Johnson Evinrude Power Pack & Mercury Switchbox
Posted by Macomb Marine on
Other than changing the spark plugs, an outboard ignition doesn't require much product maintenance. Normally, it either works or it doesn't, albeit occasionally you could have a sporadic (ghost) issue. The power pack (or switchbox), the stator, the outboard ignition trigger assembly, the ignition coils, the plug wires, and the spark plugs are a few of the groups that make up a typical outboard engine's replaceable parts. Each element is required for ignition to take place.
Some of these ignition components have been dropped from later designs of Electronic Fuel Injection (EFI) outboards.
Similar to any engine, the cables, battery, and battery state are all important, and the connections are what make the ignition work. Connections must be tight, and cables must be clean and in good shape.
The ignition control module is referred to as a "power pack" by Johnson & Evinrude, BRP, and Mercury, and a "switchbox" by BRP. The ignition timing mechanism is sometimes referred to as a "timer base" by Johnson & Evinrude and a "trigger" by Mercury. Both have the same aim, which is to choose the ideal moment for a spark to happen.
The essential technical description is as follows:
Power packs or switchboxes are akin to the ignition system's brain.
The switchbox receives inputs from the stator, trigger, temperature switch, shift interrupt switch, and kill switch.
The switchbox decides when to fire the spark plug and provides outputs for the ignition coil(s).
The trigger and flywheel are the only two moving parts of the ignition mechanism. The flywheel has magnets that send an impulse to the stator, and the trigger rotates on the engine block beneath it to alter the timing of the ignition.
The trigger's movement controls the progress of the engine timing. For optimum performance, the ignition coil must be fired by the switchbox at the proper moment. Additionally, a stator located beneath the flywheel supplies the switch box's electrical input.
Related products:
Johnson & Evinrude Power Packs
CDI-113-4808 Johnson & Evinrude power pack
CDI-113-4037 Johnson & Evinrude ignition power pack
CDI-113-6292K 1 Johnson & Evinrude ignition power pack
CDI-113-6212 Johnson & Evinrude 6-cyl power pack
CDI-113-4041 Johnson & Evinrude 4-cyl power pack
CDI-113-3865 Johnson & Evinrude Ignition power pack
CDI-113-1726 Johnson & Evinrude 6-cyl. power pack with cover
CDI-113-4767 Johnson & Evinrude 2-cyl. power pack
CDI-113-1731 Johnson & Evinrude 4-cyl. power pack with cover
CDI-113-5316 Johnson & Evinrude 2-cyl. power pack
CDI-113-4028 Johnson and Evinrude 4- & 8-cyl. looper power pack
CDI-117-6E5-12 Yamaha ignition 4-cyl. power pack
CDI-113-3110 Johnson & Evinrude 4-cyl. power pack
Mercury Switchboxes
CDI-114-5772 Mercury switchbox
CDI-114-4953-32 Mercury switchbox
CDI-114-6222 Mercury switchbox
CDI-114-7509 Mercury/Force switchbox
CDI-114-7778 Mercury switchbox
CDI-114-7452K 1 Mercury switchbox
CDI-114-9052 Mercury/Mariner switchbox 3-cyl.
CDI-114-5713 Mercury/Mariner switchbox 2-cyl.
Trigger - Mercury
CDI-134-6452 - Mercury 4-cyl. Trigger
Optical Power Packs & Optical Sensor Note for Johnson & Evinrude
The method used to activate the ignition system is described as an optical power pack. A photocell is used in an optical power pack. A timing wheel passes an open or closed window by the stationary optical sensor as the engine crankshaft revolves, sending a signal to the power pack.
The signal to the power pack controls the crankshaft's position, rotational direction, and when to ignite a particular cylinder. As RPMs rise, the optical sensor turns in conjunction with the throttle position to enable ignition advance.
Related Products:
CDI-133-6343 - Johnson & Evinrude 4- & 6-cyl. Timer Base Optical Sensor
CDI-113-6367K 1 Johnson & Evinrude Optical Power Pack & Sensor w/Plug Wire Set
CDI-113-6292 Johnson & Evinrude 4-cyl. Optical Power Pack
CDI-113-4985 - Johnson & Evinrude 6-cyl. Optical Power Pack
Stators
A stator serves two functions and represents an integral part of the ignition system:
It charges the battery through the regulator/rectifier.
