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Cresco750

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Posts: 58
Reply with quote  #1 
Hi guys

This morning i had the warning buzzer come on twice while at idle, and the associated 'check engine' message. The engine was running slightly rougher at idle than normal; almost like it was only idling on five, then randomly it would smooth out and idle revs would increase by 100rpm or so. The engine ran fine while under way right throughout the rev range.
I plugged in my Evdiag back at the wharf and it showed error code 17 (55 volt circuit voltage low at low rpm).
the boats batteries are both five years old (house and start), but i do try and keep them topped up between use. I have noticed that on the last few outings thge cranking speed has been a little slower (I put this down to cooler weather?), and the anchor winch is getting slow to retrieve (running off house battery). It looks like the batteries are probably due for replacement,  but is a failing battery likely to cause thuis fault code,or something else?

Many thanks.

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2006 Etec 250
Model E250DPXSDR
olypopper

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Reply with quote  #2 
55 volt circuit is what the engines injectors, oil pump and ignition system run on. You need to inspect your flywheel, stator and wiring.

Model and serial? We have no idea what engine you have if you don't post this basic information.

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Cresco750

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Reply with quote  #3 
Sorry, just updated my signature. S/N 05126270.
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2006 Etec 250
Model E250DPXSDR
rickmcd53

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Posts: 2,492
Reply with quote  #4 
Likely causes are corroded flywheel magnets or big blue capacitor condition/connections. You can read your system voltage on EVDiag monitor screen.
Cresco750

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Posts: 58
Reply with quote  #5 
An update on this...

By turning the engine over by hand I could hear this "ting ting ting" noise. Peering through the slots in the top of the flywheel with a torch I could see quite a number of the magnets rocking back and forth as they passed the stator windings, and some had moved around the circumference out of place.
Looks like my next job is trying to coax the flywheel off, and see if it's salvageable?

I'll keep you posted.


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2006 Etec 250
Model E250DPXSDR
Cresco750

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Posts: 58
Reply with quote  #6 
Good news, so far. The flywheel came off without too much trouble at all using an inexpensive harmonic balancer puller and a gentle tap with an aluminium hammer.
Sure enough, my flywheel was in a real mess; thirteen of the magnets were either loose, slid out place or completely fallen out. All rusty and peeled. Fortunately though none were missing or broken.
I cleaned it all up with a wire brush in a drill, and soaked the magnets in rust killer. I used the JB Weld method that others had used with good success to reattach the magnets, being sure that I got the poles alternating correctly and the spacing right using an 8mm thick piece of polycarbonate as a guide.

After the JB Weld set I gave it a quick tidy up with a dremmel sanding wheel to ensure nothing was binding on the stator, and give it a spray with CorrosionX.
Reassembly was straight forward enough; I managed to hold the flywheel from turning while setting the torque by wedging a large screw driver in the ring gear teeth and braced it against the starter pinion shroud.
I didn't have access to an Etec timing device so I was able to establish TDC using a dial gauge threaded into the spark plug hole (those of you who have tested Rotax ultralight engine bearing clearance with one of these will know what I'm referring to?). It started right up and idles smoothly Then confirm timing was still ok and no faults showing via EvDiag.





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2006 Etec 250
Model E250DPXSDR
steelhead

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Reply with quote  #7 
Need to find the source of the salt water spray causing the corrosion.
PRV, hoses, transom/gunwale spray going in cowling, head gasket, thermostat caps
Cresco750

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Posts: 58
Reply with quote  #8 
It appears to have had the PRV replaced at some stage prior to my ownership so I'm thinking that was the original root cause of the issue and the rust has been there for a while? I can't see any other evidence of rust / corrosion / water leaks anywhere.
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2006 Etec 250
Model E250DPXSDR
PhilH12

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Reply with quote  #9 
Just pull the cowling when getting back from a 'run', and take a peek?  See what there is to see - anything wet?  Probably the PRV then, as you say, but just so you're not doing the job again soon.  [wink]

Phil

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20' Weeres fishing pontoon
90 HP E-Tec E90DPLSUM  05184332
Lake Tawakoni, TX - Catfish Capital of Texas
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