IGNITION

ELECTRICAL
Section 2A - Ignition
Table of Contents
2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Theory of Operation - Electronic Spark
A
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Component Description . . . . . . . . . . . 2A-15
Stator/Trigger (Electric Models) . . . . . . . . . . . 2A-4 Mercury/Mariner 30/40 (2 cyl.) ADI Ignition
Starter Motor Components . . . . . . . . . . . . . . . 2A-6 System (with Electronic Spark Advance) . . . 2A-16
Electrical Components (S/N-0G380074/ Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-18
BEL-Manual-9928507/BEL-Elec-9928480 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-24
& Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-26
Electrical (S/N-USA-0G380075 through Testing Ignition Components . . . . . . . . . . . . . . 2A-27
0G589999/BEL-Manual-9928508/ Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-27
BEL-Elec-9928481 through 9973099) . . . . . . 2A-10 Flywheel Removal and Installation . . . . . . . . . 2A-31
Electrical Components
(S/N-USA-0G590000/ BEL-9973100
& Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12

Specifications
IGNITION Type Capacitor Discharge
SYSTEM Spark Plug Type (NGK) BPZ8H-N-10
Spark Plug Gap 1.0 mm (0.040 in.)
Spark Plug Hex 18 mm
Spark Plug Torque 27 Nm (20 lb. ft)
Firing Order 1-2
TIMING Electronic Spark Advance (Non-Adjustable Idle - 3° BTDC ± 3°
SPECIFICATIONS Trigger) (not adjustable)
1997 and Prior
USA S/N 0G589999 & Below 2500 - 5500 rpm - 25° ± 3°
Belgium S/N 09973099 and Below (not adjustable)
Mechanical Spark Advance
(Adj stable Trigger)
(Adjustable 8° BTDC ± 1°
Idle - 8 1
1998 and Newer
USA S/N 0G590000 & Above Maximum - 1 turn clockwise
g
Belgium S/N 09973100 and Above after contacting throttle plate
(22° - 28° BTDC reference
only)

90-826148R03 JULY 2003 Page 2A-1

IGNITION

Special Tools
1. Flywheel Holder 91-52344

2. Flywheel Puller 91-849154T1

3. Protector Cap 91-24161

4. Volt/Ohm/DVA Meter 91-99750 or DMT 2000 Digital Tach Multi-meter 91-854009T1

5. Spark Gap Tester 91-63998A1 or Spark Board 91-850439T1

91-63998A1 91–850439T

Page 2A-2 90-826148R03 JULY 2003

 IGNITION

6. TPI/CDM Test Harness 84-825207A1

1996 1/2 and Prior
USA S/N-0G380074 & Below
BELGIUM Manual Start S/N 09928507 and Below
Electric Start S/N 09928480 and Below

7. TPI/CDM Test Harness 84-825207A2

1996 1/2 and Newer
USA S/N-0G380075 & Above
BELGIUM Manual Start S/N 09928508 and Above
Electric Start S/N 09928481 and Above

90-826148R03 JULY 2003 Page 2A-3

IGNITION

Stator/Trigger (Electric Models)

1 4

6 2

3
7

8
5
9

10

12

11

13
51

14
17

15

16

51 Loctite 222 Thread Locker

Page 2A-4 90-826148R03 JULY 2003

 IGNITION

Stator/Trigger (Electric Models)(Continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SEAL–REST (use where applicable)
2 1 REST (OIL INJECTION) I.D. of rest rope hole is 1/4 IN.
3 1 PLUG–STARTER HANDLE
2 1 REST KIT I.D. of rest rope hole is 1/3 IN.
3 1 PLUG–STARTER HANDLE
4 1 GROMMET–OIL TANK
5 1 PLUG–PRIMER HOLE
6 2 NUT (M6 x 1)
7 2 WASHER
8 2 SPACER
9 4 WING NUT
10 4 WASHER
11 4 WASHER (NEOPRENE)
12 1 COVER–FLYWHEEL
13 5 SCREW (M5 x 30) 50 5.6
14 1 STATOR
15 1 O RING (S/N-USA-0G589999/BEL-9973099 & BELOW)
16 1 TRIGGER ASSEMBLY
17 1 TRIGGER ASSEMBLY (S/N-USA-0G590000/BEL-9973100 & ABOVE)

90-826148R03 JULY 2003 Page 2A-5

IGNITION

Starter Motor Components

2 4
5

10
14
8

9
1 6 7

25

12 11 8
15 14

13

25

25

25 Liquid Neoprene

Page 2A-6 90-826148R03 JULY 2003

 IGNITION

Starter Motor Components(Continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 STARTER MOTOR
2 1 THRU BOLT 70 7.9
3 1 DRIVE KIT
4 1 DRIVE ASSEMBLY
5 1 DRIVE CAP
6 1 ARMATURE
7 1 COMMUTATOR CAP
8 1 BRUSH & SPRING KIT
9 1 BRUSH HOLDER
10 2 SCREW
11 1 LOCKWASHER
12 1 NUT (1/4-20) 60 6.8
13 1 BATTERY CABLE (5/16) (POSITIVE)
14 3 SCREW (M8 x 45) 16.5 22.3
15 1 CABLE (BLACK–6 IN. – 1/4 IN. TERMINALS)

90-826148R03 JULY 2003 Page 2A-7

IGNITION

Electrical Components (S/N-0G380074/

BEL-Manual-9928507/BEL-Elec-9928480 & Below)
25
12 14
3
51 13

25 17 15
10
4 16
25 2
1 25
9 6 8

11 7 5

43 18
44
40 19
42 2021
22
41

25
23
38
25

24
39

36 31

34 25
37 33
35 25
25 32
27

25
28
30 25
29

26
25 Liquid Neoprene
51 Loctite 222 Threadlocker

NOTE: Note: Apply Liquid Neoprene to all ring eyelet wiring terminals.

