1994 mercury 150 wont start

[tonydl86]

( thanks for this forum) i have a mercury outboard og039265 manufactured 1993,1994 model.i think the model number is 1125412pd. i have owned it for about three years. its always been hard to start at the begining of a fishing day,but after it started a bit better.start now and then when its put up, till now. it just wont start.there is no dealers in laredo tx. so i got a seloc manual and checked it my self. have no spark, switch box black and yell is ok, crank it up and with a regular digital meter i have 30 vac coming from stator at blue & bl/white and 15 vac at red & red/white, have no peak reading volt adapter. i have zero at four greens going to ignition coils.continuity check of stator is not up to manual spec, but not open.always had small drain on battery but never checked it i just disconected the neg. cable. the drain disapears when i diconect the 2 yell wires going to the rectifier. rectifier seams to check ok per manual but not sure if it is.cant remember trigger voltage but its also low.plugs are fairly new.sw box # is 332-5772a7 i think, last time engine made any noise was when i cranked it up on my driveway,engine reved up hard for a second and it quit. i´ll apreciate any advice you throw my way.<br />thanks

 

[clanton]

Re: 1994 mercury 150 wont start

I not real sure about this, but looks like you are using incorrect method to check the ignition system. When you check the output of the stator low speed the red lead of meter to blue, black lead to engine ground, then red lead to blue/white, black to ground. High speed red meter lead to red, black to ground, red lead to red/white, black lead to ground. The voltage at low speed leads 100-265 volts at 400 rpms. The voltage at the high speed leads 25-50 volts at 400 rpms. No voltage specs for the trigger. Meter readings X .414 should get you close to DVA voltage.<br /><br />I would also check the magnets and key in the flywheel.

 

[tonydl86]

Re: 1994 mercury 150 wont start

Thanks Clanton for your help.<br />Let me say that I´m real new at this, before my engine quit I never thought of going past gasing it adding oil and lubricating it. the test that i perfomed on it are the way i understood them in the manual, which I probably got wrong. the chart in the book for ignition testing, has a column taht says charge coil cranking DVA H speed L speed<br />and high speed is 20 V and low speed is 180 V.<br />the charge coil wire testing colors are high red to red and white, and low blue to blue and white. should i be measuring from each wire to ground ? also remember I dont have a peak reading voltage adapter. Do you know if a digital volt meter can be used with out this adapter,and can I get a true reading when Im only cranking.

 

[clanton]

Re: 1994 mercury 150 wont start

Useing your meter, test each wire to ground. your test results X .414 should give you the DVA numbers. Cranking rpms is the test method, then after engine is running check at 1000 rpms and 3000 rpms. If you remove the switch boxes/power pack to excess the wires, you must ground them with a jumper wire. All of the specs I posted came from Mercury OEM manual.

 

[jhreed]

Re: 1994 mercury 150 wont start

"Mr" Clanton, I believe that the method to obtain peak readings is to multiply by 1.414 and to get averages is to use .707 times the readings. I'm offering this to help, not to be critical about your help... I've read you many times and found you very helpful. I have also found it very hard to use a digital meter to read the ac voltages. Seems the old fashioned analog meter types did a much better job on the coils of flywheels. Jim Reed

 

[tonydl86]

Re: 1994 mercury 150 wont start

Thanks for your replies. I just recheked my readings, my stator is # 332-5772 its a rectangular module with five terminals on one side for stator high and low and blk. & yell in the middle for cutoff. on the opposite side are eight terminals four greens go to the ignition coils the other four come from the trigger coil.<br />My s-260 meter is not working but with a digital, I get the folowing readings.<br />stator: R-17vac R&W-17vac BL-32vac BL&W-32vac<br />trigger: VIO-.8vac WHT-.8vac BRN-.8vac BLK-.8vac. these readigs are after having multiplied X 1.414, 0 volts on greens to ignition coils

 

[clanton]

Re: 1994 mercury 150 wont start

jim reed, You are right I dropped the 1, and now that I think about it, I probley have a few more post with the incorrect number. I never use this method, I have a several meters that will read peak voltage. But that method should help someone that does not need a peak reading meter.

