Big motor=Big trouble!!

[SHickey]

Hello,

I inherited a 65 rude 90 hp Starflite that had not been run in years. I mounted it to my Super Sport and with very little effort got the motor cranking BUT no spark. Bought a service manual for the engine and began diagnosing the problem (maybe a faulty coil or condenser). Pulled the distributor cap off to check points and gap. Tried removing the spark plug wires from the cap and guess what?? They were all corroded or rusted in the cap and I snapped some of the wires off leaving their ends inside the cap ruining the cap and the wires.

What should I do now?? I was reading about some owners converting their old ignition systems to newer electronic systems which are more reliable and less fussy. I am thinking that would be the way to go BUT there seems to be a number of electrical components in the "box" and on the motor and I'm not sure if I will be just dumping alot of money into this old motor with few results.

If I can get it running again, I'm not even sure if the electric shift works in the lower unit but I believe there is a way to test the lower unit without the motor actually running.

If any of you guys have an engine like this and believe it is worth salvaging, I would appreciate any advice/guidance you can give me. I am a little intimidated by electrical problems but I am willing to try to work out the challenges this motor is giving me so far.

Thanks again

Steve H.

 

[BonairII]

Re: Big motor=Big trouble!!

Any way you can get the wires out of the distributor cap?

I have the same motor(i think). Mine is a '67 johnson 80hp.

You should be able to another cap somewhere. Def replace the condenser/points regardless of how they look. I got my points, condenser, and plug wires from Lang's(Buffalo).

 

[boobie]

Re: Big motor=Big trouble!!

IMHO I wouldn't stick any money into it. I worked on a lot of them back in their day but now it's just to costly to keep them running. Plus a lot of parts are obselete.

 

[SHickey]

Re: Big motor=Big trouble!!

I'm afraid the ends of the wires are buried in the cap and the wires that have not broken are not coming out easily. I can invest in a new cap, wires, condenser, and points. Then I will need to decide whether or not to replace my coil or invest in an electronic ign system some owners have been substituting for their old systems.

Do you have any experience with these electronic ignition systems?

SH

 

[SHickey]

Re: Big motor=Big trouble!!

Yes, I can see your point. Parts for this motor are sold at a premium price and they are not easy to find. It's hard to look at that old motor and imagine how nice it would be running WOT on the back of a boat.

SH

 

[BonairII]

Re: Big motor=Big trouble!!

http://www.ebay.com/itm/Distributor..._Accessories_Gear&hash=item3a6ec9f847&vxp=mtr

Offer the seller $75. Since it does come with wires, probably not a bad price.

I made sure to pick up a parts motor, so I have spare parts when I need them. My parts motor is electric shift and my main motor is manual, so I sold the LU.

IMO, it's still cheaper to get it running than buying a newer motor....only to have the power pack go bad and have to spend $350 to replace it.

OMCDave on ebay has a huge supply of new 'old stock' OMC parts btw.

 

[Willyclay]

Re: Big motor=Big trouble!!

Tried removing the spark plug wires from the cap and guess what?? They were all corroded or rusted in the cap and I snapped some of the wires off leaving their ends inside the cap ruining the cap and the wires.

Steve; If those were OEM plug wires, they should have had the screw-in "terminals". BTDT with this same problem. You may be able to unscrew them by wedging a screwdriver into them and save the distributor cap. If successful, you can then purchase some solid-core tinned-copper plug wire sold in bulk, some terminals (p/n0510364), boots and make your own. The link below is the original parts catalog for your motor. You will need those numbers as a starting point. Good luck!

http://www.marineengine.com/parts/v...ntage-evinrude-johnson/278654/27865400001.htm

 

[BonairII]

Re: Big motor=Big trouble!!

Steve; If those were OEM plug wires, they should have had the screw-in "terminals".

Yikes, I never considered that he might be trying to yank them out of the distributor cap without unscrewing them.

 

[SHickey]

Re: Big motor=Big trouble!!

Wow!! Do I feel stupid!! It never occurred to me that the spark plug wires were screwed into the dist cap. No wonder why they we so hard to remove. This Sunday I may be selling an old lawn tractor, repairing my son's car, possibly looking at a larger boat to "fix-up" and then I will mess around with that cap and see if I can unscrew the remaining wires and possibly retrieve the screw ends left in the cap.

