ELECTRICAL and IGNITION 2 A IGNITION SYSTEM

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1 ELECTRICAL nd IGNITION 2 A IGNITION SYSTEM

2 Tle of Contents Pge Desription A-1 Test Proedures A-1 Diret Voltge Adpter (DVA) Tests A-1 Test Sequene A-2 Ignition System Test Chrt A-3 Sttor Test A-4 Ignition Coil Test A-5 Trigger Test A-5 ADI Ignition using RED Sttor with n Adpter Module A-5 RED Sttor with Adptor nd Ignition Coils A-6 RED Sttor DVA Test A-6 Eletri Strt Engines A-6 Mnul Strt Engines A-6 Trouleshooting Proedures A-6 Ignition (Key) Swith Test A-7 Pge Ignition Components Removl nd Instlltion A-7 Flywheel A-7 Removl A-7 Instlltion A-8 BLACK nd RED Sttor A-8 Removl A-8 BLACK Sttor Instlltion A-9 RED Sttor Instlltion A-9 Trigger A-10 Removl A-10 Instlltion A-10 Ignition Coils A-11 Swith Box A-11 2A-0 - ELECTRICAL nd IGNITION R1 DECEMBER 1996

3 Desription The outord ignition system is lterntor-driven with distriutor-less pitor dishrge. Mjor omponents of the ignition system re the flywheel, sttor, trigger, swith ox, ignition oils nd sprk plugs. The sttor ssemly is mounted sttionry elow the flywheel nd hs 2 pitor hrging oils. The flywheel is fitted with permnent mgnets inside the outer rim. As the flywheel rottes the permnent mgnets pss the pitor hrging oils. This uses the pitor hrging oils to produe AC voltge. The AC voltge then is onduted to the swith ox where it is retified nd stored in pitor. The trigger ssemly (lso mounted under the flywheel) hs 3 oils. The flywheel hs seond set of permnent mgnets (loted round the enter hu). As the flywheel rottes the seond set of mgnets pss the trigger oils. This uses the trigger oils to produe n AC voltge tht is onduted to n eletri Silion Controlled Retifier (SCR) in the swith ox. The swith dishrges the pitor voltge into the ignition oil t the orret time nd firing order sequene. Cpitor voltge is onduted to the primry side of the ignition oil. The ignition oil multiplies this voltge high enough to jump the gp t the sprk plug. The preeding sequene ours one-per-engine-revolution for eh ylinder. Sprk timing is hnged (dvned/retrded) y rotting the trigger ssemly whih hnges eh trigger oil position in reltion to the permnent mgnets on the flywheel enter hu. IMPORTANT: If the engine misfires, runs rough or does not strt, the ignition system should e heked using Multi-Meter/DVA Tester ( ), or voltmeter (ple of mesuring 400 volts DC, or higher) nd Diret Voltge Adptor ( ). Test Proedures Diret Voltge Adpter (DVA) Tests! WARNING DANGER HIGH VOLTAGE/SHOCK HAZARD! Do not touh ignition omponents nd/or metl test proes while engine is running nd/or eing rnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, eh individul sprk plug led should e grounded to engine.! CAUTION To protet ginst meter nd/or omponent dmge, oserve the following preutions: 400 VDC* test position (or higher) MUST BE used for ll tests. INSURE the Positive (+) led/terminl of DVA is onneted to the Positive (+) reeptle of meter DO NOT CHANGE meter seletor swith position while engine is running nd/or eing rnked. Swith ox MUST BE GROUNDED during tests. Running or rnking engine with swith ox ungrounded my dmge swith ox. *If using meter with uilt in DVA, the DVA/400 VDC test position should e used. NOTE: Test leds re not supplied with the DVA. Use test leds supplied with meter. Test proedures nd speifitions re provided for heking primry ignition voltge while the engine is running nd/or eing rnked. TROUBLESHOOTING TIPS: 1. Intermittent, wek, or no sprk output t two sprk plugs usully indites d TRIGGER. 2. Intermittent, wek, or no sprk output t ll three sprk plugs usully indites d STATOR or SWITCH BOX. 3. Intermittent, wek, or no sprk t ny one sprk plug usully indites d SPARK PLUG, COIL, or SWITCH BOX R1 DECEMBER 1996 ELECTRICAL nd IGNITION - 2A-1

