2004 mercury 90hp outboard.......help!!

wrenchman

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Apr 24, 2009
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Hello,
1st time here and posting but i have a concern that i hope someone might be able to help with and would be much appreciated.. I have a 2004 nitro bass boat with a 90 hp outboard, I bought the boat new...the issue is #2 cyl keeps blowing the module/coil. no other cyl ever affected.......I have spent many years as a auto mechanic so am not a newbi when it comes to mechanical stuff......this has been going on since the 1st year of having the boat......i have went thur and removed all grounds and sanded down due to paint over grounds...at 1st thought it fixed the concern, but yesterday it did it again......this will be the 5th module i have had to buy for this concern.(which isn't cheap)
There is no special times it happens, as it has done this under full power, and other times at very slow speeds........once it drops that module..its done...most times, motor runs great for days, or even weeks to afew months.
I have checked, double checked all wiring to that module, all test out good.
i have looked at a shop book and appears all modules....(3) run off pick-ups of flywheel, but they are all wired together, and #2 is the only cly ever affected. Has anyone ever heard of this or had this issue........any helpful ideas would be great as i'm pulling my hair out...............Thank you in advance
 

Don S

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Aug 31, 2004
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62,321
Re: 2004 mercury 90hp outboard.......help!!

Lots of unknowns here. Is this a 2004 motor, or just the boat? 4 stroke or 2 stroke, EFI, or carbed, got a SN handy, that would help me, maybe not others.
How long has this been going on? Since it was new? Any warranty claims on it?
 

wrenchman

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Apr 24, 2009
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Re: 2004 mercury 90hp outboard.......help!!

Hey Don, sorry about the lack of info........the motor is a 2004 , It is a 2 stroke. Bought it all new, (boat) in 2004......its oil injected, but is carb. (It's a 3cyl). this concern happened the 1st year i owned it...did take it in for service as was under warranty at that time, they looked it over and said they found nothing, as motor was running on all cly. at that time........they had it for 2 days......i then took it to lake that weekend....ran great for afew hours, then droped that module again, and this time it never came back to life..was done.
since then it has happened 4 times over the years, the lastest being this week....the 1st time it did that and after shop.it did set for 4 days before i took it out, since that time, whenever it has done this.......setting for afew days makes no difference, that module is dead...i have swapped modules to different cly, makes no difference, does not follow.always stays #2cly.....without taking off flywheel to inspect pick-ups, trigers....wiring appears good as far as can be seen down in motor......... hope this explains alittle better
 
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wrenchman

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Apr 24, 2009
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Re: 2004 mercury 90hp outboard.......help!!

Thank you kindly Don, as i dont have a service manual, so this is of great help, again, thank you for your reply and help..
 
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