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Troubleshooting
Mercury Outboard Battery CD ignitions
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******** This information
is supplied as a service guide only and Outboardparts.com is not
liable for any misunderstandings, errors or omissions regarding
this information. The information has been obtained from actual
Unit analysis, parts manuals, and other
sources. ********
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| Recommended
Tools: |
| for DVA: |
Fluke Multimeter with CDI
#511-9773 Peak Adapter, (or CD-77) |
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CDI #511-9701 Battery CD
Tester |
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CDI #511-9710 Trigger
Tester |
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CDI #511-9766 Spark Gap
Tester |
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Jumper Wires |
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A Reliable Volt/Ohm Meter (it the
CD-77 is used for the DVA) |
| CAUTIon; DO NOT Use A
FREE Battery with these TypeS of ignitions As theY TEND To
OVERCHARGE and BLOW the Packs.> Typically 17 Volts
+. |
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| Note:
A large portion of the problems with the battery
CD units are caused by low battery voltage or bad ground
connections or high battery voltage. Low Voltage symptoms
are weak erratic firing of cylinders. Misfiring after a few
minutes of running can be caused by excessive (Over 15.5 Volts
DC) voltage at the pack. - Warning
: Check the voltage on the red
(or purple) Wire at the CD Unit through the RPM range. At no time
should the voltage exceed 15.5 Volts DC. |
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Warning!! Battery REVERSAL
WILL USUALLY DESTROY Battery CDs and
TRIGGERS.
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| 1) Check all battery and ground
connections. |
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| 2) Dead
or no fire until you release the key
switch: |
| Disconnect the Mercury Outboard switch and
reset, if the engine fires, replace the Mercury Outboard switch.
Check the voltage on the red and white Ignition wires at the CD
Unit. If the voltage is less than 9 1/2 volts during cranking
there is a problem in the battery s or the Ignition switch Box.
These units require at least 9 1/2 volts to fire properly. On a
332-2986 switch Box, check the voltage on the brown terminal
(white/black for 332-47960 where the Trigger is hooked up. It
requires at least 9V at cranking. DVA check between the
white and black wires (black and blue on 332-4796). You should
read at least 2 1/2 volts at cranking. Connect a jumper Wire
directly from the battery POS (+) terminal to the red and white
Ignition wires (the red Wire is not needed for the CDI units).
CAUTIon: DO NOT Connect the JUMper Wire To the WHITE Trigger
Terminal. Retest: ATTENTIon: in order to kill the
engine if it cranks, the jumper Wire has to be disconnected
and/or choke the engine. If the engine still fails to crank,
recheck voltage as above. If low, replace the battery and retry.
If there is still no fire, disconnect points Wire (or Trigger
wires) and connect the Battery CD tester (511-9701), according to
the instructions in the manual, and align the rotor with a spark
plug Wire. Connect a spark gap tester (511-9766) to all spark
plug wires and turn the Ignition switch on. If the CD Unit fires
to only one spark plug Wire, check points Wire (for breaks or
shorts) or Trigger. If ANY other spark plug fires besides the one
the rotor is aligned with, the distributor cap and rotor should
be replaced. The Battery CD tester will fire the system to
approximately 3000 RPM. If the Battery CD tester is not used, see
related drawings on the Schematic page (following). If the CD
Unit fails to fire with this hookup, it is usually bad. Following
the instructions included with the Trigger Tester (511-9710)
check the Trigger to see if it is good or bad. |
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| 3) Engine cranks and fires as long as starter is
engaged: |
| This problem usually indicates a bad
Trigger. |
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| 4) Check the Ignition coil. |
| An open, cracked or poorly grounded coil can
burn out a battery CD. |
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| 5) Check the DVA voltage on the primary input Wire to the
coil. |
| Using the fluke meter with the peak reading
voltage adapter (5111-9773), or CD 77. The reading should be
approximately 100 volts or more for OEM CD's, and 200+ for
CDI electronics units. |
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| 6) Inline engines with internal exhaust
plate: |
| If the engine speeds up when you remove one
spark plug Wire, the internal exhaust plate is more than likely
warped. The following tests can be performed on the bench or on
the engine. NOTE: Disconnect the Trigger mechanism prior to
testing. |
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Return to: Mercury Outboard Troubleshooting
Section
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