IGNITION

ELECTRICAL
Section 2A - Ignition

Table of Contents 2
A
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Recommended Test . . . . . . . . . . . . . . . . . . 2A-15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Testing Ignition Components . . . . . . . . . . . . . . 2A-17
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4 Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-17
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5 Engine Coolant Temperature
Electrical Components . . . . . . . . . . . . . . . . . . . 2A-6 (ECT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . 2A-21
Electrical Components . . . . . . . . . . . . . . . . . . . 2A-7 Flywheel Removal and Installation . . . . . . . . . 2A-22
Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-22
Ignition Component Description . . . . . . . . . . . 2A-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-23
Electronic Control Module (ECM) . . . . . . . 2A-8 Stator Removal and Installation . . . . . . . . . . . 2A-24
Crank Position Sensor . . . . . . . . . . . . . . . . 2A-9 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 (ECM) Removal and Installation . . . . . . . . . . . 2A-26
Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-10 Ignition Coil Removal and Installation . . . . . . 2A-27
Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-10 Voltage Regulator Removal
Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-11 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-27
Tool: Multimeter/DVA Tester . . . . . . . . . . . 2A-12 Crank Position Sensor Removal
Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-14 and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-28

90-854785R2 DECEMBER 2001 Page 2A-1

IGNITION

Specifications
Type Capacitor Discharge Ignition
Spark Plug
Type NGK DPR6EA-9
Gap 0.035 in. (1.0 mm)
Hex Size 18 mm
Hole Size 12 mm
Torque 150 lb-in. (17 Nm)
Firing Order 1-2
Ignition Timing:
Below 800 RPM
ECM (p/n 855311--) 10° B.T.D.C
ECM (p/n 856058--/856190--) 5° B.T.D.C
IGNITION ECM (p/n 856190-–/856482-–) 5° B.T.D.C
SYSTEM ECM (p/n 856177--/856178-–) 5° B.T.D.C
Readings taken @ ECM (p/n 878433--) 5° B.T.D.C
68°F (20°C). Fully Advanced (6000 RPM) 30° B.T.D.C
Charge Coil Resistance 660 - 710 Ω (GRN/WHT - WHT/GRN)
Crank Position Sensor Resistance 300 - 350 Ω (RED - WHT)
Ignition Coil Resistance:
Primary 0.08 - 0.7 Ω
Secondary (W/o Boots) 3.5 - 4.7 kΩ
ECM Engine Speed Limiter
Soft Reduction (Retards Timing) 6200 RPM
Spark Cut-Out Reduction (Percent-
ages of ignition spark are Cut-Out) 6250 RPM
ECM Overheat/Low Oil Pressure
Speed Control Approximately 2000 RPM
Oil Pressure Switch Below 2.5 psi (17 kPa) Continuity
Alternator Type Single Phase (12 Pole)
6 AMP Manual Alternator:
Output 12 Volts-6 Amps.
CHARGING Battery Charging Resistance 0.9 - 1.1 Ohms (YEL-YEL)
SYSTEM 15 AMP Electric Alternator:
Readings taken @ Output 12V-15 Amps. (Rectified/Regulated)
68°F (20°C). Battery Charging Coil Resistance 0.22 - 0.24 Ohms (YEL-YEL)
Power Bobbin Resistance
(For Electrothermal Valve) 6.7-7.1 Ohms (YEL/BLK-YEL/BLK)
Quicksilver Tachometer Setting “6P” or “4”

Page 2A-2 90-854785R2 DECEMBER 2001

 IGNITION

Special Tools
1. Flywheel Holder P/N 90-83163M.

