1993 mercury 90hp blowing fuses

Spilly

Recruit
Joined
Aug 20, 2024
Messages
1
So I took it out one day ran great then shut it off to get the truck as soon as I went to fire it up nothing happened just cranked and cranked, time goes by we tested the stator and found it was bad, got a new one from a marina (a red stator). Only had 2 yellows, a white and green. I seen in a different forum you can just hook the yellows together and then the white and green could hook up to the red or blue it didn’t matter because of polarity. Still no spark. Tried taking the kill switch off the switch box to see if it would fire without it. Now as soon as I turn the key it blows my 20 amp fuse. Need to resolve this asap before duck season.
 

airshot

Vice Admiral
Joined
Jul 22, 2008
Messages
5,374
My 1992 Merc had a similar problem last summer. Suddenly no start and blowing fuse. Searched high and low thinking there was a bad wire/ connection somewhere. Carefully searching found a tiny little mark on the wire wrapping used to protect the wires in tight areas. Would never noticed except for a bright flashlight and closeup searching. This group of wires were forced thru a very tight space and up against a bolt head that was a ground. This little burn mark was the size of a mosquito head, put a pointed awl into this burn hole and felt wires, figured it arc's thru the wrap. Replaced that section of wrap with heavier stuff and glued a little piece of plastic on the bolt head. Put everything back and all was good once again !
With the way the wires are packed in and thru tight spaces, it could be anywhere....good luck...
 
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