OMC 60 DEGREE V6 OPTICAL IGNITION TIPS
- Johnson - Evinrude Service Manual Application: Outboard & Sea Drive (Sea Drives) For 48 50 55 60 65 70 75 85 88 90 100 110 115 120 135 140 150 175 185 200 225 & 235 HP (Horsepower - Horse Power) Outboard & Sea Drive Marine Engine Johnson/Evinrude 2Stroke 2-Stroke Two Stroke & 4Stroke 4-Stroke Four Stroke models.
- Clean Used 1998 Johnson FastStrike 150 HP V6 2 Stroke 20' (Long Shaft) Outboard Motor. Model number: J150GLECD. Serial number: G04360161. Weight - 370 lbs. 110-118 psi compression on all 6 cylinders. Oil Injection Disconnected. Electric Start. Power Tilt/Trim. Motor has been inspected and ready to mount and run.
A guide to troubleshooting the Johnson/Evinrude
60 Degree V6 Optical ignition (OIS 2000) 1991-2003 model years.
The following information is presented for the use of MASTERTECH'S customers as a courtesy by CDI Electronics. This ignition system produces very high voltages and due care and caution must be practiced in working with it.
The timing wheel cover is a machinery guard. Use care and caution when working on a running engine. MASTERTECH MARINE, CDI Electronics and their respective employees cannot be held responsible for any injuries or damage resulting from the use of, or application of the following data. Please read the final paragraph below.
How to install front license plate bracket honda odyssey. We have chosen to narrow this troubleshooting guide to the Johnson/Evinrude 60° 6-cylinder ignition (OIS 2000) 1991-2003 model years.
Evinrude/johnson 1952-2010 evinrude/johnson motors ship with champion spark plugs. We recommend ngk instead, and traditional electrode-gap rather than surface-gap plugs where possible. We have found that the surface-gap plugs, while lasting longer, seem to have a slight performance hit over the standard plugs.
Due to the differences in this ignition system, troubleshooting can be somewhat difficult if you are not familiar with the design. The other Johnson/Evinrude QuikStart ignitions use stator charge coils and a power coil to provide high voltage and power for the QuikStart and rev limiter circuits. They require a timer base for triggering and use separate magnets for the high voltage and triggering the timer base.
The OIS 2000 optical system uses the stator charge coils to provide high voltage for the firing of the ignition coils and a power coil to provide power for the electronics both inside the power pack and inside the sensor. The other QuickStart models will run the engine without the power coil being connected (of course this will burn out the control circuits inside the power pack).
The OIS 2000 ignition has to have the power coil supplying power in order to operate the QuickStart, S.L.O.W., rev limiter, and fire the coils beyond cranking speed. The optical sensor located on the top is fed power from the power pack and sends crankshaft position, cylinder location and direction of rotation back to the power pack.
The pack is smart enough to know not to fire if the engine is not turning in the right direction. S.L.O.W. functions to reduce the engine RPM to approximately 2,500 when the engine overheats. QuikStart (a 10° timing advance) activates as long as the engine RPM is below 1,100, the engine temperature is below 105 F and the yellow/red wire from the starter solenoid is not feeding 12 volts DC to the power pack all of the time. QuikStart also will activate for five to 10 seconds each time the engine is started regardless of engine temperature.
At cranking speed the voltage from the stator may not be enough to operate the circuits inside the power pack, therefore there is battery voltage supplied from the starter solenoid via the yellow/red striped wire. The extra voltage is needed in order for the optical sensor to operate correctly as low voltage from the battery and/or stator can cause intermittent or no fire at all.
There are a couple of critical items you need to be aware of on these engines. First, the spark plug wires need to be the gray inductive resistor wires - these are not automotive wires. Secondly, the spark plugs should be the factory recommended QL78YC. Use of other spark plugs or wires can cause problems inside the power pack from RFI and MFI noise. CDI Electronics has the spark plug wires available as a set P/N: 931-4921.
A breakthrough at CDI Electronics has allowed the use of microprocessor digital control circuits to handle the timing, QuikStart, S.L.O.W., rev limiter and data logging inside the power pack. This allows the timing to be set using a timing light, remote starter, spark gap tester, piston stop tool and a jumper wire.
