Tow of shame!! 1972 Evinrude 65hp no spark

[mike64]

It finally happened to me. Nice day out on the water, buzzing around on my boat with a friend, seemed to be running well all day. Topped out at its typical high speed. Then I'm cruising slowly through a no wake zone and the motor just cut out dead. Starter cranked but no hint of startup. Got towed in by the sheriff.

I replaced the plugs, which looked pretty fouled. New plugs I got are not sparking. I had an OEM manual for a '71 Johnson 60HP which I had hoped was similar enough. Not for the ignition system it's not. I'm not familiar enough with outboards in general to follow the troubleshooting procedures when parts look different and wires are different colors. I just ordered an OEM manual off ebay for my exact model, which is 65273S. Hopefully I get it in a couple days.

Can anybody help me get started with troubleshooting the problem, keeping in mind I'm not familiar with outboard repair (yet), or would asking be a waste of time until I get the manual?

 

[CATransplant]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

You can start by checking for fuses. I don't know your outboard, but if there are any fuses in the system, start there. After that, check the kill wire circuit. If it isn't one of those things, wait for the manual.

 

[tx1961whaler]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

When the engine died, did you notice if the engine RPM's went up for a couple of seconds, then back down and then it sputtered and died, or was it just like turning off a light switch?

 

[bigpoppakdog]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

get a dva meter and check if the pack blew...there is a method for checking the pack w/o it,but I can't remember it. Somebody else should post the method for you shortly. Could be ignition coil also. Check your ground wires. Get the manual.

 

[mike64]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

When the engine died, did you notice if the engine RPM's went up for a couple of seconds, then back down and then it sputtered and died, or was it just like turning off a light switch?

I don't have a tach on my boat, but I didn't notice the sound of the engine revving a couple seconds before it died. I'd say more like a light switch.

 

[HighTrim]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

If the starter is cranking, the 20 amp fuse is ok

Go to the FAQ and follow the steps provided by JB in the thread, "Outboard Wont Start", and let us know what you find.

 

[tx1961whaler]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Yeah, I think the guys are right. If it didn't rev a bit and kind of sputter, then it probably isn't fuel related. I had a pick-up tube that fell off in a full tank of gas, and the motor just quit. Took a bit of sleuthing to figure that one out.....

 

[mrcj001]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Yeah, I think the guys are right. If it didn't rev a bit and kind of sputter, then it probably isn't fuel related. I had a pick-up tube that fell off in a full tank of gas, and the motor just quit. Took a bit of sleuthing to figure that one out.....

Check out this link.........

http://forums.iboats.com/showthread.php?t=271796

 

[tx1961whaler]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Too funny! I'm glad (not really) that I'm not the only one this has happened to. Funny thing was, it was a new tank.....and I'm glad I had my 3 hp kicker (built in tank!) with me. I took it back to Wallyworld, stinking of gas. They probably put it back on the shelf.....

 

[jay_merrill]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Mike, PM me an email address and I'll send you a PDF of the ignition chapter from a 1972 Johnson 65hp motor. Its the same motor as yours. so the info will be the same (except for the control unit) as the manual that you have coming.

Based on experience with my own motor, my guess is that your problem is with either the key switch or the power pack. I had exactly the same thing happen, except that the motor didn't fail while underway. In my case, i went out one day with no problems, and the next time I tried to use the motor, it wouldn't start at all. In my case, the power pack was the culprit.

The key switch is readily available from your local OMC/BRP dealer and the power pack can be obtained from either the dealer, or aftermarket sources. The OMC/BRP pricing is a bit insane, so I suggest an aftermarket unit from CDI or Sierra. My personal preference is CDI, just because I have heard that the quality is higher.

I also recommend that you budget for a complete ignition system rebuild. When things start going wrong with these motors in that area, usually the entire system is on its last leg. I fought this reality with mine but ended up deciding to replace it all. Three new coils, a new power pack and a new timer base later, my motor runs like a top and is very dependable. I still haven't replaced the stator but plan to, just to finish the job.

