n96cuda Sport Jet

[kend301]

Got another PM from N96Cuda , Another new member !! Here is what he sent me and we need to get this guy on the water !

hello sir and thanks for taking time to read my question. from what i have read you are the guy to talk to. i have a 94 searayder with the famous 90hp sportjet. i bought it with the magnets on the flywheel that had come loose. i replaced it with part number 200-859241t10. i now do not have any spark. i ran the tests in your posts but still nothing. it does have the red stator already replaced on it. is it possible the staor could have been damaged by the loose magnets? or did i not get the right flywheel? the dealer told me this is the right one but you know how that goes. any help would be greatly accepted and i am sure your are getting tired of going through the same thing over and over. thanks,joe.

p.s. i will tell you i am a heavy equiptment and auto mechanic so all this is foreign to me so be gentle and patient!!!!

 

[kend301]

Re: n96cuda Sport Jet

First of all the flywheel number is correct as long as you have a switchbox ignition system . Some of this might be redundant to what you have tested but I need the readings and test results.
1. Check all grounds.
2. Check battery voltage , You need at least 10.2 to fire a CDI system.
3. Disconnect the Black/Yellow wire from the switchbox and check for spark.
4. Disconnect the yellow wires from the voltage regulator and check for spark.
5. Ohm the stator . Green/white to White/green , Post results.
6. Ohm the trigger , check each wire individually using White/black as your ground . First to brown , then to purple and finally white . Post the readings .

REMEMBER !!! Never run this boat out of the water without a dealer type flush kit hooked up with just water flow , NO PRESSURE it will get into the engine !

This should get us started and I will monitor this thread several times a day

 

[n96cuda]

Re: n96cuda Sport Jet

thanks for getting back with me!

ok
1. grounds are good and cleaned
2. battery voltage is good
3. black and yellow wire disconected and still no spark
4.yellow wires disconected and still no spark (but i am getting sparks or draw from the voltage reg when you disconect ground wire and it gets warm when you hook up the red wire?)
5. stator ohm is 704
6.trigger ohm is brown 1254
purple 1255
white 1251

 

[n96cuda]

Re: n96cuda Sport Jet

i forgot to mention that i checked(with a test light) the blue wire that goes into cdi box from the little rectangle box that has a ground and the two white and green and green and white wires and i get a light on and off when i crank it over so it is getting a signal from the staor to the cdi.

 

[kend301]

Re: n96cuda Sport Jet

Next get a DVA reading from the stator and trigger (while cranking the engine) using the same wires listed in above diag thread . Then test the blue wire out of the stator adapter box test blue to ground , Should just show open circuit .

Your stator is just out of spec that is why I want to see a DVA reading .

 

[kend301]

Re: n96cuda Sport Jet

Also 2 things ,

The fact you are getting a pulse signal from the wire is no indication of enough voltage to charge the switchbox and coils .
Do not worry about the Hot volt reg wire at this time . If it continues after we get spark we will diag it.

 

[n96cuda]

Re: n96cuda Sport Jet

sorry i put the wrong numbers in on the stator it should have been 680 ohms

 

[kend301]

Re: n96cuda Sport Jet

ok , DVA readings are the next test anyway .

 

[n96cuda]

Re: n96cuda Sport Jet

my be a while on the dva readings. i don't have an adapter and i built one but haven't found the correct capacitor yet.

 

[kend301]

Re: n96cuda Sport Jet

We will need those numbers but until then run a switchbox bias test .
Set voltmeter to 20 volts DC
connect red meter lead to good ground
connect black meter lead to White/black at the box
Crank engine , Volts should be between 2 and 10 volts.
if over or under the switchbox is bad.