It provides the electrical current, e.g. voltage, to the ignition system.
Stators are OEM designed and specified to a single engine model or a family of engines. One thing that’s changed over the last 10-20 years is the physical and output size of stators. This is due to the increased electrical demands in boats today.
DC power demand is high, so the outboard manufacturers have increased the size of the stator to provide as much charging amperage to the battery as they can, given the space limitations under the flywheel.
Some Mercury outboards use a belt-driven alternator for charging rather than a charging stator under the flywheel. Because current demand is so high, they prefer to mount a belt-driven alternator to provide battery charging.
Related Products:
CDI-173-4643 Johnson & Evinrude 6 & 8-cyl. Stator
CDI-173-4292 Johnson & Evinrude 6-cyl. Stator
CDI-174-9710K 1 Mercury 2-, 3- & 4-cyl. Stator (16 amp)
CDI-174-8778K 1 Mercury 2-,3- & 4-cyl. Stator (9 amp)
CDI-174-9610K 2 - Mercury 6-cyl. stator (40 amp)
CDI-174-5454K 1 - Mercury 3- & 4-cyl. Stator (9 amp)
CDI-174-5456 - Mercury 6-cyl. Stator (9 amp)
CDI-173-4981 Johnson & Evinrude 6-cyl stator (9 amp)
CDI-174-2075K 2 Mercury stator 2-, 3- 4-cyl (16 amp)
Rectifiers/Regulators
As stated above, rectifiers/regulators are used for battery charging and are part of the whole electrical ignition system.
A rectifier converts AC voltage to DC. Based on the AC input voltage and amperage, the amount of DC charge output will change. As an outboard speeds up in RPMs, the amount of current which the stator is capable of producing increases. Outboards that use a rectifier are typically smaller outboards and the amperage isn't regulated like on larger horsepower engines.
A voltage regulator not only acts as a rectifier to convert AC voltage from the stator to DC but also controls the amount of charge current into the battery. It regulates or manages the charging of the battery so there is no harm to the battery from overcharging. The regulator is a more sophisticated part than a rectifier.
Related Products:
CDI-194-5279 Mercury Voltage Regulator
CDI-193-4093 Johnson & Evinrude Voltage Regulator
CDI-193-5204 Johnson & Evinrude Voltage Regulator (35 amp)
CDI-194-2115K 1 Mercury Voltage Regulator
CDI-193-6048 Johnson & Evinrude 35-amp Rectifier - Sierra & Johnson & Evinrude replacement
CDI-193-3689 Johnson & Evinrude 35-amp Rectifier - Johnson & Evinrude replacement (GR)
Ignition Coils
Ignition coils are unique to an engine family. Its function is to provide an electrical pulse to the spark plug that jumps the gap creating a spark. The switchbox provides the voltage and current to the coil along with the signal for the coil to fire.
There is no maintenance, other then spark plugs and spark plug wires with these components, but if there is no spark, make sure connections are good, tight, the wiring is intact, and nothing has been pinched, clipped or cut by mistake.
Related Products:
CDI-183-2508 - Ignition Coil
CDI-182-4475R - Chrysler Force Ignition Coil
CDI-183-2366 - Johnson & Evinrude Ignition Coil 2,3,4,6-cyl. replacement
Timer Bases - Johnson & Evinrude
The timer base provides a signal to the switchbox telling it what the crankshaft and piston position is in and when to fire the ignition coil. The timer base rotates and timing of when the spark occurs changes depending on the RPMs of the engine. The trigger base part numbers vary depending on the make and family of engines. For example, with OMC you have the V4, V6, inline 2-cylinder and 3-cylinder engines. Knowing the correct year, the engine model, and the serial number is vital to ordering the correct part.
Related Products:
CDI-133-3533 Johnson & Evinrude Timer Base
CDI-133-3853 Johnson & Evinrude 6-cyl. Timer Base for engines with Quick Start
Marine Ignition System Diagnostics
Outboard ignition systems are a technical item, so the typical boat owner won’t necessarily have the knowledge about how the ignition system works. It can be difficult to diagnose exactly what’s failed in the ignition system and why spark doesn't occur.
Ignition component failure can be due to another part of the ignition system not functioning properly. You should be aware that replacement of a failed part with a new part can occur again due to another part not functioning correctly.