2. Flywheel Puller P/N 91-83164M.

3. Timing Light P/N 91-99379

4. Direct Voltage Adapter P/N 91-89045

5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

90-854785R2 DECEMBER 2001 Page 2A-3

IGNITION

FLYWHEEL
51 Loctite 222 Thread Locker
110 4-stroke Outboard Oil

14
1

110 13
7
8
6
9 5 4

10

51

11

12

Page 2A-4 90-854785R2 DECEMBER 2001

 IGNITION

FLYWHEEL
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FLYWHEEL COVER ELECTRIC
2 4 SCREW (M6 x 25) 45 5
3 1 FLYWHEEL (ELECTRIC)
4 1 FLYWHEEL (MANUAL)
5 1 DECAL-Warning Spinning flywheel
6 1 DECAL-Timing Marks
7 1 DECAL-Warning-Neutral
8 1 NUT 116 157
9 1 WASHER
3 SCREW MANUAL 85 9.5
10
3 SCREW ELECTRIC 85 9.5
11 1 STATOR
11 1 STATOR
12 1 LOAD RING
13 1 DECAL Bodensee Certification
14 1 DECAL-EPA INFORMATION (1999)(SEE NOTE)
NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY
MISSING OR UNREADABLE EPA LABEL.

90-854785R2 DECEMBER 2001 Page 2A-5

IGNITION

ELECTRICAL COMPONENTS

6 Dielectric Grease
9 Loctite PST Pipe Sealant

Page 2A-6 90-854785R2 DECEMBER 2001

 IGNITION

ELECTRICAL COMPONENTS
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SOLENOID ASSEMBLY
2 2 BUSHING
3 2 GROMMET
4 2 NUT (8-32) (ELECTRIC) 25 3
5 3 NUT (1/4-20) 60 7
6 1 BATTERY CABLE (POSITIVE)
7 1 INSULATOR BOOT
8 1 CABLE
9 1 BATTERY CABLE (NEGATIVE)
10 1 STARTER MOTOR (See breakdown on Starter Motor)
3 SCREW (M8 x 45) (ELECTRIC) 22 29
11 1 SCREW (M8 x 25) (MANUAL) 22 29
2 SCREW (M6 x 30) (ELECTRIC) 75 8.5
12 1 SCREW (M6 x 16) (MANUAL) 75 8.5
13 1 J CLIP (ELECTRIC)
14 1 J CLIP (MANUAL)
15 1 PRESSURE SWITCH 50 5.5
16 1 SENSOR-Crank Position
17 2 SCREW (M5 x 16) 45 5
18 1 BRACKET (ELECTRIC)
19 1 RETAINER (ELECTRIC)
20 1 RETAINER (ELECTRIC)
21 3 SCREW (M6 x 25)
22 3 WASHER
23 1 PLATE
24 3 BUSHING
25 3 GROMMET
26 1 ECM
27 1 DECAL-Caution Start in Gear
28 3 BUSHING
29 3 SCREW (M6 x 40) 45 5
30 2 SPARK PLUG (NGK DPR6EA-9) 150 12.5 17
1 DECAL-Coil Identification
31 1 DECAL-Coil Identification
32 1 IGNITION COIL
33 2 GROMMET
34 2 HI–TENSION CABLE
35 2 SCREW (M6 x 30) 75 8.5
36 1 J CLIP
1 ENGINE WIRING HARNESS (MANUAL)
37 1 ENGINE WIRING HARNESS (ELECTRIC)
38 1 FUSE (SFE 20 AMP) (ELECTRIC)
39 1 COVER-Autofuse Housing (ELECTRIC)
40 1 SCREW (M6 x 10) (ELECTRIC)
41 1 HARNESS-EXTENSION (ELECTRIC HANDLE)
42 AR STA-STRAP
43 1 J CLIP (MANUAL)
44 1 VOLTAGE REGULATOR
45 2 SCREW (M6 x 40) ELECTRIC 105 12
46 1 OVERSLEEVE
47 1 TEMPERATURE SENSOR
48 1 RETAINER
49 1 SCREW (M6 x 13) 75 8.5
50 1 HORN DRIVER (MANUAL)

90-854785R2 DECEMBER 2001 Page 2A-7

IGNITION

Ignition Description
The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick
voltage buildup and strong spark required for high power and high performance engines.
The CDI ignition system does not incorporate mechanically operated points, therefore mak-
ing this CDI unit virtually maintenance free.
As the flywheel rotates, electrical power (alternating current) is produced by the capacitor
charging coil. This power is rectified by diodes so that direct current voltage is utilized by
the ignition system. When the ignition driver is off, the D.C. voltage is stored by the capacitor.
Once capacitor voltage is charged to its potential, a gate signal is applied on the SCR and
the residual current is dissipated through the capacitor charging coils.
The electronic control module (ECM) activates the ignition driver in the ECM which allows
the capacitor to discharge, causing the spark to occur. Ignition timing is regulated by the
ECM which receives status input from a variety of sensors. These sensors include the crank
position sensor, engine temperature and oil pressure sender.
The voltage discharged to the primary winding of the ignition coil causes a surge of high volt-
age to be induced in the secondary winding of the ignition coil. This induced voltage of suffi-
cient amplitude causes the spark plugs to fire.

