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Troubleshooting Chrysler / Force Outboard Motor Battery CD ignitions

********      This information is supplied as a service guide only and Outboardparts.com is not liable for any misunderstandings, errors or omissions regarding this information. The information has been obtained from actual Unit analysis, parts manuals, and other sources.      ********

Recommended Tools:
for DVA: Fluke  Multimeter with CDI #511-9773 Peak Adapter, (or CD-77)
CDI #511-9701 Battery CD Tester
CDI #511-9710 Trigger Tester
CDI #511-9766 Spark Gap Tester
Jumper Wires
A Large proportion of the problems with the battery CD units are caused by low battery voltage or bad ground connections. Low voltage symptoms are weak fire or weak erratic firing of cylinders. Warning: Battery reversal will cause severe damage to the CD units and to the rectifier. NOTE: While the Chrysler battery ignitions are similar to OMC's, care must be taken with regards to the color codes of the wires. The chart below will assist you as a general guideline:
1. Red: +12V direct battery Conn. (RF Noise filter) 4. White: OEM Tachometer                         
2. Blue:+12V Ignition switch 5. White/Black Stripe: Points or preamp
3. Gray: +Terminal of Ignition Coil 6. Black: Engine ground
1) Check all battery and ground connections
2) Check the voltage on the blue Wire at the CD Unit. If the voltage is less that 9 1/2 volts,
during cranking there is a problem in the battery circuit. Theses units require at least 9 1/2 volts to fire properly. Connect a jumper Wire directly from the battery (+) terminal to the blue Wire on the CD and retest. ATTENTIon: In order to kill the engine if it cranks, the jumper Wire must be disconnected and/or choke the engine. If the engine still fails to crank, recheck voltage as above. If low, replace and retest.
3) Disconnect points/sensor Wire and connect the Battery CD tester (CDI #511-1701)
according to the instructions on the back of the tester, and align distributor rotor with a spark plug Wire. Connect a spark gap tester (CDI #511-9766 is ideal) to all spark plug wires and turn the Ignition switch on. If the CD Unit fires to only one spark plug Wire, check the points/sensor (white/black) Wire for internal breaks. If ANY spark plug Wire fires besides the one the rotor is aligned with, the distributor cap and rotor should be replaced. The Battery CD tester will fire the system to approximately 3000 RPM. If the Battery CD tester is not used, strike the points/sensor Wire against engine ground. The CD Unit should fire every time. If the CD Unit fails to fire, check the Ignition coil (open, cracked or poorly grounded coil can burn out a battery CD). Connect the spark gap tester (CDI #511-9766) directly to the Ignition coil. If it doesn't fire, replace the coil with any known good CD coil. If the Unit still fails to fire, it is usually bad.

4) Check the DVA voltage on the gray Wire primary input Wire to the coil using the Fluke

meter with the peak reading adapter (CDI #511-9773), or CD 77, and the piercing probe (CDI #511-9770). Reading should be approximately 200 volts or more while connected to the coil.
the FOLLOWING is for OEM and Repair REMANUFACTURED Packs Only

1) Disconnect the white and blue 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 should see voltage appearing on the meter, there is a problem with the Harness or Ignition switch. AT No TIME SHOULD YOU See Battery Voltage on A Kill CIRCUIT

2) Connect a spark gap tester to all Ignition coils and test with the spark plugs in and

If the coils fire only with the plugs out, check compression with all spark plugs removed. A blown gasket on these engines can cause a no fire problem if the plugs are installed. NOTE: This is an unexplainable situation, but experience has shown it can occur.

3) Check the DVA voltage on the T1 and T4 terminals using the Fluke meter with the peak

reading adapter (CDI #511-9773), or CD 77, by cranking the engine over and stopping to read the voltage. You should read between 170-270 volts.

4) If either T1 or T4 has a low reading, disconnect the Trigger module wires (white/blue and

green/white) and retest. If the readings are now correct, the Trigger module is probably bad. If there still is a low reading, use as a set of jumpers and swap the green and white capacitor leads. If the low reading stays on the same terminal, the CD is bad. If it follows one lead of the capacitor, then the capacitor is bad. 

5) Check to see if the Ignition coils are wired properly. On a 2 cylinder engine #1 is connected

as NEGATIVE ground and #2 is POSITIVE ground. with a 4 cylinder, #1 & #2 are NEGATIVE ground and #3 & #4 are POSITIVE ground.

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