With these new digital power packs, you disconnect the port temperature switch/sensor leads and use a jumper wire to short the tan temperature sensor wire to engine ground. Once you have verified the timing pointer using a piston stop tool (or a dial indicator), connect all spark plug wires to a spark gap tester, and connect a remote starter to the engine and a timing light to the No.1 spark plug wire.
When you crank the engine over with the remote starter and check the timing, you will notice the timing is set to approximately 4°- 6° ATDC (after top dead center). By advancing the throttle all the way and rechecking the timing for WOT (wide open throttle), you should see approximately 19° - 20° BTDC (before top dead center). Without this timing feature built into the power pack, you would not be able to easily set the timing for idle or WOT without the Johnson/Evinrude optical diagnostic tool.
Another nice features allowed by the digital circuitry include the ability to compensate for a bad temperature switch, a smoother rev limit, customized rev limiters and special timing curves.
Additional items to be aware of:Early 150 and 175 HP engines did not have the tension washer on top of the sensor encoder wheel. This washer is necessary to keep the encoder locked in place. https://aa-torrent.mystrikingly.com/blog/apple-desktop-keyboard-cover. If it is not on the engine, you may experience erratic firing of the cylinders or no fire at all. If it is missing, please install the correct washer.
1991 and 1992 engines did not have a shift interrupter switch. This resulted in hard shifting and required a conversion to fix.
The shift interrupter switch killed the fire on the starboard bank of cylinders from 1993 through mid 1990s. By 1998, a change was made for the shift interrupter switch to kill the fire on the port bank.
1991 through late 1990s engines sometimes developed a crack in the water jacket allowing water into the intake at high speed. This typically resulted in #1 cylinder-ingesting water. You can usually see signs of the head looking like it has been steam-cleaned inside the combustion chamber.
1991 and 1992 engines came out with a black-sleeved power pack (P/N 584122) and stator (P/N 584109) and used a P/N 584265 sensor. In 1993 the power packs were changed to a gray sleeve (production) power pack (P/N 584910). The stator was changed to a gray sleeve (P/N 584981) and the sensor was changed to P/N 584914. Engines with ignition problems had a service replacement power pack with a blue sleeve and a replacement sensor installed as a set. The blue-sleeved power pack was only available as a service replacement. The gray-sleeved stator could be used with all of the power packs, but the black-sleeved stator was to be used only with a black-sleeved power pack. The sensor P/N changed to 586343 in the late 1990s.
Some engines do not have the RFI/MFI noise shield between the ignition coils and the power pack. If it is missing, replace it!
The gray inductive spark plug wires replace the black copper spark plug wires that were used on the early 1990s engines.
Originally the spark plugs were the QL82YC, but that recommendation was changed to the QL78YC for improved performance. Helpful tools used by the author in troubleshooting these engines:
- DVA Adapter P/N: 640
- Fluke Multimeter P/N: 530
- Spark Gap Tester P/N: 511-9766
No fire at all
Check the kill lanyard and key-switch position.
Verify the engine rotation (The engine needs to be turning in a clockwise direction).
Check the power pack and ignition coil ground wires for corrosion and tightness.
Connect a spark gap tester to all cylinders.
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.
Disconnect the 5-pin connector on the port side of the power pack and see if the spark returns. If it does, use the fluke meter set to ohms and see if the black/yellow wires are shorted to engine ground.
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.
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.
Check the sensor eyes for dirt, grease and the like. If you need 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.
Disconnect the voltage regulator/rectifier and retest. If the engine now has spark, replace the regulator/rectifier.
Using piercing probes and DVA adapter or DVA Multimeter, check the resistance and DVA voltage on the 6-pin stator connector while connected as follows:
| RED LEAD TO: | BLACK LEAD TO: | RESISTANCE | DVA READING |
| Orange | Orange/Black | 50-60 OHMS | 12V or more |
| Brown | Brown/Yellow | 450-600 OHMS | 150V or more |
| Brown/White | Brown/Black | 450-600 OHMS | 150V or more |
Low readings on all checks indicate a possible problem with the flywheel magnets that needs to be checked.
Service note:It is recommended that liquid neoprene be applied to the areas where piercing probes were used.
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 TO: | BLACK LEAD TO: | DVA READING |
| Orange/Blue | Engine Ground | 130 or more |
| Orange | Engine Ground | 130 or more |
| Orange/Green | Engine Ground | 130 or more |
Note:
If the DVA values are below these specifications, the power pack or sensor is likely bad.
