ELECTRICAL 2 A IGNITION

Transcription

1 ELECTRICAL 2 A IGNITION

2 Tble of Contents Pge Specifictions A-1 Specil Tools A-2 Notes: A-3 Flywheel And Sttor (Electric) A-4 Flywheel And Sttor (Mnul) A-5 Electricl Components 40/ A-6 Electricl Components 55/ A-8 Theory of Opertion A-10 Cpcitor Chrging #1 CDM A-10 Cpcitor Chrging #2 & #3 CDM A-11 #1 Cylinder Trigger Circuit A-12 Ignition Coil Circuit A-13 Stop Circuit A-14 Rev Limiter Circuit A-15 Ignition Component Description A-16 Cpcitor Dischrge Module (CDM).... 2A-16 Trigger Coil A-16 Sttor Assembly A-16 Flywheel A-16 CDM (P/N A) Trouble Shooting.... 2A-17 Chrt 1- CDM Trouble Shooting Flowchrt A-17 CDM Stop Diode Trouble Shooting A-18 Chrt 2-CDM Trouble Shooting Flowchrt A-19 Chrt 3-CDM Trouble Shooting Flowchrt A-21 CDM Test with DMT 2000 Multi-meter A A-22 CDM Test with Volt/Ohm/DVA Meter A A-23 Ignition Test Procedures A-24 Direct Voltge Adptor (DVA) Test A-24 Resistnce Tests A-25 Flywheel Removl nd Instlltion A-26 Sttor Removl nd Instlltion A-27 Trigger A-27 CDM A-28 2A-0 - ELECTRICAL R02 NOVEMBER 2002

3 Specifictions IGNITION SYSTEM TIMING *Suppressor (resistor) sprk plug Type Sprk Plug Type Sprk Plug Gp Firing Order Idle Mximum Crnking Speed -Model 40/50/60 -Model 55/ RPM Model 40/50/60 Model 55/60 Sepro-Mrthon Cpcitor Dischrge NGK BP8H-N-10 *NGK BPZ8H-N-10 NGK BUZ8H NGK BP8HS in. (1.0mm) T.D.C. ± 2 24 B.T.D.C. 18 B.T.D.C. 22 B.T.D.C. 16 B.T.D.C R02 NOVEMBER 2002 ELECTRICAL - 2A-1

4 Specil Tools 1. Flywheel Holder Sprk Gp Tester A1 2. Flywheel Puller T1 7. TPI/CDM Test Hrness A A1 Multi Meter/DVA Tester 4. DMT 2000 Digitl Tchometer Multi-meter A01 8. Sprk Gp Tester DVA Adptor DVA Adptor A-2 - ELECTRICAL R02 NOVEMBER 2002

5 Notes: R02 NOVEMBER 2002 ELECTRICAL - 2A-3

6 Flywheel And Sttor (Electric) Loctite 222 Thred Locker 2-4-C with Teflon TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 1 1 FLYWHEEL COVER 2 1 NUT WASHER 4 1 FLYWHEEL 5 1 STATOR 6 4 SCREW (M5 x 30) TRIGGER 8 1 SWIVEL BALL 9 1 SWIVEL BASE 10 2 CABLE TIE 11 1 DECAL-EPA INFORMATION 2A-4 - ELECTRICAL R02 NOVEMBER 2002

7 Flywheel And Sttor (Mnul) Loctite 222 Thred Locker 2-4-C with Teflon TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 1 1 FLYWHEEL 2 1 NUT WASHER 4 1 STATOR 5 4 SCREW (M5 x 30) TRIGGER 7 1 SWIVEL BALL 8 1 SWIVEL BASE 9 2 CABLE TIE 10 2 PLUG R02 NOVEMBER 2002 ELECTRICAL - 2A-5

