1993 150 60* Johnson. What the ***#%$% ignition system.

Rebuilt the fuel pump as this could not pull fuel thru a water trap filter. Pulled her out and put her in the barrel. Tried to Fire the motor and had a struggle to get her started. She ran just fine before the pump rebuild. Would not run for long and one rev burst and she died.No sparks anywhere. Went thru the whole thing and found the Stator resistances not good. Fitted a new CDI stator and got sparks. Pulled her out and fired her. One rev burst and no sparks again. Happened to have an optical sensor and fitted it. Great, got sparks again. Pulled her out and she fired ok. Great I thought. Revd her a couple of times all ok. Revd her again and she quit again. Disconnected the Rectifier regulator and it runs real good no problem. A new rect/reg is on order. Whats next, the power pack. Does anyone understand what is going on. I certainly don't.

Re: 1993 150 60* Johnson. What the ***#%$% ignition system.

Have you got all covers in place when running the engine? Covers must be in place or stray light will cause problems. My experience is that the optical ignition goes out. That calls for replacing pack and eye. Check your rotor, the windows may have breaks in them. Make sure you have the right rotor. Make sure you are running only champion plugs. NGKs are OUT. Check the flywheel. If you replaced the flywheel with the old bolts you may have a flywheel that is wobbling around, replace the bolts with new. The regulator has no effect on the running of the engine, only charging the battery. Disconnect the boat harness and see if that improves running.

Re: 1993 150 60* Johnson. What the ***#%$% ignition system.

Thank you for your response multimech. I should have said that I have had a little experience with these beasties. A bad regulator/rectifier will kill the sparks, Disconnecting it will prove it good or bad. If you get the sparks back on disconnecting it, the Reg/Rect is defective.
I am wondering if the failure of one of the components could lead to what appears to be a chain reaction and if anyone else has experienced this problem.
Thanks again.

Re: 1993 150 60* Johnson. What the ***#%$% ignition system.

The regulator has no effect on the running of the engine, only charging the battery.

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Your are correct JamesR as a rectifier/reg can cause ignition problems. I have seen the CDI optical sensors off center and cause problems also as you have to shim them up .Make sure it has the new RFI grey wires and if its a original pack the biggest problems was the internal rectifier failing on this year model. As for chain reaction, never seen one as I install update kit with pack,eye wires on my customer when one fails. Keeps it from coming back and biting yer butt....

Re: 1993 150 60* Johnson. What the ***#%$% ignition system.

Thanks for the response Faztbullet. Will have to see what the new Rect/Reg does for us. The optical sensor replacement is an old OEM but I take note of your info on CDI shimming. Not sure about your reference to an update kit. Perhaps you can elaborate a little. Thanks again.

Re: 1993 150 60* Johnson. What the ***#%$% ignition system.

CDI part # 113-6367

Re: 1993 150 60* Johnson. What the ***#%$% ignition system.

Fitted A CDI replacment Rect/Reg and we now have big fat sparks again. Motor runs well in the tub. Looking forward to taking her out.
Thanks for all your interest.