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IG N IT IO N AND ELECTRICAL SYSTEMS 5-43

04709P04

Fig 44 A two part battery cable ceaning too w il o an excelentjob of ceaning the insie of the cable connectors

0409P05

Fig 45 The secon pat of the battery cable cl eani ng tool contains abrush for cle aning the battery terminals

Eectrolyte eve

See Fi ges 46 and 47

The most common procedure fo checking the eectroyte level i n a battery isto remove the cell caps and vsalyobserve the level in the c ells. The bottom ofeach cel l has a split vent which wil l cause the surface of the electrolyte toappear distorted when it makes contact When the d istortion first appears at thebottom of the split vent, the e lectrolyte leve i s corect

0409G03

Fig. 46 A check of the eectrolyte in the battery shou be on themaintenance scheule for any boat

0470P03

Fig. 47 Testing the el ectrolyte's specific gravity using a temperature

correcte hyrometer

Durin g hot weather and periods of heavy use the e lectrolyte level sho uld bechecked moe often than dring nomal operation Add disti lled water to bringthe leve o e lectroyte ineach cell to the proper level ake care not to overfil l,because adding an excessive amount of water wil l case loss o f electroyte and

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5-44 IG NIT ION AND E ECTRICA SYSTEMS

any loss wll resul n poor performance, shor baery lfe and w ll conrbuequckly o corroson

Never elecrolye from noher bery. Use only is ille wer

ery esin

A hydromeer s a devce o measure he percenage of sulfurc ac d n hebaery eecrolye n erms of specfc gravy When he cond on of he baerydrops from ful ly charged o d scharged, he acd leaves he solu on and enershe plaes, causng he specfc gravy of he elecrolye o drop

l may no be common knowledge, bu hydromeer floas are ca lbraed foruse a 80F (27C) If he hydromeer s us ed a any oher emperaure, ho er orcolder a correcon facor mus be apple d

Remember liqui will exn if i is hee n will conrc ifcoole. uch exnsion n conrcion will cuse efinie chnge inhe secific grviy of he l iqu i in his cse he elecrolye.

A qual y hydromeer w ll have a hermomeer/empe raure correcon able nhe lower poron, as ll usraed n he accompanyng l lusraon By knownghe a r emperaure around h e baery and from he able, a corre con facormay be appl ed o he specf c gravy read ng of he hydromeer floa In hsmanner, an accurae deermnaon may be made as o he condo n of he baery

When u sng a hydromeer, pay careful aenon o he follo wng pons1 Never aemp o ake a readn g mmedaely afer addng waer o he

baery Allow a leas % hour of chargn g a a hgh rae o horoughly m x heel ecrolye wh he new waer Ths m e wll also al low for he necessary gaseso be creaed

2 Always be sure he hydromeer s clean ns de and ou as a precauonagans conamnang he elecrolye

3 If a hermomeer s an negral par of he hydromeer, draw lqu d no several mes o ensure he correc emperaure before akng a readng

4 Be sure o hold he hydromeer vercally and suck up l qud only unlhe floa s free and floa ng

5 Always hold he hydromeer a eye level and ake he readn g a he surface of he lq ud wh he floa free and floang

Dsregard he slgh curvaure appearng where he l qu d rses aganshe floa sem hs phenomenon s due o surface enson

7 Do no drop any of he baery flud on he boa or on your clohn g,because s exremely caus c se waer and bak ng soda o neuralz e any baery l qu d ha does accdenall y drop

8 Afer drawng elecrolye from he baery cell unl he floa s barelyfree, noe he level of he l qud ns de he hydromeer f he level s wh n heGreen band range for all cells , he con d on of he baery s sasfacory f helevel s wh n he whe band for all cells he baery s n far condon

9. If he level s whn he Green or whe band for all cells excep onewhch re gsers n he red, he cell s shored nernally No amoun of chargngwl l brng he baery back o sasfacory condon

