1997 Ocean Pro 115 lost all spark, any suggestions?

[backstop13]

Well I just finished rebuilding the carbs on my 97 Ocean Pro 115 and pulled it outside to run it. A little hard starting, but I've become accustomed to that since removing the VRO, but started and was running fine. Stopped and restarted several times to make sure it would idle, which was the reason for rebuilding the carbs, and it was acting fine, no alarms or anything not acting normal. Then, I was just about to shut it off when it just died! Cranks wonderfully, but wouldn't start so I got a spark plug gap tester and checked, and now I have no spark. I disconnected the yellow wire plug from the stator and still had no spark, the plugs are new, well I ran them once, so it shouldn't be them, what else can I check before throwing parts at it? I did notice the tach was inop, which I've been told was a rectifier issue, but would the rectifier failing cause me to lose spark because the engine was running fine for 20-30 minutes and restarted 6-7 times with no issues. I'm at a loss here and have no reputable boat mechanics within 60 miles of me so most of the repairs that have been done have been done by me with help from this forum. Any advice?

 

[Bosunsmate]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Have a look for no spark condition on your motor in this guide, sometimes they suggest disconnecting the rectifier and re checking for spark
ISSUU - CDI Electronics Practical Outboard Ignition Troubleshooting by CDI Electronics

 

[backstop13]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Thanks, I'll try that. I checked everything else again, cleaned up the grounds on the coils and plug wires, even disconnected and checked the 5way plug at the power pack and still no luck. I let it sit for about an hour, went back out and hit the key and it started? Let it run for 4-5 minutes and it died again, but this time when I would try to restart it the motor acted like it wanted to start, what the heck is going on? Checked for spark again and NOTHING! I'm thinking power pack and/or coils, any support on that diagnosis? Stator appears fine, no signs of heat failure or melting, rectifier is charging, but did notice some cracking on the bottom of the coils to the gel packing and some signs of rust on the grounding tabs around the mounting holes. I understand the power pack creates the spark, but could damaged or weak coils stop producing spark? I'm lost here, any and ALL help would be welcomed.

 

[daselbee]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Not saying this is the problem, but you have optical ignition on that engine.
You have mentioned everything, stator, pack, coils, etc., but you did not mention the optical sensor for the ignition system.
Just wanting to make sure you knew it was there.

Often, erratic starting/spark issues like you are describing turn out to be the optical sensor.

 

[daselbee]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Ooops....also forgot to mention cranking speed. Must be turning 250 rpms or so to gen spark. Don't forget to use a good, fresh battery.
If necessary, remove spark plugs for engine to turn faster, and re-check spark.

 

[boobie]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Agree +1............

 

[backstop13]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Did not check the optic sensor, would that cause erratic spark? Nothing I have read indicated to check that sensor, it was all focussed on the power pack, coils and stator. I had the battery fully charged, 13.23 volts, when I started and when it started acting up the battery was at 13.01 volts, it's cranking like a champ. I just thought it was odd that it sat for a few hours then restarted without hesitation, however it did have a slight miss at idle. Checked the rectifier and it was charging the battery, still no tach though so I'll address that later. Am I wrong to assume that erratic spark could be a result of failing coils? I'm confused here, this thing is trying to make me trade it! I'm leaning toward power pack simply because of Evinrudes history with their packs and the majority of symptoms are pointing that way but I'll test the optic sensor and see how that works. Thanks everyone for the input and advice.

 

[racerone]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

When a motor " is a little hard starting " there is something wrong.---------These motors will fire up near instantly in good condition.-----------My suggestion is to inspect the starter as they do not like excessive cranking and are easily damaged.--------------Inspection is the key, but I know many folks just go out and buy new $$$ parts on a hunch.

 

[rothfm]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

I don't have the optical but my 115 this summer died also with no spark.

Ran in driveway just fine as I always test run before heading out.

Got to ramp 30mins later no spark at all

Back to house and resistance check showed bad stator. Had a spare and 2hrs later back I'm action. The stator was physically fine looked great.

The manual is pretty good for checking the components as is the Cdi website.

Good luck

 

[backstop13]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Maybe I'm overthinking all of this or there are too many components linked together that can cause one to appear failed? Is it possible to test the optic sensor or is it strictly a replacement part ? I don't mind replacing the coils and optic sensor, they're relatively inexpensive, but like everyone else I don't want to just throw parts at it and see what sticks I would rather test and diagnose the actual cause of failure. Can I isolate the power pack and coils and test them individually? I unplugged the double yellow wire connection and still had no spark and like I said the bottom side of the coils showed signs of cracking, but if that doesn't affect functions then maybe I should narrow my testing to the power pack, the optic sensor and the stator. Am I chasing a shadow here or am I on the right track?

 

[Bosunsmate]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Is it possible to test the optic sensor or is it strictly a replacement part ? I don't mind replacing the coils and optic sensor, they're relatively inexpensive, but like everyone else I don't want to just throw parts at it and see what sticks I would rather test and diagnose the actual cause of failure. Can I isolate the power pack and coils and test them individually?

The link i gave you above shows how to test the individual components

 

[boobie]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

OMC made a special tool to check the sensor but it never worked right. If I ever had any doubt about it, I'd just replace it. It's easy to do.

 

[Bosunsmate]

Re: 1997 Ocean Pro 115 lost all spark, any suggestions?

Check out page 62, you can check voltage out of those optical sensors