Ignition Component Description

Electronic Control Module (ECM)

Under normal operating conditions the ECM unit controls the following:
1. Controls ignition spark timing by monitoring the crank position sensor, the engine tem-
perature sensor, and the oil pressure sensor.
2. Maintains normal idle timing (see specification).
3. Engine stall.
a. The stall saver feature will advance the ignition timing to 15° BTDC if engine falls
below 615 RPM.
4. Advances spark timing quickly to 30° BTDC under hard acceleration conditions.
5. Limits RPM of the engine in the event of a over speed condition (cavitation, no load on
propeller, and/or under propped), as listed in the following steps:
a. Soft Reduction: Ignition timing is gradually retarded to keep engine RPM below 6200.
b. Spark Cut-Out Reduction: Percentages of ignition spark will be cut-out according to
the degree of over speed RPM reached.

Page 2A-8 90-854785R2 DECEMBER 2001

 IGNITION

RPM % Spark Cut-Out

6250 11%
6281 33%
6313 66%

6. Over Heat Protection: Limits engine RPM to 2000 if the engine temperature exceeds
194° F (93° C). The ECM will sound the over heat warning horn (a continuous tone) and
turn on the optional Over Heat Warning lamp. Over heat warning will subside if the
engine temperature drops below 188° F (87° C) and engine RPM is momentarily
dropped below 1000 RPM as a reset condition. The ECM incorporates a 60 second
warning system delay to compensate for a warm restart (heat soak) condition.
7. Low Oil Pressure Protection: Limits the engine RPM to 2000 if oil pressure drops below
2.25 +/– 0.75 psi. The ECM will sound the low oil pressure warning horn (intermittent
1 second on - 1 second off) and turn on the optional Low Oil Pressure Warning lamp.
Low oil pressure warning will reset by shutting the engine off and restarting at a normal
oil pressure.
NOTE: The ECM controls all timing operations. There are no timing adjustment required on
this engine.

Crank Position Sensor

56790

Contains a permanent magnet and is positioned 0.030 ± 0.010″ (0.762 ± 0.254mm) from
the flywheel teeth. The timed passing of the flywheel teeth through the sensor’s magnetic
field enables the ECM to determine engine RPM and crankshaft angle.

Stator Assembly

a b

a - S/N 0G960499 and Below

b - S/N 0G960500 and Above
The stator assembly located under the flywheel contains the Ignition, auto enrichener, and
battery charge coils. All of these coils make up the stator assembly.
As the flywheel permanent magnets pass the respective stator coil windings, an AC pulse
current is produced at each coil winding when magnet polarity changes. (South to North),
(North to South) etc.

90-854785R2 DECEMBER 2001 Page 2A-9

IGNITION

Flywheel Assembly

The flywheel assembly contains six permanently charged magnet segments which are
bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a
south pole providing a 12 pole system.

Ignition Coil

The primary (+) side of the ignition coil receives voltage discharged from a capacitor in the
ignition (CDI) circuit located inside the ECM. The voltage is multiplied by the coil until it can
jump the spark plug gap. The ignition coil will produce a high voltage current each crankshaft
revolution, producing a spark at each cylinder at the same time (Waisted Spark Ignition).
Ignition coil maximum output is approximately 40,000 volts.

Ignition Test Procedures

Direct Voltage Adapter (DVA)

WARNING
DANGER – HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components
and/or metal test probes while engine is running and/or being “cranked”. STAY
CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark
plug lead should be grounded to engine.

WARNING
When testing or servicing the ignition system, high voltage is present. DO NOT
TOUCH OR DISCONNECT any ignition parts while engine is running, while key
switch is on or while battery cables are connected.