Page 2A-8 90-826148R03 JULY 2003

 IGNITION

Electrical Components S/N-0G380074/BEL-Man-9928507/

BEL-Elec-9928480&Below(Continued)
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 2 NUT (1/4-20) 50 5.6
2 2 LOCKWASHER
3 1 CABLE ASSEMBLY (BLACK–4 IN.)
4 1 SOLENOID ASSEMBLY
5 1 BUSHING ELECTRIC
6 1 GROMMET
7 2 SCREW (M6 x 25) 40 4.5
8 2 NUT (8–32) 20 2.3
9 1 CABLE (RED) ELECTRIC
10 1 BATTERY CABLE (NEGATIVE)
11 1 INSULATOR
12 1 RETAINER
13 1 STATOR (MANUAL)
14 5 SCREW (M5 x 30) 50 5.6
15 1 O-RING
16 1 TRIGGER
17 1 HARNESS ASSEMBLY
18 1 PLATE–Electrical
19 3 BUSHING–Flanged
20 3 GROMMET
21 3 WASHER
22 3 SCREW (M6 x 25) 100 11.3
23 1 SCREW (M6 x 14) Drive Tight
24 1 TPM ASSEMBLY
25 3 SCREW (M5 x 20) 80 9.0
26 1 HARNESS ASSEMBLY–ENGINE (MANUAL)
27 1 HARNESS ASSEMBLY–ENGINE(ELECTRIC)
28 1 TERMINAL BLOCK
29 2 SCREW (M5 x 12) MANUAL
30 2 SCREW (10–16 x 3/8 IN.)
31 AR CABLE TIE
32 1 VOLTAGE REGULATOR
33 1 J–CLIP ELECTRIC
34 1 CABLE (BLACK–11 IN.)
35 2 SCREW (M6 x 35) 80 9.0
36 1 CABLE (BLACK–9 IN.)
37 1 SCREW (10-16 x 3/5 IN.)
38 2 CDM ASSEMBLY
39 4 SCREW (M6 x 14) 80 9.0
40 2 HI–TENSION CABLE KIT
41 2 BOOT KIT
42 2 SPARK PLUG (NGK# BPZ8H-N-10) 20 27.1
43 1 SOCKET ASSEMBLY–FUSE ELECTRIC
44 1 FUSE

90-826148R03 JULY 2003 Page 2A-9

IGNITION

Electrical (S/N-USA-0G380075 through 0G589999/

BEL-Manual-9928508/BEL-Elec-9928481 through 9973099)

1
13 2
14 7

5
11 3
15 10
24 4
6 8
9
22
7
12
23
25 25 25
19 21
17 29
30 31
32 25

18
26
27
16 26
28
20

34
35
25

36 37 33
44

40
39
41

38
25

42 25
43

7 Loctite 271 Thread Locker

25 Liquid Neoprene

NOTE: ApplY Liquid Neoprene to all ring end wiring terminals.

Page 2A-10 90-826148R03 JULY 2003

 IGNITION

Electrical (S/N-USA-0G380075 through 0G589999/

BEL-Manual-9928508/BEL-Elec-9928481 through
9973099)(Continued)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 5 SCREW (M5 x 30) MANUAL 50 5.6
2 1 STATOR
3 1 O-RING
4 1 TRIGGER
5 1 SOLENOID ASSEMBLY
6 2 BUSHING
7 2 GROMMET
8 2 NUT (8-32)
9 2 SCREW (M6 x 25) ELECTRIC 40 4.5
10 2 NUT (1/4-20) 50 5.6
11 2 LOCKWASHER
12 1 INSULATOR (RED)
13 1 RETAINER (ELECTRIC HANDLE)
14 1 SCREW
15 1 BATTERY CABLE (NEGATIVE–ELECTRIC)
16 2 CDM ASSEMBLY
17 2 HI-TENSION CABLE
18 1 BOOT
19 2 SPARK PLUG (NGK#BPZ8H–N–10) 20 27.1
20 4 SCREW (M6 x 14) 80 9.0
21 1 PLATE–Electrical
22 1 CABLE (MANUAL)
23 1 SCREW (M6 x 14) 80 9.0
24 1 SCREW (M5 x 12)(ELECTRIC)
25 1 SCREW (M8 x 12)(MANUAL)
26 6 BUSHING
27 3 GROMMET DESIGN I
28 3 SCREW (M6 x 30)
29 3 BUSHING–Flanged
30 3 GROMMET DESIGN II
31 3 WASHER
32 3 SCREW (M6 x 35) 100 11.3
33 1 TPM ASSEMBLY
34 3 SCREW (M5 x 20) 80 9.0
35 3 CABLE TIE
36 1 VOLTAGE REGULATOR ELECTRIC
37 2 SCREW (M6 x 35) 80 9.0
38 1 CONDUIT
39 1 TERMINAL BLOCK
40 2 SCREW (10–16 x 3/8 IN.) MANUAL
41 2 SCREW (M5 x 12)
42 1 HARNESS ASSEMBLY–ENGINE (MANUAL)
43 1 HARNESS ASSEMBLY–ENGINE (ELECTRIC)
44 1 HARNESS (ELECTRIC)

