MARK-3® DIS Digital Ignition Solution
Contents
1. WATERAX Wi USER INSTRUCTIONS WE MOVE WATER MARK 3 DIS Digital Ignition Solution Overview WATERAX offers a conversion kit Digital Ignition Solution DIS for users that want to convert a MARK 3 from breaker points and mechanical cut out switch to the upgraded electronic ignition and Digital Overspeed Switch systems These instructions will guide you through the conversion process Parts Breakdown ID ITEMNO DESCRIPTION 600556 DIS MK 3 CONVERSION KIT UPG TO CDI DOS 1 600125 B 7592 ELECTRONIC IGNITION BOX ASSY 2 701109 R 668E MAGNETO FOR 185CC 3 800073 R 661 CDI STATOR COIL ARMATURE ASSEMBLY 4 800544 R 150 NUT M6X1 0 HEX FUJI LOCK ZINC 5 800408 B 5562 18 CLAMP PLASTIC COATED 9 16 ID 6 700593 B 6289 1 DOS PRODUCTION UNIT 7 700616 B 6289 2 DOS MK 3 BRACKET 8 800443 B 6289 3 SCREW M4X0 7X35 PHILLIPS CHEESE HEAD ZINC 9 800402 B 6289 4 SCREW M4X0 7X8 PHILLIPS RAISED CHEESE ZINC 10 800413 B 6289 5 SCREW M4X0 7X8 PHILLIPS FLAT ZINC 800400 B 6289 6 LOCKWASHER M4 EXTERNAL TOOTH ZINC 801116 CABLE TIE 4 NYLON BLACK 701161 USER INST DIGITAL IGNITION SOLUTION DIS Figure 1 Digital Ignition Solution DIS 600556 Tools and Materials Required To complete the installation you will require the following tools ID ITEMNO DESCRIPTION QTY 1 600154 R 929 FLYWHEEL HOLDING TOOL PLATED STEEL 1 2 701159 PISTON LOCKING TOOL FOR 185CC 1 3 700723 R 927 PULLER MAGNETO M38 X 1 5 1 4 701158 JIG FOR2. DOS BRACKET DRILLING 1 5 801117 DRILL BIT 30 HIGH SPEED STEEL 2 3 4 LG 1 6 801118 TAP M4X 7 D4 SPRIAL POINT PLUG HIGH SPEED STEEL 1 7 801146 CDI IGNITION TIMING ADJUSTMENT TOOL 1 8 801162 DIS FRAME DRILLING TOOL 1 Figure 2 Special tools for conversion available from WATERAX 03 2015 1 WATERAX Wl USER INSTRUCTIONS WE MOVE WATER DESCRIPTION TORQUE WRENCH 13 MM WRENCH 10 MM WRENCH 7 16 WRENCH 13 MM SOCKET 10 MM SOCKET 7 16 SOCKET 17 MM SOCKET RATCHET WRENCH CUTTER FLAT SCREWDRIVER PHILLIPS SCREWDRIVER NEEDLE NOSE PLIERS 17 64 DRILL BIT VARIABLE SPEED ELECTRIC DRILL M4X0 7 TAP 30 DRILL BIT TAPPING LUBRICANT 1 PENCIL OR MARKER IF NOT EQUIPPED WITH DOS DRILLING JIG 1 CENTER PUNCH IF NOT EQUIPPED WITH DOS DRILLING JIG 1 THREAD LOCKER LOCTITE 243 OR EQUIVALENT RTV SILICONE SEALANT LOCTITE 5910 OR EQUIVALENT Figure 3 Required tools for conversion 03 2015 2 WATERAX Y Shs ee WE MOVE WATER Procedures 1 Remove the 12 16 pump end 2 Remove the fuel connection and disconnect the fuel line from the carburetor 3 On the carburetor rotate the fuel strainer cover by 180 degrees from position A to B see picture 4 Remove the frame 5 Use the Drilling Jig to drill two 17 64 holes on the right leg see images If not equipped with tool use the hole pattern provided The CDI box assembly will be mounted on the left and the fuel con
3. the cause of the overspeed condition has been identified and corrected before attempting to restart the engine When attempting to restart the engine after an overspeed condition or after pressing the OFF button wait 10 seconds from the time the engine shut down This will enable the DOS to reset itself Failure to wait the prescribe duration of time will make it difficult to start the engine It may lead to a flooding condition Warranty Service and Support Product and service documentation such as tech notes data sheets manuals and information on the limited warranty provided on products manufactured by WATERAX can be found on our Web site at www waterax com WATERAX Inc 6635 Henri Bourassa Blvd W Montreal QC H4R 1E1 Tel 855 616 1818 514 637 1818 Fax 514 637 3985 E mail info waterax com Copyright 2015 WATERAX Inc Publication Number 701161 Rev 6 All rights reserved Printed in Canada 03 2015 9
4. DOS iv bracket drilling jig ro install it on the top 8 mm hole and lock it in place Drill the three holes with a 30 drill bit Fan cowl before drilling of 3 holes Drilling jig 25 Carefully tap all three holes with an M4x0 7 tap Important use tapping lubricant 26 If you are not equipped with the drilling jig you can use the bracket to position the holes To correctly position the bracket and prevent any interference install the DOS on the bracket Position the assembly on the side of fan cowl and ensure that e There is no interference with the carburetor shroud e There is no interference with the Spark plug cover e The bracket lays flat on the fan cowl be careful of the radius on the fan cowl 27 Mark the holes with a center punch 28 Remove the fan cowl Drill and tap 03 2015 6 WATERAX SSS se WE MOVE WATER 29 Install the fan cowl Do not install the top lock nut air filter side It will be used as a ground at a later step eee Grounding stud 30 Install the DOS bracket using the three 8 mm long screws and two tooth lock washers 31 Install the DOS using the two 35 mm long screws and two tooth lock washers Ensure that the DOS is firmly mounted on the bracket to ensure proper ground contact Y IA 4 PRIMING CAP amp SUCTION ooun NNECT DISCHARGE HOSE NOZZLES ET MEABOSE CHOKE ONLY IF ENGINE t8 COLD 32 Install the electronic ignition box asse
