ELECTRICAL AND IGNITION

2
A

54637

IGNITION SYSTEM
Table of Contents
Page
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Ignition Troubleshooting . . . . . . . . . . . . . . . . . . . 2A-2
Checking For Loss Spark . . . . . . . . . . . . . . . 2A-2
Troubleshooting Test Equipment . . . . . . . . . 2A-2
Ignition Troubleshooting (Engines With
Black Stator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
Ignition Troubleshooting (Engines With
Red Stator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-7
Ignition Component Testing . . . . . . . . . . . . . . . 2A-10
Trigger Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . 2A-10
Test For Spark . . . . . . . . . . . . . . . . . . . . . . . 2A-12
Running Voltage Output Test . . . . . . . . . . . 2A-12
Ignition (Key) Switch Test . . . . . . . . . . . . . . 2A-13
Mercury (Tilt) Stop Switch Test . . . . . . . . . 2A-13
Flywheel Removal and Installation . . . . . . . . . 2A-14
Flywheel Removal . . . . . . . . . . . . . . . . . . . . 2A-14
Manual Start Model . . . . . . . . . . . . . . . . 2A-14
Electric Start Model . . . . . . . . . . . . . . . . 2A-14
Flywheel Installation . . . . . . . . . . . . . . . . . . 2A-15
Ignition Components . . . . . . . . . . . . . . . . . . . . . 2A-15
Stator Assembly Removal . . . . . . . . . . . . . 2A-15
Black Stator Assembly Installation . . . . . . 2A-17
Red Stator Assembly Installation . . . . . . . 2A-18
Trigger Plate Assembly Removal . . . . . . . 2A-21
Trigger Plate Assembly Installation . . . . . . 2A-22
Ignition Coil Removal . . . . . . . . . . . . . . . . . 2A-23
Ignition Coil Installation . . . . . . . . . . . . . . . . 2A-23
Switch Box Removal . . . . . . . . . . . . . . . . . . 2A-23
Switch Box Installation . . . . . . . . . . . . . . . . 2A-24

2A-0 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition System
Black Stator Models Red Stator Models

Adapter Module

Description
The ignition system is alternator-driven with distribu- The switch discharges the capacitor voltage into the
tor-less capacitor discharge. Major components of ignition coil at the correct time and in firing order se-
the ignition system are the flywheel, stator assembly, quence.
trigger assembly, switch box, ignition coils and spark
Capacitor voltage is conducted to the ignition coil pri-
plugs.
mary. The ignition coil multiplies this voltage to a val-
The stator assembly is mounted below the flywheel ue high enough to jump the gap at the spark plug.
and has 2 coils. The flywheel is fitted with permanent
The preceding sequence occurs once-per-engine-
magnets inside the outer rim. As the flywheel rotates,
revolution for each cylinder.
the permanent magnets pass the stationary stator
ignition coils. This causes the ignition coils to pro- Spark timing is changed (advanced/retarded) by ro-
duce AC voltage. The AC voltage then is conducted tating the trigger coil position in relation to the perma-
to the switch boxes where it is rectified and stored in nent magnets on the flywheel hub.
a capacitor.
The trigger assembly (also mounted under the fly-
wheel) has 2 coils. The flywheel likewise has a se-
Red Stator Models
cond set of magnets (located around the hub). As the Red stators require an adapter module that gets con-
flywheel rotates, the second set of permanent mag- nected between the stator and switch box. Without
nets passes the trigger coils. This causes the trigger the adapter module, the voltage supplied by the sta-
coils, in turn, to produce an AC voltage that is con- tor would exceed the voltage capability of the switch
ducted to an electronic switch (SCR) in the switch box.
box.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-1

Ignition Troubleshooting Troubleshooting Test Equipment

WARNING Multimeter / DVA Tester 91-99750

DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do
not touch ignition components and/or metal test
probes while engine is running and/or being
“cranked”. STAY CLEAR OF SPARK PLUG
LEADS. To assure personal safety, each individu-
al spark plug lead should be grounded to engine.
Before troubleshooting the ignition system, check the
following:
a. Make sure that electrical harness, lanyard
switch, ignition switch, and mercury switch
are not the source of the problem.
b. Check that plug-in connectors are fully en-
gaged and terminals are free of corrosion.
c. Make sure that wire connections are tight and
free of corrosion. Spark Tester 91-850439

d. Check all electrical components, that are

grounded directly to engine, and all ground
wires to see that they are grounded to engine.
e. Check for disconnected wires and short and
open circuits.

