES WHILE THE ENGINE IS RUNNING AS THIS WILL DAMAGE THE CDI UNIT. DO NOT ATTEMPT TO START THE ENGINE WITH THE SPARK PLUG WIRES NOT CONNECTED EITHER TO THE SPARK PLUGS OR A SPARK TESTER.
GENERAL NO SPARK OR WEAK SPARK ON ANY CYLINDER: 1. Verify the stop lanyard is not engaged. 2. Disconnect the White kill wire from the CDI unit and retest. If the engine now has spark, the stop circuit has a fault. Check the key switch, harness and shift switch. 3. Check the Charge coil resistance and DVA: Read from Read to Ohms Brown (Charge) Blue (Charge) 684-836 Ω 4. Check Pulser coil resistance and DVA:
DVA (Connected) 190 V Minimum
DVA (Disconnected) 330 V Minimum
DVA 1,500 RPM & Above 190 V Minimum
Read from Read to Ohms DVA (Disconnected) DVA (Connected) DVA 1,500 RPM White/Red (#1 Pulser) Black 311-380 Ω 7 V Minimum 4 V Minimum 10 V Minimum White/Black (#2 Pulser) Black 311-380 Ω 7 V Minimum 4 V Minimum 10 V Minimum
DVA 3,500 RPM 17 V Minimum 17 V Minimum
NOTE: If engine develops a high miss or stall, check the CDI Unit DVA to ignition coils. NOTE: Never test the CDI unit disconnected or damage to the CDI unit could occur! 5. Check the CDI unit DVA: Read from Black/Orange (Cyl #1) Black/White (Cyl #2)
Read to Black Black
DVA Connected 180 V Minimum 180 V Minimum
DVA 1,500 RPM 180 V Minimum 180 V Minimum
DVA 3,500 RPM 170 V Minimum 170 V Minimum
NOTE: If reading is low on one cylinder, disconnect the CDI wire from the ignition coil for that cylinder and reconnect it to a pack load resistor and retest. If the reading is now good, the ignition coil is likely bad. A continued low reading means a bad Pulser coil or CDI unit. The CDI Electronics Pack Load Resistor part number is 511-9775.
NO SPARK OR WEAK SPARK ON ONE CYLINDER: 1. Check sparkplug condition for carbon build up or cracks/ damage. 2. Measure the ignition coil resistance. Read from Black/White (Primary coil) Spark plug wire (Secondary coil)
Read to Black Spark plug wire
Ohms 0.32-0.44 Ω 5.4-7.4K Ω
3. Check the Resistor boots from the input to the sparkplug terminal (if present). You should read between 4 -6K Ω. If outside this range, replace the Resistor boot.
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TROUBLESHOOTING GUIDE - Yamaha Troubleshooting