Also it is never a waste of time to check the ignition switch as follows :
1 remove the switch
2 set Ohm meter to Rx1 scale
3 test between black/yellow and black (C to M )should be 0 but reading , Turn switch to Run position and retest there should be no reading
4 next test from accessory terminal to red/purple (A to B ) in run position , you should have continuity , turn to start , should be same reading , back to run , push key in .. same reading, Hold in key to start , same reading.
5 next red/purple and yellow/black ( B to C ) switch to run , No continuity should be present, Push key in in run position and you should have continuity .
6 red/purple to Yellow/red (B to S) in run position , no continuity , to start you should have continuity , push in key at start position you should have continuity.
Send readings !

 

[n96cuda]

Re: n96cuda Sport Jet

checked switchbox and it never gets over 1 volt. must be the problem. what would have caused this to go bad? is it just old or would the magnet problem cause it?

 

[kend301]

Re: n96cuda Sport Jet

If you only have 1 volt do the following due to the cost of a switchbox and the bias test is the only one you can do . Be sure the battery is fully charged and engine is cranking at a min of 250 rpm !
1. recheck trigger ohms , rotate engine 1/3 turn and retest trigger , rotate another 1/3 and retest trigger again. ( sometimes a trigger will give you a false reading due to all the magnetic stuff)
2. Retest switchbox , be sure you are testing it with the white/black wire connected !
3. If still 1 volt get a switchbox it is bad .

I will post part numbers for the box as soon as you confirm the test.

 

[n96cuda]

Re: n96cuda Sport Jet

trigger checked aout about the same around 1265-1270 but i am getting a
-0.50 now at the switchbox

 

[kend301]

Re: n96cuda Sport Jet

Switchbox is bad you need a new one . Do not buy used as these are prone to failure when something else fails and they will still pass the bias test .
part numbers are :

Mercury 18495a12 .. may be updated to new number
CDI Aftermarket 114-4953

Both should be available at the parts store on this forum.

Remember we still need to do a DVA test on the stator and trigger ! I would wait to get the switchbox as it is around 275.00

 

[n96cuda]

Re: n96cuda Sport Jet

ok, if my dva adapter is built correctly numbers below

stator 228

all trigger wires 6.5

 

[kend301]

Re: n96cuda Sport Jet

Your DVA readings seem to be in line, that would make the switchbox bias test next and the switchbox did fail .
I would replace the switchbox.

 

[n96cuda]

Re: n96cuda Sport Jet

ok, i apreciate all the help, i will keep you updated thanks again, joe.

 

[kend301]

Re: n96cuda Sport Jet

Please post your results , as you have found out these things are a "female dog" to work on and like an "Ex Female Dog" to Diagnose .

 

[n96cuda]

Re: n96cuda Sport Jet

finally received new cdi today. hooked up and we have good spark. a few questions though. there is an extra black and yellow wire on new cdi that my old one didn't have and instructions state that it is to be used with rev limiter if so equipt. mine already had a limiter on it with just the one wire. so i guess i am asking in what combo do i wire the black and yellow? also i have read that if a rectifier is bad it will cause a new cdi to go bad. i am getting spark with rectifier disconected and am afraid to connect it and retry. is there any truth to this because i don't care to spend another $205 on another cdi.

and thanks again for all the help.

 

[kend301]

Re: n96cuda Sport Jet

There is a test for this , calibrate ohm meter to 1k , Disconnect all regulator/rectifier leads . You will be testing a series of wires , then reversing the meter leads on the exact same wires. Note the readings , For every test there is no reading just should all be continuity one way and no continuity when meter leads are reversed .
1 Red to one of the yellow wires note reading , reverse meter leads , note reading.
2 Repeat test on other yellow wire.
3 regulator housing to yellow wire , note reading , reverse leads , note reading.
4 repeat with other yellow wire.
5 meter yellow to yellow note reading , reverse leads , note reading.

In all above tests you should have continuity in one hook up and no continuity when meter leads are reversed . If this is the result , hook it up put some fresh gas in and enjoy a fun summer of boating !!

If you get duplicate readings on the same circuit test when leads are reversed you need to replace the rectifier .