97 Johnson 200 no start after sitting a month...

[murrayra53]

1997 Champon 191 Johnson 200 Mod-J200STLEUB Ser-G04299048
testing w/Fluke 115 DMM,CDI pva adapter
amatuer hour is over, need help from the big guns....
boat ran fine when parked, month later no start:
step 1 - total ouput test no start weak/no spark wet plugs.
step 2- repl sticking 6 pin ignition switch ( currently does not have an emg stop switch)
step 3- shift switch failed ohm test repl switch/harness
step 4- after repl cranking battery, starter rpm 250-260 charge coil passed ohm, failed dva 118v port,122v starbd repl new stator dva 140v port,143v star magnets are tight
step 5- tb failed had open lead on starbd blue pin, crack inside hub, repl tb new tb passed
step 6- pp failed dva test, repl new pp reads only 1.4v at primary coil leads, spark gap tester set @7/16 ths shows spark on all cylinders but 1,4v is way below >100v
what an i missing??

[ChampioNman]

Top dead center #1 confirmed?

[murrayra53]

Will check today. Thank you for your help.

[ChampioNman]

Possible that the woodruff key is not on the crankshaft or sheared. But if TDC #1 isn't on mark you will have erratic spark or no spark.

[murrayra53]

Using the pencil method, pointer was at 0 degree TDC flywheel mark when #1 piston was at TDC. Checked and cleaned the key and the flywheel/crank keyways when i pulled the flywheel. no metal,wallowing or shearing that i could see.like i said last time out ran the river all day ,fished 4-5 spots no misfires,power loss

[316jughead]

1.4 volts, good spark? I would suspect that you have the meter set on wrong scale or are reading wrong scale or meter failure. Time to check fuel supply, bulb gets hard, primer working, fuel in carbs not just oil. You know how to check it out. Let us know how it goes.

[murrayra53]

Thanks really appreciate the tips. Rechecked the primary coil voltage again with my old analog meter compared to the Fluke on auto and pos 600 ranges, still only getting 1.4v Rudetech1 advised a serious wiring/connector inspection so I'm trying to go through everything with a fine toothed comb. After that looks like fuel supply, will let you know.

[ChampioNman]

Find a blown OMC 97 and up and buy a wiring harness. Tap it in and run the motor that will save you from metering.

[murrayra53]

Good idea, just might come down to that. I'm going down to Falcon at the end of the month.

[316jughead]

I think you said good spark on all cylinders at 7/16 gap. Is that correct? Are the power pack to coil primary wires connected correctly? Is the timer base returning to the stop and not hung up? When you check primary coil wire voltage are you using a Stevens PL-88 load adapter?

[murrayra53]

I may not have been clear on the spark quality, there's enough to jump the 7/16ths gap on all cylinders, but quality seems poor more white than blue w/low output voltage. Coil wires are attached per the ignition coil servicing diagram. Timer base is returning to stop, can hear some coil binding inside the linkage assembly on the return none on the extention. Not using Stevens load adapter have a CDI adapter on a Fluke 115 meter.

[murrayra53]

Blind pig finds acorn, she runs like she's supposed to. Sincere thanks to ChampioNman, 316jughead and Rudetech1 for all the help and advice.

[Bassmeister]

Good deal, enlighten us on what you found to be the problem please.

[murrayra53]

As Rudetech 1 suspected there was a bad wire. I pulled off the rigging tube and noticed there was about 12" of shielding missing off the ignition harness and covered with electrical tape. When I got the tape off I found about an inch of exposed wire on the where the harness crossed the splashwell. Repaired the wire, separated all amphenol connecters in the harness checked each pin and cleaned. Also cleaned any ground wires going to block/starter.

[ChampioNman]

I use a wiring harness and key eliminates a lot.

[murrayra53]

believe me i can see how that would save a ton of time. got a spare harness spotted on ebay we'll see how it comes out.