1996 Honda TRX300EX, Diagnosing ignition and starter issues, $700 Craigslist ATV., traced 12VDC from battery, to the fuse box, to the wire harness, thru the key switch, thru the hand bar switches.

IGNITION SYSTEM

SERVICE INFORMATION
TROUBLESHOOTING
IGNITION SYSTEM INSPECTION
IGNITION COIL
IGNITION TIMING

SERVICE INFORMATION - GENERAL

Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. When servicing the ignition system, always follow the steps in the troubleshooting on page. The ignition timing cannot be adjusted since the ignition control module (ICM) is factory preset. The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the ICM. Always turn off the ignition switch before servicing. A faulty ignition system is often related to poor connections. Check those connections before proceeding. Use a spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. For ignition switch and engine stop switch inspection. For ignition pulse generator (alternator stator) removal/installation.

SPECIFICATIONS

• Spark plug Standard - DPR7EA-9 (NGK) X22EPR-U9 (DENSO)
• For cold climate (below 5°C/41°F) - DPR6EA-9 (NGK) X20EPR-U9 (DENSO)
• Spark plug gap - 0.8 0.9 mm(0.03 0.04 in)
• Ignition coil primary peak voltage - 100 V minimum
• Ignition pulse generator peak voltage - 0.7 V minimum
• Ignition timing (‘‘F’’ mark) - 11° BTDC at idle

TORQUE:Timing hole cap - 10 N·m (1.0 kgf·m , 7 lbf·ft)

IGNITION SYSTEM - TROUBLESHOOTING

Inspect the following before diagnosing the system:

• Faulty spark plug
• Loose spark plug cap or spark plug wire connections
• Water got into the spark plug cap (Leaking the ignition coil secondary voltage)

Ignition coil primary voltage: Low peak voltage.

Incorrect peak voltage adaptor connections. (System is normal if measured voltage is over the specifications with reverse connections.)

• The multimeter impedance is too low; below 10M / DCV.
• Cranking speed is too low. (Battery is undercharged.)
• The sampling timing of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.)
• Poorly connected connectors or an open circuit in ignition system.
• Faulty gear position switch.
• An open circuit or loose connection in No. 6 related circuit (light green/red wire).
• Faulty ignition coil.
• Faulty ignition control module (ICM). (when above No. 1 through 8 are normal.)

No peak voltage:

• Incorrect peak voltage adaptor connections. (System is normal if measured voltage is over the specifications with reverse connections.)
• Battery is undercharged. (Voltage drops largely when the engine is started.)
• Faulty ignition switch or engine stop switch.
• Loose or poorly connected ICM connector.
• No voltage at the black/white wire of the ICM.
• Open circuit or poor connection in ground (green) wire of the ICM.
• Faulty gear position switch.
• An open circuit or loose connection in No. 7 related circuit (light green/red wire).
• Faulty peak voltage adaptor.
• Faulty ignition pulse generator. (Measure peak voltage.)
• Faulty ICM. (when above No. 1 through 10 are normal.)

Peak voltage is normal, but no spark jumps at plug:

• Faulty spark plug or leaking ignition coil secondary current ampere.
• Faulty ignition coil.

Ignition pulse generator: Low peak voltage

• The multimeter impedance is too low; 10M /DCV.
• Cranking speed is too slow. (Battery is undercharged.)
• The sampling timing of the tester and measured pulse were not synchronized. (System is normal if measured voltage is over the standard voltage at least once.)
• Faulty ignition pulse generator. (when above No. 1 through 3 are normal).

No peak voltage:

• Faulty peak voltage adaptor.
• Faulty ignition pulse generator.

If the result of the troubleshooting was likely to malfunction the ‘‘ICM’’, check as follows. Disconnect the sub-ICM connectors and connect the main harness side 8P (gray) connector to the ICM and perform the spark test. If the plug is no spark, faulty ICM. If the plug is sparks, faulty sub-ICM.

IGNITION SYSTEM INSPECTION

If not spark jumps at the plug, check all connections for loose or poor contact before measuring each peak voltage. Use recommended digital multimeter or a commercially available digital multimeter (impedance 10 M /DCV minimum). The display value differs depending internal impedance of the multimeter. Connect the peak voltage adaptor to the digital multimeter, or use the peak voltage tester.

