Omc Johnson Warning Module Wiring Diagram Help

[N1NE1]

I PURCHASED A WIRING HARNESS WHICH CAME WITH A OMC MODULE (176736) AND IM TRYING TO START MY 96' JOHNSON 112 SPL AND CANT GET ANY SPARK, THERES A PART OF THE HARNESS THAT ATTACHED TO KEY SWITCH AND ONE PART TO TRIM/TILT SWITCH,AND ONE PART GOING TO MODULE THAT HAS SOME WIRES WITH LOOP CONNECTOR ENDS ON IT THAT I HAVE NO CLUE WHERE THEY GO TO ,THERE IS ALSO A HORN. THE WIRES WITH LOOPS THAT ARENT ATTACHED YET ARE,2 GRAYS,2 PURPLES AND ONE PURPLE COMING OFF THE HORN ALSO,2 BLACKS AND ONE WHITE/TAN.ANYONE HAVE A WIRING DIAGRAM OR KNOW HOW TO HOOK THIS UP.??

 

[tashasdaddy]

Re: Omc Johnson Warning Module Wiring Diagram Help

you need a Johnson OEM service manual for your specific motor. the loop wire are for guages.

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

without this part of the harness not connected would this be the reason i dont have spark on any coil.?

 

[tashasdaddy]

Re: Omc Johnson Warning Module Wiring Diagram Help

no. most boats do not have guages. miss wire ignition, would cause the problem.

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

would anyone happen to have a key switch wiring diagram for this motor its a 96' johnson 112 spl, maybe the wires are switched around... wiring is a headache....

 

[ezeke]

Re: Omc Johnson Warning Module Wiring Diagram Help

The diagram at the end of the following thread should be similar: http://continuouswave.com/whaler/reference/ignitionSwitch.html

Typical starting circuits are described here: http://continuouswave.com/whaler/reference/electricStart.html

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

ok checked all keyswitch wiring, everything fine with that, still no spark, where to start now? is it possible to test a powerpack? or better off just buying a new one? this is a headache i wish upon no ones boat!!!!!!

 

[jhebert]

Re: Diagnosing Spark Ignition Problems

Re: Diagnosing Spark Ignition Problems

In a spark ignition circuit you generally find the following components:

--plug
--high-tension wire
--coil, high voltage or secondary winding
--coil, low-voltage or primary winding
--low-voltage wire
--coil driver circuit
--driver circuit timing source
--driver circuit voltage source

The driver circuit timing source is usually a pick-up coil under the flywheel which is excited by magnets. These coils are sometimes called the "timer base." The driver circuit voltage source is usually one or more coils under the flywheel which are excited by magnets.

All these coils are sometimes integral with other coils and are called "the stator." On some motors there may be dual coils for generating the driver circuit voltage, each optimized for a certain engine rotation speed range, and these are sometimes called "the low speed stator" and "the high speed stator."

If you are not getting spark, begin at the spark plug and work backwards toward the stator. If you have an engine with multiple cylinders you have a source of alternative parts to swap into the circuit for testing for many of the elements.

An in-line spark tester (20610 LISLE In-line Ignition Spark Tester) is a good way to determine if your cylinder is getting spark while the engine is running and the spark plug is in place. An in-line spark tester is a test device which can be inserted in the high-voltage spark wire. They typically have one connector which mimics a spark plug electrode and another which is a spark plug boot connector. You can remove a spark plug wire from the spark plug and insert the in-line spark tester on that cylinder. The tester has a small spark gap contained inside a transparent glass cylinder. This allows you to visually observe the spark. You can typically find these at stores that sell automotive supplies.

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

i've tested all cylinders theres no spark on any....i have the inline tester.i guess i just have to start with buying a new powerpack

 

[ezeke]

Re: Omc Johnson Warning Module Wiring Diagram Help

I would check with the main harness plug disconnected to eliminate the kill circuit and jump the starter at the engine. Note that if the engine starts, you will have to choke it or disconnect the fuel to cut it off.

 

[daselbee]

Re: Omc Johnson Warning Module Wiring Diagram Help

Hold off dude!!!
Don't shotgun it just yet.
In fact, you can actually run the engine with the electrical connections to the helm control DISCONNECTED. The engine does not need battery power to do anything except turn the starter motor.

There are a couple of tests that you can do first.
1. The engine must be turning 250 - 300 rpm with the starter before the power pack will let it fire. So, make absolutely certain that the battery is fully charged, and that the engine battery cables/connections are clean and tight.
2. At the power pack, you will see a black/yellow stripe wire that has an inline connector. That is your kill wire. Disconnect the black/yellow stripe at the pack, and allow it to "float". Crank the engine, and check for spark.
If you have spark, you have something hosed in the wiring from the control to the engine regarding that black/yellow stripe wire.
If you have no spark, the problem lies in the ignition system components; timer base, stator, power pack....

