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2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
2b electrical and ignition
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2b electrical and ignition

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'95, '96, '97 Sport Jet Models 90 and 120

'95, '96, '97 Sport Jet Models 90 and 120

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  • 1. ELECTRICAL ANDIGNITION 2 BCDM IGNITION90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-–1
  • 2. Table Of Contents Page PageSpecial Tools Required . . . . . . . . . . . . . . . . . . . 2B-1 Removing Flywheel . . . . . . . . . . . . . . . . . . . . . . 2B-8General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Installing Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 2B-9Principles of Operation . . . . . . . . . . . . . . . . . . . . 2B-1 Removing Stator . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Installing Stator . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Testing For Spark . . . . . . . . . . . . . . . . . . . . . 2B-2 Removing Trigger . . . . . . . . . . . . . . . . . . . . . . . . 2B-9Ignition Diagnostic Procedures . . . . . . . . . . . . . 2B-3 Installing Trigger . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Testing Voltage Output to CDM . . . . . . . . . 2B-3 Removing CDM . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Testing Stator Resistance - 95/120 HP . . . 2B-5 Installing CDM . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Trigger - 95/120 . . . . . . . . . . . . . . . . . . . 2B-5 Wiring Diagram 95 HP . . . . . . . . . . . . . . . . . . . 2B-12 Capacitor discharge Module . . . . . . . . 2B-6 Wiring Diagram 120 HP . . . . . . . . . . . . . . . . . . 2B-13Ignition Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 2B-72B-0 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996
  • 3. Special Tools Required Principles of OperationMultimeter/ DVA Tester 91-99750 Capacitor Discharge Module (CDM) Ignition System The ignition system is alternator driven with distribu- torless capacitor discharge. Major components of the ignition system are the flywheel, stator, trigger, capac- itor discharge module, and spark plugs. The stator assembly is mounted stationary below the flywheel and has one capacitor charging coil.Spark Tester 91-850439 The flywheel is fitted with permanent magnets inside the outer rim. As the flywheel rotates the permanent magnets pass the capacitor charging coil. This causes the capacitor charging coils to produce AC voltage. The AC voltage is conducted to the CDM (Capacitor Discharge Module) where it is rectified and stored in a capacitor. The trigger assembly (also mounted under the fly- wheel) has one coil for each cylinder. The flywheel has a second set of permanent magnets located 55117 around the center hub. As the flywheel rotates the second set of magnets pass the trigger coils. ThisIgnition Test Harness 84-825207A2 causes the trigger coils, in turn, to produce an AC volt- age that is conducted to an electronic switch (SCR) in the CDM. The SCR switch discharges the capacitor voltage into the primary side of the ignition coil. The ignition coil multiplies this voltage to a value high enough to jump the gap at the spark plug. The preceding sequence occurs once per engine rev- olution for each cylinder. Spark timing is changed (advanced/retarded) by ro-General tating the trigger assembly which changes each trig- ger coil position in relation to the permanent magnetsThe ignition system is self-energizing (creates it’s on the flywheel hub.own power for ignition) and has proven reliability.Should testing be required it is important to check all Test Procedurescomponents in the order outlined.IMPORTANT: Read the entire procedure before at-tempting to test components. CAUTION Failure to comply with the following items mayThe procedures in this section are designed to test result in damage to the ignition system.the complete ignition system. In an actual situation,test only the components that control the misfiring cyl- S DO NOT reverse battery cable connections. Theinder(s). battery negative cable is (–) ground. DO NOT “spark” battery terminals with battery cable con- nections to check polarity. WARNINGWhen testing or servicing the ignition system S DO NOT disconnect battery cables while enginehigh voltage is present; be extremely cautious! is running.DO NOT TOUCH OR DISCONNECT any ignition Before troubleshooting the ignition system:components while engine is cranking or running.90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-1