IGNITION PRIMARY PEAK VOLTAGE

Check all system connections before this inspection. Poor connected connectors can cause incorrect readings. Check the cylinder compression and check that the spark plug is installed correctly in the cylinder. Disconnect the spark plug cap from the spark plug. Connect known good spark plug to the spark plug cap and ground the spark plug to the cylinder head as done in a spark test. With the connector connected, connect the peak voltage tester or adaptor probes to the ignition coil primary terminal and body ground.

CONNECTION: Black/yellow (-)-Body ground (+)

Turn the ignition switch ON. Crank the engine with the starter motor and read the ignition coil primary voltage.

PEAK VOLTAGE: 100 V minimum

If the peak voltage is lower than the standard value, follow the checks described in the troubleshooting in your service manual.

IGNITION PULSE GENERATOR PEAK VOLTAGE

Check that the cylinder compression is normal and the spark plug is installed correctly in the cylinder head. Disconnect the ignition control module (ICM) 8P (gray) connector. Connect the peak voltage tester or adaptor probes to the connector terminals of the wire harness side.

CONNECTION: Blue/yellow (+) Green/white (-)

Turn the ignition switch ON. Crank the engine with the starter motor and read the peak voltage.

PEAK VOLTAGE: 0.7 V minimum

If the voltage measured at ICM connector is abnormal, measure the peak voltage at the alternator connector. Disconnect the alternator 5P (white) connector and connect the peak voltage tester or adaptor probes to the Blue/yellow wire terminal of the alternator side connector and ground. In the same manner as at the ICM connector, measure the peak voltage and compare it to the voltage measured at the ICM connector.

If the peak voltage measured at the ICM connector is abnormal and the one measured at the alternator connector is normal, the Blue/yellow wire has an open or short circuit, or loose connections. If both peak voltages are abnormal, follow the checks described in the troubleshooting in your service manaul and see your service manual for stator/ignition pulse generator assembly replacement.

IGNITION COIL - REPLACEMENT

Remove the left side cover. Release the spark plug wire fromthe clip. Remove the spark plug cap from the plug. Disconnect the connectors and remove the ignition coil from the stay of the frame. Install a new ignition coil in the reverse order of removal.

IGNITION TIMING

Remove the recoil starter cover. Start the engine and warm it up operating temperature. Stop the engine and remove the timing hole cap. Connect the timing light and tachometer. Start the engine, let it idle (1,400 rpm) and check the ignition timing. The ignition timing is correct if the F mark on the flywheel aligns with the index mark on the rear crankcase cover at idle. Increase the engine speed and make sure the F mark begins to move. Coat a new O-ring with engine oil and install it onto the timing hole cap. Install the timing hole cap and tighten it.

TORQUE: 10 N·m (1.0 kgf·m , 7 lbf·ft)

Install the recoil starter cover.

FUSE BOX - (FUSE 15A/30A AND DIODE)
STARTER RELAY SWITCH
GEAR POSITION SWITCH
STARTER MOTOR
IGNITION SWITCH
STARTER SWITCH
BATTERY

.

Service Manual Application: 2004, 2005, 2006, 2007 Honda Aquatrax ARX1200T3, ARX1200T3D, ARX1200N3 (ARX1200, ARX-1200-T3-T3D-N3)F-12X, F12X, F12-X Personal Watercraft PWC.

Contents of this Honda Aquatrax PWC (Personal Water Craft) service. This instant eBook contains fully detailed step-by-step repair procedures with hundreds of picture illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure. This expert text guide book will give you the knowledge and experience you need to perform simple basic maintenance or more complicated service procedures like engine overhaul. Covers every thing you will ever need to know to fix anything on your 2004, 2005, 2006, 2007 Honda ARX1200T3, ARX1200T3D, ARX1200N3 (ARX1200, ARX-1200-T3-T3D-N3) Personal Watercraft PWC Aquatrax.

