2000 90hp No Spark to anything

[2000Johnson90]

Motor and boat has never given me a problem when starting. It has always started up right away as soon as I turn the key. Fishing the other night and it just stalls, it sounded like it had no spark.

Got home and sure enough no spark to any cylinder. I checked the emergency kill circuit. The black yellow wire at the power pack was grounded, so I disconnected it from the ignition switch. No dice. Checked all connections/fuses, everything is clean and good to go.

I'm looking for some advice on what wires/connections to meter so I can test stator output. I'm under the impression that if the power pack were grounded, the stator would still put out its voltage. If this is so and I can test it, then I will know if either the stator is bad or if the kill circuit is faulted.

Any help?

 

[jonesg]

Re: 2000 90hp No Spark to anything

Disconnect the black/yeller kill wire at the power pack end, try again.

And post the model number.

 

[R.Johnson]

Re: 2000 90hp No Spark to anything

You need a nanual to trouble shoot this system.It will save you money in the long run. You must check the whole system top to bottom.Seem's most everyone want's to replace the pak before any testing at all. Guessing a fix can be quite exspensive, plus frustrating.

 

[2000Johnson90]

Re: 2000 90hp No Spark to anything

Yes, I am working on finding the manual.

In the meantime I am checking what I can. Is the power pack supposed to have 12v going to it (not from the stator), if so from where? I don't read any voltage from the stator when cranking, but before I pull the flywheel I want to be sure that it is not a failure somewhere else that would cause the stator to not produce. (Like the optical sensor or pack?)

My bottom line concern is to know that I have performed the checks properly. I checked every wire coming from the stator while cranking, I disconnected the stator wires from the pack and metered them to a good ground and got no voltage. Does this mean the stator is shot, or could there be another problem?

 

[2000Johnson90]

Re: 2000 90hp No Spark to anything

90vlsss

 

[2000Johnson90]

Re: 2000 90hp No Spark to anything

Disconnected the back.yellow at the pack, still no spark. I also checked with a meter to ensure that the black/yellow is not grounded, its not. And I disconnected it from the ignition switch.

Shouldn't the red/yellow wire coming into the power pack be a 12v source? It reads nothing.

 

[wilde1j]

Re: 2000 90hp No Spark to anything

Shop manual: outboardbooks.com You REALLY need one.

DVA adapter (peak picker):
http://www.usatoolwarehouse.com/usatoolwarehouse/ESI-640.html

NO SPARK ON ANY CYLINDER:
1. Disconnect the Black/Yellow stop wire(s) AT THE POWER PACK(S) and retest. If the engine's ignition has spark, the stop
circuit has a fault. Check the key switch, harness and shift switch.
2. Disconnect the Yellow wires from the rectifier and retest. If the engine has spark, replace the rectifier.
3. Check the cranking RPM. A cranking speed of less than 250-RPM will not allow the system to spark properly. This can be
caused by a weak battery, dragging starter, bad battery cables or a mechanical problem inside the engine.
4. Inspect and clean all engine and ignition ground connections.
5. Check the stator and timer base resistance and DVA output as given below for BOTH banks:
WIRE READ TO RESISTANCE DVA (Connected) DVA (Disconnected)
Brown Brown/Yellow 450-550 150 V + 150 V + (*)
White Purple 35-55 0.6 V + {1988 & newer 100 V + (a)} 0.6 V + (#)
White Blue 35-55 0.6 V + {1988 & newer 100 V + (a)} 0.6 V + (#)
White Green 35-55 0.6 V + {1988 & newer 100 V + (a)} 0.6 V + (#)
White Pink 35-55 0.6 V + {1988 & newer 100 V + (a)} 0.6 V + (#)
(*) This reading can be used to determine if a stator or pack has a problem. For instance, if you have no spark on any cylinder and the
stator?s DVA reading is out of spec ? disconnect the stator wires and recheck the DVA output. If the reading is still out of spec ? the stator
is bad. If the reading is now within spec ? the pack is bad.
(#) This reading can be used to determine if a pack has a problem in the triggering circuit. For instance, if you have no spark on one
cylinder and the timer base?s DVA reading for that cylinder is low ? disconnect the timer base wires and recheck the DVA output. If the
reading stays low ? the timer base is bad. If the reading is now within spec ? the pack is bad.
(a) Check stator DVA first. Then if timer base DVA is 0.6 - 1.5 V, the pack is faulty. If below 0.6 V or 1.5 - 99 V, the timer base is faulty.
6. Check the center hub triggering magnet in the flywheel. A loose magnet can cause this problem.
7. Check the triggering and charge coil flywheel magnets for cracked, broken and loose magnets.