Checking for Loss of Spark

The use of an inductive timing light while cranking or
running the engine will show whether there is spark
present or not. The timing light will not show the
strength of the spark. Incorrect spark strength may
not allow the spark plug to fire under compression
The use of a spark gap or spark gap board will give
a visual indication of the strength of the spark. Nor-
mal ignition spark is BLUE in color. A YELLOW or
RED spark indicates a weak ignition.

2A-2 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Troubleshooting (Engines With Black Stator)

Troubleshooting Sequence Chart – (Engines with Black Stator)

Start the ignition troubleshooting by first performing Step 1, then continue the series of steps to locate the problem.
Refer to the troubleshooting steps on the following pages.

Test Trigger
Low or No Voltage at two coils
Page 2A-10

Go To
Low or No Voltage at all coils Step 2
Step 1 –
Primary Voltage At The
Ignition Coils Test Go To
Low or No Voltage at one coil
Step 3

Test for Spark

Good Voltage at all coils
Page 2A-11

DVA TESTS – 9 AMP BLACK STATOR

Selector Reading At Reading At
Tested Part Red Black
Position 300 - 1000 RPM 1000 - 4000 RPM

Coil (+) Coil (-)

Coil Primary 400 VDC* 160 - 250 180 - 275
Terminal Terminal
Black/Yellow
Stop Circuit 400 VDC* Terminal Ground 200 - 360 200 - 360

Blue Sw.
Stator Low Speed 400 VDC* Box Term. Ground 210 - 310 190 - 310

Red Sw.
Stator High Speed 400 VDC* Ground 25 - 90 140 - 310
Box Term.

DVA TESTS – 16 AMP BLACK STATOR (398-9710A33 & 398-9710A42)

Selector Voltage Voltage Voltage
Tested Part Red Black
Position @ 300 RPM @ 1000 RPM @ 4000 RPM

Coil (+) Coil (-)

Coil Primary 400 VDC* 110 - 140 250 - 300 215 - 265
Terminal Terminal
Black/Yellow
Stop Circuit 400 VDC* Terminal Ground 160 - 200 315 - 385 270 - 330

Blue Sw.
Stator Low Speed 400 VDC* Box Term. Ground 160 - 200 315 - 385 270 - 330

Red Sw.
Stator High Speed 400 VDC* Ground 8 - 10 27 - 33 165 - 205
Box Term.
White/Black
20 VDC or Switch Box
Switch Box Bias Ground 2 - 10 10 - 30 10 - 30
40 VDC Terminal
* If using a meter with a built-in DVA, place selector switch in the DVA/400 VDC position.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-3

Ignition Troubleshooting (Engines With Black Stator)

STEP 1 – Primary Voltage At The Ignition Coils Test

TEST RESULTS
(+) • No voltage output or low voltage output on all
DCV ACV
coils. Go to STEP 2 – Stop Circuit Test.

DVA
• Good voltage on two coils. Go to Trigger Test.
(–) • Good voltage on all coils. Go to Testing For
Spark.
1. Use Multimeter / DVA Tester 91-99750.
2. Crank engine and observe meter reading.
IGNITION VOLTAGE – 9 AMP STATOR
Selector Reading At Reading At
Tested Part Red Black
Position 300 - 1000 RPM 1000 - 4000 RPM
Coil (+) Coil (-)
Coil Primary 400 VDC 160 - 250 180 - 275
Terminal Terminal
IGNITION VOLTAGE – 16 AMP STATOR (398-9710A33 & 398-9710A42)
Selector Voltage Voltage Voltage
Tested Part Red Black
Position @ 300 RPM @ 1000 RPM @ 4000 RPM
Coil (+) Coil (-)
Coil Primary 400 VDC 110 - 140 250 - 300 215 - 265
Terminal Terminal

