Rapair powerpack

[mikeyzx2]

Hey OBJ, or anyone else with experience, I got to foolin around with my motor again before getting rained out (again). I'm still getting lack of spark after changing the coils out. I've got the wires fully seated and every nut and bolt tightened and cleaned up, and the grounds from the part the coils mount on cleaned up and the grounds to block cleaned up. I did replace the wire on the starboard side that grounds from the sideplate to the lower cowl, the wire was cruddy like a corroded old battery cable. Is it possible that the other ground wires may be in similar condition also? I also pulled the powerpack off and wiped it down and looked it over and noticed it's a Rapair(ed) powerpack, the date mfd was 6(month), 1(week) and 0(year). Is that from 1990 or 1980? It's just funny that it fired up with no problem before bustin out some new coils and now I get nada.....one more thing I turned the motor over for about 8-10 seconds and it tried to fire weakly a couple times. I'm running out of the simple things to look at before getting into more complicated tinkering. It is getting fuel the plugs are wet and I could smell the gas when plugs were out. The jury is still out on looking into the kill switch itself also...<br /><br />1977 V4 Rudi, 85 horse 85799S

 

[Prkranger2]

Re: Rapair powerpack

You state the it is a repaired powerpack. I was under the impression that powerpacks could not be repaired?

 

[mikeyzx2]

Re: Rapair powerpack

no it's a Rapair(ed) that's the name on the back. the spelling is correct, and you're correct they can't be repaired just a good object to test your arm strength when you throw it across the yard

 

[OBJ]

Re: Rapair powerpack

Well....yes Rapair does repair them and merc switch boxes and stators.....then resells them for a few dollars cheaper than OEM. I've used some of there stuff and don't have any complaints. Just some of their stuff you have to modify a little to get it to fit. Lot of their stuff is good.<br /><br />Mikey...did ya' ever get the service manual yet? That would help you in trouble shooting your problem. Next thing to do is check for voltage to the power pack. Which engine you workin' on any ways???

 

[mikeyzx2]

Re: Rapair powerpack

OBJ, it's my V4 Rude, the 1977 model 85hp, and no haven't got manual yet, trust me I'm looking at getting one. I've got a Clymer which is good for basic troubleshooting but like everyone says they're vague and instead of focusing on one motor it covers a variety and I have to sit there and flip through several pages till I find what I need. Until then ya'll can be the surrogate manual <br />I compare it my Chilton truck manual and the ALLDATADIY.COM I'm subscribed to. The book covers the generic stuff, the website covers TSB's, recalls, and breaks down all the electrical components the book never even mentions. <br />Hey OBJ I noticed some of the bolts have corroded threads and heads, you don't suppose this motor may have rested it's laurels near some salty air or water in it's past do you?

 

[McGR]

Re: Rapair powerpack

Mike - what exactly is your symptom? - no spark on any cylinder? I'll give my .02 if you can provide a more detailed description of the problem/history. I became very intimate with this ignition system last year when I ressurected a negelected old '76 Johnson 85hp.

 

[mikeyzx2]

Re: Rapair powerpack

McGR, I like the term "intimate" in conjunction with high voltage. I hope you didn't snuggle up with a spark plug lead once you got it running <br /><br />Anyways this is the downlow: I got this boat and motor back in December and it started up without a problem and ran alright except for surging at WOT. So I rebuilt the carbs for good measure and started giving the electricals a once over since this is the first "real" outboard I've ever had and wanted to learn a thing or two. The lady who co-owns the local shop said likely powerpack. Since then I've joined this forum and picked up some tips so I checked the coils and three of them where visibly cracked so better safe than sorry I got all new coils. Fought with putting them together but after couple tries got them right and now I don't get sh**. I tweaked with the mounting bolts and stuff and started intermittently getting sparks but one day I do, the next I don't. I tweaked with grounds again and WAM the thing fired up. Shut it off couple times and fired right up again. Let it sit a couple minutes to check a couple other things and NOTHING. Back to square one. So now McGR I still spinning my wheels.....and for all those who want to tell me...my factory service manual is on order as we speak I won't ever have to be advised again!

 

[OBJ]

Re: Rapair powerpack

Mike....did you pull the cover off the power pack and check the connections? All the wires from the charge coil and timer base are screwed to the power pack. Losening and "jiggling" the terminal and retighting is a shot. There should be one black w/yellow stripe wire from the pack that is the kill "circuit". Disconnect it from the pack and see what you get.

 

[mikeyzx2]

Re: Rapair powerpack

ok OBJ, will give a try, and I have loosened and tightened all the screws. if the blk/ylw wire's disconnected does that somewhat bypass the kill switch? I'll look at wiring diagrams and see for myself. BTW I ordered a new service manual like a good little boy.<br /><br />What does OBJ stand for, OutBoard Junkie?