1 0 If he level n al l cells s abou he same, even f falls n he ed band,he baery may be echarge and reurned o servce f he le vel fals o rseabove he ed band afer chargng , he only sol uon s o replace he baery

ery Cle nin

Dr and corroson sho uld b e cleaned from he baery as soon as s d scovered Any accumulaon of acd flm or d r wll perm curren o flowbeween he ermnals Such a curren flow wll dran he baery over a perod of

meClean he exeror of he baery wh a solu on of d l ued ammona or a pase

made from bakng soda o neuralze any acd whch may be presen Flush heclean ng so luon off wh c lean waer.

ke cre o reven ny of he neurlizin soluion from enering hecells by keeing he cs igh.

A poor conac a he ermnals wll add ressance o he chargng cr cu.hs ressance wll cause he volage regulaor o regser a fully charged baery, and hus cu down on he saor assembly or lghng col oupu addng ohe low baery charge problem

Scrape he baery poss c lean wh a s uable ool or wh a sff wre bru shCl ean he nsd e of he cable clamps o be sure hey do o cause any ressancen he crcu

BATRY RMINAS

A leas once a season, he baery ermnals and cabl e clamps s hould beclean ed Loosen he clam ps and remove he cables, negave cable frs O n beres wh op mouned poss, he use of a puller specally made for hs purpose s recommended These are nexpensve and avalable n mos pars so

Cl ean he cable clam ps and he baery ermnal wh a wre brush, un l alcorroson, grease, ec, s removed and he meal s sh ny l s es pecally mp

an o clean he nsde of he clamp horoughly (a wre brush s useful here),snce a small depos of foregn maeral or oxdaon here wll preven a souelecrcal connecon and nh b eher sarng or chargng l s also a gooddea o apply some delecrc grease o he ermnal, as hs wll ad n he prevenon of corroson

Afer he clam ps and ermnals are clean, rensall he cables, negave cablas do no hammer he clamps ono baery poss Tghen he clamps secu rbu do no dsor hem Gve he clamps and ermnals a hn exernal coangrease afer nsallaon , o reard corroson

Chec k he cables a he same me ha he ermnals are cleaned If he nslaon s cracked or broken, or f s end s frayed, ha cable shoul d be replacwh a new one of he same lengh and gauge

SAFY RECAUTONS

Always follow hese safey precauons when chargng or h andln g a bae

Wear eye proecon when workng around baeres Baeres conan c

rosve acd and produce explosve gas a byproduc of her operaon Acd ohe skn s houl d be neuralzed wh a soluon of bak ng soda and waer madno a pase n case acd conacs he eyes, flu sh wh cl ear waer and seekmedcal aenon mmedaely Avod flae or sparks ha cou ld gn e he hydrogen gas produced by baery and cause an explos on C onnecon and dsconnec on of cables o bery erm nals s one of he mos common causes of sparks Always urn a baery charger before connecng or dsconnec nghe leads When conn ecng he leads, c onnec he posve lead frs, hen hnegave lead, o avod sparks When lfng a baery, use a baery carrer or l f a oppose corner s ohe base nsure here s good venlaon n a room where he baery s bengcharged Do no aemp o charge o r load-es a manenance-free baery when charge nd caor do s nd cang nsuffcen elecrolye

Dsconnec he negave baery cable f he baery s o reman n he b

dur ng he chargng process Be sure he gno n swch s before connecng or urnng hecharger . Sudden power surges can desroy elecronc com ponens se prope r adapers o onnec charger leads o baeres wh non-convenonal ermnals

BATTERY CHARGRS

Before usn g any baery charger, co nsul he manufacurer's nsruco ns fs use Baery chargers are el ecrcal devces ha change Aernang C urren(AC) o a lower volage of Drec Cu rren (DC) ha can be used o charge amar ne baery. here are wo ypes of baery chargersmanual and auoa

A manual baery charger mus be physcally dsconneced when he baerhas come o a ful l charge f no, he baery can be overcharged, and poss bl

fal xcess chargng curren a he end of he chargng cycle wll hea he elerolye, re sulng n loss of waer and acve maeral, subsanall y reducng bery lfe