4 Test Sequene 1-A) Chek primry input voltge to oils (See Test Chrt) 1. If voltge redings to oil(s) re BELOW speifition, proeed with Step 2-A. 2. If voltge redings to oil(s) re WITHIN speifitions, proeed with Step 1-B. 1-B) Chek oils for sprk. [Connet Sprk Gp Tester ( A1) etween oil high voltge tower nd sprk plug.] 1. No sprk or wek sprk. COIL is d. 2. Sprk is OK, proeed with Step 1-C. 1-C) If Step 1-A nd 1-B hek OK, reple sprk plugs. If prolem exists fter repling sprk plugs, proeed with Step 1-D. 1-D) If Steps 1-A, 1-B, nd 1-C hek OK, hek ignition timing. 1. If ignition timing does not hek to speifition (or sudden or unexplined timing hnge ours) hek trigger dvne linkge for loose nd/or roken prts nd hek trigger mgnet ring (on flywheel hu) for looseness nd/or shift in position. 2. If ignition heks to speifition nd engine does not run or runs poorly, troule exists with fuel system or engine mehnil. 2-A) Chek swith ox stop iruit. (See Test Chrt). 1. If reding is BELOW speifitions, proeed with Step 2-B. 2. If reding is ABOVE speifitions, the Trigger or Swith Box is d (test trigger s outlined in this servie mnul setion; if trigger heks OK, reple swith ox nd repet hek). 3. If reding is WITHIN speifitions, proeed with Step 3-A. 2-B) Chek ignition swith/wiring, s follows:! CAUTION To prevent engine from strting, remove sprk plug leds from ALL sprk plugs nd ground leds to engine. 1. Disonnet ignition swith nd stop swith leds from swith ox nd isolte the leds. 2. Repet hek in Step 2-A.. If reding is still BELOW speifition, proeed with Step 3-A.. If reding is WITHIN speifition, either the ignition swith, stop swith, or wiring is d. 3-A) Chek sttor low speed nd high speed input to swith ox. (see Test Chrt). 1. If either the low speed or high speed reding to swith ox is BELOW speifition, Sttor or Swith Box is d (test sttor s outlined in this servie mnul setion; if sttor heks to speifition reple swith ox nd repet hek). 2. If oth the low speed nd high speed reding re WITHIN speifition, reple swith ox nd repet test. 2A-2 - ELECTRICAL nd IGNITION R1 DECEMBER 1996

