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  1. #1

    Join Date
    Jan 2010
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    el paso
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    1

    Unhappy 900 zxi magneto coil melted

    Hi im new on pwc i have a 96 900 zx and the other day i turned on and suddenly came a lot of smoke from the inside, and i saw the magneto coil completed melted, and i dont know how to change can sombody help me please, already bought a new cdi and installed already just im missing how to change the magneto


  2. #2
    steve45's Avatar
    Join Date
    Feb 2008
    Location
    Texas
    Posts
    5,006
    +1
    281
    The oil pump has to come off of the front cover--2 screws.

    Remove the two cooling water hoses.

    The front cover comes off next, 6 screws (I think).

    When you pull the cover off, be careful you don't lose the spring and bearing for the starter drive. They may fall out in the bottom of the 'Ski.

    Follow the wiring harness back to the CDI box and remove the cap--2 screws. Unplug the 2 plugs. Don't lose the O-ring.

    You can now remove the front cover from the 'Ski.

    The stator winding is mounted inside the cover with 3 screws. There is also a seal where the harness passes through the housing, and a magnetic pickup that need to be removed. Most people buy/sell the complete assembly with the housing.

    Blow through the cooing water fittings to check for blockage. I've found a couple that were plugged with debris. If plugged, remove the plate on the front of the cover (5 screws) and clean the water passage and elbows.

    I'd suggest replacing the 3 O-rings on the cover, too.

    Picks to follow tonight.

  3. #3
    Chris03HD's Avatar
    Join Date
    Sep 2009
    Location
    Jersey Shore
    Posts
    582
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    3
    I have a front cover with stator and pickup as well as a pdf manual if you need one.

    Click image for larger version. 

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  4. #4
    john zigler's Avatar
    Join Date
    Aug 2006
    Location
    WI
    Posts
    2,545
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    33
    i also have a good, clean, freshwater stator/ triger assy, with mag cover. 150.00 + s&h. this is from a good running, low hour machine.


    be sure to check all your grounds in the electrical box. i have also see the stator harnes melt, from people hooking up the battery backwards.

    please email, or call the shop, if you want to order. thank you

  5. #5
    Quote Originally Posted by steve45 View Post
    Blow through the cooing water fittings to check for blockage. I've found a couple that were plugged with debris. If plugged, remove the plate on the front of the cover (5 screws) and clean the water passage and elbows.
    +1.
    Heat kills the stator.

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