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!