5 Ignition System Test Chrt IMPORTANT: BEFORE ttempting the ignition system heks, following, thoroughly red the preeding pges of these instrutions to eome fmilir with the proper Automti Distriutorless Ignition (ADI) test sequene nd proedures (prtiulrly ny Sfety Wrnings nd Cutions ). ALL tests re performed with led wires onneted terminls exposed. SWITCH BOX MUST BE GROUNDED (CASE TO ENGINE BLOCK) FOR ALL TESTS IF NOT, SWITCH BOXES MAY BE DAMAGED. 55/60 MARATHON/SEAPRO ( A-5 printed on the sttor) USA S/N 0G nd BELOW BELGIUM S/N (Not Aville t Time of Printing) 45 JET, 50/60 ELECTRIC ( A22, A23, or A34 printed on the sttor) USA S/N 0G nd BELOW BELGIUM S/N (Not Aville t Time of Printing) NOTE: When serviing unit prior to the listed seril numer nd elow, it is reommended tht the flywheel e removed nd the sttor prt numer verified to determine proper testing pplitions. ADI Test Seq. Test Seletor Sw. Position Red 1 A Coil Primry 400 VDC* Coil (+) Terminl 2 A Swith Box - Stop Ciruit 3 A 4 A 3 A 4 A Sttor - Low Speed Sttor - High Speed 5 A Swith Box - Bis 400VDC* 400VDC* 400VDC* 20 VDC or 40 VDC Blk/Yellow(3) Sw. Box Terminl Blue Sw. Box Terminl Red Sw. Box Terminl Ground (1) (1) Using meter only, REVERSE LEAD POLARITY, onnet leds s speified. (*) If using meter with uilt-in DVA, ple seletor swith in the DVA/400 VDC position. 55/60 MARATHON/SEAPRO ( A21 printed on the sttor) USA S/N 0G nd ABOVE BELGIUM S/N (Not Aville t Time of Printing) 45 JET, 50/60 ELECTRIC ( A24 printed on the sttor) USA S/N 0G nd ABOVE BELGIUM S/N (Not Aville t Time of Printing) ADI Test Seq. Test Seletor Sw. Position 1 A Coil Primry 400 VDC* Coil (+) Terminl 2 A Swith Box - Stop Ciruit 3 A 4 A 3 A 4 A Sttor - Low Speed Sttor - High Speed 5 A Swith Box - Bis 400VDC* 400VDC* 400VDC* 20 VDC or 40 VDC DVA Leds Voltge (1) Voltge RPM Coil ( ) Terminl DVA Leds Red Blk Blk/Yellow(3) Sw. Box Terminl Blue Sw. Box Terminl Red Sw. Box Terminl Ground (1) (1) Using meter only, REVERSE LEAD POLARITY, onnet leds s speified. (*) If using meter with uilt-in DVA, ple seletor swith in the DVA/400 VDC position. Ground Ground Ground White/Blk Sw Box Terminl (1) Voltge Voltge RPM Coil ( ) Terminl Ground Ground Ground White/Blk Sw Box Terminl (1) R1 DECEMBER 1996 ELECTRICAL nd IGNITION - 2A-3

6 ! WARNING When testing or serviing the ignition system, high voltge is present, e extremely utious! DO NOT TOUCH OR DISCONNECT ny ignition prts while engine is running, while key swith is on, or while ttery les re onneted.! CAUTION Filure to omply with the following items my result in dmge to the ignition system. 1. DO NOT reverse ttery le onnetions. The ttery negtive le is (-) ground. 2. DO NOT sprk ttery terminls with ttery le onnetions to hek polrity. 3. DO NOT disonnet ttery les while engine is running. 4. DO NOT rnk engine when swith ox is not grounded to engine. A proess of elimintion must e used when heking the ignition system without Multi-Meter/DVA Tester ( ) or voltmeter (ple of mesuring 400 volts DC, or higher) nd Diret Voltge Adptor ( ), s the swith ox nd ignition oils nnot e thoroughly heked with onventionl test equipment. All other omponents n e tested with n ohmmeter. Before trouleshooting the ignition system, hek the following: 1. Mke sure tht eletril hrness nd ignition swith re not the soure of the prolem. 2. Chek tht plug-in onnetors re fully engged nd terminls re free of orrosion. 3. Mke sure tht wire onnetions re tight nd free of orrosion. 4. Chek ll eletril omponents, tht re grounded diretly to engine, nd ll ground wires to see tht they re grounded to engine. 5. Chek for disonneted wires, nd short nd open iruits. STATOR TEST NOTE: Sttor n e tested without removing from engine. 1. Disonnet sttor leds from swith ox. 2. Use n ohmmeter nd perform the following tests. IMPORTANT: If sttor is mounted on engine, lk sttor led must e grounded to powerhed when testing. Connet test led to lk sttor led if sttor is removed from engine. NOTE: Redings re for old engine (room temperture). Resistne will inrese slightly, if engine is wrm. 3. If meter redings re other thn speified, reple sttor ssemly. 55/60 MARATHON/SEAPRO ( A-5 printed on the sttor) USA S/N 0G nd BELOW BELGIUM S/N (Not Aville t Time of Printing) 45 JET, 50/60 ELECTRIC ( A22, A23, or A34 printed on the sttor) USA S/N 0G nd BELOW BELGIUM S/N (Not Aville t Time of Printing) NOTE: When serviing unit listed Seril Numer nd Below, it is reommended tht the flywheel e removed nd the sttor prt numer verified to determine proper testing pplitions. Test Leds Between Blue Sttor Led nd Red Sttor Led (Low Speed) Between Red Sttor Led nd Engine Ground* (Hi-Speed) Resistne (OHMS) (90 140) Sle Reding (x ) (R x 1000) (R x 1) *If sttor is mounted on engine, lk sttor led must e grounded to powerhed when testing. Connet test led to lk sttor led if sttor is removed from engine. 55/60 MARATHON/SEAPRO ( A21 printed on the sttor) USA S/N 0G nd ABOVE BELGIUM S/N (Not Aville t Time of Printing) 45 JET, 50/60 ELECTRIC ( A24 printed on the sttor) USA S/N 0G nd ABOVE BELGIUM S/N (Not Aville t Time of Printing) Test Leds Between Blue Sttor Led nd Red Sttor Led (Low Speed) Between Red Sttor Led nd Engine Ground* (Hi-Speed) Resistne (OHMS) Sle Reding (x ) (R x 1000) (R x 1) *If sttor is mounted on engine, lk sttor led must e grounded to powerhed when testing. Connet test led to lk sttor led if sttor is removed from engine. 2A-4 - ELECTRICAL nd IGNITION R1 DECEMBER 1996

