Hard or will not start. '97 Johnson 150

[levittownnick]

Model J150EXEUE S/N G04209751
Compression #1-105, #2-102, #3-107, #4-102, #5-97, #6-107. Did the link & sync procedure. Replaced the optical pick-up because the analyzer indicated a problem. Measured spark voltage using the 7/16 gap method, (good results). Working on the "step 4-power coil test. The meter I'm using is an automotive type that has a Maximum scale instead of a Peak scale-I am thinking that they are the same (I could be wrong). Manual specifies measuring the orange then the orange/black stator leads to ground on the 500V range, results should be zero. I see about 0.6V? Next measure the orange to the orange/black wire. should be 50V. I see about 5V (not good). Ohmmeter test indicate 58 Ohms (spec 55 +/- 10 Ohms) Ok. Removed flywheel. The coils look new (they are the original). One of the magnets has a cracked corner. Is this acceptable and normal? The starter drive gear was jammed into the flywheel and the bearing that is in the cover melted the cover and shifted position about 1/16 inch. I would think that I need a new cover or should I try to drill out the cover and put in a bushing to hold the bearing? Right now I'm lost and would like advise:
1) Is the voltage reading misleading because I possibly am using the wrong type meter?
2) Do I have to replace the flywheel?
3) What would you do with the housing cover?
4) Even starting fluid would not get the engine to start or kick today.
5) Any other items that I should be doing?

Sincerely,
Nick

 

[reeldutch]

Re: Hard or will not start. '97 Johnson 150

if you have good spark and compression results, that means that hard starting could be:

- timing wrong
- not the right fuel air ratio.

i suggest you put the meter down and start all over at the beginning.

you have 2 things that you verified, spark and compression.

the other two things are fuel and timing.

because you replaced some ignition components and hat trouble with the flywheel, i would defenatly check out if your timing is set proper.

if that checks out good, you have only fuel left.

DO NOT USE STARTING FLUID IN A TWO STROKE

you will wash away the oil that lubricates the engine.
use a spray bottle with premix in it. 50:1

1 - stop using meter you have spark
2 - if the teeth are not damaged i thing your fine
3 - if its damaged replace it
4 - dont use starting fluid in 2 smoke
5 - verify systems operating propper one at the time.
eliminate what you can.

good luck
i would replace the cover.