1990 Mercury 90HP ELOPT 3cyl, problems

btcox123

Cadet
Joined
Jan 10, 2009
Messages
23
Problem;
My boat runs great for short periods of time, then bogs/ looses power, then goes back to running well (briefly).
This cycle of running good, power loss, running good again varies greatly, both run good, and wait time to run again.
Sometimes 5 min good run with 2 min wait, sometimes 30 sec good run with min wait, some times several min good run, wait time less than 30 sec. and runs good for 5 mins.
I have read as many related post to both mercury and other motors alike most all of them say fuel, in my case, I do not think its fuel.
Please read over what I have done so far, and give me any suggestions or similar problems that were solved.
Thanks in advance.


BOAT SIDE; 1990 Astro quickfire 16 F/S
1 Replaced fuel in tank.
2 Confirmed tank ventilation open.
2 Checked pickup tube.
3 Replaced fuel filter and water separator.
4 Replaced all fuel lines and clamps with 3/8" I.D.
5 Replaced primer bulb.

Motor Side; 1990 Mercury 90HP ELOPT 3cyl
Prop/motor/boat factory
Compression check WOT cyl-1 135psi, cyl-2 125psi, cyl-3 130psi checked twice. First time cyl-2 only 120psi
1 Replaced all fuel lines and clamps with 3/8" I.D.
2 Replaced fuel filter.
3 Replaced all other tubes hoses and clamps.
4 Rebuilt fuel pump 1st time OEM kit (only comes with plastic disc).
5 Rebuilt fuel pump 2nd time Sierra kit (has plastic disc and rubber valve).
6 Removed cleaned and rebuilt carbs.
7 Set floats to factory specifications.
8 While carbs were off, inspected reeds through intake manifolds.
9 Confirmed main jet and bowl vent orifice size.
10 Adjusted low speed mixture per OEM manual.
11 Timing/Synchronizing/Adjusting per OEM manual.
12 Confirmed good spark on muffs, idle.
13 Muffs @idle, ran on cyl1 only, cyl2 only,and cyl3 only (ran surprisingly well).
14 At lake When motor started to loose power, pumped bulb, was firm, no changes.
15 At lake When motor started to loose power, touched ea coil, not to hot and even.
16 Has new water pump. Also touched heads over ea cyl, not to hot and even.

After all this, It started first attempt, idled in gear @ 700 rpm perfectly.
hole shot was better than ever, WOT at 45 mph @ 5100 rpm for about 15 mins.
Suddenly looses power (as if lack of fuel) tach reads 3000 rpm, pumped primer again, no change.
move throttle from WOT to just under half rpm drop from 3000 to 2900, Seems to be powered correctly for that rpm range.
hold their for a min or two (to get out of the way) drop to neutral, idles good, but not as good as before.
wait 2 mins or so(at idle), then take off again like before, but this time and next several times only get a min or two of good ride time.
I did check coils with my hands, did not seem overly hot.
worth mentioning, about the 4th or 5th time of power loss, waiting, going well again for brief period, something odd happened.
as I took off and after planning off I immediately lost power like all the previous times for about 2 or 3 seconds, but before I touched anything, it jumped right back up and kept going for several more minutes.
Please advise.
 

4JawChuck

Chief Petty Officer
Joined
Aug 7, 2009
Messages
504
Re: 1990 Mercury 90HP ELOPT 3cyl, problems

Sounds like an ignition problem, ign coils and stator coils are common failure points on these engines especially if they are cranked with a plug disconnected.

Get a manual and check the resistance of the coils.
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: 1990 Mercury 90HP ELOPT 3cyl, problems

I'd be suspicous of an ignition related heat problem.

This method of testing does not involve any special tools or specs and can save you a lot of hunt time.

1. Go to Home Depot and get one of the big plastic storage bins. These are just deep enough to submerge a prop. This will help to simulate back pressure.

Put the muffs on it and let the tub fill up with water. Fire it up and let it warm up. Use a hair dryer to warm the coils, the switch box and the rectifier/regluator.

If it starts to run different, disconnect the rectifier/regulator. Re apply the heat to the various components and if it stays normal, you probably found the problem.

If the problem returns then break out the test equipment and get voltages from the coils. You will use the hair dryer method to get it to the point where it changes and watch the mulit-meter for a sharp drop in voltage or erratic readings.

Erratic readings could be a damaged coil. Remove the rubber cover and look for cracks or other damage.

If all the coils look good an have little or no resistance to ground. Then break out the manual and perform all the other electrical systems tests. You will need a multimeter and a DVA at this point.

This method often gets you back out on the water the quickest. It is backyard mechanic stuff and not a purest technician model but it works pretty darn good.
 

btcox123

Cadet
Joined
Jan 10, 2009
Messages
23
Re: 1990 Mercury 90HP ELOPT 3cyl, problems

After using the hair dryer on the coils, on an already warm motor, the coils would indeed drop out. I thought the problem had been found, so I stopped testing at this point and ordered my new coils. After replacing the coils took the boat out, and same old story. SO I started testing further into the electrical and found that the trigger coils did not test correctly according to the manual. The new trigger is on the way.
But I have a comment/question.
"from the manual";

The trigger assembly (also mounted under the
flywheel) has 3 coils. The flywheel has a second set
of permanent magnets (located around the center
hub). As the flywheel rotates the second set of
magnets pass the trigger coils. This causes the
trigger coils to produce an AC voltage that is
conducted to an electric Silicon Controlled Rectifier
(SCR) in the switch box.
The switch discharges the capacitor voltage into the
ignition coil at the correct time and firing order
sequence.

The trigger test was supposed to show a specific resistance, but instead all trigger coils tested open, as in no continuity. I checked the meter, it works fine.

I understand that three things are needed to create electricity 1. a conductor 2. a magnetic force and 3. relative motion.

So if the trigger coils (probably the ground as it is 1 wire common to all 3 coils) have a break in the conductor how was it able to run at all?
 

btcox123

Cadet
Joined
Jan 10, 2009
Messages
23
Re: 1990 Mercury 90HP ELOPT 3cyl, problems

Replaced the trigger. Now It will not go over 3000 rpm.
What should I do next?
Thanks.
 
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