  • 4. S Check that plug-in connectors are fully engaged No spark Go to next step. and free of corrosion (trigger connectors are lo- No spark on 1 or 2 cylin- Go to Ignition Diagnos- cated behind the ignition plate). ders tic Procedures.S Check that electrical components are grounded 8. Disconnect all CDM plugs and verify that each to the ignition plate and that ignition plate is ground lead has continuity to engine ground. grounded to the engine block.S Check for disconnected wires, short and open circuits. aTesting For Spark1. Adjust spark tester to a 7/16” gap setting. a - Each CDM ground wire is labeled “A”. 7/16 in. 9. Re-connect all CDMs.2. Secure spark tester to a good engine ground.3. Remove leads from spark plugs.4. Connect spark plug leads to corresponding spark tester leads.5. Remove spark plugs.6. Turn the ignition key to the “on” position.7. Crank motor.NOTE: Battery voltage must be a minimum of 10 voltsat the starter solenoid to adequately crank the en-gine. Results: Action Required:Spark jumps 7/16” gap Ignition system opera-(all cylinders) tional - If required, check timing & setup.2B-2 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996
  • 5. 10. Check that safety stop switch lanyard is in place. 120 HP If safety lanyard is NOT in place, spark plugs will IMPORTANT: The voltage return path for #1 and #2 not fire. CDM is through either #3 or #4 CDM. The return11. Sport Jet Models Only: Isolate the rev limiter by path for #3 and #4 is through either #1 or #2 CDM. disconnecting the black/yellow lead to the rev lim- iter. Tape back the black/yellow lead. Re-test for spark. If all cylinders spark, replace rev limiter. No spark: continue with next step.12. Isolate the stop circuit by disconnecting black/ yellow bullet connector located on the ignition plate wire bundle.IMPORTANT: Be sure this lead is not grounded.13. Crank motor. #1 #2 Results: Action Required: All cylinders spark nor- Repair stop circuit: igni- mally tion key switch and/or boat wiring. #4 #3 No spark (all cylinders) Go to Ignition Diagnos- tic Procedures.14. Re-connect rev limiter and/or stop circuit.95 HP Ignition DiagnosticIMPORTANT: The voltage return path for #1 CDM is Proceduresthrough either #2 or #3 CDM. The return path for #2 PROBLEM CORRECTIONand #3 is through #1 CDM. If the #1 CDM is discon-nected the engine will loose fire on all cylinders as 1. No spark on one cylin- 1. Plug in a CDM that isthe capacitors cannot be charged. der known to be good. If spark returns, replace bad CDM. 2. No change: go to Test- ing Voltage Output to CDM. 3. No spark on all cylin- Go to Testing Voltage ders Output - Test all CDMs. Testing Voltage Output to CDM #1 CAUTION To protect against meter and/or component dam- age, observe the following precautions: #3 #2 S INSURE that the Positive (+) meter lead is con- nected to the DVA receptacle on the meter. S DO NOT CHANGE meter selector switch position while engine is running and/or being “cranked”.NOTE: Each CDM is grounded through the engine wir-ing harness via the connector plug. It is not necessary NOTE: Each CDM is grounded through the engine wir-to have the CDM mounted on the ignition plate for test- ing harness via the connector plug. It is not necessarying. to have the CDM mounted on the ignition plate for test- ing.90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-3
  • 6. 1. Make sure all CDMs are plugged in. Trigger Output Test 2 DVA Scale2. Test Stator and Trigger voltage to CDM: Positive Meter Negative DVA a. Install test harness between Ignition Harness Lead (+) Meter Lead (–) Reading and CDM. White Test Har- Black Test Har- c ness Lead ness Lead 0.2 - 2.0 a b If reading is below specifications replace trigger. If read- ing is above specifications check CDM. NOTE: If voltage remains low after installing a new trig- ger, replaced CDM.a - Stator/Trigger Harnessb - Test Harnessc - Capacitor Discharge Module http://motorka.org b. Perform the following tests: BLK WHTCRANKING ENGINE:Test each CDM. Stator Output Test 400 DVA Scale Positive Meter Negative DVA Lead (+) Meter Lead (–) Reading Connect to Connect to Green Test Black Test Har- 100 - 350 Harness Lead ness Lead ENGINE RUNNING AT IDLE:If only one CDM stator reading is below specifications,replace that CDM. If all CDM stator voltage readings It is not necessary to perform this test if the voltage out-are low, go to Testing Stator Resistance. put was tested in the previous step CRANKING EN- GINE. Stator Output Test 400 DVA Scale Positive Meter Negative DVA Lead (+) Meter Lead (–) Reading Connect to Connect to Green Test Black Test Har- 200 - 350 Harness Lead ness Lead BLK GRN If stator output is low, go to Testing Stator Resistance. Trigger Output Test 20 DVA Scale Positive Meter Negative DVA Lead (+) Meter Lead (–) Reading White Test Har- Black Test Har- ness Lead ness Lead 2 - 8 Volts If reading is below specifications replace trigger. If read- ing is above specifications check CDM. NOTE: If voltage remains low after installing a new trig-Test each CDM. ger, replaced CDM.2B-4 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996
