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Spark or No Spark?

Woodybelle

Contributing Member
I have a 1996 Evinrude 150 hp 60 degree (Looper) engine. Simple question: OMC manual states that output test Ignition spark should arc 7/16”.on spark tester. If spark will only jump 3/8” on spark tester on port bank cylinders and no spark on starboard bank cylinders, in accordance with the manual’s “troubleshooting sequence chart” should that be considered “No Spark on Any Cylinder” or “No Spark on Three Cylinders?”
And yes, I have performed the "shift switch test" and achieved the following result: Full 7/16” arc on port bank cylinders and weak 3/8” spark on starboard bank cylinders. Stator voltage output test indicated bad ground or stator, yet resistance tests are within limits. Stator is new. Removed stator and saw no issues or potential grounding issues.
 
Unplug connector on pack with blk/yellow wires and retest
Quick follow-up. Disconnecting connector (with b/y wire) at pack proved unproductive. Disconnected b/y wire at helm key switch and regained full (7/16") spark on all cylinders. Bullet connector at switch seemed loose. Repaired connection. Prior to re-testing for spark, I also discovered what I believed to be poor grounding of rectifier/regulator. Rectifier machine screws had some corrosion and seemed suspect. So, can’t be certain which problem was most contributory to spark issues, although I suspect the poor connection at key switch was the major culprit. Could be both issues were problems, since ignition symptoms were in inconsistent. Regardless, engine starts and runs, although idle speed varies a bit. After getting the engine running, I noticed some fuel bubbling from gasket between the vapor separator and fuel bracket. Since carbs were rebuilt, timing reset, and subsequent to vapor separator inspection (warpage) / gasket replacement, tuning / tweaking to follow. Thanks for your help.
 
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