1996 Rude Power Pack questions

SparkieBoat

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I have been having problems with my motor, I have now fixed all of the problems since I purchased the motor, down to the last one I think. i have a 19 pitch prop on a 17.5 McKee Craft..I been getting just over 5K rpms and it seems to just bog out past that..I put a 17 pitch prop on the boat and it reached the exact same rpms and did the same thing. I read this on CDIs website

Johnson/Evinrude Optical Ignition Troubleshooting
Troubleshooting the Johnson/Evinrude 60? 6 Cylinder Ignition (OIS 2000)
1991-2006 Model Years (Continued)
High Speed Miss:
1. If the engine runs fine until you get above 4900 RPM and then starts missing, check the Orange to
Orange/Black power coil wires with an oscilloscope (If available) or replace the pack. A breakdown inside
the pack could cause RFI noise to activate the rev limiter for no apparent reason.
2. Using the Piercing Probes and DVA adapter, check the DVA voltage at the RPM where the problem is
occurring while connected as follows:
Red Lead Black Lead DVA Bank/Cylinder
Brown Brown/Yellow 150V + Starboard (1,3,5)
Brown/White Brown/Black 150V + Port (2,4,6)
NOTE: The readings should rapidly increase as the engine RPM increases and stabilize below 400 volts (voltage
exceeding 400 V DVA indicates a bad pack). A sharp drop in voltage right before the miss becomes apparent usually
indicates a bad stator charge coil.
3. Connect an inductive tachometer to the spark plug wires one at a time and compare the readings. If most of
the cylinders show the same reading and one or two show different readings, check the primary wires with
the inductive pickup to see if the readings are the same coming out of the power pack. A difference in
readings between the primary and secondary coil wires usually indicate bad ignition wires. No difference
indicates a bad power pack.


So my question is; Is there anyway to bypass the rev limiter on my power pack? It appears to be the original OEM power pack. I assume it may have the same problem outlined in the CDI web Site.
 

bktheking

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Re: 1996 Rude Power Pack questions

Is the motor missing above 4900 rpm? If the rev limiter was kicking in at the time you are at WOT you'd hear it , the motor would start missing. And No I don't think you can bypass the rev limiter , it's built into the circuitry of the powerpack. This may or may not be a powerpack problem, did you do the tests as outlined in what you posted? Are the symptoms the same as the post?
 

CharlieB

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Re: 1996 Rude Power Pack questions

Have you done the tests as spelled out by CDI?

What were your results?

Are your carbs and main jets clean? Fuel pump and hoses in good shape, no air leaks?

You need to be sure this is an electrical problem and not one of a limited fuel supply.

Have you tried squeezing the primer bulb while at WOT to see if that makes any difference in RPM?
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

I do not have the tools to do the test outlined. It does not seem to be missing when I get over 5K, it seems like it wants to go for a split second then it feels like it bogs down to around 4900K. If i do not go WOT but slowly get close to WOT, it will go to almost 5300K. It did the same thing with the 19 pitch prop and the 17. once I held it at WOT for about 5 mins and it surged a few times to about 5500 rpms but I have not been able to get it to do that again. the engine seems to run perfectly up to around WOT. I have installed a new fuel pump ( the non-vro, one so I premix), checked/replaced all fuel lines and the pick-up line in the tank and a new bulb, cleaned carbs and replaced intake manifold gaskets. I doubt it is a fuel issue. I suspected a faulty rev limiter on the power pack, then I read about possible rev limiter problems and though Ahah..but maybe not. I figured that this motor should spin a 19 prop over 6K on this boat easily, and I am sure it should spin the 17 prop faster than the 19. so I got an issue some where.
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

yes I did try squeezing the bulb while running....no difference.
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

carbs all seem to be spraying evenly, and I gave them a good cleaning, all needle valves seem to be working fine.
 

jonesg

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Re: 1996 Rude Power Pack questions

Is this the engine you run without the carb intake cover?
Thats got to mess with the air/fuel ratio at WOT (lean).
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

i have only run the motor a few times with out the cover, and only for short test runs. I left the cover off because it ran better without it..It was doing the same thing with the cover on. I have since put the cover back on, I highly doubt it will result in any improvement. I am very suspicious of a rev limiter issue, I am almost sure this is my problem, but not sure enough to cough up another $200..so any more suggestions would be appreciated.
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

roger on the throttle roller, it is adjusted properly. I feel like I have exhausted every other possible problem. I am trying to stop the flow of $$ for now. Christmas really hit hard along with property taxes and brake work on my car, truck and my sons truck, plus I just ordered a 23 pitch prop...got to slow it down somewhere, $$$ just flying. I need to sell one of my other boats, but boats are not selling real well right now. When the new prop gets in I will test run again and see what happens. I really would just rather run at 4500-4700 RPMs anyway, So I may hold off on the PP. Thanks for all of the help from all. and Merry Christmas to all and to all a smooth idle.
 