8 Electricl Components 40/ Liquid Neoprene 2A-6 - ELECTRICAL R02 NOVEMBER 2002

9 Electricl Components 40/50 TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 1 1 PLATE Electricl 2 1 SCREW (M5 x 12) WASHER 4 1 STA STRAP 1 REV LIMITER (MANUAL) 5 1 REV LIMITER 6 1 CLAMP 7 3 SCREW (M5 x 12) SOLENOID ASSEMBLY 9 2 BUSHING 10 2 GROMMET 11 2 SCREW (M6 x 25) ELECTRIC NUT (1/4-20) LOCKWASHER 14 1 CABLE 15 1 CABLE 16 2 NUT VOLTAGE REGULATOR 18 2 SCREW (M6 x 35) J CLAMP 20 1 BOOT 21 1 BATTERY CABLE (NEGATIVE) 22 1 WASHER (QTY. OF 3 ON ELECTRIC) 23 AR STA STRAP 24 2 SCREW (M6 x 25) CABLE 26 1 SCREW (M8 x 20)(MANUAL) SCREW (M6 x 10)(MANUAL) J CLAMP (QTY. OF 3 ON ELECTRIC) 29 1 HARNESS ASSEMBLY Engine (ELECTRIC) 30 1 FUSE 31 3 GROMMET 32 3 BUSHING 33 3 WASHER 34 3 SCREW (M6 x 25) HARNESS-Ignition 2 CDM ASSEMBLY (5 IN. LEADS) 36 1 CDM ASSEMBLY (8 IN. LEADS) 37 3 HI-TENSION CABLE 38 3 BOOT 3 SPARK PLUG (NGK# BP8H-N-10) SPARK PLUG (NGK#BPZ 8H N 10) SPARK PLUG (NGK#BUZ8H) SCREW (M6 x 14) HARNESS-Power (MANUAL) 42 1 HARNESS 1 HARNESS ASSEMBLY. -Adptor (MANUAL) 43 1 HARNESS ASSEMBLY. -Adptor (ELECTRIC) R02 NOVEMBER 2002 ELECTRICAL - 2A-7

10 Electricl Components 55/ HP ONLY Dielectric Grese ( ) 25 Liquid Neoprene ( ) 31 2A-8 - ELECTRICAL R02 NOVEMBER 2002

11 Electricl Components 55/60 TORQUE REF. NO. QTY. DESCRIPTION lb. in. lb. ft. N m 1 1 PLATE Electricl 2 1 SCREW (M5 x 12) WASHER 4 1 STA STRAP 1 REV LIMITER (MANUAL) 5 1 REV LIMITER 6 1 CLAMP 7 3 SCREW (M5 x 12) SOLENOID ASSEMBLY 9 2 BUSHING 10 2 GROMMET 11 2 SCREW (M6 x 25) NUT (1/4-20) ELECTRIC LOCKWASHER 14 1 CABLE 15 1 CABLE 16 2 NUT VOLTAGE REGULATOR 18 2 SCREW (M6 x 35) J CLAMP 20 1 BOOT 21 1 BATTERY CABLE (NEGATIVE) 22 2 WASHER 23 AR STA STRAP 24 2 SCREW (M6 x 25) CABLE 26 1 SCREW (M8 x 20)(MANUAL) SCREW (M6 x 10)(MANUAL) J CLAMP (Qty. of 2 required on Mnul) 29 1 HARNESS ASSEMBLY Engine 30 1 FUSE ELECTRIC 31 1 PLUG 32 3 GROMMET 33 3 BUSHING 34 3 WASHER 35 3 SCREW (M6 x 25) HARNESS-Ignition 37 3 CDM ASSEMBLY 38 3 HI-TENSION CABLE 39 3 BOOT 3 SPARK PLUG (NGK# BP8H-N-10) SPARK PLUG (NGK#BP8HS-10) SCREW (M6 x 14) HARNESS-Power MANUAL 43 1 HARNESS 3 SPARK PLUG (NGK#BPZ 8H N 10) SPARK PLUG (NGK#BUZ8H) R02 NOVEMBER 2002 ELECTRICAL - 2A-9

