SwitchBox Help!!

[crowbuttedweller]

I have narrowed down my problem to the switchbox // supposedly....

Now I am getting ready to order and want to know why one of these has a ground wire and the other doesn't. They both say they will fit my motor and list the HP and serial number as a viable option.

Is there a difference between the two in functionality?

 

[CharlieB]

Re: SwitchBox Help!!

Interchangable

Factory aluminum case grounded thru the case mounting screws

CDI plastic box couldn't and requires a ground wire.

Parts are interchangable.

CDI usually a fine product and generally costs LESS than Merc.

 

[CharlieB]

Re: SwitchBox Help!!

Just a reminder, NO return on electrical, yada, yada, yada.....

You properly tested the stator and trigger with a DVA meter to arrive at your diagnosis that the box is bad?

Ohms test only, unless obviously wrong/shorted out, are not the most reliable.

 

[crowbuttedweller]

Re: SwitchBox Help!!

I did all of the tests from the CDI troubleshooting manual and everything matched up.

Most conclusive in my mind (let me know if I am wrong) -

Swapped stator leads (red w/ red white) and (blue w/blue white) and the problem stayed on the same cylinders.

Troubleshooting guide stated it was 'likely' the switchbox.

 

[crowbuttedweller]

Re: SwitchBox Help!!

I found a supply of the factory switchboxes at $109 each (without the ground wire) and just wanted to make sure it would work. My motor has the plastic version on it now with the ground wire so it has been changed before at some point.

I figure the $109 is not an exhorbinant investment even if all it does is rule out the switchbox. (The tester for the switchbox is 80...)

Since I know the stator is fine (swapped leads and still fired on 3 & 4), and the coils are all fine (swapped them every which way I could and problem stayed at 1&2), then to me the switchbox and trigger are only things left.

Trying the switchbox first (easier swap).

Let me know if that reasoning is not sound!

Thanks.

 

[CharlieB]

Re: SwitchBox Help!!

You are right on target.

Since the firing order is 1 3 4 2 if it was the trigger it would have been 1 & 4 or 3 & 2, not 1 & 2.

That's a good price for a box, if I could afford it I would pick me up another spare.

 

[crowbuttedweller]

Re: SwitchBox Help!!

Installed the new switchbox....

I now have intermittent fire on #2 but nothing on #1.

Also getting backfire out the exhaust that was not happening before.

Switched stator leads again and it stayed that same way.

Swapped coils and stayed the same way.

Moved plug wires around....stayed the same way.

I am now wondering if the previous owner set timing while running on two cylinders... Is that possible?

Could that throw everything off so much that number one would not fire?

 

[crowbuttedweller]

CharlieB - Advice needed please!

CharlieB - Advice needed please!

I found a guy who had a complete lectrical system from my same engine. He had a destroyed lower unit and I got a great deal.

So, I now have replacements for: stator, trigger, another switchbox, coils, plug wires

After doing the ohm test on the replacement parts I am going to tear down the engine and replace everything.

Are there any other components that I should purchase that could be causing my problem? I just want this thing running!

I literally live at the boat launch for world class small mouth bass fishing, and want to get everything right this time.

Is there anything you would recommend I replace while I have her torn down?

Thanks!

 

[CharlieB]

Re: SwitchBox Help!!

Sound like you have broken wires in the trigger, NOT switching the ignition module.

Triggers and stators can Ohms test and look fine, but under an electrical load as with the DVA Meter they will fail.

Sometimes a trigger works in one throttle position and fails when the wires are flexed/when the throttle is moved, broken wires.

A backfire out the exhaust is often late timing, possibly caused if you switched a couple of trigger wire incorrectly.

BE SURE that the color codes on the box match the wires.

 

[crowbuttedweller]

Re: SwitchBox Help!!

The trigger wires had all been redone (poorly) before I got the boat.

They were all black wires with labels taped on them with the color code it was supposed to be.

It's possible they did that incorrectly.

Is there a way to figure out which wire belongs where? Can I swap them around? Maybe #1 and #2 are crossed?

The 'new' parts that I am getting have all of the original wires and are the right color (imagine that!!), so I will be able to fix that later, but if this is simply crossed wires I will just keep all of those parts as spares.

 

[CharlieB]

Re: SwitchBox Help!!

Your stator tested good and is providing voltage to make spark.

The trigger wires having been 'replaced/repaired' can be cause for concern as we do not know if the wires were soldered, crimped or simply twisted together. Whichever method it must have failed.

Install the trigger and retest.

 

[crowbuttedweller]

Re: SwitchBox Help!!

Replaced the trigger, and she is fixed! Runs like a champ.

Gets out of the hole instantly on plane and tops out around 48-50.

Thanks CharlieB and everyone else for your assistance. I actually got it going about a week ago. Didn't want to be one of those people that gets the problem solved and doesn't let everyone that helped know how much their assistance is appreciated.

This forum is the best.

Thanks All!