90-826148R03 JULY 2003 Page 2A-11

IGNITION

Electrical Components
(S/N-USA-0G590000/ BEL-9973100 & Above)
1
15 14
7
2
6
12 40
16 11
4
7 9
10 3
8
5
21
13
22
25
28
27
18 20
26
25 25

19 29
30
29
17 33
31
23
24
32

25 35
34

25 36

37

39
38 7 Loctite 271 Thread Locker
25 25 Liquid Neoprene

NOTE: Apply Liquid Neoprene to all ring end wiring terminals.

Page 2A-12 90-826148R03 JULY 2003

 IGNITION

Electrical Components
(S/N-USA-0G590000/ BEL-9973100 & Above)(Continued)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 5 SCREW (M5 x 30) 50 5.6
2 1 STATOR MANUAL
3 2 PLUG
4 1 TRIGGER
5 1 CABLE TIE (4 IN.)
6 1 SOLENOID ASSEMBLY
7 2 BUSHING
8 2 GROMMET
9 2 NUT (8-32)
10 2 SCREW (M6 x 25) ELECTRIC 40 4.5
11 2 NUT (1/4-20) 50 5.6
12 2 LOCKWASHER
13 1 INSULATOR (RED)
14 1 RETAINER (ELECTRIC HANDLE)
15 1 SCREW
16 1 BATTERY CABLE (NEGATIVE–ELECTRIC)
17 2 CDM ASSEMBLY
18 2 HI-TENSION CABLE
19 1 BOOT
20 2 SPARK PLUG (NGK#BPZ8H–N–10) 20 27.1
21 1 CABLE MANUAL
22 1 SCREW (M8 x 12)
23 4 SCREW (M6 x 14) 60 6.7
24 1 PLATE–ELECTRICAL
25 1 SCREW (M5 x 12) 60 6.7
26 1 WASHER
27 1 SCREW (M6 x 14) 60 6.7
28 1 WASHER
29 6 BUSHING
30 3 GROMMET
31 3 SCREW (M6 x 30)
1 REV LIMITER (MANUAL)
32
1 REV LIMITER (ELECTRIC)
33 2 SCREW (M6 x 25) 30 3.4
34 4 CABLE TIE (8 IN.)
35 1 VOLTAGE REGULATOR
36 2 SCREW (M6 x 35) ELECTRIC 60 6.7
37 1 CONDUIT
38 1 HARNESS ASSEMBLY–ENGINE (MANUAL)
39 1 HARNESS ASSEMBLY–ENGINE (ELECTRIC)
40 1 CONDUIT
1 POWERHEAD

90-826148R03 JULY 2003 Page 2A-13

IGNITION

Theory of Operation - Electronic Spark Advance

1997 and Prior
USA S/N 0G589999 and Below
Belgium S/N 09973099 and Below
The ignition system is alternator-driven with distributor-less capacitor discharge. Major
components of the ignition system are the flywheel, stator, trigger, timing protection module
(TPM), capacitor discharge modules (CDM) and spark plugs.
The stator assembly is mounted stationary below the flywheel and has 2 (red stator has 3)
capacitor charging coils wound in series. The flywheel is fitted with 6 permanent magnets
inside the outer rim. As the flywheel rotates, the permanent magnets pass the capacitor
charging coils causing the coils to produce AC voltage (230 - 330 volts). The AC voltage then
is conducted to the capacitor discharge module (CDM) where it is rectified and stored in a
capacitor. Part of the stator voltage (20 - 25 volts) is sent to the timing protection module
(TPM) to power the timing circuit.
The trigger assembly (also mounted under the flywheel) has 1 coil. The flywheel has a
another permanent magnet located around the center hub. As the flywheel rotates, this hub
magnet passes the trigger coil. This causes the trigger coil to produce a AC voltage pulse
which is sent to the TPM. The TPM delays this signal depending on engine RPM and for-
wards a trigger signal to a electronic switch (SCR) within the CDM.
The SCR switch discharges the stored voltage of the capacitor into the primary side of the
CDM’s ignition coil.
Capacitor voltage within the CDM is amplified as high as 40000 volts to jump the gap at the
spark plug.
The preceding sequence occurs once per engine-revolution for each cylinder.
Spark timing is changed (advanced/retarded) electronically by the TPM monitoring trigger
pulses.
IMPORTANT: If the engine misfires, runs rough or does not start, the ignition system
should be checked using a Digital Tachometer/Multimeter DMT 2000 (91-854009A1),
or a Volt/Ohm/DVA Meter (91-99750), or a voltmeter (capable of measuring 400 volts
DC, or higher) and Direct Voltage Adaptor (91-89045).