 

[McGR]

Re: Rapair powerpack

Yes, removing terminal #1/ the black/yellow wire disables the kill (key) switch. The key switch grounds terminal #1 in the off position. In the on position it is open or "hanging in the breeze".<br />Another thing worth doing for diagnostic purposes is to disconnect the red harness plug. As long as the engine cranks you should get spark with the plug disconnected (assuming everyting is working correctly). You can still easily crank the engine with the harness disconnected by simply jumping from the positive small terminal on the starter solenoid to the large terminal that is attached to the cable from battery +. Disconnecting the key switch and the harness will allow you to be sure the symtoms are specific to the engine ignition system and not the harness or key switch.

 

[mikeyzx2]

Re: Rapair powerpack

OBJ!!!!! OBwan Jenobi!!! I went out, washed truck, and decided to give the thing a shot. I unhooked the kill wire from powerpack and VROOOOM fired right on up! I pulled it out hooked up to water and the ******* fired up, kicked and sputtered, and then evened on out. Now the kicker: of course I couldn't turn it off with the key so I choked it out. I hooked the the wire back up. Fired right up. Yanked the lanyard off, fired right up again. So looks like you got it narrowed down. I'll try it again probably tomorrow and hopefully the same results. I'm hot, sweaty, and tired, but I'm STOKED. I owe you one so far, and let's keep our fingers crossed!

 

[mjash]

Re: Rapair powerpack

Mike,<br /><br />Are they the original controls...I dont have a kill switch on mine.

 

[mikeyzx2]

Re: Rapair powerpack

Mark, I'm assuming they are. You don't have a kill switch? Here in Bama you would get a ticket because it's the law to have a kill switch with lanyard attached to person. The switch is on the side of mine, below the handle. It's a little black fixture with a smaller nipple in center that pushes in.

 

[John Bett]

Re: Rapair powerpack

Actually you can repair a powerpack. I have had time on my hands and frustration about the cost of powerpacks for my 69-72 evinrudes and have actually disassembled powerpacks and repaired them. It is usually a short on the circut board or a loose solder connection, but the problem is that they blob it with epoxe and sometimes you can hold it up to a really bright light and actually see the short and cut away the epoxe with an exacto knife and repair it. I am experimenting with ways to melt away the epoxe away and better repair the board as the components are rather low tech. I will share my information when I perfect it.

 

[OBJ]

Re: Rapair powerpack

Let's not get excited yet Mikey. Yanking the lanyard/key off the kill switch (if that's the lanyard your refering to) should NOT have let it start. Could be working against two problems here. Possibly a broke wire and a bad kill switch. Let's see what happens when you set everything up normal....and try and run it agian.<br /><br />OBwan Jenobi?????? Well...that's different.....but let's just stay with OBJ....that's short for outboardjim...a moniker my youngest son hung on me....

 

[mikeyzx2]

Re: Rapair powerpack

Use the force........BTW I know not to get too excited cause the problem is still there. It sure was nice to hear it running though It gets too hot out in the sun for me to want to mess with a long time, so I've just been messing with it for a couple hours at a time. The kill switch worked before, I tested it over at my folks a while back while the boat was still out there. I'll poke around the wiring, but is there an area that maybe the wiring gets stressed? And I'm assuming the controls will have to get cracked into to check out the switch. I can live with a bad switch until I fix it, if it's the culprit. The Law can't.....<br /><br />I do appreciate you pointing me in the right direction. I'm getting cherry picker from guy tomorrow, and I'm gonna knock that steering tube out too, maybe two birds with one stone!

 

[OBJ]

Re: Rapair powerpack

Main area of stress for the wire harness is right where it goes into the engine. Bends a lot there. If the engine won't start, might try the engine at different angles...like your steering it. May put you onto the problem.

 

[mikeyzx2]

Re: Rapair powerpack

okey doke, I'll play around with it today. There is enough slack in the cables on this boat that the cables don't really get stressed any that I can tell. I can't say the same for the boat this motor was originally on, I don't know what kind it was.

 

[mikeyzx2]

Re: Rapair powerpack

ok time for update....went out cranked it like it is, nothing. popped that wire off, cranked and fired up. the kill switch does work, but it takes a few seconds to kill the motor. I hooked the tach back up, but I don't know how it works, it's an old tach (25 years old) and all it has on back is a little knob that'll point to a setting of 1-4. anyways I can't verify it works right so a new one is on my xmas list. OBJ, I noticed sometimes after setting when it starts it's a little rough, then it settles down and runs more smooth. what it does though puzzles me: it doesn't backfire, and it's not a loud "sneeze" like some say. I describe it as a "puff" and I can barely make out a slight noise back through carbs. that's indicative of reed valves right? I'm gonna snoop on some other posts later relating to that. in the meantime I'm going to go get hoist, I'll check back later.<br />Thanks

 

[mjash]

Re: Rapair powerpack

Mikey,<br /><br />I was havin the same thing, when I would turn the key off it would keep running for a bit...I would keep thinking electrical. Your kill switch goes through the powerpack. When it runs, does it stay running when you turn off the key? If I am not mistaken that pack should ground out once the kill switch is pulled or the key is turned off. Once that happens there is supposed to be no spark. Powerpack, in my opinion is intermitent(sp?).