Check the DVA voltage on the black/orange and orange/red sensors leads as follows:
| RED LEAD TO: | BLACK LEAD TO: | DVA READING |
| Orange/Red | Engine Ground | 12V or more |
| Black/Orange | Engine Ground | 12V or more |
If an oscilloscope is available, check the white/blue (crank position signal) and white/green (cylinder position signal) sensor wires while connected to the sensor. With the engine cranking over, you should see a square toothed pattern on both wires. The white/blue wire should show one pulse per revolution and the white/green should show seven pulses per revolution of the engine. See example chart below:
No spark on one bank of cylinders
Using piercing probes and DVA adapter or DVA Multimeter, check the resistance and DVA voltage for the bank without spark on the 6-pin stator connector while connected as follows:
Note:
If the power pack has no spark on one bank and the readings are good, replace the power pack.
Disconnect the 5-pin connector on the port side of the power pack and see if the spark returns. If it does, use the fluke meter set to ohms and see if the black/yellow or black/orange wire is shorted to engine ground. Check to see if the shift interrupter switch is located in the circuit where there is no spark.
1994 Johnson 150 Fast Strike Manual
If the engine runs fine until you get above 4900 RPM and then starts missing, check the orange to orange/black power coil wires with an oscilloscope (if available) or replace the pack. A breakdown inside the pack could cause RFI noise to activate the rev limiter for no apparent reason.
Using piercing probes and DVA adapter or DVA Multimeter, check the DVA voltage at the RPM where the problem is occurring while connected as follows:
| RED LEAD TO: | BLACK LEAD TO: | DVA | BANK/CYLINDER |
| Brown | Brown/Yellow | 150+V | Starboard (1-3-5) |
| Brown/White | Brown/Black | 150+V | Port (2-4-6) |
Note:
The readings should rapidly increase as the engine RPM increases and stabilize below 400 volts (voltage exceeding 400 V DVA indicates a bad pack). A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator charge coil.
Connect an inductive tachometer to the spark plug wires one at a time and compare the readings. If most of the cylinders show the same reading and one or two are different, check the primary wires with the inductive pickup to see if the readings are the same coming out of the power pack. A difference in readings between the primary and secondary coil wires indicates bad ignition wires. No difference indicates a bad power pack.
Will not rev up
Engine will not rev up above idle speed or only has spark as long as the starter solenoid is engaged:
Using piercing probes and DVA adapter or DVA Multimeter, check the DVA voltage while connected as follows:
| RED LEAD TO: | BLACK LEAD TO: | DVA |
| Orange | Orange/Black | 11 - 24V |
Fast Strike 150 Troubleshooting
Note:
The readings should rapidly increase as the engine RPM increases and stabilize below 24 volts (voltage exceeding 24 volts DVA indicates a bad pack). A sharp drop in voltage right before the miss becomes apparent usually indicates a bad stator winding. A sharp drop in voltage when you let off of the starter solenoid indicates a bad power coil on the stator.
Engine will not rev up above 2500 RPM and shakes hard (S.L.O.W. activated):
Verify the engine is not actually overheating by using a digital pyrometer.
Check the routing of the tan temperature wires, an example of a bad location is shown below. The tan wires need to be located as far as possible away from the spark plug wires.
Disconnect the temperature sensors and see if the engine performs normally. If it does, check both temperature sensors and replace the defective one.
If there is not any indication of a problem at this point, replace the power pack
Check the yellow/red wire for 12 volts while the engine is running. You should only see voltage on this wire while the starter solenoid is engaged.
As you can see, there are several critical steps involved with the troubleshooting of outboard ignition systems. The electronic components are not 'magic black boxes' mysteriously making spark appear, but rather a complex system giving the engine the correct voltages at the correct time for years of trouble-free boating. Additional information for other engines can be obtained by visiting www.am-tech.org or www.rapair.com. I would like to give a special thanks to the technical service personnel at CDI Electronics for their help with this article.
Author Clark Beard is a senior technical service advisor for CDI Electronics and also serves on the advisory board of AMTECH.
IF you wish to service or repair your own ignition system, I HIGHLY RECOMMEND you obtain an OEM model-specific service manual to help you. We have most available Right Here at Mastertech.
