Very slow crank when spark plug is fitted

[Per Björklund]

That little cdi is loose in a carved out hole in the chassi. This is it... No ebox...nothing more except the rotor and the spark plug wire which is attached to the rotor. So this pack must atleast contain an ignition timing module and a starter relay I guess? All cables in the whole craft is fitted to this module... Never seen anything like it before.

It contains 1 red cable going to the battery, other red going to the starter. A cable pack going to the rotor, a cable pack going to the start, stop and kill switch and a 30a fuse.

Vumad : it will not start at all now. With or without spark plug. No voltage beyond the cdi. I managed to measure the last breath at the starter which was 2 volts, cables are fine, everything is loose and inspected.

Ocd: how do you build your own cdi? Have no idea on the ignition curve of this machine

 

[Per Björklund]

Ground cable runs from the battery all the way to the starter. But basically voltage is fine until it enters the little cup shaped cdi... Since I managed to measure 2 cranks beyond the cdi before the final breathe I am like 100 percent certain that's the issue. I am also 100 percent uncertain on how to solve it

 

[Per Björklund]

 

[OCD Solutions]

Ocd: how do you build your own cdi? Have no idea on the ignition curve of this machine

I did not realize that it held a CDI unit as well. I was thinking it was just the starter solenoid in there.

Have you priced out a replacement? Visited any of the forums dedicated to those types of crafts?

 

[Per Björklund]

Well that's the problem... There is no replacement. It's a prototype, sold in i would guess at maximum a 100-300 crafts. The US company who sold thoose are out of business... There are Chinese copies but they are not built the same at all. Most components in this one is high class, wössner forged pistons, Yama starter, ngk wires and so on. So I thought that this cdi unit might have been used for something else aswell... When I bought new pistons I would have to contact woessner directly... So parts are I would say... Hard to find

 

[OCD Solutions]

Send these guys an email and see what they have for parts laying around, they designed the new system;
Electrex USA Ltd http://electrexusa.com

http://www.powerski.com/press/PR7_19_2004b.htm

Press Release Source PowerSki International Corporation

Electrex USA Ltd. Signs Contract with PowerSki for a Compact Electrical System
Monday July 19, 15:30 PST

SAN CLEMENTE, Calif. (BUSINESS WIRE)—July 19, 2004- PowerSki International
Corporation (PSI) announced today that it has signed a contract with Electrex USA Ltd http://electrexusa.com to design and produce a complete electronics package for the PowerSki Jetboard. Electrex USA specializes in supplying high quality replacement parts used in power sports electrical and charging systems. Electrex new offices are located in Oceanside, CA.

This new electronics system will include in addition to ignition control and over-rev limiting, full battery charging, over-temp detection, automatic starter shut-off, and internal water-cooling. According to Bob Montgomery, CEO PowerSki International, "This unique and proprietary new system provides state of the art electronics for the Igniter 330 PowerSki Jetboard. It will actually fit inside and be part of the patented Super Torque XT Marine Engine. This new proprietary electrical system will bring down the cost of production since the current system is purchased of the shelf.” “Reducing the size of the overall electrical system and eliminating the external connections, will improve the electrical system 10 fold,” says Leo Greene, Vice President of Engineering. “No longer will there be an external electrical box with multiple entry and exits that may allow water intrusion and possible electrical failure,” Leo Greene adds.
Bob Mac Kay, Director of Marketing states, “By having Electrex USA Ltd., produce this system specifically for the Super Torque XT Marine Engine gives flexibility for our patented propulsion package and makes it more attractive as an alternate power plant for other applications."
There are plans being discussed with Electrex USA Lt d., to develop a complete electrical wire harness for the Igniter 330 PowerSki Jetboard.




Contact info@powerski.com or telephone (949) 369-3920
Web: http://www.powerski.com/



Source: PowerSki International Corporation
150-A Calle Iglesia
San Clemente, Ca 92672

 

[Per Björklund]

Thanks alot ocd, thought I had read it all. Have looked for this for hours...thats a huge help. Thanks!

 

[OCD Solutions]

Thanks alot ocd, thought I had read it all. Have looked for this for hours...thats a huge help. Thanks!

And I stumbled upon that in minutes. Let me know if you need someone here on US soil to deal with them. I'd be happy to help out if you need it.

Also, If they don't have the parts but can give you an idea as to what to use instead, I am sure I could build you something.

 

[Per Björklund]

Thanks ocd, the best thing would probably be me paying you for building another one with known parts although I guess that's nearly impossible without knowing the ignition curve... Something like the yama ebox would be far better so it's possible to swap parts.

 

[Per Björklund]

Guess what, you where right the whole time ocd. Turns out this is a solenoid pack. Had to open up the engine to find the cdi which of course also was hidden behind tons of epoxi resin. Anyway got an answer from the company that they do not make thoose units anymore, however it is just a Mc relay and a fuse they say so it should be easy to make one. Guess I would have to open up fort Knox to check how it looks.
Up for the task of making one for me? Thanks in advance

 

[OCD Solutions]

I could probably whip something up if you gave me some dimensions, or, depending on how handy you are, I could walk you through how to build something yourself and save some shipping.

 

[Per Björklund]

I will try and open the box up at this weekend and send you all the specs how cables are connected. I think you are much better in electronics than me. Let me know after that what you think. I gladly pay you for the job...

 

[Per Björklund]

Finally I had the time to take it apart.... here comes some pictures

Below is the solenoid pack... One big red positive cable runs to battery

Other to the starter

One of the ISO connectors goes to the rotor and ECU

Other ISO goes to start/ stop button and killswitch

green from relay seems to be positive to one ISO

Brown seems to be positive to the other ISO

Black and black-white connects between ISO

Red should have gone to the Fuse which is cut in the picture

What do you think, could you get something similar together?

 

[OCD Solutions]

I think I can replicate it. I just wonder if I can improve it, make it serviceable, or if that would even be required.

Can you clearly identify what went wrong with that one so we don't replicate the same issue?

I see copper connectors which should be done with tinned marine wire, I also wonder if the epoxy is trapping too much heat in the solenoid.?.?.?

 

[Per Björklund]

Hi

I am pretty sure the solenoid is killed, but I think it would be good to switch out all cables in the pictures aswell. New power, ground, new "iso" connectors and so forth if that would be possible

I think you are right, the epoxy was probably not good at all.... i have plenty of space in the front so it could be fitted in something else instead

Correct, the copper wire is for the red and black cables going from the solenoid- to the starter and battery

I have more pictures if you want to see anything particular

 

[OCD Solutions]

I actually have a couple of pelican cases that could work perfectly for this. I bought them for a similar project that never happened. I even have a system for mounting them with stainless brackets and rubber straps already. They might be a little too big for just a solenoid though.



Can you email the pics to ocdsolutions88@gmail.com.

 

[Per Björklund]

Case looks great, I think that will be perfect. Sent an email

 

[OCD Solutions]

I wonder if the connectors on this could be reconfigured to plug into your existing wiring;



It's a rear electrical box from a Kawasaki Ultra 150. It's sealed already, rugged and would give you a serviceable unit. The only unknown might be that the terminals for the cables are outside the ebox.

 

[Per Björklund]

Hi, sorry for the late reply. Didn't see the email. I think it would, looks good. Does it have six wires to the handlebar? Do you know what all cables in that box was attached to?

 

[OCD Solutions]

I don't but it wouldn't be hard to reconfigure the harness so it would plug into your existing harness.