Why Me???? Electrical

verne1972

Seaman
Joined
Mar 22, 2008
Messages
66
You have got to be kidding? So I have been having electrical issues with my 97 150EFI Magnum since early spring. I have read, replaced, reread, and read some more..... My problem has always been intermitted spark, or sometimes no spark at all. I have replaced the switch boxes, and replaced or exstensivley cleaned every wire and ground on the entire engine. So heres the new issue. Once my engine has spark, it runs like brand new. All day, continually starting and stoping the engine for as much as an hour at a time. I bring it home. The next weekend I always crank it up befor i leave the house with ears on it, just to make sure everythingis working properly, and it never has spark on one side of the engine. I have to remove the switch boxes, loosen all the wires, one at a time, and put it back together befor it gets spark. Now i know what your probably thinking, bad connection. Yes, but where? I have never been able to methodically take one wire off at a time and replece it and get spark. Now Saturday Im working on getting it spark and i realized it has nothing to do with any wire, it the switch boxes themself. When i loosen the two screws that attach the boxes to the engine there is spark and when i tighten them there is no spark. I am not pinching any wires, the boxes have a ground wire from each box to the other, and another wire to the block. The have SS machine screws going through them with a spacer between each other and nothing ealse. What is going on? I just dont get it. Once i initally get spark and the engine cranks, i can tighten the screws and never have a minutes trouble out of the motor all day. Its diving me crazy. Sorry for the long disertation, I just didnt want anything to get lost in translation. Thanks for any input in advance. Verne
 

crazyclam

Cadet
Joined
Apr 22, 2009
Messages
29
Re: Why Me???? Electrical

It seems you have narrowed the source down to the switch box screws....Pay close attention to anything moving and where its touching when you loosen those screws.....Maybe a wire is getting in the wrong place....or its a bad ground somewhere.....check check and re check.....at the connections make sure no paint is causing a bad connection..
 

j_martin

Admiral
Joined
Sep 22, 2006
Messages
7,474
Re: Why Me???? Electrical

If the ground wires are on and good, loosening the mounting screws shouldn't have any effect....but it does.

Which bank does not have spark? If it is the bank wired to the inside switchbox, then tightening the mounting may be shorting something on the inside switchbox against the bare back of the outside box.

This is about the time I closely inspect each crimped terminal. I pull on each wire, then try to push it back into the terminal. If I feel any motion at all, I replace the connector.

When I install a ring terminal in marine use, I use a Fastenal shrink insulated terminal. I cut a little insulation away to I can see the end of the crimp tube. Then I solder the wire in, which will flow a little insulation back over the cut off part. Shrink the sleeve, and you have a perfect marine connection.

hope it helps
John
 

green4themoney

Petty Officer 1st Class
Joined
Jul 21, 2004
Messages
318
Re: Why Me???? Electrical

i had the exact same problem but fo me i had a bad coil and mine was only intermittantly running on one cylinder
 
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