Mercury 40 Service Manual

2
A
IGNITION
90-828631R3 MARCH 1999 Page 2A-1
ELECTRICAL
Section 2A - Ignition
Table of Contents
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-26. . . . . .

Mercury 40 Specifications

General

Horsepower	40 hp
Starting System	Electric
Steering	Remote
Fuel Induction System	EFI (Electronic Fuel Injection)
Shaft Length	20"
Full Throttle RPM Range	6000