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1991 Evenrude vro 200hp initial start no spark

JimmyL

Member
When first started cold, it will crank with no spark. If I keep trying it starts to sputter and then will start, sputters till it cleans the fouled plugs. after that it will start up with a touch of the key. Any and all help will be appreciated.
 
Have you actually removed "all" of the spark plug and checked the spark which should jump a 7/16" gap at cranking speed with a strong blue lightning like flame... a real SNAP!? Or are you assuming the engine has no spark due to the way it acts?

Did this engine start properly in the past for you or has it been this way since day one?

What is your engine starting procedure?
 
I have verified no spark with a spark tester. I am a retired chevy tech. I just purchased this boat recently and it was always hard to start. I verified timing when it was warm. I usually to start pump the fuel primer till hard, pump the oil primer till hard give a little throttle and crank engine. But once it starts and runs it will be ok and start great until it gets cold again.
 
The engine must crank over at least 300 rpm with the electric start in order for the stator under the flywheel to energize the powerpack. A slow cranking engine will have erratic, weak, or no ignitiion.

Also... check the two coils at the rear of the stator (Ones that supply approx 300 AC volts to the pack's capacitor). If either or both of those coils are leaking/dripping a sticky looking substance down on the powerhead area, that indicates a meltdown of the stator which results in a voltage drop. If either of those coils are leaking, replace the stator.

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That engine has the "Fast Start" feature which automatically/electronically advances the timing to obtain a fast idle when starting cold. As the engine warms up, an additional sensor (notice 2 wires on heat sensor of port cyl head) drops the idle to a normal rpm at a certain heat range. Bottom line... no need to advance the throttle to start on that engine.

I have no idea what your statement of "pump the oil primer till hard' means, however it has no business being in the start procedure. Try the following recommended starting procedure.

Pump the fuel primer bulb up hard.
Leave the throttle lever in neutral and dead idle position.
Turn the key to the START position... and push the key in and hold it there to engage the Fuel Primer Solenoid.
When the engine fires and starts, release the key.

(Fuel Primer Solenoid Function)
(J. Reeves)

The RED lever...... The normal operating/running position is to have that red lever positioned over top of the solenoid and aimed at the other end of the solenoid, gently turned to its stop. This is the normal/automatic mode position.

Pushing the key in opens the valve within the solenoid allowing fuel to pass thru it in order to prime and start the engine. Looking upon this solenoid as a electric choke results in a better understanding of it.

Having that red lever turned in the opposite direction, facing away from the solenoid, allows fuel to flow thru it to the crankcase area. One would only turn the red lever to this position in a case where the battery might go dead and the engine had to be started via the rope pull method. Look upon putting the red lever in this position as moving a choke lever on a choke equipped engine to the full closed position. Either one would supply fuel to the crankcase/engine for starting purposes BUT if left in that position while running would flood the engine.

The later model primer solenoids are equipped with a schrader valve, used for attaching a pressurized can of fogging oil etc, available at your local dealership with complete instructions.

Pumping the fuel primer bulb up hard fills the carburetor float chambers of course, but that process also applies fuel pressure to the primer solenoid.

The two small hoses leading from the primer solenoid branch off via tees to each fuel manifold section that would feed fuel to the individual cylinders.

Pushing the key in activates the primer solenoid to allow fuel to flow thru it to the intake manifold passageways.

Cranking the engine over causes the fuel pump to engage which in turn sends fuel pulses to the primer solenoid via the 3/8" fuel hose.

Some engines incorporates the "Fast Start" feature which automatically advances the spark electronically so no advance of the throttle is required for starting.

Engines that do not have the "Fast Start" feature will be required to have the throttle advanced slightly.

Starting procedure: pump fuel bulb up hard, crank engine and push the key in at the same time. When the engine fires/starts, release the key so that it falls back to the run position.

Bottom line..... Look upon the primer solenoid as an electric choke.

Thousands of parts in my remaining stock. Not able to list them all. Let me know what you need and I'll look it up for you. Visit my eBay auction at:

http://shop.ebay.com/Joe_OMC32/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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I will pull the flywheel and inspect the stator. Should I look at anything else while I have the flywheel off. It just to me feels like a poor connection but I am not by no means an outboard tech. Because it puzzles me that by extended cranking or removing the plugs and crank it to clean out the cylinders it starts runs a little rough till the plugs clean themselves then runs like a bear with no start or run concerns until it sits a day.
And thank you for the starting procedure and the red lever was in the right position.
 
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Flywheel removed ohmed out stator and charge/sensor coil all are within their proper specs. passed key switch test also any other ideas want to be on water and this is driving me nuts thanks
 
Does anyone have any ideas to the nature of this problem. I do not want to throw parts at it. Want to find and repair the fault by testing and verify faulty part. thanks. Any Evenrude techs in the Lacey twp area that I can pick your brain would be appreciated. Thanks to all that reply
 
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At the engine... disconnect the Black/Yellow wire from the powerpack that leads to the ignition switch and kill switch. If you now have spark, there is intermittent short in either the ignition switch or the wiring harness leading from the engine to the ignition switch.

To determine which.... connect that Black/Yellow wire back to the powerpack, then disconnect the Black/Yellow wire from the ignition switch and kill switch.

If no spark... the short is in the wiring harness (somewhere).

If spark exists... the ignition switch is shorted, possibly the kill switch.
 