Do those two things first, before you blow money.

 

[daselbee]

Re: Omc Johnson Warning Module Wiring Diagram Help

I would check with the main harness plug disconnected to eliminate the kill circuit and jump the starter at the engine. Note that if the engine starts, you will have to choke it or disconnect the fuel to cut it off.

Just like ezeke said....disconnect the electricals at the engine, crank it by slapping battery voltage directly to the starter positive lead, and look for spark.
Careful, it may start on ya! Keep it out of gear...etc, and be prepared to choke it down.

I am not a fan of shotgunning a problem. It is the most costly way of fixing something, and you end up with a bunch of "no defect found" parts.

 

[ezeke]

Re: Omc Johnson Warning Module Wiring Diagram Help

If you download the CDI Electronics Troubleshooting Guide, page 32 gives a checklist that can be useful to you if you follow the sequence as written. There is a great deal of other useful information in other sections of the manual as well.

To download, right mouse the title and use "save target as" to save to your drive. Because the file is large, opening it on line will take quite a while. http://cdielectronics.com/Downloads/tabid/55/language/en-US/Default.aspx

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

Ok I Tried Disconnecting The Single Black/yellow Wire And Starting It Both With And Without Harness-no Spark,i Tried Taking The Plugs Out So Theres Less Compression And Engine Spins Faster,still No Spark. I've Tried Just About Everything To Try For Spark. ...nothing... Can Stator Be Tested? Can Powerpack Be Tested?

 

[daselbee]

Re: Omc Johnson Warning Module Wiring Diagram Help

Well,
I am very surprised that it didn't start right up.

But, since you have been working on the control side of the wiring harness, is it possible that you accidentally shorted +12v to the black/yellow wire up at the key switch? If so, you can blow the power pack from that type of error.

I guess if it were me, I would replace the PP now.

Again, it will run with the harness disconnected, so try to get it running like that to eliminate ANY control harness problems. Leave that black/yellow disconnected at the new pack also, just in case you have a +12v short on that wire. That will keep you from blowing a new pack. Plug it back only when you are sure it is NOT shorted to any voltage source.

Key on, harness plugged in, black/yellow unplugged at the pack, engine not running, measure the voltage to ground from the harness side (not the pack side) of the black/yellow wire.
No voltage is allowed....zero volts is correct. Maybe switch the key on and off (jiggle the key) with the meter still connected, to make sure that the black/yellow wire NEVER has any voltage on it.

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

ok im going to buy a new pack, and being on the safe side when i connect the black/yellow wire im going to add in a temporary low volt fuse. i'l get back to you in about a week once it gets here. thank you everyone for your help so far

 

[daselbee]

Re: Omc Johnson Warning Module Wiring Diagram Help

ok im going to buy a new pack, and being on the safe side when i connect the black/yellow wire im going to add in a temporary low volt fuse. i'l get back to you in about a week once it gets here. thank you everyone for your help so far

Fuse won't help. Just leave it disconnected. Measure that voltage as I described to make sure it is zero volts with key on, engine off.
When the key is OFF, that blk/yel wire is grounded inside the switch. That is what kills the engine. So, if you read the voltage when the key is off, it will always be zero volts...the circuit is grounded. When the key is ON, the circuit basically floats, and when the engine is running, you will read maybe 250volts on that wire... AC voltage, low current, coming from the PP.
It will shock you too.

A fuse will not protect that line.

By the way, do you think maybe you accidentally shorted 12v to that blk/yellow when you were wiring the switch?

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

When I First Got The Harness There Were Some Wires Disconnected All Colors Matched With Colors On Each End So I Did Have Them Hooked Together For A Bit, This Was On The Warning Module Side, This May Be What Killed The Pack.hopefully Thats All That Died

 

[N1NE1]

Re: Omc Johnson Warning Module Wiring Diagram Help

ok got the new powerpack on and still no spark, kept turning the key and trying over and over again, and now a new issue. as soon as the batterys connected the starter engages, even when keyswitch is unpugged completely,I GIVE UP .. IF THERES ANYONE AROUND THE NEW JERSEY AREA WHO KNOWS HOW TO FIX THIS OR WANTS TO ATTEMPT, I'L GLADLY PAY YOU. OR IM JUST GOING TO TAKE IT TO A MARINA AND GET RAPED FOR MONEY. EITHER OR

 

[daselbee]

Re: Omc Johnson Warning Module Wiring Diagram Help

It is not that tough...don't give up.

Send me a private e-mail...

Doug