STEP 2 – Stop Circuit Test TEST RESULTS

BLK/
• Good voltage output. Go to STEP 3 – Sta-
YEL tor Low Speed and High Speed Test
• High voltage output. The trigger or switch
DCV ACV box is defective. Go to Trigger Test and
test trigger. If trigger tests OK, replace
DVA
switch box and repeat step.
• No voltage output or low voltage output.
Remove BLK/YEL wires from switch box
terminal and repeat test. If voltage output
1. Use Multimeter / DVA Tester 91-99750. is now OK, either the ignition switch, stop
switch or wiring is defective. If no voltage
2. Crank engine and observe meter reading. or low voltage remains, go to STEP 5 –
Stator, Low and High Speed Test.
IGNITION VOLTAGE – 9 AMP STATOR
Selector Reading At Reading At
Tested Part Red Black
Position 300 - 1000 RPM 1000 - 4000 RPM
Black/Yellow
Stop Circuit 400 VDC Terminal Ground 200 - 360 200 - 360

IGNITION VOLTAGE – 16 AMP STATOR (398-9710A33 & 398-9710A42)

Selector Voltage Voltage Voltage
Tested Part Red Black
Position @ 300 RPM @ 1000 RPM @ 4000 RPM

Stop Circuit 400 VDC Black/Yellow Ground 270 - 330

160 - 200 315 - 385
Terminal

2A-4 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Troubleshooting (Engines With Black Stator)

STEP 3 – Stator Low Speed and High Speed Test

Stator Low Speed Test Stator High Speed Test

DCV ACV DCV ACV

DVA DVA

1. Use Multimeter / DVA Tester 91-99750.

2. Crank engine and observe meter reading.
IGNITION VOLTAGE – 9 AMP STATOR
Selector Reading At Reading At
Tested Part Red Black
Position 300 - 1000 RPM 1000 - 4000 RPM
Blue Sw.
Stator Low Speed 400 VDC Box Term. Ground 210 - 310 190 - 310

Red Sw.
Stator High Speed 400 VDC Ground 25 - 90 140 - 310
Box Term.

IGNITION VOLTAGE – 16 AMP STATOR (398-9710A33 & 398-9710A42)

Selector Voltage Voltage Voltage
Tested Part Red Black
Position @ 300 RPM @ 1000 RPM @ 4000 RPM
Blue Sw.
Stator Low Speed 400 VDC Box Term. Ground 160 - 200 315 - 385 270 - 330

Red Sw.
Stator High Speed 400 VDC Ground 8 - 10 27 - 33 165 - 205
Box Term.

TEST RESULTS
• If voltage output is low to either the stator low
speed or stator high speed, the stator or switch
box is defective. Go to stator test and test stator.
If stator tests OK, replace switch box and repeat
step.
• If voltage output is good to either the stator low
speed or stator high speed, replace the switch
box and repeat step

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-5

Ignition Troubleshooting (Engines With Red Stator)

Troubleshooting Sequence Chart – (Engine with Red Stator)

Start the ignition troubleshooting by first performing Step 1, then continue the series of steps to locate the problem.
Refer to the troubleshooting steps on the following pages.

Go To
Low or No Voltage at all coils
Step 2

High Voltage at all coils Replace Adapter

Module
Step 1 –
Primary Voltage At The Test Trigger
Ignition Coils Test Low or No Voltage at two coils Page 2A-10

Go To
Low or No Voltage at one coil
Step 5

Test for Spark

Good Voltage at all coils
Page 2A-11

RED Stator DVA Test

Test Selector RED DVA BLACK DVA Voltage @ Voltage @ Voltage @
Switch Posi- Lead Lead 300 RPM 1000 RPM 4000 RPM
tion
Coil Primary 400 VDC Coil (+) Coil (–) 130 Volts 195 to 275 195 to 275
Terminal Terminal Minimum
Stop Circuit 400 VDC Black/Yellow Ground 190 Volts 275 to 320 260 to 320
Sw. Box Minimum
Terminal
Blue Sw. Box 400 VDC Blue Sw. Box Ground 190 Volts 275 to 320 260 to 320
Terminal Terminal Minimum
Blue/White Sw. 400 VDC Blue/White Sw. Ground 190 Volts 275 to 320 260 to 320
Box Terminal Box Terminal Minimum

2A-6 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Troubleshooting STEP 2 – Stop Circuit Test
(Engines With Red Stator)
BLK/
YEL
STEP 1 – Primary Voltage At The
Ignition Coils Test
DCV ACV

DVA

(+) a

DCV ACV

b
a
a - Connect (+) Test Lead To BLK/YEL Wire Terminal On
DVA
Switch Box
(–) b - Connect (–) Test Lead To Engine Ground
b
1. Use Multimeter / DVA Tester 91-99750. Set
switch position to – 400 DVA.
a - Connect (+) Test Lead To (+) Coil Terminal
b - Connect (–) Test Lead To (–) Coil Terminal
2. Crank engine and observe meter reading.

