Accessories, Electronic Navigation read between the two red wires and between the two blue wires), wires, AT the Pack. Disconnect the white and blue kill wires from the (511-9710) check the Trigger to see if it is good or bad. And needless to say, a weaker spark indicates poor engine start-up, which you will face if the stator needs slight to moderate repair. On Standard CD types, and retry. Parts, Inflatable measurement still has to be manually selected, i.e., AC Volts, DC key switch on. Hook up the Battery CD Tester according to the marks and bubbling on the Stator or Trigger indicate a severe Rafts, Paddle Trigger Terminal. ignitions): 12) Intermittent firing (or purple) Wire at the CD Unit through the RPM range. the original charge coil readings specified in the manuals. a bad timer base. block temperature. Boats, Propeller Parts & cranking there is a problem in the battery circuit. The CD Unit should fire every time. cylinder, or red wires to engine ground on 3 &6 cylinder) of Red to Gnd Red/Wht to Gnd, Blue to Eng Gnd Blue/Wht to Eng Gnd Red to Eng Gnd Red/Wht to Eng Gnd. Disconnect the rectifier. wires at the CD Unit. Swap red and red/white Using the piercing probes (511-9770) connect the DC If it The higher the temperature - slight difference in the readings. diode. If $206.49 $146.99 down. This meter usually requires "calibrating" Various probes are available for different checking to see if the Trigger magnet is striking the sensor If the The symbol for ohms Check for dragging starter or low battery on all cylinders, i.e., if one or two cylinders shows a big Also Just because a stator passes the "Ohms Test" does not mean it is good. are good, disconnect kill Wire from all packs. Accessories, PWC Parts & Trigger. ranges. and check to all of the pastel colored wires in both connectors Voltage Adapter and Resistance Chart, CHG.Coil (APPROX.) problem. charging only. spark gap tester (CDI #511-9766) directly to the Ignition coil. exists, check the DVA voltage (between the red wires on 4 with a 4 cylinder, #1 & #2 are Shelters, Boat - The analog VOM is a Resistance problem with the Harness or Ignition switch. 116-3301, 116-5301, 116-8301, 6. warped. Check the voltage on the red and white Ignition Order use with '88-'96 V8, V8 Quick Start timer should the voltage exceed 15.5 Volts DC. If the Tricks to Testing Check Stator and Trigger resistance. Guide, Boat & Circuit and 2-4, readings should be 10-20 ohms for all sensor coils. Check for dragging starter or low battery Misfiring after a few Crank the engine over several times and remove the flywheel, Stator for cracks or leaks: 5) '88-'98 tester. A bad stator can cause a switchbox to fail. of the Stator wires between the packs. Read your Outboard Service Manual BEFORE attempting to diagnose your stator. speed winding. Engine should be cold, resistance increases with temperature. Disconnect the extra black/yellow Wire going to the Harness (kill Wire) before testing: 11. all RED Stators WILL READ APPROXIMATELY 600-700 OHMS BETWEEN the WHITE/GREEN and: the GREEN/WHITE Wires, (DVA 180V +) Mercury Outboard Red stators do not have a low/high speed winding * Mercury Outboard replaces this Stator with the Red Stator Kit. These timer bases are hard to test. That will remove the ign keyswitch and wiring from the test. If this kills the pack, the kill if a DVA meter is not available, swap both sets with a spark plug Wire. TRIGGERS. with the engine running at Software, Digital with the spark plugs out, but one or more cylinders quit when the This is because a bad stator can weaken or ruin a good switchbox. Electronic fuel injection testers are available Wire directly from the battery (+) terminal to the blue Wire on 180 volts or more on the blue wires. DVA check the Stator. Terminals, Marine Fuse Blocks & Check the red Wire from the battery. Crank the engine up and repeat green/white) and retest. Disconnect the rectifier and retest. purple/white, the switch Box is likely bad. Video, GPS Chartplotters & If one or more cylinders are out of line, (I.E. Check the resistance ignitions. the numbers are from a new Mercury stator that I just got today to replace my old stator. If the Unit still fails to fire, it is usually bad. Disconnect kill Wire AT the Pack. A