And yet another Johnson won't start!

[walkerhound270]

Hello everyone! While this is my first post I have been coming here for a while and have always been able to solve my outboard issues through thread research.....this time, however, I need some help.

There have been a lot of "no spark, no start" threads here recently, so I apologize if this one sounds like a broken record. So here we go.....

I purchased a pontoon boat last year with a 1993 Johnson 60HP 3 cyl. outboard. This motor is the first one that I have owned larger than a 25. It has run like champ since last June, and I have been more than pleased with it. I took out it out a month ago.....fired first crank as usual. I took it out two weeks ago.....fired first crank as usual. Well of course last weekend when the inlaws were here......it would just turn over. I checked for fuel, made sure the priming cylenoid was clicking, and even checked the plugs to make sure they were getting fuel to them. That all checked out. After reading numerous threads I went to NAPA and bought an inline spark tester. I have no spark to any cylinder. After going the CDI link, I tried to follow its testing order. It says to disconnect the Black/Yellow wire at the powerpack. This wire is obviously encased with gel, but runs to a plug with other orange wires. Do I just disconnect the plug or am I missing something? I went ahead and unhooked the yellow wires from the rectifier like step 2 says, and I still had no spark.

Unlike my Evinrude and Johnson 25's, this motor does not have the kill switch attachment by the key. Earlier today I went to pull the ignition switch to make sure everything was hooked up and not damaged. I noticed that this is not the original throttle/ ignition box for this pontoon. This one is mounted on the right of the console, but is set up to be on the left side. (meaning when i push the throttled lever forward, it says reverse on the handle.) When I removed the box off of the console, there was a hole covered with a piece of tape and I am wondering if that may have been the Kill switch. I couldn't get the ignition switch out because the SS screws holding the box together started to strip.

I really would like to try to diagnose this myself. After speaking to the local boat mechanic it seems he just likes to replace parts until it gets fixed! Thanks for your expert help and most importantly allowing me to learn! In 15 years of owning small outboards the only thing I've ever had to do was tune-up maintenance. Thanks again!

[boobie]

You'll have to take the plug with the black/yellow wires apart, push out the black/yellow wire with a small nail or something and then reconnect the plug. Then check your spark. If you have spark you have a boat prob. If not, you have a mtr prob.

[walkerhound270]

Thanks for the reply, I will try that. I was doing some research and found a part by part breakdown of the throttle/ignition box. I was correct in assuming that the hole covered up with the piece of tape was for the safety kill switch. Since it is not there was it possibly by-passed? I will update thread as soon as I conduct the test.

[walkerhound270]

Ok, was able to get home early enough to mess with the motor. I was able to remove the black/yellow wire from the plug exactly how boobie suggested. (Thank you, sir!) I hooked everything back up and turned the battery switch on. I encountered another issue while trying to get the motor to turn over. When I turn the key on, the lights on the console light up...well when I turned the key....i got nothing. This has happened a few times before, but never been a consistant problem. With a multi meter I checked the voltage at the batteries, then on the output side of the battery switch, then where the power wire goes to the cylenoid. Had 12.8 at all these locations. I made sure the large red plug on the back of the block was tight, and then the small red one right behind the cylenoid. After messing with this I tried again and the starter engaged. Not sure if it was just luck, those red plugs being loose, or if this may be a ignition switch issue. Any thoughts?

I then had my wife turn the key while I watched the spark tester.......nothing on all 3 cylinders. What now? Any other tests I can do? Thanks everyone in advance!

[BonairII]

I probably won't be of much help, but I have turned my key before and got 'silence'.

Turns out I had left the motor in gear and throttle forward...the safety interlock kept the motor from cranking. Any chance that was the case when you got 'nothing' when turning the key?

[walkerhound270]

Thanks, Bonairll, for the response. I did check that and make sure it was clicked in the neutral position. Now, the only reason I did that is because I have left it slightly in gear before. The second weekend I had the boat we were on a sandbar and the motor wouldn't do squat. I got to fussin' a little bit and a good friend of mine walked over to the console and fired it right up. "How the hell did you do that?" I asked. "Helps if ya' got it in neutral, dude." he replied. I haven't forgot that...talk about feelin' dumb!