Yamaha Troubleshooting C75, P75, C80, C90, 90 1996-2009 (3 Cyl) (6H0-85540-07-00)
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.
GENERAL NO SPARK ON ANY CYLINDER:
Yamaha
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.
1. Disconnect the White stop wire and retest. If the engine’s ignition now has spark, the stop circuit has a fault. Check the key switch, harness and shift switch. 2. Inspect and clean all engine and ignition ground connections. 3. Check the resistance and DVA of the Charge coils, Pulser coils, Crank Position Sensor, and CDI unit:
Read from Brown (Low speed Charge coil) Blue (High speed Charge coil) White/Red (Pulser coil wire) Blue/White (Crank Position) Black/Orange (#1 Primary) Black/White (#2 Primary) Black/Yellow (#3 Primary)
Read to Ohms Red (Low speed Charge coil) 191-288 Ω Red (High speed Charge coil) 64-96 Ω White/Black(Pulser coil wire) 241-362 Ω Blue/Red(Crank Position) 158-236 Ω Engine Ground Engine Ground - Engine Ground -
DVA (Connected) DVA (Disconnected) 100 V Minimum 100 V Minimum 60 V Minimum 60 V Minimum 5 V Minimum 7 V Minimum 5.5 V Minimum 5.5 V Minimum 100 V Minimum 0 V (at idle) 1 00 V Minimum -
NOTE: The #2 Cylinder is Triggered by the CDI unit, it is normal for it to have no fire at cranking or idling. All cylinders should fire by 1,500 RPM. NOTE: Check the cranking RPM. A cranking speed of less than 250 RPM may not allow the system to fire properly. NOTE: Never test the CDI unit disconnected or damage to the CDI unit could occur!
NO SPARK OR INTERMITTENT ON ONE OR MORE CYLINDERS: 1. Check the resistance and DVA of the Pulser coil, Crank Position Sensor, and CDI unit:
Read from White/Red (Pulser coil) Blue/White (Crank Position) Black/Orange (#1 Primary) Black/White (#2 Primary) Black/Yellow (#3 Primary)
Read to White/Black (Pulser coil) Blue/Red (Crank Position) Engine Ground Engine Ground Engine Ground
Ohms 241-362 Ω 158-236 Ω - - -
DVA (Connected) 5 V Minimum 5.5 V Minimum 100 V Minimum 0 V Minimum 100 V Minimum
DVA (Disconnected) 7 V Minimum -
NOTE: The #2 Cylinder is Triggered by the CDI unit, it is normal for it to have no fire at cranking or idling. All cylinders should fire by 1,500 RPM. NOTE: If the reading is low on one cylinder, disconnect the wire from the ignition coil for that cylinder and reconnect it to a Pack load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a bad CDI unit or Pulser coil (test per above). The CDI Electronics Pack Load Resistor part number is 511-9775.
ENGINE WILL NOT ACCELERATE ABOVE APPROXIMATELY 2000 RPM: 1. Verify the engine is not overheating and causing the CDI unit to limit the RPM. 2. Disconnect the Pink wire from the CDI unit and retest. If the engine now performs correctly, check the overheat sensor, oil level in the oil tank mounted on the engine, and the wiring harness. 3. Check the position of the Pink wire and make sure it is not next to a spark plug wire. 4. Verify the ignition timing is advancing to the WOT setting (19-21 Degrees BTDC).
TECH SUPPORT: 1.866.423.4832 CUSTOMER SERVICE: 1.800.467.3371 www.cdielectronics.com
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