  • 7. Testing Stator Resistance - 95/120 HPDisconnect stator leads. Stator Resistance Test R x 10 Ohms Positive Meter Negative Scale Lead (+) Meter Lead (–) Connect to Connect to White/Green Green/White 500 - 600 stator lead stator lead ± 10% Connect to Connect to en- White/Green gine ground No continuity stator lead Connect to Connect to en- Green/White gine ground No continuity stator leadIMPORTANT: If all CDM stator output voltage is lowand stator resistance tests are within specifica-tions, then each CDM (one at a time) must be re-placed with a CDM known to be good until statoroutput voltage returns to proper levels. This pro-cess of elimination will reveal a defective CDM. RX10TRIGGER - 95/120A resistance test is not used on the trigger. Test triggeras outlined under “Testing Voltage Output to CDM”.90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-5
  • 8. CAPACITOR DISCHARGE MODULE A B C D A - Ground IMPORTANT: Spark plug wires are B - Black/Yellow screwed into CDM. C - Trigger Connection D - Stator ConnectionA resistance check, although not necessary for any troubleshooting procedure, can be made of the CDM as fol-lows:NOTE: This test can be performed using the test harness (p/n 84-825207A2). Do Not connect the test harnessplug to the stator/trigger engine wire harness. CAPACITOR DISCHARGE MODULE 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 " 100 Ohms test harness lead harness lead Green (D)/ or Green test Ground Pin (A)/ or Black Rx1 Continuity harness lead test harness lead Diode Reading* Ground Pin (A) or Black Green (D)/ or Green test Rx1 No Continuity test harness lead harness lead Diode Reading* Green (D)/ or Green test Black/Yellow (B)/ or Black/ Rx1 No Continuity harness lead Yellow test harness lead Diode Reading* Black/Yellow (B)/ or Black/ Green (D)/ or Green test Rx1 Continuity Yellow test harness lead harness lead Diode Reading* Spark Plug Terminal Ground Pin (A) or Black R x 10 1050 " 150 Ohms (At Spark Plug Boot) test harness lead*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such acase, reverse meter leads and re-test. If test results then read as specified CDM is O.K.. The diode measurementsabove will be opposite if using a Fluke equivalent multimeter.2B-6 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996
  • 9. Ignition Components Removal and Installation WARNING 1Engine could possibly start when turning flywheelduring removal and installation; therefore, dis-connect (and isolate) spark plug leads from spark 2 aplugs to prevent engine from starting. 3 4 1 - Cap, Plastic 2 - Flywheel Nut 3 - Washer 4 - Flywheel 5 - Stator 6 - Trigger 7 - Screw b 7 5 B 6 Quicksilver Lubrication/Sealant Torque Specifications Application Points a 125 lb. ft. (170 N·m) B Loctite “271” (92-823089--1) b 50 lb. in. (5.6 N·m)90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-7
  • 10. Ignition Components Removal and Installation(4 - Cylinder Shown) 1 - CDM (Capacitor Discharge Module) 2 - Voltage Regulator 3 - 20 Ampere Fuse 4 - CDM Wire Harness 5 - Engine Wire Harness 6 - Ignition Plate 7 - Rev Limiter 6 4 1 5 2 7 32B-8 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996
  • 11. S Hold flywheel tool with wrench while tightening boltRemoving Flywheel down on protector cap. Tighten bolt until flywheel comes free. WARNINGAlways disconnect battery and remove sparkplug leads from spark plugs before working on amotor.1. Remove flywheel guard.2. While holding flywheel with Flywheel Holder (91-52344), remove flywheel nut and washer. 51124 a - Flywheel Puller (91-73687A1) NOTE: Neither heat nor hammer should be used on flywheel to aid in removal as damage to flywheel or electrical components under flywheel may result. S Remove flywheel. Remove flywheel key. a CAUTIONCrankshaft damage may result if a protector capis not used between crankshaft and puller.S Install a crankshaft Protector Cap (91-24161) on end of crankshaft, then install Flywheel Puller a - Flywheel Key (91-73687A1) into flywheel. 3. Inspect flywheel. S Carefully inspect flywheel for cracks or damage. a WARNING A cracked or chipped flywheel must be replaced. At high RPM a damaged flywheel may fly apart and throw metal over a large area. b S Inspect crankshaft and flywheel tapers for worn or damaged key ways. S Check for loose or damaged flywheel magnets (outer rim and center hub).a - Flywheel Puller Arc burns on magnets are normal.b - Protector Cap (Included in Flywheel Tool 91-73687A1) S Replace flywheel if necessary.90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-9