Files in 'Johnson Evinrude'
- 115 Johnson Outboard Manual
- 15HP JOHNSON OUTBOARD MOTOR HEAD GASKET TORQUE SEQUENCE
- 1966 evinrude 40 hp lark elec
- 1970 18 HP evinrude timing plate
- 1971 40 hp johnson wiring diagram
How to cut image on macbook. - 1971 Evinrude 125 HP Outboard no spark
- 1971 johnson 4hp 4r71 direct drive service manual
- 1971 johnson 6hp service manual
- 1973 85 hp evinrude wiring schematic
- 1976 Evinrude 4 hp outboard information
Fallout 4 weapon condition mod. - 1978 johnson 2 hp seahorse
- 1979 115hp evinrude repair manual download
- 1979 25 hp johnson no spark on one cylinder
- 1982 johnson seahorse 4hp outboard manual
- 1983 35 hp evinrude owner manuals
- 1987 50 horse evinrude for sale
- 1988 johnson 40 hp timing/maintenance
- 1988 johnson 60 VRO hand control
- 1989 60 horse johnson electric choke
- 1989 johnson 9.9 hp outboard motor
- 1990 super sea horse
- 1990s yamaha 140 outboard
- 1991 Johnson 40 hp vro engine specs
- 1991 Johnson Evinrude Service Manual 9.9 thru 30 HP Models
- 1992 evinrude 60 fuel diagrams
Dune 1984 the alternative edition v2 subtitles greek. - 1993 25hp evinrude outboard manuals
- 1993 70 hp evinrude manual s
- 1993 evinrude 90 hp manual
Wavelab 6 free full version with crack. - 1993 johnson 200 hp outboard has no spark
- 1994 evinrude 150 image
- 1994 johnson 70 hp outboard
- 1997 johnson 15 hp 4 stroke outboard electric start conversion
- 1998 evinrude spl90 will not trim down
- 1998 johnson 115 spl manual
- 1998 johnson 15 hp outboard service manual amazon
- 1998 johnson outboard manual pdf
- 1999 johnson 35 hp outboard
- 1999 johnson outboard motor servise manual
- 2 hp evinrude outboard service manual
- 2000 johnson 35 hp outboards
- 2000 johnson 4 hp outboard motor owners manual
- 2003 johnson 4 stroke 9.9 outboard motors
- 2004 25 hp johnson
- 2004 johnson outboard 50 hp 2 stroke
- 2007 evinrude etec 90 service manual
- 2hp johnson seahorse 1976
- 3 cyl 30 hp johnson
- 60 HP Evinrude Outboard Diagrams
- 9.9 hp johnson outboard 2006 model j10tel4su
- 98 evinrude 35 problems
- carb adjustment on 78 Johnson 55 hp
- Choke diagram for a 1976 johnson motor
- download 1978 evinrude outboard service manual
- download Johnson Outboard 1980 V6 Service Manual 150 175 200 235hp
- DT30 30HP 1989 1997 electrical diagram
- evinrude 100 hp outboards
- Evinrude 28 SPL Manual
- evinrude 4 stroke 70 hp
- evinrude 50 hp outboard runs on one cylinder
- Evinrude 9 9 Manual PDF
- Evinrude model 2502D owners manual download
- Evinrude Outboard Motors Manuals
- evirnrude 55 hp manual etec
- how to change fuel pump on 15 hp johnson outboard
- how to chenge timing belt johnson 8hp 4stroke
- is the 1995 115hp johnson faststrike a dependable motor
- johnson 115 1978 workshop manual
- johnson 1970 twin outboard
- johnson 2hp sea horse service manual pdf
- johnson 3 0hp j30elco 1985
- johnson 40 hp vro manual
- Johnson 4hp two stroke motor 1998 service manual
- johnson 85 hp 1972 owners manual
- jOHNSON EVINRUDE BOAT MOTOR SPECS
- johnson four stroke 5hp 2005
- johnson motor 60esl71c fuel pump
- johnson omc 1995 225 manual
- johnson seahorse 2 manual
- johnson seahorse torrent 4hp
- johnson service manual 9.9 thru 30 1988
- johnson ski twin 40hp
- loop charged johnson fast strike 175
- manual for 1972 Evenrude 2hp outboard motor
- manual johnson 60 pdf
- manual motor evindure 25hp 2 t
- of 1984 65hp johnson outboard motor
- oil ratio on 1972 evenrude
- online1972 evinrude mate 2hp outboard service manual
