Mod: Junkie Swap eBox edit

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Mod: Junkie Swap eBox edit

Written by Air Gramps

Monday, 10 March 2008 12:36

Junkie Swap eBox

Purpose: The purpose of this mod is the facilitate the quick and independent swapping of Yamaha motors and electrical boxes. 99.9% of all Yamaha motors have their stator and positive starter wires hard-wired to the electrical box. This mod will work on all 650, 701, and 760 motors, possibly others; although, mix-matching cdi's between motors may affect performance - ask around in the trash talk forum for more info.
Recommended for: Any wrencher needing quick and independent swap motor/ebox swapping capabilities. All wavejunkies should highly consider this mod for assistance with troubleshooting.
Difficulty: Basic electrical wiring skills help.
Time: 2hrs first attempt?

Supplies

Tools

Battery and Starter Posts

2 - 6" 4 gauge battery cable made with lugs (Inside box)
2 - SS 1/4x20 1.5" carage bolts
4 - 1/4x20 SS nuts
4 - 1/4x20 SS flat washers
2 - 1/4x20 SS lock washers
2 - 1/4x20 SS captive nuts
1 - 18guage terminal lug (for hot wire from solenoid to CDI)
2" of 1/4" heat shrink (to increase the size of the 1/4x20 bolt to seal inside the rubber pass through)

External Battery Cables (Not shown)

2 - 4-gauge terminal lugs (since you have to cut the battery cables to get the eBox rubber pass through off)
4" of Heavy Duty 3/4 inch epoxy heat shrink (for cut battery cable)

Stator Wires

Deutsch Connectors DT06-6S and DT04-6P (eBay $9 – Look for DEUTSCH 6 PIN CONNECTOR)

Wire cutters/strippers

HDT-48-00 Crimp tool

Adjust Pin depth so the base of the contact is flush with the tools pin well. (must be adjusted for male and female pins)
Adjust wire gauge thickness knob to 16

Razor knife

Modification Steps

Remove electrical box from ski:
1. Cut Battery Cables at the electrical box just above the rubber pass through.
2. If doing Stator leads, cut wire harness 19” from the rubber pass through located at the flywheel cover.
3. Unplug Start/Stop assembly
4. Unbolt and remove.
Remove eBox cover
1. Cut and remove the fuse tube from cover to allow room for new cables:
2. Mark a Positive sign “+” on the pass through hole closets to the coil holes.
3. Remove the fuse assembly and reconnect the red male to red female plug.
4. Cut the RED 18 gauge wire from battery cable (source) at the starter solenoid. You will add a terminal lug later to this wire.
5. Remove the remaining battery cable ends.
6. Rotate the starter solenoid 90 degrees so the solenoid control wires are facing the CDI module. (Unwrap rubber base and turn):
7. Prepare new internal 6” 4gauge cables for posts:
8. Using the 1.5” 1/4x20 Carriage bolts, install to one end of the battery cables. Tighten down. (The carriage boss will prevent the bolts from turning when installed)
9. Install 1/4x20 washer
10. Slice the raised tower off the rubber pass through. (see below – right Bat. Post compared to the flat left side):
11. Add 3 layers of 1/4” heat shrink to each of the battery posts to increase the diameter to the size of the pass through.(see below – right Bat. post)
12. Add washer and nut and leave loose.
13. Install cables onto the starter solenoid and route accordingly over the coil:
14. Install 18gauge terminal lug onto Red CDI wire and attach to the lower solenoid post.
15. Close up eBox:
16. Add silicone under washers and around posts to fill any voids
17. Tighten nut to expand and seal the rubber pass through.