Chronomania Sport Jet 90

[kend301]

The following was posted by a new member Chronomania , Welcome to Iboats !! Help!

I have a sport jet 90 that was running fine until starting it one day at the boat ramp.

While the engine was turning, it started shedding the flywheel magnets. I took the boat home and removed the flywheel. The flywheel magnets were all missing except for one (they appeared to be glued-on). The red stator was damaged from the magnet fragments. I purchased a new flywheel and red stator, installed a spark tester and cranked. No spark! I purchased a DVA adapter for my multi-meter and the highest reading that I am getting is 60 volts. I replaced the starter and battery to assure that I had maximum cranking speed and voila-----no spark and still only 60 volts! Is it possible that I received a bad (new) red stator or am I missing something obvious? Anybody in south Florida to recommend to take the boat to; I am out of ideas?

I have removed the flywheel three times to verify that I have aligned the stator properly. I have changed the trigger and voltage regulator and have disconnected the black/yellow wire from the rev limiter for testing purposes. The stator resistance tests within range (about 600 Ohms). Are there supposed to be six magnets (end-to-end) inside of the flywheel for a three cylinder (my old flywheel was too battered to tell)? This engine does not have a switchbox; the stator green/white and white/green wires goe directly to the coil assemblys.

I appreciate all and any information that you may offer!!!

Sparkless in Florida..........

I started an new thread for him so his boat will not be mixed up with others I am helping on here.

 

[kend301]

Re: Chronomania Sport Jet 90

Chrono , First of all please post what year your motor is .
FIRST : NEVER run one of these jet drives out of the water without a flush kit , You will blow the ride plate off the hull !!
It does have a switch box , Green/white and white/green wires on my 94 hook up to a rectifier and then a single blue wire goes to the switch box. They do not go to the coils , you must fix this first . AFTER doing this if you still have no spark read on ! 600 ohms is good for the stator . Try this to start:
1 Check all engine grounds
2 Unhook both yellow wires coming from the stator see if spark returns
3 reconnect yellow wires , unplug the black/yellow wire from switchbox and check spark.
4 Ohm the trigger assy ( center of the stator) Disconnect all 4 trigger wires and hook one end of the ohm meter to white/black wire and test each other wire separately they should ohm 1100 to 1400

Also check each cylinder for spark separately and see if all 3 have none or just one or two .

Post up results and we can go from there !

 

[chronomania]

Re: Chronomania Sport Jet 90

Hi and thanks for the quick response.

The boat was running fine prior to the flywheel magnets shedding.

My boat is a 1994 Sea Rayder (Searay) Sport Jet 90. I am the third owner. The second owner did not upgrade to the red stator so I assume that was accomplished by the first (original) owner.

Since only the flywheel and stator had damage during the start (the start attempt was being conducted in the water at the boatramp...I am familiar with the caution against starting out of the water), I naturally assumed that changing these two parts would have me up and running promptly.

I had the flywheel and stator overnighted to me so that I could be on the water for the long Easter weekend. I removed the spark plugs and attached the spark plug wires (all three) to a spark tester so that I could check the timing at WOT (wide open throttle) while dry cranking the engine. This is when I discovered that the timing light did not work (there was no spark) and that there wasn't spark on all three of the spark plug wires hooked-up to the spark tester.

On my Sea Rayder Sport Jet 90 four wires come out of the stator: two yellow ones that connect to the voltage regulator and the other two which are Green/White and White/Green. One White/Green wire goes to the coil pack on the top cylinder and the other wire (Green/White) splits in two and goes to the middle coil pack and lower coil pack. In my research, earlier versions did have switch boxes, however the newer CDM coils eliminate the switchbox.

I purchased a Direct Voltage Adaptor to measure peak A/C voltage from the Stator. I hooked-up the DVA directly to the White/Green and Green/White Stator wires. Was this correct or should I have had the system connected and tapped a reading with everthing hooked-up? In either case I measured a peak voltage reading at cranking speed of only 60 volts. With each subsequent crank, the reading is lower each time. I installed a new starter with the idea that perhaps the engine wasn't cranking fast enough for the stator/flywheel and coil packs? This did not change my DVA results.

I have disconnect the Black/Yellow wire from the Rev-Limiter and I also disconnected each coil, one at a time and there still is no spark.I had also disconnected the yellow stator wires. The Ohm reading for the Green/White to White/Green is just under 700 Ohms.

Is it possible that I got a bad Stator? Like I said previously, she was running fine until the magnets let loose and damaged the stator. What do you think??? Thank you in advance for any information......

 

[kend301]

Re: Chronomania Sport Jet 90

I will first tell you that I am not familiar with the CDM system but I called a buddy at manufacturer and he told me that the DVA must be tested with the coils hooked up and should read Green/White to White /Green 180+ DVA ( setting must also be 400DVA scale on meter for proper reading ). If it is low he said to disconnect the yellow wires and retest .

Also he said to check the stator orientation the stator goes in one position for a 90 and another for the 120 ... And are you sure you have a trigger for the 90 and not the 120 they are not interchangeable.

