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  1. #1
    Member
    Join Date
    Jun 2004
    Location
    Spanish Fort, AL
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    1,199

    Help needed pleaassseeee

    Ok, I know this is simple for many of you but I have NO experience working on an optimax until now
    I done a compression check on my 2002 200 XS (2.5 liter) and changed the plugs while I was at it.

    Well, as I was removed the swivel socket on the bottom port side (passenger side) plug, the wrench hit the "piece" where the plug wire connects and it broke off.

    This shows the hole where the piece broke off


    This is what broke off


    It's the bottom of 3


    Here's pics but my questions are:
    1. what is the broke piece called, "coil pack" ????
    2. How do I get the friggin thing off, the bolts seem to turn but not travel
    3. How much does this piece cost?
    2023 Allison XB-21 BasSport Pro Elite / 2023 Mercury 300R
    2024 Xpress X21 / Yamaha 250 SHO (SOLD)

    2022 Allison XB-21 BasSport Pro Elite / 2022 Mercury 300R (Sold)

  2. Member
    Join Date
    Jun 2004
    Location
    Spanish Fort, AL
    Posts
    1,199
    #2

    Re: Help needed pleaassseeee (JOEALLY)

    Ok, found some info on the net, seems its called a "coil kit". Also seems to have nuts on the backside of the coil plate holding the coil kits on. That's why the bolts are only turning.
    So now my questions are:

    1. Do I pull the coil plate to get to these nuts in order to remove the coil kit?
    2. Any special precautions or concerns to pulling the coil plate in order to do this?

    Thanks
    2023 Allison XB-21 BasSport Pro Elite / 2023 Mercury 300R
    2024 Xpress X21 / Yamaha 250 SHO (SOLD)

    2022 Allison XB-21 BasSport Pro Elite / 2022 Mercury 300R (Sold)

  3. Mercury 3L/4 Stroke/Verado Moderator EuropeanAM's Avatar
    Join Date
    Apr 2008
    Location
    Greenville, SC (US)
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    98,315
    #3

    Re: Help needed pleaassseeee (JOEALLY)

    You'll need ONE (1) each 856991A1 Coil Kit.

    Best way to access:

    -Remove lower cowlings.

    -Remove FOUR (4) bolts that retain coil plate to back of engine block

    -Slide coil plate out far enough to get a wrench on the nuts BEHIND the plate. If necessary, unplug various sensors, coils, drivers, etc- making note of where each plug goes.

    -Replace coil, ensuring coils and driver are stacked back precisely as previously installed.

    -Reinstall coil plate mounting bolts- use BLUE liquid loctite on the bolts.

    -Reconnect any disconnected wires/wiring.

    Sherm @ Sherm's Marine (or I) would be happy to assist you with a replacement coil.... Email or Phone are the BEST means of contacting the Parts Department(s).



    Dual Mercury Master Technician- for Mercury Outboards, Mercruiser and Mercury Racing at European Marine in Greenville, SC.
    Still consider myself a "Marine Apprentice" after 48 years (learn something new every day).
    Mercury Parts, Mercury Outboards, Smartcraft & Accessories, Injector Service, TDR Reeds- BBC Sponsor

  4. Member
    Join Date
    Jun 2004
    Location
    Spanish Fort, AL
    Posts
    1,199
    #4

    Re: Help needed pleaassseeee (EuropeanAM)

    Thanks Don AGAIN
    2023 Allison XB-21 BasSport Pro Elite / 2023 Mercury 300R
    2024 Xpress X21 / Yamaha 250 SHO (SOLD)

    2022 Allison XB-21 BasSport Pro Elite / 2022 Mercury 300R (Sold)

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