Voltage at 300 RPM Voltage at 1000 – 4000

1. Use Multimeter / DVA Tester 91-99750. Set (cranking) RPM (Running)
switch position to – 400 DVA. 190 Volts 275 to 320 Volts
2. Crank engine and observe meter reading.
TEST RESULTS
Voltage at 300 RPM Voltage at 1000 – 4000
(cranking) RPM (Running) • Voltage output is high. The adapter module is de-
fective. Replace adapter module.
130 Volts 195 to 275 Volts
• Good voltage output. Go to STEP 3 – Switch Box
(BLU Wire) Circuit Test.
TEST RESULTS
• No voltage output or low voltage output. Remove
• Voltage output is high on all coils. The adapter BLK/YEL wires from switch box terminal and re-
module is defective. Replace adapter module. peat test. If voltage output is now OK, either the
• No voltage output or low voltage output on all ignition switch, stop switch or wiring is defective.
coils. Go to STEP 5 – Stator, Adapter Module, If no voltage or low voltage remains, go to STEP
and Switch Box Test. 5 – Stator, Adapter Module, and Switch Box Test.
• Good voltage on two coils. Go to Trigger Test.
• Good voltage on all coils. Go to Testing For
Spark.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-7

Ignition Troubleshooting STEP 4 – Switch Box (BLU/WHT
Wire) Circuit Test
(Engines With Red Stator)
BLU/
STEP 3 – Switch Box (BLU Wire) WHT

Circuit Test

DCV ACV

DVA

a
DCV ACV

b
DVA

a - Connect (+) Test Lead To BLU/WHT Wire Terminal On

BLU Switch Box
b - Connect (–) Test Lead To Engine Ground
b a
1. Use Multimeter / DVA Tester 91-99750. Set
a - Connect (+) Test Lead To BLU Wire Terminal On Switch switch position to – 400 DVA.
Box
b - Connect (–) Test Lead To Engine Ground 2. Crank engine and observe meter reading.

Voltage at 300 RPM Voltage at 1000 – 4000

1. Use Multimeter / DVA Tester 91-99750. Set (cranking) RPM (Running)
switch position to – 400 DVA.
190 Volts 275 to 320 Volts
2. Crank engine and observe meter reading.

Voltage at 300 RPM Voltage at 1000 – 4000 TEST RESULTS

(cranking) RPM (Running) • Voltage output is high. The adapter module is de-
190 Volts 275 to 320 Volts fective. Replace adapter module.
• Good voltage output..
TEST RESULTS • No voltage output or low voltage output. Go to
• Voltage output is high. The adapter module is de- STEP 5 – Stator, Adapter Module and Switch Box
fective. Replace adapter module. Test.
• Good voltage output. Go to STEP 3 – Switch Box
(BLU/WHT Wire) Circuit Test.
• No voltage output or low voltage output. Go to
STEP 5 – Stator, Adapter Module and Switch Box
Test.

2A-8 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Troubleshooting 7. Disconnect the GRN/WHT and WHT/GRN (sta-
tor) leads from the adapter module.
(Engines With Red Stator)

STEP 5 – Stator, Adapter Module, and

Switch Box Test
Elimination Test

DCV ACV

DVA

DCV ACV
BLU
DVA

BLU/
WHT

DCV ACV
8. Measure the resistance between the GRN/WHT
and WHT/GRN (stator) leads.
DVA
Ohm Meter
Test Leads To –
Scale Reading
Between GRN/WHT and 660-710
R x 100
WHT/GRN (Stator) leads Ohms
1. Set multipurpose switch position to – 400 DVA.
TEST RESULTS
2. Disconnect only the BLU wire from the switch
• If the resistance is OK (660 to 710 ohms), the
box. Connect test leads between BLU wire and
adapter module is defective. Replace adapter
engine ground.
module.
3. Crank engine and observe meter reading.
• If the resistance is incorrect, the stator is defec-
4. Reconnect BLU wire. tive. Replace stator.
5. Disconnect only the BLU/WHT wire from the
switch box. Connect test leads between BLU/
WHT wire and engine ground.
6. Crank engine and observe meter reading.