One last thing could you post the part numbers for the Flywheel , Stator and Trigger you have installed

 

[kend301]

Re: Chronomania Sport Jet 90

Check your PM's sent link that should help you .

 

[chronomania]

Re: Chronomania Sport Jet 90

Hi:

I purchased the parts from Boat.Net out of Lake Placid Florida. Of course the old part numbers are superceeded to new numbers although all new parts look the same as the old ones. After I had replaced the flywheel, stator, starter and battery with no spark, I changed the trigger too (once again with no spark).

I have sent the stator back to Boats.net and ordered another stator from them. The low voltage reading occurred when I had the green/white and white/green wires directly to the DVA/meter. I then tried to measure the stator with everything hooked-up with the same low voltage results (60 volts at cranking speed--my meter has 200volt range and 750 volt ranges; I tried to read in the 750 volt range anticipating a 180+ volt AC result). Unless I damaged the stator when I first tried to read directly from the stator wires, my thoughts are at this point that I received a bad stator. It still reads just under 700 Ohms between the green/white and white/green wires. What do you think?

It will be interesting to see what happens when I receive the next stator and crank the motor for the test. If I receive the same low readings, I will be besides myself trying to figure-out what the issue might be! I'll let you know in either case what happens. Thanks........

 

[kend301]

Re: Chronomania Sport Jet 90

Well 700 is the max for factory spec , Mine is 640 ohms . The 60 DVA is low , I don't think you hurt the stator with the test because if you read the diag tree on the link I sent you will see toward the bottom (page 18 not 19 )that you should unplug the CDM's one at a time to check for a bad CDM . If the new stator has the same output based on what I could research I would then suspect that when the old flywheel ate the stator it might have shorted 2 CDM's . thus killing all spark .

 

[chronomania]

Re: Chronomania Sport Jet 90

Hi:


You posted:

"If the new stator has the same output based on what I could research I would then suspect that when the old flywheel ate the stator it might have shorted 2 CDM's . thus killing all spark"

I was thinking the same thing. If the new stator does not provide spark then perhaps all three cdm's are shot? I have previously tried to isolate each pack per a similar troubleshooting blog to no avail. I am looking forward to receiving and installing the new stator to see which direction I need to go...

 

[chronomania]

Re: Chronomania Sport Jet 90

I installed the new (returned other "new" for a new "new") stator and hooked everything up. I dry cranked the engine and the DVA voltage showed 274 volts and......NO spark! The new stator came with instructions and a box with the part number: 398-832075A21 (like the one I had returned) however the part number on the stator has: 398-832075A17. Note: my original stator has the part number: 398-832075A3. Is there any signifigance with the different "A" numbers?

I tried disconnecting the CDM's one at a time to see if there would be spark on the remaining CDMs. I tried swithing the CDM harnesses to other CDMs too. I checked the ground wires from all three CDMs to ground. I removed all three CDM coils and tested them per the troubleshooting manual. They all checked OK.

So far I have replaced the following:

Battery
Starter
Flywheel
Stator (twice)
Trigger
Voltage Regulator

Where did the spark go??? I need a stimulus package!!!

 

[kend301]

Re: Chronomania Sport Jet 90

OK time to regroup and check basics , Please post up manufacturer and part numbers of the trigger , flywheel , volt reg and CMD packs ... Also these boats did have a ignition switch problem ,For 20 bucks you might want to try one But from your readings I doubt it is the cause .. I really suspect some mismatched parts . Are you sure the wires to the CMD's are hooked up properly ? How did you test the CDM's and what were the readings ? Also since you had a bad stator , re OHM the trigger and post readings

PS the "A" part number just indicates updates on the part

 

[chronomania]

Re: Chronomania Sport Jet 90

I will need to pull the flywheel off again (hopefully tomorrow) to access the trigger to check the ohms.

As far as the CDM's, they have a plug-in four wire connector that can only lock-in when oriented properly. Their wires from left to right are: Black (ground), Black/Yellow (for kill circuit), Trigger wire, Stator wire (either Green/White or White/Green).

Here are the part numbers of what I have changed:

Flywheel 859241T10 (previous online order number was 817494A2)
Stator 832075A21 (I received an A17) (number on old part was 832075A3)
Voltage Regulator 883071A1 (previous online order number was 815279-4)
Trigger 828302A1

My CDM's have the following number although I have not replaced them yet: 0526 827509-A2

I performed the Diode and resistance check per the troubleshooting guide and all three CDM's have very similar readings per the guide so I do not presently suspect them as the problem.

Physically, the flywheel, stator, voltage regulator and trigger look just like the old parts that I had replaced.

I am now getting 274 volts from the stator when I dry crank; would that rule-out the ignition switch?

What do you think of the part numbers above for effectivity?

I have worked as an aircraft mechanic before and may have to put wings on this thing to fix it!

 

[kend301]

Re: Chronomania Sport Jet 90

Please double check the trigger number , I can't get 828075a21 to cross ref or pull up as a valid part number !

 

[chronomania]

Re: Chronomania Sport Jet 90

My apologies. The stator number I had written down above the trigger number and I merged the numbers.

The trigger number is: 828302A1

Now, out to the shed to pull the flywheel.....

