ELECTRICAL

2
A

55042

IGNITION
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Flywheel And Stator (Electric) . . . . . . . . . . . . 2A-2
Flywheel And Stator (Manual) . . . . . . . . . . . . 2A-3
Electrical Components 40/50 . . . . . . . . . . . . 2A-4
Electrical Components 55/60 . . . . . . . . . . . . 2A-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . 2A-8
Capacitor Charging #1 CDM . . . . . . . . . . 2A-8
Capacitor Charging #2 & #3 CDM . . . . . . 2A-9
#1 Cylinder Trigger Circuit . . . . . . . . . . . . 2A-10
Ignition Coil Circuit . . . . . . . . . . . . . . . . . . . 2A-11
Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Rev Limiter Circuit . . . . . . . . . . . . . . . . . . . 2A-13
Ignition Component Description . . . . . . . . . . 2A-14
Capacitor Discharge Module (CDM) . . . . 2A-14
Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
Stator Assembly . . . . . . . . . . . . . . . . . . . . . 2A-14
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14
CDM (P/N 827509) Trouble Shooting
Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-15
CDM (P/N 827509) . . . . . . . . . . . . . . . . . . 2A-15
Spark Gap Tester P/N 91-850439 . . . . . . 2A-15
CDM Test Harness 84-825207A2 . . . . . . 2A-15
CDM Stop Diode Trouble Shooting . . . . . . . 2A-16
CDM Trouble Shooting Flowchart . . . . . . . . 2A-17
CDM Trouble Shooting Flowchart . . . . . . . . 2A-18
Ignition Test Procedures . . . . . . . . . . . . . . . . . 2A-20
Direct Voltage Adaptor (DVA) Test . . . . . 2A-20
Resistance Tests . . . . . . . . . . . . . . . . . . . . 2A-21
Flywheel Removal and Installation . . . . . . . . 2A-22
Stator Removal and Installation . . . . . . . . . . 2A-23
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23
CDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-24

2A-0 - ELECTRICAL 90-852572R1 JANUARY 1998

Specifications
Type Capacitor Discharge
Spark Plug Type NGK BP8H-N-10
*NGK BPZ8H-N-10
IGNITION SYSTEM NGK BUZ8H
NGK BP8HS-10
Spark Plug Gap 0.040 in. (1.0mm)
Firing Order 1-2-3
Idle T.D.C. ± 2°
Maximum Timing
@ Cranking Speed
-Model 40/50/60 24° B.T.D.C.
TIMING
-Model 55/60 Seapro-Marathon 18° B.T.D.C.
@ 5000 RPM
– Model 40/50/60 22° B.T.D.C.
– Model 55/60 Seapro-Marathon 16° B.T.D.C.
*Suppressor (resistor) spark plug

4. Spark Gap Tester 91-63998A1

Special Tools
1. Flywheel Holder 91-52344

2. Flywheel Puller 91-73687A2

5. TPI/CDM Test Harness 84-825207A2

3. Volt/Ohm/DVA Meter 91-99750A1

6. Spark Gap Tester 91-850439

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-1

Flywheel And Stator (Electric)

6
51

5
7

51 Loctite 222 (92-809818) 10 10

8 95
95 2-4-C With Teflon (92-850736A1) 9

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FLYWHEEL COVER
2 1 NUT 100 135.6
3 1 WASHER
4 1 FLYWHEEL
5 1 STATOR
6 4 SCREW (M5 x 30) 60 5 6.8
7 1 TRIGGER
8 1 SWIVEL BALL
9 1 SWIVEL BASE
10 2 CABLE TIE

2A-2 - ELECTRICAL 90-852572R1 JANUARY 1998

 Flywheel And Stator (Manual)

51
5

6
9

10

7 95
8 9

51 Loctite 222 (92-809818)

95 2-4-C With Teflon (92-850736A1)