5. mbly and the fuel connection 33 Install the frame 03 2015 7 WATERAX v WE MOVE WATER 34 Connect the green wire from the stator in the second terminal from the right 35 Connect the red wire from the DOS on the far right terminal 36 Install the ground wire red coming from the CDI module on the fan cowl grounding stud 37 Install the split loom 38 Install the plastic coated clamp and tighten the lock nut 39 Install the ignition cable clamp 40 Connect the ignition wire to the spark plug 41 Secure the wiring with cable ties 42 Install the spark plug cover 43 Install the pump end 03 2015 8 WATERAX Ww USER INSTRUCTIONS WE MOVE WATER Impact on Field Use Below are the minor changes to the operation of the MARK 3 equipped with the DOS Starting the engine Before starting the engine slowly pull the starter rope and crank over the engine a couple of times in order to charge up the DOS The LED will light up and flash to indicate that the DOS has been charged and that the MARK 3 is ready to be started Start the engine as directed in the MARK 3 Instruction amp Service manual Note that there is no ON switch Stopping the engine To stop the engine press and hold the OFF button until the engine shuts down Overspeed condition If the engine overspeeds e g during a loss of prime the DOS will immediately shut down the engine Always ensure that
6. nection will move to the right 6 Remove the ON OFF switch and disconnect the cut out switch wire Discard 1Z 44 4 HOLES 7 Remove the ignition cable clamp 10 8 Remove the fan cowl 9 Uninstall and discard the mechanical cut out switch and grommets 10 Remove the pulley and gasket 11 1f equipped with an aluminum fan use the fan flywheel holding tool R 929 and remove the nut R 303 that locks the flywheel assembly onto the crankshaft 03 2015 3 WATERAX Wi USER INSTRUCTIONS WE MOVE WATER 12 Using the fan flywheel holding tool R 929 the flywheel assembly puller R 927 and an adjustable wrench remove the flywheel assembly 13 NOTE If equipped with a thermoplastic fan use piston locking tool 701159 instead of R 929 Screw tool onto the cylinder head and rotate crankshaft until the piston reaches the tip to lock the shaft rotation 701159 can be used with both fans 14 Remove the point magneto by removing the three nuts Discard If the magneto is stuck on the backing plate it can be pried off witha soft hammer and a flat screw driver Be careful not to damage the fan New magneto for CDI 15 Install the new magneto for CDI using thread locker Loctite 243 or equivalent Tightening torque for the three nuts 8 10 Nm 16 Remove the point stator assembly and replace with the CDI stator assembly Discard point stator 17 To position the s
7. tator remove labyrinth ring and install ignition timing adjustment tool 801146 Turn stator clockwise until coil rests on adjustment tool Tighten the three screws with flat and lock washers Point stator assembly CDI stator assembly 03 2015 4 WATERAX V WE MOVE WATER Tightening torque 2 5 3 Nm Be careful not to squeeze pinch the green wire r ie 18 If you are not equipped with the timing adjustment tool fit the stator plate so that the oblong holes are centered with the crankcase threaded holes then rotate the stator plate 1 1 5 mm counter clockwise and tighten the three screws Refer to the MK 3 Service Manual for dynamic ignition verification procedures Coil resting on tool Stator plate adjustment 1 1 5 mm CCW 19 First pass the green wire through the crankcase hole and then through the grommet Install the grommet on the crankcase 20 Pull the green wire through the grommet and apply a dab of RTV silicone sealant 2 Install the flywheel assembly Ensure that the key is properly installed Apply Loctite 243 on the hex nut R 303 and tighten using the fan flywheel holding tool R 929 Tightening torque 45 50 Nm 22 lnstall the gasket pulley and pulley 03 2015 5 WATERAX Ww WE MOVE WATER USER INSTRUCTIONS 23 10 install the DOS i three holes will need to be drilled and tapped on the side of the fan cowl 24 If you re using the
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