- outboard lower unit oil seal replacement 2000 johnson 15 hp outboard
- outboard one cylinder not drawing fuel
- owners manual 1994 25 hp outboard johnson
- repair manual evinrude 737
- repair/service manual for a 2008 150 hp v6 Evinrude etec outboard motor
- sea hores 4hp 1975 parts
- SERVICE MANUAL-1994 EVINRUDE 25
- SERVICE MANUAL P/N 508282
- starting a johnson j25reeb
- trouble shooting johnson 2oo4 9.9 4-stroke
- used 50-70 hp 1995 jonson
- Weight of 1974 johnson 40 hp outboard
- what is an evinrude EC model
- 1993 evinrude 90 hp manual
Wavelab 6 free full version with crack. - 1993 johnson 200 hp outboard has no spark
- 1994 evinrude 150 image
- 1994 johnson 70 hp outboard
- 1997 johnson 15 hp 4 stroke outboard electric start conversion
- 1998 evinrude spl90 will not trim down
- 1998 johnson 115 spl manual
- 1998 johnson 15 hp outboard service manual amazon
- 1998 johnson outboard manual pdf
- 1999 johnson 35 hp outboard
- 1999 johnson outboard motor servise manual
- 2 hp evinrude outboard service manual
- 2000 johnson 35 hp outboards
- 2000 johnson 4 hp outboard motor owners manual
- 2003 johnson 4 stroke 9.9 outboard motors
- 2004 25 hp johnson
- 2004 johnson outboard 50 hp 2 stroke
- 2007 evinrude etec 90 service manual
- 2hp johnson seahorse 1976
- 3 cyl 30 hp johnson
- 60 HP Evinrude Outboard Diagrams
- 9.9 hp johnson outboard 2006 model j10tel4su
- 98 evinrude 35 problems
- carb adjustment on 78 Johnson 55 hp
- Choke diagram for a 1976 johnson motor
- download 1978 evinrude outboard service manual
- download Johnson Outboard 1980 V6 Service Manual 150 175 200 235hp
- DT30 30HP 1989 1997 electrical diagram
- evinrude 100 hp outboards
- Evinrude 28 SPL Manual
- evinrude 4 stroke 70 hp
- evinrude 50 hp outboard runs on one cylinder
- Evinrude 9 9 Manual PDF
- Evinrude model 2502D owners manual download
- Evinrude Outboard Motors Manuals
- evirnrude 55 hp manual etec
- how to change fuel pump on 15 hp johnson outboard
- how to chenge timing belt johnson 8hp 4stroke
- is the 1995 115hp johnson faststrike a dependable motor
- johnson 115 1978 workshop manual
- johnson 1970 twin outboard
- johnson 2hp sea horse service manual pdf
- johnson 3 0hp j30elco 1985
- johnson 40 hp vro manual
- Johnson 4hp two stroke motor 1998 service manual
- johnson 85 hp 1972 owners manual
- jOHNSON EVINRUDE BOAT MOTOR SPECS
- johnson four stroke 5hp 2005
- johnson motor 60esl71c fuel pump
- johnson omc 1995 225 manual
- johnson seahorse 2 manual
- johnson seahorse torrent 4hp
- johnson service manual 9.9 thru 30 1988
- johnson ski twin 40hp
- loop charged johnson fast strike 175
- manual for 1972 Evenrude 2hp outboard motor
- manual johnson 60 pdf
- manual motor evindure 25hp 2 t
- of 1984 65hp johnson outboard motor
- oil ratio on 1972 evenrude
- online1972 evinrude mate 2hp outboard service manual
- outboard lower unit oil seal replacement 2000 johnson 15 hp outboard
- outboard one cylinder not drawing fuel
- owners manual 1994 25 hp outboard johnson
- repair manual evinrude 737
- repair/service manual for a 2008 150 hp v6 Evinrude etec outboard motor
- sea hores 4hp 1975 parts
- SERVICE MANUAL-1994 EVINRUDE 25
- SERVICE MANUAL P/N 508282
- starting a johnson j25reeb
- trouble shooting johnson 2oo4 9.9 4-stroke
- used 50-70 hp 1995 jonson
- Weight of 1974 johnson 40 hp outboard
- what is an evinrude EC model
- what mix ratio do u in a seahorse jhonson 50hp boat motor
- wiring connections evanrude 33hp twin
How do i update safari on my imac. - wiring diagram jonson 70 hk 1992
