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Sportjet 90 - lost spark

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  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    I ordered and installed a new CDI switchbox and now have tons of spark. Do you suppose the under testing trigger (low ohms on one wire) could have blown out the switchbox?

    Thanks for your advice it helped a lot.
    My_Jet90

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    Hate to ask you to do this but redo all ohm tests in the Sport Jet Info nad Basics post as a switchbox will be the only option unless you have a DVA adapter to do some more testing , I hate getting to this step !!

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    2.15 to 2.38 range for the white/black switchbox test. This test reading was taken from the trigger white/black billet connection point to the switchbox.

    My new trigger ohms are looking good. All 3 test at 1270 ohms.

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    Hook up all the wires to the rev limiter , disconnect only the black / yellow and check spark , if none disconnect the black/yellow at the switchbox and check spark . If none hook all wires up , be sure everything is grounded then run a switchbox bias test as follows

    Ohm meter set to 20v DC
    Ground red meter lead , Black meter lead to white/black at switchbox
    Crank engine and postup voltage reading

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    I am learning in this process.

    I removed the switchbox and see that it does have the adapter with the green/white , white/green should run to an adapter that has a ground wire , and a blue wire coming out of it. That adapter box is velcro'd to the switchbox and was so secure that I thought it was a part of that.

    So now I do know the 2 blue wires are suppose to connect to each other. I ahve removed all wires from the Rev limiter and still no spark on any plug.

    I wonder if I fried my switchbox. I have been using new plugs and can see that plugs #2 and #3 had been firing at some point in my early testing prior to changing out the trigger. Since then I have had all 3 being tested at the same time.

    New photo's attached. Do you think it is worth a new switchbox, I could re-sell if that didn't fix me up.


    Thanks
    Attached Files

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    I think you may have an old ring connector type switchbox , or perhaps an aftermarket box , pull the switch box off and see if there is a cover that removes to expose the wire terminal hookups if so post a pic of the terminals (with wires hooked up ) and I can figure out what is what

    Also Is the brown wire from the rev limiter disconnected ??

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    It seems like I have an odd switchbox. Both blue wires come out of the same switchbox. On on the side and one from the end of the same box by itself no other wires nearby.

    No atapter before the switchbox. It has the correct colored wires to go directly to the stator and trigger (brown, purple, white and white/black stripe). I am wondering if the sole blue wire from the end of my switchbox should go to the brown rev limiter. That blue wire is extra long and has an extra schielding jacket on it like it was meant to run to the starter side of the motor.

    That would leave me with an extra blue wire to tape up running out of the switchbox. How much do new switchboxes run. I can't find any branding or numbers on mine, maybe on the backside.

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    I'm going to dig out my old switchbox in a bit and look at the wires , Your red stator has green/white , white/green wires that replace the red and blue wires from the black stator . the green/white , white/green should run to an adapter that has a ground wire , and a blue wire coming out of it . the blue wire coming from the adapter should be hooked up to the switchbox blue wire used for the black stator and the red wire for the old stator should just be taped up so it can't ground out . I am thinking someone just used some blue wire for harness repair and that is why you have an extra one. if this is the case you need to trace the other blue wire and see where it goes to

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    Still no spark with a new trigger installed. The flywheel looks like new magnets all firmly in place. I tested each cylinder for spark now. The RPMs are super fast now that I have all three plugs removed.

    I attached a picture of the back of the wiring chasis.

    I am wondering if I have the 2 blue wires connected correctly. I looked at my Clymer wiring diagram for the late 90 hp model billet connector style, but it looks like I have a different switchbox because instead of red and blue wires going to the stator I have white/green and green/white. The 2 blue wires that are suspiciously connected to each other. Should one go to the brown rev limiter?

    The picture shows one blue wire coming out the end of the switchbox by itself. The other blue wire comes out the side of the switchbox. Maybe the bottom one is unused?
    Attached Files

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    keep posting up , the trigger is out of spec and hopefully it is the only thing bad .

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    That is what I almost ordered last Saturday.
    I'll have to dig in the harness to find the other rev limiter connection.

    Will let you know how it goes when I get that replaced.

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    Looking at your first pic , Left to right is ,
    Coils , above them the box if the voltage regulator
    Next big black box , Switchbox with the red stator adapter on top
    last box is the rev limiter
    The 2 red wires do not go together one should plug into a harness and tape the other one up .

    ORDER a trigger it is bad if you need part numbers they are :
    Mercury : 817029a9
    CDI 134-7029-3 (GOOD Aftermarket stuff)

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    I tested for spark with the mystery box (Rev limiter) wires unplugged. Black wire to the ground was removed. Purple was still connected, Black/yellow was unplugged and I don't know where the 2 brown wires go. The box has a single brown wire comming out of it and then splits into 2 brown (one female and one male connector). LOL...I should plug them to each other...lol!


    Attached are a couple of pictures. The box on the right must be my rev limiter. The other picture shows the brown wire split.


    Does the trigger have a wire for each coil?

    I uploaded 2 pictures but not sure where they are. I'll email a copy to you just in case they didn't make it here. The PN# on the mystery box is: x21889 A48 xx75
    Attached Files

    Leave a comment:


  • kend301
    replied
    Re: Sportjet 90 - lost spark

    Black / yellow wire is the kill circuit , can you post a pic of the "mystery box" could be the rev limiter as purple and brown run to it , Unplug the black /yellow from the mystery box and check spark , If not reOHM the trigger , purple is out of spec . BUt I want to see the BOX before I recommend trigger replacement .

    Leave a comment:


  • My_Jet90
    replied
    Re: Sportjet 90 - lost spark

    Thanks...I've got the red stator.

    Volts read 12.95 and cranks over as fast as it normally does

    Stator green/white to white/green reads 680 ohms

    Trigger reads
    Brown: 1208 ohms
    Purple: 1063
    White: 1208

    I'm also looking for a wiring diagram. I can identify the 3 coils and the voltage regulator. That still leaves 2 boxes. One I think is the switchbox with lots of wires coming out of the side and a blue wire from one end.

    The other mystery box has a black/yellow, purple, brown and black wire only. Is this my switchbox? The brown wire splits into 2 billets and I'm not sure where to reconnect these up. That is why I'm looking for the RED stator wiring diagram.

    And I think the rev limiter has been removed as I see nothing where it shoudl be bolted on the starter side of the engine.

    Thanks again for any light you can shed.
    Last edited by My_Jet90; July 20th, 2010, 08:53 PM. Reason: type-O

    Leave a comment:

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