"! • Setting the Ignition Timing Correction • Selecting an Advance Curve • Selecting Sea-Doo Model • Setting Rev Limit RPM These Instructions are for Tempest 3 Ignitions Only All Sea-Doo Rave Engines Rev. H 08-20-01 Caution: Severe engine damage is possible if the engine timing is not properly set. This information is not intended to be a negative statement regarding the Rotax engine, but to make clear how important this Calibration Procedure is to set engine timing correctly. Engine Timing Overview: The Sea-Doo RAVE engine is built with excessive tolerance in the positioning of its ignition pulser coil. The pulser coil must be correctly positioned relative to the piston to achieve accurate ignition timing. Otherwise, poor engine performance or engine damage may result. An example of the effect a timing error will have on your engine will be helpful for a clearer understanding. Assume that the trigger sensor has a position error of 3° advance. This means the ignition will have a timing error of 3° advance over the entire timing curve. The chart below shows the effects of this kind of error. The ignition trigger sensor in the RAVE engine can be as much as 4° retarded to 3° advanced from the correct setting as compared to a 0.1° error which other engine manufactures routinely achieve. The Rotax RAVE has up to 70 times this error. Operating Mode Cranking Idle Acceleration Acceleration High speed Correct Timing 11° BTDC 18° BTDC 22° BTDC 22º BTDC 19°–15° BTDC Actual Timing 7° BTDC 14° BTDC 18° BTDC 25º BTDC 22°–18° BTDC Result Hard starting, backfiring, engine damage Uneven idle, stalling in water poor acceleration. Poor acceleration Detonation in mid and high RPM Overheating, detonation, engine damage Proper engine timing is every bit as important as mixing oil with your gas. It must be set precisely to match the requirements of the engines configuration and the type of riding you plan to do. 1 -----------------------------Setting the Timing Correction Switches----------------------------Using a Timing Light to Determine Timing Correction Value Calibrating the engine timing must be preformed when the T3 ignition is installed on any model Sea Doo. If this procedure is not preformed severe damage can result. Note: If you do not have the required tools or are not confident in performing the procedure as outlined, please consult your local dealer or other qualified person for assistance. Tools Required: Tools you supply • 12mm wrench • 13mm wrench • Spark plug wrench • Tachometer (if boat not equipped with one) • TDC dial gauge • Timing Light Tools supplied with Ignition • TDC gauge • Pointer tool • Timing calibration tape • Alcohol wipes Set Ignition timing correction 1. Set the timing correction switches to the most retarded timing calibration. Set switches Sw B 3,4,5 as shown in Figure 1x. 2. Set the Curve Selector to curve 1 (stock, pump gas), Sw 1 & 2 both OFF. Setup the Engine for Timing Measurement 1. Remove the two breather hoses just forward of the gas tank along with the accompanying grommets used to hold them in place in the hull. 2. Remove the black or gray plastic drive shaft safety cover from the rear of the engine. There is a drive shaft ‘hanger’ bolted to the bottom of the safety cover. This hanger bracket must be removed first. Locate the two 12mm bolts, one on each side. Remove these bolts and lift out the hanger. 3. Remove the two 13mm bolts and flat washers, one on each side of the safety cover. Remove the cover and set it aside. 4. Remove both spark plugs. Ground the spark plugs case so they will spark when the engine turns over. Failure to do this will cause damage to the ignition coils. 5. Using a dial gauge, insert it into either spark plug hole and locate Top Dead Center (TDC). DO NOT use the starter motor to turn the engine. Manually turn the power take off (PTO) that is exposed in step 1. Leave the dial gauge in place. 6. Using the alcohol wipe provided, clean the top area of the PTO’s outer edge between the10 and 2 o’clock positions. 2 7. Using a pen highlight the 25º mark on the timing tape so it can be easily distinguished form the other marks. 8. Remove the backing paper from the Timing Calibration Tape and fasten it to the area just cleaned. The arrow on the chart must point in the counter clockwise direction when viewed from the rear of the engine toward the front. Be sure the 0.0º mark (TDC) on the tape is positioned near the top center, 12 o’clock position of the PTO. Note: the timing tape can be lifted and repositioned if required. 9. Insert the nylon ‘jam washer’ into the ¼” hole in the rear engine mount. This hole is located directly above the 12 O’clock position of the PTO. 10. Insert the short end of the pointer tool bracket into the jam washer. Apply firm pressure to the bracket until it is inserted completely into the nylon jam washer. The bracket is properly inserted when it comes to rest on the head of a cap bolt directly beneath the jam washer. 11. Slide the pointer along the bracket until it is precisely aligned with the 0.0º (TDC) mark on the timing tape. Next, rotate the pointer downward so it is close to the timing tape. This reduces the parallax error. 