Tble of Contents Specifictions........................... A- Specil Tools........................... A- Flywheel............................... A- Flywheel............................... A-5 Electricl Components................... A-6 Electricl Components................... A-7 Ignition Description...................... A-8 Ignition Component Description........... A-8 Cpcitor Dischrge Unit (CDI)......... A-8 Trigger Coil.......................... A-9 Sttor Assembly...................... A-9 Flywheel Assembly................... A-10 Ignition Coil.......................... A-10 Ignition Test Procedures.................. A-11 Direct Voltge Adpter (DVA).......... A-11 Ignition Troubleshooting.................. A-1 Tool: Multimeter/DVA Tester 91-99750A1 A-1 Ignition Dignostic Procedures............ A-1 Suggested Testing Procedures....... A-1 *Recommended Test.................. A-1 ELECTRICAL Section A - Ignition IGNITION Testing Ignition Components.............. A-15 Resistnce Tests..................... A-15 Trigger Coil Test................... A-15 Sttor Test (Ignition Chrge Coil).... A-16 Lighting Coil...................... A-16 Ignition Coil (Primry).............. A-17 Sprk Plug cp Removl........... A-17 Ignition Coil (Secondry)........... A-17 Sprk Plug Cp Resistor Test....... A-18 Thermo Switch.................... A-18 Flywheel Removl nd Instlltion......... A-19 Flywheel Removl.................... A-19 Flywheel Instlltion.................. A-0 Flywheel without lod ring & Spcer. A-0 Flywheel with lod ring & Spcer.... A-1 (CDI) Unit Removl nd Instlltion........ A- Ignition Coil Removl nd Instlltion...... A- Rectifier Removl nd Instlltion......... A- Sttor Removl nd Instlltion........... A-5 Trigger Coil Removl nd Instlltion...... A-6 A 90-8861R MARCH 1999 Pge A-1
Specifictions IGNITION SYSTEM* *Redings tken @ 68 F (0 C). Type Sprk Plug Type (NGK) Sprk Plug Gp Firing Order Ignition Timing: 0/5 hp Fully Retrded Fully Advnced (500-000 rpm) 50 hp Fully Retrded Fully Advnced (500-000 rpm) Chrge Coil Resistnce Trigger Coil Resistnce Ignition Coil Resistnce: Primry Secondry C.D.I. Engine Speed Limiter C.D.I. Overhet Speed Control Engine Temperture Switch Above 11 F (55 C) Below 10 F (0 C) Cpcitor Dischrge Ignition NGK DPR6EA-9 0.05 in. (1.0 mm) 1--- 5 B.T.D.C 5 B.T.D.C 5 B.T.D.C 5 B.T.D.C 7-08 Ω (BRN-BLU) 96-59 Ω (WHT/BLK-WHT/RED) 0.1-0.7 Ω.5 -.7 kω 610-680 rpm 1600-00 rpm No Continuity Continuity Pge A- 90-8861R MARCH 1999
Specil Tools IGNITION 1. Flywheel Holder P/N 91-816M.. Flywheel Puller P/N 91-816M. 90-8861R MARCH 1999 Pge A-
Flywheel 19 18 1 17 5 6 8 7 51 9 10 16 15 1 11 1 1 110 51 Loctite Smll Screw Thredlocker (9-809818) 110 -stroke Outbord Oil (9-88000A1) Pge A- 90-8861R MARCH 1999
Flywheel REF. TORQUE NO. QTY. DESCRIPTION lb-in. lb-ft Nm 1 1 COVER GROMMET 1 TUBING (19 IN.) DAMPER 5 1 NUT 116 157 6 1 WASHER 7 1 FLYWHEEL 8 1 DECAL-Wrning Spinning flywheel 9 SCREW (M6 x 5) 75 8.5 10 1 STATOR 11 1 BASE Sttor 1 SCREW 100 11.5 1 PIN 1 1 KEY 15 1 COIL Pulser 16 SCREW (M5 x 10) 5 5.0 17 1 DECAL-Wrning Neutrl 18 1 DECAL-Engine Oil/Vlve clernce 19 1 DECAL-EPA INFO (1999)(SEE NOTE) NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL. 90-8861R MARCH 1999 Pge A-5
