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WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

DVA

Black/Yellow

Engine GND

3250-3650

2200-2400

180V or more

Black/White

Engine GND

150-250

200-250

25V or more

Brown/Yellow

Brown/White

750-1400

925-1050

4V or more

Brown/Yellow

Engine GND

Open

Open

1V or more

Brown/White

Engine GND

Open

Open

1V or more

Mercury

Two Cylinder Engines 1979-1996 (With the 332-7452 Switch Box) NO SPARK ON ANY CYLINDER:

  • 1.

    Disconnect the Black/Yellow stop wire and retest. If the ignition system now has spark, the stop circuit has a problem.

  • 2.

    Check the stator and trigger resistance and DVA output:

3.

Connect a inductive tach to each cylinder and compare the RPM readings at the RPM where the problem is occurring. If only one cylinder is dropping out, swap the ignition coil locations and retest. If the problem follows a coil, replace the coil.

4.

If it stays on the same spark plug, replace the switch box. Check the flywheel magnets to see if one has come loose and moved.

NO SPARK OR INTERMITTENT ON ONE CYLINDER:

1.

Check the DVA output on the green wires from the switch box while connected to the ignition coils. Check the reading on the switch box terminal AND on the ignition coil terminal. You should have a reading of at least 150V or more at both places. If the reading is low on one cylinder, disconnect the green wire from the ignition coil for that cylinder and reconnect it to a load resistor. Retest. If the reading is now good, the ignition coil is likely bad. A continued low reading indicates a

2.

bad switch box. Check the trigger resistance and DVA output as shown below:

WILL NOT ACCELERATE BEYOUND 3000-4000 RPM:

1.

2.

3.

(*) This reading can be used to determine if a pack has a problem in the triggering circuit. For instance, if you have no fire on one cylinder and the DVA trigger reading for that cylinder is low – disconnect the trigger wire and recheck the DVA output to ground from the trigger wire. If the reading stays low – the trigger is bad.

Wire Color

Check To (Wire Color)

Resistance

DVA Reading

Brown wire

White wire

800-1400 4V or more Connected

Brown wire

Engine GND

Open

1V or more (*)

White wire

Engine GND

Open

1V or more (*)

Check the stator resistance and DVA output:

Connect a DVA meter to the Black/White wire/terminal and while under load, run the engine up to the RPM where the problem is occurring. The stator high speed voltage should increase with RPM. If the stator voltage falls off or if it does not increase with RPM, replace the stator. Connect an inductive tach to each cylinder and compare the RPM readings at the RPM where the problem is occurring. If only one cylinder is dropping out, swap the ignition coil locations and retest. If the problem follows a coil, replace the coil. If it stays on the same spark plug, replace the switch box. If both cylinders become intermittent, replace the switch box.

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

DVA

Black/Yellow

Engine GND

3250-3650

2200-2400

180V or more

Black/White

Engine GND

150-250

200-250

25V or more

Two Cylinder Engines 1994-1996 (With the 18495A4, A5, A6, A8, A11 or A13 Switch Box)

NO SPARK ON ANY CYLINDER:

1.

Disconnect the black/yellow stop wire AT THE PACK and retest. If the engine’s ignition now has spark now, the stop circuit has a fault-possibly the key switch, harness or shift switch.

  • 2.

    Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.

  • 3.

    Check the stator resistance and DVA output as given below:

WIRE

Read To

OEM RESISTANCE

Blue

Blue/White

3250-3650

Red

Red/White

75-90

Black Stator

CDI RESISTANCE 500-600 28-32

DVA 180V or more 25V or more

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

White/Green

Green/White

500-700

500-600

WIRE Blue

Red Stator

Red Stator Adapter (Not Available from CDI)

Read To Engine GND

OEM RESISTANCE OPEN

DVA 180V or more

DVA 180V or more

49

Mercury Troubleshooting

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