12. Repeat step 5 and confirm that the pointer is at TDC on the tape. Readjust the pointer as required. 13. Remove the dial gauge and reinstall the spark plugs and plug wires. 14. Attach a timing light per its operating instructions. Note: Make sure the timing light is attached to the spark plug of the cylinder you’re using to find TDC. Measure and Calibrate Engine Timing The timing tape displays crankshaft angles from TDC 20º in through 35º in1.0º increments. 1. Turn switches 1 and 2 OFF on Switch B. This sets the ignition to curve # 1. 2. Look on page 5 to see what the timing is on curve #1 at 3000 RPM. 3. Start the engine (Do not Rev. it up past 5000 RPM it could cause damage to your engine). 4. Using the idle adjustment screw, set the engine RPM close to 3000 RPM. 5. Using a timing light, determine the number of degrees advanced or retarded your engine is based on curve #1 at 3000RPM as shown on page 5. Stop the engine. NOTE: On all models except the GTX-L sight through one of the holes used by the vent tubes to get a clear view of the timing tape and pointer. Set the Timing Correction Switches 1. Referring to Figure 1, locate the degrees of advance (Adv) or retard (Ret) you measured in step 5 above. Set Sw B, switches 3, 4 & 5 as indicated in Fig 1. Example: With engine running at 3000 RPM. The timing pointer indicates 27º. The curve on pg5 says it should be 25°°, so retard the ignition 2º. Set sw3=ON, sw4=OFF, sw5=ON. 3 Put the Boat Back Together 1. Remove the timing pointer and jam washer from the rear engine-mounting bracket. The timing tape can be removed or remain in place. Save these parts for later use. 2. Reinstall the safety shield using the 2 flat washers, 13mm bolts, and wing nuts. 3. Reattach the hanger bar using the 12mm bolts. 4. Insert the grommets and breather tubes in their mounting holes. 5. Proceed to the next section: “Selecting an Advance Curve.” ----------------------------------- Selecting the Sea-Doo Model ----------------------------------The T3 ignition for Sea-Doo must be set for the correct model of boat. Even though the engines are the same there are two types of electrical systems. Setting the model type switch informs the ignition how to handle these different signals from the engine. 1. Set SwB position 6 according to Figure 3 to match your model of Sea-Doo. Note: If the switch is set incorrectly the engine will not be harmed. However, the engine will start very badly then die. If it does idle, you’ll know things are not right. Set the switch to the other position and it will start and run properly. ----------------------------------- Selecting an Advance Curve ----------------------------------Curve Selection Overview: The T3 Ignition has four built-in advance curves. The curve you select must be properly suited to the engine configuration and how you ride your boat. Do not assume the curve with the more advanced timing is the best. Adding too much timing can lead to a large engine repair bill – please be careful – see Figure 4 for information on selecting the correct advance curve. The best advance curve is the one that gives you the best performance. If you are not sure which curve to select, please consult with your local dealer or other qualified person to determine the optimal curve to use. Using Figure 1 as a guide, set Switch B, positions 1 and 2, to the desired curve. Curve 1: "Closed-course" for racing applications on IJSBA closed courses. Curve 2: “Sport" for stock applications to boost performance over entire RPM range. Curve 3: "Offshore" timing retard at higher RPM for extended periods of wide-open throttle. Curve 4: “Twin Pipe” all twin pipe applications. 4 Blank Page Replace with Fig 5 page 5 --------------------------------Setting the Rev Limiter Switches-------------------------------Proper setting of the Rev Limiter RPM is important to ensure that the engine is not damaged from over-revving. The following procedure is recommended for determining the ideal limiter setting. 1. Turn all five rev limiter setting switches to the ON position (Switch A, positions 1 through 5). This sets the limit to its maximum setting of 9000 RPM. 2. Run your Sea-Doo on smooth water at the highest speed you can attain. 3. Note the RPM reading on your tachometer. 4. Return to shore and set the limiter RPM to the tachometer reading rounded up to the next 100 RPM. Example: If you got a reading of 7750 RPM on your tachometer, set the switches at the next highest RPM setting. This would be 7800 RPM. Programming Example: Switch setting for 7800 RPM is (5900) + 1900. To program 1900, refer to figure 5 and turn ON switch #1 (1600), #4 (200), and #5 (100). All other switches are OFF. Note: Whenever you make changes to your engine or boat hull (from the air cleaner, exhaust system to ride plate), remember to repeat this test to determine if rev limiter settings must be changed. If you determine that a lower setting is required, this is a strong indication that the changes have cost you power and performance and it might be advisable to rethink what you did. ADVENT PRODUCTS, INC. 3154 E. La Palma Ave., Suite F Anaheim, CA 92806 714 630-0446 714 632-5438 FAX tech-support@adventproducts.com Sea-Doo® is a registered trademark of Bombardier 6