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Waterax MARK-3 User Instructions

Dis digital ignition solution
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USER INSTRUCTIONS
Overview:
WATERAX offers a conversion kit Digital Ignition Solution (DIS) for users that want to convert a MARK-3
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
ITEM NO 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
11
800400
B-6289-6 LOCKWASHER M4 EXTERNAL TOOTH ZINC
-
801116
CABLE TIE 4" NYLON BLACK
-
701161
USER INST DIGITAL IGNITION SOLUTION DIS
Tools and Materials Required:
To complete the installation, you will require the following tools:
ID
ITEM NO
DESCRIPTION
1
600154
R-929 FLYWHEEL HOLDING TOOL, PLATED STEEL
2
701159
PISTON LOCKING TOOL FOR 185CC
3
700723
R-927 PULLER - MAGNETO (M38 X 1.5)
4
701158
JIG FOR DOS BRACKET DRILLING
5
801117
DRILL BIT #30 HIGH SPEED STEEL 2-3/4"LG
6
801118
TAP M4X.7 D4 SPRIAL POINT PLUG HIGH SPEED STEEL
7
801146
CDI IGNITION TIMING ADJUSTMENT TOOL
8
801162
DIS - FRAME DRILLING TOOL
03/2018
®
MARK-3
DIS Digital Ignition Solution
Figure 1: Digital Ignition Solution (DIS) (600556)
Figure 2: Special tools for conversion (available from WATERAX)
QTY
1
1
1
1
1
1
1
1
2
2
1
4
3
1
QTY
1
1
1
1
1
1
1
1
®
from breaker
1

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Summary of Contents for Waterax MARK-3

  • Page 1: Parts Breakdown

    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.
  • Page 2 USER INSTRUCTIONS 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...
  • Page 3 USER INSTRUCTIONS Flywheel (magneto housing): On very old engines, the flywheel may need to be replaced in order for the DIS and CDI to be correctly timed. On these older engines, the flywheel magneto mounting stud hole location differs from the newer flywheel. To differentiate between old and new flywheel, locate the center hub.
  • Page 4 USER INSTRUCTIONS 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). Position A Position B 4.
  • Page 5 USER INSTRUCTIONS 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 rotate crankshaft until...
  • Page 6 USER INSTRUCTIONS Tightening torque: 2.5- 3 Nm. Be careful not to squeeze/pinch the green wire. 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;...
  • Page 7 USER INSTRUCTIONS 23. To install the DOS, 8 mm hole three holes will need to be drilled and tapped on the side of the fan cowl. 24. If you’re using the DOS bracket drilling jig, install it on the top 8 mm hole and lock it in place.
  • Page 8 USER INSTRUCTIONS 29. Install the fan cowl. Do not install the top lock nut, air filter side. It will be used as a ground at Grounding a later step. stud 30. Install the DOS bracket using the three 8 mm long screws and two tooth lock washers.
  • Page 9 USER INSTRUCTIONS 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.

  • Page 10: Warranty Service And Support

    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.