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FLYWHEEL
2 1 NUT 100 135.6
3 1 WASHER
4 1 STATOR
5 4 SCREW (M5 x 30) 60 5 6.8
6 1 TRIGGER
7 1 SWIVEL BALL
8 1 SWIVEL BASE
9 2 CABLE TIE
10 2 PLUG

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-3

Electrical Components 40/50

41
21
43 20

25 4

37 1 3
39 2

23
42 25

38 26

36
19 25
40
24
5
22
18
27

7
28
25
18
17
6 16
8 15
25
25

35 13
12
25
10 14
13

32 12
9 22
31 33
34 23
11
7 30

29

25 Liquid Neoprene (92-25711--2)

2A-4 - ELECTRICAL 90-852572R1 JANUARY 1998

 Electrical Components 40/50
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 PLATE–Electrical
2 1 SCREW (M5 x 12) 40 3.3 4.5
3 1 WASHER
4 1 STA–STRAP
1 REV LIMITER (MANUAL)
5
1 REV LIMITER
6 1 CLAMP
7 3 SCREW (M5 x 12) 40 3.3 4.5
8 1 SOLENOID ASSEMBLY
9 2 BUSHING
10 2 GROMMET
11 2 SCREW (M6 x 25) ELECTRIC 60 5 6.8
12 2 NUT (1/4-20) 30 2.5 3.4
13 2 LOCKWASHER
14 1 CABLE
15 1 CABLE
16 2 NUT 20 2.3
17 1 VOLTAGE REGULATOR
18 2 SCREW (M6 x 35) 60 5 6.8
19 1 J CLAMP
20 1 BOOT
21 1 BATTERY CABLE (NEGATIVE)
22 1 WASHER (QTY. OF 3 ON ELECTRIC)
23 AR STA–STRAP
24 2 SCREW (M6 x 25) 40 3.3 4.5
25 1 CABLE
26 1 SCREW (M8 x 20)(MANUAL) 30 2.5 3.4
27 1 SCREW (M6 x 10)(MANUAL) 60 5 6.8
28 2 J CLAMP (QTY. OF 3 ON ELECTRIC)
29 1 HARNESS ASSEMBLY–Engine (ELECTRIC)
30 1 FUSE
31 3 GROMMET
32 3 BUSHING
33 3 WASHER
34 3 SCREW (M6 x 25) 100 8.3 11.3
35 1 HARNESS-Ignition
2 CDM ASSEMBLY (5 IN. LEADS)
36
1 CDM ASSEMBLY (8 IN. LEADS)
37 3 HI-TENSION CABLE
38 3 BOOT
3 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
39 3 SPARK PLUG (NGK#BPZ–8H–N–10) 240 20 27.1
3 SPARK PLUG (NGK#BUZ8H) 240 20 27.1
40 6 SCREW (M6 x 14) 60 5 6.8
41 1 HARNESS-Power (MANUAL)
42 1 HARNESS
1 HARNESS ASSY. -Adaptor (MANUAL)
43
1 HARNESS ASSY. -Adaptor (ELECTRIC)

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-5

Electrical Components 55/60

21

42

20
55 HP ONLY
25 4
6

38 3
40 1 2
43
25 23

39 26

37
19 25
41
24
5
22
18
27

7
28
25
18
17
6 16
8 15
25
25
13
36 12
25
10 14
13
12
33 9
32 34 22
35 11 23
7
30