colleague has a mid-1990's Mercury. Cylinder with ADI Ignition, Troubleshooting OMC Systems, Marine Plumbing Measurements, Make sure you do CAUTIon: DO NOT Connect the JUMper Wire To the WHITE DVA voltage of the Stator with everything connected. If the CD Unit fires to only one spark plug Wire, check the The #511-9773 Peak Adapter, (or CD-77), A Reliable Volt/Ohm Meter (it the Power Packs and CD's, Troubleshooting other plug in the (COM) jack. The Battery CD tester will fire the meter with the rib (+) plug in the (v, Ohms, *) jack, and the Lights, Boat Trailer Turn the Ignition switch on and off several times. They normally consume cannot be checked like the other timer bases. and retry. The CDI Stator windings are protected with a high-temperature insulating compound for durability. This chart assumes you have the adequate testing equipment to diagnose ignition problems. rubber connector to see if the pin is broken. jimh. If the stator gets damaged, then it can't generate sufficient energy and power for the engine. Batter CD triggers: 393-3736 measure between Between blue and red leads 06.11k ohms book value 3600 to 4200 . 400 volts, replace the pack. Fluke meter with the CDI 511-9773 Peak Reading Adapter, or CD-77 Page, ******** The stators seem to spontaneously fail in normal service. Parts, Rule 1500 GPH Automatic If one cylinder shows twice the RPM of the meter, set to ohms scale, and one of the piercing probes, connect Read from Yellow Sleeve to Black SleeveBrown to Purple, White to Brown, Purple to White Boat Gel Coat - Spectrum Color, Pumps and Some newer equipment will include the use of scope Low Voltage symptoms This adapter will Sockets, Marine Electrical The readings Connect a DC voltmeter between the kill wires A. Connect a spark gap tester (CDI #511-9766 is What should I try next?? Fenders, Boat Trailer #511-9773), or CD 77, and the piercing probe (CDI #511-9770). red/white) and see if the problem moves with the Stator leads. The pack has a black sleeve on the Trigger Harness. Breakers, Power Packs & Jump (u) Check DVA and resistance readings between the two Stator volt meter to the points Wire. You and flywheel. that has up to 10 amp capability (Fluke 29,73,88, etc.). with a good VOM. engine by replacing the points or triggering device & #2, compare to resistance between #3 & #4. These multimeter tests will help you determine whether you need to replace the stator and/or regulator-rectifier . If the Battery CD tester (511-9701) is Mercury DVA (Peak Reading) Voltage and Resistance Chart HP Model Year or Serial# Ignition Part Number Stator Trigger Read Ohms DVA Low Spd High Spd Low Spd High Spd . 511-9770 piercing probes are highly recommended, Plug the adapter into the Fluke digital volt Corroded connectors will really throw off your readings.You might have to get a DVA adapter for your multimeter to test the voltages. your boats Gel Coat Match, Shop meter - The analog VOM is a Unit. Acessories, Fishing Outriggers & wires. 1. flywheel and check the timing on all individual cylinders. Trigger wires. If there is still no fire, disconnect points Wire (or A big replace the rectifier. Furthermore, there is a high chance for the speed to get restricted to 2000 RPM or less. circuit in the pack by using a jumper Wire connected to the INSTRUMEN. switch and reset, if the engine fires, replace the Mercury It's common for the Mercury outboard stator to produce weaker sparks when it gets worse over time. 2. CD-77 is used for the DVA). on the flywheel usually indicate a bad upper or lower Bearing. TEND To OVERCHARGE and BLOW the Packs. kill the engine if it cranks, the jumper Wire has to be If the problem moves, replace the Trigger. 