boat parts

Outboard ignition parts for Mercury Mariner outboard motors. Power pack, stator, timerbase, regulator.


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Page 24 - Index - Page 26
Four Cylinder Engines 1978-1997
Four Cylinder Engines Using a Single Switch Box and Four Ignition Coils
(continued)
  1. Connect a DVA meter to the stator’s Blue wire and Blue/White wires and do a running test. The DVA voltage should jump up to well over 200V and stabilize. A drop in voltage right before the problem occurs indicates a bad stator. (Green/White to White/Green if the engine has a Red stator kit installed).
  2. Connect a DVA meter to the Red wire and Red/White wires and do a running test. The DVA voltage should show a smooth climb in voltage and remain high through the RPM range. A reading lower than what is on the Blue wires indicates a bad stator.

High Speed Miss:
  1. Connect an inductive Tachometer to all cylinders and try to isolate the problem. A high variance in RPM on one cylinder indicates a problem usually in the switch box or ignition coil. Occasionally a trigger will cause this same problem. Check the trigger as described above under “No fire or Intermittent on One or More Cylinders”.
  2. Perform a high-speed shutdown and read the spark plugs. Check for water. A crack in the block can cause a high speed miss when the water pressure gets high, but a normal shutdown will mask the problem.
  3. Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets.


Four Cylinder Engines 1996-2000
Four Cylinder Engines Using a Combination Switch Box and Ignition Coil (CDM Modules)

No fire at all:
  1. Disconnect the black/yellow kill wires from the harness and retest. If the engine’s ignition fires now, the kill circuit has a fault-possibly the keyswitch, harness or shift switch.
  2. Disconnect one CDM module at a time and see if the other modules start firing. If they do, the module you just unplugged is bad.
  3. Disconnect the yellow wires from the stator to the rectifier and retest. If the engine fires, replace the rectifier.
  4. Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.
  5. Check the stator resistance and DVA output as given below:
  Wire Read To Resistance DVA  
  White/Green Green/White 500-700
180V or more  

No fire or Intermittent on One or More Cylinders:
  1. If the cylinders are only acting up above an idle, connect an inductive RPM meter to all cylinders and try to isolate the problem cylinders.
  2. Using a set of piercing probes, check the trigger DVA output as given below:
  Wire Read To Resistance DVA  
  Purple wire(#1)
White wire(#2)
Brown wire(#3)
White/Black wire(#4)
Engine GND
Engine GND
Engine GND
Engine GND
Open
Open
Open
Open
3V or more
3V or more
3V or more
3V or more
 

  • NOTE: These triggers have the bias circuitry built into them, therefore you cannot measure the resistance like you could the older engines. In addition, there are four triggering coils used.
  1. Disconnect one of the CDM modules that are firing at a time and see if the dead module start firing. If it does, the module you just unplugged is bad.
High speed miss:
  1. Connect an inductive RPM meter to all cylinders and try to isolate the problem. A high variance in RPM on one cylinder indicates a problem usually in the switch box or ignition coil. Occasionally a trigger will cause this same problem. Check the trigger as described above under “No fire or Intermittent on One or More Cylinders”.
  2. Perform a high-speed shutdown and read the spark plugs. Check for water. A crack in the block can cause a high speed miss when the water pressure gets high, but a normal shutdown will mask the problem.
  3. Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets.
Page 24 - Index - Page 26