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2004 Johnson 175 no spark problem, NEED HELP!

Jeepsycho83

New member
Hello, I have a 2004 Johnson 175 2 stroke outboard that is on the boat I purchased last year. I rebuilt the carbs (float bowls, gaskets, etc), 2 new 24 series batteries, new NGK plugs to replace the old champions,plastic timing wheel on top (old one cracked pulling it off to replace bad starter, raw water pump, lower unit gear lube. All items were Johnson factory, no aftermarket junk. I was running it on the main fuel tank then switched over to a clean 6 gallon fuel tank.
I have a spark checker attached, and also tried cranking it with a few squirts of ether (I don't like using it but just wanted to see if any cylinder would hit). I had it running on the driveway last year after I bought and and did the above work to it and it did seem to cut out a few times on me.
All of the connections are clean, I have proper 12v and ground to the starter and engine block, trim works just fine, key switch cranks the engine just fine, key switch also operates the choke. When you turn the key on the dash gauges do come to life and the 4 red LEDS come on as well as the ignition beep.

The one thing I have noticed is someone ran and additional grey wire (tapped into the tach grey wire above the voltage regulator and run all the way up to the tach, the original grey wire was removed and left there). When I was running the boat in the driveway and boat ramp, the tach was working but I do remember it jumping around a bit. When I crank the engine now, the tach does not move.

The engine is clean and not all corroded (on a 1997 21' hardtop walk around fishing boat-saltwater use).

Thank you in advance!!
 
OIS 2000 ignition systems like yours needs to have OEM spec Champion QL78YC spark plugs. On many motors you can cross to NGK but not these. I can’t say that’s your exact problem, but you do need the proper plugs in the engine.
 
Ok, here is an update, went and purchased the correct Champion spark plugs and disconnected the stop circuit wire (black with yellow tracer). I turned the engine over and I think it hit for a split second and the starter disengaged. Everything was back in place, wires on the plugs, etc. However, nothing after that. Tried for another 5 mins or so. I let the starter cool in between.
 
Hello, No there is no spark what so ever. We tested the voltage regulator today and found 4.3-5.5 volts on the grey tach wire so I have already ordered a new one but I do not know if that will keep it from firing.
 
Hello, still waiting for the new voltage regulator. I also ordered another johnson key switch because they seem to be quite problematic with the lanyard switch inside so I'm just going to change it out anyway. It looks to be original. Hoping to have everything tuesday.
 
Ok, so I installed a Johnson OEM new key switch as well as a used (working) voltage regulator. I also found a broken wire on a black wire right before a 4 wire (black, grey, brown w/ yellow tracer, and purple) plug. This plug is on the front of the engine down low in between the carbs. I cut the end and installed a heat shrink butt connector. Tried starting and nothing. The tach still does not move while cranking. Any other thoughts?
 
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