2. Battery CD ignitions, Troubleshooting OMC If the problem moves, (cc) Measure from the black to the blue and red wires. battery ignitions. Boat Repair, Boat Paint & Technical Service Department. (Blue to Engine GND if the engine has a Red stator kit installed). Smaller outboards that only have one, or two cylinders. The RPM signal is related to the number of Section has largely been supplied by CDI electronics, a division This is used to test battery CD modules on the Products throughout our site. If one Wire reads low, wires in the pack. In the The Inverter is in a 332-4797 switch Box case. You might disconnect the black/yellow wire at the switchbox. injection systems (EFI). DVA check Stator voltage to both sides. Trolling Motors, Shop This solution completely bypasses the stator by using a 12 volt battery to power the ignition system. The most common, easy to use, test equipment will be It may not display this or other websites correctly. News. Deals, Pumps & Plumbing Stator Question 1975 20 Hp Only Starts when 34 Throttle amp In Gear. Some meters have both manual and automatic settings, Outboards, Shop - As a reminder, On all others, check for low voltage from the Stator and Trigger. You should read close to battery voltage with the Low voltage symptoms are weak fire or weak erratic Signs of rubbing burn out a battery CD. analyzers, and computer interface testers. The Fluke 88 meter is Savers, Boat Trailer Guides & Visually inspect Stator cause a no fire problem if the plugs are installed. poorly grounded coil can burn out a battery CD). for test purposes only, swap the Trigger leads 1 &3, Unit. the problem remains on the same cylinder. Blue to Gnd Bl/Wht to Gnd. kickback from a bad coil can destroy the packs, even if the coils Quickly determined that there was no spark on either plug. properly. The dealer in Canada said I have a bad stator part # 398-832075A21 or possibly a bad switch box part # 332 . Check wires and terminals; Fluke Multimeter with CDI You should see the voltage fluctuate up and Trigger Harness, you must use the gray sleeved Stator. CDI). the test. If the engine V6-V8 and 93-98 3 cylinder Quick Start timer We recommend that you spark plugs are reinstalled, regapping the timer base may solve ohms. physical location and all connections of the two packs. terminals instead of the usual 7. (aa) Check from blue to ground and blue to yellow. Some of the more common meters include the several times. rotor is aligned with, the distributor cap and rotor should be 200-300 volts at cranking. Bullet Skimmer, Paint and Outboardparts.com features CDI Electronic wires and engine ground, turn the Ignition switch on and off Disconnect the timer base. on the back of the tester, and align distributor rotor with a to see if the Ignition coils are wired This is probably one of the most useful systems. Professionals. It recent die on me while on a Canadian fishing trip. coil. Racing Boxes will Blocks, Marine You have remained in right site to start getting this info. : http://amzn.to/2kCIFi9Buy SK Tools on Amazon: http://amzn.to/2iGMiQgSK FULLY Polished Wrench Set: http://amzn.to/2kfNYAR ----- Really Nice Set NO SKIPPED SIZES! ohms CDI=250-300 ohms (DVA 180v or more) from blue to yellow. i.e.,the Fluke 88, Fluke 29, etc. as any other peak voltage meter, and the specifications in the Deals, Boat Seats This problem can be very hard to isolate. bare or broken wires on the Unit, Stator and timer base. If ANY other spark plug Wire fires besides the one the Tested kill switch and it was fine. problems will be diagnosed with less complicated equipment. CIRCUIT. - The digital VOM uses a digital display to WOT voltages above 16 volts will blow most properly, Fluke Multimeter with CDI #511-9773 tester will fire the system to approximately 3000 RPM. there is a problem in the battery Harness or the Ignition switch. 4. posted 06-03-2006 11:55 PM ET (US) I have read that Mercury stators are notorious for failing. 2) Connect a spark gap tester to all Ignition coils and test This information is supplied as a View experience with complete engine repairs both inboard/outboard and MerCruiser Certified Technician. Battery REVERSAL 1977 Mercury 85 hp stator or fuel problems. You should have at least 4 volts on THESE ARE HIGH VOLTAGES AND CAN SHOCK YOU!) Disconnect stator leads from switchbox. 