Re: 1990 120 johnson,does not fire,How to troubleshoot?
This is whats on the web page:
Installation and Troubleshooting Guide
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CDI Electronics ? 111 Commerce Circle ? Madison, AL 35758 ? Fax 256-772-5701 ?
www.cdielectronics.com
CDI P/N: 173-3410
This stator replaces P/N: 583410
WARNING! This product is designed to be installed by a professional marine mechanic. CDI
Electronics cannot be held liable for injury or damage resulting from improper installation, abuse,
neglect or misuse of this product.
SERVICE NOTE: Discoloration of all the battery windings is an indication of a problem in the
rectifier/regulator. Discoloration of only one post of the battery windings indicates a problem in the
stator.
Installation
1. Remove the negative battery cable.
2. Remove the flywheel.
3. Disconnect the original stator wires.
4. Remove the original stator, saving the original bolts.
5. Install the new stator using the original bolts with a good thread-locker applied (CDI 989-3977 is
recommended) to the bolts and tightened to the factory torque specifications.
6. Connect the new stator to the power pack.
7. Connect the new stator to the regulator/rectifier (ignore any stripes on the rectifier as the new
stator does not require the Yellow wires to be connected to a particular rectifier wire).
8. Replace the flywheel according to the service manual.
9. Replace the battery cable.
Troubleshooting the stator
No fire at all:
1. Disconnect the kill wire and retest. If the ignition now has fire, check the kill circuit.
2. Check the resistance between the brown and brown/yellow wires. You should read approximately
500-700 ohms. DVA (peak voltage) should be 150v or more.
3. Check the resistance between the orange and orange/black wires. You should read approximately
95-105 ohms. DVA (peak voltage) should be 12v or more while connected to the power pack.
4. Inspect the flywheel outer and trigger magnets to see if they are loose or broken.
5. Disconnect the rectifier/regulator and retest. If the fire returns, replace the rectifier/regulator.
No fire on One Cylinder:
1. Swap the brown wire and brown/yellow wire and see if the problem moves. If it does, the stator is
likely bad.
2. Check the power pack and trigger.
High speed miss or weak hole shot:
1. Connect a DVA meter between the brown and brown/yellow wires in each set and do a running
test. AT NO TIME SHOULD THE VOLTAGE EXCEED 400v. If it does, the regulator circuit in the
power pack is bad. The voltage should show a smooth climb and stabilize, gradually falling off at
high RPM (above 5000). If you see a sudden drop in voltage right before the miss becomes
apparent, the problem is likely in the stator.
2. Disconnect the rectifier and retest. If the problem disappears, replace the rectifier and retest to
verify that the problem was in the rectifier.
Thank you for using CDI Electronics 7/21/2009
