1993 90hp intermittantly dies

[nathan619]

Re: 1993 90hp intermittantly dies

The part number on my switchbox is 332-7778a10. CDI states their product to replace it is 114-7778R2 which has an extra terminal with a nut on it and also has a couple of wires running from it that I don't have and also I read where you shouldn't mix RACE components and the "114-7778R2" is a RACE part.

The 114-7778 looks right, except for that wire coming from it and the extra terminal with the nut on it, but I can't find where it's equal to a 332-7778A10 that I have.

What do I order? I'm real confused.

My box has 6 zig zag terminals and 4 vertical terminals and that's all.

IBoats has them. I'm guessing, but I'm pretty sure this one matches the one you've got. Take a close look at the pictures to make sure they match yours. Your serial number looks to be in the 1991 range, but the model number indicates like you say, 1993. I've seen a lot of mistakes in the documentation on line and in manuals regarding S/N and year of manufacture. The type of ignition setup you have looks to be a 1991 though, if it has the threaded posts.

CDI P/N 114-7778, Sierra Ign. P/N 18-5775, Mallory Ign. P/N 9-25100.

Force Switch Boxes - iboats

Here's one. Used, but with a guarantee.

Switchbox 90 HP Force 908F92C Outboard Powerpack Ignition Control Module | eBay

Here's another one. P/N 114-7778. Cost a little more, but brand new.

Chrysler or Force CD Ignition

 

[pnwboat]

Re: 1993 90hp intermittantly dies

That extra wire on the 114-7778 is just a ground wire. I believe that this replacement version of the switchbox has a plastic case. The original version has a metal case and relied on the ground connection created when the switchbox case is bolted to the mounting plate. The ground wire just gets attached to the metal plate with a screw (any screw that's convenient) that the switchbox is mounted on. If you look at the PDF installation instructions on the CDI site for P/N 114-7778, top section labeled "Installation" step 5, it says to attach the black wire to engine ground. Clean off any paint under the attachment point to insure a good ground connection.

The 114-7778 is the one you need, or the equivalent one from Sierra or Mallory. The CDI parts have a reputation for being very reliable.

Just thought of one other thing. Make sure the magnets underneath the inner circumference of the fly wheel are intact and not broken or missing. There should be six of them.

 

[nathan619]

Re: 1993 90hp intermittantly dies

Ok. I ordered the 114-7778. Thanks.

They were trying to get me to order the 7778A12 since it suppose to go with my motor's model number. The serial number really throws me off.

Right now my minds mush from trying to figure this out and going back and forth.

 

[pnwboat]

Re: 1993 90hp intermittantly dies

Yeah, if you try and use just the serial number or just the model number, sometimes you don't get what you need.

These motors have been out of production for some time and the parts listings and S/N and model numbers don't match up correctly. Especially if your motor is in the date range where they changed the ignition system.

Also you never know what some previous owner has modified or changed so it is no longer like it came from the factory. Then you have to go by pictures and or diagrams. But even then you have to be sure the picture or diagram represents the actual part. Sometimes they post a generic version and it looks nothing like the part.

I edited my post above and mentioned checking the magnets under the flywheel. Make sure they are in place. Not very likely they are broken or anything based on what you're experiencing.

 

[nathan619]

Re: 1993 90hp intermittantly dies

I took the switch box off to change it out and on the back it had 332-7778. I got the 114-7778 in hand. I figured I couldn't send it back anyhow so I put it on. The motor started right up and I ran it for about 10 minutes and I shut it off. It seem good.

Should I be concerned about the switch box number being wrong? The paperwork that came with the part said it (114-7778) replaces 332-5524, 332-7778a1, 332-7778a3, 332-7778a5, 332-7778a6, ...a9, and ...a12.

 

[pnwboat]

Re: 1993 90hp intermittantly dies

Nope, no need to be concerned.....you are good to go. Next step would be to test it out on the water. At least it is running now. Before it wouldn't even start. That's a good sign. At least you're making some headway.

 

[nathan619]

Re: 1993 90hp intermittantly dies

I took it out Friday evening fishing and so far, so good. I was afraid to take it too far down the lake so I stayed within a 1/4 mile or so just in case.

Thanks a lot for your help.

 

[pnwboat]

Re: 1993 90hp intermittantly dies

Glad to hear that it seems to have passed the "Lake Test".