1978 Merc 20hp Thunderbolt Ignition - NO SPARK

Olde Merc

Seaman
Joined
Jul 30, 2002
Messages
65
I have a 1978 Mecr 200 20hp motor with the thunderbolt igntion. I went to go fishing this morning and the thing wouldn't start on me. Ever since I took it out this year it has been starting hard compared to before (it used to be one or two pulls). <br /><br />After messing around with the motor all morning, I found a broken wire at the kill switch, and the ground wire at the "black box" (ignition module?) had a break in the insulation. I replaced the two wires, hoping that they were the problem, but the engine still won't start. <br /><br />The engine has new plugs; the proper NGK gapless units from the dealer. It's getting plenty of fuel, so I know it's not a fuel problem. <br /><br />Any suggestions on what to check next? I would test the coils and the "black box", but I don't know how to as I don't have a service manual. <br /><br />Any help would be greatly appreciated.
 

Olde Merc

Seaman
Joined
Jul 30, 2002
Messages
65
Re: 1978 Merc 20hp Thunderbolt Ignition - NO SPARK

Thanks for the reply, but that site didn't have too much info in regards to my motor. However, I did find out that the switch box (what I was calling the black box) part number on my motor is for a 75-76 Merc 20hp. So, perhaps my motor is actually a '76, which is what I thought the previous owner said, but someone decoded the serial number and said it was a '78. <br /><br />Anyway, I still don't know how to test the coils, the switch box and the stator. Does anyone know how to check the ignition components so I can find the reason I have no spark?
 

12Footer

Fleet Admiral
Joined
Mar 25, 2001
Messages
8,217
Re: 1978 Merc 20hp Thunderbolt Ignition - NO SPARK

there is a black wire with a yellow stripe on it, going to the switchbox, pull it loose and tape it off for testing. Let it float in the air, and see if spark returns. If so, the kill circuit still has a short to ground somewhere.<br />About this vintage and earlier, the wire could also be orange. if grounded, your ignition is in "OFF" posistion.
 
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