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03-05-2015, 10:25 AM #1
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1980 Black Max 200 2.4 has no spark on two cylinders
My 1980 Black Max 200 is giving me problems. Serial number is 5465262. Motor will start perfect. Idle etc...I did a compression check and got 120 to 121 across the board. When I went to check the spark I found I did not have a spark on top left cylinder and middle right cylinder. I could swear that the middle one began to spark after warm, but when I checked the next day I could not repeat. Motor is new to me and I want to make sure it is all ok before water testing the boat. I keep hearing about stator issues, does this sound like a coil issue, switch box or other? I plan to take off the coils and clean the contacts. Motor had sat for a few years without running.
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03-05-2015, 11:23 AM #2
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Coils are pretty good on these Mercs. I would take the switch boxes and swap them with each other. You should see your two dead cylinders move to differenc cylinders. If this happens get new switch boxes. Best to replace both as one could damage the other.
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03-05-2015, 02:42 PM #3
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kinda sounds like a trigger. two cyls on opposite sides right one port one star
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03-05-2015, 03:08 PM #4
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I vote trigger.
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03-06-2015, 09:25 PM #5
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Check the trigger with an ohmmeter. If the results are inconclusive, swap the switchboxes. If the bug moves, it's the switches, if it doesn't, it's the trigger.
Odds are good that one coil (driving 2 cylinders) is open on the trigger.To fish or not to fish? What a STUPID question.
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03-10-2015, 08:49 PM #6
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Replaced the trigger with new from CDI since I had already purchased one. The problem still exists. Going to check the switch boxes tomorrow. The trigger housing was cracked. Was sure it was that, but the problem is still there.
Tom
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03-17-2015, 08:07 AM #7
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Swith box it is. The trigger looked toasted so I replaced it. The whole top material (tar like) was cracked everywhere. I replaced both switch boxes and now have spark on all six cylinders.
Thanks for all the help.
Tom
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03-18-2015, 06:23 AM #8
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Its probably the stator...tiggers normally affect two successive cylinders 1-2 or 3-4 (based on design)...and I doubt both switch boxes carpped out at the same Time...but then again, never say never
Go Time
2003XS GS 225 Promax/ 260 / 280
26 Regulator twin 250 EFI
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03-18-2015, 08:35 AM #9
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Would a bad stator start firing again? I hope I got this fixed. Going to attempt a linc and sync this weekend.
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03-18-2015, 09:18 AM #10
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Stators can be intermitent and if both switch boxes went bad, I would be worried that it resulted from a stator problem.
Do you have a DVA and did you take output readings? I've had porblems with stators and switch boxes at the same time before...Go Time
2003XS GS 225 Promax/ 260 / 280
26 Regulator twin 250 EFI
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03-18-2015, 08:29 PM #11
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Well, I went ahead and replaced the stator since I had a new one already ordered. Did a link and sync. Going to test this weekend.
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03-21-2015, 08:53 PM #12
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Did my link and sync. Set the WOT at 22 and idle at 6 both while cranking with muffs. Will adjust idle timing in water. Currently idles at 1900 rpm on muffs. Hoping it will drop down to 750 800 in gear with back pressure at marina. After replacing the stator I still had a weak spark on one cylinder. Finally found a postive lead that was chafed behind some electrical tape and corroded so bad I could not strip wire to splice. Replace wire from coil to switchbox and voila. A perfect spark.
Thanks to all that offered advice.
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