12 Theory of Opertion This outbord ignition system is lterntor driven (distributor-less) cpcitor dischrge system. Mjor components of the ignition system re the flywheel, sttor, trigger, cpcitor dischrge modules (CDM s) nd sprk plugs. Ech cpcitor dischrge module functions s combintion switchbox nd secondry ignition coil. Cpcitor Chrging #1 CDM The STATOR ssembly is mounted to the block below the flywheel nd hs 3 CAPACITOR CHARGING COILS wound in series. The FLYWHEEL is fitted with 6 permnent mgnets inside the outer rim. The flywheel rottes the permnent mgnets pst the cpcitor chrging coils cusing the coils to produce AC voltge ( volts). The AC voltge is then conducted to the CAPACITOR DISCHARGE MOD- ULES (CDM), where it is rectified (DC) nd stored in cpcitor. The sttor voltge return pth is through the ground wire of the other CDM nd bck through tht CDM s chrging coil wire to the cpcitor chrging coils. b 3 d 1 2 /YEL WHT/GRN PPL c j YEL YEL WHT/GRN GRN/WHT e WHT i /YEL f CAPACITOR- COIL- /YEL PPL g SCR- DIODE- h - Bttery Chrging Coils b - Trigger Coils c - Cpcitor Chrge Coils d - CDM #1 e - CDM #2 f - CDM #3 g - Rev. Limiter (Not Used On All Models) h - To Ignition Switch i - Stop Switch j - To Voltge Regultor 2A-10 - ELECTRICAL R02 NOVEMBER 2002

13 Cpcitor Chrging #2 & #3 CDM The flywheel rottes the permnent mgnets pst the cpcitor chrging coils cusing the coils to produce AC voltge ( volts). The opposite voltge pulse is then conducted to the CAPACITOR DIS- CHARGE MODULES (CDM), where it is rectified (DC) nd stored in cpcitor. The sttor voltge return pth is through the ground wire of the other CDM nd bck through tht CDM s chrging coil wire to the cpcitor chrging coils. NOTE: #1 CDM sttor voltge return pth is through either CDM #2 or #3. The return pth for CDM #2 nd #3 is through CDM #1, if #1 sttor wire is disconnected the engine will die (the sttor circuit is incomplete nd the cpcitors cnnot be chrged). b 3 d 1 2 /YEL WHT/GRN PPL c j YEL YEL WHT/GRN GRN/WHT e WHT i /YEL f CAPACITOR- COIL- /YEL PPL g SCR- DIODE- h - Bttery Chrging Coils b - Trigger Coils c - Cpcitor Chrge Coils d - CDM #1 e - CDM #2 f - CDM #3 g - Rev. Limiter (Not Used On All Models) h - To Ignition Switch i - Stop Switch j - To Voltge Regultor R02 NOVEMBER 2002 ELECTRICAL - 2A-11

14 #1 Cylinder Trigger Circuit The TRIGGER ssembly (lso mounted under the flywheel) hs one coil for ech cylinder. These coils re mounted djcent to the flywheel center hub. The center hub of the flywheel contins permnent mgnet with two north south trnsitions. As the flywheel rottes, the mgnet north south trnsitions pss the trigger coils. This cuses the trigger coils to produce voltge pulse which is sent to the respective cpcitor dischrge module (CDM). A positive voltge pulse (N S) will ctivte the electronic switch (SCR) inside the cpcitor dischrge module (CDM). The switch dischrges the cpcitor voltge through the coil primry windings. The return voltge pulse exits the CDM through the ground wire nd returns through the trigger ground. b 3 d 1 2 /YEL WHT/GRN PPL c j YEL YEL WHT/GRN GRN/WHT e WHT i /YEL f CAPACITOR- COIL- /YEL PPL g SCR- DIODE- h - Bttery Chrging Coils b - Trigger Coils c - Cpcitor Chrge Coils d - CDM #1 e - CDM #2 f - CDM #3 g - Rev. Limiter (Not Used On All Models) h - To Ignition Switch i - Stop Switch j - To Voltge Regultor 2A-12 - ELECTRICAL R02 NOVEMBER 2002

15 Ignition Coil Circuit As the cpcitor voltge flows through the primry windings of the ignition coil, voltge is induced into the ignition coil secondry windings. This secondry voltge rises to the level required to jump the sprk plug gp nd return to ground. This secondry voltge cn, if necessry, rech pproximtely 40,000 volts. To complete the secondry voltge pth, the relesed voltge enters the ground circuit of CDM module. b 3 d 1 2 /YEL WHT/GRN PPL c j YEL YEL WHT/GRN GRN/WHT e WHT i /YEL f CAPACITOR- COIL- /YEL PPL g SCR- DIODE- h - Bttery Chrging Coils b - Trigger Coils c - Cpcitor Chrge Coils d - CDM #1 e - CDM #2 f - CDM #3 g - Rev. Limiter (Not Used On All Models) h - To Ignition Switch i - Stop Switch j - To Voltge Regultor R02 NOVEMBER 2002 ELECTRICAL - 2A-13