As rule on mnu l chrers when he mmeer on he chrer risers hlf he re merge of he chrger he bery is fullychrge. This cn vry n i is recommene o use hyromeer ccurely mesure se of chre

Auomac baery charg ers have an mporan advanagehey can be lefconneced (for nsance, overngh) whou he poss b ly of overchargng hbaery Auoac chargers are equpped wh a sensng devce o allow he bery charge o aper off o near zero as he baery becomes full y charged Whchargng a low or comp leely dscharged baery, he meer wl l read close o raed oupu I f only parall y dscharged, he n al readng may be less han

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I GN IT IO N AND E LECTRICAL SYSTEMS 5-45

ated output, as the chage esponds to the c ond to n of the battey As the battey contnues to chage, the sens ng devce montos the state of chage andeduces the chag ng ate As the ate of chage tapes to zeo amps, the cha gew ll c ontnue to supply a few m l amps of cuentjust enough to mantan achaged condton

ATRY CAS

Battey cables don't go bad vey often, but l ke anythng ese they can weaout If the cabes o n you boat ae cacked, fayed o boken they sh ou d beepaced

When wokng o n any electcal component, t s always a good dea to dsconnect the negatve (-) battey cabe h s wl pevent potental damage tomany senstve electcal components

Always eplace the battey cables wth one of the same e ngth, o you w ncease esstance and poss bly cause had statn g Smea th e battey postswth a l ght fl m of d electc gease, o a battey temnal potectant spay onceyou've nstalled the new cabes f you epace the cables one at a tme, youwon't mx them up

Ay ime you iscoec he bery cbes i is recommee hyou iscoec he egive () bery cble fi rs. This wil preve youfrom cciely groui g he posiive (+) ermil whe iscoec-ig i hereby preveig mge o he eecric sysem.

STARTN G C IRCU IT

Descripton and Operation

See Fgure 8

In th e ealy days all outboad engnes wee stated by smply p ull ng o n aope wound aound the flywhee l As tme passed and ownes wee euctant touse mus cle powe, t was necessay to eplace the ope state wth some fomof powe cankng system Today, many small engnes ae stll stated by pulngon a ope, but othes have a poweed state moto nstalled

he system ut zed to eplac e the ope m ethod was an elect c state motocoup ed wth a mechancal ge a mesh between the state moto and the powehead flywheel, sm la to the method used to cank an automob le eng ne

As the name mp les the sole pupo se of the state moto ccut s to con

tol opeaton of the state moto to cank the powehead unt l the e ngn e sopeatng T he ccu t nclu des a elay o magnetc swtch to connect o dsconnect the moto fom the battey The o peato contols the sw tch wth a keyswtch

Befoe you dsconnect the cable(s), fst tun the gnt on to the pos tonThs wl pevent a daw on the battey whch cou ld cause acng When the battey cable(s) ae econnected (negatve cable last), be sue to check all electcalaccessoes ae all wokng coectly

ATRY SORAG

the boat s to b e la d u p fo the wnte o fo moe than a few weeks, specal

attenton must be gven to the battey to pevent complete dschage o poss bledamage to the temnals and w ng Befoe puttn g the boat n stoage, dsconnectand emove the battees Cl ean them thooughly of any d o cooson, and thenchage them to full specfc gavty eadng Afte they ae fully chaged, stoe them na clean cool dy pace whee they wl not b e damaged o knocked ove pefeabyon a coupl e blocks of wood Stong the battey up of the deck wl l pemt a toccu ate feely aound and unde the battey and wl l h elp to pevent condensaton

Neve stoe the battey wth anythn g on top of t o cove the battey n sucha manne as to pevent a fom ccu latn g aound the f lle caps Al l battees,both new and old, w ll dschage dung peods of stoage, moe so f they aehot than f they eman cool heefoe the electoyte leve and the specf cgavty shoud be checked at egula ntevas A dop n the spec fc gavtyeadng s cause to chage them back to a full eadng

