Re: 1989 Suzuki DT115 CDI Box Needed
A little history here. I bought this used 1989 DT115 on a boat last fall, it was sitting for 3-4 years. Compression was low 130's on all four cylinders but there was NO spark on any cylinder. Bought junk 1990 DT115 over the winter. Found source of No spark on original engine to be bad CDI box.
Took CDI box off junk motor and spark now good on original motor. Fired motor up and it ran good for several days but Suzuki Caution System monitor NOT flagging any faults, indicators always green, even on startup. My boat has NO buzzer so I only had the visual display to monitor. Started troubleshooting oil pump
pressure/flow switch, found it was always open. appears that it should be
normally closed and open with oil pressure/flow. (opposite of how I thought it
should work) Forced closed position(no oil) with motor running and red oil indicator illuminated as expected, engine then shut itself down. Unable to clear red oil alarm, had to removed battery power from engine to clear. Repeated with same results except a few seconds after engine shut down
there was a loud bang, thought engine backfired. Smoke poured out of the cowling. Found face of CDI box physically cracked and a large section of the plastic housing blew off ,exposing the Printed Circuit Board. There is a large burn mark on the PCB and i have no spark. Installed original CDI module on a prayer, no spark. Original CDI module shows NO physical damage.
Net is I bought this engine with bad CDI module and a second one basically blew up. Don't know if this is just bad luck or whether a sensor is shorting the module out. I do have a defective voltage rectifier on my engine, have one on order. Not sure if this is somehow affecting the CDI performance
Any help/advice would be appreciated.