29

6 Dielectric Grease (92-823506--1) 31

25 Liquid Neoprene (92-25711--2)

2A-6 - ELECTRICAL 90-852572R1 JANUARY 1998

 Electrical Components 55/60
TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 PLATE–Electrical
2 1 SCREW (M5 x 12) 40 3.3 4.5
3 1 WASHER
4 1 STA–STRAP
1 REV LIMITER (MANUAL)
5
1 REV LIMITER
6 1 CLAMP
7 3 SCREW (M5 x 12) 40 3.3 4.5
8 1 SOLENOID ASSEMBLY
9 2 BUSHING
10 2 GROMMET
11 2 SCREW (M6 x 25) 60 5 6.8
12 2 NUT (1/4-20) ELECTRIC 30 2.5 3.4
13 2 LOCKWASHER
14 1 CABLE
15 1 CABLE
16 2 NUT 20 2.3
17 1 VOLTAGE REGULATOR
18 2 SCREW (M6 x 35) 60 5 6.8
19 1 J CLAMP
20 1 BOOT
21 1 BATTERY CABLE (NEGATIVE)
22 2 WASHER
23 AR STA–STRAP
24 2 SCREW (M6 x 25) 40 3.3 4.5
25 1 CABLE
26 1 SCREW (M8 x 20)(MANUAL) 30 2.5 3.4
27 1 SCREW (M6 x 10)(MANUAL) 60 5 6.8
28 3 J CLAMP (Qty. of 2 required on Manual)
29 1 HARNESS ASSEMBLY–Engine
30 1 FUSE ELECTRIC
31 1 PLUG
32 3 GROMMET
33 3 BUSHING
34 3 WASHER
35 3 SCREW (M6 x 25) 100 8.3 11.3
36 1 HARNESS-Ignition
37 3 CDM ASSEMBLY
38 3 HI-TENSION CABLE
39 3 BOOT
3 SPARK PLUG (NGK# BP8H-N-10) 240 20 27.1
3 SPARK PLUG (NGK#BPZ–8H–N–10) 240 20 27.1
40
3 SPARK PLUG (NGK#BUZ8H) 240 20 27.1
3 SPARK PLUG (NGK#BP8HS-10) 240 20 27.1
41 6 SCREW (M6 x 14) 60 5 6.8
42 1 HARNESS-Power MANUAL
43 1 HARNESS

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-7

Theory of Operation Capacitor Charging #1 CDM
This outboard ignition system is alternator driven The STATOR assembly is mounted to the block be-
(distributor-less) capacitor discharge system. Major low the flywheel and has 3 CAPACITOR CHARGING
components of the ignition system are the flywheel, COILS wound in series. The FLYWHEEL is fitted with
stator, trigger, capacitor discharge modules (CDM’s) 6 permanent magnets inside the outer rim. The fly-
and spark plugs. Each capacitor discharge module wheel rotates the permanent magnets past the ca-
functions as a combination switchbox and secondary pacitor charging coils causing the coils to produce
ignition coil. AC voltage (260–320 volts). The AC voltage is then
conducted to the CAPACITOR DISCHARGE MOD-
ULES (CDM), where it is rectified (DC) and stored in
a capacitor. The stator voltage return path is through
the ground wire of the other CDM and back through
that CDM’s charging coil wire to the capacitor charg-
ing coils.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _
BLK/YEL

N WHT/GRN

S
PPL

S
BLK

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

2A-8 - ELECTRICAL 90-852572R1 JANUARY 1998

Capacitor Charging #2 & #3 CDM
The flywheel rotates the permanent magnets past NOTE: #1 CDM stator voltage return path is through
the capacitor charging coils causing the coils to pro- either CDM #2 or #3. The return path for CDM #2 and
duce AC voltage (260–320 volts). The opposite volt- #3 is through CDM #1, if #1 stator wire is discon-
age pulse is then conducted to the CAPACITOR DIS- nected the engine will die (the stator circuit is incom-
CHARGE MODULES (CDM), where it is rectified plete and the capacitors cannot be charged).
(DC) and stored in a capacitor. The stator voltage re-
turn path is through the ground wire of the other CDM
and back through that CDM’s charging coil wire to the
capacitor charging coils.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-9

#1 Cylinder Trigger Circuit coils to produce a voltage pulse which is sent to the
respective capacitor discharge module (CDM). A
The TRIGGER assembly (also mounted under the positive voltage pulse (N–S) will activate the elec-
flywheel) has one coil for each cylinder. These coils tronic switch (SCR) inside the capacitor discharge
are mounted adjacent to the flywheel center hub. module (CDM). The switch discharges the capacitor
The center hub of the flywheel contains a permanent voltage through the coil primary windings. The return
magnet with two north–south transitions. voltage pulse exits the CDM through the ground wire
As the flywheel rotates, the magnet north–south tran- and returns through the trigger ground.
sitions pass the trigger coils. This causes the trigger

