CDI test procedure question for 1988 johnson 200

[anauburnfan]

Looking at the CDI electronics test procedure, it provides DVA ranges for the stator and timing base in a connected and unconnected condition. I assume for the disconnected I just separate the wiring harness to test the timing base side. How are you supposed to test in the "connected" condition?

Also, the procedure and my manual reference a orange and a orange/black wire from stator/timing base to the CDI. However, on my engine there are no orange or orange/black wires from under the flywheel though these two wires do come out of the power pack. They are not connected to anything. Of course there are another set of plain orange along with orange/blue and orange/green that connect to the coils. Am I missing some wires from under the flywheel?

The engine runs, but tends to cutoff at idle speed in the water frequently. Runs fine on hose.

 

[SparkieBoat]

Re: CDI test procedure question for 1988 johnson 200

you have to pierce the wires some how to check while connected. I have some pointed probes which I press into the wire ..when I am finished I paint some liquid electrical tape over the hole. I have a 1989 200, I think yours is the same, the orange and orange/black wires go from your stator to under your power pack to the screw connectors..I am pretty sure these connect to the rectifier/regulator wires. there is a yellow wire running with them. look under your flywheel on the back right side facing the back of the motor. You do have a DVA adapter right?? also have you ruled out fuel pump/clog?? is the motor hard to crank sometimes??

 

[daselbee]

Re: CDI test procedure question for 1988 johnson 200

There is a tool called a Stevens breakout box that you can use to do the connected/unconnected testing with.

It has sets of cables to match the rubber connectors used in the ignition system, and there are switches on the box to connect and unconnect the circuit, along with a probe point. See here: http://www.stevensinstrument.com/breakout_remote.htm
I picked up one on Ebay for 10 bucks a while ago.

Before I went to the trouble of doing the CDI tests you are referring to, I would simply measure the DVA voltage at each orange coil primary wire. They should all be around 200 volts or more, engine running. If it were me, and those voltages were correct at the coils, I would look elsewhere for your idle problem, most likely a lean sneeze killing it at idle.

 

[anauburnfan]

Re: CDI test procedure question for 1988 johnson 200

Ok. I was wondering if you had to pierce or use a special adapter. I only have two yellow and the 4 (I think) brown wires coming from stator. The only wires from the pack not connected to anything are these 2 orange and orange/black wires. They have bullet style ends on them, but there is nothing to plug them into. I have looked under flywheel to double check and dont see anything else but the wires from the timer base. I built a DVA so I am good to go there. The motor cranks great and runs good above idle.

I will go ahead and check the dva at the coil wires.

It does seem to sneeze when cutting out and it cuts out consistently when in water. I have pulled all the plastic carb bodies off and cleaned them up, but it did not help.

Another strange thing is that the motor starts up like a champ, but if I put a gap tester on the plug wires while cranking, I dont see any spark even if I dial it down to a pretty small gap. But when I put the plugs back in it still cranks right up. Not sure how it sparks to get started. If I put the gap tester on one plug wire and start the motor (I left the plug in place to avoid fireworks) then I can see it jumping the 7/16" gap with the motor running.

 

[levi_tsk]

Re: CDI test procedure question for 1988 johnson 200

do hasselby' s test first and then try this:

i think you have two problems one is your carbs are gunked up id try a little omc engine tuner run through your fuel system and see if that clears em up if not youll have to do a complete carb teardown with new kits and such

problem 2 is that i think you have a power pack (or two) on the frits try warming the engine up on the hose shut it down and un plug the connector to your powerpack coming from the stator insert your probe from your multimeter into one of these holes and ground the other one out now reverse the leads you should get a reading in one dirrection and not the other do this with all three pins in there and both packs and make sure the engine is warm -ive had them read good when they are cold and then crap out once i brought it up to temp

 

[daselbee]

Re: CDI test procedure question for 1988 johnson 200

This is from memory, so double check it...
On the stator, there are coils all around which you can see the large wire windings....these are the alternator coils used for charging the battery.
Then, there are three other coils, two at the rear of the stator with the pairs of brown wires coming from them, and one in the front of the stator with the orange wires coming from it. You appear to have those orange wires missing. Look for the coil to simply not be there, or the wires to be cut off....something like that.

I am unsure of the function of that coil. Somewhere in the back of my mind I am thinking it is for QuickStart. You may have a powerpack for a newer model...you mention bullet connectors....older models had the screw terminals....but anyway, there is a major mismatch of the parts under there.

If it is for Quickstart, it is feasable that the engine would run without the orange wires, just no quickStart feature. But that is pure speculation.

Not sure I am helping any.....

 

[anauburnfan]

Re: CDI test procedure question for 1988 johnson 200

Just checked the dva at the coils. All 6 read 145 to 155. The service manual says they should be over 100 if I am reading the right thing.

I thought it would be carbs too, but I have already disassembled and cleaned them. They didnt look bad but I shot cleaner everywhere. I did not find any blocked passages. After getting them re-installed, I was sure it would work fine, but like always ran good on hose. Once I dragged down to the water though same problem.