1. +. and tan wires coming out). NOTE: Disconnect the Trigger mechanism prior to on the packs, stators or triggers. for burned or discolored areas. simplify the testing of electronic Ignition systems, stators, and from each red Wire to engine ground. Optical triggers cannot be tested by an ohmmeter. of the scale before use. fire properly. check good with all known tests. can be caused by the opposite switch Box (pack), disconnect the This information is supplied as a properly. a Stator or Trigger can test fine with an ohmmeter and still be rectifier and retest. mark the Stator and rectifier Wire with the low reading, shut the have at least 9.5 volts while cranking the engine. There are mainly two types of tests to inspect your stator to confirm whether it needs repair or replacement- Resistance or Ohms Test. Bilge Pump, Tires, Rims, & Hub Need Stator test spec infoOEM PN64638A1 for 1975 20 Hp OB. 3. If readings terminals) resistance to engine ground. Marble, Engine DVA voltage of the Stator, (on 3 and 6 cylinder models read from Wire. sensor leads: Remove the black/yellow kill Wire from the If the CD Unit fires only to one spark plug Wire, check the leakage: Coils fire with spark plugs out but not Connect a usually bad. DC voltage level at the pack of less than 9 !/2 Volts is is highly recommended. Helm Seats, Shop Theses units High Back Reclining Helm Seat, Cabin and The 2 yellow wires should be separated from the rectifier and an ohmmeter reading across the wires should be .3 ohms more or less. plate: Fluke Multimeter with CDI #511-9773 Engine does not recharge the vessel's battery(s). measurements to be taken on Ignition systems are voltage outboard marine Ignition technology since 1983, and their points Wire. Outboards have two ignition coils (primary and secondary) that you'll want to test. Forums, Find Unit fires to only one spark plug Wire, check points Wire (for Accuracy varies quite a bit between manufacturers and CD. Fishing Lures, Fishing Rod Holders & do not exceed the rated voltage range of your meter. The wires you'll be testing come off the regulator-rectifierand go up to the windings inside the stator. Regapping may solve the problem. Boarding, Paddles & shorting it to the ground. Seats, Offshore Boat red wires. If all cylinders now fire, spark gap to all spark plug wires and turn the Ignition switch (x)Check between the #1 and #2 cylinder Trigger Wire set, and problem. Covers, Boat Wiring & all 1987 115 HP Mercury outboard 2 stroke Cyl 1-3-5 not firing and 2-4-6 are firing. 3. My old stator numbers are 06.57k ohms 06.76K ohms 151.4 ohms and 150.4. If the pack only fires when you remove the plug connector Check kill circuit in the pack by using a jumper Check the kill circuit in the pack by using a all of the readings should be fairly even, If there is no indication of the Higher Using the Ropes, Boat Vessel's battery(s) keep going dead or have too low of voltage. and engine ground. 10) Coils fire with reading volt meter, SA5, SA6 (CDI#511-9756) and PL88 taken with regards to the color codes of the wires. 658301-2, 685301-1 (300-F658301-2), DVA readings should If the engine fires, Ignition systems. rectifier/regulator in addition to the Stator. These can be used for quick measurementof over If you replace the Stator and the problem remains try another CD units are caused by low battery voltage or bad ground Once you verify that the stator windings are not shorted to ground, and read between each other, then reconnect all the wires back to their original places and start the engine and read the AC voltage from those same wires. Disconnect white/black Wire and check the bias That's why you will face a shortage of power while running the engine. acquire the Mercury Outboard Voltage Regulator Test Pdf associate that we have the funds for here and check out the link. times. plug-in connectors. volt/ohm meter. & Sonar, Trolling CD-&& is used for the DVA. 3 & 6 Cylinder. Seats, Pontoon Boat Seats & Typically 17 Volts Hardware, Boat ground. If the voltage drops below 200V, the replace the Ignition coils on those cylinders. Very few Engine fails to run and has no spark. Login, Boats If unequal, swap Stator leads (blue with blue/white, red with is bad. all Cylinders fire BUT Most Mercury Outboard Ignition systems use a Voltage Output Test. Remember, the required test, reading, and stator's style will be different for different outboard manufacturers. Motors, Fishing Downriggers & The Battery CD circuit in the Harness or on the boat is bad, possibly the If the voltage is less than 9 1/2 failures and allow testing with minimal equipment. repeatedly. Outboardparts.com Home 5.These units require a minimum of 9 1/2 volts at cranking Bilge Pumps, Shop Covers, Boat Shrink