Download DC CDI Troubleshooting

DC CDI Troubleshooting
Navigation Instructions
You will need to become familiar with these
buttons to navigate this lesson.
When your
mouse
cursor
changes to a
pointed
hand, a click
will cause
an action.
©UTI, Inc.
The forward button will go
forward one screen. Click
this button when you are
ready to proceed from this
screen. Notice the cursor
change.
The back
button will go
back one
screen.
Sea Doo CDI
DC CDI Troubleshooting
DC CDI
Troubleshooting
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Objectives
The participants will identify components
and testing procedures for a Sea Doo Battery
Powered Ignition system. This will be
demonstrated by the participants completing
a written exam with 80 percent accuracy.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Systematic Approach
To insure an efficient and accurate diagnosis, the
following systematic approach must be used:
1. Battery inspection
2. MPEM advanced diagnostic test
3. Spark test
4. MPEM CDI Output Test
5. Trigger Coil Output Test
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
1. Battery Inspection
 The first step is to insure that the craft has a
fully charged battery .
 Battery service should begin with a thorough
visual inspection:
 Check for cracks in the battery case and
broken terminals.
 Check for cracked or broken cables.
 Check for loose battery cable connections.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Battery Inspection (cont’d)
 Visual inspection (cont’d):
 Check the electrolyte fluid level.
 Check for cloudy or discolored electrolyte
caused by overcharging or vibration.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Battery Load Test (cont’d)
 The next step is to
perform a battery load
test.
 A battery load tester
provides important
information consisting
of open battery
voltage, voltage under
load and internal
resistance.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Battery Load Test (cont’d)
 Battery Load Testing procedures:
 Install the load tester in parallel with the
battery.
 Load the battery by turning the load
increase control until the ammeter reads 3
times the amp-hour rating of the battery.
 Maintain the load for 15 seconds, and note
the voltmeter reading.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Battery Load Test (cont’d)
If the voltmeter
reading during 15
second test is:
• 9.6 volts or
higher, the
battery is good.
• 9.5 volts or
lower, the
battery is
defective and
needs
replacement.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
2. MPEM advanced diagnostic test
 The next
step is the
MPEM
diagnostic
test.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
2. MPEM advanced diagnostic test
 Start by
removing
the safety
lanyard
from DESS
post.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
2. MPEM advanced diagnostic test
 Press 5 times on the
watercraft
start/stop button.
 1 short beep and 1
long beep must be
heard (they validate
beginning of
diagnostic mode).
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
MPEM advanced diagnostic test
 Install safety lanyard on watercraft DESS post.
 Press the watercraft start/stop button again.
 If everything is correct, the engine will start.
 Otherwise, refer to the following chart.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
MPEM advanced diagnostic test
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
MPEM advanced diagnostic test
 If no beeps occur and the engine does not start
or crank over, then test for battery voltage at
the MPEM.
 Meter connection:
 Positive meter lead to Amphenol connecter
number 3, pin 26
 Negative meter lead to Amphenol connecter
number 3, pin 24
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Disconnect Amphenol Connector #3
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Amphenol Connector #3
Pin #24
©UTI, Inc.
Pin #26
Sea Doo CDI
DC CDI Troubleshooting
Amphenol Connector #3
Pin #24
Pin #26
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Meter reading should be near battery voltage
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
MPEM advanced diagnostic test
 If battery voltage is not present at the
Amphenol connector, then test the main
battery fuse.
 If the main battery fuse checks okay, then use
a test light to trace the wire for an open.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
3. Spark Test
 The next step is to
test for strong,
quality spark that
will fire the spark
plugs under
compression.
 A neon spark tester
should be used for
this test.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
3. Spark Test (cont’d)
 Install the neon
testers in series
with the high
tension leads.
 While cranking
the engine,
observe for
spark on both
cylinders.
Observe for spark in the neon spark testers
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
3. Spark Test (cont’d)
 If spark occurs in both cylinders then the
ignition system is operating properly and no
other tests are needed.
 If spark does not occur in either cylinder, then
an ignition system failure is present.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Direct Voltage Adapters
 The input or output voltages of the remaining
ignition system tests are pulse voltages.
 Ignition pulse voltages increase and decrease
within extremely short periods of time and can
not be tested with a typical volt meter.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Peak Voltage Adapters (cont’d)
 Rather than using an expensive oscilloscope,
which is suitable for measuring short-length
pulses, the marine industry utilizes a direct
voltage adapter (DVA).
 The DVA must be used with a commercially
available digital multimeter (impedance
10M/DCV minimum).
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Peak Voltage Adapters (cont’d)
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Peak Voltage Adapters (cont’d)
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
4. MPEM CDI Output Test
 The 4th step is to check for CDI output.
 The CDI output of the MPEM should be 100
volts or higher at engine cranking speeds.
 CDI output is checked at the ignition coil.
 Proper connection to the ignition coil is
imperative, the correct polarity must be
observed.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Proper connection
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Positive DVA lead to white wire at ignition coil
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Negative DVA lead to chassis ground
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
While cranking the
engine the meter reading
should be 100 volts or
more
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
MPEM CDI Output Test (cont’d)
 If the peak voltage is lower than 100 volts,
reverse the meter leads and recheck the peak
voltage.
 If the peak voltage is still lower than
specifications, disconnect the ignition coil’s
primary leads and test again.
 If the peak voltage is still lower than
specification, reverse the meter leads again.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
MPEM CDI Output Test (cont’d)
 If the voltage reading is 100 volts or more,
then the ignition system from the MPEM
back is operating properly, and the problem
is in the ignition coil area.
 If the voltage reading is 100 volts or more
only with the MPEM disconnected from the
ignition coil, then the problem is in the
ignition coil area.
 If the voltage reading is less than 100 volts,
then the MPEM is defective and must be
replaced.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
5. Trigger Coil Output Test
 The last step in the systematic
troubleshooting procedures is testing the
output of the trigger coil.
 The output of the Trigger coil is .2 volts or
higher at engine cranking speeds
 In order to test trigger coil output a 6-pin
break-out harness is needed
 The 6-pin break-out harness is connected in
series with the magneto Deutsch connector
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
6-pin break-out harness
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Magneto Deutsch connector
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
6-pin break out harness
Magneto Deutsch connector
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Trigger Coil Output Test (cont’d)
 Proper meter connection to the trigger coil is
imperative (see next slide).
 The output of the Trigger coil should be .7
volts or higher at engine cranking speeds.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Sea Doo 6-pin break out harness
DVA Meter Leads
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
While cranking the engine,
the meter reading should .7
volts or higher.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Trigger Coil Output Test (cont’d)
 If the peak voltage is lower than .7 volts,
reverse the meter leads and recheck the peak
voltage.
 If the peak voltage is still lower than
specifications, disconnect the trigger coils
leads and test again.
 If the peak voltage is still lower than
specification, reverse the meter leads again.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
Trigger Coil Output Test (cont’d)
 If the voltage reading is between .7 volts, or
higher then the trigger coil is operating
properly.
 If the voltage reading is .7 volts or higher
only with the trigger coil disconnected, then
the problem is in the MPEM.
 If the voltage reading is less than .7 volts,
then the trigger coil is defective.
©UTI, Inc.
Sea Doo CDI
DC CDI Troubleshooting
End
Return to home page
©UTI, Inc.
Sea Doo CDI