In cold c lmates, cae shoul d be execsed n select ng the battey stoage aeaA ful y-chaged battey w l feeze at about 0 degees below zeo A d schagedbattey almost dead, w ll have ce fomng at about 9 degees above zeo

A neutal safety swtch s nstalled nto the ccut to pemt opeaton of thestate moto onl y f the shft contol leve s n neutal hs swtch s a safetydevce to pevent accdenta engn e stat when the engn e s n gea

The state moto s a sees wound e lectc moto whch daws a heavy cuent fom the battey t s desgned to be used onl y fo shot peods of tme tocank the engn e fo statng To pevent oveheatng the moto, cankng shou ldnot be contn ued fo moe than 30-seconds wthout al owng the moto to coolo at least thee mnutes Actually, ths tme can be spent n m akng p elm naychecks to detemne why the e ng ne fals to stat

Powe s tansmtted fom the state moto to the powehead flywheelthough a Bendx dve Ths dve has a p non gea mounted on scew theadsWhen the moto s opeated the pn on gea moves upwad and meshes wththe teeth on the flywheel ng gea

When the powehead stats, the p n on gea s dven faste than the shaft,and as a esult, t scews out of mesh wth the flywheel A u bbe cusho n sbu lt nto the Bendx dve to absob the shock when the pn on meshes wth theflywheel ng gea he pats of the dve must be popely assembled fo eff

FLYWHEEL8852BG5

ig. 48 A ypicl srig sysem covers elecricl eergy io mechicl eergy o ur he egi e. The compoes re Bery o provieelecriciy o opere he srer Igiio swich o corol he eergizig of he ser rely or rely; Srer rely or rely o mke b rek he

circui bewee he bery srer; Srer o cover elecricl eergy io mechicl eergy o roe he egie Ser rive ger orsmi he srer roio o he egie fywheel

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5-46 IG NIT I ON AND ELECTRICAL SYSTEMS

cient operation If the drive is removed for cleaning take care to assemble theparts as il lustrated i n the accompanying i ll ustrations in th is section If the screwshaft assembly is reversed, it will strike the splin es and the rubber cushi on wil lnot absorb the shock

The soud of the motor during crankig is a good in dication of whether thestarter motor is operating properly or not Naturally, temperature coditions wil laect the speed at which th e starter motor is ab le to crank th e egin e h e speedof crankig a cold engie will be much s lower tha when cranking a warm

engin e An experienced operator will learn to recognize the favorable sounds ofthe powerhead cranking under various condition s

Troubleshooting the Starting System

If the starter motor spins, but fails to crank the engine, the cause is usually acorroded or gummy Bendix drive he drive shou ld be removed, cleaned andgiven an inspection

1 Before wasting too much time troubeshooting the starter motor circuitthe following checks should be made Many times the problem will be corrected Battery fully charged Shif control lever in neutral Main 2-amp fuse I ocated at the base of the fuse cover i s good (not

blown) All e lectrical connections clean and tight

Wirig in good coditi on, in sulation not worn or frayed2 Starter motor cranks slowly or not at al l

Faulty wir ing connectio Short-circuited le ad wire Sh it control not engaging eutral (not activating ne utral startswitch) Defective eutral start switch Starter motor not properly grounde d Faulty contact point inside ignition switch Bad connec tions o negative battery cable to ground (at battery sid eand engine side) Bad conecti ons on posi tive battery cable to mageti c switch termi-nal Open circ uit i the coil of the magnetic switch (relay) Bad or run-down battery Excessively worn down starting motor brushes Burnt commutator in starting motor

Brush spring tesion slack

Short circ uit i n starter motor armature3 Starter motor keeps runn ig Melted contact plate i side the magnetic switch Poor igni tion switch retur action4 Starter motor picks up speed put pin ion wi ll not mesh with ring

gear Worn down teeth on clutch p inio Worn down teeth o nflywheel ring gear5 wo more areas may cause the powerhead to crank slowly even though

the starter motor circuit is i n excellen t condition A tight or frozen powerhead Water in the lower unitStarter Motor