16 Stop Circuit To stop the engine, the stop switch is closed llowing the cpcitor chrge current from the sttor to drin directly to ground. NOTE: The CDM contins zener diode (not shown for clrity). This diode prevents overchrging of the cpcitor (nd possible filure) if the SCR does not receive trigger pulse. b 3 d 1 2 /YEL WHT/GRN PPL c j YEL YEL WHT/GRN GRN/WHT e WHT i /YEL f CAPACITOR- COIL- /YEL PPL g SCR- DIODE- h - Bttery Chrging Coils b - Trigger Coils c - Cpcitor Chrge Coils d - CDM #1 e - CDM #2 f - CDM #3 g - Rev. Limiter (Not Used On All Models) h - To Ignition Switch i - Stop Switch j - To Voltge Regultor 2A-14 - ELECTRICAL R02 NOVEMBER 2002

17 Rev Limiter Circuit The rev limiter is ctivted through the purple wire when the key switch is rotted to the on position. The rev limiter uses trigger signl (brown wire) to determine engine speed or rpm. If the engine speed exceeds the specified rpm, the rev limiter will ground out the CDM cpcitor chrge. The cpcitor voltge flows through the blck/yellow wires into the rev limiter nd to engine ground through the blck wire. b 3 d 1 2 /YEL WHT/GRN PPL c j YEL YEL WHT/GRN GRN/WHT e WHT i /YEL f CAPACITOR- COIL- /YEL PPL g SCR- DIODE- h - Bttery Chrging Coils b - Trigger Coils c - Cpcitor Chrge Coils d - CDM #1 e - CDM #2 f - CDM #3 g - Rev. Limiter (Not Used On All Models) h - To Ignition Switch i - Stop Switch j - To Voltge Regultor R02 NOVEMBER 2002 ELECTRICAL - 2A-15

18 Ignition Component Description Cpcitor Dischrge Module (CDM) Ech module contins n ignition coil nd mplifier circuitry which produces pproximtely 45,000 volts t the sprk plugs. Sttor Assembly Locted under the flywheel in the sttor ssembly re 12 coils (6 for mnul sttor), 3 ignition chrge coils nd 9 uxiliry (3 for mnul) power coils wound in series tht provide voltge to the CDM s nd bttery/ uxiliry circuits respectively. Trigger Coil Locted under flywheel. Is chrged by single mgnet on flywheel hub. Trigger pulses re sent to CDM. Flywheel Contins 6 mgnets (12 pole) round circumference. Hs one mgnet on inner hub for trigger. Outer mgnets re for bttery chrge coils nd ignition chrge coils. NOTE: Electric strt model flywheel shown. 2A-16 - ELECTRICAL R02 NOVEMBER 2002

19 CDM (P/N A) Troubleshooting Chrt 1- CDM Trouble Shooting Flowchrt Step Action Vlue Yes No Tools 1 Verify High Tension Leds, Sprk Plug nd Sprk Boots re in good condition. Inspect wires for chfing. Visul Inspection 2 Verify 4 Pin Connector Integrity Visul Inspection 3 Verify Ground from CDM connector to block 4 Test ll CDMs t Crnking with Sprk Gp Tester Sprk on All CDMs? Will sprk jump 7/16 in. (11.11 mm) gp? Step 2 Replce Filed Component Step 2 Step 3 Repir/Replce Connector Components Step Ohms nd below * 7/16 in. (11.11 mm) gp Step 4 If t lest one CDM hs sprk, continue with Chrt #3 Correct Ground Pth Step 4 Continue with Chrt #2 High Tension led pin P/N A56 DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor Test Hrness P/N A2 Sprk Gp Tester P/N NOTE: * To obtin ccurte reding, short test meter leds together nd subtrct vlue from reding or dust meter to zero. CDM (P/N A) A B C D - Ground b - Blck/Yellow c - Trigger Connection d - Sttor Connection R02 NOVEMBER 2002 ELECTRICAL - 2A-17