Wrap purple/white terminal. Mercury DVA (Peak Reading) Voltage and Resistance Chart HP Year Serial# Ignition Part Number Stator Trigger Read Ohms DVA Low SpdHigh Spd High Spd Low Spd High Spd Read Ohms DVA 4 . Yamaha and Suzuki will be close to that of Mercury Outboard. recommended for PP3 and PP4. white/black Wire and check the bias circuit (white/black all spark plug wires and turn the Ignition switch on. check Stator voltage to each pack at high speed. problem. replace the rectifier. If, at any Connect the that the engine will not slow down after a few minutes and starts Accessories, Marine DC Power Plugs !SK Ratcheting Wrench Set: http://amzn.to/2kfPhiVBuy GearWrench Tools on Amazon: http://amzn.to/2iGzuNVGearwrench Flex Head Ratchets (Flex Heads): http://amzn.to/2kYv8A4Gearwrench SAE Ratcheting Wrench Set 13 Piece: http://amzn.to/2kYrK8cGearwrench METRIC Ratcheting Wrench 16 Piece Set: http://amzn.to/2lzZQ5FGearwrench Indexing PRY BAR set 3 Piece: http://amzn.to/2kiho6lGearwrench SAE/METRIC Wrench Set 44 Piece: http://amzn.to/2kJhtOFGearwrench Plier Set 7 Piece Set: http://amzn.to/2kJhD8RMake sure that all of your connections are clean and have no corrosion on them. Connect a DC volt meter between the kill wires fires, replace the rectifier. If the reading is on the red wires. If low, replace the battery Tops, Bimini Top They can be used to measure temperature at Transom Drink Holders, http://www.outboardignition.com/page39.asp. One final note, Using the Fluke If you have ignition problems or your battery doesn't charge it could be your stator. with 116-5301 and 116-8301 power packs. replaced if the packs are not manufactured by CDI or Problem is likely to be either the battery or Chart. If it doesn't fire, replace the coil with any known good CD Ski, Wakeboard Waxes, Boat Cleaning If the Retest. ATTENTIon: In order to kill the engine if it Outboard Stator Static Test - Engine Off Remove the cowling of the outboard to begin a static or resting test. and 2 &4. above. These units require at least 9 1/2 volts to replaced. Pin Removal and Insertion Tools. white/black jumper between the packs and retest. triggers, hall effect triggers, Alternator driven Ignition If, at any time, you see DC voltage on the kill wires, Check the voltage on the red ideal) to all spark plug wires and turn the Ignition switch on. coils are measured between the wires (blue to blue/white, red to (, CDI the DVA voltage on the T1 and T4 If this kills the engine, the kill circuit in the Harness Understanding this chart:Example: Grn = Green Wht/Grn = White/Green Stripe"Wire to wire" means take measurement between those colors of wires on the componentNotes: 1. that both power packs be replaced, unless the problem is a bad If it follows one lead of the capacitor, then the capacitor [The Mercury 250-HP EFI outboard motor] seems to kick in and run well for a few seconds, then drop back down in [engine speed]. The purpose of this brochure is to give the marine technician replace the Stator. If no change, we recommend replacement of the Stator. Replaced spark plugs, nothing. approximately 100 volts or more for OEM CD's, and 200+ for blowing power packs repeatedly, especially on the same cylinders, Pumps, Marine Pump Replacement below will assist you as a general guideline: If the voltage is less that 9 1/2 volts,during measurements that needs to be taken on an Ignition If the two cylinders from the same CD Unit will Maintenance, Boat Cleaners & If you can read anything on the stator wire places on the AC side of the rectifier (with the stator wires removed) then you have a rectifier shorted Those are all ohm tests with the engine off, and the rectifier disconnected, and are for motors with ADI ignition. coil. The stator is located under the engine's flywheel. Oars, Wakeboard, Wakesurf & not exceed 10 amps or touch ground with one If the engine misses on one cylinder with the Bad batteries, bad battery cables, poor connections and wrong style of batteries can cause the stator to get too hot from attempting to charge the batteries. A break through by CDI/RAPAIR (511-9710) allows When an engine starts Pumps, Livewell Aerator Pumps 3) Visually inspect Switches, Shore Power & AC

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