'77 Mercury 1500 No Spark

eggs712

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I had a no spark situation with my '77 Merc 1500, and it was caused by a bad trigger. I bought a used Distributor in good, working condition from ebay and installed it last night. However, I did something really stupid when testing for spark. I was working alone, so I decided to jump the starter so that I could watch for spark in the spark gap tester. I jumped the red wire going into the switch box to the positive post on the starter, and the starter made only a click and then nothing else after that. I got worried and cranked the motor from the control, and the starter turned over great like usual. However, I no longer have power getting to the red wire going into the switch box from the harness :confused: . I have 12V on the white wire going into switch box and 12V on the brown wire on the distributor side of the box, but zero power to the red wire. I'll also note that I only very briefly held the jumper wire to the starter, there were no sparks, and I didn't smell anything burn.

Does anyone know what I screwed up? Also, how do I properly jump the starter next time I need to test for spark alone?
 

Chris1956

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Mar 25, 2004
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Re: '77 Mercury 1500 No Spark

Well, there is no fuse in the harness, so you must have burned out a conductor. Trace the red wire back to the battery cable and see where it opened.
 

eggs712

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Re: '77 Mercury 1500 No Spark

Thanks for answer, Chris. I got lucky, and the wire melted where it splices to a wire coming from the rectifier. I followed the wire to the splice and the splice fell apart when I only tapped it. I laughed at my terrible splice job; it had been done when I very first worked on the motor by installing a new wiring harness. This time I just used a wire connector cap, which is now much sturdier than before. I re-tested for spark, but with a buddy this time. I have spark now! The new trigger fixed the problem, so thanks for helping me diagnose that problem previously. Now I can properly winterize the motor now that it'll start, and then the awfully long wait for spring.....
 

Chris1956

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Re: '77 Mercury 1500 No Spark

A wire connector cap is not a good fix. The best way to repair the harness (for us amateurs) is to remove the insulation from a butt splice. Now slide a piece of shrink tube onto the wire. Now flux it up and stick the wires into the butt splice and crimp it. Solder it well, and pull the shrink tube over it when cold and shrink it with some heat.

Of course if you can make a vapor proof crimp, that would be better.
 

eggs712

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Re: '77 Mercury 1500 No Spark

I can make a butt splice and I have some heat shrink, but I don't have any soldering tools or materials. Can I get away with sealing the cap with some RTV black silicone to make it vapor proof?

Also, for the next time I have to test spark alone, how do I properly jump the starter? I was thinking that I could just jump the positive battery cable going into the starter solenoid to the positive terminal on the starter, but I don't wanna try that without knowing it won't fry something.
 

Chris1956

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Re: '77 Mercury 1500 No Spark

Solder is best. Crimping will work for a while.

Jumper from red battery cable on starter solenoid to small yellow wire on solenoid to spin the motor. Ign key must be on if you want motor to start, or have spark.
 

eggs712

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Re: '77 Mercury 1500 No Spark

Sounds like I need to learn to solder; I'll probably love it once I get the hang of it though.

And awesome, thanks again.
 

Chris1956

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Re: '77 Mercury 1500 No Spark

Have someone who is experienced show you how to solder. The solder needs to flow, to avoid a "cold" joint. It is not obvious to the beginner, when the solder joint is cold or good.
 

mercurymang

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Jul 14, 2012
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Re: '77 Mercury 1500 No Spark

I have soldered wires a million times and still have problems soldering connections on these old wires.
 

Chris1956

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28,108
Re: '77 Mercury 1500 No Spark

Yes, you must introduce flux to the individual wire strands. Those old harnesses are tinned marine wire, so you have a chance.
 
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