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I have a 1995 150 Ocean Runner with OIS ignition system. The…

I have a 1995 150...

I have a 1995 150 Ocean Runner with OIS ignition system. The engine quit last month with no spark at any cylinders. I checked the obvious including the lanyard, and the ignition switch. Both checked out okay using the testing methods in the repair manual. What I did notice was on the day the engine quit, the tach quit working and the battery gauge showed low charging; around 12 volts on the gauge. Further troubleshooting pointed to the power pack as the reason for no spark. So today I replaced it and all the coils. At first I did not change the regulator. I charged the batteries. I turned the key and the engine started right up and ran for about 5 minutes. Then it seems as the engine transitions from "COLD" to WARM" the engine misses and shakes badly. Thinking the bad rectifier is contributing to the problem, I replaced it also. The engine runs the same. Did I damage the power pack by running the engine with a bad regulator/rectifier?
What could the problem be?

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Answered in 22 minutes by:

12/28/2013

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

Tan, MerCruiser Certified Technician

Category: Boat

Satisfied Customers: 11,507

Experience: 40 yrs. experience with complete engine repairs both inboard/outboard and MerCruiser Certified Technician.

Verified

Hello. My name is XXXXX XXXXX I will be assisting you today.

No you haven't damaged the power pack. Now what you most likely have is a stator breaking down from heat. The stator makes electricity for the ignition and charging system. So when it got hot you lost spark and charge capability. The clue was the tach quiting.

Now the powerr pack and the rec/reg could have caused loss of spark and charge capability. But since you have replaced both of them that leaves the stator as the problem.

Now there is a way to test the ignition system you need a peak reading volt meter or a DVA adapter for your digital volt meter. But since you have already eliminated everything else the stator is the culprit.

We always test these systems with a peak reading volt meter before we replace any components as it can get expensive.

Does this all make sense to you?

Post back with questions.

Customer reply replied 9 years ago

Thanks for the reply. I have a new stator ready to go in. The electrical components were a Christmas from my wife including the stator 'cause I had a feeling it could be an issue. I have the proper DVM that I will use to check things out further. Can you list the tools I will need to pull the flywheel safely to change out the stator...I know that the magnets attraction between the stator and flywheel can be an issue. It seems I need a special flywheel puller, etc...to do the job. I really enjoy working on the engine myself. Your answer seems to be acceptable. If I can I will let you know how it turns out.

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

The volt meter needs to have a peak reading voltage capability. Most meters don't have this feature.

You can use a standard puller to remove the flywheel. On the OIS ignition system you have a series of 5 bolts # XXXXX holding the flywheel on. Remove covers #66 then 60, 59 & 83 then the flywheel bolts# XXXXX The magnets are not an issue on this flywheel. Diagram of 1995 J150GLEOM Evinrude / Johnson Johnson Outboard IGNITION SYSTEM Diagram and Parts

Do you need the torques specs for the flywheel?

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

The puller goes in to holes # XXXXX and 4 using 2 3/8 x 24 bolts. Here a diagram

http://peapull.com/o.php?n=1388275053.jpg The torque specs of the bolts in the flywheel in the pattern in the diagram are 23-25 ft. lbs.

Tan, MerCruiser Certified Technician

Category: Boat

Satisfied Customers: 11,507

Experience: 40 yrs. experience with complete engine repairs both inboard/outboard and MerCruiser Certified Technician.

Verified

Tan and 87 other Boat Specialists are ready to help you

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Customer reply replied 9 years ago

Hi Tan,

Well, we replaced the stator yesterday. It was in bad shape with quite a bit of the resin having dripped down below it onto the top of the block.The engine started and ran great for about 6-10 minutes. Idled good, throttle response was good. Then all of a sudden the severe miss started again.

The engine will buck and shake violently with a severe miss. The RPM's will increase to about 2500-3000 rpm. There isn't any indication of engine overheating. The cylinder temperature is about 150-160 degrees when I measured it with a digital laser thermometer.

So far we have replaced:

1) Power Pack

2) Stator

3) Voltage rectifier/regulator

4) All three coils.

4) plugs(QL78YC)

Plug wires are the grey suppression type. I will try to upload some videos of the engine running today.

Jim

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

Hi Jim try to determine which cylinders are misfiring. On the port side cylinder head is a sensor with a white/black wire disconnect and ground the wire going to the power pack does the engine run better? Disconnect the shift interrupt switch. Does the engine run better? Check for a misfire at the coils.

Customer reply replied 9 years ago

Hi Tan

We checked and replaced the port side sensor to eliminate the engine possibly not coming out of QuickStart. The shake and shutter continued. We also verified the diode as well. I am out of ideas except for the timing wheel and sensor.

Any thoughts?

Jim

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

Did you happen to inspect the timing wheel? The timing wheel can crack and cause intermittent timing. If you disconnect the rec/reg power supply start the engine does the misfire go away?

Customer reply replied 9 years ago

Hi Tan,

We did pull and check the timing wheel and I did not see any cracks or areas that would suggest it is bad. We also did check the shift interrupter circuit and it operated as designed. Since the engine was missing it almost died when I tested it.

I did also check the sensor and of course visually it checked out.

Jim

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

Replace the sensor. I always replaced the sensor whe ever I replaced the power pack. The sensor isn't that expensive $62.75 at the site. click here. Have you checked the spark with a timing light to verify it is a ignition misfire?

Customer reply replied 9 years ago

Hi Tan,

The weird thing is that the engine runs normally for the first 6-8 minutes then starts this awful misfire.

Jim

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

Something is getting hot and breaking down or you have a fuel starvatiuon issue. That is the purpose of the spark check with a tioming light. We need to determine it is either a fuel related issue or ignition. Fuel starvation can cause the engine to run rough also. Try choking the engine when it acts up and squeezing the primer bulb this will eliminate a fuel issue.

Customer reply replied 9 years ago

Hi Tan,

I will check it. Do you have an email address other than this so I can send you some videos of the engine running without the miss and running with the miss.

Jim

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

O we aren't allowed to communicate anyother way except through this link. Here is a link to upload a video then send me the link. click here

Customer reply replied 9 years ago

http://www.youtube.com/watch?v=R_esLorCczI&feature=youtu.be

Good running session

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

That sounds good.

Customer reply replied 9 years ago

Yes I agree...the next video is what I am talking about.

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

Customer reply replied 9 years ago

Hi Tan.

I couldn't remember if I sent this to you...this is the mis-fire, stumble, I am referring.

Jim

http://www.youtube.com/watch?v=zz3ztgfvzc4

Marine Mechanic: Tan, MerCruiser Certified Technician replied 9 years ago

in the water? These engines when they first start up they are in quick start mode with the timing advanced. Then when the engine reaches engine temp quick start shuts off and the engine timing is retarded. This would explain the initial start being smooth. These engines don't idle vey well out of the water as there is no back pressure in the exhaust housing which causes a lean fuel condition. So what I thing you are experiencing is lean idle pop. The test with the timing light will verify that there is no misfire. Leaving this a fuel related issue. I would put the boat in the water and test for the issue. You can just back the boat down into the water leaving it on the trailer for this test. I think you will find the engine runs better and there isn't an issue.

Does this make sense?

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