Page 2A-14 90-826148R03 JULY 2003

 IGNITION

Ignition Component Description

PRINCIPLE OF OPERATION WITH TIMING PROTECTION MODULE (TPM)
Under normal circumstances, the TPM controls:
1. Spark timing by monitoring the trigger pulses and engine temperature.
2. Advances spark timing quickly to 25° BTDC under hard acceleration conditions.
3. Provides over-speed protection if engine RPM exceeds 5800. This occurs in 2 stages.
Initially, timing is retarded from 25° BTDC to 14° BTDC. If RPM continues to increase
above 6500, TPM will shut ignition off momentarily until RPM drops below 6500.
4. Provides an idle stabilizer function by advancing timing when engine RPM drops below
600. At crank speed of 300 RPM, timing can be as high as 10° BTDC.
5. Provides warning control of OVER-HEAT and LOW-OIL conditions. Warning is provided
through activation of a continuous tone warning horn for either condition. An OVER-HEAT
condition occurs when engine temperature rises above 88° C ± 13° (190° F ± 8° ). The TPM
will intermittently interrupt the ignition voltage to the capacitor discharge modules (CDM) to
reduce maximum RPM to approximately 2500. The RPM will be limited and the warning
horn will activate until engine temperature drops below 77° C ± 13° (170° F ± 8° ).
During a LOW-OIL condition, the TPM activates the warning horn when switch in
engine-mounted oil tank is shorted to ground (closed). Engine RPM is NOT limited dur-
ing a LOW-OIL condition.

90-826148R03 JULY 2003 Page 2A-15

IGNITION

Mercury/Mariner 30/40 (2 cyl.) ADI Ignition System (with

Electronic Spark Advance)

b d
S
N c
N e
S

S
N
GRN/WHT
BLK/YEL g
N
BLK
f
h
BLK
S BLK/YEL
WHT

GRN
WHT

GRN/WHT
WHT
S

GRN/WHT
N
N WHT/BLK

GRN/WHT
S
e
g
BLK/YEL
YEL

BLK/YEL

a f i
YEL

Wires to
Voltage
Regulator WHT
WHT/BLK
GRN/WHT

WHT
GRN/WHT
WHT

BLK

#1 Power
Acceleration
Cylinder
GRN

Detector Supply
Control
j
k
RPM Timing
Counter Control
TAN/BLU

BLK
LT BLU

BLK
PUR

#2
TAN

Speed Warning
Cylinder Circuit
Limiter
LT BLU

n Control
m l

a - Battery charging coils (8) h - CDM #2

b - Ignition charge coils (2) i - Stop switch
c - Trigger j - Neutral start switch
d - CDM #1 k - Temperature sender
e - Capacitor l - Low oil switch
f - SCR m - Warning horn
g - Coil n - Timing & protection module

Page 2A-16 90-826148R03 JULY 2003

 IGNITION

PRINCIPLE OF OPERATION - MECHANICAL SPARK ADVANCE

1998 and Newer
USA S/N 0G590000 and Below
Belgium S/N 09973100 and Below
The ignition system is alternator-driven with distributor-less capacitor discharge. Major
components of the ignition system are the flywheel, stator, trigger, capacitor discharge mod-
ules (CDM) and spark plugs.
The stator assembly is mounted stationary below the flywheel and has 3 capacitor charging
coils wound in series. The flywheel is fitted with 6 permanent magnets inside the outer rim.
As the flywheel rotates, the permanent magnets pass the capacitor charging coils causing
the coils to produce AC voltage (260 - 320 volts). The AC voltage then is conducted to the
capacitor discharge module (CDM) where it is rectified and stored in a capacitor.
The trigger assembly (also mounted under the flywheel) has 2 coils. The flywheel has anoth-
er permanent magnet located around the center hub. As the flywheel rotates, the magnet
passes the trigger coil. This causes the trigger coil to produce a AC voltage pulse which is
sent to an electronic switch (SCR) within the CDM.
The SCR switch discharges the stored voltage of the capacitor into the primary side of the
CDM’s ignition coil.
Capacitor voltage within the CDM is amplified as high as 40000 volts to jump the gap at the
spark plug.
The proceeding sequence occurs once per engine-revolution for each cylinder.
Spark timing is changed (advanced/retarded) by rotating the trigger assembly which
changes each trigger coil position in relation to the permanent magnets on the flywheel cen-
ter hub.
A rev-limiter (over-speed protection) circuit is contained inside the trigger assembly. The
trigger pulse provides power for the rev-limiter circuit. The rev-limiter circuit counts the trig-
ger pulses to determine engine RPM. If the engine RPM increases above the specified RPM
limit, the rev limiter will prevent the trigger pulses from reaching the CDM eliminating spark
delivery to the cylinder. The rev limiter will start to limit at 5900 ± 150 RPM and fully limit at
6200 ± 150 RPM.
TRIGGER COIL
One piece assembly, containing two trigger coils; one for each cylinder located under fly-
wheel is charged by single magnet on flywheel hub. Trigger pulses are sent to TPM or CDM.
NOTE: Trigger assemblies are different between TPM and non-TPM systems.
STATOR
Located under the flywheel in the stator assembly are 3 charge coils wound in series. They
provide voltage to the capacitor discharge modules (CDM). The charge coils also provide
voltage to power the timing circuit in the TPM or CDM.
CAPACITOR DISCHARGE MODULES (CDM)
Each module contains an ignition coil and amplifier circuitry which produces approximately
45000 volts at the spark plugs.
FLYWHEEL
Contains 6 magnets (12 pole) around circumference. One magnet located on inner hub for
trigger. Outer magnets are for battery charge coils and ignition charge coils.
NOTE: The inner trigger hub are different between TPM and non-TPM systems.

