'96 Johnson 50 hp cranks, has fuel, no start

[cptmarvel]

Waiting on girlfriend to get home with spark checker. Compression is 140 in both cylinders. What SHOULD it be, minimum?

 

[boobie]

Compression sounds good. Spark should jump a 7/16" open air gap on tester.

 

[Rudi2]

Waiting on girlfriend to get home with spark checker. Compression is 140 in both cylinders. What SHOULD it be, minimum?

140 should be good

 

[cptmarvel]

Ok. No spark on tester. No spark holding plug to head. Either plug. Check wires first, then......?

 

[Silvertip]

It's very likely NOT the spark plug wires. It is very likely the kill switch is not engaged, bad ignition switch, bad wiring from the two "M" terminals on the switch, or you have a bad ignition module. It probably is NOT the ignition switch but more likely the kill switch or wiring. Verify all that before you spring for a module.

 

[cptmarvel]

Where is the kill switch? PO stated that it didn't have one, which I find odd as boat and motor are both '96 models. There is a graphic of a kill switch on the control housing. There is also a thumb screw looking thing right under the key switch, which I took to be a tension adjuster for something.

 

[racerone]

Check the flywheel key.

 

[cptmarvel]

Thanks. Can I see if it's offset or intact by just taking off the nut? Looks like I need a puller to get the flywheel off.

 

[racerone]

Correction ---If there is no spark the flywheel key is not the issue.--Likely it is the powerpack or kill switch.

 

[cptmarvel]

No Title

I fingered that. Even if keys broke or offset, as long as the flywheel is spinning it'll still fire but be outta time. Considering snipping the black/yellow. Thoughts?

 

[interalian]

Don't snip it, poke it out of the rubber connector for test.

 

[cptmarvel]

The rubber connector in engine area don't seem to come apart (which don't make sense but I find no seams) that the one you're talking about?

 

[jakedaawg]

At power pack there is a five pin amphenol connnector. Jump all four wires that are not blk/yel. This leaves blk/yel open. There is a seam on connector. They can be tight.

After opening the blk/yel wire test for spark. If there is spark test key switch, kill switch and related wires.if they trest good replace pack

 

[cptmarvel]

Isolated black/yellow wire. No spark. Downloading service manual now for testing instructions. What is this "pack" that you speak of?

 

[cptmarvel]

So if it calls for a "peak meter reading" I'm going to make the connections, do the test and watch for the highest read out. Yay/nay? Got the factory service manual and don't have all the high speed test equipment. Just a digital multimeter and a bunch of wires and stuff. Hammer. Crescent wrench. You know.

 

[cptmarvel]

No Title

First test

 

[Fed]

CDI also say to test with the Yellow wires disconnected from the rectifier, quick & easy before going off to test stator outputs.

 

[Fed]

FWIW you could have also used a simple Ohm meter test on the Black/Yellow to test the boat side of the kill circuit.
Connect meter between boat side Black/Yellow and power pack ground then operate the key switch & lanyard switch and diagnose the results.
That way you're testing the complete circuit and components in one go.

 

[cptmarvel]

CDI also say to test with the Yellow wires disconnected from the rectifier, quick & easy before going off to test stator outputs.

What is "CDI" and how do I get some? Going off factory manual right now. So far the circuit tests as it should. Except for the no spark crap

 

[Fed]

http://www.cdielectronics.com/wp-content/uploads/2013/08/Troubleshooting-Guide-Inside-Pages.pdf

Page 39, the first 4 bullet points should be tried before progressing to the harder stuff.