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

2A-10 - ELECTRICAL 90-852572R1 JANUARY 1998

Ignition Coil Circuit
As the capacitor voltage flows through the primary
windings of the ignition coil, a voltage is induced into
the ignition coil secondary windings. This secondary
voltage rises to the level required to jump the spark
plug gap and return to ground. This secondary volt-
age can, if necessary, reach approximately 40,000
volts. To complete the secondary voltage path, the
released voltage enters the ground circuit of CDM
module.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK

Source Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-11

Stop Circuit
To stop the engine, the stop switch is closed allowing
the capacitor charge current from the stator to drain
directly to ground.
NOTE: The CDM contains a zener diode (not shown
for clarity). This diode prevents overcharging of the
capacitor (and possible failure) if the SCR does not
receive a trigger pulse.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN
BLK
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

2A-12 - ELECTRICAL 90-852572R1 JANUARY 1998

Rev Limiter Circuit
The rev limiter is activated through the purple wire
when the key switch is rotated to the “on” position.
The rev limiter uses a trigger signal (brown wire) to
determine engine speed or rpm. If the engine speed
exceeds the specified rpm, the rev limiter will ground
out the CDM capacitor charge. The capacitor voltage
flows through the black/yellow wires into the rev limit-
er and to engine ground through the black wire.

a b
S N

N
S
S

3 +
N d
_ N S _

+ 1
+
2 _

BLK/YEL

WHT/GRN
N

PPL
S

BLK
N

N S c
e
WHT/GRN
j YEL
YEL GRN/WHT
BLK

WHT
BRN

i
Return Voltage
BRN

Source Voltage
BLK

Trigger Voltage
BLK/YEL

CAPACITOR-
BLK/YEL
BRN

PPL
COIL- BLK
g
SCR-
h
DIODE-

a - Battery Charging Coils f - CDM #3

b - Trigger Coils g - Rev. Limiter (Not Used On All Models)
c - Capacitor Charge Coils h - To Ignition Switch
d - CDM #1 i - Stop Switch
e - CDM #2 j - To Voltage Regulator

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-13

Ignition Component Stator Assembly
Description Located under the flywheel in the stator assembly are
12 coils (6 for manual stator), 3 ignition charge coils
and 9 auxiliary (3 for manual) power coils wound in
Capacitor Discharge Module (CDM) series that provide voltage to the CDM’s and battery/
auxiliary circuits respectively.
Each module contains an ignition coil and amplifier
circuitry which produces approximately 45,000 volts
at the spark plugs.

Flywheel
Contains 6 magnets (12 pole) around circumference.
Trigger Coil Has one magnet on inner hub for trigger. Outer mag-
Located under flywheel. Is charged by single magnet nets are for battery charge coils and ignition charge
on flywheel hub. Trigger pulses are sent to CDM. coils.

NOTE: Electric start model flywheel shown.

2A-14 - ELECTRICAL 90-852572R1 JANUARY 1998

CDM (P/N 827509) Trouble Shooting Flowchart
Chart 1
Step Action Value Yes No Tools
1 Verify High Tension Leads, Spark – Step 2 Replace High Tension
Plug and Spark Boots are in good Failed Com- lead pin
condition. Inspect wires for chafing. ponent P/N
Visual Inspection Step 2 84-813706A56
2 Verify 4 Pin Connector Integrity – Step 3 Repair/Re- –
place Con-
Visual Inspection nector Com-
ponents
Step 3
3 Verify Ground from CDM connector 0.2 Ohms Step 4 Correct DVA/Multimeter
to block and below Ground Path P/N 91-99750
Step 4 Test Harness
P/N
84-825207A2
4 Test all CDMs at Cranking with 7/16 in. If at least Continue Spark Gap Tes-
Spark Gap Tester (11.11 mm) one CDM with Chart #2 ter
gap has spark, P/N 91-850439
Spark on All CDMs? continue with
Will spark jump a 7/16 in. Chart #3
(11.11 mm) gap?
CDM (P/N 827509)

