IGNITION

ELECTRICAL
Section 2A - Ignition
Table of Contents
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-8
A
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-8
Ignition Coil Mounting . . . . . . . . . . . . . . . . . . . . 2A-4 Testing Ignition Components . . . . . . . . . . . . . . 2A-9
Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-6 Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-9
Ignition Component Description . . . . . . . . . . . 2A-6 High Tension Lead Removal/Installation . 2A-9
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 High Tension Lead Resistance . . . . . . . . . 2A-10
Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-7 Ignition Coil Removal and Installation . . . . . . 2A-11

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Specifications
Type Capacitor Discharge Ignition
Spark Plug:
Type Champion RA8HC
Gap 0.040 in. (1.0 mm)
Hex Size 5/8 in. (16 mm)
Torque 150 lb-in. (17 Nm)
Hole Size 12 mm
Firing Order 1-3-4-2
Ignition Timing:
@Idle Controlled by ECM
@1500-1800 14° B.T.D.C
@ WOT (6000 rpm) 28° B.T.D.C
Stator Resistance 0.20 - 0.30 Ω (YEL-YEL)
Crank Position Sensor (CPS)
Resistance 300 - 350 Ω (RED - WHT)
Ignition Coil Resistance:
Internal Shielding 0 - 10.0 KΩ (Pin A - Mounting Bracket)
Electronic Spark Trigger (EST) 8.5 - 12KΩ (Pin B - Pin C)
Secondary 3.0 - 7.0 kΩ (Pin A - Coil Tower)
IGNITION High Tension Lead/Boot
SYSTEM Resistance 0.600 - 1.100 KΩ
Readings taken @ ECM Engine Speed Limiter
68°F (20°C). Fuel/Spark Cut-out on Cylinders
#2 and #3 6225 rpm
Fuel/Spark Cut-out on All
Cylinders 6350 rpm
ECM Overheat Speed Control Guardian System is activated. Power
limit will vary with level of overheat.
ECM Low Oil Pressure Speed Control Guardian System is activated. Engine
power is limited to 10% of maximum
(Approximately 2000 RPM)
MAT/ECT Temperature Sensor See Graph Section 3B - EFI
Manifold Absolute Pressure (MAP)
Sensor Resistance See Table Section 3B - EFI
Fuel Injector Resistance 10.0 - 13.5Ω
Main Power Relay 81-99 Ω (Pin 85 - Pin 86)
Idle Air Control (IAC) 24-30 Ω (Between Pins)
Throttle Position Sensor Typical
Range
Output Voltage @Idle 0.39-1.00 Volts
Output Voltage @WOT (6000) 3.66-4.80 Volts

IMPORTANT: Use resistive spark plugs only.

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Special Tools
1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

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IGNITION COIL MOUNTING

25 Liquid Neoprene (92-25711--3)

66 Loctite 242 (92-809821)

1
13

11 16 15
25
17

66
9
3 18 14 8
10

19
4
11 7
6
5

2 6 10

12

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IGNITION COIL MOUNTING

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 COIL PLATE
2 4 IGNITION COIL
3 4 HIGH TENSION CABLE
4 7 SPACER
5 7 NUT 30 3.4
6 3 TRIM RELAY
7 3 BRACKET
8 3 GROMMET
9 3 BUSHING
10 3 SCREW (M6 X 25) 60 6.8
11 2 J CLIP
12 1 TRIM HARNESS
13 3 BUSHING
14 3 GROMMET
15 1 CABLE
16 1 WASHER
17 1 SCREW (M6 X 10) 45 5.1
18 3 SCREW (M6 X 30) 75 8.5
19 3 WASHER

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Ignition Description
When the ignition key switch is turned to the “RUN” position battery voltage is applied to both
the Electronic Control Module (ECM) through the purple wire, and the main power relay
through the red/purple wire. As the ECM receives the “RUN” signal it internally completes
the ground circuit of the main relay for a period of two seconds, energizing the ignition/injec-
tion systems for start-up. As the engine is cranked with the starter motor, the ECM receives
the run signal from the Crank Position Sensor (CPS) and completes the ground circuit to
the main relay for engine operation.
With the main relay closed (completed circuit) D.C. current from the battery/charging system
is transferred through the 20 ampere main relay fuse to the positive terminal of all ignition
coil primary windings. The negative terminals of the ignition coil primaries are connected
to the engine ground through the coils internal driver, which is triggered by the ECM. With
the coil drivers closed, an electric magnetic field is allowed to build up within the ignition coil.
As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel and sup-
plies the trigger signal information to the ECM. The ECM utilizes the CPS information and
determines when to remove the trigger signal from the coil driver of each ignition coil. The
coil driver then opens the coil primary ground circuit which allows it’s magnetic field to rapidly
collapse across the coil secondary winding which induces a high voltage charge (50,000
volts) that fires the spark plug.

