sport jet 90 boerdoc

[boerdoc1]

My problem is similar but different to the others with sport jet 90s.
My boat 1994 sea ray Rayder engine #0e050827.

It has always been finicky to start. (only had it one season). This year I left the gas in it over winter and it would not start. I drained the gas and removed and cleaned all the carbs and hoses.
Back to the lake and it started within 20 seconds. a couple laps around the lake (15 min). Then it would not start for a couple hours. Then it would not at all.

I assumed that it was ignition issues so I began to perform the test in the manual.

My stator is red yellow to yellow is 0.3 ohms
g/w to w/g wires is 695 ohms

My flywheel had loose magnets, all of them, and one broken. it is #43 817409 1

my trigger #828302 476 All wires measure open, no ohms from the grounded wire to the white brown and purple.

voltage regulator 815279 measures 632/645 ohms between red and yellows.


Unfortunately since I felt the magnet loose I pulled the flywheel and can't check for spark.
Battery is new and cranks over easily so voltage should be good.

My question is. Obviously I need a new flywheel. What part #s are compatible. are the trigger and stator also toast? What part #s are compatible with them.

Finally has this boat been upgraded to CDM? please see the attachment

Thanks in advance
Kent

 

[kend301]

Re: sport jet 90 boerdoc

I need to do some research on this one , Stator looks good , 302 triggers may not show an ohm reading , I need to verify that before I can advise on it. Flywheel is indeed toast , I will get some numbers today when I get home and post what I have found.

 

[jerryjerry05]

Re: sport jet 90 boerdoc

You can glue the magnet back in.Just make sure ALL the old glue is gone and I mean ALL.Then glue using a strong thin glue.J

 

[boerdoc1]

Re: sport jet 90 boerdoc

Any luck Kend301. When I get the new flywheel Where is the best place to get a DVA to perform the other tests? Any local places or do I need to order online?

 

[kend301]

Re: sport jet 90 boerdoc

well first I can not get 817409 1 ,to cross to anything , it is an invalid part number . the conversion kit flywheel pn is 817494a18 is no longer available and does not update , You need to call mercury and find out what the replacement part number is and also have them do a search for the part number to see if anyone has it in old inventory , the number is 920-929-5040 (I think option 3 )I will also tell you that pn 859236t14 will NOT fit your crankshaft that is the XR flywheel that had a different crankshaft .

 

[swally07]

Re: sport jet 90 boerdoc

I need some help as well. I have a 1997 sea ray sea rayder F16 with a Mercruiser Sport Jet 120. I just bought it a year ago, and it seems a little slow. It goes 37 mph at 5000 rpm. Is this about right or is it slow, and if it is slow, what can I do to fix it?
Thank-you very much

 

[kend301]

Re: sport jet 90 boerdoc

Not Good , I just called mercury and the only option is to get a full CDM conversion kit . I would start by calling your local mercury dealer have them run the 817494a18 part number and see if anyone has it in stock . The other option I need to try to confirm as I have only heard it works .

 

[kend301]

Re: sport jet 90 boerdoc

SWALLY07 , Please start a new thread for your boat , It gets confusing if there are 2 or 3 problems on one thread ... Thanks !

 

[kend301]

Re: sport jet 90 boerdoc

OK 3 ways to go here , The flywheel is available on ebay for 499.00 just search the part number in boat parts
Second you can reglue the non broken magnets and find a "junk" flywheel and remove a complete magnet and replace the broken one.
Third you can try to make the switchbox flywheel and trigger work with the CDM system , this would be a huge test but I think it should work .

Let me know where you want to go with this as it is your money and time .

 

[boerdoc1]

Re: sport jet 90 boerdoc

Here is where we are now.
Kend301
I followed the advice that you were recommended for Chronomania That he did not do.
I replaced the flywheel with a #859241T10 also referenced #817494A2.

I matched it with a trigger #817029A9 (Reference Part #: CDI 134-7029-3)

I also replaced the stator just in case with 398-832075A-4 - A21.

In the garage I got good spark visibly by placing a spark plug in the wire and cranking it over on all three wires. Yet on the water It does not start. I cleaned the carbs earlier and it ran well after that. How do I test for the reason for not starting. I do not have a DVA but will order one if needed.

Help.
Thanks,
Kent

 

[kend301]

Re: sport jet 90 boerdoc

WOW , you took a big chance doing this without me doing more research , But if you have spark the next step is to check the timing , have you done this and did you run the white/black trigger wire to ground ?

 

[boerdoc1]

Re: sport jet 90 boerdoc

Kend301
It was a risk but I felt that it would be easier to get a whole new system than to try to part together something with mismatched parts. I will check the timing today when I get to the lake.

Kend301, Do you see any problems that I have overlooked so far? I just put in new spark plugs also. I will also check the fuel pump output.

Thanks for the help.
Kent

 

[boerdoc1]

Re: sport jet 90 boerdoc

Timing checked and the strobe is 120 degrees off from 32 degrees before tdc with the throttle wide open at cranking speed. When looking from the top of the engine the strobe lights on a mark 10 o'clock on a clock when the 32 degree mark is at 6 o'clock. I checked the trigger to verify that I had the wires correct, purple to purple, white to white and brown to brown of the coils. BTW I did verify that the flywheel mark 0 degrees corresponds to TDC of the top piston.
I just now thought of checking the "timing " of the other plug wires to see if one is close to 32 degrees. I will do that and be right back.

 

[boerdoc1]

Re: sport jet 90 boerdoc

We have liftoff.!!!! I had to run the wires from the trigger on cylinders 1,2,3 in colors brown, purple, white. Then the engine started right up. I shut it down and restarted it several times and it is starting immediately everytime. I do not have the same top speed as before 32mph according to the speedo, but I will dial that in. Right now I am only about 26 mph. I do not understand how this changed from before flywheel removal to reinstalling the new one. For all I know my cat could have changed the order. Or the coils could have been incorrect from the beginning.

Any tips on fine tuning the performance now that I have it running again?

 

[kend301]

Re: sport jet 90 boerdoc

Check your PM's sending my cell number , I just want to be sure of a few things.

 

[kend301]

Re: sport jet 90 boerdoc

So glad you sorted it out , I really felt it would work just had no one else try it ! Keep me up to date as to the carb adjustments and performance

 

[boerdoc1]

Re: sport jet 90 boerdoc

Just a Quick update. The next morning after getting everything worked out I took it out for a cruise. On a reasonably calm lake (small wind waves but not choppy) I got it up to 32.5 mph with a half tank of fuel and one passenger. 200 lbs..
That is a fast as ever. I still have to dial in the carburetion and recheck the timing at WOT. I am very happy with the flywheel conversion. It is very responsive from start also. When I dial in the carbs I will post any performance changes. I just wanted to let everyone know that this worked for me and the parts are readily available.
Thanks again Kend301.
Kent