Page 2A-10 90-854785R2 DECEMBER 2001

 IGNITION

CAUTION
Failure to comply with the following items may result in damage to the ignition
system.
1. DO NOT reverse battery cable connections. The battery negative cable is (–)
ground.
2. DO NOT “spark” battery terminals with battery cable connections to check
polarity.
3. DO NOT disconnect battery cables while engine is running.
4. DO NOT crank engine with CDI or Ignition Coils not grounded.

CAUTION
To protect against meter and/or component damage, observe the following
precautions:
• 400 VDC* test position (or higher) MUST BE used for all tests.
• INSURE the Positive (+) lead/terminal of DVA is connected to the Positive (+)
receptacle of meter
• DO NOT CHANGE meter selector switch position while engine is running and/or
being “cranked”.
• ALL COMPONENTS MUST BE GROUNDED during tests. Running or “cranking”
engine with CDI or Ignition Coils ungrounded may damage components.
* If using a meter with a built-in DVA, the DVA/400 or DVA/500 VDC test position should
be used.

NOTE: Test leads are not supplied with the Direct Voltage Adapter. Use test leads supplied
with multi meter.
Test procedures and specifications are provided for checking primary ignition voltage
while the engine is running and/or being “cranked” with all harnesses connected.

Ignition Troubleshooting
WARNING
DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do not touch ignition components
and/or metal test probes while engine is running and/or being “cranked”. STAY
CLEAR OF SPARK PLUG LEADS. To assure personal safety, each individual spark
plug lead should be grounded to engine.

WARNING
When testing or servicing the ignition system, high voltage is present. DO NOT
TOUCH OR DISCONNECT any ignition parts while engine is running.

90-854785R2 DECEMBER 2001 Page 2A-11

IGNITION

Tool: Multimeter/DVA Tester 91-99750A1

Voltage
Selector
Component DVA Lead DVA Lead Reading(1)
Sw.
Test Red Black @300-3000
Position
RPM
Coil Coil (–) Black (B) Coil (+) Orange
400 DVA* 250 - 320 (1)
Primary Lead (2) ** (O) Lead (2) **
Stator
400 DVA* Green/White (2) Ground 250 - 330 (1)
Charge Coil
Stator
400 DVA* White/Green Lead (2) Ground 250 - 330 (1)
Charge Coil

*If using a meter that requires a DVA adapter, place selector switch to the 400 VDC position.
** Reverse Polarity
(1) Readings may vary at cranking speed or at idle speed.
(2) Back probe the electrical lead bullet connector in order to make connection.

Multimeter Ohm Checks

Tested Part Multimeter Connected To: Meter Meter
Wires Scale Reading
Red Green/White (2)
Stator Charge Coil Rx1Ω 660 - 710
Black White/Green (1)
Power Bobbin Red Yel/Blk
Charge Coil Rx1Ω 6.7-7.1
Black Yel/Blk
Red Yel
Stator Battery Charge
Rx1Ω 0.9-1.1
Coil (6 Amp.)
Black Yel
Red Yel
Stator Battery Charge
Rx1Ω 0.22-0.24
Coil (15 Amp.)
Black Yel
Red Red (1)
Crank Position Sensor Rx1Ω 300 - 350
Black White (2)
Ignition Coil Primary Red Orange (O)
(with wires Rx1Ω 0.08 - 0.7
disconnected) Black Black (B)
Ignition Coil Red High Tension Lead
Secondary #1
(test with coil leads Black High Tension Lead kΩ 3.5 - 4.7
disconnected and the #2
high tension lead cap
removed)***

NOTE: Copper is an excellent conductor, however, resistance may notably vary between
low and high temperature. Therefore, reasonable differences can be accepted between
resistance readings and specifications. The above readings are for a cold (room tempera-
ture) engine. Resistance will increase if the engine is warm.
*** High tension lead cap contain a 5k ohm resister. Remove caps when making secondary
ignition coil test.