Proper diagnosis and troubleshooting are essential to determining a failed ignition component. In some cases, boat owners or dealers will order and replace all the ignition components to save time diagnosing an issue or intermittent problem. It's up to the individual what works best for them.
Some of these ignition components have been dropped from later designs of Electronic Fuel Injection (EFI) outboards.
Similar to any engine, the cables, battery, and battery state are all important, and the connections are what make the ignition work. Connections must be tight, and cables must be clean and in good shape.
The ignition control module is referred to as a "power pack" by Johnson & Evinrude, BRP, and Mercury, and a "switchbox" by BRP. The ignition timing mechanism is sometimes referred to as a "timer base" by Johnson & Evinrude and a "trigger" by Mercury. Both have the same aim, which is to choose the ideal moment for a spark to happen.
The essential technical description is as follows:
Power packs or switchboxes are akin to the ignition system's brain.
The switchbox receives inputs from the stator, trigger, temperature switch, shift interrupt switch, and kill switch.
The switchbox decides when to fire the spark plug and provides outputs for the ignition coil(s).
The trigger and flywheel are the only two moving parts of the ignition mechanism. The flywheel has magnets that send an impulse to the stator, and the trigger rotates on the engine block beneath it to alter the timing of the ignition.
The trigger's movement controls the progress of the engine timing. For optimum performance, the ignition coil must be fired by the switchbox at the proper moment. Additionally, a stator located beneath the flywheel supplies the switch box's electrical input.
Related products:
Johnson & Evinrude Power Packs
CDI-113-4808 Johnson & Evinrude power pack
CDI-113-4037 Johnson & Evinrude ignition power pack
CDI-113-6292K 1 Johnson & Evinrude ignition power pack
CDI-113-6212 Johnson & Evinrude 6-cyl power pack
CDI-113-4041 Johnson & Evinrude 4-cyl power pack
CDI-113-3865 Johnson & Evinrude Ignition power pack
CDI-113-1726 Johnson & Evinrude 6-cyl. power pack with cover
CDI-113-4767 Johnson & Evinrude 2-cyl. power pack
CDI-113-1731 Johnson & Evinrude 4-cyl. power pack with cover
CDI-113-5316 Johnson & Evinrude 2-cyl. power pack
CDI-113-4028 Johnson and Evinrude 4- & 8-cyl. looper power pack
CDI-117-6E5-12 Yamaha ignition 4-cyl. power pack
CDI-113-3110 Johnson & Evinrude 4-cyl. power pack
Mercury Switchboxes
CDI-114-5772 Mercury switchbox
CDI-114-4953-32 Mercury switchbox
CDI-114-6222 Mercury switchbox
CDI-114-7509 Mercury/Force switchbox
CDI-114-7778 Mercury switchbox
CDI-114-7452K 1 Mercury switchbox
CDI-114-9052 Mercury/Mariner switchbox 3-cyl.
CDI-114-5713 Mercury/Mariner switchbox 2-cyl.
Trigger - Mercury
CDI-134-6452 - Mercury 4-cyl. Trigger
Optical Power Packs & Optical Sensor Note for Johnson & Evinrude
The method used to activate the ignition system is described as an optical power pack. A photocell is used in an optical power pack. A timing wheel passes an open or closed window by the stationary optical sensor as the engine crankshaft revolves, sending a signal to the power pack.
The signal to the power pack controls the crankshaft's position, rotational direction, and when to ignite a particular cylinder. As RPMs rise, the optical sensor turns in conjunction with the throttle position to enable ignition advance.
Related Products:
CDI-133-6343 - Johnson & Evinrude 4- & 6-cyl. Timer Base Optical Sensor
CDI-113-6367K 1 Johnson & Evinrude Optical Power Pack & Sensor w/Plug Wire Set
CDI-113-6292 Johnson & Evinrude 4-cyl. Optical Power Pack
CDI-113-4985 - Johnson & Evinrude 6-cyl. Optical Power Pack
Stators
A stator serves two functions and represents an integral part of the ignition system:
It charges the battery through the regulator/rectifier.
It provides the electrical current, e.g. voltage, to the ignition system.
Stators are OEM designed and specified to a single engine model or a family of engines. One thing that’s changed over the last 10-20 years is the physical and output size of stators. This is due to the increased electrical demands in boats today.
