Troubleshooting the Stator
NOTICE: Any sign of leakage out of the high voltage coils or bubbling around the battery charge windings indicate a bad stator. Check for burned marks on each pole. If a problem is found on the battery windings, we recommend the rectifier/regulator be closely checked or replaced.
No spark on any cylinder:
1. Disconnect the stop (kill) wire and retest. If the ignition now has spark, check the stop circuit.
2. Check resistance between the Brown/Yellow and the Brown wires. You should read approximately 450-600 ohms. DVA (peak voltage) should be 150v or more while connected to the power pack for each .
3. Inspect the flywheel outer and trigger magnets to see if they are loose or broken.
4. Disconnect the rectifier and retest. If the fire returns, replace the rectifier.
No spark on One Bank:
1. Swap the power packs from side to side and see if the problem moves. If it does, the power pack not sparking is likely bad.
2. Check the trigger leads and compare the readings for both sides. The readings should be very close.
3. Disconnect the stop wires and separate them. If the pack that had no spark now has spark, replace the pack that initially had spark.
4. Check resistance between the Brown/Yellow and the Brown wires. You should read approximately 450-600 ohms. DVA (peak
voltage) should be 150v or more while connected to the power pack for each.
High speed miss or weak hole shot:
1. Connect DVA meter between the Brown/Yellow and the Brown wires and do a running test on each set. 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.
Overcharging
1. Using a voltmeter, check the voltage on the battery and compare it to the voltage on the red wire connected to the starter solenoid to engine ground.
2. If the voltage is high on the engine compared to the voltage on the battery, do a voltage drop test and try to isolate the area where the problem is.
3. If the voltage is the same on the battery and the engine, but is over 15.5 volts at 4500 RPM, replace the battery with a known good high quality MARINE battery.
4. A continued high voltage reading may indicate the need for a regulator/rectifier combination instead of a rectifier only.