jonesg

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Re: 1996 Rude Power Pack questions

If its the PP it will degrade to the point where you will know for sure.
I think you can get a better price on a pack if you shop around, mine was $150.
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

yea I priced the CDI for that,
But I also will have to get the inductive grey plug wires which are another $35, then add shipping, and I was also going to get some champions to replace my NGKs and put my NGKs in another motor I have. The CDI site specifically said to use the Champion QL78YC with their power pack. Just got to struggle through Christmas and end of the year...hopefully money will pick up in the new year and I can sell one of the boats I have for sale or both which would be wonderful. Then I get a T-top and GPS depth finder with blue water map...whoo hoo and maybe even a 15 HP motor for my aluminum boat.
 

CharlieB

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Re: 1996 Rude Power Pack questions

Spark plugs first!

I use NGK's on most everything, except J/E's that don't run right, screw in a set of the CORRECT Champions, it will make a difference.

And make double sure that any temp sender wires are routed well away from all plug wires.
 

jonesg

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Re: 1996 Rude Power Pack questions

Spark plugs first!

I use NGK's on most everything, except J/E's that don't run right, screw in a set of the CORRECT Champions, it will make a difference.

And make double sure that any temp sender wires are routed well away from all plug wires.

Ditto what Charlie says, install the correct plugs first.!

Mine runs fine on the black plug wires.
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

CDI power pack says it requires the grey plug wires..I had champions in it..but they were used..put in the NGKs and saw a huge improvement on cranking and idle..I will try the champions but I would have a hard time believing that the NGKs will cause the 5300 RPM limit..this has almost got to be a rev limiter issue.
 

ezeke

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Re: 1996 Rude Power Pack questions

" I have installed a new fuel pump ( the non-vro, one so I premix), checked/replaced all fuel lines and the pick-up line in the tank and a new bulb, cleaned carbs and replaced intake manifold gaskets. I doubt it is a fuel issue."

What fuel pump are you using if as you say you have removed the VRO? If you are using conventional lift pumps you need two of them for a V6.

I believe that the rev limit on your power pack is 6100 RPM unless you have a pro pack which is much higher.

The section of the CDI guide was updated in August; you might want the changes: http://cdielectronics.com/downloads...oting Guide 2009 - OMC 6 Cylinder Optical.pdf
 

ondarvr

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Re: 1996 Rude Power Pack questions

roger on the throttle roller, it is adjusted properly. I feel like I have exhausted every other possible problem. I am trying to stop the flow of $$ for now. Christmas really hit hard along with property taxes and brake work on my car, truck and my sons truck, plus I just ordered a 23 pitch prop...got to slow it down somewhere, $$$ just flying. I need to sell one of my other boats, but boats are not selling real well right now. When the new prop gets in I will test run again and see what happens. I really would just rather run at 4500-4700 RPMs anyway, So I may hold off on the PP. Thanks for all of the help from all. and Merry Christmas to all and to all a smooth idle.

Putting a 23" prop on because you want to lower the RPMs to the 4700 range is a bad idea, it can destroy an otherwise very good motor pretty fast.

Get the problem fixed before you spend money on a prop and make sure you have the correct fuel pump, if it is running lean bad things will happen.

Try hitting the primer button (or push in the key) while its bogging, if it runs better for even a second its fuel related.
 

SparkieBoat

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Re: 1996 Rude Power Pack questions

thanks for all of the great info guys...I used the VRO style pump part # 5007422.
I tried pumping the bulb..but not pressing in the key to activate the primer..I will try that.
I have another question...if the stock rev limit is at 6100 RPMs could my tach be off...I purchased a new tach to make sure my old one was not off. the old one did not have the pulse settings but it seemed to work right on the 4 cyl setting. I then purchased a new tach and the paper said to set it at the 6P setting, for all J/E V-6 1992 to present..something like that..is the 6P the right setting???? the motor does not sound like it is over revving to me..but how much difference would 6100RPMs sound from 5300.....so hard to tell from sound. it defiantly feels like the motor should have more to give.
 
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