Here is some info to get you started :
Four Cylinder Engines
(1991-1996)
Four Cylinder Engines Using a Single Switch Box and Four Ignition Coils
No Fire At All:
1. Disconnect the black/yellow stop wires AT THE PACK 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. Disconnect the yellow wires from the stator to the rectifier and retest. If the engine has spark, replace the rectifier.
3. Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to spark properly.
4. Check the stator resistance and DVA output as given below:
Flywheel with Bolted in Magnets
WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA
Blue Blue/White 5000-7000 2200-2400 180V or more
Red Red/White 125-155 45-55 25V or more
Flywheel with Glued-in Magnets
WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA
Force Troubleshooting
Blue Blue/White OHMS :3250-3650 DVA: 180V or more
Red Red/White OHMS:75-90 DVA 25V or more
Red Stator
WIRE Read To OEM RESISTANCE CDI RESISTANCE DVA
White/Green Green/White OHMS:500-700 DVA: 180V or more
Red Stator Adapter
WIRE Read To OEM RESISTANCE DVA
Blue Blue OPEN 180V or more
Blue (Each) Ground OPEN 180V or more
NO SPARK OR INTERMITTENT SPARK ON ONE OR MORE CYLINDERS:
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. Check the trigger resistance and DVA output as given below:
Wire Color Check to Wire Color Resistance DVA Reading
Purple wire White wire 800-1400 4V or more Connected
Brown wire White/Black wire 800-1400 4V or more Connected
Purple wire Engine GND Open 1V or more (*)
White wire Engine GND Open 1V or more (*)
Brown wire Engine GND Open 1V or more (*)
White/Black wire Engine GND Open 1V or more (*)
(*) This reading can be used to determine if a pack has a problem in the triggering circuit. For instance, if you
have no fire on one cylinder and the DVA trigger reading for that cylinder is low ? disconnect the trigger wire
and recheck the DVA output to ground from the trigger wire. If the reading stays low ? the trigger is bad.
Note: If #1 and #2, or #3 and #4 are misfiring, check the trigger as described above. The trigger uses two coils to
spark four cylinders. #1 & 2 share one trigger coil and #3 & 4 share the other trigger coil. Also, the switch box is
divided into two parts. The #1 and #2 cylinders spark on one half, and #3 and #4 spark on the other half of the
switch box. If the trigger tests fine by the chart above, but you have two cylinders not sparking (either #1 and #2 or
#3 and #4), the switch box or stator is bad.
3. If you have two cylinders not sparking (either #1 and #2 or #3 and #4), swap the stator leads end to end on the
switch box (Red with red/white and blue with blue/white). If the problem moved to the other cylinders, the
stator is bad. It the problem stayed on the same cylinders, the switch box is likely bad if the trigger tests within
specifications.
4. Check the DVA output on the green wires from the switch box while connected to the ignition coils. Check the
reading on the switch box terminal AND on the ignition coil terminal. You should have a reading of at least
150V or more at both terminals. If the reading is low on one cylinder, disconnect the green wire from the
ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition
coil is likely bad. A continued low reading indicates a bad power pack.
PLEASE post test results prior to getting any parts , This is a general guide and sometimes results can take you the wrong way due to other bad parts effecting test results !