Electricl Components NOTE: APPLY LIQUID NEOPRENE TO ALL EYELET WIRING TERMINAL CONNECTIONS. 6 1 17 6 1 16 1 15 18 17 6 8 7 5 1 9 1 0 19 9 10 1 6 11 9 7 0 1 6 5 8 6 9 Dielectric Grese (9-8506--1) Loctite PST Pipe Selnt (9-8098) Pge A-6 90-8861R MARCH 1999
Electricl Components TORQUE REF. NO. QTY. DESCRIPTION lb-in. lb-ft Nm 1 SCREW (M6 x 5) 100 11.5 1 ELECTRIC CONTROLLER (50) 1 ELECTRIC CONTROLLER (05) 1 BRACKET (NON-BIGFOOT) 1 BRACKET (BIGFOOT) 5 SCREW (M8 x 5) 10 17.5.7 6 1 SOLENOID PLATE 7 1 SCREW (M6 x 16) 75 8.5 8 NUT 0.5 9 1 STARTER SOLENOID 10 1 BRACKET 11 1 VOLTAGE REGULATOR 1 SCREW (M6 x 5) 100 11.5 1 1 PRESSURE SWITCH 75 8.5 1 PLATE 15 1 TEMPERATURE SWITCH 16 1 TEMPERATURE SWITCH 17 SCREW (M6 x 1) 75 8.5 18 GROMMET 19 HI TENSION CABLE 0 SPARK PLUG 150 1.5 17 1 IGNITION COIL SCREW (M6 x 0) 75 8.5 1 DECAL-(Coil Identifiction #1) 1 DECAL-(Coil Identifiction #) 1 DECAL-(Coil Identifiction #) 1 DECAL-(Coil Identifiction #) 1 ENGINE WIRING HARNESS 5 1 FUSE 6 7 1 SCREW (M6 x 1) 8 AR STA STRAP 9 1 BATTERY CABLE (NEGATIVE) 0 1 INSULATOR BOOT 1 BATTERY CABLE (POSITIVE) 1 HARNESS Auxiliry (HANDLE) 1 SCREW (M5 x 10) (NON-BIGFOOT) 0.5 1 SCREW (M6 x 1) (BIGFOOT) 0.5 90-8861R MARCH 1999 Pge A-7
Ignition Description The ignition system uses CDI (Cpcitor Dischrge Ignition). This system provides quick voltge buildup nd strong sprk required for high power nd high performnce engines. The CDI ignition system does not incorporte mechniclly operted points, therefor mking this CDI unit virtully mintennce free. As the flywheel rottes, electricl power (lternting current) is produced by the cpcitor chrging coil. This power is rectified by diodes so tht direct current voltge is utilized by the ignition system. When the silicone controlled rectifier (SCR) is off, the D.C. voltge is stored by the cpcitor. As the flywheel rottes 60 from the point t which chrging of the system begn, the trigger coil produces voltge which is rectified nd pplied to the (SCR) gte. This gte signl then turns on the (SCR) nd the stored voltge is shorted to ground thru the primry winding of the ignition coil. The voltge dischrged to the primry winding of the ignition coil cuses surge of high voltge to be induced in the secondry winding of the ignition coil. This induced voltge of sufficient mplitude cuses the sprk plugs to fire. The voltge stored by the cpcitor holds the (SCR) on until the ignition coil current is dischrged. Then once the cpcitor hs dischrged, the (SCR) turns off nd the ignition cycle is repeted. Actuting the stop switch shorts the power being produced by the chrge coil to ground. This prevents chrging of the cpcitor nd thus stops sprk plug firing. Ignition Component Description Cpcitor Dischrge Unit (CDI) -Ignition CDI Unit (Cpcitor Dischrge Ignition) Under norml operting conditions the CDI unit controls the following: 1. Control ignition sprk timing by monitoring the trigger pulses.. Mintins n idle timing of 5 BTDC.. Advnces sprk timing quickly to 5 BTDC under hrd ccelertion conditions.. Limits rpm of the engine to 000 rpm in the event of low oil pressure conditions. 5. Limits rpm of the engine to 000 rpm in the event of overhet condition. 6. Limits rpm of the engine in the event of over-speed (@ 600 rpm). NOTE: The CDI unit controls ll timing opertions. There is no timing djustment required on this outbord engine. Pge A-8 90-8861R MARCH 1999