7 IGNITION COIL TEST IMPORTANT: Ohmmeter tests n only detet ertin fults in the ignition oil. Reple ignition oil, if ohmmeter redings (listed in hrt, following) re not s speified. If oil tests OK, nd oil is still suspeted of eing fulty, use Multi-Meter/DVA Tester ( ) or voltmeter (ple of mesuring 400 volts DC, or higher) nd Diret Voltge Adptor ( ) to thoroughly hek oil. 1. Disonnet wires from oil terminls. 2. Pull sprk plug led out of oil tower. 3. Use n ohmmeter nd perform the following tests. ADI Ignition using RED Sttor with n Adpter Module Red sttors require n dpter module tht is onneted etween the sttor nd swith ox. Without the dpter module, the voltge supplied y the sttor would exeed the voltge pility of the swith ox. Test Leds Between (+) nd (-) Coil Terminls Between Coil Tower nd (-) Coil Terminl Resistne (OHMS) * ** Sle Reding (x ) * (R x 1) 8-11** (R x 100) * The primry DC resistne of these oils generlly is less thn one (1) OHM. If reding resemling short is otined, this would e eptle. ** Copper wire is n exellent ondutor, ut it will hve notiele differene in resistne from old to hot tempertures. Resonle vritions from these redings re eptle. 4. If meter redings re not s speified, reple ignition oil. TRIGGER TEST 1. Disonnet ll trigger leds from swith ox. 2. Use n Ohmmeter nd perform the following tests. Test Leds Between Brown Trigger Led nd White/Blk Trigger Led Between White Trigger Led nd White/Blk Trigger Led Between Violet Trigger Led nd White/Blk Trigger Led Resistne (OHMS) Sle Reding (x ) (R x 100) (R x 100) (R x 100) NOTE: Aove redings re for old engine (room temperture). Resistne will inrese slightly, if engine is wrm. 3. If meter redings re not s speified, reple trigger R1 DECEMBER 1996 ELECTRICAL nd IGNITION - 2A-5