DESCRPON & O ERAION

See Fes 4, 50, 5 d 52

As the name impl ies, the sole pur pose of the cranking motor circuit is tocontrol o peration of the cranking motor to crank the powerhead un til the egi neis operating T he circui t inclu des a relay or magnetic switch to conn ect or discon nect the motor from the battery The operator controls the switc h with a keyswitch

A neutral safety switch is i nstalled into the circui t to permit operation of thecranking motor only if the shif control lever is in neutral This switch is a safetydevice to prevent accidental engi ne start when the en gin e is in gear

The cranking motor is a series wound e lectric moto r which draws a heavy

current from the battery I! is designe d to be used only for short periods of timto crank the engin e for starting To prevent overheatig the motor, crank ingshould not be contiued for more than 3seconds without alowing the mototo cool or at least three mi utes Actually, this time can be spent in mak ing plim inary checks to determine why the engine fail s to start

Power is transmitted from the cr anki g motor to the powerhead flywheelthrough a Bedix drive his drive has a pini on gear mounted on screw thread

0000

Fig 9 Typc l loc tio o the strter motor (OT)

1 . Motor assy, staing2. Relay sare3 Backet sarer

00G9

Fig. Typcl strter moto d rely ssembly

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C Bracket

IG N IT IO N AND ELECTRI CAL SYSTEMS 5-47

Brush hoder cover assy. Fied co caseG Brush (-@ Brush (+) Brush holder assy( Arma tu re Pnio stoppe set Piio assy

Fig Tyic l 3bush stte moto ssembly

C Bracket Pinon stopper set Pnon assy.

@ Armture Brush (+) Brush (-)

Fig. 2 Tycl 2bush stte moto ssemby

C

55G97

559

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5-48 IG NIT ION AND ELECTRI CAL SYSTEMS

When he mr s peraed he p n n gear mves upward and meshes whhe eeh n he flywheel rn g gear

When he pwerhead sars he p n n gear s dr ven faser han he shafand as a resul screws u f mesh wh he flywheel. A rubber cushn sbul n he Bendx drve absrb he shck when he p n n meshes wh heflywheel rng gear. The pars f he drve mus be prperly assembled fr effcen peran. f he drve s remved fr clean ng ake care assembe hepars as l lusraed n he accmpanyng l usrans n hs secn. f he screw

sha assembly s reversed w ll srke he spl nes and he rubber cush n wl ln absrb he shckhe sund f he mr durng crankng s a gd nd can f wheher he

crank ng mr s perang prp erly r n. Naurally emperaure cndnswll affec he speed a whch he crankng mr s able crank he engne Thespeed f crankng a cld engn e wll be much slwer han when crankng awarm eng ne. An experenced perar wl l learn recgne he favrablesunds f he pwerhead crankng und er varus cndns.

ESNG

See ccompyg ill usros

1 Usn g a mul meer see f here s any cn nuy beween he cmmuarand armaure cre he eser wl l nd cae nf ne ressance f he nsu lan sn gd cndn

2 Usng he eser check fr cnnu y beween each par adjacen cmmuar segmen f dscn nu y s ned a any par f he cmmuar replacehe whle sub-assembly f he armaure

3 f he surface f he cmmuar s gummy r herwse d ry wpe ffwh a clh dpped n kersene If he surface s carse r n burn smh wh sandpaper f he surface s grved deeply may be necessary remve he grved marks by urn ng he cmmu ar n a ahe; su ch urn ngs fen successful n recnd n ng he cmm uar f he exra sck necessary fr remval by cung s aval able whu reducng s dameer hel m .

55G89

Step 1

Step 2

55G91

Step

050592Step

55G93

Step 5

4. Usng a mulmeer check be sure ha he psve brush hlder snsulaed frm he negave brush h lder. The eser shul d n dcae an absencf any cnnuy beween any w brush hlders pp se plary If c nny s n dcaed replace he brush h lder.