Trigger Coil IGNITION 1 Sttor Assembly -Trigger Coil A single wound coil with mgnet core mounted to one side of the sttor mounting bse. The trigger is positioned on the outside of the flywheel ssembly nd is chrged when rised boss on the flywheel psses the trigger/mgnet winding. A pulse voltge is then sent to n (SCR) switch within the CDI unit. The trigger is mounted in fixed timing position. b 1 1 -Ignition Chrge Coil b-lighting System Coils nd Electrotherml Vlve Coils The sttor ssembly locted under the flywheel contins the Ignition Chrge Coils, nd lighting system Coils. All of these coils mke up the sttor ssembly. As the flywheel permnent mgnets pss the respective sttor coil windings, n AC pulse current is produced t ech coil winding when mgnet polrity chnges. (South to North), (North to South) etc. 90-8861R MARCH 1999 Pge A-9
Flywheel Assembly Ignition Coil The flywheel ssembly contins one permnently chrged mgnet which is bonded nd retined to the inner wll of the flywheel. This mgnet is segmented with positive nd negtive poles. (1 pole) (6 positive pulses per revolution). -Ignition Coil nd High Tension Led Assembly The primry (+) side of the ignition coil receives voltge dischrged from cpcitor in the ignition (CDI) unit. The voltge is multiplied by the coil until it cn 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 (Wisted Sprk Ignition). Ignition coil mximum output is pproximtely 0,000 volts. Pge A-10 90-8861R MARCH 1999
Ignition Test Procedures IGNITION Direct Voltge Adpter (DVA) WARNING DANGER HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components nd/or metl test probes while engine is running nd/or being crnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, ech individul sprk plug led should be 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 bttery cbles re connected. CAUTION Filure to comply with the following items my result in dmge to the ignition system. 1. DO NOT reverse bttery cble connections. The bttery negtive cble is ( ) ground.. DO NOT sprk bttery terminls with bttery cble connections to check polrity.. DO NOT disconnect bttery cbles while engine is running.. DO NOT crnk engine with CDI or Ignition Coils not grounded. CAUTION To protect ginst meter nd/or component dmge, observe the following precutions: 00 VDC* test position (or higher) MUST BE used for ll tests. INSURE the Positive (+) led/terminl of DVA is connected to the Positive (+) receptcle of meter. DO NOT CHANGE meter selector switch position while engine is running nd/or being crnked. ALL COMPONENTS MUST BE GROUNDED during tests. Running or crnking engine with CDI or Ignition Coils ungrounded my dmge components. * If using meter with built-in DVA, the DVA/00 or DVA/500 VDC test position should be used. NOTE: Test leds re not supplied with the Direct Voltge Adpter. Use test leds supplied with multi meter. Test procedures nd specifictions re provided for checking primry ignition voltge while the engine is running nd/or being crnked with ll hrnesses connected. 90-8861R MARCH 1999 Pge A-11