It was the first thing I did thinking it would be an easy fix. I even used my meter to record voltage to coils no voltage was present when cranking. And thanks for the replies, It just puzzles me that I have no spark but after I remove the plugs blow out the cylinders and reinstall it will catch sometimes or I have to do it again, once it starts and clears out the excess fuel and all cylinders are firing I can shut it off and to start at that point just tap the key and she fires right up
 
Are you pushing the key in for starting while cranking it over ?---------Is the starter in good shape.--------These starters are easily damaged by reckless cranking.
 
tried both ways key pushed and not pushed., Joe Reeves explained the starting procedure to me also. plenty of cranking rpm's starter is good when it does start you could never tell it has a problem. I may just start with a stator and go from there. Don't know what else to do. I want to be on the water
 
If the aftermarket (3rd party) parts are from reliable sources such as Sierra etc whereas the parts are new... I have no problem with them and have used some of those components from time to time with no complaints... BUT... if it is a company that takes faulty parts and rebuilds them, I'd suggest you avoid that sort of thing.

Parts off a running engine? That's a toss up really as you may be buying a part that's just about to fail... or on the other hand, you may be lucky and obtain a part that was replaced yesterday so to speak, just before a connecting rod let loose and flew thru the side of the block. In the past, I've sold quite a few used parts and always stood behind them, a few failed and were replaced or money was returned, whatever the customer preferred, but for the major portion of the sales (many years ago), as far as I know... those engines are still running.

I can only wish you luck in that area.
 
Thanks Joe for your assistance in this. Being an auto tech for over 50 years I understand about reman parts. The aftermarket stuff would have to be new. I think aftermarket parts are bandades they check what failed and only replace that part, may toss in a set of brushes but if another part in it is short on life it will fail soon enough.
 
Racer I have checked the starter, I have good cranking RPM's and about 140 amp draw from the starter but once it starts all I have to do is tap the key and it srarts.
 
As far as I am concerned these starters are elegantly easy to inspect and repair. ---Costs nothing to do the inspection.----------Some folks will install expensive ignition components only to report " still won't start properly "--------I guess I use a different approach to repair?
 
I have checked the starter the motor spins fast I wish that was the concern. i inspected it looked at the brushes and armature no burn marks and brushes are good, bushing are good too. . And thank you for giving me things to look at. I am open to all suggestions. Took the stator to a marine tech who said it has melted and needs to be replaced.
 
Racer one you got me thinking with all the cranking I have been doing for piece of mind inspected the starter. All looked good greased the ends of the armature and the starter drive.
 
If the large black coils that are located to the rear of the stator have started to melt down a leak/ooze a sticky looking substance down on the powerhead area, that would result in a AC voltage drop to the powerpack's capcitor.... yeah, that would reasult in weak, erratic, and eventually no ignition.

Strange thing is..... normally when cold, if the melt down has just started a short time back, the stator would function like new when cold but act up when hot... not vice versa.
 
It is driving me crazy,I really do not like throwing parts at it. I have to see a failed part to verify the concern. yesterday got it running again and realized it is only running on one bank. I remembered when I first got the boat there was a ground wire disconnected to the stud at the power pack. I have an Evinrude service manual coming for it, the seloc manuals are not really detailed like I am use to compared to the factory manuals. Reading up on this today I will be checking the shift switch and look into where that ground wire comes from, maybe there is a light at the end of this tunnel.
 
My problem was the power pack. Had a local marine repair shop let me try the stator, timing base and power pack. did one at a time, final results was the power pack. Got a new cdi power pack with the rev limiter, runs great time to go fishing and the stripers will be here soon. I want to thank all who gave me advise with my problem.
 
Had a local marine repair shop let me try the stator, timing base and power pack. did one at a time, final results was the power pack.

I assume there's no need for me to advise you... BUT... that's a marina you really want to stick with. Marina's that are more interested in having your problem corrected then in selling non refundable components are hard to come by.

You might want to list there name and location if it's permissible on this site.
 
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They were very helpful, other places said try this or try that and told me the cost of the part and said it is non refundable. They were used parts I tried off a motor that they had there and after I found the bad part I did buy it from them. And if the admin can let me know if I can post their name it would be appreciated. And they told me different things to check. Other places didn't want to be bothered, told me to bring it to them and they will let me know what it needs. And Joe you and racerone were very helpful leading me in the right direction. And I would always seek your advise in the future if I need it.
 
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At the engine... disconnect the Black/Yellow wire from the powerpack that leads to the ignition switch and kill switch. If you now have spark, there is intermittent short in either the ignition switch or the wiring harness leading from the engine to the ignition switch.

To determine which.... connect that Black/Yellow wire back to the powerpack, then disconnect the Black/Yellow wire from the ignition switch and kill switch.

If no spark... the short is in the wiring harness (somewhere).

If spark exists... the ignition switch is shorted, possibly the kill switch.
Isn't this the same as plugging a remote key switch into red harness connector on engine? This would eliminate original ignition and kill swith at drivers postion - correct. I have the same problem on a boat I am working on. Starts right up and then another day it won't. Have a spark plug gap testor, no spark and then fool around a little more spark comes back and motor fires. All spark was gone then come back abd warms up runs great. Hard to image bad stator or trigger would run that well once running??
 
My problem was the power pack. Had a local marine repair shop let me try the stator, timing base and power pack. did one at a time, final results was the power pack. Got a new cdi power pack with the rev limiter, runs great time to go fishing and the stripers will be here soon. I want to thank all who gave me advise with my problem.
I am having the same exact problem on a boat I am repairing right now. No way is it the starter or slow cranking because when it starts it fires right up and runs great. I find it hard to believe stator or trigger are bad as it runs to smooth when running. Was thinking flaky CDI unit. Glad to hear you got a fix. Jim
 
Poster has not been back since 10 years ago.---So it was a good fix.---Or he has switched to a new 4 stroke.---Money solves all issues.
 
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