No spark on my 95 60hp Merc/Tracker 2 stroke.

[AChotrod]

Just bought the boat, and the previous owner said there may be a problem with the kill switch as it wouldn't start sometimes but just play with the switch. Well I've had it out a few ties with no prob. Today I hit the water and....nothin. Wouldn't start so I start checking things out an there's no spark. I never touched the kill switch, but who knows maybe it jiggled loose. So I find the black and yellow wires disconnect them and try it, nothing. Try looping them and nothing, try switching them and nothing. So I don't think its the switch. No Spark at all on all 3 cylinders.

Where would you go from here? Please help me out Its snowing and I have a vendetta with some fish! :mad-new:

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Regulator? CDI? I dont want to throw parts at it but these are the 2 things that MIGHT cause this. Any way to check them?

Plugs are new and gapped wires look good to me. Actually the entire motor looks new.

 

[carholme]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

What is the engine s/n?

If you send me a PM with an email address, I can send you the service manual.

Gerry

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Thanks Gerry. I have a complete Service manual, and parts manual along with the org boat and engine manuals. I was hoping for some ideas on what the most common issues for a no spark conditions are.

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Ok I have been reading a bit. Should I have just disconnected the black/yellow wire from the switch box? I unhooked them from the actual kill switch and then tried looping them.

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Service manual says,
Intermittent, weak, or no spark output at all 3 spark plugs usually indicates a bad stator or switch box. Are these common problems?

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Well put in a new switch box and there is a tiny bit of spark but not much. Also tried disconnecting the black/yellow wire on the switch box same results. Tried a little starting fluid in the cylinders and it still wouldnt fire(although Im pretty sure it was getting fuel anyways). Checking the stator now.

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Now this is strange. I pulled out a plug to see if was getting spark and it was and the engine fired with 2 plugs still in. Put it back in with wire connected and didnt fire up. So I did the same thing with all 3 cylinders testing each and it fired every time I had 1 plug disconnected. So then I tried starting it with all 3 plugs in and one wire disconnected and it fired and stayed running when I put the wire back on. All the plugs are getting spark now.

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

That didnt last long. All the sudden there was no spark or very weak spark. Seems when it is getting spark and I disconnect one of the plugs the other 2 get enough spark to start the motor, but its intermittent. So leads me back to the stator, possibly trigger.


I did a compression check and all 3 cylinders are exactly the same and visually checked them out and they all look fine. All the wires look good all the fuses look good. The only thing I can see that looks strange is there is a little tarnish looking stains under the regulator.

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

Ok I went a head and ordered a new CDI stator, trigger and regulator. Just want to make sure everything is new and not have to worry about it down the road.

 

[AChotrod]

Re: No spark on my 95 60hp Merc/Tracker 2 stroke.

It was the stator. I changed out the switch box, trigger, regulator, plugs and while it hardly improved it to the point you could at least see spark the new stator lit the fire and she runs great now and has a brand new ignition. Should be good for years to come.