I'm struggling to identify the faulty component in a 1990 Evinrude 200hp. I bought the boat in May and the seller tested it in the yard with muffs on and it started right up and ran it for about 10 minutes. The seller had told me that the batteries were not charging and that the regulator/rectifier may be bad. Once I got it home I tested the regulator/rectifier and it tested faulty. I replaced the regulator/rectifier with a new replacement from Sierra. Additionally, I replaced the water pump, both T-stats (6/8 bolts snapped! 
), the tilt trim unit , disabled the VRO pump and removed the remote oil tank, installed new gapped plugs and rehabbed the entire engine cosmetically.
After all this work was completed the batteries were charged and it was ready to fire up and when I turned the key I had no spark on any cylinder. It's been 3 weeks now (only have the weekends to work on the boat) and I'm still trouble shooting the issue. I went through the SELOC manuals and followed to a T the CDI trouble shooting guide for this (disconnect black/yellow shift wire, yellow regulator/rectifier wires, check all engine grounds, etc.). The first round of trouble shooting indicated to me that the power pack had failed. The DVA connected from the charge coils was ~50v and when disconnected was ~190v. See the table below. All "-" were data points that I did not take. As I continued to trouble shoot in different iterations I realized that there was more data I could capture.
I purchased a new Sierra power pack and installed it last weekend. Unfortunately, the results were the same ~40DVA connected and ~190 DVA disconnected. I did not take any other readings as this indicated to me that there was something else wrong and that the original power pack was good, therefore I did not take any additional data. See data below.
During the week, I called CDI and spoke with their technical support for almost an hour and the rep could not tell me exactly why but was adamant that it was the stator that was faulty. So I bought a stator (overnight Saturday delivery!). I pulled the flywheel off this morning and all the magnets and components looked good. I then installed the new stator and again there was no spark. I went through all of the testing and found that the charge coil DVA was ~30v connected and ~150v connected (battery was getting a bit weak as well). Additionally, the Timer base resistance and DVA were out of spec. I tested everything 2-3x’s and I’m starting to go crazy. See the third round of data below.
I’ve been fortunate so far and was able to return the power pack and hope to do the same with the stator. I’m happy to buy a new timer base if this really is the problem since the new power pack and stator seemed to make no difference but I don’t want to unmethodically throw parts at this. I don’t understand if there is or could be a relationship from the charge coil connected DVA being low and a bad timer base. I am very mechanically inclined and it is very bothersome to be stuck at this point, not to mention the boating season is closing fast here in MA! It would be greatly appreciated if there are any helpful suggestions or confirmation that this data does conclude that the Timer base is the faulty item.
), the tilt trim unit , disabled the VRO pump and removed the remote oil tank, installed new gapped plugs and rehabbed the entire engine cosmetically. After all this work was completed the batteries were charged and it was ready to fire up and when I turned the key I had no spark on any cylinder. It's been 3 weeks now (only have the weekends to work on the boat) and I'm still trouble shooting the issue. I went through the SELOC manuals and followed to a T the CDI trouble shooting guide for this (disconnect black/yellow shift wire, yellow regulator/rectifier wires, check all engine grounds, etc.). The first round of trouble shooting indicated to me that the power pack had failed. The DVA connected from the charge coils was ~50v and when disconnected was ~190v. See the table below. All "-" were data points that I did not take. As I continued to trouble shoot in different iterations I realized that there was more data I could capture.
I purchased a new Sierra power pack and installed it last weekend. Unfortunately, the results were the same ~40DVA connected and ~190 DVA disconnected. I did not take any other readings as this indicated to me that there was something else wrong and that the original power pack was good, therefore I did not take any additional data. See data below.
During the week, I called CDI and spoke with their technical support for almost an hour and the rep could not tell me exactly why but was adamant that it was the stator that was faulty. So I bought a stator (overnight Saturday delivery!). I pulled the flywheel off this morning and all the magnets and components looked good. I then installed the new stator and again there was no spark. I went through all of the testing and found that the charge coil DVA was ~30v connected and ~150v connected (battery was getting a bit weak as well). Additionally, the Timer base resistance and DVA were out of spec. I tested everything 2-3x’s and I’m starting to go crazy. See the third round of data below.
I’ve been fortunate so far and was able to return the power pack and hope to do the same with the stator. I’m happy to buy a new timer base if this really is the problem since the new power pack and stator seemed to make no difference but I don’t want to unmethodically throw parts at this. I don’t understand if there is or could be a relationship from the charge coil connected DVA being low and a bad timer base. I am very mechanically inclined and it is very bothersome to be stuck at this point, not to mention the boating season is closing fast here in MA! It would be greatly appreciated if there are any helpful suggestions or confirmation that this data does conclude that the Timer base is the faulty item.