1990 25 HP Mercury Outboard Problems

vibroluxe

Cadet
Joined
Aug 2, 2010
Messages
13
Have a 1990 25 HP Mercury that I was getting ready for my 13 foot Boston Whaler. Had the carb rebuilt, did the annual maintenance and it seemed to be fine out of the water. Revved up nicely using the fast idle lever.

I put it in the water and took out for a test spin. It was OK in the lower revs but bogged down terribly when I applied any throttle. No power, couldn?t even get it up on plane. Checked the tank and fuel bowl for air intrusion and couldn't find any. Even borrowed a known good working gas tank from a friend but nothing changed.

At some point I thought maybe the best thing would be to get some professional help so I brought it into the shop for the mechanics to take a look at. They saw the same performance I did. So they did some basics like adjusted the timing, idle speed etc and all of a sudden it started running fine! But - the mechanic wasn't so sure that it wasn't an underlying intermittent electrical problem that caused the problem(stator, trigger, switch box). He said run the heck out of it and see how it did, bring it back if it started behaving badly again.

So I ran it home and it seemed to run great. Started right up, got up on plane and ran like a top. Excited to take the kids out for a spin, I got them out on the boat and went to start it up and it cranked but wouldn?t start. Checked for spark and got nothing to either cylinder.

I checked the various components with my ohm meter and got the following:

Trigger ? 750 ohms (acceptable range 650-850). Seems to be OK

Stator ?
B/W wire to ground ? 48 (acceptable range 120-180)
B/Y wire to ground ? 2649 (acceptable range 3200-3800)
B/W wire to B/Y wire ? 2581 (acceptable range 3100-3700)

Unless I?m reading something wrong in the service manual, the stator seems to need replacing. Values are not in the range they should be, but it is not a totally open circuit. (would a bad ground give false readings?)

Think I?m on the right path with the bad stator?

Thanks for the help guys? John
 

jackd1023

Petty Officer 1st Class
Joined
Aug 15, 2006
Messages
269
Re: 1990 25 HP Mercury Outboard Problems

Sounds like low side of the stator, I would pick up a DVA and Check it first.

This forum has the paramaters, just do a search,

Either the switchbox or the stator.
 

vibroluxe

Cadet
Joined
Aug 2, 2010
Messages
13
Re: 1990 25 HP Mercury Outboard Problems

OK, makes sense - but - I don't have a DVA.

I do have a multimeter that has a 400 volt DC range. Can I use it?

If so, what is the process? Which leads etc, try to start the motor to get the voltage?

Computer guy, not an outboard tech :redface:

Thanks for the help! John
 

vibroluxe

Cadet
Joined
Aug 2, 2010
Messages
13
Re: 1990 25 HP Mercury Outboard Problems

Argh! Don't know if I should celebrate or scream! Went out there to see if I could get any voltage readings off the stator. So I hooked up the leads the way I thought they should go according to the test info and cranked the motor. Don't you know it started right up!?!? Started it about 10 more times without a problem and decided to take it out. Ran like a top with plenty of power. Driving me nuts...

So I think I'll go through it and clean all the connections and check all the grounds.

I think I'm happy but - don't feel real confident that it won't happen again when I'm out in the bay somewhere...
 
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