Voltage at 300 RPM (cranking)

190 to 260 Volts

TEST RESULTS
• If voltage output is good on both wires, the switch
box is defective.
• Voltage output is low on either wire, continue with
test.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-9

Ignition Component Testing Ignition Coil Test

Trigger Test
DCV ACV

DVA

DCV ACV

DVA

DCV ACV

DVA

1. Disconnect wires from coil terminals.

2. Pull spark plug lead out of coil tower.
3. Use a VOA meter and perform the following
DCV ACV
checks.
DVA Ohm Meter
Test Leads To –
Scale Reading
Between (+) and (–) Coil .02-04*
Rx1
Terminals Ohms
Between Coil Tower and (–) 800-1100**
R x 100
Coil Terminal Ohms

1. Disconnect all trigger leads form switch box. * The primary DC resistance of these coils generally is less
than one (1) OHM. If a reading resembling a short is ob-
2. Use a VOA meter and perform the following tained, this would be acceptable.
checks. ** Copper wire is an excellent conductor, but it will have a no-
ticeable difference in resistance from cold to hot tempera-
Ohm Meter tures. Reasonable variations from these readings are ac-
Test Leads To – ceptable.
Scale Reading
Between BRN lead and BLK 700-1000 4. If meter readings are not as specified, replace
R x 100
lead Ohms ignition coil.
Between WHT lead and 700-1000
R x 100
PUR trigger lead Ohms
NOTE: Above resistance readings are for a cold en-
gine (room temperature). Resistance will increase if
engine is warm.
3. If meter readings are not as specified, replace
trigger.

2A-10 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Stator Test (Red Stator) Stator Test (Black Stator)
Electric Start Engines

Manual Start Engines

1. Disconnect all stator leads.

2. Use a VOA meter and perform the following
checks.
9 AMP Stator
Ohm Ohm
Test Leads To –
Scale Reading
Blue and Blue/White R x 1000 5.7-8.0
1. Disconnect all stator leads. Red and Red/White Rx1 56-76
2. Use a VOA meter and perform the following Blue and Engine Ground R X 1000 No Reading
checks. Red and Engine Ground R X 1000 No Reading
Electric Start Engines YEL and YEL Rx1 .5-1.0
Ohm Ohm 16 AMP Stator (398-9710A33 & 398-9710A42)
Test Leads To –
Scale Reading
Ohm Ohm
GRN/WHT and WHT/GRN R x 100 660-710 Test Leads To –
Scale Reading
YEL and YEL Rx1 0.165–0.181 Blue and Blue/White R x 1000 1000-1400
Manual Start Engines Red and Red/White Rx1 15-30
Ohm Ohm Blue and Engine Ground R X 1000 No Reading
Test Leads To –
Scale Reading
Red and Engine Ground R X 1000 No Reading
GRN/WHT and WHT/GRN R x 100 660-710
YEL and YEL Rx1 .10-.50
BLK/WHT and BLK R x 100 130-145
NOTE: Above resistance readings are for a cold en-
YEL and YEL Rx1 0.17–0.19 gine (room temperature). Resistance will increase if
NOTE: Above resistance readings are for a cold en- engine is warm.
gine (room temperature). Resistance will increase if If meter readings are other than specified, replace
engine is warm. stator.
If meter readings are other than specified, replace
stator.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-11

Test For Spark (Cranking) Primary Voltage Test (Engine
Running)

a
d
a

b
b

a - Spark Tester 91-850439

b - Connect Ground Lead To Engine Ground
c
1. Remove the spark plug leads from the spark
plugs.
2. Adjust the spark tester to 1/2 in. (12mm) gap set-
ting. a - Plug into Meter
b - Attach to Appropriate Terminals
3. Connect the spark plug leads to the tester. Attach c - Attach to Engine Ground
the tester ground lead to engine ground. d - Selector Switch
4. Crank the engine. Spark should jump each tester 1. If the ignition system tests OK, it may be neces-
gap. sary to check the output voltage while running the
engine under load up to 4000 RPM. Using Test
TEST RESULTS Harness 91-14443A1 allows performing DVA
NOTE: Normal ignition spark is BLUE in color. A Tests from the driver seat inside the boat. Refer
YELLOW or RED spark indicates a weak ignition. to DVA Tests preceding.