90-826148R03 JULY 2003 Page 2A-17

IGNITION

Theory of Operation
This outboard ignition system is alternator-driven (distributor-less) capacitor discharge sys-
tem. Major components of the ignition system are the flywheel, stator, trigger, capacitor dis-
charge modules (CDM’s) and spark plugs. Each capacitor discharge module functions as
a combination switchbox and secondary ignition coil.
CAPACITOR CHARGING #1 CDM
The STATOR assembly is mounted to the block below the flywheel and has 3 CAPACITOR
CHARGING COILS wound in series. The FLYWHEEL is fitted with 6 permanent magnets
inside the outer rim. The flywheel rotates the permanent magnets past the capacitor charg-
ing coils causing the coils to produce AC voltage (260-320 volts). The AC voltage is then
conducted to the CAPACITOR DISCHARGE MODULES (CDM), where it is rectified (DC)
and stored in a capacitor. The stator voltage return path is through the ground wire of the
other CDM and back through that CDM’s charging coil wire to the capacitor charging coils.

a   b



c
_ 1 
 
+
+

2 _





f  
BLK

YEL
h YEL

BLK
WHT/GRN
PPL
 
d
  
BLK/YEL
g
BLK

 
 
 BLK
GRN/WHT

 WHT

a - Battery charging coils e - CDM #2

b - Trigger coils f - Rev. limiter
c - Capacitor charge coils g - Stop switch
d - CDM #1 h - To voltage regulator

Page 2A-18 90-826148R03 JULY 2003

 IGNITION

CAPACITOR CHARGING #2 CDM

The flywheel rotates the permanent magnets past the capacitor charging coils-causing the
coils to produce AC voltage (260-320 volts). The opposite voltage pulse is then conducted
to the CAPACITOR DISCHARGE MODULES (CDM), where it is rectified (DC) and stored
in a capacitor. The stator voltage return path is through the ground wire of the other CDM
and back through that CDM’s charging coil wire to the capacitor charging coils.

 
b
a 


c
_ 1 
 
+
+

2 _






f BLK 

h YEL
YEL

BLK
WHT/GRN
PPL
 
d
  
BLK/YEL
g
BLK

 
 
BLK
 WHT
GRN/WHT



e

a - Battery charging coils

b - Trigger coils
c - Capacitor charge coils
d - CDM #2
e - CDM #2
f - Rev. limiter
g - Stop switch
h - To voltage regulator

90-826148R03 JULY 2003 Page 2A-19

IGNITION

#1 CYLINDER TRIGGER CIRCUIT

The TRIGGER assembly (also mounted under the flywheel) has one coil for each cylinder.
These coils are mounted adjacent to the flywheel center hub. The center hub of the flywheel
contains a permanent magnet with one north-south transition. As the flywheel rotates, the
magnet north-south transitions pass the trigger coils. This causes the trigger coils to pro-
duce a voltage pulse which is sent to the respective capacitor discharge module (CDM).
A positive voltage pulse (N-S) will activate the electronic switch (SCR) inside the capacitor
discharge module (CDM). The switch discharges the capacitor voltage through the coil pri-
mary windings. The return voltage pulse exits the CDM through the ground wire and returns
through the trigger ground. Once inside the trigger the voltage will supply the bias capacitor
with a negative charge. For the next trigger in sequence to activate its CDM (SCR), the posi-
tive trigger voltage must first over come this offset bias capacitor voltage. The delay pro-
duced by having to over come this offset bias capacitor voltage prevents the timing from
electronically advancing as engine speed increases.

  b

a 
 c


_ 1 
 
+
+

2 _






f 
BLK

YEL
h YEL

BLK
WHT/GRN
PPL
  d
  
BLK/YEL
g
BLK

 
 
 BLK


 WHT
GRN/WHT

a - Battery charging coils e - CDM #2

b - Trigger coils f - Rev. limiter
c - Capacitor charge coils g - Stop switch
d - CDM #1 h - To voltage regulator

Page 2A-20 90-826148R03 JULY 2003

 IGNITION

IGNITION COIL CIRCUIT

As the capacitor voltage flows through the primary windings of the ignition coil, a voltage is
induced into the ignition coil secondary windings. This secondary voltage rises to the level
required to jump the spark plug gap and returns to ground. This secondary voltage can, if
necessary, reach approximately 40,000 volts. To complete the secondary voltage path, the
released voltage enters the ground circuit of the CDM module.

 
b
a 


c
_ 1 
 
+
+

2 _





 
f
BLK

h YEL
YEL

BLK
WHT/GRN
PPL
   d

  
BLK/YEL g
BLK

 


 BLK
GRN/WHT
 WHT

a - Battery charging coils

b - Trigger coils
c - Capacitor charge coils
d - CDM #1
e - CDM #2
f - Rev. limiter
g - Stop switch
h - To voltage regulator

90-826148R03 JULY 2003 Page 2A-21

IGNITION

STOP CIRCUIT
To stop the engine, the stop switch is closed allowing the capacitor charge current from the
stator to drain directly to ground.
NOTE: The CDM contains a zener diode (not shown for clarity). This diode prevents
overcharging of the capacitor (and possible failure) if the SCR does not receive a trig-
ger pulse.

