Electrical. Section 2A - Ignition

Transcription

1 Electricl Ignition Tle of Contents Section 2A - Ignition 2 A Ignition Specifictions...2A-2 Electricl Components...2A-4 Ignition Components...2A-8 Ignition Description...2A-12 Crnk Position Sensor...2A-12 Electronic Control Module (ECM)...2A-12 Ignition Chrge nd Alterntor Coils...2A-12 Ignition Coil...2A-12 Ignition Test Procedures...2A-13 Ignition Trouleshooting...2A-13 Ignition Dignostic Procedures...2A-13 Recommended Tests...2A-13 Testing Ignition Components...2A-15 Flywheel Removl nd Instlltion...2A-17 Flywheel Removl...2A-18 Flywheel Instlltion...2A-19 Ignition Chrge Coil Removl nd Instlltion...2A-20 Non Electric Strt Model...2A-20 Electric Strt Models...2A-21 Timing Belt Removl nd Instlltion...2A-23 Timing Belt Removl...2A-23 Timing Belt Instlltion...2A-24 Crnk Position Sensor Removl nd Instlltion...2A-24 Electric Strt Models...2A-24 Non Electric Strt Models...2A-26 Ignition Coil Removl And Instlltion...2A-27 Ignition Coil Removl...2A-27 Ignition Coil Instlltion...2A R01 JUNE 2005 Pge 2A-1

2 H z OFF IG IP TEMP Ignition Ignition Specifictions Ignition 20 C (68 F) Ignition Type Cpcitor Dischrge Ignition Sprk Plug Type NGK DCPR6E Sprk Plug Gp mm ( in.) Firing Order 1 2 (Lost Sprk) Ignition Idle 0 10 B.T.D.C. Ignition WOT 30 B.T.D.C ECM RPM Limiter RPM Over Speed 6250 RPM Low Oil 3000 RPM Ignition Chrge Coil 295 Ohms ± 20% Crnk Position Sensor 185 Ohms ± 20% Ignition Coil Primry 0.30 Ohms ± 15% Secondry 8.50 Ohms ± 15% Specil Tools Timing Light Allows technicin to check ignition timing DVA/Multimeter Kit A 1 Tests the electricl nd ignition systems; consists of VOA meter with uilt in direct voltge dpter DMT 2004 Digitl Multimeter A01 V mv A H z TEMP m A A m A C O M V H z Mesures RPM, ohms, mperes, AC nd DC voltges; records mximums nd minimums simultneously, nd ccurtely reds in high RFI environments Flywheel Remover Aids in the removl of the flywheel. Pge 2A R01 JUNE 2005

3 Crnkshft Holding Tool Holds crnkshft while servicing the powerhed R01 JUNE 2005 Pge 2A-3

4 Electricl Components Pge 2A R01 JUNE 2005

5 Electricl Components Torque Ref. No. Qty. Description Nm l. in. l. ft. 1 1 Strter 2 1 Pinion 3 1 Positive rush kit 4 1 Negtive rush kit 5 1 Brush holder 6 4 Bolt Wsher 8 1 Brcket 9 1 Rectifier 10 1 Bolt Switch 12 1 Neutrl switch 13 1 Actutor 14 1 Bttery cle 15 1 Cle tie 16 1 Bolt Boot 18 1 Brcket 19 1 Link rod 20 2 Rod snp 21 1 Cle 22 1 Screw Choke solenoid 24 1 Plunger 25 3 Screw Dowel pin 27 1 Hook 28 1 Strter cle 29 1 Sleeve 30 1 Boot 31 1 Boot 32 1 Strter solenoid 33 1 Fuse cle 34 2 Fuse 35 1 Brcket 36 1 Wire rcket 37 1 Brcket 38 1 Collr 39 1 Bolt Bolt R01 JUNE 2005 Pge 2A-5