Page 2A-12 90-854785R2 DECEMBER 2001

 IGNITION

Ignition Diagnostic Procedures

TROUBLESHOOTING TIP: With engine running, use inductive timing light to check spark
advance of each cylinder as throttle is opened and closed. If timing advances and retards
on each cylinder, ignition system is MOST LIKELY functioning properly.
IMPORTANT: If outboard appears to have an ignition system failure, it is recom-
mended that before beginning in-depth troubleshooting:
a. Ensure that the engine is mechanically sound condition. (Fuel System, Cylinder
Compression etc.).
b. Check all engine ground leads for loose or corroded connections.
c. Disconnect and reconnect ignition harness connectors to verify proper continuity.

SUGGESTED TESTING PROCEDURES

NOTE: The following recommended tests and probable causes are not listed in any specific
order. The technician should use this table as a guide to help isolate and test the specific
problem/condition. Always perform the DVA tests first (if applicable), then perform resis-
tance test to validate suspected component failure.

90-854785R2 DECEMBER 2001 Page 2A-13

IGNITION

*Recommended Test
(1) DVA TEST (Direct Voltage Adapter)
(2) OHM TEST (Resistance Testing)
(3) Replace Component and Retest
(4) Mechanical Test/Repair

PROBLEM/CONDITION Probable Cause *Perform

Test No.
No Spark Condition (Both Cylinders) Crank Position Sensor 2
Stator 1-2
(ECM) 3
Stop Circuit Short to Ground:
a - stop circuit lead 2
b - lanyard stop switch 2
c - tiller handle stop button (if sup- 2
plied) 2
d- remote control harness 2
Ignition Coil 2
Primary Circuit Shorted to Ground 3
Spark Plugs
Open Ground Condition: 2
a - ignition coil 3
b - stator ground 3
c - (ECM)
No Spark Condition (One Cylinder) High Tension Lead 2
Spark Plug Cap (Resistor) 2
Spark Plug 3
Weak Spark Condition Ground Connection at:
a - Ignition Coil Primary Leads 2
b - Stator 2
c - (ECM) Primary Coil Supply Leads 3
High Resistance To Ground at:
a - stop/lanyard switch (water/ 2
corrosion)
Weak Charge Coil 1-2
Ignition Coil/High Tension Lead(s) 1-3
Spark Plug(s) 2
Spark Plug Cap (Resistor) 3
Spark Plug Cap Leak 3
(ECM) Failure 3

Timing Fluctuates Loss Of Oil Pressure/Over Heating:

NOTE: It is considered normal for the timing to a - timing retards and fluctuates, rpm 4
fluctuate approximately 1° - 2° within the desig- will drop below 2000 rpm
Flywheel Key Sheared 4
nated timing window.
(ECM) Unit 3

Page 2A-14 90-854785R2 DECEMBER 2001

 IGNITION

*Recommended Test (continued)

(1) DVA TEST (Direct Voltage Adapter)
(2) OHM TEST (Resistance Testing)
(3) Replace Component and Retest
(4) Mechanical Test/Repair

PROBLEM/CONDITION Probable Cause *Perform

Test No.
Timing Will Not Advance Low Oil Pressure/Engine Over Heating:
a - timing retards and fluctuates, rpm 4
will remain below 2000 rpm
(ECM) 3
Engine Misfires At High RPM
Low Oil Pressure/Engine Over Heating:
a - timing retards and fluctuates, rpm 4
will remain below 2000 rpm
Ignition Coil/High Tension Lead(s) 2
Spark Plug Cap(s) 5k Ω Resistor 2
Spark Plug(s) 3
(ECM) Unit 3
Ground Connection:
a - (ECM) 3
b - ignition coil 2
c - stator 2
Engine Hard To Start Cold Debris In Carburetor Enrichener Circuit 4
Weak Spark Condition 1
Throttle Plate in Open Position 4
Engine Hard To Start Hot Weak Spark Condition 4
Vapor Lock 4
Engine Will Not Run Over 2000 RPM Low Oil Pressure/Engine Over Heating:
a - timing retards and fluctuates, rpm
will remain below 2000 rpm 4
Stator 1-2
Ignition Coil/High Tension Lead(s) 2
(ECM) 3
Spark Plug(s) 3
Engine Occasionally Misfires Charge Coil 1-2
Ignition Coil/High Tension Lead(s) 2
Spark Plug Cap(s) 5k Ω Resistor 2
Spark Plug(s) 3
Ground Connection at:
a - ignition coil 2
b - (ECM) 3
c - stator 2
High Resistance To Ground at:
a - stop/lanyard switch (water/corro-
sion) 2
(ECM) 3
Engine Surges Over Boat Under Propped 4
6200 RPM While Under Load Propeller Hub Spun 4
NOTE: The engine (ECM) will retard timing
and reduce RPM above 6200 RPM.