 

[mike64]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Mike, PM me an email address and I'll send you a PDF of the ignition chapter from a 1972 Johnson 65hp motor. Its the same motor as yours. so the info will be the same (except for the control unit) as the manual that you have coming.

I sent you a PM, jay_merrill. Thanks a lot, for the pdf and for your advice!

bigpoppakdog recommended getting a DVA meter, and I've seen them mentioned in other "no spark" posts. I looked into them and they're not cheap. Do I have to have a DVA meter, or can I get by with a digital multimeter?

 

[HighTrim]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

You could always get a DVA adaptor for you current meter, or you can make your own adaptor.

 

[mike64]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

You could always get a DVA adaptor for you current meter, or you can make your own adaptor.

Thanks HighTrim, I took a look at DVA adaptors and this is the cheapest I found. would this work for outboard troubleshooting?
http://www.esitest.com/cart/640.html

I also found this post which mentions o-scopes (2nd post. last para). Can one be used in place of a DVA adaptor then? i think we still have an old oscilloscope that my wife got from her dad. We tried to sell it on ebay or craigslist once but no takers.
http://forums.iboats.com/showthread.php?t=180482

 

[HighTrim]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

That is the adaptor that will work. You can make your own, but personally, I like having something neat and tidy that I can throw in my toolbox.

As far as the o scope goes, I will let someone more experienced handle that. I have never used one.

 

[jay_merrill]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Email sent with ignition chapter from OEM service manual. See my comments about testing the sensor coils and charge coils via an ohms check. Having the DVA capability is better but the ohms testing does work.

 

[mike64]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Email sent with ignition chapter from OEM service manual. See my comments about testing the sensor coils and charge coils via an ohms check. Having the DVA capability is better but the ohms testing does work.

got it, thanks!!

 

[mike64]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Thanks to everyone for your help so far!

Okay, taking a look at the ignition chapter that jay_merrill kindly sent me, I have a couple questions.

How important is a needle-type spark tester? I just took the plugs out, connected them and looked for spark on the plug. since it was a sunny day, I put a hole in a box and put the plug in it to make it dark to see any spark easier. Is this a sufficient way to test for spark?

The manual says: "Do not hold spark plug wires in your hand to check for electrical discharges. A severe electrical shock will result. Use insulated pliers designed for this purpose". Can you actually get a shock by holding the insulated spark plug wire while cranking? That's exactly what I was doing. Or is this just a safeguard against careless people who might accidentally touch the spark plug contact?

Here's a pic of an old oscilloscope that I have. I don't know if it even works-- power light comes on but I have no connectors for it. Looks like it takes old bnc connections. Can anyone tell me if this will work for testing peak voltage? Can anyone give me any clue as to how it works...? I'm looking for a manual for it online.

 

[HighTrim]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Mike, make things easy on yourself and get an adjustable spark tester. The important thing here is the distance of the gap that the spark will jump. In your case, you want the spark to jump a gap of 7/16 of an inch with a bright blue ZAP!! These testers are so cheap nowadays, usually 10 bucks or under, and can be picked up at about any auto parts store. This is the best way for checking the spark on an outboard.

 

[mike64]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

Mike, make things easy on yourself and get an adjustable spark tester. The important thing here is the distance of the gap that the spark will jump. In your case, you want the spark to jump a gap of 7/16 of an inch with a bright blue ZAP!! These testers are so cheap nowadays, usually 10 bucks or under, and can be picked up at about any auto parts store. This is the best way for checking the spark on an outboard.

View attachment 16820

Thanks for the tip HighTrim. I had in mind the 4-prong needle type spark tester from the manual. Stopped at a boat store on the way home from work and asked about it-- guy said he could order one for $100...??? I know boating supply stores are pricey but a benjamin? For a piece of circuit board and a little bit of metal? 10 bucks sounds much more reasonable.

 

[chris mandella]

Re: Tow of shame!! 1972 Evinrude 65hp no spark

yea the jolt you can get from a plug or coil is not pleasant ,wont kill you unless your wearing a pacemaker, but not a joke,it will make you say waaaayyaaajeeeezzzzzzzzus!!!!!!!!!!!!!!!!!!!!