 
a b


 c
_ 1 
 
+
+

2 _





 
f
BLK

YEL
h YEL

BLK
WHT/GRN
PPL
  d

BLK/YEL
g
BLK

 
 
 BLK
GRN/WHT

 WHT

a - Battery charging coils

b - Trigger coils
c - Capacitor charge coils
d - CDM #1
e - CDM #2
f - Rev. limiter
g - Stop switch
h - To voltage regulator

Page 2A-22 90-826148R03 JULY 2003

 IGNITION

To bypass a CDM with a failed stator voltage return path, install the DVA adaptor harness
(to allow easy access to the wire connectors) and using the test jumper P/N 91-818812A1
(or equivalent) connect the stator charge wire to the CDM ground lead. This will allow the
remaining CDM to function correctly.
NOTE: This test will work on 3 and 4 cylinder engines; however, the number of CDM’s (cylin-
ders) that function correctly will vary.
NOTE: It is possible to ground one of the stator leads to ground (bypassing the CDM and
harness). Do not damage the wire connector by clamping the connector to ground with a
bolt.

 

b
a 



_ 1  c
 
+
+

2 _






e 
BLK

g YEL
YEL

BLK
WHT/GRN
PPL
  d
  
BLK/YEL
f
BLK

 
 
 BLK
GRN/WHT

 WHT

i
a - Battery charging coils f - Stop switch
b - Trigger coils g - To voltage regulator
c - Capacitor charge coils h - DVA Adaptor Harness
d - CDM #1 84-825207A2
e - Rev. limiter i - Test Jumper 91-818812A1

90-826148R03 JULY 2003 Page 2A-23

IGNITION

Ignition Test Procedures

DIRECT VOLTAGE ADAPTER (DVA) TEST FOR STATOR

WARNING
DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components
and/or metal test probes while engine is running and/or being cranked. STAY
CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark
plug lead should be grounded to engine.

WARNING
When testing or servicing the ignition system, high voltage is present. DO NOT
TOUCH OR DISCONNECT any ignition parts while engine is running, while key
switch is on or while battery cables are connected.

CAUTION
Failure to comply with the following items may result in damage to the ignition sys-
tem.
Do not reverse battery connections. The battery NEGATIVE (–) cable is ground.
Do not spark battery terminals with battery cable connections to check polarity.
Do not disconnect battery cables while engine is running.
Do not crank engine when CDMs or TPM are not grounded to engine.

CAUTION
To protect against meter and/or component damage, observe the following precau-
tions: 400 VDC* test position (or higher) MUST BE used for all tests.

INSURE the POSITIVE (+) lead/terminal of DVA is connected to the POSITIVE (+) re-
ceptacle of meter.

DO NOT CHANGE meter selector switch position while engine is running and/or be-
ing cranked.

ALL COMPONENTS MUST BE GROUNDED during tests. Running or cranking en-

gine with TPM or CDM ungrounded may damage components.
NOTE: *If using a meter with a built-in DVA, the DVA/400 VDC (or higher) test position
should be used.
NOTE: Test leads are not supplied with the DVA. Use test leads supplied with meter.

Page 2A-24 90-826148R03 JULY 2003

 IGNITION

Test procedures and specifications are provided for checking primary ignition voltage
while the engine is running and/or being cranked with all harnesses connected.
1. Install test harness between ignition harness and CDM as shown.

a - Stator/trigger harness
b - Test Harness (84-825207A1)
c - Capacitor discharge module (822779)

a b c

a - Stator/trigger harness
b - Test Harness (84-825207A2)
c - Capacitor discharge module (827509)
Voltage Reading*
Selector Switch
TEST RED Lead BLACK Lead @ (300 - 4000)
Position
RPM
RED Test Harness
Stator 400 DVA Ground 190 - 320
(GREEN/WHITE)
Stator 400 DVA GREEN or WHITE/GREEN Ground 190 - 320

NOTE: * If voltage is low, disconnect one Capacitor Discharge Module (CDM) connector at
a time while monitoring voltage reading.
NOTE: If voltage rises, replace that CDM. If voltage does not rise, replace stator.

90-826148R03 JULY 2003 Page 2A-25

IGNITION

Ignition Diagnostic Procedures

TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark
advance of each cylinder as throttle is opened and closed. If timing advances and retards
smoothly on each cylinder, ignition system is MOST LIKELY functioning properly.
IMPORTANT: If outboard appears to have an ignition system failure, it is recom-
mended that before beginning in-depth troubleshooting:
a. Check ground leads on Timing Protection Module, Capacitor Discharge Modules
and ground lead between ignition plate and engine block for proper continuity.
b. Disconnect and reconnect ignition harness connectors to verify proper continuity.