6 Ref. No. Qty. Description 41 1 Cover 42 1 Wire digrm decl Torque Nm l. in. l. ft. Pge 2A R01 JUNE 2005

7 Electricl Components R01 JUNE 2005 Pge 2A-7

8 Ignition Components Pge 2A R01 JUNE 2005

9 Ignition Components Torque Ref. No. Qty. Description Nm l. in. l. ft. 1 1 Flywheel 2 1 Nut Wsher 4 1 Ignition Chrge Coil 5 2 Bolt Alterntor Coil 7 4 Bolt Crnk Position Sensor 9 2 Screw Clmp 11 1 Bolt Sleeve 13 1 Ignition Coil 14 2 Cp, Plug 15 2 Bolt ECM 17 2 Bolt Wsher 19 1 Hrness 20 1 Grommet 21 1 Bolt Plug, Terminl 23 1 Sleeve 24 1 Clmp 25 1 Bolt Switch, Oil Pressure Brcket 28 3 Bolt Wsher 30 3 Wsher, Ruer 31 3 Grommet 32 3 Collr 33 1 Hrness 34 1 Plug, Terminl 35 1 Lmp, Pilot 36 1 Stop Switch 37 1 Lnyrd 38 1 Retiner 39 1 Brcket 40 3 Bolt R01 JUNE 2005 Pge 2A-9

10 Ref. No. Qty. Description 41 1 Clmp 42 6 Wsher 43 3 Wsher, Ruer 44 3 Grommet 45 3 Collr Torque Nm l. in. l. ft. Pge 2A R01 JUNE 2005

11 Ignition Components R01 JUNE 2005 Pge 2A-11

12 Ignition Description The ignition system uses CDI (Cpcitor Dischrge Ignition). This system provides quick voltge uildup nd strong sprk required for high power nd high performnce engines. As the flywheel rottes, electricl power (lternting current) is produced y the ignition chrging coil. This power is rectified y diodes so tht direct current voltge is utilized y the ignition system. When the ignition driver is off, the direct current (DC) voltge is stored y the cpcitor. Once cpcitor voltge is chrged to its potentil, gte signl is pplied on the SCR nd the residul current is dissipted through the cpcitor chrging coils. The Electronic Control Module (ECM) ctivtes the ignition driver in the ECM which llows the cpcitor to dischrge, cusing the sprk to occur. Ignition timing is regulted y the ECM which receives sttus input from vriety of sensors. These sensors include the crnk position sensor nd oil pressure sender. The voltge dischrged to the primry winding of the ignition coil cuses surge of high voltge to e induced in the secondry winding of the ignition coil. This induced voltge of sufficient mplitude cuses the sprk plugs to fire. Crnk Position Sensor The crnk position sensor contins permnent mgnet nd is positioned in front of the flywheel. The timed pssing of the flywheel teeth through the sensors mgnetic field enles the ECM to determine engine RPM nd crnkshft ngle. Electronic Control Module (ECM) Under norml operting conditions the ECM unit controls the following: Controls ignition sprk timing y monitoring the crnk position sensor nd the oil pressure sensor. Mintins norml idle timing of 5 BTDC. Advnces sprk timing quickly to 30 BTDC under hrd ccelertion conditions. Limits RPM of the engine in the event of over speed condition due to cvittion, no lod on propeller, nd/or under propped. Soft Reduction: Ignition timing is grdully retrded to keep engine RPM elow Low Oil Pressure Protection: Limits the engine RPM to 3000 if oil pressure drops elow 25 kp (3.6 PSI). The ECM will turn on the Low Oil Pressure Wrning lmp. NOTE: The ECM controls ll timing opertions. There re no timing djustment required on this engine. Ignition Chrge nd Alterntor Coils Ignition Coil The coils locted under the flywheel contins the ignition chrge coil nd lterntor coil. The flywheel ssemly contins six permnently chrged mgnet segments which re retined to the inner wll of the flywheel. Ech mgnet contins north nd south pole providing 12 pole system. As the flywheel permnent mgnets pss the respective coil windings, n AC pulse current is produced t ech coil winding when mgnet polrity chnges (south to north, north to south, etc.). The primry (+) side of the ignition coil receives voltge dischrged from cpcitor in the ignition circuit locted inside the ECM. The voltge is multiplied y the coil so it will jump the sprk plug gp. The ignition coil will produce high voltge current ech crnkshft revolution, producing sprk t ech cylinder t the sme time. This is referred s wsted sprk ignition. Ignition coil mximum output is pproximtely 40,000 volts. Pge 2A R01 JUNE 2005

