Inconsistant spark on bottom 2 cylinders? Need some help

[CharlieB]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Rectifier failed diode tests, it is dead.

Stator yellow to yellow NO Ohms, the charging circuit is dead.

Replace both.

Check the CDI Electronics prices, often much better than Merc and higher quality parts.

Most all CDI stators are no longer epoxy coated is that tends to trap more heat and contribute to earlier failure.

That battery didn't contribute to this failure unless its age is so great that it requires far more current to recharge. Just to be sure, take it in and have it load tested with a REAL carbon pile type variable load tester. Don't waste your time with one of those electronic meters, many of us still don't trust them.

 

[Faztbullet]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

The way you tested rect/geg is incorrect below is correct way for that unit....
Bench Test
Diode plate check:
Test the forward diodes between the two yellow wires and the red wire. You should get a reading of about 45K (45,000)
on one and a high reading on the other. Check the resistance from each of the yellow wires to case ground, you should
get a reading of about 56K (56,000) on one and a high reading on the other. The red wire should read about 14K (14,000)
ohms to ground.
Tachometer Circuit:
Check the resistance between the gray wire and engine ground. You should read above 100K (100,000) ohms. Gray to
red, and gray to the yellow wires should be a high reading, usually in the M range.

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

This is sticktly with a DVA correct?

 

[Faztbullet]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

No standard meter....

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Ran the regulator tests above and it tested bad. Got 65,000 and 66,000 ohms between the 2 yellow wires nothing with the red. Checked resistance from yellow wires to ground and red to ground. Yellows to ground got 109,000 ohms and red to ground got nothing. next I checked the tach and got 9,500ohms coming out of gray tach wire. Red wire to gray wire got 787,000 ohms. So from the looks of it I have a bad stator and regulator. The stator had no ohms coming out of the yellow wires. So now I am looking at buying replacement parts. Boaterisland.com had the 40amp stator and regulator for 510$. Any other cost effecient suppliers that anyone else knows of?

 

[CharlieB]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Call CDI and get a price with freight for their parts direct

1.800.467.3371

Mercury / Mariner Voltage Regulator: 194-1873

Mercury / Mariner Stator: 174-9610K2

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Will they sell to the general public? I figured they only sold to dealers and distributors

 

[Dukedog]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Sounds like someone put a old 220EFi on a 1991 midsection, check the compression as this is a chrome bore motor.

Think ya on ta something here FB. Those heads (picture) are pre '87 2.0/2.4. For sure its not a '91 2.5 anything...........

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

The motor will still take a 40 amp stator correct?

 

[carholme]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Max;

To verify your s/n, check for a disc like this on the powerhead:

http://imageshack.us/a/img84/8224/391496208.jpg

Does it have the same numbers as the s/n you posted in your first post?

Gerry

 

[Dukedog]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Tha one in tha picture is a 40 "water cooled" regulator. If that is an earlier model block assy. (which it appears ta be) tha serial number on tha welsh plug (if its there) may not jive with tha chargin system that's on it.......I know that system didn't come out till after '88 with tha lost foam (one piece) type heads............

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

The serial # was taken off the block. All I had was the part # off the black which I posted earlier. It does in fact have a water cooled regulator on it which looked very tired. I ordered the stator regulator kit part CDI#174-9610A18. How can I tell if this peiced together motor will take a 40 amp stator or 16 amp stator? If you go down in amps for the stator does the voltage regulator change as well?

 

[Dukedog]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Those parts are good for ya. Tha regulator and flywheel are tha first "visual" signs of what chargin' system is on it. Flywheels (all 40's will work with either water cooled or dual reg system), stators (two different kinds of 40's), regulators need ta be a matched combination. It may/may not be a pieced together motor. Looks ta be like its just fine. Those type heads went away for "most" production motors in '87/'88. But that don't mean much with tha Merc/Mariner production line. '90/'91 was a screwy time with tha different block/head configurations. Just tha year you were told may be off a little. There is a build date stamped on tha block that will tell ya exactly when it was built............Might be a little too much information but kinda bored (rain) this morning. GL with it.

 

[carholme]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

That s/n comes up as:

MERCURY - (200XRI H.P. (1991 ))
Serial No: 0C291520 Model No: 1200413LD

Parts and Service bulletin list for s/n 0C291520:

Search Results - Crowley Marine

CDI stator list for your XR1:

Results | CDI Electronics

which lists the 40A for your s/n.

and the Voltage Regulator for your XR1:

Results | CDI Electronics

and if you have any doubt or confusion, call them at their toll free number and speak to tech support. I have found them very helpful. If they are busy, leave a number as they will call.

Gerry

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

I called CDI the other day to get part #'s. They gave me part # 174-9610A18 which is different than the volt reg above. The one in the kit has 2 small regulators to make one. I cant seem to tell the different in the 2 regulators. They both supply 40 amp stators and both replace water cooled reg. Is one better than the other? My main concern on the motor is that it really is a 200 rather than a 150. If it is a 150 I suppose I will need to change the prop out as well. It has 3 blade 25p Trophy prop on it which would probably be to big for a 150 correct? It was VERY slow out of the hole

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Update:

Put new stator and volt reg on the motor today. Went to the lake to test run and it didnt overheat, die, or run on low voltage. When I put the meter on the battery it read 12.4 V and the tachometer now works. So I beleive I did fix the problem with the voltage in the motor. I do have one concern with how it ran though. When I took off out of the hole it was very doggy and once I got up to top speed which was 48 mph, the motor would only turn 4,000 RPM's? Suggestions of where to trouble shoot this one? All you guys are awesome. Thank you for the help this far.

 

[stevefishes]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Check your previous post number 35. Sounds like you answered your own question.

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

The motor will not even rev past 4000 rpms in the water in neutral. Also seems like a small miss when you are running around 3500rpms

 

[mkeleher]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

I have a potential culprit. Pulled all the spark plug wires off and got the following readings on all of them, #1 3440 ohms #2 3350 ohms #3 3350 ohms #4 3350 ohms #5 3420 ohms #6 10 ohms. Judging by the ohm readings plug wire #6 is faulty and may have only been allowing the motor to run on 5 cylinders. With that being said, would the motor be able to run more than 4000 RPMs if it was only running on 5 cylinders?

 

[CharlieB]

Re: Inconsistant spark on bottom 2 cylinders? Need some help

Ahhhhhhhhh, plug wires should be LESS THAN 10 Ohms per foot.

#6 is your BEST wire.

Replace them ALL.

Please do NOT rev that motor in Neutral, a thermal run-away is very likely to occur, leaving you with a big hole in the side of the block once the rods depart.

Once the wires are replaced try another WOT run and repost you max RPM.

Your earlier posting may be correct, that prop may be a bit too much pitch. But first ensure the motor is tuned perfectly, fuel pump rebuilt, carbs clean, floats height correct. No air sucking into the fuel system as that will not allow the fuel pump to keep the carbs filled. Air leaks can easily be checked using a temporary clear hose between the fuel pump and carbs. Simply run the motor and see if any air bubbles continue to pass thru, showing you a leak. Just REMEMBER to remove the clear hose once finished testing as it is NOT rated nor recommended for fuel use.