 

[clanton]

Re: 1994 mercury 150 wont start

Looks like the stator is out, if you trust your meter and readings. you can get an DAV adapter for your meter from www.esitest.com. You may be able to make one, poster Schematic posted a schematic of an adapter, try search.

 

[tonydl86]

Re: 1994 mercury 150 wont start

thanks for staying with me clanton.<br />the meter is a fluke 77, its always been dependable. one other reading I failed to mention is the resistance check recomended in the manual of the low speed side of the charge coil 3250-3650<br />with my fluke i get 1.1 meg ohms ??? I cheked the price of the sw. box I can imagine what the stator is going to cost. do these tests pretty much determine that the stator is bad, or is there other tests, aside from replacing it with a known good one.? Also about the costant drain on the batt. do you think that the voltage regulator could be out since removing the two yellow leads stop the drain. Are you fermiliar with the tools needed to remove the flywheel, and who I can get them from. It takes one to pull the flywheel up from the center and another to hold it while removing the center bolt.

 

[KIWI MERCMAN]

Re: 1994 mercury 150 wont start

tonydl86<br />I wont get into your engine problem but I can tell you that the Voltage reg does have a drain all the time , it senses battery volts and it's the sensor that causes the spark at the battery. Only small milliamps though, your batt will last 2 months with this still hooked up.<br /><br />Kiwi

 

[clanton]

Re: 1994 mercury 150 wont start

40 amp stator, between red and blue 3500-4200 ohms.<br />Between blue/white and red/white 3500-4200 ohms.Between red and black 90-140 ohms.<br />Between red/white and black 90-140 ohms.<br /><br /> The flywheel puller will have to come from Mercury, www.screamandfly.com or used.

 

[bret walters]

Re: 1994 mercury 150 wont start

we need more accurite info about your problem. no spark ? all cyl. or just one or two? no spark on all cyl. could be bad ignition switch stop circut or bad emergency stop switch, or bad remote harness. start trouble shooting by remomving and grounding all spark plug leads, next locate remote key swicth harness connector at engine- this is a large black plug on the stater side of engine- disconnect this. you have now isolated the engine from the boat with the exception of battery and fuel. use a remote starter switch connected to the solenoid ( starter switch can be purchased cheap at most auto parts stores)red and yellow wire 18ga. on solenoid and battery pos. terminal, when switch is hooked up, crank engine and observe spark at each spark plug by installing one plug in spark plug wires one at a time. leave the other 5 wires grounded to block- stick them on head bolts- check each cyl this way , if spark is present on all cyl. then problem is related to boat wiring and key switchs or large harness connector perform contenuity tests on these componets, IF STILL NO SPARK then problem is on engine. this test will work on all mercury cd ignitions that are remote start and have no spark problem. this is the first test to do!!! if you find that you have no spark then search out dva and spark gap tester or a good tech. to determine faulty componet it will be cheaper than 1 wrongly replaced part and you still have to buy the right one. switch boxes should always be replaced in pairs!!!!! because of bias circut interaction.

 

[tonydl86]

