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What you are describing is that of a failing coil or a bad powerpack. Do you have a timing light so that you can check for spark on each cylinder? Also, what is the model number on the engine?
Hi Tom. This is pretty simple to do. What you want to do is hook up the light and see which cylinders show spark and which do not. If the light flashes there is spark present, no flash means no spark. After that, take the ignition coil that is sparking and swap it for the one that isn't. If the lack of spark follows the coil, it is a bad coil. If the lack of spark stays on the same cylinder, it is a bad powerpack. Does that make sense?
I don't understand, are you asking how to use a timing light? Did you see my last reply?
Unless yours is self powered you would hook up the timing light to the battery first to power up the light. After that it is as simple as hooking up the sensor lead to each plug wire one at a time, hitting the button, and seeing if the light flashes or not. DOes that make sense?
Are you still with me?
Have a helper turn the key just to crank the engine over. If there is spark it would spark regardless if the engine was running, or cranking.
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It was more than likely just a fluke with the new optical sensor. When electrical parts go bad they will work when cold, fail when hot, and work when cold again. But there is no time frame in between cold and hot.
As far as the testing goes. It all takes special equipment that you won't have, so thats whey when we do this we try to do it by symptoms. To test the optical sensor takes an oscilliscope. To test the power pack takes a high quality meter such as as a Fluke, as well as a special adapter for that meter called a "Direct Voltage Adaptor", or DVA for short.
The tool is called a tamper proof torx bit/screwdriver.
The symptoms still point to the powerpack. Perform the aforementioned testing and that will tell you if it is a bad coil, or in fact the powerpack.
Did you replace it with a brand new powerpack, and if yes, was the powerpack the correct part number for that engine? Some have quickstart and others do not.
Did you ever check spark with the timing light to see if any of the cylinders were actually dropping spark?
If all cylinders were firing then it is not an ignition issue. Have the carbs ever been professionaly gone through on this engine?