A B C D

a - Ground
b - Black/Yellow
c - Trigger Connection
d - Stator Connection

Spark Gap Tester P/N 91-850439 CDM Test Harness 84-825207A2

55117

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-15

CDM Stop Diode Trouble Shooting
2 Cyl.:
CDM #1 gets its charging ground path through CDM #2
CDM #2 gets its charging ground path through CDM #1
A shorted Stop Diode in either CDM would prevent the opposite one from sparking.

1 2

3 Cyl.:
CDM #1 gets its charging ground path through CDM #2 or #3
CDM #2 and #3 get their charging ground path through CDM #1
A shorted Stop Diode in CDM #1 would prevent CDMs #2 and #3 from sparking.
A shorted Stop Diode in CDM #2 or #3 would prevent CDM #1 from sparking.

1 2 3

4 Cyl.:
CDM #1 and #2 get their charging ground path through CDM #3 or #4
CDM #3 and #4 get their charging ground path through CDM #1 or #2
A shorted Stop Diode in CDM #1 or #2 would prevent CDMs #3 and #4 from sparking.
A shorted Stop Diode in CDM #3 or #4 would prevent CDM #1 and #2 from sparking.

1 2 3 4

6 Cyl.:
All CDMs get their charging ground path independently through the stator’s white leads.
A shorted Stop Diode in any one CDM will prevent at least 2 other CDMs from sparking

1 3 5 2 4 6

2A-16 - ELECTRICAL 90-852572R1 JANUARY 1998

CDM Trouble Shooting Flowchart
Chart #2 (No Spark on any CDM)

Step Action Value Yes No Tools

1 With the key switch ON: NO continuity Step 2 Repair or DVA/Multimeter
Verify continuity between BLK/YEL Replace Com- P/N 91-99750
harness wire and ground. ponent
This Test Checks: Run Engine
Lanyard Switch Verify Repair
Key Switch Step 6
Rev Limiter (external)
Chafed BLK/YEL wire
CDM Stop Circuit
2 Check Stator 660-710 Step 3 Replace DVA/Multimeter
Resistance between GRN/WHT Ohms Stator P/N 91-99750
and WHT/GRN 2, 3 & 4 Cyl. Run Engine
Models Verify Repair
Open circuit voltage at cranking
should be no less than 100 Volts 990 - 1210 Step 6
on the DVA Ohms 6 Cyl.
3 Check Trigger/Crank Shaft Posi- 1 Volt and Step 5 2, 3, & 4 Cyl DVA/Multimeter
tion Sensor Output: above - CDM Replace Trig- P/N 91-99750
disconnected. ger TPI/CDM Test
Cranking with CDM disconnected. 0.2 - 5 Volts- Run Engine Harness
CDM Verify Repair 84-825207A2
Cranking with CDM connected. connected. Step 6
6 Cyl. - Step 4
4 V-6 Models 900 - 1300 Step 5 Replace DVA/Multimeter
Ohms Crank Posi- P/N 91-99750
Resistance Check Crank Position tion Sensor
Sensor Run Engine
Verify Repair
Step 6
5 Test all CDMs at Cranking with 7/16 in. Step 6 Verify All Pre- Spark Gap Tes-
Spark Gap Tester (11.11 mm) ceding Steps ter P/N
gap 91-850439
Spark on All CDMs?
Will spark jump a 7/16 in.
(11.11 mm) gap?
6 If mis-firing is in a repeatable Stator: Run Engine Refer to *Note DVA/Multimeter
range: 200 Volts and Verify Repair Below P/N 91-99750
Perform DVA readings on stator above TPI/CDM Test
and trigger at all running speeds.* END Harness
Trigger: 84-825207A2
2 Volts and
above
* Note: Stator tests will only isolate problem down to
a charging pair. Further testing is necessary to deter-
mine faulty CDM. Disconnecting one CDM of the
charging pair is recommended.

