Mercury 2006 50-HP: Bad Spark Coil - Moderated Discussion Areas

  ContinuousWave
  Whaler
  Moderated Discussion Areas
  ContinuousWave: Whaler Repairs/Mods
  Mercury 2006 50-HP: Bad Spark Coil

search | FAQ | profile | register | author help

Author Topic:   Mercury 2006 50-HP: Bad Spark Coil

CountryClark posted 09-23-2014 11:51 PM ET (US)
I [am] trying to figure out [a remedy to a problem with] a 2006 Mercury 50-HP EFI. [I] found that the #2 spark coil was burned at the connector, and the [connector] pins were shot. [I] replaced the coil and installed a new plug to [connect to] the new coil. The [2006 Mercury 50-HP EFI] ran on all four cylinders for half the summer. Then, the #4 spark coil [burned at the connector and the connector pins were shot].
Mercury has a recall on the voltage regulators for some model motors.
Are there any testing specifications for the voltage regulator? The stator? The trigger? I [have] checked the wiring harness and the ground [connections].
jimh posted 09-24-2014 12:28 AM ET (US)
If you want to perform your own service work and your own diagnosis of problems with an outboard engine, the best investment and first investment should be in the factory service manual. The factory service manual will typically give you test procedures for electrical circuits and components.
I think there is a very good probability the Mercury factory service manual for your Mercury outboard will have the test procedures you are seeking. Sometimes you can find PDF copies of service manuals with a web search using GOOGLE. Hint: some European distributors have archives of them online.
jimh posted 09-24-2014 12:32 AM ET (US)
The problem you have seems to be with the connectors. They are probably not making good connection. You ought to inspect them carefully. If there is any sign of corrosion on the electrical contacts of the connectors, either on the coil assembly or on the wiring harness that connects to them, try to clean the connectors and remove the corrosion. When you have clean, dry, corrosion-free electrical contacts, mate the connector. Apply some insulating grease to the connector body--not to the contacts themselves--so that the connector becomes sealed against intrusion of moisture.
The service manual will have recommendations for servicing the connectors and what to use when mating them to prevent corrosion.
Edje posted 09-24-2014 04:28 AM ET (US)
There is a Mercury service bulletin for the 40 to 50 models with 0T980000 [to] 1C104332 serial numbers. If one coil fails you have to replace all the coils as a set. The old part number [is] superseded by a new number.
jimh posted 09-24-2014 08:59 AM ET (US)
I am inferring there is a new design for the spark coils. Otherwise it makes no sense why you'd need to replace them as a set. Usually it is possible to manufacture a device like a spark coil with enough repeatability that each one is not a unique part.
CountryClark posted 09-25-2014 11:31 PM ET (US)
Thanks[.] [I] found the problem. [I] replaced one coil [but it was] no[t covered by] warranty. [W]hen [I] order the new coils, should [I] order three coils? The one [I] already replaced is under 10-hours old. Or, replace all four (like the bulletin says)[?]
jimh posted 09-26-2014 11:18 AM ET (US)
If the coil you already replaced matches the three new coils you will be ordering, I don't see why you would need to replace it again after only ten hours of use. A spark coil ought to have a service life of at least 1,000-hours. I would not expect that ten hours of use is going to represent any sort of degredation of the service life or affect the performance.
jimh posted 09-29-2014 10:22 AM ET (US)
Also see this concurrent discussion about problems with a Mercury outboard that may be caused by a bad spark coil:
http://continuouswave.com/ubb/Forum3/HTML/020990.html

Hop to:

Contact Us | RETURN to ContinuousWave Top Page

Powered by: Ultimate Bulletin Board, Freeware Version 2000
Purchase our Licensed Version- which adds many more features!
© Infopop Corporation (formerly Madrona Park, Inc.), 1998 - 2000.

Author	Topic: Mercury 2006 50-HP: Bad Spark Coil
CountryClark	posted 09-23-2014 11:51 PM ET (US) I [am] trying to figure out [a remedy to a problem with] a 2006 Mercury 50-HP EFI. [I] found that the #2 spark coil was burned at the connector, and the [connector] pins were shot. [I] replaced the coil and installed a new plug to [connect to] the new coil. The [2006 Mercury 50-HP EFI] ran on all four cylinders for half the summer. Then, the #4 spark coil [burned at the connector and the connector pins were shot]. Mercury has a recall on the voltage regulators for some model motors. Are there any testing specifications for the voltage regulator? The stator? The trigger? I [have] checked the wiring harness and the ground [connections].
jimh	posted 09-24-2014 12:28 AM ET (US) If you want to perform your own service work and your own diagnosis of problems with an outboard engine, the best investment and first investment should be in the factory service manual. The factory service manual will typically give you test procedures for electrical circuits and components. I think there is a very good probability the Mercury factory service manual for your Mercury outboard will have the test procedures you are seeking. Sometimes you can find PDF copies of service manuals with a web search using GOOGLE. Hint: some European distributors have archives of them online.
jimh	posted 09-24-2014 12:32 AM ET (US) The problem you have seems to be with the connectors. They are probably not making good connection. You ought to inspect them carefully. If there is any sign of corrosion on the electrical contacts of the connectors, either on the coil assembly or on the wiring harness that connects to them, try to clean the connectors and remove the corrosion. When you have clean, dry, corrosion-free electrical contacts, mate the connector. Apply some insulating grease to the connector body--not to the contacts themselves--so that the connector becomes sealed against intrusion of moisture. The service manual will have recommendations for servicing the connectors and what to use when mating them to prevent corrosion.
Edje	posted 09-24-2014 04:28 AM ET (US) There is a Mercury service bulletin for the 40 to 50 models with 0T980000 [to] 1C104332 serial numbers. If one coil fails you have to replace all the coils as a set. The old part number [is] superseded by a new number.
jimh	posted 09-24-2014 08:59 AM ET (US) I am inferring there is a new design for the spark coils. Otherwise it makes no sense why you'd need to replace them as a set. Usually it is possible to manufacture a device like a spark coil with enough repeatability that each one is not a unique part.
CountryClark	posted 09-25-2014 11:31 PM ET (US) Thanks[.] [I] found the problem. [I] replaced one coil [but it was] no[t covered by] warranty. [W]hen [I] order the new coils, should [I] order three coils? The one [I] already replaced is under 10-hours old. Or, replace all four (like the bulletin says)[?]
jimh	posted 09-26-2014 11:18 AM ET (US) If the coil you already replaced matches the three new coils you will be ordering, I don't see why you would need to replace it again after only ten hours of use. A spark coil ought to have a service life of at least 1,000-hours. I would not expect that ten hours of use is going to represent any sort of degredation of the service life or affect the performance.
jimh	posted 09-29-2014 10:22 AM ET (US) Also see this concurrent discussion about problems with a Mercury outboard that may be caused by a bad spark coil: http://continuouswave.com/ubb/Forum3/HTML/020990.html