• Normal spark on all cylinders. Go to Primary Volt-

age Test (Engine Running).
• Intermittent, weak or no spark output on all cylin-
ders usually indicates a defective trigger. Go to
Trigger Test.
• Intermittent, weak or no spark output on any one
cylinder indicates a bad ground, defective igni-
tion coil, defective spark plug lead, or switch box.
Go to Ignition Coil Test.

2A-12 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition (Key) Switch Test Mercury (Tilt) Stop Switch Test
1. Disconnect remote control wiring harness and in- 1. Remove mounting screw that secures mercury
strument panel connector. switch to outboard.
NOTE: Wiring diagram for control boxes is located in 2. Connect Ohmmeter (R x 1 scale) between black
SECTION 2D. lead and black/yellow lead or terminal stud on
mercury switch.
2. Set ohmmeter on R x 1 scale for the following
tests: 3. Test mercury switch as follows:
COMMANDER KEY SWITCH a. Position mercury switch as it would be
BLK
BLACK (PUR) installed when engine is in “down” position.
PUR
PURPLE A The meter should indicate no continuity.
RED
RED M (BLK)
YEL
YELLOW (BLK/YEL) M b. Tilt mercury switch up. The meter should indi-
cate continuity.
(RED) B S (YEL/RED
c. If these readings are not obtained, replace
C (YEL/BLK) mercury switch.
CONTINUITY SHOULD BE INDICATED
KEY AT THE FOLLOWING POINTS:
POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK
OFF • •
RUN • •
• •
START • •
• •
• • a
CHOKE* • •
• •
c
* Key switch must be positioned to “RUN” or “START” and key pushed
in to actuate choke, for this continuity test. 10
20
30
0 40
3. If meter readings are other than specified in the 0
2 4 6 8
10

preceding test, verify that switch and not wiring is

faulty. If wiring checks OK, replace switch.
x100x10
x1K x1
OFF
400 400
200 D 200A
D C
C 40 40 V
V
20 20
400
200

54638

a - Red Ohm Lead

b - Black Ohm Lead
c - Mercury Switch

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-13

Flywheel Removal and 2. Use strap wrench to hold flywheel while removing
flywheel nut and washer.
Installation
b
a
Flywheel Removal

CAUTION
To prevent accidental starting of outboard while
removing engine components, on electric start
models - remove engine battery cables from bat-
tery and verify ignition key is in the “OFF” posi-
tion. When servicing manual start engines, verify
lanyard switch is in the “OFF” position.

MANUAL START MODEL

54639
1. Remove 3 bolts securing rewind starter and re-
move rewind from outboard. a - Strap Wrench
b - Flywheel

ELECTRIC START MODEL

1. Remove 3 bolts securing flywheel cover and re-
move cover from outboard.

b
a

a - Rewind Starter

54640
a - Bolts
b - Flywheel Cover

2A-14 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

2. Use flywheel holder (91-52344) to hold flywheel Flywheel Installation
while removing flywheel nut and washer.
CAUTION
Inspect magnet side of flywheel for any debris
clinging to magnets. Installing flywheel with de-
bris on magnets will cause damage to flywheel
b and/or electrical components located under fly-
wheel when outboard is initially started.
1. Secure flywheel on crankshaft with flat washer
and nut.
2. On electric start type flywheel, use flywheel hold-
a er (91-52344) to hold flywheel while tightening
flywheel nut. On manual start type flywheel, use
strap wrench to hold flywheel while tightening fly-
wheel nut.
3. Torque flywheel nut to 75 lb. ft. (101.7 N·m).
54641
4. Reinstall rewind starter, if manual start, or fly-
a - Flywheel Holder (91-52344) wheel cover, if electric start, with 3 bolts. Torque
b - Flywheel bolts to 100 lb. in. (11.3 N·m).
NOTE: Use flywheel puller (91-73687A1) on both
manual and electric start type flywheel. Always install
crankshaft protector cap onto end of crankshaft be-
fore threading flywheel puller into flywheel. Do not Ignition Components
strike flywheel puller bolt with hammer as crankshaft
may be damaged. CAUTION
To prevent accidental starting of outboard while
CAUTION removing or installing engine components, on
Do not apply heat to flywheel or strike flywheel electric start models – remove engine battery
with hammer as flywheel or electrical compo- cables from battery and verify ignition key is in
nents under flywheel may be damaged. the “OFF” position. When servicing manual start
engines, verify lanyard switch is in the “OFF”
position.

