No spark 1985 Johnson 150

[jasoncooperpcola]

On my 1985 Johnson 150, i tried to run it today but it would not run because i believe it has no spark. Last time I ran it was in early May. Since then i have cut the triangular trim and tilt plug off and straight wired the trim and tilt in the gunnel because it was corroded, fixed a wire for the tachometer that got smashed in the control box between the two halves, epoxied filled the remote control throttle gear because a tooth broke off, and straightened out all the motor wires, and cables and put them in a hose to make them neater. Would any of this cause it to not have spark? I am certain it is a spark issue because none of the plug wires would spark my spark tester. Also the black and yellow wire "ignition kill" is grounded when the key is on. Is this correct?

I have taken my remote control box apart and checked for smashed wires, none.
I have pulled the rod box out and checked for broken wires, none.

What else can i check?

[tsubaki]

For some reason, I'm having a hard time comprehending what your saying.

See if this thread helps to confirm the wire termination.
http://www.wellcraftv20.com/community/showthread.php?t=7589

[spareparts]

black and yellow wire should not be grounded with the key on, its like your lawn mower, you ground out the spark plug to shut it off.

[jasoncooperpcola]

Thanks tsubaki when it quits raining i will go out and check to see if all the wires are in the right place on the ignition switch.

FYI, it is cranking but not firing.

[tsubaki]

Here is a way to rule out it being part of the wire harness or if it's a problem at the engine, if you know how to jump the starter solenoid.
One problem in doing this, there is no way to shut the engine down being you have a primer system and not the butterfly choke. You will have to unplug the gas hose and let it run out of fuel.
Run a water hose to the engine, just like you are confident it's gonna start and run.
Unplug the big red harness at the engine, manually prime the carbs (instructions on the air silencer), jump the starter solenoid to see if it wants to fire.

[jasoncooperpcola]

Just tried unplugging the main harness, it didn't crank. I will try it again just to see if it has spark. Also i will check the bumblebee wire.

[jasoncooperpcola]

It was the bumblebee wire! Disconnected it from the ignition, and hit the key, fired right up. Then i realized during my moment of "awe" i never turned the water on. Dove off the side and turned the water on. Hopefully didn't mess the pump up. It ran for about 15 seconds without water. Now where do i go from here.

[tsubaki]

At least it ain't power packs or worst.
You gonna have to help me.
What the hell is the bumblebee wire?

[jasoncooperpcola]

The black and yellow wire is the bumble bee wire. I don't know why i chose that name for it. I guess i thought it would be easier to type than black and yellow.:you:

[tsubaki]

Pay attention to what spare was saying and go through the wiring diagrams.
Let us know what you find, it sounds like wrong wire on wrong terminal.

[jasoncooperpcola]

I checked the wiring diagrams online and on the link. Everything matches up. If i disconnect the ground or the black/yellow (bumblebee) wire the motor will run. The only way to shut it off is to reconnect the wire i disconnected.

Could it be the ignition switch?

That's what i am leaning towards right now but don't want to spend money on an ignition switch till i am 100% sure its the culprit.

[tsubaki]

Do it, it's a cheap answer to rule that out.

[jasoncooperpcola]

According to my test light the ignition switch is working fine. The black and yellow contact on the ignition switch only is grounded when the ignition is off.
I have completely pulled the big red plug apart on the motor and on the black and yellow wire contact on the motor side of the plug i have a dim ground.

What the hell?? That contact feeds two black yellow wires one of each go to the power packs.

[spareparts]

have you checked the kill switch?

[jasoncooperpcola]

There is no kill switch that i know of Spare.

Although i may buy one just to fix this problem and use it to shut the motor off. :bat:

I have isolated the problem to the motor based on the fact that, with the big red plug unplugged, the motor side of the plug where the black yellow wires come out have a dim ground. I checked the other side of the harness that goes to the remote control and it is ok.

[jasoncooperpcola]

After further investigation, if i unplug both yellow/black wires to the power packs and put my test light on the connectors, they both very very dimly light up my test light(which one end is hooked to positive to check for ground).
What now? :head:

[jasoncooperpcola]

So this morning i go out and play with it some, and it wont crank now!
After some digging around i found a blown fuse(that comes out of the solenoid on the red wire) on the motor. I Replace it and now it cranks AND shuts off! :clap:

Could the fuse have been the whole problem?

[tsubaki]

There's a bunch that don't make sense to me, reason for not suggesting deeper.
Normally if the lone fuse is bad, you won't get anything related to the control box to work. The trim, the choke (primer) or the starter. That fuse basically works everything related to the harness.
Bunches of stuff just didn't sound right or at least I didn't comprehend it.

You know, I take that back.
My son in law couldn't get his engine to start and I found out it was that fuse.
He couldn't tell me he had shorted anything or not. Normally if the key switch is turned on and you short anything it will blow that fuse.

[jasoncooperpcola]

I spoke too soon. When i put the remote control back together it wont turn over, its dead. When i take it apart, it will turn over. :head:

Now here's the real kicker: I now have ALL the wires (ignition, neutral safety switch jumped) outside the remote control hanging out the gunnel. Same thing, if the remote control is together the motor is dead. If the remote control is apart it will start.

How the hell is this possible?

I was planning to take it out tomorrow and run it for a little bit just for the helluvit. Its already cost me the last day of snapper season so its already on my sh*t list. :bat:

[jasoncooperpcola]

So now i believe it is the ignition switch. Every time i touch the yellow/red wires together it starts. When i put them pack on the ignition i get nothing. Tomorrow i will get another ignition switch from west marine unless, someone can recommend a better place to get one?

[jasoncooperpcola]

Well i think i finally broke the electrical curse of my Johnson. A new ignition switch and a jumper around the harness due to a bad connection and she's working like she's supposed to. Also went ahead and moved the ignition switch to the dash. Now i just have to get used to turning the key up there rather than behind me on the remote control.

[tsubaki]

Last time I went into the control box, I relocated mine too. Just extended the neutral switch wires.

[jasoncooperpcola]

I almost decided not to hook the neutral safety switch up, but figured what the hell, its open why not? I kept getting crushed wires in between the halves of the box, that's my main reason for relocating the ignition.

Hopefully i can put her in the water tomorrow and run a six gallon tank of gas/oil and seafoam through the engine at full throttle. Plus i want to see how my tach is working now.