Mercruiser IV intermittent stalling when warm issue found

Robert D

Petty Officer 1st Class
Joined
Feb 21, 2009
Messages
338
Posting this as an example when faced with an engine that runs fine, until it warms up.....then stalls, difficult to start or no start until it cools down. The wire pictured below was encased in wire wrap, basically black electrical tape, all the way up to 1" before the end. I removed the harness wrap on the entire engine harness looking for an electrical defect, and found this wire burned. The wire itself was still attached, but apparently when it got hot enough, the electrical current went elsewhere. This is the purple wire carrying voltage to the coil, which comes off the purple alternator wire. Back side of coil had evidence of overheating, possible oil leaking out the top of it. Replaced coil and this wire, problem solved. Hours involved searching for the culprit.

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Bill Hancock

Cadet
Joined
Sep 20, 2001
Messages
17
Re: Mercruiser IV intermittent stalling when warm issue found

Really appreciate this post!
Thanks a lot.
 

smykowski

Cadet
Joined
Apr 22, 2013
Messages
14
Re: Mercruiser IV intermittent stalling when warm issue found

Great post, people often overlook electrical when it is one of, if not THE most, critical systems in your boat. Sketchy grounds or burnt up wires wrapped in electrical tape will cause headaches for weeks trying to find an "intermittent" issue. Well done!
 

Robert D

Petty Officer 1st Class
Joined
Feb 21, 2009
Messages
338
Re: Mercruiser IV intermittent stalling when warm issue found

An update....as it's raining this week.....I went through every single ring and spade connector on the boat, crimping & soldering new stainless steel ends on, and double heat shrink tubing over the solder. I would estimate that 10% of the original connections were 'questionable.' Basically just crimped on, but a few of the connectors were one or two bends away from breaking. Most were brass connectors that had corroded pretty good, so I went with stainless steel. Behind the dash was the worst for some reason. (Vintage 1972 Chris Craft.) Replaced all the wires & connectors as well, and installed a marine fuse panel on the bulkhead with standard ATC fuses. (The factory switches each have a glass fuse with a screwed on cap next to the switch. 4 of them cracked to pieces just getting the fuse out!) Fuse holders are still there, just not connected anymore. 100% cleaner under/behind the dash now. I do give Chris Craft 'extra credit' for quality work. Every fastener on the boat that I've messed with is brass or stainless steel. It seems the items that have worn are usually plastics that have become brittle with age, such as the original fuse holders. Same vintage as an old Reinell I used to own, and the Reinell was full of cheap nuts and bolts that would simply snap if you tried to remove them. This boat is much more enjoyable to work on!
 

achris

More fish than mountain goat
Joined
May 19, 2004
Messages
27,468
Re: Mercruiser IV intermittent stalling when warm issue found

Nice work... Finding intermittent electricals in my migraine trigger... I usually bung 30 or 40 amps down the wire and see where is fries... :D :D
 

makonnen

Petty Officer 2nd Class
Joined
Apr 4, 2012
Messages
184
Re: Mercruiser IV intermittent stalling when warm issue found

Thanks for sharing!

I'll do the same to my boat.
 
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