Re: 1994 mercury 150 wont start

Again thanks for your replies. Merctech, I have zero exp.at this but I do have some knowledge in trouble shooting electrical and electronic stuff.<br /> There is no spark at all four of the spark p. wires checked with a spark tester, there is no voltage of any kind at all four green wires that go from the sw box to the coils while cranking. my engine has one swich box as described above, I started out by cheking for the posibility that the yell. and blk. wire going to my sw. box might be grounding the spark. So I first checked the emergency cutoff sw. and it was ok, when the sw. is in one pos. there is no ground at the sw. box blak-yell wire, throw the sw. and there is. Next the start swich is in the off position there is ground at the sw. box, turned on before cranking and the ground is lifted. If I understand this right the black and yellow wire ground the spark at the sw. box if the emergency sw. is thrown, or when I turn off my engine. one other thing that I did,which might not have been such a good idea, was to remove the black and yell. wire all together, and there was still no spark. Do you think that these tests would remove any doubt about the emergency and start swich and harness, or do you still recomend your procedure?<br />The best time of the year for Bass fishing in my area is fast approaching, so I may just have to pull my boat over to Alice or San Antonio Tx. to have it checked.

 

[clanton]

Re: 1994 mercury 150 wont start

How many cylinders does this motor have, and how many are you checking? If you disconnected the black yellow at the switch box this bypasses all switches and harness problems. How did the ohms test compare to the specs I posted?

 

[bret walters]

Re: 1994 mercury 150 wont start

just a little confused ? orginal post said merc 150? i gather from your second post this is a 4 clyinder engine? <br />testing is still the same, check stator output at the switchbox. you will need dva to get good results. switchbox is just that a box with electronic switches ( actually scr's )inside. it does not make any electricity, it only routes it. think of them like the cap on a distributer and the timer base ( thats the other componet under the flywheel. ) as the advance mechanisiam in the distributer.<br />when testing the stator output note your voltages.<br />if you get no voltage with the red and blue wires connected to switch test agin with wires off of the switchbox. correct voltage now means switch is bad replace it. if no voltage stator is bad/stator wires are shorted to ground. " CDI " makes a dva that will plug into fluke meters and works great.

 

[tonydl86]

Re: 1994 mercury 150 wont start

Clanton, as far as checking the ohms to the stator; I'm out of town now but will check it out on Saturday. Thanks for keeping me in mind. My Merc is a 1994 model with a streight 4 cylinders, and one switch box.

 

[clanton]

Re: 1994 mercury 150 wont start

The specs I posted above are for a V6 engine, and may be incorrect for your engine.<br /> The stator pn you posted is not listed in the Mercury manual I have. What color is the stator? If stator is red, the stator is probley bad. System may also have an adapter module between the stator and switch box, the adapter coild cause no fire to all cylinders.

 

[tonydl86]

Re: 1994 mercury 150 wont start

Hey Clanton; I can´t see any color on the stator, just aluminum like material. Ive seen other engines where you can see color not this one. The manual I have speaks of a short and a long rim stator and going by the drawings in the book it looks like mine is a short rim. I cant see the adapter you speak of, one of the diagrams in the manual also has that adapter. I guess its time to look further inside. I was on the road during last week like every week, I did´t get a chance to thank Kiwi mercman for the regulator input, and Merctech for yours, I have a strong feeling that my engine is going to be up and runing soon thanks to you guys !!!

 

[tonydl86]

Re: 1994 mercury 150 wont start

I´ve just been going over the past messages and I realized that I never clarified the fact that my engine is a 125 HP Merc. outboard. Someone prior to this forum told me that there was no such thing as a 125 HP that it must be a 150, hence my mistake. Also Clanton the number I posted 332-5772A7 is not for th stator, but for the swich box sorry about that.Do you have the the specs for a contiuity test for the stator of a 125 HP. 4 cyl. The number for the pack I got from MercuryMarine.com I think but I could not find the number for the stator.

 

[bret walters]

Re: 1994 mercury 150 wont start

mercury lists part number 389-9710a45 for your serial number. <br />stator voltage output needs to be checked on both the red and blue , and the red and blue with the white stripes. this test will confirm stator good or bad. you do need a "dva" to get correct readings. test once with these 4 wires connected to switch and then again with them disconnected from switch. if readings are correct with them off, switch is bad. Did you ever check for spark with the black and yellow wire disconnected at the switchbox, this is the stop circut, if it is grounded even slightly engine will not start?