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Points wire replacement

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StevenR

New member
Hi everyone, I am in the process of having to replace all the wires on a 1974 Evinrude 15hp model 15404S after mice got in it and chewed them to shreds. I replaced them all with a good grade wire of the same gage but it refuses to start just pops every once in a while, now thinking that it must be some other problem I have now replaced every part that constitutes the ignition system and it still just goes pop,pop,pop..and absolutely refuses to start! The spark is there but very weak and only seems to spark every 5-6 rotations of the pistons. Now I'm wondering, are the wires used on the points motors, (the blue with a white stripe ) some kind of resistor type of wire or some other special kind of wire? I have replaced many a set of points in my time and yes they are set at 020 and the timing is correct , the condensers are new after trying 5 other sets but never have I had to replace the wires for any reason so this is the question of the day. Thanks for your help in advance...
 
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There is nothing special about the wires, except possibly more flexible to withstand the constant flexing back and forth with throttle movement.
 
Does spark jump a gap of 5/16" , yes or no ?-----Even a new set of points must be cleaned.------Clean points are a must on that ignition system.-----Have you tested the driver coil ?----The popping may indicate wires are crossed and timing is out by 180 degrees.
 
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StevenR, I have basically that same engine - 15R74G (the Johnson). During the first rebuild I reversed one of the stator wires, and I remember a clicking sound and intermittent spark when testing (testing with the plug in the boot and alligator clip wires running from the side electrode to ground). I re-traced everything to confirm I was 180 out of phase, switched the wires, and everything worked.

One other thought... you probably already knew this... but you're using copper core spark plug wire, correct?
 
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