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-17

CDM Trouble Shooting Flowchart
Chart #3 (At least one CDM has spark)
Step Action Value Yes No Tools
1 Resistance Check ALL CDMs Refer to chart Step 3 Replace any DVA/Multimeter
CDMs that P/N 91-99750
do not pass
specifica-
tions even if
they fire
Step 2
2 Test all CDMs at Cranking with 7/16 in. Run Engine Step 3 Spark Gap Tes-
Spark Gap Tester (11.11 mm) Verify Repair ter
gap Step 6 P/N 91-850439
Spark on All CDMs
Will spark jump a 7/16 in.
(11.11 mm) gap?
3 Check Trigger Output: 1 Volt and Step 5 2, 3, & 4 Cyl DVA/Multimeter
above - CDM - Replace P/N 91-99750
Cranking with CDM disconnected. disconnected. Trigger TPI/CDM Test
0.2 - 5 Volts - Run Engine Harness
Cranking with CDM connected. CDM Verify Repair 84-825207A2
connected. Step 6
6 Cyl–Step 4
4 V6 Models 900 - 1300 Step 5 Replace DVA/Multimeter
Ohms Crank Posi- P/N 91-99750
Resistance Check Crank Position tion Sensor
Sensor Run Engine
Verify Repair
Step 6
5 Test all CDMs at Cranking with 7/16 in. Run Engine Replace any Spark Gap Tes-
Spark Gap Tester (11.11 mm) Verify Repair non-firing ter
gap Step 6 CDMs P/N 91-850439
Spark on All CDMs? Step 6
Will spark jump a 7/16 in.
(11.11 mm) gap?
6 If mis-firing is in a repeatable Stator: Run Engine Refer to DVA/Multimeter
range: 200 Volts and Verify Repair *Note Below. P/N 91-99750
Perform DVA readings on stator above END TPI/CDM Test
and trigger at all running speeds.* Harness
Trigger: 84-825207A2
2 Volts and
above
* Note: Stator tests will only isolate problem down to
a charging pair. Further testing is necessary to deter-
mine faulty CDM. Disconnecting one CDM of the
charging pair is recommended.

2A-18 - ELECTRICAL 90-852572R1 JANUARY 1998

CAPACITOR DISCHARGE MODULE
IMPORTANT Spark plug wires are screwed into CDM.

A B C D

a - Ground
b - Black/Yellow
c - Trigger Connection
d - Stator Connection

A resistance check is required and can be performed on the CDM as follows:

NOTE: This test can be performed using the test harness (P/N 84-825207A2). Do Not connect the test harness
plug to the stator/trigger engine wire harness.

CAPACITOR DISCHARGE MODULE

Connect Negative Connect Positive
Ohms
Circuit Test (–) (+) Results:
Scale
Meter Lead To: Meter Lead To:
Green (D)/ or Black/Yellow (B)/ or
Stop Diode R x 100
Green test harness Black/Yellow test Continuity
Forward Bias Diode Reading*
lead harness lead
Black/Yellow (B)/ or Green (D)/ or
Stop Diode R x 100
Black/Yellow test Green test harness No Continuity
Reverse Bias Diode Reading*
harness lead lead
Return Ground Green (D)/ or Ground Pin (A) or
R x 100
Path Diode, Green test harness Black test harness No Continuity
Diode Reading*
Reverse Bias lead lead
Return Ground Ground Pin (A)/ or Green (D)/ or
R x 100
Path Diode, Black test harness Green test harness Continuity
Diode Reading*
Forward Bias lead lead
Ground Pin (A)/ or
CDM Trigger Input White (C)/ or White 1000 - 1250
Black test harness R x 100
Resistance test harness lead Ohms
lead
Spark Plug
Ground Pin (A) or Terminal
Coil Secondary
Black test harness R x 100 900 - 1200 Ohms
Impedance (At Spark Plug
lead Boot)

*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In such
a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measure-
ments above will be opposite if using a Fluke equivalent multimeter.