8 RED Sttor with Adptor nd Ignition Coils RED Sttor DVA Test NOTE: If using meter with uilt -in DVA, ple seletor swith in the DVA/400 VDC position. NOTE: Red sttors require n dpter module tht is onneted etween the sttor nd swith ox. Without the dpter module, the voltge supplied y the sttor would exeed the voltge pility of the swith ox. Test Seletor Swith Position RED DVA Led Coil Primry 400 VDC* Coil (+) Terminl Stop Ciruit 400 VDC* Blk/Yellow Sw. Box Terminl Blue Sw. Box Terminl Blue/White Sw. Box Terminl 400 VDC* Blue Sw. Box Terminl 400 VDC* Blue/White Sw. Box Terminl NOTE: The sttor for mnul strt engines hve BLUE/ WHITE nd BLACK wire whih provide power for the overhet horn nd overspeed limiter module. BLACK DVA Led Coil ( ) Terminl Ground Ground Ground 300 RPM 130 Volts Minimum 190 Volts Minimum 190 Volts Minimum 190 Volts Minimum 1000 RPM 4000 RPM 195 to to to to to to to to 320 NOTE: Resistne vries gretly with temperture. Mesurements should e mde within n mient rnge of 65 to 85 degrees F Eletri Strt Engines Red Sttor Resistne Test (ll wires disonneted) Positive Meter Led (+) Connet to White/Green sttor led Connet to Yellow sttor led Negtive Meter Led ( ) Connet to Green/White sttor led Mnul Strt Engines Red Sttor Resistne Test (ll wires disonneted) Positive Meter Led (+) Connet to White/Green sttor led Connet to Blue/White Connet to Yellow sttor led R x 1 Ohms Sle Connet to Yellow sttor led Negtive Meter Led ( ) Connet to Green/White sttor led Connet to Blk R x 1 Ohms Sle Connet to Yellow sttor led Trouleshooting Proedures If the DVA reding is HIGH 1000 RPM) the ADAPTER MODULE is defetive. If the DVA reding is LOW, the sttor, dpter module or swith ox my e defetive. Refer to the prtiulr engine model proedure, following, to isolte the prolem. Disonnet the BLUE dpter led from the swith ox. Connet the DVA meter etween the BLUE dpter led nd ground. Crnk the engine (mnul or eletri). If the DVA is norml (190 to 260 volts), the swith ox is defetive. If the DVA reding is still low, either the sttor or the dpter is defetive. Disonnet the GREEN/WHITE nd WHITE/ GREEN sttor leds from the dpter. Mesure the resistne etween the GREEN/ WHITE nd WHITE/GREEN sttor leds. If the resistne is norml (660 to 710 ohms), the dpter is defetive. If the resistne is inorret, the sttor is defetive. 2A-6 - ELECTRICAL nd IGNITION R1 DECEMBER 1996

9 Ignition (Key) Swith Test 1. Disonnet remote ontrol wiring hrness nd instrument pnel onnetor. NOTE: Wiring digrm for ontrol oxes is loted in SEC- TION 2D. 2. Set ohmmeter on R x 1 sle for the following tests: COMMANDER 2000 KEY SWITCH COMMANDER KEY SWITCH Ignition Components Removl nd Instlltion Flywheel REMOVAL 1. Remove flywheel over from engine.! WARNING Engine ould possily strt when turning flywheel during removl nd instlltion; therefore, disonnet (nd isolte) sprk plug leds from sprk plugs to prevent engine from strting. 2. Disonnet sprk plug leds from sprk plugs. 3. While holding flywheel with Flywheel Holder () ( ), remove flywheel nut nd wsher. (BLK/YEL) M (PUR) A M(BLK) (RED) B S(YEL/RED) C (YEL/BLK) CONTINUITY SHOULD BE INDICATED KEY AT THE FOLLOWING POINTS: POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK OFF RUN START CHOKE* 4. Instll Crnkshft Protetor Cp ( ) on the end of rnkshft, then instll Flywheel Puller () ( A1) into flywheel (). 5. Remove flywheel. NOTE: Neither het or hmmer should e used on flywheel to id in removl s dmge to flywheel or eletril omponents under flywheel my result. *Key swith must e positioned to RUN or START nd key pushed in to tute hoke, for this ontinuity test. BLK BLACK PUR PURPLE RED RED YEL YELLOW 3. If meter redings re other thn speified in the preeding test, verify tht swith nd not wiring is fulty. If wiring heks OK, reple swith R1 DECEMBER 1996 ELECTRICAL nd IGNITION - 2A-7