PROBLEM CORRECTION
1. No spark or weak spark on both cylinders No spark - Trigger, Stator or Timing Protection
Module (TPM)
Weak spark - stator
2. No spark or weak spark on 1 cylinder Capacitor discharge module (CDM)
3. Timing fluctuates - Note: It is normal for timing to Defective engine temperature sensor
fluctuate 2°-3° @ Idle. Defective TPM
- If engine over-heats [above
88° C (190° F)], TPM will limit
engine RPM to 2500.
- If engine RPM exceeds 5800,
TPM will retard timing from 25
BTDC to 14° BTDC.
- If RPM exceeds 6500 RPM,
TPM will momentarily shut
ignition off until RPM drops
below 6500.
- If engine RPM drops below
600, idle stabilizer in TPM will
advance timing to as high as
10° BTDC @ cranking speed
of 300 RPM.
4. Timing will not advance on both cylinders Defective TPM
5. Timing will not advance on 1 cylinder Check wiring between CDM and TPM. If wiring is
OK, replace CDM.
6. Engine misfires @ high RPM Defective CDM
Defective TPM
7. Engine hard to start when cold Defective fuel enrichment valve
Defective TPM
8. Engine misfires @ low RPM but runs smooth Defective harness (loose connections) between
@ high RPM TPM and CDM
Defective CDM
Defective TPM
Defective Stator
9. Engine starts hard when hot Defective TPM
10. Engine will not run over 2500 RPM and is not Defective temperature sensor
over-heating. Defective TPM
11. Engine occasionally misfires Replace standard spark plug with inductor plug

Page 2A-26 90-826148R03 JULY 2003

 IGNITION

Testing Ignition Components

Resistance Tests
TIMING PROTECTION MODULE
Normally, if timing advances and retards with corresponding changes in RPM, most likely
the TPM is functioning correctly. Refer to Ignition Diagnostic Procedures preceding, for
individual failure scenarios.

STATOR
A resistance check can be made on charge coils. Ohmmeter should indicate as follows:
BLACK Stator – between GREEN/WHITE and GREEN leads (525-625 ohms)
RED Stator – between GREEN/WHITE and WHITE/GREEN leads (660-710 ohms).

TRIGGER 1997 AND PRIOR

(USA S/N-0G589999 & BELOW/BEL S/N 09973099 AND BELOW)
A resistance check can be made on trigger coil between WHITE/BLACK and WHITE leads.
Ohmmeter should indicate between 1100 - 1300 ohms.

90-826148R03 JULY 2003 Page 2A-27

IGNITION

TRIGGER 1998 AND NEWER

(USA S/N-0G590000 & ABOVE/BEL S/N 09973100 AND ABOVE)

55767
A resistance test is not used on the trigger. Test trigger as outlined under Trigger Output
Test.

Trigger Output Test 20 DVA Scale

POSITIVE Meter Lead (+) NEGATIVE Meter Lead (–) DVA Reading
WHITE Test Harness Lead BLACK Test Harness Lead 2 - 8 Volts

If reading is below specifications replace trigger. If reading is above specifications check

CDM.
NOTE: If voltage remains low after installing a new trigger, replace CDM.
CAPACITOR DISCHARGE MODULE (822779)

a - Test Harness 84-825207A1

b - Capacitor discharge module 822779

Page 2A-28 90-826148R03 JULY 2003

 IGNITION

A resistance check can be made of the CDM as follows:

CAPACITOR DISCHARGE MODULE RESISTANCE CHECK-ANALOG METER

Connect POSITIVE (+) Connect NEGATIVE (–) Ohms
Reading
Meter Lead To: Meter Lead To: Scale
WHITE Pin or WHITE
Ground Lead RX1 40  10
Test Harness Lead
GREEN/WHITE Pin or Ground Lead RX1
Continuity
RED Test Harness Lead Diode Reading
GREEN/WHITE Pin or R X 1K
Ground Lead No Continuity
RED Test Harness Lead Diode Reading
BLACK/YELLOW Pin or
GREEN/WHITE Pin or R X 1K
BLACK Test Harness No Continuity
RED Test Harness Lead Diode Reading
Lead
BLACK/YELLOW Pin or GREEN/WHITE Pin or
RX1
BLACK Test Harness RED Test Harness Lead Continuity
Diode Reading
Lead
Coil Tower Ground Lead R X 10 1000  300

NOTE: Due to the differences in test meters battery polarity, results other than specified may
be obtained. In such a case, reverse meter leads and re-test. If test results then read as spe-
cified on all tests CDM is O.K.. The diode measurements above will be opposite if using a
Fluke
equivalent multimeter.

CAPACITOR DISCHARGE MODULE RESISTANCE CHECK-DIGITAL METER

Connect POSITIVE (+) Connect NEGATIVE (–) Ohms
Reading
Meter Lead To: Meter Lead To: Scale
WHITE Pin or WHITE
Ground Lead Ω or 200 40  10 Ohms
Test Harness Lead
GREEN/WHITE Pin or Ground Lead
OL or OUCH
RED Test Harness Lead
GREEN/WHITE Pin or
Ground Lead 0.400 - 0.900
RED Test Harness Lead
BLACK/YELLOW Pin or
GREEN/WHITE Pin or
BLACK Test Harness 0.400 - 0.900
RED Test Harness Lead
Lead
BLACK/YELLOW Pin or GREEN/WHITE Pin or
BLACK Test Harness RED Test Harness Lead OL or OUCH or 1.
Lead
Coil Tower Ground Lead Ω or 2K 0.800 - 1.200 KΩ

NOTE: Due to the differences in test meters battery polarity, results other than specified may
be obtained. In such a case, reverse meter leads and re-test. If test results then read as spe-
cified on all tests CDM is O.K.. The diode measurements above will be as specified if using
a Fluke
equivalent multimeter.

