1994 Johnson 120 looper V4. Noticed late last year that there was a no start issue occasionally. Before the season this year, I traced it down to a short/internally broken black/yellow kill wire as it goes into the resin on the power pack. Instead of fighting a 25 year old pack, I ordered a new on, installed it, and life pulled me away until today. Tried to take it out today and it sounded off and wouldn't climb on plane. Brought it home and started troubleshooting. Quickly discovered no spark on upper cylinders. Moving coils and wires didn't change anything so I started looking at the pack. When I unplugged the connectors, 2 out of 5 metal sleeves they use as pin couplers I guess were left on the stator pins. It was the same pair on both sides. I pulled them off the pins, reinserted them in the correct spots, and had spark. Took it to the water to test. Much better, except it would stumble coming out of the hole then go. Pulled the connectors apart, reassembled the sleeves, and re-tested because I'm thinking still a bad connection. I was now running on 3 cylinders I would guess, no plane, and at idle, you could tell at least one cylinder was cutting in/out. At this point, I'm relatively certain the connectors for this power pack are just not making a solid connection. The design appears to be a regular post, with these metalsleeves around them, then the engine side harness pins slide in and I would assume pinch the post against the sleeves. It looks like the sleeves are too big or something. Every time I re-seat the connectors, I get a different result of what fires and what doesn't. Maybe the harness pins are pushing the posts mack and not really plugging in. Anyone run into this before and find a solution?