20 CDM Stop Diode Troubleshooting 2 Cyl.: CDM #1 gets its chrging ground pth through CDM #2. CDM #2 gets its chrging ground pth through CDM #1. A shorted Stop Diode in either CDM would prevent the opposite one from sprking Cyl.: CDM #1 gets its chrging ground pth through CDM #2 or #3. CDM #2 nd #3 get their chrging ground pth through CDM #1. A shorted Stop Diode in CDM #1 would prevent CDMs #2 nd #3 from sprking. A shorted Stop Diode in CDM #2 or #3 would prevent CDM #1 from sprking Cyl.: CDM #1 nd #2 get their chrging ground pth through CDM #3 or #4. CDM #3 nd #4 get their chrging ground pth through CDM #1 or #2. A shorted Stop Diode in CDM #1 or #2 would prevent CDMs #3 nd #4 from sprking. A shorted Stop Diode in CDM #3 or #4 would prevent CDM #1 nd #2 from sprking A-18 - ELECTRICAL R02 NOVEMBER 2002

21 Chrt 2-CDM Trouble Shooting Flowchrt (NO SPARK ON ANY CDM) Step Action Vlue Yes No Tools 1 With the key switch ON: Verify continuity between /YEL hrness wire nd ground. This Test Checks: Lnyrd Switch Key Switch Rev Limiter (externl) Chfed /YEL wire CDM Stop Circuit 2 Un-plug ll CDMs nd verify continuity between disconnected / YEL hrness wire nd ground. This Test Checks: CDM Hrness 3 Connect CDM one t time This Test Checks: Individul CDM Stop Circuits 4 Check Sttor Resistnce between GRN/WHT nd WHT/GRN Open circuit voltge t crnking should be no less thn 100 Volts on the DVA 5 Check Trigger/Crnk Shft Position Sensor Output: Crnking with CDM disconnected. Crnking with CDM connected. NO continuity Step 2 Repir or Replce Component Run Engine Verify Repir Step 7 NO continuity Step 3 Repir or Replce Component Run Engine Verify Repir Step 7 Resistnce will rise with ech CDM connected, full continuity indictes shorted CDM stop circuit.* Ohms 2, 3, 4 Cyl. Models 1 Volt nd bove - CDM disconnected Volts- CDM connected. Step 4 Step 5 Step 6 Repir or Replce Component Run Engine Verify Repir Step 7 Replce Sttor Run Engine Verify Repir Step 7 2, 3, & 4 Cyl Replce Trigger Run Engine Verify Repir Step 7 DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor P/N DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor P/N TPI/CDM Test Hrness A2 DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor TPI/CDM Test Hrness A2 NOTE: *Diode Redings: Due to the differences in test meters, results other thn specified my be obtined. In such cse, reverse meter leds nd re-test. If test results then red s specified CDM is O.K. The diode mesurements bove will be opposite if using Fluke equivlent multimeter R02 NOVEMBER 2002 ELECTRICAL - 2A-19

22 CHART #2 (NO SPARK ON ANY CDM) (CONTINUED) 6 Test ll CDMs t Crnking with Sprk Gp Tester Sprk on All CDMs? 7/16 in. (11.11 mm) gp Step 7 Verify All Preceding Steps Sprk Gp Tester P/N Will sprk jump 7/16 in. (11.11 mm) gp? 7 If mis-firing is in repetble rnge: Perform DVA redings on sttor nd trigger t ll running speeds.* Sttor: 200 Volts nd bove Trigger: 2 Volts nd bove Run Engine Verify Repir END Refer to *Note Below DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor TPI/CDM Test Hrness A2 NOTE: * Sttor tests will only isolte problem down to chrging pir. Further testing is necessry to determine fulty CDM. Disconnecting one CDM of the chrging pir is recommended. 2A-20 - ELECTRICAL R02 NOVEMBER 2002

