Johnson/Evinrude Troubleshooting Four Cylinder Engines 65-140 HP 1985-1987 (4 Cyl)
Single Power Pack Carbureted Engines (Without Quick-Start) (763795, 763797, 113-3072, 113-3101)
Service Notes:
1. Please refer to the General Troubleshooting section in the beginning of the Troubleshooting Guide for a better understanding of basic outboard principles, terminology, and repair techniques prior to attempting any troubleshooting or repairs. 2. All DVA tests are done at cranking speed unless otherwise noted. 3. All resistance tests are done disconnected from all other components. 4. Please use the Factory recommended spark plug specified and gapped at the correct setting. WARNING!!! NEVER DISCONNECT THE SPARK PLUG WIRES WHILE THE ENGINE IS RUNNING AS THIS WILL DAMAGE THE POWER PACK. DO NOT ATTEMPT TO START THE ENGINE WITH THE SPARK PLUG WIRES NOT CONNECTED EITHER TO THE SPARK PLUGS OR A SPARK TESTER.
GENERAL NO SPARK ON ANY CYLINDER: 1. Disconnect the Black/Yellow stop wire AT THE POWER PACK 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 triggering and charge coil flywheel magnets for cracked, broken and loose magnets. 6. Check the stator and timer base resistance and DVA as given below for BOTH banks: Read from Brown (Stator) White (Common) White (Common) White (Common) White (Common)
Read to OEM Ohms Brown/Yellow (Stator) 450-550 Ω Blue (#1 Timer Base) 30-50 Ω Purple (#2 Timer Base) 30-50 Ω Green (#3 Timer Base) 30-50 Ω Pink (#4 Timer Base) 30-50 Ω
CDI Ohms 500-620 Ω 38-48 Ω 38-48 Ω 38-48 Ω 38-48 Ω
DVA (Connected) DVA (Disconnected) 150-400 V 150-400 V 0.6 V Minimum 0.6 V Minimum 0.6 V Minimum 0.6 V Minimum 0.6 V Minimum 0.6 V Minimum 0.6 V Minimum 0.6 V Minimum
NO SPARK OR INTERMITTENT SPARK ON ONE CYLINDER OR ONE BANK: 1. Swap the stator’s Brown for Brown/Yellow and see if the problem moves. If it does, the stator is bad. 2. Check the stator and timer base resistance and DVA (see NO SPARK ON ANY CYLINDER). 3. Check the DVA on the Orange wires from the power pack while connected to the ignition coils. You should have a reading of at least 150 V or more. 4. Visually inspect the ignition coils for burned or discolored areas and cracks in the casing (indicating arcing inside the coil). 5. Swap the ignition coil with one that is sparking correctly. 6. Rare causes include a weak trigger magnet. If possible, try another flywheel. NOTE: If the Orange Primary DVA reading is low on one cylinder, disconnect the wire from the ignition coil for that cylinder and reconnect it to a pack load resistor (CDI P/N 511-9775). Retest. If the Reading is now within specifications, the ignition coil is likely defective. If it still measures low, it indicates a bad power pack if timer base test good.
POWER PACK OR TIMER BASE REPEATEDLY BLOWS ON SAME CYLINDER: 1. Check the timer base wires for shorts to engine ground as a shorted timer base wire can destroy a SCR inside the power pack. 2. In contrast, a shorted SCR inside the power pack can destroy a timer base coil. Check the timer base resistance and DVA (see NO SPARK ON ANY CYLINDER). 3. Replace the ignition coil on the cylinder dropping spark.
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TROUBLESHOOTING GUIDE - Johnson/Evinrude Troubleshooting