13 Ignition Test Procedures Ignition Trouleshooting IMPORTANT: Filure to comply with the following items my result in dmge to the ignition system. Do not reverse ttery cle connections. The ttery negtive ( ) cle is ground. Do not sprk ttery terminls with ttery cle connections to check polrity. Do not disconnect ttery cles while engine is running. Do not crnk engine with ECM or ignition coils not grounded.! WARNING High voltge shock hzrd! Do not touch ignition components or metl test proes while engine is running or eing crnked. Sty cler of sprk plug leds. To ssure personl sfety, ech individul sprk plug led should e grounded to engine.! WARNING When testing or servicing the ignition system, high voltge is present. Do not touch or disconnect ny ignition prts while engine is running, while key switch is on or while ttery cles re connected. Ignition Dignostic Procedures NOTE: With engine running, use inductive timing light to check sprk dvnce of ech cylinder s throttle is opened nd closed. If timing dvnces nd retrds on ech cylinder, ignition system is most likely functioning properly. Timing Light If outord ppers to hve n ignition system filure, it is recommended tht efore eginning in depth trouleshooting: Ensure tht the engine is mechniclly sound in the fuel system, cylinder compression etc. Check ll engine ground leds for loose or corroded connections. Disconnect nd reconnect ignition hrness connectors to verify proper continuity. Recommended Tests NOTE: The following recommended tests nd prole cuses re not listed in ny specific order. The technicin should use this tle s guide to help isolte nd test the specific prolem/condition. Alwys perform resistnce tests to vlidte suspected component filure. (1) Ohm test (resistnce) (2) Replce component nd retest (3) Mechnicl test/repir R01 JUNE 2005 Pge 2A-13

14 Prolem/Condition Prole Cuse Test # Crnk Position Sensor 1 2 Sttor 1 2 ECM 2 Stop circuit led 1 Lnyrd stop switch 1 Stop circuit short to ground No sprk on oth cylinders Tiller hndle stop utton 1 Remote control hrness 1 Ignition coil primry circuit short to ground 1 Ignition coil 1 2 Open ground condition Sttor ground 1 2 ECM 2 No sprk on one cylinder High tension led 1 2 Sprk plug 1 2 Engine surges over 6250 RPM while under lod Bot under propped 3 Propeller hu spun 3 Timing will not dvnce Low oil pressure ECM 2 Low oil pressure Ignition coil high tension leds 1 2 Sprk plugs 1 2 Engine misfires t high RPM ECM 2 ECM 1 2 Ground connection Ignition coil 1 2 Ignition chrge coil 1 2 Low oil pressure Ignition chrge coil 1 2 Engine will not run over 3000 RPM Ignition coil high tension leds 1 2 ECM 2 Sprk plugs 1 2 Ignition chrge coil 1 2 Ignition coil high tension leds 1 2 Sprk plugs 1 2 Engine occsionlly misfires Ignition coil 1 2 Ground connection t ECM 2 Ignition chrge coil 1 2 High resistnce to ground t Stop/lnyrd switch (corrosion) 1 2 ECM 2 Pge 2A R01 JUNE 2005

15 lu e rown Ignition Prolem/Condition Prole Cuse Test # Ignition coil primry leds 1 2 Ground connection t Ignition chrge coil 1 2 ECM 2 High resistnce to ground t Stop/lnyrd switch (corrosion) 1 2 Wek sprk Wek ignition coil 1 2 Ignition coil high tension leds 1 2 Sprk plugs 2 Sprk plugs cp lek 1 2 ECM 2 Low oil pressure Timing fluctutes Flywheel key shered 2 Testing Ignition Components IGNITION CHARGE COIL ECM 2 When performing resistnce tests, ll component leds must e disconnected. Redings my very slightly due to temperture differences. NOTE: Redings listed tken t 20 C (68 F) DVA/Multimeter Kit A 1 DMT 2004 Digitl Multimeter A01 Meter Test Leds Meter Scle Reding (Ω) Red Blck SPARK PLUG CAP REMOVAL/INSTALLATION Brown Blue R x ± 20% NOTE: High tension cles must hve the sprk plug cp removed efore testing. The cp contins 5k ohm resistor R01 JUNE 2005 Pge 2A-15