I am contemplating a photo shoot with my motor and putting it on CL and see if anyone looking for a challenge would want to buy it.

Thank you all for your input.

 

[BonairII]

Re: Big motor=Big trouble!!

I am contemplating a photo shoot with my motor and putting it on CL and see if anyone looking for a challenge would want to buy it.

I'm sure someone will be happy to lowball you and pick that motor up for $200.

If you decide to get it running, you're only looking at $50 for a coil(OMC Dave), $60 for wires, $25 for points/condenser. That's pretty cheap to have a running 90hp.

I see old 60-90hp motors selling for $800 on CL regularly(I'm only 90 miles from you btw)

 

[Willyclay]

Re: Big motor=Big trouble!!

Don't feel bad Steve because most of us have done the same thing or worse, if the truth be known! I took my lumps before there was an internet and can tell you that this forum is a great resource. Your motor is essentially an automotive-type ignition system prior to electronics. I have a 1968 Johnson 100HP with the first gen OMC electronic system and it is a real mess. Don't give up on it. The only thing simpler is a magneto system that does not require 12V to run. Come back to this thread and tell what you did. Good luck!

 

[yorab]

Re: Big motor=Big trouble!!

Yessir, as Willyclay points out, those leads unscrew from the cap. Although many of the parts from your motor are classified as "Obsolete", you can still find nearly all of 'em with a bit of online research. Sure, it takes time, but it's cheaper than a new motor and besides, nothing is quite as satisfying as fixin' it yourself, especially when others tell you it can't/shouldn't be done.

 

[Willyclay]

Re: Big motor=Big trouble!!

Member yorab's rebuild thread is an outstanding source of info for anyone working on an 1958-1968 OMC V-4 at the link below:

http://forums.iboats.com/showthread.php?t=458745

 

[SHickey]

Re: Big motor=Big trouble!!

All right, you guys have convinced me to keep chipping away at that motor until I get it running or get frustrated to the point of using it as an anchor. I have a good manual and I will see about getting some parts from OMC Dave. I will probably put this oldie onto my heavy duty motor stand and and put my trusty Johnson 40 back on to my Starcraft. These boats and motors begin to become an obsession and they keep eating away at you when you can't get them working right.

Does anyone have contact information for OMC Dave??

 

[Willyclay]

Re: Big motor=Big trouble!!

If I can get it running again, I'm not even sure if the electric shift works in the lower unit but I believe there is a way to test the lower unit without the motor actually running.

Steve; I do not want you to feel hoodwinked if you find out there are problems with that electric shift gearcase. FYI, that is potentially the most problematic area with that motor. However, I think electric shift is great when it works. I'll dig around in my manual for the electrical testing procedures and also tell you from first hand experience that some previous owners refill the gearcase with the wrong oil. Only Type "C" will allow it to work correctly. Worst case, you could find a donor motor and swap gearcases for a standard mechanical shift if you have a good powerhead. I would regress a little and check the compression to determine the motor is mechanically sound before spending any money on it. Then, try to resolve the ignition problem. Also, before you open up the carburetor, you might want to PM forum guru F_R and ask him if any special tools are needed to overhaul the carb. He is the man! Hope this helps.

 

[BonairII]

Re: Big motor=Big trouble!!

Does anyone have contact information for OMC Dave??

PM sent

 

[Willyclay]

Re: Big motor=Big trouble!!

Bought a service manual for the engine....Steve H.

Regarding testing the electric shift gearcase controls, I pulled out my manual(non-factory) and read through it. It is pretty straight-forward stuff with a VOM checking for proper resistance and continuity. If your manual does not have the procedures, I can copy mine.

 

[SHickey]

Re: Big motor=Big trouble!!

Thank you for the contact information!!

 

[SHickey]

Re: Big motor=Big trouble!!

Thank you Willyclay for your input. This weekend I will perform a compression test and work on testing the lower unit. I do have a factory manual and a VOM. I will get the type C lower unit fluid too. This motor will be put through the paces!!