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File Format: PDF
Delivered In: PDF Format
Pages: 498
Language: English
Fully Indexed: Yes
Zoom In/Out: Yes
Quality Of Manual: Clear A+

BELOW IS JUST A SMALL SAMPLE OF SOME OF ITS CONTENTS:

AIR FILTER
AIR SCREW ADJUSTMENT
AIRBOX – ARX1200-N3 – ARX-1200T3/T3D
ALTERNATOR STATOR
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
ANODE
BATTERY
BATTERY/CHARGING SYSTEM SPECIFICATIONS
BEARING HOUSING
BILGE STRAINER
BOARDING STEP (ARX1200T3D)
BODY PANEL LOCATIONS
CABLE & HARNESS ROUTING – ARX-1200-N3 – ARX1200T3/T3D
CABLE REPLACEMENT
CAMSHAFT INSTALLATION
CAMSHAFT POSITION SENSOR
CAMSHAFT REMOVAL
CHARGING SYSTEM INSPECTION
COMBINATION METER
COMPONENT LOCATION
BATTERY/CHARGING SYSTEM
ELECTRIC STARTER
FUEL SYSTEM (Programmed Fuel Injection)
IGNITION SYSTEM
METER/SWITCHES
COOLING SYSTEM
COOLING SYSTEM FLOW PATTERN
COOLING SYSTEM FLUSHING
COUPLER COVER
CRANKCASE ASSEMBLY
CRANKCASE SEPARATION
CRANKPIN BEARING
CRANKSHAFT
CRANKSHAFT/BALANCER (ARX1200T3/T3D)/PISTON
CYLINDER COMPRESSION
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD COVER INSTALLATION
CYLINDER HEAD COVER REMOVAL
CYLINDER HEAD DISASSEMBLY
CYLINDER HEAD INSTALLATION
CYLINDER HEAD REMOVAL
CYLINDER HEAD/VALVE SPECIFICATIONS
DECK MAT REPLACEMENT
DRAIN PLUG
DRAIN PLUG REPLACEMENT
DRIVE SHAFT AND BEARING HOUSING
DTC INDEX
DTC TROUBLESHOOTING
ECT SENSOR
ELECTRIC STARTER SPECIFICATIONS
EMISSION CONTROL INFORMATION LABEL
EMISSION CONTROL SYSTEMS
ENGINE & BODY TORQUE VALUES
ENGINE CONTROL MODULE (ECM)
ENGINE IDLE SPEED
ENGINE INSTALLATION
ENGINE OIL FILTER
ENGINE OIL TEMPERATURE SENSOR
ENGINE OIL/OIL FILTER
ENGINE REMOVAL
EXHAUST BODY
EXHAUST COMPONENT CLEANING AND INSPECTION
EXHAUST MANIFOLD
EXHAUST PIPE/TURBOCHARGER (ARX1200T3/T3D)
FLYWHEEL INSTALLATION
FLYWHEEL REMOVAL
FRONT CRANKCASE COVER INSTALLATION
FRONT CRANKCASE COVER REMOVAL
FRONT HOOD
FUEL GAUGE/FUEL LEVEL SENSOR
FUEL LINE INSPECTION
FUEL PUMP
FUEL PUMP RELAY
FUEL SYSTEM (Programmed Fuel Injection)
SPECIFICATIONS
FUEL TANK
FUEL TANK/FUEL LINE
GENERAL SPECIFICATIONS – ARX1200N3 – ARX1200T3 – ARX1200T3D
GPS RECEIVER (ARX1200T3D)
HANDLEBAR
HANDLEBAR COVER
HANDLEBAR SWITCH
IAT SENSOR
IF THE WATERCRAFT IS SUBMERGED
IGNITION COIL
IGNITION PULSE GENERATOR
IGNITION SYSTEM INSPECTION
IGNITION SYSTEM SPECIFICATIONS
IGNITION TIMING
IMPELLER
INDICATORS
INJECTOR
INTERCOOLER (ARX1200T3/T3D
JET PUMP ASSEMBLY
JET PUMP DISASSEMBLY/INSPECTION
JET PUMP INSTALLATION
JET PUMP REMOVAL
KNOCK SENSOR
LIGHTS/METERS/SWITCHES SPECIFICATIONS
LUBRICATION & SEAL POINTS
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM SPECIFICATIONS
MMAIN JOURNAL AND BALANCER (ARX1200T3/T3D) BEARING
MAIN RELAY
MAINTENANCE SCHEDULE
