Okay bigcrappie here ya go.
First, I have to give a shout out to a new customer from Illinois and thank him for his patience, understanding, and giving me a chance to work for him, I will call him Ken and I gotta tell ya, Ken is a great guy!!
He brought his ailing Merc to me after following me on this forum in hopes that I could save it, well, I did, three times!! but it wasnt a fun battle but we won the war and I hate it he had to come back twice more.
The first time it showed up what a mess, Corroded battery cables, ailing battery, two out of three CDM modules not firing well, burnt out voltage regulator and associated wiring and a warped cylinder cover just pouring water out of the top and all over the spark plugs.
So it got a new stator, new trigger, four new CDM modules, voltage regulator and harness, and of course a new cylinder cover, gasket, poppet valve, and thermostat.
I even gave the motor its own dedicated battery and we added a battery solely for his electronics.
Three runs on the dyno and it performed perfectly, he came and got it and about a week later I get a call, a call that I hate getting!!
He was broke down on the water, two dead trolling motor batteries and a motor that wouldnt fire at all, but it did the last try and was barely able to get him to the dock.
This was on a big lake on a windy day, I can only imagine the stress.
Ken brought it back and I found the problem immediately, the dang link arm from the trigger ring to the control arm was disconnected and the timing went full retarded, producing spark mind you, but way after top dead center, wth!!
I know dang well I had it snapped in place, but after a couple of calls to my tech help line we figured reusing the ball and socket may have finished off the fit required to keep it in place, hmmm, new one on me but anything is possible so I replaced it with a used one as I didnt have any new ones on hand at the moment, I made sure it fit tightly with a rock solid snap that you could feel.
I rechecked the timing at idle and full throttle on the dyno, sent Ken home again.
And a week later, I get another call, CRAP!! yep, from Ken,, sigh, it ran twenty minutes this time, but this time instead of the link being disconnected, the entire arm is broken off!!! GGGRRRRR!! WTF now!!!
So for a third time this rig is back in my shop and while I was waiting on him I called my vendor from whom I buy ninety nine percent of my charging and ignition system parts through, CDI Electronics and Ken’s parts came from them and I have become friends with a tech there over the years and we hashed this issue out of what was going on.
After I got the flywheel back off and confirmed what was going on I had another trigger on the way overnight UPS.
The issue was human laziness in the QC department and that issue was addressed immediately with that issue no longer there, thankfully not many parts got out the door once it was discovered.
There is a fitment gauge to ensure that the trigger ring has the proper clearance so it wont grab the trigger itself when things warm up, we are talking about five thousands clearance between a spinning part and a moveable part where operating speeds exceed five thousand RPM’s!!
That fitment step wasnt being used,,, it is now!!!!
What happened was the inside diameter of the trigger was too small to clear the trigger ring on the flywheel, after running and clearances got to zero the trigger ring grabbed the trigger, the first time it popped the ball out of the socket, the second time it welded itself and broke the arm off killing the motor instantly.
Oh, and I performed a clearance check on the replacement trigger, perfect!
So my second shout out is to CDI Electronics, the tech there, and the management as they reimbursed me for the parts and treated me well enough I was able to reimburse Ken for his extra two trips that should have never happened!!
So now Ken and his lovely bride are back on the water with a tuned to the hilt Mercury, WHEW!!
Attachments:
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