2003 9.9 4Stroke Elec Start Tiller - Coil and Ignition Question

[Consigliere]

Have no spark on this motor. Very strongly believe no issues with kill switch or neutral switch. (Pulled kill wire from CDI and will not spark, measured right continuity on neutral switch in various positions). Checked resistance on both pulse and pickup(?forget name) coils and they are in spec according to service manual. Ignition coil measures 0.6Ohm on primary side, with 2 specs in the manual. 0.2-0.4ohm and 0.08-0.11 ohm are the quoted value for the primary coil and again the reading is 0.6ohm. There is also a plug cap that measures out of spec for resistance, 20ohm instead of 8-12ohm.

Is the 0.2 to 0.5 ohm out of spec seem significant for the primary coil? Do not have a direct voltage measurement to test the CDI..so cannot rule out CDI but most evidence says coil and cap replacement. No spark at all on either plug.

Looked grounds over etc and nothing obvious there.

Any help or thoughts? Have no spare parts to swap in and out to test either...

 

[schematic]

your resistance measurements sound fine. Don't forget, the meter leads usually have .2 ohm resistance which skew low resistance readings....
You best be doing voltage readings on the stator and timer coil. Resistance is not a definite test...
If the voltage readings are fine.....suspect the pack

 

[Consigliere]

Thanks for the help on the resistance readings. Have ordered the gear to make a DVA adapter for the multimeter to measure the voltages of all the relevant components and do the full diagnostics.

 

[Consigliere]

So some more follow up because I think I need some more help here. This issue troubleshooting has not gone well. Still no spark...here's what I've done.

I bought a timing coil since it was highest chance of failure, and replaced and no change.

Built a DVA adapter based off an online circuit diagram so I could read all the pulse voltages. The timing coil reads about 5-6V and in spec according to the manual.

The battery charge coil outputs about 6V as well, also within spec according to the manual

This is the DVA I built

https://www.google.ca/search?q=dva+...hUKs4MKHcVaA3gQ_AUIBigB#imgrc=RCueyTKBv_tWmM:

The primary magneto coil reads about 16V. This was well out of spec according to the manual - should be above 144V. So bought a new one and replaced it and have the exact same reading (so that is an issue) but still no spark. Assuming now that I have a measurement issue and not an actual magneto coil problem. Any other way could be seeing low voltage off that with a DVA adapter?

Out of all the parts - the only thing left to replace is the CDI and ignition coil. The ignition coil resistance readings are in spec. So that leaves CDI....is there anything that can be tested to confirm this and that I haven't missed something fundamental? Don't love having to spend $300 on a $1000 engine.

I have tried with disconnected kill switch from CDI (Blue/Red wire) to ensure this is not the issue.

Any help...seeming like over my head on this.