1995 DT25C Pulsar coils question

[schnewj]

Hi everyone,

I'm new to the board and I need some expertise. I am in the process of getting a 1995 DT25C up and running after sitting idle for awhile. I've gone through the motor and it runs OK, but I'm still trying to tweak it to run right.

I have some issues to address but in tracking down a bad coil under the magneto I checked the air gap on the three pulsar coils. My Clymer manual says, that, the air gap should be set to 0.003. However, when I check the three coils they all measured out at around 0.020. I'm the original owner of the motor and I know that nobody has worked on these. So, they came from the factory adjusted to 0.020. Is the Clymer manual wrong on the gap?

What is the correct air gap for this motor? Should I leave the air gaps as they originally came from Suzuki, or do they need to be readjusted to a different spec?

 

[99yam40]

Re: 1995 DT25C Pulsar coils question

I would go by the peak voltage outputs, if they are in spec ,I would leave them alone.

Hopefully some one with a different manual will post what the spec is

 

[schnewj]

Re: 1995 DT25C Pulsar coils question

I would go by the peak voltage outputs, if they are in spec ,I would leave them alone.

Hopefully some one with a different manual will post what the spec is

I appreciate the reply but I don't think that adjusting for peak voltage is most efficient route. Besides, I don't know what the peaks should be.

Unless someone could give me the optimal voltage range specs, I would hesitate to adjust the three coils looking for the peak voltage output. The process to adjust them is just to involved. It requires the removal of the magneto to adjust the air gap, re-removal of the mag to tighten the coils once they are set right, then verifying the gap; repeating until the gap is correct and uniform for all three. This would just be an overall pain. Especially, if you are constantly moving the coils looking for peak voltage output.

However, it is a viable option to consider if all else fails.

I just can't believe that the Clymer manual would list the spec as 0.003 and the factory set them at 0.020! Somebody is wrong, but who? I can't believe that the factory setting is incorrect and I have found a couple of inconsistencies in the Clymer manual already.

I was hoping there was a Suzuki tech on the board that could shed some light and insight for me.

The motor ran beautifully for the first seven or eight years, then developed a slight miss. I had it worked on and the "authorized Suzuki repair dealer" just took my money and didn't resolve the issue, then they went out of business. Surprise! In retrospect, with my mechanical knowledge and abilities I should have just done it myself, but I was just too busy at the time to bother.

Subsequently, a series of event forced me to set up the boat and motor. I am now in the process of getting it back into action. I have had it running, but it is still not running as smoothly as it should.

So, any help out there would be greatly appreciated. I'm still looking for the "official Suzuki air gap spec".

 

[schnewj]

Re: 1995 DT25C Pulsar coils question

Sorry guy, in rereading my original post I had the Clymer spec wrong...it should read 0.030 NOT 0.003.

So, the coils were set at the factory at approximately 0.020 and the Clymer manual say, 0.030. Any Idea if the 0.030 is correct or should I just leave them be at the original 0.020?

 

[99yam40]

Re: 1995 DT25C Pulsar coils question

the manual will give the minimum peak voltage spec and as long as it meets that spec leave it alone and find out what other problem you have as that is not your problem.
How are you measuring the gap on a curved mechanism?

 

[schnewj]

Re: 1995 DT25C Pulsar coils question

The Clymer manual doesn't list a peak voltage, only an air gap measurement. The manual calls out 0.030 but the coils were obviously set at 0.020 at the factory.

As with any magneto type system a simple brass feeler gauge is sufficient. In my case I use non-magnetic brass instead of steel, so the magnet doesn't grab it. With small motors, like a Briggs a standard business card works on setting the gap. An outboard is a little bit more sensitive. Hence, the feeler gauge in order to get the measurement as close as possible to what it should be, if it needs adjusted.

Bottom line I'll leave them as they are for now. I have to replace the ignition coil first to see if that smooths out the motor. If the motor doesn't smooth out after that I'll dig a little deeper and see it there is anything else that I may have missed during troubleshooting.

If nothing else shows up then I may consider adjusting the Pulsar coils.

 

[99yam40]

Re: 1995 DT25C Pulsar coils question

That is one reason I do not like after market manuals, they do not give all the specs some times.

Even with a brass feeler gauge .030 is stiff enough that you may not get a true reading with it on a curved surface is all I was getting at. The thin ones are flexible enough it does not matter too much as they bend and conform to the curved surface well

 

[schnewj]

Re: 1995 DT25C Pulsar coils question

I have to agree about aftermarket manuals. I personally don't like using anything but "official shop manuals". However, sometimes the cost far outweighs the need and aftermarkets have to suffice for occasional use. This is why I don't hesitate to seek out experienced advice when I'm not familiar with a specific piece of machinery.

One of the advantages to using brass over steel feeler gauges is not only the fact they are a non-Ferris material but they are more flexible and tend to conform to a contour better then steel. In reality, the contact surface(s) on the coil and the magneto magnet is tiny. So, it is easy to get a good reading as the contact points are flat and parallel and there is plenty of room to get the gauge in to measure...no obstructions!

Your absolutely correct about adjusting to voltage outputs...much more desirable and accurate, but not always feasible. Years ago, I used to routinely set VW air cooled motor distributors with a test light rather than measure the gap. Very accurate once you got the feel for it. However, not all adjustments are simple and these three pulsar coils fall into that category. The adjustment procedure is just to labor intensive to perform just to see if it will help.

The motor was set, apparently at 0.020 and ran beautifully for years. But the disparity bothers me between the two specs and factory settings are not always the most efficient for the application. So, I had to ask the question hoping someone had some firsthand experience with this particular part.

 

[99yam40]

Re: 1995 DT25C Pulsar coils question

I get your drift, and hope some with more info chimes in.

 

[swick]

Re: 1995 DT25C Pulsar coils question

Just a quick note, this Helen09 is not a real person. She/ he is copying peoples posts on various threads and replying with them. See above.