93' Johnson 60 HP no spark

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lucas565g

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Hi ya?ll. Longtime member (my old account was so old it got deactivated and made me create a new one today) but I don?t post much, usually my answers are found by searching!
I have a 1993 Johnson 60HP 3 cylinder model TJ60TLETD that lost all spark. I don?t have the meter necessary to measure the spikes in the powerpack just a regular sears multi-meter nor am I sure I understand how to..my boat ran fine all last year and for several years before without a hiccup. I have NO idea if this is related but I was working on the rear navigation light on my pontoon mounted on the bimini top and I looked down and saw white smoke coming from the engine cowl. I jumped off and immediately took the cover off, it wreaked of fried electronics but I could NOT pin point a warm area or where it was coming from. It only lasted a few seconds and dissipated rather quickly. I had not started my boat prior to that this year, and when I went to start it a couple days after that (once I finally located the keys) it turns over like crazy, well over the 250-300 RPM needed but I have no spark on any cylinder..only thing I can think is MAYBE when I saw that smoke I somehow shorted the light the pole, causing the wire to melt and melt the black/yellow wire and apply voltage to the power pack. I have not found any faults in the wire yet nor have I found any trace of voltage on that wire. I have pulled the red cable connector and tried, unplugged all connectors from the power pack in all combinations and still no spark anywhere.
I know this could be stator, regulator or powerpack, I find it hard to believe I lost all 3 coils at once. Anyone have any advice before I start throwing money at it? Do I need a special puller to get the flywheel off? How do I test the stator? I tried metering the powerpack according to the pdf I got from CDI electronics but my meter doesn?t do spikes, how do I test the regulator? It the white smoke ironic or did I fry something?! ANY HELP IS APPRECIATED!
 

jakedaawg

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Jun 26, 2012
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Well, sounds like the magic smoke came out of the box...lets figure out which box.

Find the power pack. Disconnect the fitting with all the wires coming from it. Jump all the wires that are not blk/yel back together leaving the blk/yel open. Crank and look for spark. Do you have spark now?
 

lucas565g

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Well, sounds like the magic smoke came out of the box...lets figure out which box.

Find the power pack. Disconnect the fitting with all the wires coming from it. Jump all the wires that are not blk/yel back together leaving the blk/yel open. Crank and look for spark. Do you have spark now?

well i'll be darned...i had disconnected the red main harness when i had it at the cabin and no luck, did as you suggested tonight and clipped the wire coming right out of the power pack and it fired right up and ran like a champ! i'm thinking that black/yellow wire is shorted someone where it wraps around the block? would that be right? i had towed it home after taking it to the cabin and just to safe i was thinking i should hook the wire back up where i cut it to verify i don't have spark just to make dang sure its isolated to within that foot of wire..thoughts? i just wanna make sure that something didn't get bounced just right on the way home and its only going to intermittently run!
 

jakedaawg

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You cant run it with the blk/yel cut, this is just a test.

Now it is time to test the key and kill switch. There is a sticky at the top that shows which pins of switch should have continuity with the key in various positions.
Isolate the key switch and use your ohmmeter to test.

Also test the bulk/yel wire from key switch to red plug for short to ground. There is a pic of the red plug in the sticky that tells which terminal is which.

Test blk/yel from connector at power pack to connecto at red plug engine side for shorts to ground.

You should NOT need to cut wires to do any of this unless a hack has been in there before you. All wires unplug somewhere.

Good luck, report results.
 

lucas565g

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I ran it for ten minutes just out of curiosity I guess and used the choke to kill it. I will meter the switch, but its literally only been used a dozen times, brand new from the evinrude dealer last year. i did a bunch of testing while at the cabin with the key switch and found no faults. I planned on testing the black yellow tonight with a meter and seeing if I can find a short somewhere. I also thought about hooking a wire to where I clipped the black/yellow out of the power pack and running it all the way up to the key switch and testing that as well. I only cut a wire last night because I'm pretty proficient with soldering electronics and figured I could put the wire back together WAY easier than making a bunch of jumpers and hoping I made connections while loosing the ONE I wanted to!! Will test tonight and get back. Do you have a link to sticky I'm looking for? I looked but must be overlooking something..
 

lucas565g

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so i went through and decided to start the evening by hooking the black wire back up (just for giggles and to make sure my problem was isolated) and what do you freaking know it runs with the black/yellow wire attached...i tried just about every combination of hooking crap up and disconnecting stuff and it works as if i never had a problem...i tested the switch and have continuity when I'm suppose to where I'm suppose to...so whatever it is must be intermittent...suggestions? i know the switch is bad good.. i know i struggled for 3 hours to find the problem while at the cabin and NEVER obtained spark...bring it home and what do you freaking know...
 

seedtreater

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Oct 17, 2020
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Well, sounds like the magic smoke came out of the box...lets figure out which box.

Find the power pack. Disconnect the fitting with all the wires coming from it. Jump all the wires that are not blk/yel back together leaving the blk/yel open. Crank and look for spark. Do you have spark now?
I hope you are still available to help me with the same problem, no smoke but no spark at the plugs. I replaced ; 1. timer base, 2. stator, 3. power pack, 4. 3 ignition coils, 5. plugs. Flywheel appears to be OK. Engine will turn over and cough but will not start. I then check for spark at the plugs and have none. The power pack has lots of wires but I do not have any blk/yel wires. I also rebuilt the carbs, cleaned gas tank, it appears I am getting fuel. Appreciate any help
 

GA_Boater

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I hope you are still available to help me with the same problem, no smoke but no spark at the plugs. I replaced ; 1. timer base, 2. stator, 3. power pack, 4. 3 ignition coils, 5. plugs. Flywheel appears to be OK. Engine will turn over and cough but will not start. I then check for spark at the plugs and have none. The power pack has lots of wires but I do not have any blk/yel wires. I also rebuilt the carbs, cleaned gas tank, it appears I am getting fuel. Appreciate any help
He isn't.

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