5 Che ck he le ngh f each brush If he brushes are wrn dwn he sevce m replace hem.

REMOAL & IN SALAIO N

See ompy sttios

1 Dscnnec he negave baery cable2 Remve he engne cver3 Dscnnec he sarer relay elecrcal relay ead a he bul le cnnecr

Remve he grund wre

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IG N IT IO N AND ELECTRICAL SYSTEMS 5-49

55P6

Sep 7

4 Di scnnec he baery and sarer cabe s5 If equipped, rem ve he saer mr camp emve he muning bs hlding he sare mr he muning

backe7 emve he sarer mr

i:8 nsall he sarer mr n h e muing bracke D n frge

insal he clamp if s equipped9 Insall he muning bls and ighen snugy.

1 0 Cn nec he sarer mr cabe s Make sure all cnecin s are igh and free f any crrsin

Insal he engine cver.2 . Cnnec he negaive baery cabl e

OVERAU

See mpyi ii

he fllwi ng is a ypical sarer mr verhaul prcedure Sme md elsmay vary slig hly

emve he erminal nu and remve he mr cable2. emve he w bls frm he bm f he mr3 Separae he brush hld er cver assembly and he w brus spri ngs4 Separae e armaure frm he feld cil case

G8

Sep 1

G81

Sep 2

55G8

Sep 3

G83

Sep 4

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5-50

Step 5

Step 6

Step 7

Step 8

IG N IT I ON AND ELECTRI CAL SYSTEMS

00G84

00G8

000G86

000G8

000G88

Step 9

5 emve the screw and nut t remve the brushes6 Push dwn n the pn n stpper A, remve the stpper rng B and

take the p nnTo sseme:

Assembly s the reverse f dsassembly but the llwn g steps need t beaddressed dur ng assembly7 Apply water resstant grease t the meta seals and brush hl der cver8 When setng a brush t each brush hl der, be sure t place a brush

sprng n pstn befre nstang the brush9. When nstall ng the frnt cver and the hlder cver n the feld cl ca

al gn the mark "A n the fel d c l case wth the mark B n bth cvers Whnstal ng the hl der cver take care nt t break the brush

Starter Motor elay Switch

DESCRI PON & OPERAON

See Fe 52

he j b the starer mtr relay s t c mplete the crc ut between the battery and starter mtr t des th s by cl sn g the starter crcu t ele ctrmagnetcally when actvated by the key swtch Ths s a cmpl etely sealed swtchwhc h meets SAE standards f r marne appl catns DO N OT substtute an aumtvetype relay fr ths appl catn lt s nt sealed and gasl ne fumes can gnted upn starng the pwerhead he relay cnssts f a c wnd ng,plu nger return sprng, c ntact dsc and ur externally munted termnals Threlay s nstalled n seres wth the pstve battery cables munted t the twlarger termnals he smaller termnals cnnect t the neutral swtch andgrund

T actvate the relay, the sh f lever s placed n neutral, cls ng the n eutralswtch Electrcty cmng thrugh the g nt n swtch ges nt the relay c wndng w hch creates a magnetc fed The electrcty then ges n t grundn the pwerhead The magnetc feld sur runds the plu nger n the relay, whchdraws the dsc cntact nt the tw larg er termnals pn cntact f the term

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IG N IT ION AND ELECTRI CAL SYSTEMS 551

000P01

g 53 Typcl stte motor ely swtch locto

nals, h havy ampag cic ui h sa m is cl sd and acivas hsa m Whn h ky swich is lasd, h magnic fi ld is n l ng suppd and h magnic fild cl apss Th n sping wking n hplung pns h d isc cnac pni ng h cicui h sa

Whn h ama pla is f psi in h shif lv is mvd i nfwad vs ga h nual swich is placd i n h pn psii n and hsa cnl cicui c ann b acivad This pvns h pwhad fmsaing wh il in ga