  • 12. 4. Remove screws and lift stator off bearing cage.Installing Flywheel1. Clean tapered surfaces of flywheel and crank- shaft with solvent. aS Blow dry tapered surfaces with compressed air.If the flywheel key appears damaged in any way re-place it.2. Install flywheel key in crankshaft slot with outer a edge of key parallel to center line of crankshaft. a - Stator Screws a Installing Stator 1. Set stator on bearing cage. Secure with screws. IMPORTANT: Be sure the stator is positioned so the wire harness is on the port side of the motor. 2. Connect yellow stator leads to yellow voltagea - Flywheel Key regulator leads.3. Install flywheel. 3. Connect all stator leads to corresponding CDMS Place flywheel down over crankshaft. wire harness.S Install flywheel nut. 4. Install flywheel.S Torque flywheel nut to 125 lb. ft. (169.5 N·m). Removing Trigger 1. Remove flywheel. SEE “REMOVING FLYWHEEL” IN THIS SECTION. 2. Remove stator. SEE “REMOVING STATOR” IN THIS SECTION. 3. Disconnect trigger leads from CDM wire harness. 4. Disconnect spark control link from tower shaft.Removing Stator1. Remove flywheel.SEE “REMOVING FLYWHEEL” IN THIS SECTION.2. Remove yellow stator leads from rectifier/regula- tor leads.3. Disconnect all stator leads from CDM wire har- ness.Removal of ignition plate may be necessary to gainaccess to stator leads.2B-10 ELECTRICAL AND IGNITION 90-831996R1 JUNE 1996
  • 13. 5. Lift trigger off bearing cage. 5. Route lead wires under ignition plate and down to the CDM wire harness. a 6. Connect corresponding trigger leads to CDM wire harness. 7. Install stator. SEE INSTALLING STATOR IN THIS SECTION. b 8. Install flywheel. SEE INSTALLING FLYWHEEL IN THIS SECTION. 9. Check engine timing. SEE ENGINE TIMING IN THIS SECTION.a - Trigger Removing CDM (Capacitorb - Spark Control Link Discharge Module)Installing Trigger WARNING1. Install spark control link on new trigger. Always disconnect battery and disconnect spark plug leads from spark plugs before working on motor. aa - Spark Control Link 1. Disconnect CDM wire harness plug.2. Lubricate outer ring of trigger with grease. 2. Remove screws securing CDM to ignition plate.3. Place trigger on bearing cage.4. Secure spark control link to towershaft. Installing CDM 1. Position CDM on ignition plate. Install screws. 2. Connect CDM wire harness plug to CDM. aa - Towershaft90-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-11
  • 14. Wiring Diagram 95 HP2B-12 a b PUR BLK WHT/GRN BLK/YEL c e GRN/WHT WHT/GRN YEL YEL d PUR WHT BRN BLK YEL YEL WHT/GRN GRN/WHT GRN/WHT WHT #1 BLK GRN/WHT BLK/YEL PUR WHT BRNELECTRICAL AND IGNITION YEL YEL g YEL YEL f BLK/YEL BLK/YEL BLK/YEL BRN BLK/YEL BRN RED GRY BRN #2 BLK GRN/WHT BRN BLK/YEL BLK BLK RED RED/PUR BRN GRY BLK/YEL BLK/YEL RED BLK BLK PUR YEL YEL l TAN/GRN BLK YEL/RED #3 i h PUR j RED RED TAN/LT.BLU BLK k GRY90-831996R1 JUNE 1996 6 5 7 YEL/RED 4 8 RED/PUR 3 1 BLK/YEL 2 PUR TAN/LT.BLU a - Flywheel h - Rev. Limiter b - Stator i - Voltage Regulator c - Trigger j - Turn Key Start Valve d - 20 Ampere Fuse k - Engine Wire Harness Connector e - Starter Motor l - CDM (Capacitor Discharge Module) f - Starter Solenoid g - Cylinder Head Temperature Sender
  • 15. Wiring Diagram 120 HP TAN/GRN TAN/LT.BLU l - CDM (Capacitor Discharge Module) g k - Engine Wire Harness Connector f RED j - Turn Key Start Valve RED i - Voltage Regulator YEL/RED BLK BLK h - Rev. Limiter BLK BLK RED g - Cylinder Head Temperature Sender RED/PUR e BLK BRN BLK/YEL PUR PUR a b d d - 20 Ampere Fuse f - Starter Solenoid h e - Starter Motor c a - Flywheel c - Trigger b - Stator i YEL YEL YEL YEL RED RED BLK/YEL BLK/YEL BLK/YEL BLK/YEL BLK/YEL GRY GRY BLU DRK.BLU BLK BRN BRN BRN BRN BRN j WHT WHT PUR PUR YEL YEL YEL YEL YEL YEL WHT/GRN WHT/GRN WHT/GRN GRN/WHT GRN/WHT GRN/WHT TAN/LT.BLU RED/PUR YEL/RED BLK/YEL BLK BLK BLK BLK BLK/YEL BLK/YEL BLK/YEL BLK/YEL BRN DRK.BLU PUR GRY PUR WHT BLK WHT/GRN WHT/GRN GRN/WHT GRN/WHT 5 6 7 3 2 1 4 8 k l #4 #2 #3 #190-831996R1 JUNE 1996 ELECTRICAL AND IGNITION 2B-13

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