1980 Mercury 40 hp Key switch?

[hi salenity]

Re: 1980 Mercury 40 hp Key switch?

AHHHA! I knew that black wire did not go on the orange wire, It goes from the coil ground to the SB ground. That is one thing that is wrong. Thank you Laddies.

I have the Comander 2000 controlls it is a 8 wire plug NOT the 6 wire in the diagram. On my controlls it has a Black/Yellow wire that is the "kill" wire this wire is only a ground if the key is off just like the Orange wire C in the diagram.

The ground going from the SB to the coil is Black.

 

[Lone Duck]

Re: 1980 Mercury 40 hp Key switch?

I have the Comander 2000 controlls it is a 8 wire plug NOT the 6 wire in the diagram. On my controlls it has a Black/Yellow wire that is the "kill" wire this wire is only a ground if the key is off just like the Orange wire C in the diagram.

__(The ground going from the SB to the coil is Black.)_

That is what I am saying. In pictures # 36 I see the pic of SB ,to the left of that pic. You have red to red ,blue to blue,orange to black, white to white , brown to brown. If that black wire on the orange goes to the coil ground. Then it should be hooked to the SB ground. Not the orange wire. Check diagram (C) Also until you get that engine running , I would leave the control cable disconnected. Who knows what the previous owner has done? If I am wrong , then I sincerely apologize .

 

[hi salenity]

Re: 1980 Mercury 40 hp Key switch?

That is what I am saying. In pictures # 36 I see the pic of SB ,to the left of that pic. You have red to red ,blue to blue,orange to black, white to white , brown to brown. If that black wire on the orange goes to the coil ground. Then it should be hooked to the SB ground. Not the orange wire. Check diagram (C) Also until you get that engine running , I would leave the control cable disconnected. Who knows what the previous owner has done? If I am wrong , then I sincerely apologize .

The wire I have my finger on is the ground from the box to the coil.

The B/Y wire is routed under the switch box and goes to the 8 pin harness.

 

[Lone Duck]

Re: 1980 Mercury 40 hp Key switch?

The wire I have my finger on is the ground from the box to the coil.

The B/Y wire is routed under the switch box and goes to the 8 pin harness.

Thank you!

 

[Maxz695]

Re: 1980 Mercury 40 hp Key switch?

View attachment 180765 My switchbox 332 4911 does not have that black yellow wire and it should not be hooked with the salmon wire. The only other wire that hooks to the salmon terminal is the tilt kill switch located here on the engine. View attachment 180766 Disconnect the black yellow wire from the salmon terminal.Retest. Correction yes it does belong there I changed out the wire and didn,t notice it disregaurd. I wish I still had the parts to give you ohm readings to compare but they have al been sold. You can make a DVA fairly shep and someone may give you the instruction on how to do it. I would try disconnecting the black yellow key kill wire to test anyway as you said you had a spark at one point. also if the Key kill wire is running under th switchbox as it appears to be in the picture it may be grounding it out preventing spark Just a thought

 

[hi salenity]

Re: 1980 Mercury 40 hp Key switch?

View attachment 180765 My switchbox 332 4911 does not have that black yellow wire and it should not be hooked with the salmon wire. The only other wire that hooks to the salmon terminal is the tilt kill switch located here on the engine. View attachment 180766 Disconnect the black yellow wire from the salmon terminal.Retest. Correction yes it does belong there I changed out the wire and didn,t notice it disregaurd

My switchbox is the same # as yours and the B/Y wire is routed UNDER the box.


Guys I do have the harness unhooked and the B/Y KILL WIRE unhooked from the Orange wire wen I try to start it.
I'm sure that is not the problem I am either going to get a DVA tester or take it to BPS

 

[Maxz695]

Re: 1980 Mercury 40 hp Key switch?

You can unhook the stator and with the ohm meter on 1 K hook the red lead to the red and the black lead to the ground. Turn the flywheel and see if it moves the needle indicating some output and do the same for the blue wire.

 

[hi salenity]

Re: 1980 Mercury 40 hp Key switch?

You can unhook the stator and with the ohm meter on 1 K hook the red lead to the red and the black lead to the ground. Turn the flywheel and see if it moves the needle indicating some output and do the same for the blue wire.

Cool, I'll report back my findings... Do I need to unhook the Yellow wires also?
I also am going to try to see if I get anything going to and coming fron the trigger wile turning over. Can I just test the trigger for 12v?

 

[Maxz695]

Re: 1980 Mercury 40 hp Key switch?

remove the plugs to make it easier to turn. You might not have to even unhook it but to be sure it is best. If the reading show movement the stator is putting at least something out and should through spark. If you don,t get a reading swap the metter leads and try again. It,s been a while scince i,ve done it. I would suppose yes the trigger out would also show some indication of current being sent if connected but i,m not positive. GL No testing the trigger for 12 V probably won,t work. I don,t know the voltage for the trigger signal. But the ohm meter should pick something up when attached when the trigger aligns for the signal. JMO not a fact.

 

[hi salenity]

Re: 1980 Mercury 40 hp Key switch?

We narrowed it to the switch box so we put the old box back on it and scabbed new wires back on it and it now has spark!!!!! YAY. I have ordered a new box so I should be good to go.


THANKS to all

 

[Maxz695]

Re: 1980 Mercury 40 hp Key switch?

Great to hear that I would have suggested it was but I wouldn,t want you to pay for the unessecary things if I was wrong. Great job in being patient and learning much more about that engine. The work accomplishments and failures are worth there weight in gold. You can take total comfort in knowing the flywheel is not now rubbing the stator and you can replace it without causing damage to it. The reward of trial and error as well as your accomplishment is worth it,s weight in gold. If you choose to re read the entire post from the begining of your original post you should see the posts much differently, and may give more insite on what was reviewed how it was described and the hesitancy not to jump to conclusions as Proper testing on this site is 100% advised and a poster suggesting to replace a part without proper testing get reemed by the crew.

 

[Lone Duck]

Re: 1980 Mercury 40 hp Key switch?

We narrowed it to the switch box so we put the old box back on it and scabbed new wires back on it and it now has spark!!!!! YAY. I have ordered a new box so I should be good to go.


THANKS to all

That is great!! I was wrong and you proved it. So you went to other possibilities . Isn't diagnostics fun?

 

[hi salenity]

Re: 1980 Mercury 40 hp Key switch?

After the new switch box. Thanks to ALL!

 

[CrossCurrent50]

Re: 1980 Mercury 40 hp Key switch?

Your welcome Scincerely Maxz695. Account deleted with well over 2000 posts helping others. All my loose ends are now cleared up. Happy to hear your engine is now running properly. I am OFFICIALLY retired as of now from I Boating. Thank You for posting your success. I have some boating and fishing of my own to do. Happy Boating everyone.