DC power demand is high, so the outboard manufacturers have increased the size of the stator to provide as much charging amperage to the battery as they can, given the space limitations under the flywheel.
Some Mercury outboards use a belt-driven alternator for charging rather than a charging stator under the flywheel. Because current demand is so high, they prefer to mount a belt-driven alternator to provide battery charging.
Related Products:
CDI-173-4643 Johnson & Evinrude 6 & 8-cyl. Stator
CDI-173-4292 Johnson & Evinrude 6-cyl. Stator
CDI-174-9710K 1 Mercury 2-, 3- & 4-cyl. Stator (16 amp)
CDI-174-8778K 1 Mercury 2-,3- & 4-cyl. Stator (9 amp)
CDI-174-9610K 2 - Mercury 6-cyl. stator (40 amp)
CDI-174-5454K 1 - Mercury 3- & 4-cyl. Stator (9 amp)
CDI-174-5456 - Mercury 6-cyl. Stator (9 amp)
CDI-173-4981 Johnson & Evinrude 6-cyl stator (9 amp)
CDI-174-2075K 2 Mercury stator 2-, 3- 4-cyl (16 amp)
Rectifiers/Regulators
As stated above, rectifiers/regulators are used for battery charging and are part of the whole electrical ignition system.
A rectifier converts AC voltage to DC. Based on the AC input voltage and amperage, the amount of DC charge output will change. As an outboard speeds up in RPMs, the amount of current which the stator is capable of producing increases. Outboards that use a rectifier are typically smaller outboards and the amperage isn't regulated like on larger horsepower engines.
A voltage regulator not only acts as a rectifier to convert AC voltage from the stator to DC but also controls the amount of charge current into the battery. It regulates or manages the charging of the battery so there is no harm to the battery from overcharging. The regulator is a more sophisticated part than a rectifier.
Related Products:
CDI-194-5279 Mercury Voltage Regulator
CDI-193-4093 Johnson & Evinrude Voltage Regulator
CDI-193-5204 Johnson & Evinrude Voltage Regulator (35 amp)
CDI-194-2115K 1 Mercury Voltage Regulator
CDI-193-6048 Johnson & Evinrude 35-amp Rectifier - Sierra & Johnson & Evinrude replacement
CDI-193-3689 Johnson & Evinrude 35-amp Rectifier - Johnson & Evinrude replacement (GR)
Ignition Coils
Ignition coils are unique to an engine family. Its function is to provide an electrical pulse to the spark plug that jumps the gap creating a spark. The switchbox provides the voltage and current to the coil along with the signal for the coil to fire.
There is no maintenance, other then spark plugs and spark plug wires with these components, but if there is no spark, make sure connections are good, tight, the wiring is intact, and nothing has been pinched, clipped or cut by mistake.
Related Products:
CDI-183-2508 - Ignition Coil
CDI-182-4475R - Chrysler Force Ignition Coil
CDI-183-2366 - Johnson & Evinrude Ignition Coil 2,3,4,6-cyl. replacement
Timer Bases - Johnson & Evinrude
The timer base provides a signal to the switchbox telling it what the crankshaft and piston position is in and when to fire the ignition coil. The timer base rotates and timing of when the spark occurs changes depending on the RPMs of the engine. The trigger base part numbers vary depending on the make and family of engines. For example, with OMC you have the V4, V6, inline 2-cylinder and 3-cylinder engines. Knowing the correct year, the engine model, and the serial number is vital to ordering the correct part.
Related Products:
CDI-133-3533 Johnson & Evinrude Timer Base
CDI-133-3853 Johnson & Evinrude 6-cyl. Timer Base for engines with Quick Start
Marine Ignition System Diagnostics
Outboard ignition systems are a technical item, so the typical boat owner won’t necessarily have the knowledge about how the ignition system works. It can be difficult to diagnose exactly what’s failed in the ignition system and why spark doesn't occur.
Ignition component failure can be due to another part of the ignition system not functioning properly. You should be aware that replacement of a failed part with a new part can occur again due to another part not functioning correctly.
Proper diagnosis and troubleshooting are essential to determining a failed ignition component. In some cases, boat owners or dealers will order and replace all the ignition components to save time diagnosing an issue or intermittent problem. It's up to the individual what works best for them.