90-854785R2 DECEMBER 2001 Page 2A-15

IGNITION

Testing Ignition Components

Resistance Tests
When performing resistance tests, all component leads must be disconnected. Readings
may very slightly due to temperature changes.
NOTE: Readings listed taken at 68° (20° C).
NOTE: Refer to section 1C General Information (powerhead reference views) for location
of components.

STATOR (IGNITION CHARGE COIL)

a - S/N 0G960499 and Below

b - S/N 0G960500 and Above

METER SCALE READING

METER TEST LEADS
(

RED BLACK
GRN/WHT WHT/GRN RX1 660 - 710

Page 2A-16 90-854785R2 DECEMBER 2001

 IGNITION

STATOR AUTO ENRICHENER (POWER BOBBIN CHARGE COIL)

a - S/N 0G960499 and Below

b - S/N 0G960500 and Above

METER SCALE READING

METER TEST LEADS
(

RED BLACK
YEL/BLK YEL/BLK RX1 67-7
6.7 7.1
1

IGNITION COIL (PRIMARY)

a b

a - S/N 0G960499 and Below

b - S/N 0G960500 and Above

METER TEST LEADS METER SCALE READING

(

RED BLACK
ORANGE BLACK RX1 0 08 - 0
0.08 0.7
7

NOTE: Should show short circuit condition on meter.

90-854785R2 DECEMBER 2001 Page 2A-17

IGNITION

SPARK PLUG CAP REMOVAL

NOTE: High tension cables must have spark plug cap removed before testing. Cap contains
5k ohm resistor.
IMPORTANT: To remove spark plug cap from high tension leads, turn cap counter-
clockwise while applying slight outward pressure. DO NOT PULL HARD or lead may
be damaged. To install cap, turn cap clockwise threading cap onto high tension lead.

55852

IGNITION COIL (SECONDARY)

a - S/N 0G960499 and Below

b - S/N 0G960500 and Above

METER TEST LEADS METER SCALE READING

(

RED BLACK
#1 CABLE #2 CABLE RX1K 35-4
3.5 4.7
7

Page 2A-18 90-854785R2 DECEMBER 2001

 IGNITION

SPARK PLUG CAP RESISTOR TEST

55853

METER TEST LEADS METER SCALE READING

(

RED BLACK
RX1K 35-5
3.5 5.2
2
WIRE END PLUG END

CRANK POSITION SENSOR

2
2 1 1

METER TEST LEADS METER SCALE READING

(

RED BLACK
RX1 300 - 350
#1 #2

90-854785R2 DECEMBER 2001 Page 2A-19

IGNITION

Engine Coolant Temperature (ECT) Sensor

1. Place the engine coolant temperature sensor in a container filled with water.
2. Place a thermometer in the water and slowly heat the water.
3. Measure the resistance when the specified temperature is reached. If the reading is out
of specification, replace the sensor.

a - Temperature Sensor
Insert digital or analog ohmmeter test leads into both Tan/Black sensor leads. With engine
at temperature (F) indicated, ohm rating should be as indicated.

Temperature Sensor
Between Black and EACH Tan/Blk wire No Continuity

270
255
240
225
210
195
Temperature (
F)

180 Temperature Sensor

165
150
135
120
105
90
75
60
45
30
15
0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2

Resistance (k
)

Page 2A-20 90-854785R2 DECEMBER 2001

 IGNITION

Flywheel Removal and Installation

WARNING
Engine could possibly start when turning flywheel during removal and installation.
To prevent this type of accidental engine starting and possible serious injury, al-
ways remove spark plug leads from spark plugs.

Removal
1. Disconnect spark plug leads from spark plugs.

