Re: johnson 2003 150hp
Welcome to iboats.
You seem to have narrowed it down to the ignition system, now we have to further investigate. From the CDI troubleshooting guide.
1. Check the kill lanyard and key-switch position.
2. Verify the engine rotation (The engine needs to be turning in a clockwise direction).
3. Check the power pack and ignition coil ground wires for corrosion and tightness.
4. Connect a spark gap tester to all cylinders (It needs to jump the gap a good 7/16 of an inch with a bright blue ZAP!!).
5. Disconnect the boat side harness and connect a remote starter unit. Check for spark. If the engine has spark, check the boat side harness’s Black/Yellow wire for shorts to ground.
6. Disconnect the 5-pin connector on the port side of the power pack and see if the spark returns. If it does, get out your meter set to Ohms and see if the Black/Yellow wires are shorted to engine ground.
7. Check the battery voltage on the Yellow/Red striped wire while cranking the engine. If below 11 volts, charge the battery or check all battery cables.
8. Remove the sensor wheel and check for damage, especially where the top slots are located. Sometimes the wheels will break out where the windows overlap.
9. Check the sensor eyes for dirt, grease, etc. If you have to clean it, use denatured alcohol and a Q-tip. Do not use any other cleaning agent because damage to the optical lens will occur.
10. Disconnect the voltage regulator/rectifier and retest. If the engine now has spark, replace the regulator/rectifier.
11. Using the Piercing Probes, check the resistance, then check the DVA voltage on the 6 pin stator connector while connected as follows:
Red Lead :Black Lead :Resistance : DVA Reading
Orange :Orange/Black :50-60 ohms :12 V or more
Brown :Brown/Yellow :450-600 ohms :150V or more
Brown/White :Brown/Black :450-600 ohms :150V or more
Note: Low readings on all checks indicate a possible problem with the flywheel magnets that require checking.
12. If all the tests so far show good readings, check the DVA output from the power pack on the primary coil wires as follows:
Red Lead :Black Lead: DVA Reading
Orange/Blue :Engine Ground :130 V or more
Orange: Engine Ground :130 V or more
Orange/Green: Engine Ground :130 V or more
Note: If the DVA values are below these specifications, the power pack or sensor is likely bad.
13. Check the DVA voltage on the Black/Orange and Orange/Red sensors leads as follows:
Red Lead :Black Lead : DVA Reading
Orange/Red :Engine Ground :12 V or more
Black/Orange :Engine Ground :12 V or more
WARNING!! The Black/Orange wire should NEVER be shorted to engine ground as this will damage the sensor.
