1.HERE IS A SAMPLE OF MERCURY/MARINER FACTORY SERVICE MANUAL


Mercury Ignition System

Mercury-Mariner Outboard Service Manuals 

Download Manuals Below

1965-1989 Mercury Mariner Workshop Workshop Manual 2 To 40 Hp 2 Stroke

1965-1989 Mercury Workshop Repair Manual 45 Thru 115hp 2 Stroke

1965-1989 Mercury Outboard 90-300 HP Repair Manual

1990-2000 Mercury Mariner Workshop Repair Manual 2.5 to 275 2-Stroke Motorsf

1986-2003 Mercury Factory Service Manual 6/8/9.9/10/15HP 2 Stroke

1995-2000 Mercury Mariner Factory 40 45 50 HP Service Manual

1997-2000 Mercury Mariner Factory 40 50 55 60hp Service Manual 2 Stroke

1997 1998 Mercury Factory Optimax 200 & 225 HP Service Manual

1998-1999 Mercury Mariner Factory 9.9 & 15 HP Service Repair Manual

1998-1999 Mercury Factory 135HP (135 HP) & 150HP (150 HP) Service Manual

1999-2002 Mercury - Mariner Factory 30 HP 40 HP Service Manual 4-Stroke Outboard

1999-2000 Mercury - Mariner Factory Service Manual 4HP 5HP 6HP (4 Stroke)

2000 2001 Mercury Factory 75/90 HP (75hp & 90hp) Outboard Service Manual

2000-2001 Mercury Factory Optimax 115 135 150 175 Service Repair Manual DFI

2001 Mercury Mariner Factory 50 HP & 2001 60 HP Service Manual

2001 2002 Mercury Factory 115 HP (115HP) Service Manual 4-Stroke

2002-2004 Mercury Factory 40 HP 50 HP 60 HP Service Manual 4-Stroke


   

Topic covered in this 1995, 1996, 1997, 1998, 1999, 2000 Mercury Mariner 40hp, 45hp and 50hp Ignition system Guide include the following. 

Model and Years include:

1. Mercury-Mainer 40 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot.
2. Mercury-Mainer 45 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot and Big Foot.
3. Mercury-Mainer 50 (4-Stroke) 4 cylinder 1995, 1996, 1997 & 1998.

 

The ignition system uses CDI (Capacitor Discharge Ignition). This system provides quick

voltage buildup and strong spark required for high power and high performance engines.

The CDI ignition system does not incorporate mechanically operated points, therefor making

this CDI unit virtually maintenance free.

As the flywheel rotates, electrical power (alternating current) is produced by the capacitor

charging coil. This power is rectified by diodes so that direct current voltage is utilized by

the ignition system. When the silicone controlled rectifier (SCR) is off, the D.C. voltage is

stored by the capacitor.

As the flywheel rotates 360

° from the point at which charging of the system began, the trigger

coil produces voltage which is rectified and applied to the (SCR) gate.

This gate signal then turns on the (SCR) and the stored voltage is shorted to ground thru

the primary winding of the ignition coil.

The voltage discharged to the primary winding of the ignition coil causes a surge of high voltage

to be induced in the secondary winding of the ignition coil. This induced voltage of sufficient

amplitude causes the spark plugs to fire.

The voltage stored by the capacitor holds the (SCR) on until the ignition coil current is discharged.

Then once the capacitor has discharged, the (SCR) turns off and the ignition cycle

is repeated.

Actuating the stop switch shorts the power being produced by the charge coil to ground. This

prevents charging of the capacitor and thus stops spark plug firing.

Ignition CDI Unit (Capacitor Discharge Ignition)

Under normal operating conditions the CDI unit controls the following:

1. Control ignition spark timing by monitoring the trigger pulses.

2. Maintains an idle timing of 5

° BTDC.

3. Advances spark timing quickly to 35

° BTDC under hard acceleration conditions.

4. Limits rpm of the engine to 2000 rpm in the event of low oil pressure conditions.

5. Limits rpm of the engine to 2000 rpm in the event of overheat condition.

6. Limits rpm of the engine in the event of over-speed (@ 6200 rpm).

NOTE:

The CDI unit controls all timing operations. There is no timing adjustment required

on this outboard engine.

 
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5

Electrical Components . . . . . . . . . . . . . . . . . . . 2A-6

Electrical Components . . . . . . . . . . . . . . . . . . . 2A-7

Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-8

Ignition Component Description . . . . . . . . . . . 2A-8

Capacitor Discharge Unit (CDI) . . . . . . . . . 2A-8

Trigger Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9

Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2A-9

Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2A-10

Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10

Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-11

Direct Voltage Adapter (DVA) . . . . . . . . . . 2A-11

Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-12

Tool: Multimeter/DVA Tester 91-99750A1 2A-12

Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-13

Suggested Testing Procedures . . . . . . . 2A-13

*Recommended Test . . . . . . . . . . . . . . . . . . 2A-13

Testing Ignition Components . . . . . . . . . . . . . . 2A-15

Resistance Tests . . . . . . . . . . . . . . . . . . . . . 2A-15

Trigger Coil Test . . . . . . . . . . . . . . . . . . . 2A-15

Stator Test (Ignition Charge Coil) . . . . 2A-16

Lighting Coil . . . . . . . . . . . . . . . . . . . . . . 2A-16

Ignition Coil (Primary) . . . . . . . . . . . . . . 2A-17

Spark Plug cap Removal . . . . . . . . . . . 2A-17

Ignition Coil (Secondary) . . . . . . . . . . . 2A-17

Spark Plug Cap Resistor Test . . . . . . . 2A-18

Thermo Switch . . . . . . . . . . . . . . . . . . . . 2A-18

Flywheel Removal and Installation . . . . . . . . . 2A-19

Flywheel Removal . . . . . . . . . . . . . . . . . . . . 2A-19

Flywheel Installation . . . . . . . . . . . . . . . . . . 2A-20

Flywheel without load ring & Spacer . 2A-20

Flywheel with load ring & Spacer . . . . 2A-21

(CDI) Unit Removal and Installation . . . . . . . . 2A-22

Ignition Coil Removal and Installation . . . . . . 2A-23

Rectifier Removal and Installation . . . . . . . . . 2A-24

Stator Removal and Installation . . . . . . . . . . . 2A-25

Trigger Coil Removal and Installation . . . . . . 2A-