2. Remove flywheel cover (electric models) or manual starter (refer to section 8).

55860

a - Screws (4)

3. Hold flywheel using flywheel holder (91-83163M). Remove nut (30mm) and washer.

a 91-83163M
55774

a - Flywheel Holder (91-83163M)

90-854785R2 DECEMBER 2001 Page 2A-21

IGNITION

4. Remove flywheel using puller (91-83164M).

91-83164M

55776

a - Flywheel Puller (91-83164M)

Installation
1. Place flywheel key into slot.
2. Install flywheel. Apply oil to threads on crankshaft.

a - Key

3. Hold flywheel using flywheel holder (91-83163M) and tighten nut to the specified torque.

a
91-83163M 55774

a - Flywheel Holder (91-83163M)

Flywheel Nut Torque

116 lb. ft. (157 N·m)

Page 2A-22 90-854785R2 DECEMBER 2001

 IGNITION

Stator Removal and Installation

1. Remove sta-strap.
2. Remove stator mounting screws.
3. Reverse steps for installation (refer to wiring diagram Section 2D for correct wire con-
nections).
NOTE: Apply Loctite 222 to Threads.

51

51 Loctite 222 Thread Locker

55861

a - Stator
b - Screws (3)

Stator Screw Torque

85 lb. in. (9.5 N·m)

4. Route wires through j-clip and secure bundled connectors with sta-strap.

b 55862

a - J-Clip
b - Sta-Strap

90-854785R2 DECEMBER 2001 Page 2A-23

IGNITION

Timing Belt
Removal
1. Remove flywheel and stator. Refer to section 2B Charging and Starting System.
2. Remove timing belt from driven gear and drive gear.

a - Timing Belt

Installation
Timing Belt Installation Notes:
• Protect the timing belt from water and oil.
• Use care not to scratch the belt.
• Do not use any metal device to help stretch the belt onto the driven gear.
1. Align marks on drive and driven gear with marks on cylinder block as shown.
2. Install timing belt onto drive gear as shown. Numbers/letters on belt should be readable
once belt is installed.
3. Install stator and flywheel. Refer to section 2B Charging & Starting System.

a
d
1

b e
c
c
a - Drive Gear Mark d - Timing Belt Installed
b - Driven Gear Mark Correctly
c - Cylinder Block Marks e - Timing Belt Installed In-
correctly
Page 2A-24 90-854785R2 DECEMBER 2001
 IGNITION

(ECM) Removal and Installation

1. Remove and install ECM as shown.

55738

Starboard Connecting ECM

a - Screws (3)
b - Harness Clip

Port Connecting ECM

a - Screws (3)
b - Harness Clip

(ECM) Mounting Screw Torque

45 lb. in. (5 N·m)

90-854785R2 DECEMBER 2001 Page 2A-25

IGNITION

Ignition Coil Removal and Installation

1. Disconnect spark plug leads from spark plugs.
2. Disconnect ignition coil wires from harness (ORN and BLK/WHT).
3. Remove ignition coil mounting screws.
4. Reverse steps for installation.
a

c 55739

a - Cylinder Head Cover

b - Ignition Coil
c - Screws (2)

Ignition Coil Mounting Screw Torque

75 lb. in. (8.5 N·m)

Voltage Regulator Removal and Installation

1. Remove sta-strap.
2. Disconnect voltage regulator wires, YEL (2), GRY, and RED.
3. Remove mounting screws and ground wires.

Page 2A-26 90-854785R2 DECEMBER 2001

 IGNITION

4. Reverse steps for installation (refer to wiring diagram section 2D for correct wire
connections).

b
a

55864
b
a - Voltage Regulator c - Sta-Strap
b - Screws (2)

Voltage Regulator Mounting Screw Torque

105 lb. in. (12 N·m)

Crank Position Sensor Removal and Installation

1. Disconnect sensor from wiring harness.
2. Remove sensor mounting screws.
3. Reverse steps for installation.

a b

a - Crank Position Sensor

b - Screws (2)

Crank Position Sensor Mounting Screw Torque

45 lb. in. (5 N·m)

90-854785R2 DECEMBER 2001 Page 2A-27