 

[2000Johnson90]

Re: 2000 90hp No Spark to anything

Got the manual, but some symptoms overlap. Like no voltage from stator but There is also no voltage to the sensor. If the sensor was bad would this mean i would read no voltage from the stator?

 

[jonesg]

Re: 2000 90hp No Spark to anything

Shouldn't the red/yellow wire coming into the power pack be a 12v source? It reads nothing.

Only whilst the engine is cranking, it should read zero when starter is not being turned over. Its to ensure the ignition circuit see's 12v during cranking the starter. Try it again while you're turning the key to start.

At this point I would follow the troubleshooting section in the manual for no spark on any cyl.

 

[2000Johnson90]

Re: 2000 90hp No Spark to anything - Update

Re: 2000 90hp No Spark to anything - Update

Problem solved - thanks for all the help and tips.

I got the book from a local library. The shop manual is very detailed and specific. I followed it word for word and discovered the stator was grounded. Took the stator out and right away saw the wire pinched and broken underneath it. I got excited because I thought, hey I just saved $300 on a new stator. Fixed the wire, replaced and shielded the wires so it wont happen again and reinstalled.

Cranked her and still no spark. This wasn't a problem, I just went back to the book and picked up where I left off. Rechecked the ohms and resistance on the stator and it was all good. So I went to the next thing in the book, the power pack. Power pack ohms test was no good, coils tests were good. So I did what the book said and replaced the power pack.

It was $300, just like the stator, so I did not escape the $300 fix, but the motor started up and runs so sweet and smooth now. I think before the problem the pack was bad/faulty even though it still ran. Once the stator grounded itself the pack shorted itself as well.

The lesson is, GET THE BOOK. It saves you money, time, it solves your problem and will teach you a lot in the process.

 

[jonesg]

Re: 2000 90hp No Spark to anything

Using the manual , common sense and help from the pro's here makes it a painless job. Guessing usually ends up costing $1000

Look on ebay fror your manual. Got mine for $35.

 

[CDI Tech Support]

Re: 2000 90hp No Spark to anything

Is the power pack supposed to have 12v going to it?

No. If the Black/Yellow kill wire has 12VDC with the ignition switch either in the On and/or Off position, there's a problem in either the key switch, harness or shift switch.

And if the Black/Yellow kill wire has 12VDC, the power pack is toast.

I don't read any voltage from the stator when cranking, but before I pull the flywheel I want to be sure that it is not a failure somewhere else that would cause the stator to not produce. (Like the optical sensor or pack?)

My bottom line concern is to know that I have performed the checks properly. I checked every wire coming from the stator while cranking, I disconnected the stator wires from the pack and metered them to a good ground and got no voltage. Does this mean the stator is shot, or could there be another problem?

CDI Troubleshooting Guide

Shortcut:

OMC 4 Cylinder Optical

Follow the steps under "NO SPARK ON ANY CYLINDER:"

Keep in mind resistance is a highly unreliable check. DVA is a highly accurate measurement.

DVA Explained

 

[CDI Tech Support]

Re: 2000 90hp No Spark to anything - Update

Re: 2000 90hp No Spark to anything - Update

So I did what the book said and replaced the power pack.

It was $300, just like the stator, so I did not escape the $300 fix, but the motor started up and runs so sweet and smooth now. I think before the problem the pack was bad/faulty even though it still ran.

And this falls in line with my previous post.

Better check VDC on the Black/Yellow kill wire or you could blow another power pack. VDC should never exceed 2 Volts DC with the ignition switch in the On or Off position.