95 mercury 45 jet loss of power on top end

Lankchevy

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Apr 8, 2014
Messages
7
Hello, new to the forum. Trying to figure out what's wrong with my boat. I recently traded for a 95 merc 2stroke 45 jet (60 power head). Ran decent the first time I took it out. I cleaned the carbs and it started running great. Took it out on the river a couple more times with no issues other than poor fuel mileage, but it's a jet so that's sort of expected. It had a high idle speed that I figured out was the linkage not allowing the throttle cam return far enough to allow the center carb that controls the other two, to return to a true idle. After fishing for a few hours I adjusted the linkage to allow a true idle. All I adjusted was the position of the roller wheel on the center carb. I went for a test run and got it up on plane with no problems. Ran it a half mile or so and let out. I went to get back up on plane and it almost broke over then lost power like I pulled it to half throttle but hadn't. The linkage hadn't slipped. I rebuilt the diaphragm pump and replaced the fuel like and hand pump from the tank to motor. I tested and had spark at all three plugs. I've drained the fuel from the tank and drained the carb bowls, with fresh fuel there is no change. I ohmed out the stator and found the readings barely out of spec on the high side, I am using a matco amp clamp meter but don't have a dva? The low speed stator is putting out 60v but the high speed coil is never getting out of the mV range while being ran in the water at as high of an rpm as the motor will run under load (feels like half throttle) I think the stator is my issue but I wanted to check with the people who know these motors before I order a $200+ part. As a background I have a Bachelors in automotive technology and am a diesel mechanic by trade. Thank you for your time.
 

carholme

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Sep 4, 2010
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4,845
Re: 95 mercury 45 jet loss of power on top end

What is the s/n of the power head?

Gerry
 

carholme

Rear Admiral
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Sep 4, 2010
Messages
4,845
Re: 95 mercury 45 jet loss of power on top end

That s/n comes up as:

MERCURY - ( 60 H.P. (1995 ))
Serial No: 0G184585 Model No: 1060372RD

Parts and Service Bulletin list for s/n 0G184585:

Search Results - Crowley Marine

The service manual you require is P/N: 90-817643R1

If you don't have this manual, see my message to you in Notifications at the top of this page. It will give you complete stator testing. Do you know if you have a 9 or 16 amp stator?

Gerry
 

Lankchevy

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Apr 8, 2014
Messages
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Re: 95 mercury 45 jet loss of power on top end

I don't know which stator it has. I know that it is black and does not have exposed coils. It also doesn't have any spots that look melted or heat damaged
 

carholme

Rear Admiral
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Sep 4, 2010
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Re: 95 mercury 45 jet loss of power on top end

Well the manual will show you the testing and how to identify the stator by p/n and if you have the manual, it is in Section 2B.

Gerry
 

Lankchevy

Cadet
Joined
Apr 8, 2014
Messages
7
Re: 95 mercury 45 jet loss of power on top end

Ok. My low speed stator is producing 60 volts at idle. The high speed stator is never making the meter get out of the mV range (auto ranging). I don't have a dva, those readings are just with my meter. I can't see why the low speed would register good voltage on the meter but high speed wouldn't. So I guess my high speed stator coil is fubar'ed. Will that typically cause my complaint? The engine only feeling like its capable of running at half throttle even tho it's at WOT?
 

carholme

Rear Admiral
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Sep 4, 2010
Messages
4,845
Re: 95 mercury 45 jet loss of power on top end

You haven't answered whether or not you have the manual. Do you have one and if so, have you conducted the ohms test of the stator?

Gerry
 

Lankchevy

Cadet
Joined
Apr 8, 2014
Messages
7
Re: 95 mercury 45 jet loss of power on top end

I have the seloc manual. The ignition coils in the stator ohm specs per Page 39 - Mercury Mariner outboard ignition test specs are 75-90 and it tests at 108. And 3250-3650 and it tests out at 3730. So like I said in the original post they test a little high. What are the common symptoms of the high speed stator coil being bad?
 

Lankchevy

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Joined
Apr 8, 2014
Messages
7
Re: 95 mercury 45 jet loss of power on top end

Ok here's an update. I went ahead and ordered a stator since it was out of spec and a trigger (figured if I was pulling the flywheel I might as well put a trigger in while I was there). I also replaced the voltage regulator since it had signs of internal corrosion. I ran it and it still had the same issue. So I ordered a switch box and replaced it. I also replace all the fuel lines and filter on the engine. I cleaned the jets in carbs. It actually ran a little worse, only about 7 mph compared to 28 before it lost power. The only things I hadn't replaced were the reeds and coils, as deep as I am now I figured why not, ordered a set of new coils and a set of Boysen reeds. Installed the reeds and coils. While I was replacing the coils the #1 plug wire was full of corrosion. I replaced the corroded end and test ran it today. It still has low power but it was able to get up to 19 mph. I've got a set of plug wires on the way for it now. I also set the ignition timing to specs per the service manual. Can anyone think of what may have happened to my other 10 mph worth of power? I've replaced pretty much every component on the engine other than rebuilding the power head.
 

mgjtkt

Seaman
Joined
Apr 19, 2010
Messages
63
Re: 95 mercury 45 jet loss of power on top end

I'm thinking trash in one of the main jets. I know you have cleaned the carbs but have you looked at them with a magnifying glass. Took me three times to figure it out!
 

Lankchevy

Cadet
Joined
Apr 8, 2014
Messages
7
Re: 95 mercury 45 jet loss of power on top end

I will recheck them. I just stick the hose on the can of carb cleaner on them and blast away, if it sprays through well then I take for granted they aren't restricted. I'll put them back apart in the morning. Anyone else got a guess?
 
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