I guess the pack could be newer, it is a cdi unit not omc. This motor is new to me. The manual does show the orange wires though. Maybe the stator is a different year without the orange wires?
I will check the front of the stator tomorrow to see if there is anything up front that looks like it is missing or not connected -- too dark to see tonight.

 

[j_k_bisson]

Re: CDI test procedure question for 1988 johnson 200

Sorry to but in but will this pic help? It is for a 1987 200 evinrude. It is from CDI and is aftermarket.

 

[levi_tsk]

Re: CDI test procedure question for 1988 johnson 200

did you use new carb kits? how about the needles and seats? did you take the jets out and hose them down?

 

[anauburnfan]

Re: CDI test procedure question for 1988 johnson 200

Thanks for the reference picture. I will check tomorrow to see if mine looks like that. Not sure what I will do if I have an 87 stator with what appears to be an 88 motor. (year based on engine plug -- no plates left on motor.

As for the carbs, since this motor is new to me and boat had not run in years, I was sure the new gas might have cleansed some gunk off the inside of the tank that fouled up the carbs. Anyway, once I broke the carbs down, they looked like they had just been rebuilt, but I did it again anyway. The only thing I did not feel good about when I got done was that little seal on the back of the plastic carb body. You cant see it when mounting the carbs back up. Seems like just a little bump and one of those could shift out of place.

 

[levi_tsk]

Re: CDI test procedure question for 1988 johnson 200

hmm im all out of ideas then
power pack? or did you do that test ?

 

[daselbee]

Re: CDI test procedure question for 1988 johnson 200

Sorry to but in but will this pic help? It is for a 1987 200 evinrude. It is from CDI and is aftermarket.

View attachment 81255

Great pic JK...just what we needed to see....

Ahhh...you see....the stator for the older models is different from the newer models. You see the missing front coil. I bet you have an old model stator with a newer model powerpack. I really do not think that is your issue though. I absolutely think that those voltages are low. Should be ober 200....at least that is what all mine read...over 200.

Those voltages are generated by the two rear coils with the two pairs of brown wires. That is the source of the voltage that eventually makes it to the ignition coil orange primary wires.

 

[boobie]

Re: CDI test procedure question for 1988 johnson 200

The orange-orange/black wires are for quick start and slow. If you have the wrong stator, you will have neither. If it has a 87 stator, they didn't have QS & Slow.

 

[SparkieBoat]

Re: CDI test procedure question for 1988 johnson 200

sounds like you may not have the right stator..here is a pic of one for a 1988 200 Johnson

maybe you got the wrong power pack also. Is there a row of screws where wires attach under the power pack?? Also are you sure of your year?? what is your model number??

 

[anauburnfan]

Re: CDI test procedure question for 1988 johnson 200

j200txccr is the model number from the plug on back of engine. My stator definitely looks like the '87 one. There is a blank bar up front with no wires wrapped around it. The power pack does have a row of screws in the back to connect all the wires. Well most of the wires yellow, grey, purple attach with screws. I do have a black/white wire from the port thermostat that I thought was for the quickstart feature. I guess if I dont have the orange and orange black from the stator then I should not hook up this black/white?

Anyway, thanks for all of the help on this.

 

[anauburnfan]

Re: CDI test procedure question for 1988 johnson 200

I meant to mention with the model # that this is a counter rotating motor, but I am using it in a single motor application.

 

[SparkieBoat]

Re: CDI test procedure question for 1988 johnson 200

I just looked your part up on the CDI site and your stator should look like the pic I posted above part # 0583415 CDI number 173-4287 the black white wire should be connected.

 

[anauburnfan]

Re: CDI test procedure question for 1988 johnson 200

So if I have the previous model year stator, does that mean I just won't have the QS and SLOW features? I guess what I am asking is whether this would cause any of the idle problems. The idle problem occurs in the water regardless of whether engine is cold or hot. On the hose it will idle forever without a problem.

I guess I will go ahead and run through the power pack tests to make sure everything is ok there especially with the brown wires. I still don't understand why the orange coil wires need to be over 200 dva if the factory service manual says they should be over 100 dva. Like I said, mine are all reading about 150. If that is too low, then since all 6 are about the same, would that suggest that it is more likely a pack or stator problem rather than a problem with all six coils?

 

[j_k_bisson]

Re: CDI test procedure question for 1988 johnson 200

Can you take a pic of the top of your motor with the power pack in place. I think it would clear up some confussion. I mean which system of power pack you have. The1987 power pack system looks completely different than the 1988 one.

 

[SparkieBoat]

Re: CDI test procedure question for 1988 johnson 200

I am not sure how it will effect your idle as I have never tried using a non fast start stator on a fast start motor. But I agree with testing everything..test the 2 sets of brown brown/white wires..I would not be suspect of the coils if they are all the same. also test regulator/rectifier. I read the CDI specs and it is 150 DVA volts at brown wires (one probe in the brown wire and the other in the brown/white wire, I made me a test harness from an old power pack.) and 130 DVA volts at orange wires going to coils. cranking. remove all plugs for test.
But if you have 150 at all orange coil wires, I think you need to check possible carb or linkage or timing issues. o yea..you do have new correct champion plugs gapped properly right?