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-19

Ignition Test Procedures Stator Output Test 400 DVA
Scale
Positive Meter Negative DVA
Direct Voltage Adaptor (DVA) Test Lead (+) Meter Lead (–) Reading
Connect to Connect to
CAUTION Green Test Black Test Har- 100 - 350
Harness Lead ness Lead
DVA checks can be made while cranking engine
with starter motor. To prevent engine from start- If only one CDM stator reading is below specifications,
ing while being cranked, all spark plugs must be replace that CDM. If all CDM stator voltage readings
removed. are low, go to “Testing Stator Resistance”.

CAUTION
To protect against meter and/or component dam-
age, observe the following precautions:
• INSURE that the Positive (+) meter lead is
connected to the DVA receptacle on the me-
ter.
• DO NOT CHANGE meter selector switch posi-
tion while engine is running and/or being
“cranked”.
NOTE: Each CDM is grounded through the engine
wiring harness via the connector plug. It is not neces-
sary to have the CDM mounted on the ignition plate
for testing.
1. Remove all spark plugs.
2. Insert spark gap tool (P/N 91-63998A1) into each
spark plug boot and attach alligator clips to a
good engine ground.
Test each CDM.
3. Disconnect remote fuel line from engine.
4. Make sure all CDMs are plugged in. Trigger Output Test 2 DVA Scale

5. Test Stator and Trigger voltage to CDM: Positive Meter Negative DVA
Lead (+) Meter Lead (–) Reading
a. Install test harness (84-825207A2) between White Test Black Test Har-
ignition harness and CDM. Harness Lead ness Lead 0.2 - 2.0

If reading is below specifications, replace trigger. If

reading is above specifications, check CDM.

a - Stator/Trigger Harness
b - Test Harness (84-825207A2)
c - Capacitor Discharge Module
b. Test each CDM.

2A-20 - ELECTRICAL 90-852572R1 JANUARY 1998

NOTE: If voltage remains low after installing a new Resistance Tests
trigger, replaced CDM.
TRIGGER
A resistance test is not used on the trigger. Test trigger
as outlined under “Testing Voltage Output to CDM” -
“Trigger Output Test”.

STATOR
1. Disconnect stator leads.
NOTE: Resistance varies greatly with temperature.
Measurements should be taken with an ambient tem-
perature range of 65° to 85° F.

Stator Resistance Test

R x 1 Ohms
Positive Meter Negative Scale
Lead (+) Meter Lead (–)
ENGINE RUNNING AT IDLE
Connect to Connect to
It is not necessary to perform this test if the voltage out- White/Green Green/White 660-710
put was tested in the previous step. stator lead stator lead
Connect to Connect to en-
Stator Output Test 400 DVA White/Green gine ground No continuity
Scale stator lead
Positive Meter Negative DVA Connect to Connect to en-
Lead (+) Meter Lead (–) Reading Green/White gine ground No continuity
Connect to Connect to stator lead
Green Test Black Test Har- 200 - 350
Harness Lead ness Lead IMPORTANT If all CDM stator output voltage is
low and stator resistance tests are within specifi-
If stator output is low, go to “Testing Stator Resis- cations, then each CDM (one at a time) must be
tance”. replaced with a CDM known to be good until sta-
tor output voltage returns to proper levels. This
Trigger Output Test 20 DVA Scale process of elimination will reveal a defective
Positive Meter Negative DVA CDM.
Lead (+) Meter Lead (–) Reading
White Test Black Test Har-
Harness Lead ness Lead 2 - 8 Volts

If reading is below specifications, replace trigger. If

reading is above specifications, check CDM.
NOTE: If voltage remains low after installing a new
trigger, replace CDM.