Ignition Component Description

Ignition Coils (EST)

The negative terminals of the ignition coil primaries are connected to the engine ground
through the coils internal driver, which is triggered by the ECM. With the coil drivers closed,
an electric magnetic field is allowed to build up within the ignition coil.
As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel and sup-
plies the trigger signal information to the ECM. The ECM utilizes the CPS information and
determines when to remove the trigger signal from the coil driver of each ignition coil. The
coil driver then opens the coil primary ground circuit which allows it’s magnetic field to rapidly
collapse across the coil secondary winding which induces a high voltage charge (50,000
volts) that fires the spark plug.

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Ignition Test Procedures

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.
1. DO NOT reverse battery cable connections. The battery negative cable is (–) ground.
2. DO NOT “spark” battery terminals with battery cable connections to check polarity.
3. DO NOT disconnect battery cables while engine is running.
4. DO NOT crank engine with Ignition Coils/Coil Mounting Plate not grounded.

CAUTION
To protect against meter and/or component damage, observe the following precau-
tions:
IMPORTANT: The metal housing of the ECM is isolation mounted and MUST NOT be
externally grounded. Should the housing become externally grounded, the engine
will not run until the ground is removed and battery cables are momentarily discon-
nected from the battery to re-set the ECM.
• ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking” en-
gine with Ignition Coils/Coil Mounting Plate ungrounded may damage components.

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Ignition Troubleshooting
Refer to Section 3B “Electronic Fuel Injection” - “Troubleshooting and Diagnostics”
for complete system troubleshooting/diagnostics procedures.

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
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. Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder
Compression etc.).
b. Check all engine ground leads for loose or corroded connections.
c. Disconnect and reconnect ignition harness connectors to verify proper continuity.

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Testing Ignition Coil

Resistance Tests
Readings may very slightly due to temperature changes. Readings listed taken at 68° F (20° C).
NOTE: If using DMT 2000 turn the selector switch to
. Allow the meter to auto-range.
ELECTRONIC SPARK TRIGGER (EST) TO EST GROUND

DC BA

b a

a - Red Meter Test Lead

b - Black Meter Test Lead
METER TEST LEADS METER SCALE READING
(ANALOG) (

RED BLACK
PIN B PIN C RX1K 8 5 - 12
8.5 12.0K
0K

NOTE: Ohm readings may not be in range specified because of sensitivity of your multi-me-
ter. Meter should show almost full continuity or near zero resistance condition.

High Tension Lead Removal/Installation

REMOVAL
1. Slightly twist high tension lead while removing.
INSTALLATION
1. Push high tension lead on until it snaps in place.
NOTE: High tension leads must be removed before testing. Leads contain 5k ohm resistor.

a - High Tension Lead

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High Tension Lead Resistance

a

a - Coil End
b - Spark Plug End
METER TEST LEADS METER SCALE READING
(ANALOG) (

RED BLACK
RX100 0 600 - 1.100K
0.600 1 100K
COIL END PLUG END

IGNITION COIL (SECONDARY)

DC BA

b
a

a - Pin A
b - Coil Tower
METER TEST LEADS METER SCALE READING
(ANALOG) (

RED BLACK
COIL TOWER PIN A RX1K 30-7
3.0 7.0
0

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Ignition Coil Removal and Installation

WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark plug
boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors
under the engine cowl. To avoid damaging spark plug boots, do not use any sharp
object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.

1. Disconnect spark plug leads from spark plugs.

2. Disconnect ignition coil harness connectors.
3. Remove ignition coil mounting screws.
4. Reverse steps for installation.

c
d

b
a

a - Spark Plug Lead (4)

b - Ignition Coil Harness Connector (4)
c - Ignition Coil Mounting Nut (7)
d - Ignition Coil (4)

Ignition Coil Mounting Nut Torque

30 lb. in. (3.4 N·m)

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