Ignition Troubleshooting WARNING DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components nd/or metl test probes while engine is running nd/or being crnked. STAY CLEAR OF SPARK PLUG LEADS. To ssure personl sfety, ech individul sprk plug led should be 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. Tool: Multimeter/DVA Tester 91-99750A1 Component Test Coil Primry Selector Switch Position 00 DVA* DVA Led Red Coil ( ) Blck (B) Led () ** DVA Led Blck Coil (+) Ornge (O) Led () ** Voltge Reding (1) @00-000 RPM 160-80 (1) Sttor Chrge Coil 00 DVA* Brown (Br) Led () Ground 160-80 (1) (CDI) Unit Stop Circuit 0 DVA (CDI) Unit White (W) Led () Ground - 7 * If using meter tht requires DVA dpter, plce selector switch to the 00 VDC position. ** Reverse Polrity (1) Redings my vry t crnking speed or t idle speed. () Bck probe the electricl led bullet connector in order to mke connection. Multimeter Ohm Checks Tested Prt Multimeter Wires Connected To: Meter Scle Meter Reding Sttor Chrge Coil Red Blue () R x 1 Ω 7-08 Blck Brown (1) Trigger Coil Red White/Red (1) R x 1 Ω 96-59 Blck White/Blk () Ignition Coil Primry (with wires Red Ornge (O) R x 1 Ω 0.1-0.7 disconnected) Blck Blck (B) Ignition Coil Secondry (test with coil leds disconnected nd the high tension led cp removed)*** Red Blck High Tension Led #1 High Tension Led # k Ω.5-5. NOTE: Copper is n excellent conductor, however, resistnce my notbly vry between low nd high temperture. Therefore, resonble differences cn be ccepted between resistnce redings nd specifictions. The bove redings re for cold (room temperture) engine. Resistnce will increse if the engine is wrm. *** High tension led cp contin 5k ohm resister. Remove cps when mking secondry ignition coil test. Pge A-1 90-8861R MARCH 1999
Ignition Dignostic Procedures IGNITION TROUBLESHOOTING TIP: 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. IMPORTANT: If outbord ppers to hve n ignition system filure, it is recommended tht before beginning in-depth troubleshooting: Ensure tht the engine is mechniclly sound condition. (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. SUGGESTED TESTING PROCEDURES *Recommended Test NOTE: The following recommended tests nd probble cuses re not listed in ny specific order. The technicin should use this tble s guide to help isolte nd test the specific problem/condition. Alwys perform the DVA tests first (if pplicble), then perform resistnce test to vlidte suspected component filure. (1) DVA TEST (Direct Voltge Adpter) () OHM TEST (Resistnce Testing) () Replce Component nd Retest () Mechnicl Test/Repir PROBLEM/CONDITION Probble Cuse *Perform Test No. No Sprk Condition (Both Cylinders) No Sprk Condition (One Cylinder) Trigger Sttor (CDI) Unit Stop Circuit Short to Ground: - stop circuit led b - lnyrd stop switch c - tiller hndle stop button d- remote control hrness Ignition Coil Sprk Plugs Open Ground Condition: - ignition coil b - (CDI) unit c - sttor ground High Tension Led Sprk Plug Cp (Resistor) Sprk Plug 1-1- 90-8861R MARCH 1999 Pge A-1