RX1

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-21

Flywheel Removal and 6. Remove flywheel. Remove flywheel key.
7. Carefully inspect flywheel for cracks or damage.
Installation
8. Inspect crankshaft and flywheel tapers for worn
REMOVAL or damaged key ways.
1. Remove flywheel cover from engine. 9. Check for loose or damaged flywheel magnets
(outer rim and center hub). Replace flywheel if
WARNING necessary.

Engine could possibly start when turning fly- INSTALLATION

wheel during removal and installation; therefore,
disconnect (and isolate) spark plug leads from 1. Install flywheel key in crankshaft slot with outer
spark plugs to prevent engine from starting. edge of key parallel to center line of crankshaft.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with flywheel holder
(91-52344), remove flywheel nut and washer.

a - Flywheel Key

2. Align slot in flywheel center bore with flywheel

key and install flywheel onto crankshaft.

a - Flywheel Holder
3. Install washer and nut.
4. Hold flywheel with Flywheel Holder (91-52344);
torque nut to 125 lb. ft. (169.5 N·m).
4. Install a crankshaft Protector Cap (91-24161) on
end of crankshaft, then install Flywheel Puller
(91-73687A2) into flywheel.
5. Hold flywheel tool with wrench while tightening
bolt down on protector cap. Tighten bolt until fly-
wheel comes free.

a - Flywheel Holder

55333

a - Flywheel Puller
NOTE: Neither heat nor hammer should be used on
flywheel to aid in removal as damage to flywheel or
electrical components under flywheel may result.

2A-22 - ELECTRICAL 90-852572R1 JANUARY 1998

Stator Removal and INSTALLATION
1. Set stator on bearing cage. Secure with screws.
Installation Screws threads should be lightly coated with loc-
tite 222 and torqued to 60 lb. in. (6.8 N·m).
REMOVAL
1. Remove flywheel. See “Removing Flywheel” In
This Section.
2. Remove yellow stator leads from rectifier/regula-
tor leads.
3. Disconnect all stator leads from CDM wire har-
ness.
NOTE: Removal of ignition plate may be necessary a
to gain access to stator leads.
4. Remove screws and lift stator off bearing cage.
a

55330

a - Screws

2. Connect yellow stator leads to yellow voltage

regulator leads (electric models).
a 3. Connect all stator leads to corresponding CDM
wire harness.
a 4. Install flywheel. See “Installing Flywheel” in this
section.
55330

a - Screws
Trigger
REMOVAL
1. Remove flywheel. See “Removing Flywheel” in
this section.
2. Remove stator. See “Removing Stator” in this
section.
3. Disconnect trigger leads from CDM wire harness.

90-852572R1 JANUARY 1998 ELECTRICAL - 2A-23

4. Disconnect link arm and remove trigger. CDM

REMOVAL

WARNING
Always disconnect battery and disconnect spark
plug leads from spark plugs before working on
a b motor.
1. Disconnect CDM wire harness plug.
19459 2. Remove screws securing CDM to ignition plate.

a - Link Arm INSTALLATION

b - Trigger 1. Position CDM on ignition plate. Install screws,
torque to 60 lb. in. (6.8 N·m).
5. Lift trigger off bearing cage.
2. Connect CDM wire harness plug to CDM.
55042
INSTALLATION
1. Install trigger and connect link arm.

b a

a b

19459
a - Wire Harness Plug
b - Screws
a - Link Arm
b - Trigger

2. Place trigger on bearing cage.

3. Route lead wires under ignition plate and down to
the CDM wire harness.
4. Connect corresponding trigger leads to CDM
wire harness.
5. Install stator. See “Installing Stator” in this sec-
tion.
6. Install flywheel. See “Installing Flywheel” in this
section.
7. Check engine timing. See “Engine Timing” in
Section 2C.

2A-24 - ELECTRICAL 90-852572R1 JANUARY 1998