Mercruiser Thundervolt IV... NO SPARK

cmuller711

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Aug 7, 2011
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To start, Boat: 1990 Maxum 4.3 Merc with Thundervolt IV Ign. Problem:This has me baffled, the boat runs great for 35 mins first time out and about 3 hours second time out before cutting out as I am shifting into neutral. First time I didn't get a chance to check it on the water but when I got home I plugged on a spark tester ( I always check fuel and spark before diggin in) and it started right up on the muffs, thought it might have gotten flooded out or the coil wire was loose on dist cap.
Today I took it out and ran it for about 3 hours no prob stop start off and on. Then when shifting to neutral it cut out. First I check spark from coil to dist. cap... no spark. so I checked + to coil in run-good. Then checked wht/grn while cranking-it blinked. So I checked spark at coil again-spark. So I double checked my connections and ran it for another couple hours. Then while shifting into neutral ( I repeat this thinking maybe there is something I am missing in the neutral safety switch, yet it still cranks so that shouldn't be it. right?) it cuts out. I first check the spark from the coil-no spark. Check the positive coil terminal- has juice. check the wht/grn wire while cranking-this time it didn't blink (Ignition sensor bad?) I waved over for a tow and heavens shined the man had a spare ignition coil (he thought his was bad... it wasn't) so I hooked up his new coil and tried it out-No start.-Get towed in :mad:
I go home to try and troubleshoot more. After a hour or so it starts right up. What the heck? I probably need to check the insulators on the module the is screwed to the riser for any deterioration that might be overheating the module. Would that cause the sequence of events?? The only way I can trouble shoot is go drive around until it cuts out. What about the shifting into neutral, am I missing something? Any help would be gracious I just want to enjoy whats left of the summer

Sorry it is so long but I hope it helps diagnose the gremlin. Thanks to all
 

cmuller711

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Re: Mercruiser Thundervolt IV... NO SPARK

After reading my own post I have another thought... Shift interrupt switch? with it only happening when shifting into neutral I would think that is the problem, however what indicators should I be getting when I test the coil and terminals on the coil as well as the red/wht wire on the dist.? It grounds out the coil correct? Is the grey wire the shift interrupt switch line in? I need to get my manual back from the last borrower.
 

franktrav

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Jul 30, 2010
Messages
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Re: Mercruiser Thundervolt IV... NO SPARK

sounds like the shift interrupt switch is shuttin you down....yeah,,it grounds yer coil n kills yer spark
probably yer lower shift cable getn sloppy n keepin the switch on is my guess
goodluck
 

cmuller711

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Re: Mercruiser Thundervolt IV... NO SPARK

Update for anyone who read this: Took the boat out yesterday to try and get it to quit again, it took two hours of driving but finally. First checked again NO Spark. Unscrewed wht/grn wire from shift interrupt switch: started up. Problem found! Now I need to solve it by adjusting the switch and or cable. I still haven't gotten my manual back so does anyone have any advice on adjustments?
 

Don S

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saintlee

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Apr 25, 2011
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Re: Mercruiser Thundervolt IV... NO SPARK

i had a 1989 searay with the 4.3 Thundervolt IV Ign.
had similar problems
my bushings on the shift-shaft were binding
i replaced them and problem solved
hope this helps/good luck
 

cmuller711

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Aug 7, 2011
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Re: Mercruiser Thundervolt IV... NO SPARK

Thanks Don, I figured it was more than likely the shift cable after looking(and pondering) at it more. It wasn't doing this before I replaced the gimbal bearing, so I thought when I re-attached the shift cable and adjusted it I didn't align it properly. It could also be a corroded shift cable. Thanks again, I will look into it more tonight.
 

LX Kid

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