10 INSTALLATION! WARNING Engine ould possily strt when turning flywheel during instlltion; therefore, disonnet (nd isolte) sprk plug leds from sprk plugs to prevent engine from strting. 1. Disonnet sprk plug leds from sprk plugs. BLACK nd RED Sttor REMOVAL 1. Remove flywheel; refer to Flywheel Removl. 2. Remove srews (). 2. Ple flywheel key () into slot in rnkshft. 3. Disonnet sttor leds s shown nd remove sttor. 3. Align slot in flywheel enter ore with flywheel key nd instll flywheel onto rnkshft. 4. Instll wsher nd loknut. 5. Hold flywheel with Flywheel Holder () ( ); torque loknut to 100 l. ft. (136 N m). 6. Instll flywheel over Sttor Leds to Swith Box (2) - Yellow Leds to Retifier (2) - Ground Led (1) 2A-8 - ELECTRICAL nd IGNITION R1 DECEMBER 1996

11 BLACK STATOR INSTALLATION 1. Instll sttor s shown. RED STATOR INSTALLATION IMPORTANT: The sttor must e oriented s shown to otin orret system voltge. 1. Position red sttor so pproprite rrow on del points ft. 2. Seure sttor with four (4) tthing srews retined from disssemly. Apply Lotite 222 to threds nd torque to 60 l. in. (7.0 N m). FORWARD - Srews; pply Lotite 271 on Threds (unless Pth Srew used) nd torque to 60 ls. in. (7.0 N m) - Sttor Connet sttor leds; refer to wiring digrms in Setion 2D. AFT Orient Approprite Arrow of Del Aft - Apply Lotite 222 (otin lolly) To Srews (4) nd Torque to 60 l. in. (7.0 N m) - Sttor Hrness 3. Route sttor hrness thru top of eletril plte grommet s shown. Seure to powerhed with st-strp. 4. Position sttor dptor in vity of eletril plte with lue led towrd top of engine. 5. Refer to eletril digrm nd mke eletril onnetions s shown. 6. Bundle nd seure sttor dptor, hrnesses nd onnetions with st-strps s shown. - Sttor Leds to Swith Box (2) - Yellow Leds to Retifier (2) - Ground Led (1) R1 DECEMBER 1996 ELECTRICAL nd IGNITION - 2A-9

12 f 3. Disonnet trigger leds () from swith ox () nd remove trigger. f d f e f Eletril Plte Grommet - Blue Led of Sttor Adptor - Sttor Hrness d - Blk Ground Led of Sttor Adptor e - Sttor Adptor f - St-Strps INSTALLATION 1. Instll trigger () nd onnet link rm (). Trigger REMOVAL 1. Remove flywheel nd sttor; refer to Flywheel nd Sttor removl, preeding. 2. Disonnet link rm () nd remove trigger() A-10 - ELECTRICAL nd IGNITION R1 DECEMBER 1996

13 2. Connet trigger leds () to swith ox (); refer to wiring digrms in Setion 2D. Swith Box 1. Refer to wiring digrms in Setion 2D when onneting wires. g h d f 3. Instll sttor; refer to Sttor Instlltion, preeding. 4. Instll flywheel; refer to Flywheel Instlltion, preeding. Ignition Coils 1. Refer to wiring digrms in Setion 2D when onneting wires. e e d - White/Blk - Purple - Brown d - White e - Red f - Blue g - Blk h - Grommet e d e Coils - Cover - Hex Nuts; ot with Quiksilver Liquid Neoprene d - Bolts; torque to 20 l. in. (2.5 N m) e - Coil Tower Boots; form wter tight sel etween oil tower nd sprk plug led using Quiksilver Insulting Compound R1 DECEMBER 1996 ELECTRICAL nd IGNITION - 2A-11

ELECTRICAL AND IGNITION 2 A IGNITION SYSTEM

ELECTRICAL AND IGNITION 2 A IGNITION SYSTEM 54637 Tle of Contents Pge Ignition System.......................... 2A-1 Description........................... 2A-1 Ignition Trouleshooting...................