TESTNG

See aompayg lstatos

Th ay is usually bl f f h a suspcd pblms wih hay, fis s h bay Thn lk up h sa cicui in h wiing diagam

00G9

Step 1

000

Step 2

f ha paicla mdl pwhad N ha h a w cic is h havyampag sa m cicui and h cnl cici fm h ky swich andnal swich Whn h ky is und, lisn f a cli ck fm h lay If acli ck is had, h cnl ci cui is paing nmally hn s f vlag ah sa m f h i s vlag a h sa m, a ading f blw 9vls wih n sa acin in di cas a bad sa sisanc in h cic i A

ading a na bay vlag i nd icas ha h sa has an pn ci cu iinsid

If n cli ck is had a h lay, s a jump wi jmp bwn hbay min a f h lay and h "S mina f i nw wks, h pblm i s in h cn l cicui s ing a mu li m, s f vlag a hnal swich a h cnl (a bh min als) If h is n vlag, s ah ky swich, wih h ky swich in h sa psiin Dpnding pn hspci fic md l, h may b a fus bwn h bay and h ign iinswich

1 T s h lay cninu iy, s a mlim chck whh cninu iy xiss bwn h w mi nals h lay wih h bay cnncd

2 And whn h bay is discnncd

RMOA & I NSTALAION

1 Discnnc h ngaiv bay cabl2 mv h ngin cv3 Di scnnc h sa lay lcic al ad a h bu l cnnc

mv h gn d wi4 Dis cnnc h bay and sa cabls 5 mv h sa lay

o sta Ins all h sa lay7 Cnnc h bay and sa cabls 8 Cnnc h sa lay lcical lad a h bl l cnnc nsall h

gnd wi9. Insall h ngin cv

1 0 Cnnc h ngaiv bay cabl 1 1 Chck h saing sysm f pp pain

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5-52 IG N ITION AND ELECTRI CAL SYSTEMS

IGNITION AND ELECTRICAL WIRING DIAGRAMS

The following diagrams represet the most popula models with t he mostpopular optional equpment

1988-96 DT2 and 1997 DT2.2 Wiring Diagram

BI/R B/R

STOP SWITCH

WIR E COLOR

B . Black

B I/R Bue with Red rae MAGNETO

1988-98 DT4 and 1999 and later DTSY Wiring Diagram

I.I II II J o v l R

r, r LJ'i),

: VoltgeI ty

R ; : R

egultor : f f : : . !11 8 B I '

S ,

W/R

8

IIII(III

Emegency Stop SicCA ON R UNA O

R

,Rectifier,

Y-tube Receptacle

Engne Stop SwtchON - STOPO FF RU N

B/R

CDI UNIT

WR

88

w/

I W r " W W.

"

W

Or

L-;".* - - f : :c==1 ----- 1 I - Bayri--t-ab_:[:a- 1 2V

O Rtube Pug

Ignton Col

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IG NITI ON AN D E LECTRICAL SYSTEMS 5-53

1990-98 DT4 and 199902 DTSY Wiring Diagram

MAGNETO

''

BI/RCl

UNIT

0-0 lIGNITION11

CO I

r-J i W/RI

Y R B B - -

l II B1. jYTUBE

-! l EMAGNCYSTOP SWITCH

2V30W

CAP ON + UNW

\CA OF-+STOP

L--1 : R-TUE

RECEPTACL

-

r- -1 f i PLUG

! Lf!

l

l

L- w. I 8 _ O P T I O N A L

MAGNETO

'

BI/R

v-

W

JD

tW

/R

-

8

B

-

---------. 1 r dlvOLTAGE : REGULATORrt R R Y L----

B : B ' *, ,

'* > RECTIFIER

,#YTUBE

EMERGENCY STOP SWITCHCA PO N+RUNCAP OFF STOP

{3w_w __ - - - O P T O N A Y , t I TUBE ;-:I f! L_ B -f'1 d- B _j -t- BATTERY t 2V'-- W =W--

RECEPTACLE ;LUG

CUNIT

B

0 O

ONIGNITI

1 1COIL

= -

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554 IG NIT I ON AND E LECTRICAL SYSTEMS

TION COL

C

1

OIL LEVEL SWTCHREST .ZL-ON

O E SWTT Z

1 98 8 DT8 Wiring Diagram

CONDENSECHAGNG CO

W /G W / G

G G

B/R B/R

B BRB R/

B

PUSE COL 1BATTERYCHAGNG COL

R

y MAGNETO

TUBE FUSE A r-----------W --- l--S-- w __! BATTERY -::

: 1V35AH B l--S B B !

