Low speed coil or switch box?

cdeverocks7

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Nov 22, 2011
Messages
14
I've got a 1992 Mariner Thirty. It's a 2-stroke 30hp manual start motor running on pre-mix (no oil injection system on this motor). The engine fires right up and runs great but then dies after about 5-6 seconds. When I say dies it doesn't sputter it falls flat on it's face like someone hit the kill switch. However, if the motor is put in gear and started, quickly ran up into higher rpm range again it runs great with excellent throttle response etc. Once the throttle is brought back down to the lower rpm range the engine wants to fall on it's face again. If quickly revved back up it will come back to life but when brought back down it will die just like the kill switch was hit. I've been diagnosing this problem on my own cause I don't have a ton of money to pay a repair shop for diagnosing it and to buy parts.

So far I've rebuilt the fuel line from inside the tank to the motor including new filters, lines, bulb, fittings, etc. I've taken the carb off and apart and cleaned it (twice) and reset the float. I've replaced the spark plugs and taken the magneto off the top of the motor to inspect the stator and it's coils for any signs of damage to which there is no visual sign. The magneto and stator both look great. The CDI box also has no visual signs of damage aka heat damage or signs of electrical overheating.

I've been told by a local outboard mechanic that the problem is most likely my low speed coil and by another that the problem is probably the switch box. I can't buy a new stator but I can buy each individual coil. The stator has a lighting coil, ignition coil and pulser coil. Any idea which of these would translate to the low speed coil? Or would the problem more likely be in the CDI or "switch box"?

I'm stumped because I believe I've eliminated fuel as an issue and it gets spark to start the motor and run at high rpm's but it just falls on it face when you try to get an idle out of the engine.

Am I missing something?
 

cdeverocks7

Cadet
Joined
Nov 22, 2011
Messages
14
Re: Low speed coil or switch box?

I should mention my Mariner is a Japanese built Mariner with a Yamaha powerhead....s/n 689-536303
 

Laddies

Banned
Joined
Sep 10, 2004
Messages
12,218
Re: Low speed coil or switch box?

Start by checking the trigger wires for chaffing then disconnect the kill circurt on the engine ans test run it. many problems are caused by bad wires and switches
 

cdeverocks7

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Joined
Nov 22, 2011
Messages
14
Re: Low speed coil or switch box?

Start by checking the trigger wires for chaffing then disconnect the kill circurt on the engine ans test run it. many problems are caused by bad wires and switches

Laddies,
Thanks for the idea. To clarify do you mean disconnect the kill switch wires from the switch box and then try and run the motor?
 

cdeverocks7

Cadet
Joined
Nov 22, 2011
Messages
14
Re: Low speed coil or switch box?

Start by checking the trigger wires for chaffing then disconnect the kill circurt on the engine ans test run it. many problems are caused by bad wires and switches

Also the trigger is the Pulser coil, right?
 

cdeverocks7

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Joined
Nov 22, 2011
Messages
14
Re: Low speed coil or switch box?

ok. finally got time to work on the boat. pulled the magneto and inspected all the wires on all 3 coils. all wires look good, no visual damage or chaffing, no discoloration of the wires or the coils. put everything back together, disconnected the kill wires, test ran engine, same problem.
so i'm back to leaning towards a bad cdi (switch box) or bad coil (pulser) on stator. what does the ignition coil on the stator do? should i include this in my list of suspicion?

list of parts is as follows:
cdi= $180
Pulser coil= $54
Ignition coil (on stator)= $72

If i had the money i'd buy all 3 and be done with it but my luck would most likely be that even if i did buy all 3 it would end up being something else.
any thoughts?
obviously a good mechanic with proper spark testing equipment would be key here but.....i've already tried a mobile repair outfit and i had to tell them to leave. within 5 minutes...the guy couldn't figure out how to start the engine (manual pull...easy as it gets) and then managed to break my fuel pump. the only good that came of it is he had to get me a new fuel pump so i ruled that out of the equation. local boat shops won't work on it cause "it's too old"? it's only a '92.
at this point i'm about ready to start throwing some money at parts where should i start? cdi box?
 

cdeverocks7

Cadet
Joined
Nov 22, 2011
Messages
14
Re: Low speed coil or switch box?

ok. finally got time to work on the boat. pulled the magneto and inspected all the wires on all 3 coils. all wires look good, no visual damage or chaffing, no discoloration of the wires or the coils. put everything back together, disconnected the kill wires, test ran engine, same problem.
so i'm back to leaning towards a bad cdi (switch box) or bad coil (pulser) on stator. what does the ignition coil on the stator do? should i include this in my list of suspicion?

list of parts is as follows:
cdi= $180
Pulser coil= $54
Ignition coil (on stator)= $72

If i had the money i'd buy all 3 and be done with it but my luck would most likely be that even if i did buy all 3 it would end up being something else.
any thoughts?
obviously a good mechanic with proper spark testing equipment would be key here but.....i've already tried a mobile repair outfit and i had to tell them to leave. within 5 minutes...the guy couldn't figure out how to start the engine (manual pull...easy as it gets) and then managed to break my fuel pump. the only good that came of it is he had to get me a new fuel pump so i ruled that out of the equation. local boat shops won't work on it cause "it's too old"? it's only a '92.
at this point i'm about ready to start throwing some money at parts where should i start? cdi box?
 

oldman570

Lieutenant Commander
Joined
Mar 25, 2011
Messages
1,615
Re: Low speed coil or switch box?

The thing I would do is get a service manual for the motor. They often tell how to test almost every componet of the electrical system, and can be bought fairly cheap. Makes for a good investment if you plan on keeping the motor,and will save you $$ in the long run.
 

hereto

Seaman
Joined
Sep 25, 2009
Messages
60
Re: Low speed coil or switch box?

For what its worth, I had the exact problem with my 85hp Merc. Picked up a used switch box off Ebay for about $45 and she runs great now.
 

cdeverocks7

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Joined
Nov 22, 2011
Messages
14
Re: Low speed coil or switch box?

after another inspection this morning i found the wire leads at the switch box look like they have some damage. it almost appears they got too hot or have signs of electrical burn. the white/red wire is the pulser coil lead too. i'm really leaning towards the switch box i beleive now.
opinions?
 

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CharlieB

Vice Admiral
Joined
Apr 10, 2007
Messages
5,617
Re: Low speed coil or switch box?

Grab an inductive timing light and watch the flash, idle the motor and see if the flash dies, killing the motor.

Repeat on each cyl.

You can build your own DVA adaptor to use with any volt meter and test the charge coils a lot cheaper than replacing any parts.

http://forums.iboats.com/showthread.php?t=374544
 
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