Stator Assembly Removal

b 1. Remove top cowl.
a 2. Remove 3 bolts securing rewind starter or fly-
wheel cover and remove rewind or cover, which-
ever is applicable.
c
3. Remove flywheel as outlined in “FLYWHEEL RE-
MOVAL AND INSTALLATION”, preceding.

54642

a - Flywheel
b - Flywheel Puller (91-73687A1)
c - Crankshaft Protector Cap (Hidden); Place on end of
Crankshaft

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-15

4. Remove 4 screws which secure stator to upper 5. Remove 6 bolts securing electrical box access
cap. cover and remove cover.

b
a
a

54644
54645
a - Screws a - Bolts
b - Stator b - Access Cover
6. Disconnect stator wiring from their respective ter-
minals and remove stator assembly from out-
board.

2A-16 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Black Stator Installation
a
1. Apply Loctite Grade A (92-32609-1) to threads of
4 stator attaching screws.
2. Install stator on upper end cap and torque attach-
ing screws to 35 lb. in. (3.9 N·m).
3. Route stator wiring into electrical component
box.
a

b
c c
b

54647

a - Warning Module
54646 b - Stator Wiring to Switch Box
c - Stator Wiring to Rectifier
a - Stator
b - Wiring 4. Reconnect wires to proper terminals. Refer to
c - Sta-Strap wiring diagrams, Section 2D. Torque terminal
NOTE: Stator wiring is routed behind starter motor nuts to 30 lb. in. (3.4 N·m).
and enters electrical box through access holes under 5. Reinstall electrical box access cover.
warning module.
6. Reinstall flywheel as outlined in “FLYWHEEL RE-
MOVAL AND INSTALLATION”, preceding.
7. On manual start models, reinstall rewind starter.
On electric models, reinstall flywheel cover. On
either manual or electric models, rewind or cover
attaching bolts should be torqued to 100 lb. in.
(11.3 N·m).
8. Reinstall top cowl.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-17

Red Stator Installation 3. Install adapter module routing adapter wires
through opening in upper right corner of electrical
1. Position stator on powerhead as shown. Secure box. Connect stator, adapter module and switch
stator with 4 screws. Apply Loctite 271 to screw box wires per appropriate model wiring diagram
threads. Torque screws to 35 lb. in. (4.0 N·m). in Section 2D Wiring Diagrams.

a
b
c

a b
b b

54952
a - Stator
54954
b - Screws [Torque to 35 lb. in. (4.0 N·m)]
a - Upper Right Corner
c - Stator Harness
b - Adapter Module

2. Install BLUE and BLUE/WHITE cable adapters to

BLUE and BLUE/WHITE terminals on switch
box. Torque terminal nuts to 30 lb. in. (3.5 N·m).
Install cap nuts on unused terminals.

c
b
a

54953
a - BLUE Cable Adapter
b - BLUE/WHITE Cable Adapter
c - Cap Nuts

2A-18 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Electric Models – Secure adapter module and wir-
ing with sta-straps.

i a

f
c
b
d

g e
f
a

54957

a - Sta-Straps
b - Adapter Module (Hidden)
c - Adapter Module WHITE/GREEN Lead
d - Adapter Module GREEN/WHITE Lead
e - Stator YELLOW Leads
f - Caps
g - Adapter Module BLUE Lead
h - Adapter Module BLUE/WHITE Lead
i - Adapter Module BLACK Lead – Torque bolt to 40 lb. in.
(4.5 N·m)

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-19

Manual Models – Secure adapter module and wiring
with sta-straps.

a
j
b
l c
a
k d

j a
e

a
i h

54955

a -
Sta-Straps
b -
Adapter Module
c -
Insulator Plug
d -
Stator BLUE/WHITE Lead (not used)
e -
Adapter Module WHITE/GREEN Lead
f -
Adapter Module GREEN/WHITE Lead
g -
Stator YELLOW Leads
h -
Terminal Block
i -
Harness Extension – Secure to Terminal Block w/screws
(retained)
j - Caps
k - Adapter Module BLUE Lead
l - Adapter Module BLUE/WHITE Leads
m - Adapter Module BLACK Leads – Torque bolt to 40 lb. in.
(4.5 N·m)

