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OMC Saildrive Zephyr ignition problems (charge coil?)

struyffamily I have a 2 cyl 2 stroke 15HP inboard OMC engine (OMC Sail Drive Zephyr)with ignition problems. It's on our O'Day 25 (1978) and the model is 15S10S.

I measure merely 80V AC output doing the Charge Coil Output test(should be > 230V).
I replaced with a new charge coil, but... result is still the same...!
The charge coil resistance is 470 Ohm as per specs. Sensor coil is OK according to all three tests, 42 Ohms, no leak to ground,
0.55V AC output.

What could the problem be? Does someone know this model? Is it the power pack?

Thanks

2002-03-10
petryshyn Don't know your model, but are you using a peak reading meter or peak reading adapter when doing the test? 2002-03-10
ICEMAN HI, Struyffamily, You did not mention what kind of problem you are having, No start, rough running, mis-firing? When you tested the charge coil, was it still connected in the circuit? Do you have a manual? Is the motor cranking over fast enough, If the fl 2002-03-10
petryshyn thanks Iceman.
We don't get much for sail boats around here. My experience with them is nil.

2002-03-10
struyffamily The problem is: no start, negative spark test... And yes, we have the manuals, I even scanned 2 sections in PDF (1MB & 6MB!): http://www.geocities.com/bstruyf2000/ignition.pdf
Hard to tell if the flywheel is cranking fast enough, we're using a full battery and tested the (disconnected) output (before it goes to the power pack). How can we test this? Thanks for your tips!!
2002-03-10
petryshyn Hi
your schematic pages don't show up?
Good resume though!

Are you using a peak reading meter or peak reading adapter when measuring the charge coil test?

2002-03-10
struyffamily We're using a normal Volt-Ohm analog meter. Is this wrong? I feel so, after your comments...?

I moved the files to another web site: http://kap.bvdep.com/ignition.pdf

Thanks!

2002-03-10
petryshyn HI

I think we better start from the beginning.

Did you disconnect the yellow/black kill wire from the pack and retry for spark?
(can't use a rms meter with these tests. must use a peak to peak meter or a peak reading adapter along with a digital multi meter with an impedence no lower than 10megohm)

2002-03-10
flagrange Hi,

Sorry for jumping in; I'm 'Struyffamily's friend and the guy that actually attempted the repairs. I'm not a pro in this matter (but 'someone has to do it' ;-)
Your hints clearly pinpoint the problem !
I did the measurements with everything dis

2002-03-10
almost retired again Hi Struffamily, I would do what schematis suggested; remove the black/yellow wire out of the plug that goes to the power pack and test for spark again would sure beat buying a new pack. It could be the key switch, or cables that run to it.
Just my two cants worth
2002-03-10
petryshyn almost retired again,
your comments are always welcome and worth way more than 2 cents!

flagrange
the black/yellow wire is the kill wire for the ignition. To stop the engine, this wire gets grounded. If you still have no spark when this wire is disconnected:

>then check for loose or corroded ground connections
>pull all plugs apart and look for pins pushed back in their boots
>check for good coil grounds
>check charge coil for voltage
>check trigger coil for voltage
>if everything till now is good.....suspect the pack

I think there is a section in Murphy's Law that states.....if you miss one test in CDI troubleshooting, you'll replace the pack for nothing!!!


By the way....thanks for the nice schematic! I had no literature on sail drives....til now....

2002-03-10
flagrange Hi,
It seems everything confirms my measurement error, that is with that peak voltage 'add-on'. Besides, I did already all the other tests, and did them carefully, as well as clean up all contacts, and ensure there could be no leaks (or no obvious one
2002-03-11
flagrange By the way, I did the key switch test as well. Actually I did all the tests suggested in the service manual... but used the tools I had because I thought I wouldn't be able to find them any more.
That, actually, turns out to be blatantly wrong: spare parts are still easily available, and I saw those tools can be found eg. at CDI Electronics.
F>
2002-03-11
ICEMAN Hi Flagrange, If you still have a problem, let me know, I'm only 20 minutes away in CT. 2002-03-12

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