90-824052R3 JUNE 2002 ELECTRICAL - 2A-11
Ignition Test Procedures
WARNING
When testing or servicing the V-6 outboard
ignition system, high voltage is present. Be
extremely cautious. DO NOT TOUCH OR
DISCONNECT any ignition parts while engine is
running, while key switch is on or while battery
cables are connected.
Failure to comply with the following items may result
in damage to the ignition system.
1. DO NOT reverse battery cable connections. The
battery negative cable is (–) ground.
2. DO NOT “spark” battery terminals with battery
cable connections to check polarity.
3. DO NOT disconnect battery cables while engine
is running.
4. DO NOT crank engine when switch boxes are not
grounded to engine.
A process of elimination must be used when
checking the ignition system without a voltmeter
(capable of measuring 400 volts DC, or higher) and
Direct Voltage Adaptor (91-89045), as the switch
boxes and ignition coils cannot be thoroughly
checked with conventional test equipment.
All other components can be tested with an
ohmmeter. Before troubleshooting the ignition
system, check the following:
1. Make sure that electrical harness, ignition switch,
and mercury switch are not the source of the
problem.
2. Check that plug-in connectors are fully engaged
and terminals are free of corrosion.
3. Make sure that wire connections are tight and
free of corrosion.
4. Check all electrical components, that are
grounded directly to engine, and all ground wires
to see that they are grounded to engine.
5. 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.
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.
Direct Voltage Adaptor (DVA)
The DVA can be used with Quicksilver VOA Meter
91-62562A1, Quicksilver Volt/Ohm meter 91-93572,
Multi Meter/DVA Tester 91-99750 or an equivalent
volt meter (capable of measuring 400 volts DC or
higher) to check primary ignition voltage on
Alternator Driven Ignition (ADI) systems. (Models are
specified in Test Charts, following.)
CAUTION
To protect against meter and/or component dam-
age, observe the following precautions:
-- MAKE CERTAIN that Positive (+) lead/terminal
of DVA is connected to Positive (+) receptacle of
meter.
-- 400 VDC test position (or higher) MUST BE
used for all tests, except “switch box bias” test.
-- DO NOT CHANGE meter selector switch posi-
tion while engine is running and/or “cranked.”
-- Switch boxes MUST REMAIN GROUNDED
(mounted) during tests. Running or cranking en-
gine with switch boxes ungrounded may damage
switch boxes. If removed for easier access, a
separate ground MUST BE INSTALLED.
WARNING
DANGER - HIGH VOLTAGE/SHOCK HAZARD! Do
Not touch ignition components and/or metal test
probes while engine is running and/or
“cranked.”
Test procedures and specifications are provided for
checking primary ignition voltage while the engine is
running and/or being “cranked.”
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