 

[kend301]

Re: Chronomania Sport Jet 90

OK that trigger number is correct for a CDM conversion ... Ohm the trigger at the connectors and than Ohm them at the Cdm hookups , This Boat should have spark !!
Also could you take a pic of the stator/trigger assy installed once you pull the flywheel ? This is a real long shot but worth a try at this point .

 

[chronomania]

Re: Chronomania Sport Jet 90

Sorry, I have already removed the flywheel, made the following tests and reinstalled the flywheel. I will try to ohm from the connected trigger to the CDM's; that's a good idea. Here's what I just accomplished:

Stator readings:
Green/White to White/Green = 678 ohms
DVA at cranking speed = 274 volts

Trigger readings (old trigger had the same part # as the new one):
Purple wire to engine ground = Open ohms; DVA at cranking = 7 volts
White wire to engine ground = Open ohms; DVA at cranking = 16 volts
Brown wire to engine ground = Open ohms; DVA at cranking = 6 volts

CDM readings:
Red meter lead Black meter lead Reading 1, 2, 3
A C 1245, 1247, 1247
D A No Reading, NR, NR
A D 572, 573, 554
D B 564, 565, 557
B D No Reading, NR, NR
A B 1102, 1104, 1077
B A No Reading, NR, NR
High Tension Lead A 1093, 1081, 1072

The tests were performed with the Black/Yellow wire disconnected from the Rev Limiter. Also from the Rev Limiter, the Brown wire from the trigger goes to the Rev Limiter and splits to go to the bottom CDM. I ran the above tests with this Brown wire both connected and disconnected from the Rev Limiter. The results were the same.

On page 57 of the troubleshooting manual it states: ?Diode readings are to be read one way, then reverse the leads and read again. You should get a low reading in one direction and a higher reading in the other.? My question is when I reversed the test probes, the meter remained at ?1? with my meter set on ?Diode? mode; in other words the meter did not appear to be reading. Is this what the above text refers to as a ?low or higher reading? or are all of my CDM?s fried?

 

[chronomania]

Re: Chronomania Sport Jet 90

I checked the trigger wiring harnesses to the CDM's and they all checked OK (Open). I then went ahead and pulled the flywheel for the pictures below (don't mind the gagle of wires from the stator, trigger, CDM's, Rev Limiter and Voltage Regulator).

 

[kend301]

Re: Chronomania Sport Jet 90

GOT IT !!!! ... your stator is installed with the wrong orientation ... Unless you have to put it on in the 120 position with CDM's .... Try rotating it one hole clockwise and see what happens !

 

[chronomania]

Re: Chronomania Sport Jet 90

I checked the wiring harness from the trigger wires to the CDM's and ground. Each Trigger wire checks OK (open). Here are all of my meter readings:

Stator readings:
Green/White to White/Green = 678 ohms
DVA at cranking speed = 274 volts

Trigger readings:
Purple wire to engine ground = Open; DVA at cranking = 7 volts
White wire to engine ground = Open; DVA at cranking = 16 volts
Brown wire to engine ground = Open; DVA at cranking = 6 volts

CDM readings:
Red meter lead Black meter lead Reading 1, 2, 3
A C 1245, 1247, 1247
D A No Reading, NR, NR
A D 572, 573, 554
D B 564, 565, 557
B D No Reading, NR, NR
A B 1102, 1104, 1077
B A No Reading, NR, NR
High Tension Lead A 1093, 1081, 1072

The tests were performed with the Black/Yellow wire disconnected from the Rev Limiter. Also from the Rev Limiter, the Brown wire from the trigger goes to the Rev Limiter and splits to go to the bottom CDM. I ran the above tests with this Brown wire both connected and disconnected from the Rev Limiter. The results were the same.

On page 57 of the troubleshooting manual it states: ?Diode readings are to be read one way, then reverse the leads and read again. You should get a low reading in one direction and a higher reading in the other.? My question is when I reversed the test probes, the meter remained at ?1? with my meter set on ?Diode? mode; in other words the meter would not read. Is this what the above text refers to as a ?low or higher reading? or are all of my CDM?s fried?

 

[kend301]

Re: Chronomania Sport Jet 90

You need to look up in the posts , Somehow you double posted the same message , The Stator orientation looks wrong , rotate the stator one bolt hole clockwise and see if you have spark !

 

[chronomania]

Re: Chronomania Sport Jet 90

GOT IT !!!! ... your stator is installed with the wrong orientation ... Unless you have to put it on in the 120 position with CDM's .... Try rotating it one hole clockwise and see what happens !

That is what I thought previously and I removed the flywheel twice to verify. The alignment is the same as the old stator. I have not tried to rotate one hole, however. The green circles indicate the mounting hole pattern. This matches the installation instructions. Compare this old stator with my new one. Back to my previous question for the CDM Diode check: I get a reading one way on the CDM pins but no readout when I reverse the meter probes. The troubleshooting guide (page 57) states that I should get a low reading in one direction and a higher reading in the other direction. In one direction, my digital meter remains on "1" in the Diode position. Is this right or are the CDM's inoperative?