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09-23-2020, 04:54 AM #76
See if tlwjkw can get u straighten out. Goodluck
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09-23-2020, 07:24 AM #775000 RPM
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. I don’t know how far back you have read but I had no spark on cylinder#3, I replaced stator due to degraded wiring. Still had no spark on 3, switched wires from one switchbox to the other. Now I had spark on 3 but no spark on 4. Put two brand new cdi switch boxes on, have spark on all 6 cylinders now. When I replaced the switch boxes I did not return the wires to their original switchbox location, meaning when I swapped wires from one switchbox to the other and spark followed I figured to get the two new switch boxes. So a week later the new switch boxes show up, I wired them in exactly how I left off. In other words the wiring is on the opposite switchbox then before but the wires are on the correct studs. The only wires I moved were the cylinder/coil wires, I believe I left the stator wires in there original spot. Hopefully this makes sense. One other thing, the new switch boxes have a extra ground stud that I left alone, I used the black wire that is molded right into the new switchbox for the ground.
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09-23-2020, 07:29 AM #78
a backfire and/or poppin' is ign related and way more times than not due to a wire wrong..... do a one attta time check with all of 'em ta be sure........ jmo.
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09-23-2020, 07:33 PM #795000 RPM
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So I double checked the wiring, everything was correct. At this point nothing made sense anymore. Remember I said I flipped the wires from one switchbox to the other and the spark moved from cylinders 3 and 4. At that point I figured one of the switch boxes were bad and I went ahead and ordered two of them. I left the motor alone until the new boxes arrived, in other words I left the wiring flipped and that’s how I put them on the new switch boxes. Today I put the wires back to how they were before I flipped them and switched the two yellow wires around that come from the stator to the rectifier. Take the boat back to launch, start the motor and I could tell immediately something sounded better, shift motor in gear and it stays running. I look at my 11 year old boy and say “ you wanna give it a shot?” He shakes his head yes. We both get in, I idle the boat into deep enough water and stand on it, the boat launches like a rocket. We do a couple of hot laps and she runs like a raped ape again, almost seems better than before. The nightmare is over! Thanks to everyone that kept me from throwing in the towel.
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09-23-2020, 09:06 PM #80Junior Member
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Congratulations, Jmr1974. Glad for you and your boy that you got it resolved.
Update on my situation: I finally got back to it late today, started it up with some difficulty, but once running it stayed running. I could rev it to 3000 in neutral, briefly, which was better than when she fell on her face. In any case, after a minute or two I shut it off and with my hand noticed that the starboard cylinder head was warm, and the port side not warm. Long story short - I replaced the port side switch box (pulled from old blown parts motor), and shaaZAM! We're back in business. Btw, I still have those 2 black boxes...not touching them until I need to. Huge relief. I've seen a few comments saying you should always replace both switch boxes together. I just changed the one....
Does anyone know what causes switch boxes to fail?
Thanks all for your help.
Mike
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09-24-2020, 09:06 AM #815000 RPM
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my guess would be age that causes switch boxes to fail, in my case my stator wires were shot and could have contributed to the switch box problem. It took 6 pages in this thread for me to figure out my problem with lots of ?’s answered here from guys in the know, like I said to Merc2.5 I created another problem when I switched wires around. Easy screwup on my part, just happy as hell I figured it out
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