23 Chrt 3-CDM Troubleshooting Flowchrt (AT LEAST ONE CDM HAS SPARK) Step Action Vlue Yes No Tools 1 Resistnce Check ALL CDMs Refer to chrt Step 3 Replce ny CDMs tht do not pss specifictions even if they fire Step 2 2 Test ll CDMs t Crnking with Sprk Gp Tester Sprk on All CDMs Will sprk jump 7/16 in. (11.11 mm) gp? 3 Check Trigger Output: Crnking with CDM disconnected. Crnking with CDM connected. 4 Test ll CDMs t Crnking with Sprk Gp Tester Sprk on All CDMs? Will sprk jump 7/16 in. (11.11 mm) gp? 5 If mis-firing is in repetble rnge: Perform DVA redings on sttor nd trigger t ll running speeds.* 7/16 in. (11.11 mm) gp 1 Volt nd bove - CDM disconnected Volts - CDM connected. 7/16 in. (11.11 mm) gp Sttor: 200 Volts nd bove Trigger: 2 Volts nd bove Run Engine Verify Repir Step5 Step 4 Run Engine Verify Repir Step5 Run Engine Verify Repir END Step 3 2, 3, & 4 Cyl - Replce Trigger Run Engine Verify Repir Step 5 Replce ny non-firing CDMs Step 5 Refer to *Note Below. DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor Sprk Gp Tester P/N DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor TPI/CDM Test Hrness A2 Sprk Gp Tester P/N DMT 2000 Digitl Tchometer/ Multi-meter P/N A1 & DVA Adptor TPI/CDM Test Hrness A2 * Note: Sttor tests will only isolte problem down to chrging pir. Further testing is necessry to determine fulty CDM. Disconnecting one CDM of the chrging pir is recommended R02 NOVEMBER 2002 ELECTRICAL - 2A-21

24 CDM Test with DMT 2000 Multi-meter A1 IMPORTANT Sprk plug wires re screwed into CDM. A B C D - Ground b - Blck/Yellow c - Trigger Connection d - Sttor Connection A resistnce check is required nd cn be performed on the CDM s follows: NOTE: This test cn be performed using the test hrness (P/N A2). DO NOT connect the test hrness plug to the sttor/trigger engine wire hrness. Set meter to for diode check. Circuit Test Stop Diode Forwrd Bis Stop Diode Reverse Bis Return Ground Pth Diode, Reverse Bis Return Ground Pth Diode, Forwrd Bis CDM Trigger Input Resistnce Coil Secondry Impednce Connect Negtive ( ) Meter Led To: Green (D)/ or Green test hrness led Blck/Yellow (B)/ or Blck/Yellow test hrness led Green (D)/ or Green test hrness led Ground Pin (A)/ or Blck test hrness led Ground Pin (A)/ or Blck test hrness led Ground Pin (A) or Blck test hrness led CAPACITOR DISCHARGE MODULE Connect Positive () Meter Led To: Blck/Yellow (B)/ or Blck/Yellow test hrness led Green (D)/ or Green test hrness led Ground Pin (A) or Blck test hrness led Green (D)/ or Green test hrness led White (C)/ or White test hrness led Sprk Plug Terminl (At Sprk Plug Boot) Diode Check OUCH or O.L. Setting (Auto Rnge) OUCH or O.L V mω V OUCH or O.L V (Not perferred test) V (Not perferred test) 1-30 mω, then slowly increses to OUCH or O.L mω Ohms Ohms *Diode Redings: Due to the differences in test meters, results other thn specified my be obtined. In such cse, reverse meter leds nd re-test. If test results then red s specified CDM is O.K. The diode mesurements bove will be opposite if using Fluke equivlent multimeter. NOTE: If CDM checks good, secondry test cn be performed to ensure tht CDM is good when running hot. Het CDM with hot ir gun to pproximtely 85 C (185 F). Repet Resistnce test bove nd Test 4 on Chrt 1 while hot. 2A-22 - ELECTRICAL R02 NOVEMBER 2002

