Thanks Racerone. I troubleshot the heck out of this thing. I rebuilt my starter with new brushes and turned the com on my lathe. I even got a DVA adapter for my multimeter for the CDI troubleshooting specs. The Powerpack was a hail Mary!
None of it made sense. I even tested the old powerpacks...
UPDATE
I installed a new stator and timer base and still no spark. I finally tired a backup power pack on the port side and got spark! I swapped it to the starboard side and got spark I tested the other power packs again and they are still dead. I would have never guessed both power packs would...
Michigan Motorz are great. You can actually call them and talk to a person! I'm on Year 2 with my vortec 350 and a very happy customer. I'd use them again if I needed to.
I did some testing per the CDI Electronics troubleshooting guide. Note, I don’t have a DVI Adapter for my Fluke Multi Meter so those values are N/A.
Values according to CDI
WIRE | READ TO | RESISTANCE | DVA (Connected) | DVA (Disconnected)
Brown | Brown/Yellow | 950-1100 (35 Amp) | 150-400 V |...
It is a new battery from last year and I charged it before de-winterizing. I learned from past experience to never let the boat charge a weak battery. That lesson cost me a stater a couple years back.
It is spining as fast as ever and sounds very normal. Per CDI troubleshooting I even removed...
I tried starting my 1987 225 Evinrude today and it has no spark. It ran fine when I winterized it. I tried disconnecting the black/yellow wires at the powerpacks (1987 225 has 2 CDI's) still no spark. I tried closing the gap down on my volt tester to about 1/8 inch and checked several cylinders...
If you find water in your bellows you will have most likely found your culprit. I don't believe the output shaft has a water seal, only an oil seal. I've read others question the oil plug, filler and drain o-rings. Lots of places to fail but easy to address with a couple of bucks on OEM o rings...
I had water in my lower this year too. I tried a pressure test and and it held pressure with no drop overnight. When I switched the pump to vacuum, it started dropping pretty fast. The shift seal on mine went bad. I tore mine down for inspection which was good. If you do any tear down make sure...
Wow, That will be a project. Looking forward to following your progress. I did a partial transom repair on a Barefoot Ski Centurion a couple years ago. It turned out good, but was a lot of work. I used West Systems epoxy instead of cheaper poly resin. You get what you pay for. Do you have any...
Update (and quick question)
I replaced the shift seal and installed new o rings on the gear box, drain plug, dipstick and vent screw on top. Reassembled and performed vacuum test to 14 inHg per the manual and it held steady this time! One quick question, I was going to pull the gearbox back off...
I just replace the shift seal on mine as it was leaking pretty bad too. There is a helpful youtube video that explains the 3 different types of possible shift plates. (search AYR Cave Shop - part 5 shifting cover).
I saw the 3 options offered by Volvo in the manual, but the video did a good job...
danielkelsas, Sounds like an interesting project. There are a few questions that go beyond the outdrive. You elude to the current setup for 4 cylinder engines being swapped to v8's is that correct? If so you will need to solve some exhaust issues if you plan on keeping the 290 transom shields...