16 IMPORTANT: To remove the sprk plug cp from the high tension leds, turn the cp counterclockwise while pplying slight outwrd pressure. Do not pull hrd or the led my e dmged. To instll the cp, turn the cp clockwise, threding onto the high tension led. SPARK PLUG CAP DVA/Multimeter Kit A 1 DMT 2004 Digitl Multimeter A01 IGNITION COIL PRIMARY WINDINGS Meter Test Leds Meter Scle Reding (Ω) Red Blck Sprk plug led end Sprk plug end R x 1K DVA/Multimeter Kit A 1 DMT 2004 Digitl Multimeter A01 Meter Test Leds Meter Scle Reding (Ω) Red Blck Ornge Blck R x ± 15% Pge 2A R01 JUNE 2005

17 IGNITION COIL SECONDARY WINDINGS IMPORTANT: Both ignition coil secondry windings must e checked DVA/Multimeter Kit A 1 DMT 2004 Digitl Multimeter A01 CRANK POSITION SENSOR Meter Test Leds Meter Scle Reding (Ω) Red Blck Ornge Either sprk plug led R x ± 20% 2883 DVA/Multimeter Kit A 1 DMT 2004 Digitl Multimeter A01 Meter Test Leds Meter Scle Reding (Ω) Red Blck Red/White Blck R x ± 20% Flywheel Removl nd Instlltion! WARNING The engine could possily strt when turning the flywheel during removl nd instlltion. To prevent this ccidentl engine strting nd possile serious injury, lwys remove the sprk plug leds nd isolte the leds to engine ground R01 JUNE 2005 Pge 2A-17

18 Flywheel Removl 1. Disconnect the sprk plug leds from the sprk plugs. 2. Remove the three screws securing the recoil strter. c - Recoil strter mounting screws - Neutrl interlock o01181 c - Fuse 3. Instll the flywheel holding tool. Tighten the flywheel holding tool securely. 4. Remove the flywheel holding tool center screw. 5. Insert 19 mm socket into the center of the flywheel holding tool Flywheel holding tool - 19 mm socket Flywheel Remover Remove the flywheel nut. Pge 2A R01 JUNE 2005

19 7. Instll the flywheel holding tool center screw nd tighten until the flywheel is loose. Ignition - 19 mm socket on flywheel holding tool center screw Flywheel holding tool Flywheel Remover Remove the flywheel. Flywheel Instlltion 1. Plce the flywheel key into the slot. 2. Align the flywheel key with the flywheel slot. 3. Crefully instll the flywheel. 4. While pushing down on the flywheel, rock the flywheel ck nd forth to ensure the flywheel key hs not fllen out of the slot on the crnkshft. 5. Instll the flywheel wsher nd flywheel nut. 6. Instll the flywheel holding tool. 7. Tighten the flywheel nut to the specified torque Flywheel holding tool - 19 mm socket on torque wrench Description Nm l. in. l. ft. Flywheel Nut Flywheel Remover R01 JUNE 2005 Pge 2A-19

20 8. Remove the flywheel holding tool nd instll the recoil strter. Tighten the recoil strter mounting screws to the specified torque. c - Recoil strter mounting screws (3) - Neutrl interlock o01181 c - Fuse Description Nm l. in. l. ft. Recoil Strter Mounting Screw Reconnect the sprk plug leds to the sprk plugs. Ignition Chrge Coil Removl nd Instlltion Non Electric Strt Model REMOVAL INSTALLATION 1. Remove the flywheel cover nd flywheel. Refer to Flywheel Removl nd Instlltion. 2. Remove the ignition chrge coil mounting screws. 3. Disconnect the ignition chrge coil wires from the hrness connectors locted inside the convoluted tue. 1. Connect the ignition chrge coil wires to the hrness connectors. 2. Plce ll of the wire connectors inside the convoluted tue. Secure convoluted tue to the ottom cowl. Pge 2A R01 JUNE 2005

