Suzuki DF4 No Spark

[Dawg1968]

Outboard: Suzuki DF4 serial 00401F-982196
Problem: no spark

checked the continuity to lanyard switch - all ok. When I press the stop button I get continuity. When the lanyard is disconnected I get continuity, when attached - no continuity. I guess it's not the kill switch them.

Spark tester attached to HT lead (spark plug connector) pull start cord - Nothing. No spark. (The other end if the spark tester is attached to the engine and the gap in the tester is set as small as I can get it)

Thought it was the ignition pack (33410-91J20) - replaced it with a new one (33410-91J30) I was assured this was the correct part even though the numbers are different. Still no spark.

When I pull the start cord with a multimeter between the HT and ground I get .5v ac. This can't be right. Is the new ignition pack wrong? Is it busted?

Any help would be greatly appreciated. I am stuck!

 

[99yam40]

need to find out what feeds the pack.
I do not know much about Suzuki motor's or what feeds their ignition system.

most Yamaha's have a charge coil under the flywheel that feeds voltage to CDI and also pulser coils that tell it when to spark

might look up CDI trouble shooting to see if you can find info on your little motor

 

[Dawg1968]

Thanks for the tips.
The ignition system is a magneto. So there is no Rotor or stator as such.
There are magnets embedded in the flywheel and a U shaped ignition pack (th part I replaced) situated to the side. The pack is stationary, the magnets rotate with the flywheel.
It seems so simple. Just two elements.
Which us why it's so frustrating to have this problem.

 

[lakensea]

Not sure if it matters, but that is the wrong coil. It is for a later model engine that uses a different spark plug. I would start by bringing it back to the dealer and getting the correct unit for your engine.

Did you check the resistance of the plug cap as per the service manual?

 

[99yam40]

best I can tell looking at brownspoint.com is that the part you put in is for a 2011 and newer motor
you motor is a 2009.

not sure what the difference is

 

[Dawg1968]

The plug cap gives 10k ohms which is correct.

I agree that the coil pack is different. I was assured it was just because the previous part was superseded. I will send it back to the dealer.

The way I see it is there are only three things that can be faulty in a magneto system 1. The stop circuit / kill switch - but this tests out ok. 2. The ignition pack 3. The magnets in The flywheel - really unlikely to be faulty. This is why I replaced the ignition pack in the first place. But, I agree, it is STILL the most likely cause of the problem.

Thanks guys for advice. I will have another chat with my dealer.

 

[99yam40]

might check to see if the wiring to switches is grounded somewhere before it gets to the switches
I know you said you tested the switches, but the wiring could kill the spark if it is grounded some where else also