2A-20 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Trigger Plate Assembly Removal 6. Remove 6 bolts from electrical box access cover
and remove cover.
1. Remove top cowl.
2. Remove 3 bolts securing rewind starter or fly-
wheel cover and remove or cover, whichever is
applicable. a
3. Remove flywheel as outlined in “FLYWHEEL RE-
MOVAL AND INSTALLATION”, preceding.
4. Remove 4 screws which secure stator assembly
to upper end cap. Lift stator off end cap and move
to the side.
5. Remove locknut that secures link rod swivel into
spark arm. Pull link rod swivel out of arm.

a
b

54645

a - Bolts
e
b - Access Cover
7. Disconnect trigger leads form their respective
terminals on switch box. Remove trigger plate as-
f sembly from engine.
b

c d

54648

a - Trigger Plate Assembly

b - Link Rod Swivel
c - Spark Arm
d - Lock Nut
e - Trigger Harness
f - Sta-Straps

54649
a - Trigger Leads
b - Switch Box
8. If trigger is defective, remove and retain link rod
from trigger.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-21

Trigger Plate Assembly Installation 4. Reconnect trigger wires to proper terminals of
switch box. Refer to wiring diagram, Section 2D.
1. If link rod was removed from trigger, reassemble Torque terminal nuts to 30 lb. in. (3.4 N·m).
to trigger.
2. Place trigger plate assembly in upper end cap.
Fasten link rod swivel to spark arm lever with lock
nut.
3. Route and secure trigger harness as shown.

d a

e
b b

c a

54649

a - Trigger Harness
b - Switch Box
5. Reinstall electrical box access cover and secure
cover with 6 bolts.
54648
6. Reinstall stator as outlined in “STATOR AS-
a - Lock Nut SEMBLY INSTALLATION”, previously.
b - Link Rod Swivel
c - Spark Arm 7. Reinstall flywheel as outlined in “FLYWHEEL
d - Trigger Plate Assembly INSTALLATION”, previously.
e - Sta-Straps
f - Trigger Harness (Route as Shown) 8. Reinstall rewind starter if manual start or flywheel
cover if electric start. On either manual or electric
models rewind or cover attaching bolts should be
torqued to 100 lb. in. (11.3 N·m).
9. Reinstall top cowl.

2A-22 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Ignition Coil Removal Ignition Coil Installation
1. Remove top cowl. 1. Install spark plug high tension lead/coil tower
boot assembly (retained) onto new coil.
2. Remove 6 bolts from electrical box access cover
and remove cover. 2. Position secondary coil into electrical box.
3. Reconnect positive (+) and negative (–) leads to
their respective terminals on coil with 2 nuts.
Torque nuts to 30 lb. in. (3.4 N·m).
a
4. Reconnect spark plug boot to spark plug.
5. Reinstall electrical box access cover and secure
cover with 6 bolts.
6. Reinstall top cowl.

Switch Box Removal

1. Remove top cowl.
2. Remove 6 bolts from electrical box access cover
b and remove cover.

54645 a
a - Bolts
b - Access Cover
3. Disconnect wires from positive (+) and negative
(–) terminals on defective coil.
4. Remove spark plug boot from spark plug.
5. Remove spark plug high tension lead/coil tower
boot assembly from coil tower and discard defec-
tive coil.

c a b

54645
e a - Bolts
b - Access Cover
d

54650

a - Positive (+) Lead

b - Negative (–) Lead
c - High Tension Lead
d - Coil Tower Boot
e - Coil

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2A-23

3. Disconnect all leads from switch box. Switch Box Installation
4. Remove 4 bolts from switch box and remove 1. Secure switch box to electrical component box
switch box. with 4 bolts and their respective ground leads.
Torque bolts to 40 lb. in. (4.5 N·m).
a 2. Reconnect leads to switch box terminals. Refer
to “WIRING DIAGRAM”, SECTION 2D. Torque
switch box terminal nuts to 30 lb. in. (3.4 N·m).
3. Reinstall electrical box access cover and secure
cover with 6 bolts.
4. Reinstall top cowl.

54651

a - Bolts
b - Switch Box

2A-24 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996