21 3. Instll the ignition chrge coil to the cylinder lock. Tighten the ignition chrge coil screws to the specified torque. d c - Convoluted tue - Convoluted tue retiner 2885 c - Ignition chrge coil hrness d - Ignition chrge coil mounting screws Description Nm l. in. l. ft. Ignition chrge coil mounting screw Instll flywheel. Refer to Flywheel Removl nd Instlltion. Electric Strt Models REMOVAL 1. Disconnect the ttery. 2. Remove the flywheel cover nd flywheel. Refer to Flywheel Removl nd Instlltion. 3. Disconnect the ignition chrge coil nd the lterntor coil from the engine hrness. NOTE: The lterntor coil hs 2 wires with three connectors. - Ignition chrge coil wires Alterntor coil wires 4. Crefully pull the ignition chrge coil nd lterntor coil wires from ehind the strter R01 JUNE 2005 Pge 2A-21

22 5. Remove the wire hrness spirl conduit. c Ignition chrge coil mounting screws - Alterntor coil nd ignition chrge coil wires c - Spirl conduit INSTALLATION 6. Remove the ignition chrge coil mounting screws. 1. Instll the ignition chrge coil nd secure with the ignition chrge coil mounting screws. Tighten the screws to the specified torque. 2. Wrp the ignition chrge coil wires nd the lterntor coil wires with the spirl conduit. c Ignition chrge coil mounting screws - Alterntor coil nd ignition coil wires c - Spirl conduit Description Nm l. in. l. ft. Ignition chrge coil mounting screw Push the wire hrnesses ehind the strter nd reconnect the ignition chrge coil nd lterntor coil to the engine hrness. Pge 2A R01 JUNE 2005

23 NOTE: The lterntor coil hs 2 wires with three connectors. - Ignition chrge coil wires (lck/ red nd lue/red) Alterntor coil wires (yellow nd white) 4. Instll the flywheel nd flywheel cover. Refer to Flywheel Removl nd Instlltion. Timing Belt Removl nd Instlltion Timing Belt Removl NOTE: The ignition chrge coil nd lterntor coil must e removed efore the timing elt cn e removed or instlled. Refer to Section 2A, Ignition Chrge Coil Removl nd Instlltion nd Section 2B, Alterntor Coil Removl nd Instlltion. IMPORTANT: Do not rotte the crnkshft or cm when the timing elt is removed unless dvised to do so. Dmge to vlves nd/or pistons my occur if the cm driven ger or crnkshft re rotted when the timing elt is removed or incorrectly instlled. 1. Ensure the timing mrks on the crnkshft nd cm re in proper lignment efore removing the timing elt. Use crnkshft holding tool to rotte the crnkshft to lign timing mrks. c Crnkshft holding tool - Crnkshft drive ger timing mrk c - Cmshft driven ger timing mrk Crnkshft Holding Tool R01 JUNE 2005 Pge 2A-23

24 2. Pull the timing elt off the cm driven ger. Remove the timing elt from the crnkshft drive ger. Timing Belt Instlltion 1. Ensure the timing mrks on the crnkshft drive ger nd the cmshft driven ger re in proper lignment. 2. Plce the timing elt onto the crnkshft drive ger. 3. Align the timing elt cog with the driven ger cog. 4. Crefully push the timing elt onto the cm driven ger 5. Rotte the crnkshft with crnkshft holding tool while pushing the timing elt onto the driven ger with your fingers Crnkshft Holding Tool Check the timing mrks for proper lignment. 7. Instll the ignition chrge coil. Refer to Section 2A, Ignition Chrge Coil Removl nd Instlltion. 8. Instll lterntor coils. Refer to Section 2B, Alterntor Coil Removl nd Instlltion. 9. Instll flywheel nd flywheel cover. Crnk Position Sensor Removl nd Instlltion Electric Strt Models REMOVAL 1. Remove the sprk plug leds from sprk plugs. 2. Disconnect ttery. 3. Remove the recoil strter. Refer to Section Remove the flywheel. Refer to Flywheel Removl nd Instlltion. Pge 2A R01 JUNE 2005