Wek Sprk Condition (Low Primry Voltge) Timing Fluctutes Note: It is considered norml for the timing to fluctute pproximtely 1 - within the designted timing window. *Recommended Test (cont.) Ground Connection t: - ignition coil b - (CDI) unit c - sttor High Resistnce To Ground t: - stop/lnyrd switch (wter/corrosion) Wek Chrge Coil (CDI) Unit Filure Ignition Coil/High Tension Led(s) Sprk Plug(s) Sprk Plug Cp (Resistor) Loss Of Oil Pressure: - timing retrds nd fluctutes, rpm will drop below 000 rpm Flywheel Key Shered (CDI) Unit 1-1- (1) DVA TEST (Direct Voltge Adpter) () OHM TEST (Resistnce Testing) () Replce Component nd Retest () Mechnicl Test/Repir PROBLEM/CONDITION Probble Cuse *Perform Test No. Timing Will Not Advnce Low Oil Pressure: - timing retrds nd fluctutes, rpm will remin below 000 rpm (CDI) Unit 1- Engine Misfires At High RPM Engine Hrd To Strt Cold Engine Hrd To Strt Hot Engine Will Not Run Over 000 RPM Low Oil Pressure: - timing retrds nd fluctutes, rpm will remin below 000 rpm Ignition Coil/High Tension Led(s) Sprk Plug Cp(s) 5k Ω Resistor Sprk Plug(s) (CDI) Unit Ground Connection: - (CDI) unit b - ignition coil c - sttor Debris In Crburetor Enrichener Circuit Wek Sprk Condition Throttle Plte in Open Position Wek Sprk Condition Vpor Lock Low Oil Pressure - timing retrds nd fluctutes, rpm will remin below 000 rpm Sttor Ignition Coil/High Tension Led(s) (CDI) Unit Sprk Plug(s) 1-1 1 1-1- Pge A-1 90-8861R MARCH 1999
Engine Occsionlly Misfires Engine Surges Over 5700 RPM While Under Lod Note: The engine (CDI) unit will retrd timing nd reduce RPM bove 5700 RPM. Chrge Coil (CDI) Unit Ignition Coil/High Tension Led(s) Sprk Plug Cp(s) 5k Ω Resistor Sprk Plug(s) Ground Connection t: - ignition coil b - (CDI) unit c - sttor High Resistnce To Ground t: - stop/lnyrd switch (wter/corrosion) Bot Under Propped Propeller Hub Spun IGNITION 1-1- Testing Ignition Components Resistnce Tests TRIGGER COIL TEST When performing resistnce tests, ll component leds must be disconnected. Redings my very slightly due to temperture chnges. Reding listed tken t 68 (0 C). OHMS600001510 00 100 5 10 0 0 5 10 0 0 VOLTS 0 0 6 15 8 0 0 10 DC AMPS DCV ACV DVA 1 1 METER TEST LEADS METER SCALE OHMS READING RED BLACK 1 RX1 96-59 90-8861R MARCH 1999 Pge A-15
STATOR TEST (IGNITION CHARGE COIL) OHMS 100 6000015 10 00 5 10 0 0 10 0 5 VOLTS 0 0 6 15 0 8 0 10 DC AMPS 0 DCV ACV DVA GRN GRN GRN BRN BLU 1 1 1 METER TEST LEADS METER SCALE OHMS READING RED BLACK 1 RX1 7-08 LIGHTING COIL OHMS 100 6000015 10 00 5 10 0 0 0 5 10 VOLTS 0 0 6 15 0 8 0 10 DC AMPS 0 DCV ACV DVA GRN GRN GRN BRN BLU 1 1 1 METER TEST LEADS METER SCALE OHMS READING RED BLACK 1 RX1 1.-. 1 RX1 1.-. RX1 1.-. Pge A-16 90-8861R MARCH 1999
COIL (PRIMARY) IGNITION METER TEST LEADS METER SCALE OHMS READING RED ORANGE SPARK PLUG CAP REMOVAL IGNITION COIL (SECONDARY) BLACK BLACK RX1 01 0.1-0.7 07 NOTE: High tension cbles must hve sprk plug cp removed before testing. Cp contins 5k ohm resistor. IMPORTANT: To remove sprk plug cp from high tension leds, turn cp counterclockwise while pplying slight outwrd pressure. DO NOT PULL HARD or led my be dmged. To instll cp, turn cp clockwise threding cp onto high tension led. 5585 #1 # METER TEST LEADS METER SCALE OHMS READING RED BLACK #1 CABLE # CABLE RXKΩ 5.5 -.7 7 90-8861R MARCH 1999 Pge A-17
