1970 4hp weak spark

merc4

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Dec 9, 2008
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11
1970 Merc 40, single cylinder, thunderbolt ignition won't start. The spark appears "weak" on a spark check light as compared to my Evinrude. I've replaced the points and the plug is good.
Anybody with experience in these old units have a thought? Troubleshooting sequence?
 

Laddies

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12,218
Re: 1970 4hp weak spark

First I have never had any luck testing a Mercury with a neon but it sounds like you have lost a stator coil and here a system test fot your engine.
scan0004.jpg
 

merc4

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Re: 1970 4hp weak spark

This is a one cylinder, no capacitor. Other thoughts?
 

Laddies

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Re: 1970 4hp weak spark

Without a serial number or CD part number it's tough as all Thunderbolt Ign. systems have a capaciter
 

merc4

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Re: 1970 4hp weak spark

Serial # 2775667. None of the parts books list a capacitor for this model and I can't find anything that looks like the usual capacitor.
 

emckelvy

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Jan 16, 2004
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2,506
Re: 1970 4hp weak spark

If the 4HP has electronic ign like this:

http://www.mercruiserparts.com/Show...&bdesc=FLYWHEEL,STATOR+AND+IGNITION+COIL+(40)

the stator is completely self-contained and does not have an external capacitor, charge coil, etc.

Since you do have some spark, here's a couple of things to do before condemning the stator:

1) Replace the white insulator block where the external wire connects to the points. This block will crack/degrade with heat/age and short the stator output to ground.

Insulator: Mercury 336-3981 (NLA but may be available Old Stock at your local dlr), or Rapair 994-3981.

http://www.boatfix.com/bykeywordnew2.asp?textfield=994-3981&texttype=2&submit=Search

2) Check the coil for cracks & arc burns. Very common to see on these old-timers. Sometimes they're bad enough that you'll hear the arcing when they're running. You'll have to remove the coil and peel back the rubber cushion in order to check all sides for cracks.

While it's certainly possible for a coil to be bad and show no cracks/arcs, it's not quite as common. You can check the coil for proper resistance values with a meter, as necessary.

If the above doesn't do the trick, most likely the stator is shot. If you can get hold of a later-model parts motor, you can upgrade to the more reliable-style ign with external charge coil & capacitor. eBay would be a likely source of parts.

HTH & let us know what you find...........ed
 

merc4

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Dec 9, 2008
Messages
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Re: 1970 4hp weak spark

Finally got an insulator block. Motor started and ran for about 2 seconds. When I rotate the motor with my electric drill, it sparks for about 30 rotations, then quits! After sufficient rest, it repeats. Ever experience anything like this?
 
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