MAP/TCP SENSOR
MIL CODE INDEX
MIL TROUBLESHOOTING
MODEL IDENTIFICATION
MST SWITCH
NNUTS, BOLTS, FASTENERS
OFF-THROTTLE STEERING SYSTEM
OIL PRESSURE INSPECTION
OIL PUMP
OIL TANK COVER INSTALLATION
OIL TANK COVER REMOVAL
PPASSENGER GRAB RAIL
PGM-FI (Programmed Fuel Injection) system
PISTON/CYLINDER
POST COVER
PRESSURE REGULATOR
PROPULSION SYSTEM SPECIFICATIONS
PROTECTOR MOLDING
REARVIEW MIRROR
REGULATOR/RECTIFIER
REVERSE BUCKET/STEERING NOZZLE
REVERSE LEVER
REVERSE SYSTEM
RIDE PLATE/INTAKE GRATE
RUBBER COUPLING
SEAT
SERVICE INFORMATION
ALTERNATOR/STARTER CLUTCH
BATTERY/CHARGING SYSTEM
COOLING SYSTEM
CRANKSHAFT/BALANCER (ARX1200T3/T3D)/PISTON
CYLINDER HEAD/VALVE
ELECTRIC STARTER
ENGINE REMOVAL/INSTALLATION
EXHAUST SYSTEM/TURBOCHARGER (ARX1200T3/T3D)
FLUSHING AND STORAGE
FUEL SYSTEM (Programmed Fuel Injection)
HULL/HOOD/BODY PANELS/EXHAUST SYSTEM
IGNITION SYSTEM
LUBRICATION SYSTEM
MAINTENANCE
METER/SWITCHES
PROPULSION SYSTEM
STEERING/REVERSE SYSTEM
SERVICE RULES
SIDE COVER
SIDE PANEL
SPARK PLUG
SPEEDOMETER/SPEED SENSOR
SPONSON
STANDARD TORQUE VALUES
STARTER CLUTCH
STARTER MOTOR
STARTER RELAY SWITCH
STEERING SHAFT
STEERING SYSTEM
STORAGE
STORAGE BOX
SUB-AIRBOX (ARX1200T3/T3D)
SYSTEM COMPONENTS
ALTERNATOR/STARTER CLUTCH
CRANKSHAFT/BALANCER (ARX1200T3/T3D)/PISTON
CYLINDER HEAD/VALVE
ENGINE REMOVAL/INSTALLATION
EXHAUST SYSTEM/TURBOCHARGER (ARX1200-T3-T3D)
FUEL SYSTEM (Programmed Fuel Injection)
LUBRICATION SYSTEM
PROPULSION SYSTEM
STEERING/REVERSE SYSTEM
SYSTEM DIAGRAM
BATTERY/CHARGING SYSTEM
ELECTRIC STARTER
FUEL SYSTEM (Programmed Fuel Injection)
IGNITION SYSTEM
TTACHOMETER
TECHNICAL FEATURES
COOLING SYSTEM
DIRECT IGNITION COIL
DRY-SUMP SYSTEMS (ENGINE LUBRICATION)
GPS NAVIGATION METER (ARX1200T3D)
IDLE AIR CONTROL VALVE (IACV)
OFF-THROTTLE STEERING (OTS)
OIL PRESSURE SWITCH
OVERHEAT WARNING LAMP
SPEED SENSOR
TURBOCHARGER (ARX-1200T3/T3D)
THROTTLE BODY
THROTTLE BODY/INTAKE MANIFOLD
THROTTLE OPERATION
THRUST PLATE/INTAKE LIP
TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH
BATTERY/CHARGING SYSTEM
COOLING SYSTEM
CRANKSHAFT/BALANCER (ARX1200T3/T3D)/PISTON
CYLINDER HEAD/VALVE
ELECTRIC STARTER
ENGINE DOES NOT START OR IS HARD TO START
ENGINE LACKS POWER
ENGINE REMOVAL/INSTALLATION
EXHAUST SYSTEM/
TURBOCHARGER (ARX1200T3/T3D)
FUEL SYSTEM (Programmed Fuel Injection)
HULL/HOOD/BODY PANELS
IGNITION SYSTEM
LUBRICATION SYSTEM
POOR PERFORMANCE AT HIGH SPEED
POOR PERFORMANCE AT LOW AND IDLE SPEED
PROPULSION SYSTEM
STEERING/REVERSE SYSTEM
TURBOCHARGER (ARX-1200T3/T3D)
VALVE CLEARANCE VALVE GUIDE REPLACEMENT
VALVE SEAT INSPECTION/REFACING
WATER CHAMBER
WATER MUFFLER
WIRING DIAGRAMS
ARX1200N3
ARX1200T3
ARX1200T3D

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