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1978 25hp power pack keeps shorting out

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  • 1978 25hp power pack keeps shorting out

    Hello this is my first post so please bare with me, and I will try to give as Much information as possible. But I have a 1978 25hp outbourd Johnson that I bough used a year ago. It ran fine for me all the way up until this summer. Then one day it mysteriously lost spark in both plugs. So I traced all my wires and made sure the connections were good on my harness and decided that it was probably my coil packs were bad, because they were original and looked awful. So I got new coils and that did not fix the problem. I learned how to test the omns on the stator, trigger, and coil packs. Everything tested to be exactly in spec. So I spent $100 on a new power pack and I got spark! So now I'm on the river and I ran it for maybe 20 minutes with a couple stops in between for fishing and then all of a sudden I lost spark again when I attempted to start it. After getting towed back I brought it home and tested everything again and decided I got a bad power pack. So I got a replacement power pack under Warranty and I had spark again. It fired up in the yard and I turned right off and I brought a bucket of water to let it idle in. After bringing a bucket over I tried to start it again with no good results. I took the plugs out and looked and now I'm not getting spark again... I tested the omns on everything else and it was all still in spec. so now I am assuming that something is shorting out my power pack. But all of my wires are in good shape and I disconnected the shut off switch. I even looked under the flywheel and everything looks fine. So what could be shorting out my power pack? Its a tiller handle with an electric start button. Please any advice would be greatly appreciated

  • #2
    Disconnect the electrical plug between the wiring harness and the powerpack..... the one that contains the Black/Yellow wire (kill circuit).

    Have a volt meter set so that it would register even a very small amount of DC voltage and connect the meter wires between the Black/Yellow wire on the wiring harness side and a powerhead ground (anywhere).

    There should be NO voltage reading there, even with the electric starter engaged.

    If, for some reason, you do have voltage being applied to that Black/Yellow wire, that would be the reason for the powerpack to fail.

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