25 CDM Test with Volt/Ohm/DVA Meter A1 IMPORTANT Sprk plug wires re screwed into CDM. A B C D - Ground b - Blck/Yellow c - Trigger Connection d - Sttor Connection A resistnce check is required nd cn be performed on the CDM s follows: NOTE: This test cn be performed using the test hrness (P/N A2). DO NOT connect the test hrness plug to the sttor/trigger engine wire hrness. Circuit Test Stop Diode Forwrd Bis Stop Diode Reverse Bis Return Ground Pth Diode, Reverse Bis Return Ground Pth Diode, Forwrd Bis CDM Trigger Input Resistnce Coil Secondry Impednce Connect Negtive ( ) Meter Led To: Green (D)/ or Green test hrness led Blck/Yellow (B)/ or Blck/Yellow test hrness led Green (D)/ or Green test hrness led Ground Pin (A)/ or Blck test hrness led Ground Pin (A)/ or Blck test hrness led Ground Pin (A) or Blck test hrness led CAPACITOR DISCHARGE MODULE Connect Positive () Meter Led To: Blck/Yellow (B)/ or Blck/Yellow test hrness led Green (D)/ or Green test hrness led Ground Pin (A) or Blck test hrness led Green (D)/ or Green test hrness led White (C)/ or White test hrness led Sprk Plug Terminl (At Sprk Plug Boot) Ohms Scle R x 100 Diode Reding* R x 100 Diode Reding* R x 100 Diode Reding* R x 100 Diode Reding* R x 100 R x 100 Results: Continuity No Continuity No Continuity Continuity Ohms Ohms *Diode Redings: Due to the differences in test meters, results other thn specified my be obtined. In such cse, reverse meter leds nd re-test. If test results then red s specified CDM is O.K. The diode mesurements bove will be opposite if using Fluke equivlent multimeter. NOTE: If CDM checks good, secondry test cn be performed to ensure tht CDM is good when running hot. Het CDM with hot ir gun to pproximtely 85 C (185 F). Repet Resistnce test bove nd Test 4 on Chrt 1 while hot R02 NOVEMBER 2002 ELECTRICAL - 2A-23

26 Ignition Test Procedures Direct Voltge Adptor (DVA) Test CAUTION DVA checks cn be mde while crnking engine with strter motor. To prevent engine from strting while being crnked, ll sprk plugs must be removed. CAUTION To protect ginst meter nd/or component dmge, observe the following precutions: INSURE tht the Positive () meter led is connected to the DVA receptcle on the meter. DO NOT CHANGE meter selector switch position while engine is running nd/or being crnked. NOTE: Ech CDM is grounded through the engine wiring hrness vi the connector plug. It is not necessry to hve the CDM mounted on the ignition plte for testing. 1. Remove ll sprk plugs. 2. Insert sprk gp tool (P/N A1) into ech sprk plug boot nd ttch lligtor clips to good engine ground. 3. Disconnect remote fuel line from engine. 4. Mke sure ll CDMs re plugged in. 5. Test Sttor nd Trigger voltge to CDM:. Instll test hrness ( A2) between ignition hrness nd CDM. b c Sttor Output Test Positive Meter Led () Connect to Green Test Hrness Led Negtive Meter Led ( ) Connect to Blck Test Hrness Led 400 DVA Scle DVA Reding c. If only one CDM sttor reding is below specifictions, replce tht CDM. If ll CDM sttor voltge redings re low, go to Testing Sttor Resistnce. GRN d. Test ech CDM. Trigger Output Test Positive Meter Led () White Test Hrness Led Negtive Meter Led ( ) 2 DVA Scle DVA Reding Blck Test Hrness Led If reding is below specifictions, replce trigger. If reding is bove specifictions, check CDM. - Sttor/Trigger Hrness b - Test Hrness ( A2) c - Cpcitor Dischrge Module b. Test ech CDM. 2A-24 - ELECTRICAL R02 NOVEMBER 2002

27 NOTE: If voltge remins low fter instlling new trigger, replced CDM. Resistnce Tests TRIGGER A resistnce test is not used on the trigger. Test trigger s outlined under Testing Voltge Output to CDM - Trigger Output Test. WHT STATOR 1. Disconnect sttor leds. NOTE: Resistnce vries gretly with temperture. Mesurements should be tken with n mbient temperture rnge of 65 to 85 F. ENGINE RUNNING AT IDLE It is not necessry to perform this test if the voltge output ws tested in the previous step. Sttor Output Test Positive Meter Led () Connect to Green Test Hrness Led Negtive Meter Led ( ) Connect to Blck Test Hrness Led 400 DVA Scle DVA Reding If sttor output is low, go to Testing Sttor Resistnce. Trigger Output Test Positive Meter Led () White Test Hrness Led Negtive Meter Led ( ) Blck Test Hrness Led 20 DVA Scle DVA Reding 2-8 Volts If reding is below specifictions, replce trigger. If reding is bove specifictions, check CDM. NOTE: If voltge remins low fter instlling new trigger, replce CDM. Sttor Resistnce Test Positive Meter Led () Connect to White/Green sttor led Connect to White/Green sttor led Connect to Green/White sttor led Negtive Meter Led ( ) Connect to Green/White sttor led Connect to engine ground Connect to engine ground R x 1 Ohms Scle or Auto Rnge DMT L L No continuity No continuity IMPORTANT If ll CDM sttor output voltge is low nd sttor resistnce tests re within specifictions, then ech CDM (one t time) must be replced with CDM known to be good until sttor output voltge returns to proper levels. This process of elimintion will revel defective CDM R02 NOVEMBER 2002 ELECTRICAL - 2A-25 RX1

