Thread subject: Whaler Central - Boston Whaler Boat Information and Photos :: 1985 50hp 2 stroke 4cyl No Spark

Posted by rockinhitz34 on 06/27/17 - 4:10 PM
#1

Long story short splash-down was fun for about 20 minutes before my outboard cut out and would not start back up. Got home checked compression (engine cold, throttle neutral) in all 4 cyl was 110 PSI. Fuel was good, very fresh full tank, mixed correctly, firm bulb full carbs etc. Turns out I had no spark. Pulled up the wiring diagram and checked the fuse first. It was blown so I replaced it (20A) but still no spark. I checked the continuity of the fuse holder and that checked out. I checked the stator/trigger and one ignition coil (no spark on any of them I figured they all wouldnt die at once) and they checked out per my seloc manual ohms meter testing of the different color wire combos. Any help here, I am at a loss. Seems to me like it is a switchbox problem. Probably should mention I bought new spark plugs and they wont spark either (not a plug problem).

Any and all help is appreciated!

Posted by Walt Krafft on 06/27/17 - 4:31 PM
#2

I would check the kill switch and its wiring.

Posted by rockinhitz34 on 06/27/17 - 7:53 PM
#3

I checked the switch and it was in the "on" position, also bypassed the wiring and still didnt get a spark so I dont think its the kill switch.

Posted by Phil T on 06/28/17 - 5:09 AM
#4

If there are any connectors, pull off and re-connect.
Check for any and all grounds.


Posted by rockinhitz34 on 06/28/17 - 8:55 AM
#5

Thanks Phil, I disconnected everything and cleaned/checked all the wires I could to make sure I have good connections at the terminals, all seems good there, still no spark.

Posted by Phil T on 06/28/17 - 12:30 PM
#6

If the engine ran then you blew a fuse, you probably melted something.

Solenoid or a wire

Posted by mtown on 06/28/17 - 12:55 PM
#7

Phil T wrote:
If the engine ran then you blew a fuse, yprobably ou melted something.

Solenoid or a wire


That was my thoughts too.
Wire that has failed can be impossible to see. Check for any of the critical wires having a lot of flex in a spot.
I had a bad lead from my battery that was thick woven copper cable and looked great from outside. Only way I found it was internally failed was I used a jumper cable to "replace" it.
Once I knew it was bad I stripped the insulation and found the green failure.

Posted by rockinhitz34 on 06/29/17 - 9:10 AM
#8

It could be a portion of a wire I cannot see leading into the trigger or stator, but all the wires I have found and traced look ok. Ill see what happens when I bend them and move them. I bypassed my control box by just jumping my battery to the starter solenoid and still no spark so I think I have isolate the problem to the engine itself, specifically the ignition system.

No spark when I bypass the kill switch or rectifier so I dont think it is either of those. I tested the resistance on the stator, trigger, and ignition coils and those are all in spec. I think it is the switch box itself. Seems like it has a crack in the vinyl/plastic/electrical tape-like substance on it. Ill upload a pic. Apparently they can go bad if the kill switch carries voltage when you turn the key from off to on...although I tested and didnt see any.

Anyone know anything about these switch boxes going bad? My part # 332-5772A2

Posted by rockinhitz34 on 06/29/17 - 9:18 AM
#9

Switch box

Posted by rockinhitz34 on 06/29/17 - 9:19 AM
#10

Close-up you can see a crack to the left of the first red rubber cap

Posted by VA Whaler on 06/29/17 - 9:37 AM
#11

Good find. I replaced several back in my marine mechanic days but I don't recall one causing the fuse to blow. I'd still take the time to check all the wires and make sure they are not getting brittle and maybe laying against a piece of metal. You don't want to replace the thing twice. :)

Edited by VA Whaler on 06/29/17 - 9:37 AM

Posted by rockinhitz34 on 06/29/17 - 10:35 AM
#12

Yes very true they are annoyingly expensive. I will be sure to check over all the wires and make sure they are all still in good shape. Thanks for the advice all.