Charlesgage
New member
First off thanks to all of you for answering about 100 questions I have had on my outboard (only owned inboards before) just by reading other folks threads I have rebuilt both carbs (on the 4th in time for sandbar no less), re-propped, and replaced a regulator already with info from here. However now I need to start my own thread:
I have a 92 Mercury Classic 40 4 Cylinder on a pontoon. When I first bought it the voltmeter read 16 volts running, so I replaced the regulator. Last Summer on its third season with me it stopped charging altogether and I would have to charge it up every 3-4 weeks (i just bought a new wakeboard boat and spent all my time tinkering on that). Labor day after a full charge I went for a long ride. 7 miles away after sitting at the sandbar in the heat for a couple hours the boat wouldn't start. I finally did get it running but you had to keep on the throttle. Got the tools out and no spark on two cylinders... I limped it home that way.
I have switched the coil packs around and they are all good. It's a new regulator (less than a year old) but I can easily and cheaply replace that. I was thinking stator was bad so I checked it with an Ohm Meter and all the readings were way off, guessing I at least need the stator. I do have the service manual and it's the 9 amp stator. I'm just about to place an order for a new stator, flywheel puller etc. but I read another thread on here that had me worried about the trigger and the switchbox. The boat is two hours away and I forgot to test the trigger and the switch box when I was there today. All three are almost 400 bucks so a little much to buy them all just in case. So my questions are:
Thanks in advance! I like this motor and planned to refurb the pontoon next year. I would love to get it back in running form.
Service Manual: https://www.dropbox.com/s/bx4pvb6d1uj8p0k/Service Manual 1.pdf?dl=0
Thread I was Mentioning:http://www.marineengine.com/boat-fo...r-no-spark-at-2-cylinders-Stator-or-switchbox
http://forums.iboats.com/forum/engi...-to-remove-the-flywheel-on-50-hp-merc-mariner
I have a 92 Mercury Classic 40 4 Cylinder on a pontoon. When I first bought it the voltmeter read 16 volts running, so I replaced the regulator. Last Summer on its third season with me it stopped charging altogether and I would have to charge it up every 3-4 weeks (i just bought a new wakeboard boat and spent all my time tinkering on that). Labor day after a full charge I went for a long ride. 7 miles away after sitting at the sandbar in the heat for a couple hours the boat wouldn't start. I finally did get it running but you had to keep on the throttle. Got the tools out and no spark on two cylinders... I limped it home that way.
I have switched the coil packs around and they are all good. It's a new regulator (less than a year old) but I can easily and cheaply replace that. I was thinking stator was bad so I checked it with an Ohm Meter and all the readings were way off, guessing I at least need the stator. I do have the service manual and it's the 9 amp stator. I'm just about to place an order for a new stator, flywheel puller etc. but I read another thread on here that had me worried about the trigger and the switchbox. The boat is two hours away and I forgot to test the trigger and the switch box when I was there today. All three are almost 400 bucks so a little much to buy them all just in case. So my questions are:
- Should I just order and replace the stator and hope?
- Can / Should I test the trigger with a DVA meter (is it worth the two hour trip)?
- If I need a DVA would this work with my current multimeter?: http://a.co/gLbnFw8
- Should I invest in a spark gap tester? compression tester?
- Are there tests I can run on the switch box? I can probably get the motor running again. Probably.
- Did i do any damage running it home on 2 cylinders last year for an hour? Should I buy a new motor or pontoon instead? I only have $2600 into the whole boat and it's just a party barge, but I don't want to buy a new one if I don't have to.
Thanks in advance! I like this motor and planned to refurb the pontoon next year. I would love to get it back in running form.
Service Manual: https://www.dropbox.com/s/bx4pvb6d1uj8p0k/Service Manual 1.pdf?dl=0
Thread I was Mentioning:http://www.marineengine.com/boat-fo...r-no-spark-at-2-cylinders-Stator-or-switchbox
http://forums.iboats.com/forum/engi...-to-remove-the-flywheel-on-50-hp-merc-mariner