28 Flywheel Removl nd Instlltion REMOVAL 1. Remove flywheel cover from engine. WARNING Engine could possibly strt when turning flywheel during removl nd instlltion; therefore, disconnect (nd isolte) sprk plug leds from sprk plugs to prevent engine from strting. 2. Disconnect sprk plug leds from sprk plugs. 3. While holding flywheel with flywheel holder ( ), remove flywheel nut nd wsher. 6. Remove flywheel. Remove flywheel key. 7. Crefully inspect flywheel for crcks or dmge. 8. Inspect crnkshft nd flywheel tpers for worn or dmged key wys. 9. Check for loose or dmged flywheel mgnets (outer rim nd center hub). Replce flywheel if necessry. INSTALLATION 1. Instll flywheel key in crnkshft slot with outer edge of key prllel to center line of crnkshft. - Flywheel Key - Flywheel Holder Instll crnkshft Protector Cp ( ) on end of crnkshft, then instll Flywheel Puller ( T1) into flywheel. 5. Hold flywheel tool with wrench while tightening bolt down on protector cp. Tighten bolt until flywheel comes free. 2. Align slot in flywheel center bore with flywheel key nd instll flywheel onto crnkshft. 3. Instll wsher nd nut. 4. Hold flywheel with Flywheel Holder ( ); torque nut to 125 lb. ft. (169.5 N m). - Flywheel Holder Flywheel Puller NOTE: Neither het nor hmmer should be used on flywheel to id in removl s dmge to flywheel or electricl components under flywheel my result. 2A-26 - ELECTRICAL R02 NOVEMBER 2002

29 Sttor Removl nd Instlltion REMOVAL 1. Remove flywheel. See Removing Flywheel In This Section. 2. Remove yellow sttor leds from rectifier/regultor leds. 3. Disconnect ll sttor leds from CDM wire hrness. NOTE: Removl of ignition plte my be necessry to gin ccess to sttor leds. 4. Remove screws nd lift sttor off bering cge. INSTALLATION 1. Set sttor on bering cge. Secure with screws. Screws threds should be lightly coted with loctite 222 nd torqued to 60 lb. in. (6.8 N m) Screws - Screws Connect yellow sttor leds to yellow voltge regultor leds (electric models). 3. Connect ll sttor leds to corresponding CDM wire hrness. 4. Instll flywheel. See Instlling Flywheel in this section. Trigger REMOVAL 1. Remove flywheel. See Removing Flywheel in this section. 2. Remove sttor. See Removing Sttor in this section. 3. Disconnect trigger leds from CDM wire hrness R02 NOVEMBER 2002 ELECTRICAL - 2A-27

30 4. Disconnect link rm nd remove trigger. CDM - Link Arm b - Trigger 5. Lift trigger off bering cge. b REMOVAL WARNING Alwys disconnect bttery nd disconnect sprk plug leds from sprk plugs before working on motor. 1. Disconnect CDM wire hrness plug. 2. Remove screws securing CDM to ignition plte. INSTALLATION 1. Position CDM on ignition plte. Instll screws, torque to 60 lb. in. (6.8 N m). 2. Connect CDM wire hrness plug to CDM. INSTALLATION 1. Instll trigger nd connect link rm b b - Link Arm b - Trigger Wire Hrness Plug b - Screws 2. Plce trigger on bering cge. 3. Route led wires under ignition plte nd down to the CDM wire hrness. 4. Connect corresponding trigger leds to CDM wire hrness. 5. Instll sttor. See Instlling Sttor in this section. 6. Instll flywheel. See Instlling Flywheel in this section. 7. Check engine timing. See Engine Timing in Section 2C. 2A-28 - ELECTRICAL R02 NOVEMBER 2002