SPARK PLUG CAP RESISTOR TEST 5585 METER TEST LEADS METER SCALE OHMS READING RED BLACK RXKΩ.5-5. THERMO SWITCH -Thermo Switch 5798 1. Check continuity of switch. Thermo Switch Continuity Check Above 11 F (50 C) No Continuity Below 10 F (0 C) Continuity Pge A-18 90-8861R MARCH 1999
Flywheel Removl nd Instlltion IGNITION Flywheel Removl WARNING Engine could possibly strt when turning flywheel during removl nd instlltion. To prevent this type of ccidentl engine strting nd possible serious injury, lwys remove sprk plug leds from sprk plugs. 1. Disconnect sprk plug leds from sprk plugs.. Hold flywheel using flywheel holder (91-816M). Remove nut nd wsher. -Flywheel Holder (91-816M) 006. Remove flywheel using puller (91-816M). -Flywheel Puller (91-816M) 005 90-8861R MARCH 1999 Pge A-19
Flywheel Instlltion 1. Plce flywheel key into slot.. Instll flywheel.. Hold flywheel using flywheel holder (91-816M). Apply oil to threds on crnkshft nd tighten nut to the specified torque. FLYWHEEL WITHOUT LOAD RING & SPACER c b d 578 -Flywheel Key b-wsher c -Nut d-apply Oil to Threds Flywheel Nut Torque 116 lb-ft (157 Nm) Pge A-0 90-8861R MARCH 1999
FLYWHEEL WITH LOAD RING & SPACER IGNITION c b d e 110 578 110 -Stroke Outbord Oil (9-88000A1) -Flywheel Key b-wsher c -Nut d-spcer e -Lod Ring NOTE: Lod Ring is for one time use nd must be replced if flywheel is removed. Flywheel Nut Torque 116 lb-ft (157 Nm) 90-8861R MARCH 1999 Pge A-1
(CDI) Unit Removl nd Instlltion 1. Remove nd instll the (CDI) unit s shown.. Refer to Section Prt D for wiring digrms. b -(CDI) Unit b-mounting Bolts () 81 (CDI) Mounting Bolt Torque 100 lb-in. (11. Nm) Pge A- 90-8861R MARCH 1999
Ignition Coil Removl nd Instlltion IGNITION 1. Remove nd instll ignition coils s shown.. Refer to Section Prt D for wiring digrms. 1 c b 8 -Top Ignition Coil b-bottom Ignition Coil c -Bolt - Fsten (nd Ground) Coil Ground Leds Ignition Coil Mounting Bolt Torque 75 lb-in. (8.5 Nm). Reconnect sprk plug leds. 1 1 90-8861R MARCH 1999 Pge A-
Rectifier Removl nd Instlltion 1. Remove nd instll rectifier s shown.. Refer to Section Prt D for wiring digrms. b -Rectifier b-bolts () 5565 Rectifier Mounting Bolt Torque 100 lb-in. (11. Nm) Pge A- 90-8861R MARCH 1999
Sttor Removl nd Instlltion IGNITION 1. Remove nd instll flywheel. Refer to Flywheel Removl nd Instlltion.. Remove nd instll the sttor s shown.. Fsten wiring together with st-strp.. Refer to Section Prt D for Wiring Digrms. 51 b c 88 51 Loctite (9-809818) -Sttor b-mounting Bolts () Apply Loctite to Threds c -St-Strp Sttor Bolt Torque 75 lb-in. (8.5 Nm) 90-8861R MARCH 1999 Pge A-5
Trigger Coil Removl nd Instlltion 1. Remove nd instll the trigger coil s shown.. Fsten wiring together with st-strp.. Set the ir gp t.00 in. (0.77 mm) between the trigger nd flywheel.. Refer to Section Prt D for wiring digrms. b.00 in. (0.77 mm) d c -Trigger Coil b-screw () c -St-Strp d-air Gp.00 in. (0.77 mm) 5565 Air Gp Between Trigger nd Flywheel.00 in. (0.77 mm) Screw Torque 5 lb-in. (5.1 Nm) Pge A-6 90-8861R MARCH 1999