1997 9.9 Merc 2 stroke, no spark either cyllinder

oldcatamount

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There is no spark at either cylinder. I have disconnected the black/yellow kill wires at the switch box and still no spark. I have searched this Forum and learned that the switch box is the likely cause but I'd like to be sure of that before I continue. Is there a way to test the switch box?
 

carholme

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

If you post your s/n and PM me with an email address, I will send you a copy of the service manual which will give you the procedures.

Gerry
 

MH Hawker

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

This is a general description of the system

The ignition system is an alternator driven capacitor discharge system. Major components
of the ignition system are the flywheel, stator, trigger coil, switch box, 2 ignition coils and 2
spark plugs.
The flywheel has permanent magnets mounted in both the outer rim and the center hub.
The BLACK stator assembly is mounted below the flywheel and has a low speed (LS) and
a high speed (HS) capacitor charging coil. Low speed coil provides primary voltage to the
switch box from idle to approximately 2500 RPM. The high speed coil provides primary voltage
from 2000 RPM to the maximum RPM the outboard is capable of achieving.
The RED stator assembly is mounted below the flywheel and has only one capacitor charging
coil.
As the flywheel rotates, the magnets mounted in the flywheel outer rim pass the charging
coils creating voltage. This voltage is rectified to DC and charges the capacitor located in
the switch box.
As the flywheel continues to rotate, the magnets in the center hub pass the trigger coil creating
voltage pulses. These pulses turn on one of the two electronic switches (SCR) in the
switch box. A positive voltage pulse turns on the SCR switch associated with cylinder #1;
a negative voltage pulse turns on the SCR switch associated with cylinder #2.
The SCR switch discharges the stored capacitor voltage into the primary side of the respective
ignition coil. The ignition coil multiplies this voltage to a value high enough to jump the
spark plug gap ? 34000 volts for standard coils; 40000 volts for high energy coils.
This sequence occurs once per engine revolution for each cylinder.
Spark timing is changed (advanced/retarded) by rotating the trigger coil on mechanically
advanced models which changes the trigger coil position in relation to the magnets in the
center hub of the flywheel.
Spark timing on electronically advanced models is controlled internally by the switch box
with a fixed trigger.
The stop switch (or ignition switch) shorts the output of the stator to ground to stop the engine
on all models.
 
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oldcatamount

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

Thank you. These posts are helpful. I will post the results as soon as I can.
 

25xs

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

If it helps, the switchbox is super easy to swap out from a running engine, and the same switchbox is used on ALL these horsepower engines from similar model years: 6/8/9.9/10/15/18/20/25hp (basically, if it 'looks' the same, it will work for a quick test for spark)
Part No. 339-7452A19 is the switchbox you are seeking...

See if a dealer or a friend at the marina or boatramp will let you swap it for testing... EXTREMELY unlikey that any damage can be done to their "good part" by this simple test. You're just hooking it up with a good ground and all the wire/bullet connectors and roping it over a couple times to check for spark.
 

Hoosmatroos

Petty Officer 1st Class
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Jul 11, 2011
Messages
250
Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

The switch box is an easy replacement but you should test the voltage coming out of the stator first. You can do this with a simple multi meter. Check this out and follow the procedure to find your problem. Already put the link to the wright page ;)

Boatinfo - Mercury Service Manual for 6-8-9,9-10-15 hp
 

MH Hawker

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

And their is a black and a red ignition system
 

oldcatamount

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

Turns out it was a bad stator. The old stator looked like it was starting to melt however, it still tested ok. The low speed coil was obviously getting hot so I replaced it and also the switch box. Motor runs better than ever. Also, the motor had Champion plugs gapped at .030. I put in the correct plugs NGK gapped at .060. I wonder if the wrong plugs could have cooked the low speed coil?
 

MH Hawker

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

I wouldnt think so as long as they were the correct cross overs. When I bought mine 3 years ago the high speed was out in the CDI box . Its just one of those things. I had problems finding the NGK ones and ordered 12 off of flea bay.
 
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oldcatamount

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Re: 1997 9.9 Merc 2 stroke, no spark either cyllinder

They told me at the Auto Parts store they didn't have the Ngk's and there was no crossover for NGKBP8HS-15, so I went to a Marina and got them there. The plugs that were in the motor were Champion L78C.
 
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