90-826148R03 JULY 2003 Page 2A-29

IGNITION

CAPACITOR DISCHARGE MODULE (827509) OHMS TEST

d
e

a
A BC D

b
c

a - Spark plug wire IMPORTANT: spark plug wires are screwed into CDM.
b - Part Number: 827509
c - Pins are labeled: A : BLACK - Ground
B : BLACK/YELLOW - Stop Circuit
C : WHITE - Trigger
D : GREEN - Stator
d - Capacitor discharge module 827509
e - Test Harness 84-825207A2

A resistance check, although not necessary for any troubleshooting procedure, can be
made on the CDM as follows:
NOTE: This test can be performed using the test harness (84-825207A2). Do not connect
the test harness plug to the stator/trigger engine wire harness.

CAPACITOR DISCHARGE MODULE RESISTANCE CHECK - ANALOG METER

Connect POSITIVE (+) Connect NEGATIVE (–) Ohms
Results:
Meter Lead To: Meter Lead To: Scale
Ground Pin (A) or BLACK WHITE (C) or WHITE Test
R x 100 1250  300 Ohms
Test Harness Lead Harness Lead
GREEN (D) or GREEN Test Ground Pin (A) or BLACK R x 100
Continuity
Harness Lead Test Harness Lead Diode Reading
Ground Pin (A) or BLACK GREEN (D) or GREEN Test R x 100
No Continuity
Test Harness Lead Harness Lead Diode Reading
GREEN (D) or GREEN Test BLACK/YELLOW (B) or
R x 100
Harness Lead BLACK/YELLOW Test Har- No Continuity
Diode Reading
ness Lead
BLACK/YELLOW (B) or GREEN (D) or GREEN Test
R x 100
BLACK/YELLOW Test Har- Harness Lead Continuity
Diode Reading
ness Lead
Spark Plug Terminal Ground Pin (A) or BLACK
R x 100 1000  300 Ohms
(at spark plug boot) Test Harness Lead

NOTE: Due to the differences in test meters battery polarity, results other than specified may
be obtained. In such a case, reverse meter leads and re-test. If test results then read as spe-
cified on all tests CDM is O.K.. The diode measurements above will be opposite if using a
Fluke equivalent multimeter.

Page 2A-30 90-826148R03 JULY 2003

 IGNITION

CAPACITOR DISCHARGE MODULE RESISTANCE CHECK - DIGITAL METER

Connect Positive (+) Connect Negative (–) Ohms
Results:
Meter Lead To: Meter Lead To: Scale
Ground Pin (A) or BLACK WHITE (C) or WHITE Test
Ω or 2K 1.125-1.375 KΩ
Test Harness Lead Harness Lead
GREEN (D) or GREEN Test Ground Pin (A) or BLACK
OL or OUCH
Harness Lead Test Harness Lead
Ground Pin (A) or BLACK GREEN (D) or GREEN Test
0.400 - 0.900
Test Harness Lead Harness Lead
GREEN (D) or GREEN Test BLACK/YELLOW (B) or
Harness Lead BLACK/YELLOW Test Har- 0.400 - 0.900
ness Lead
BLACK/YELLOW (B) or GREEN (D) or GREEN Test
BLACK/YELLOW Test Har- Harness Lead OL or OUCH
ness Lead
Spark Plug Terminal Ground Pin (A) or BLACK
Ω or 2K 0.950 - 1.150 KΩ
(at spark plug boot) Test Harness Lead

NOTE: Due to the differences in test meters battery polarity, results other than specified may
be obtained. In such a case, reverse meter leads and re-test. If test results then read as spe-
cified on all tests CDM is O.K. The diode measurements above will be as specified if using
a Fluke equivalent multimeter.

Flywheel Removal and Installation

REMOVAL
1. Remove flywheel nuts and washers.
2. Remove flywheel cover.

a a

a a

55120
a - Nuts and washers

90-826148R03 JULY 2003 Page 2A-31

IGNITION

WARNING
Engine could possibly start when turning flywheel during removal and installation;
therefore, disconnect (and isolate) spark plug leads from spark plugs to prevent en-
gine from starting.
3. Disconnect spark plug leads from spark plugs.
4. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer.

55121
a
a - Flywheel Holder (91-52344)

NOTE: Neither heat, prybar or hammer should be used on flywheel to aid in removal as
damage to flywheel or electrical components under flywheel may result.
5. Install Crankshaft Protector Cap (91-24161) on the end of crankshaft, then install Fly-
wheel Puller (91-73687A1) into flywheel.
6. Remove flywheel.

a
91-24161
b

55122
a - Flywheel Puller (91-73687A1)
b - Flywheel

Page 2A-32 90-826148R03 JULY 2003

 IGNITION

INSTALLATION
IMPORTANT: Do not apply oil to crankshaft taper or flywheel taper as flywheel will not
seat properly against crankshaft when torqued.
NOTE: Inspect flywheel magnets for clinging debris before installing flywheel. Failure to re-
move debris from magnets may result in damage to electrical components under flywheel
when outboard is initially started.
1. Clean flywheel taper and crankshaft taper with solvent and assemble dry.
2. Install crankshaft key and flywheel.
3. Using Flywheel Holder (91-52344), torque flywheel nut to 129 Nm (95 lb.ft).

90-826148R03 JULY 2003 Page 2A-33