Sport Jet Spark Mystery... PLEASE HELP!!!

[spy88]

Hi All,

I have a 90HP Red Stator/Adapter Sport Jet with no/intermittent spark. Tried all the usual tricks like disconnect Blk/Yl at switch box, disconnect (temporarily) Yl & Yl for rectifier, and jump lanyard Yl/Rd wires and check again for spark with no luck. Components seem to check out in terms of resistance. Did not do a DVA check, but tried new stator, regulator/rectifier, and switch box with same results.

Interesting thing is that it will almost always spark, but only when turning key off, and quickly back on (to accy position) after cranking (but no spark during cranking). I have also seen it spark a few times while troubleshooting, and it got me stuck out on the water twice last year because it started and I though it was fixed, but it wasn't! Haven't been able to get it to start this year though.

Anyone have any ideas? Don't know how much more I can take! Thanks!

 

[spy88]

Re: Sport Jet Spark Mystery... PLEASE HELP!!!

Does anyone have an internal diagram for the key switch? This isn't in the service manual I have. Thanks!

 

[spy88]

Re: Sport Jet Spark Mystery... PLEASE HELP!!!

bump

 

[spy88]

Re: Sport Jet Spark Mystery... PLEASE HELP!!!

bump

 

[CharlieB]

Re: Sport Jet Spark Mystery... PLEASE HELP!!!

............ no/intermittent spark. .................tried new stator, regulator/rectifier, and switch box with same results. ..........(but no spark during cranking).

You've goone with an expensive method of troubleshooting your problem.

A DVA MEter can be your best Ally in determining an ignition problem.

OK, I'm done chastizing you.

The Black W/yellow kill wire switchbox system grounds this wire thru the ignition switch to the solid black wire. Disconnecting this wire at the switchbox and still a 'No Spark' is a good test which can prove a grounded ignition switch killing spark.

However, if someone has replaced the ignition switch with the WRONG switch and you have an ENERGIZED ignition switch putting 12 V to the ignition, you will immediately kill a new switchbox.

Disconnect the black w/yellow at the ignition switch or the motor and connect a volt meter to the ignition switch side of the wire, turn on the switch and read your meter, ANY voltage and the switch is wrong/bad/must be replaced.

If the switch tests OK, then your problem MAY be in the wiring to the coils, the coils, plug wires, or in the trigger that signals the switchbox to fire.

You have already replaced half of your ignition system, perhaps needlessly, perhaps not, Do not throw away any old parts, you do not know for sure if they are defective.

Get a hold of a DVA Meter and test the trigger, it may have broken wires where they 'flex' as the timer plate rotates, causing intermittent spark as the wires make/break contact. It is possible that this may have been you original problem, hense, save all your old parts.

 

[spy88]

Re: Sport Jet Spark Mystery... PLEASE HELP!!!

You've goone with an expensive method of troubleshooting your problem.

A DVA MEter can be your best Ally in determining an ignition problem.

OK, I'm done chastizing you.

The Black W/yellow kill wire switchbox system grounds this wire thru the ignition switch to the solid black wire. Disconnecting this wire at the switchbox and still a 'No Spark' is a good test which can prove a grounded ignition switch killing spark.

However, if someone has replaced the ignition switch with the WRONG switch and you have an ENERGIZED ignition switch putting 12 V to the ignition, you will immediately kill a new switchbox.

Disconnect the black w/yellow at the ignition switch or the motor and connect a volt meter to the ignition switch side of the wire, turn on the switch and read your meter, ANY voltage and the switch is wrong/bad/must be replaced.

If the switch tests OK, then your problem MAY be in the wiring to the coils, the coils, plug wires, or in the trigger that signals the switchbox to fire.

You have already replaced half of your ignition system, perhaps needlessly, perhaps not, Do not throw away any old parts, you do not know for sure if they are defective.

Get a hold of a DVA Meter and test the trigger, it may have broken wires where they 'flex' as the timer plate rotates, causing intermittent spark as the wires make/break contact. It is possible that this may have been you original problem, hense, save all your old parts.

Thanks for the response. From what I recall, I tested the switch side of the Yl/Bk and it read 0.02V or something like that with the key in the Accy position. Is that cause for concern? Ignition switch has not recently been replaced, and it ran fine in its current condition for several years. Pretty sure the coils and plug wires are ok as they do occasionally spark (see my original post). I can check again to be sure though.

Unfortunately, I was using the 1.41 DVA method from a forum member and the service manual which misguided me into getting those new parts. I know the old parts may still be good and have saved them.

I'll check the trigger this week and see what I find. Thanks for the help!

 

[CharlieB]

Re: Sport Jet Spark Mystery... PLEASE HELP!!!

Retest the Blw w/Y from the ign switch to see if that .02 was stray readings from a sensitive digital meter or if it realy is .02 then 0's out when the switch is turned OFF. Voltage will rise while the engine is running, according to factory manual AND CDI Electronics, ANY voltage is cause for concern.