1994 200 HP Mariner no spark on any 6 cly

[dstarok]

I have a 1994 200 HP Mariner, S/N 0G060891. I had trouble a couple months ago while coming in from fishing. the motor lost power and ran terribly. I found that only the starboard side of the engine was firing. We limped back in on 3 cylinders.
I took it to mechanic and he replaced the inner switch box, and everything ran good. (Knowing what I know now I would have done it myself.)
Well, yesterday I was out again and went over a large boats wake coming back in and the motor quit, won't fire at all. Checked it today and have no spark- port or starboard. Took some readings with an ohmmeter on the blue/red wires from stator and they are the same as they were before I had the new switch installed, so I believe the stator isn't broke. I checked all the wires and nothing looks burned up or anything. I do not have a kill switch. I disconected the wiring harness to see if I would get a spark when I jumped the solenoid and did not get a spark then either.
I do have the Mercury manual but it is very limited in information, doesn't tell me what kind of voltages I should be seeing from the stator, only says to check resistance. I am an electrician and do alot of repairs myself, and I sure would like to save some money on this one, boat is breaking me. I appreciate any help on trouble shooting this motor.
Dave

 

[andy6374]

Re: 1994 200 HP Mariner no spark on any 6 cly

You do have a kill switch (the mercury switch) or else it would never turn off. You probably don't have a lanyard switch.

Disconnect the blk/yel wires from each switchbox and see if it will fire up. Just note that if you do get it started you won't be able to kill the engine by turning the key switch to "off". Just hold the key switch in to flood the engine.

To really check the stator you need a DVA, but the ohm test will give you some indication how the stator and trigger is functioning.

Loosing spark on all six cylinders all of a sudden is a tell-tale sign of a bad kill switch.

 

[dstarok]

Re: 1994 200 HP Mariner no spark on any 6 cly

Thanks for the reply, I will try that tonight. But, wouldn't disconnecting the wiring harness have eliminated the effect of the kill switch being bad? I ordered a couple new manuals last night, hope to be better informed soon. Thanks.

 

[andy6374]

Re: 1994 200 HP Mariner no spark on any 6 cly

Nope the kill switch is on the motor.

This just says that the circuit that is routed bewteen the kill switch and the key switch isn't the culprit

 

[dstarok]

Re: 1994 200 HP Mariner no spark on any 6 cly

Andy, You aren't talking about the Mercurcy (Tilt) switch are you? Where is the switch you are talking about located?

 

[dstarok]

Re: 1994 200 HP Mariner no spark on any 6 cly

Please tell me if my understanding is correct. According to my interpretation of my Mercury manual, the Black/yellow wire comes from the switch box and joins with:
1) the black/yellow wire from the other switch box and
2) the black/yellow wire that goes to the"Mercury/Tilt " switch and
3) the black/yellow wire that goes to the ignition switch.
The tilt switch closes when the motor is tilted or kicks up, shorts to ground and kills the engine.
The ignition switch when in the off position completes the circuit from the black/yellow wire to the black wire which returns to the engine and goes to ground and kills the engine.
Either of these being faulty would result in no spark, correct?
I do not have a tilt switch installed, and checked the ignition switch to be open between the black/yellow and the black when the switch is in the run position. I also removed the black/yellow from the outer switch and turned the motor and had no spark from the plug associated with that switch. (Starboard side cylinder)
Thanks,
Dave