RTUBE _ _;ECEPTACLE PUG

STOP SWITCHPSH STOP

EMERGENC STOP SWTCHCAP ON?RUNCAP OFF7STOP

1 98 9-91 DT8 Wiring DiagramCRGNG COL PS COL 1

--

505W

WG WG ...""""""

rJVOLTA . :__

__G_____T_

____G G8 8

8 8RY ::: ------

; 8 (";.. ,'" i 1 RECTFER ;Rl8 - R8

l y _

" MATO !

O EVECAT

8

8

PS OIL fZ

1

_

f.. . .. ... W/R ] W . .... II:! c-; [r . _:-,-

:

1ZV35 !

8

__

j- 8 ---------------- !

STOP SWTPUSH ST

REPTAE PLUG

NCY ST SWTCAP RCAP FST

0505W

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IG N ITION AND ELECTRI CAL SYSTEMS 5-55

198802 DT6 and 1982-97 DT8 Wiring Diagram

Pulse coi

Lgtng coil

Receptacle. W /R W

B/ -

B

-BBOPTIONr

IIII

II ILJ

c /Y

-

@

C

B

c

Yellow tube.------,

lIIIIIIII

Emergency swtc

B / R

- 81/R

B R

Engine stop switch

CDI

UIT

--------------------Yellow tube

1

l

Spak pug

R s-el

j

1

. rU t

: I

- -CHOKESTART

NOFF

-----------------------J

.

OPTION

1 98897 DT9.9 and DT 15 Wiring Diagram

EMRGNCY SOP SWITCHCAPON-RUNCAPOFF SOP

-

r

w

: tUS 20A'

BQ " " RMO CONTROL BOXl O

0" jswic

c

LA

BATTER

1

CHO HOR VOL 1V3AHL y

M

SARNGMOOR_

TR METER Mr

_

_

OPT.

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5-56 GN T O N AND ELECTRCAL SYSTEMS

IGNTON COL

NTON O

1 98997 DT 1 5C (Manual Stat) Wiing Diagam

CONDENSER CHARGNG COI MAGNETO

Cl UNT

PULSER COL #2

--- --I ol BATTERY 1 2V 35AH I 'r w 8 'RECEPTACE PL UG

i

STOP SWTCH

-8 - - - PUSH STOP

OL LEVEL SWTCH

RE ST 0 .2 - O N.8

81 989-97 DT 1 5C (Electic Stat) Wiing Diagam

ODNSE CHGG C - - - --,MGNETO

EMERGENCY

STOP SWTCH

CAP O N R UN

CAP OFF STOP

OL LEV EL N DCATOR

OSOW

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PLUG

; - - - w

(,/

;

1BARY ( 1:VI 1 r r- B {,:JiL

IG N IT ION AND ELECTRI CAL SYSTEMS

1 98 8 DT20 nd DT25 (Mnul Strt) Wiring Digrm

PLU SQCE Tr - ,IL:l -

y - '\ I c Y At

In case of baery hgin k1t m und oional

1 98 8 DT20 nd DT25 (Elctric Strt) Wiring Digrm

NO SWITCH

5-57

05005W11

FF b

": . . :;t

;'"EGl iLA R 8 t J j n ru "'F: . i r) C

r

r . . .

_o

-

optional

E

2V.35AH

A

$

r

YIG-

Bl!R

S MOO

UBMEY OP tK

Ul- ON !O

05005W10