boat parts

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


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Page 29 - Index - Page 31
Johnson/Evirude Alternator Driven CD Ignitions
1972-1978 Engines
(With screw terminal type power packs)

Three Cylinder Engines
(continued)
No fire at all:
  1. Check the DVA output from the timer base. A reading of at least 0.5V or more is needed from the black/white wire to the white/black wires (while connected to the pack) to fire the pack. If the output is low, you may try to reset the air gap between the timer base sensor and the triggering magnet using a sensor gap gauge or use the following procedure outlined below.
  1. Loosen the two mounting screws on the sensors and the nuts located in the epoxy on the outside of the heat shield of the timer base.
  2. Slide the sensors in toward the crankshaft until the sensor touches the stop boss located at the base of the sensor mounting area. Tighten the mounting screws.
  3. Coat the face of the sensor with machinists bluing or equivalent.
  4. Install the flywheel according to the service manual and crank the engine over.
  5. Remove the flywheel and check to see if the trigging magnet struck the sensor face. If it did, back the sensor out approximately 0.005 and repeat steps C, D and E.
  6. If the ignition fired, finger tight the nut on the outside of the heat shield and coat it with RTV.
  7. If still no fire, replace the sensor.
  1. Check the DVA voltage on the black/white wire to engine ground. You should have a reading of at least 150V or more (while connected to the pack). If the reading is low, disconnect the trigger wires from the pack and recheck the black/white terminal on the pack. If the voltage jumps up to an acceptable reading, the timer base may have a problem in the internal wiring (A thin spot in the insulation on one wire).
  2. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to fire properly.
No fire or Intermittent on One Cylinder:
  1. Check the timer base resistance from the black/white wire to the white/black wires. Reading should be 10-20 ohms.
  2. Check the DVA output from the timer base. A reading of at least 0.5V or more is needed from the black/white wire to the white/black wires (while connected to the pack) to fire the pack.
  3. Check the DVA output on the orange wires from the power pack while connected to the ignition coils. You should have a reading of at least 150V or more. If the reading is low on one cylinder, disconnect the orange wire from the ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a bad power pack.


Four Cylinder Engines
No fire at all:
  1. (Note: If the engine fires with the spark plugs out but not with them installed, the timer base is either weak or the engine is not spinning fast enough. See # 6 and #8.)
  2. Disconnect the black yellow kill wire and retest. If the engines now has fire, the kill circuit has a fault-possibly the keyswitch, harness or shift switch.
  3. Disconnect the yellow wires from the stator to the rectifier and retest. If the engine fires, replace the rectifier.
  4. Check the stator resistance. You should read approximately 500 ohms from the brown wire to the brown/yellow wire.
  5. Check the DVA output from the stator. You should have a reading of at least 150V or more from the brown wire to the brown/yellow wire (while connected to the pack).
  6. Check the timer bases resistance from the #1 sensor wire to the #3 sensor wire and from the #2 sensor wire to the #4 sensor wire. Reading should be 10-20 ohms on each set.
  7. Check the DVA output from the timer base. A reading of at least 0.5V or more from the #1 sensor wire to the #3 sensor wire and from the #2 sensor wire to the #4 sensor wire (while connected to the pack) is needed to fire the pack. If the output is low, you may try to reset the air gap between the timer base sensor and the triggering magnet using a sensor gap gauge or use the following procedure:
  1. Loosen the two mounting screws on the sensors and the nuts located in the epoxy on the outside of the heat shield of the timer base.
  2. Slide the sensors in toward the crankshaft until the sensor touches the stop boss located at the base of the sensor mounting area. Tighten the mounting screws.
  3. Coat the face of the sensors with machinists bluing or equivalent.
  4. Install the flywheel according to the service manual and crank the engine over.
  5. Remove the flywheel and check to see if the trigging magnet struck the face of the sensors. If it did, back the sensor out approximately 0.005 and repeat steps C, D and E.
  6. If the ignition fired, finger tight the nuts on the outside of the heat shield and coat them with RTV.
  7. If still no fire, replace the sensor.

continued next page....
Page 29 - Index - Page 31