25 5. Disconnect the crnk position sensor led from the engine hrness. Ignition 6. Remove the two crnk position sensor mounting screws. Remove the crnk position sensor. c d Crnk position sensor ground led - Crnk position sensor mounting screw c - Strter solenoid d - Crnk position sensor hrness INSTALLATION 1. Align the crnk position sensor mounting holes with the cylinder lock crnk position sensor mounting holes. 2. Instll the crnk position sensor mounting screw. Do not tighten. 3. Instll the crnk position sensor ground led through the remining crnk position sensor mounting screw. Instll the mounting screw. 4. Tighten the crnk position sensor mounting screws to the specified torque. c d Crnk position sensor ground led - Crnk position sensor mounting screw c - Strter solenoid d - Crnk position sensor hrness Description Nm l. in. l. ft. Crnk Position Sensor Mounting Screw Instll the flywheel. Refer to section Flywheel Removl nd Instlltion. 6. Rotte the flywheel to ensure the crnk position sensor does not touch the flywheel. 7. Instll the recoil strter. Refer to Section Reconnect sprk plug leds to sprk plugs R01 JUNE 2005 Pge 2A-25

26 Non Electric Strt Models REMOVAL 1. Remove the sprk plug leds from sprk plugs. 2. Remove the recoil strter. Refer to Section Disconnect the crnk position sensor led from the engine hrness locted in the convoluted tuing. 4. Rotte the flywheel to lign flywheel rope notch with one of the crnk position sensor mounting screws. Remove the mounting screw. 5. Rotte the flywheel to lign the remining crnk position sensor mounting screw. Remove the crnk position sensor mounting screw. c d - Crnk position sensor ground led - Flywheel rope notch c - Crnk position sensor mounting screw d - Crnk position sensor hrness in convoluted tuing 3188 INSTALLATION 1. Rotte the flywheel to lign flywheel rope notch with one of the crnk position sensor mounting holes. 2. Align the crnk position sensor mounting screw holes with the cylinder lock crnk position sensor mounting holes. 3. Instll the crnk position sensor mounting screw. Do not tighten. 4. Rotte the flywheel to lign the flywheel rope notch with the other crnk position sensor mounting screw hole. Instll the crnk position sensor mounting screw. Pge 2A R01 JUNE 2005

27 5. Tighten the crnk position sensor mounting screws to the specified torque. c d - Crnk position sensor ground led - Flywheel rope notch c - Crnk position sensor mounting screw d - Crnk position sensor hrness in convoluted tuing 3188 Description Nm l. in. l. ft. Crnk Position Sensor Mounting Screw Rotte the flywheel to ensure the crnk position sensor does not touch the flywheel. 7. Instll the recoil strter. Refer to Section Reconnect sprk plug leds to sprk plugs. Ignition Coil Removl And Instlltion Ignition Coil Removl 1. Disconnect the sprk plug leds from the sprk plugs. 2. Disconnect the ignition coil primry wire from the engine hrness. 3. Remove the ignition coil mounting screws. Remove the ignition coil. c Ignition coil ground led - Ignition coil mounting screw c - Ignition coil primry wire Ignition Coil Instlltion 1. Instll the ignition coil ground led onto n ignition coil mounting screw. Instll the ignition mounting screw. Do not tighten R01 JUNE 2005 Pge 2A-27

28 2. Instll the ignition coil to the cylinder lock nd secure it with the ignition coil mounting screws. Tighten the ignition mounting screws to the specified torque. 3. Connect the ignition coil primry led to the engine hrness. 4. Reconnect sprk plug leds to sprk plugs. c Ignition coil ground led - Ignition coil mounting screw c - Ignition coil primry wire Description Nm l. in. l. ft. Ignition Coil Mounting Screw 6 53 Pge 2A R01 JUNE 2005