Ok so here’s what I found on this Evinrude as I try to diagnose the lower cylinder issue:
when I went to test the coils and plugs wires and rebuild the mag, there was quite a bit of oil on the plate.
I removed it and the mounting ring below to discover that parts 91 and 92 in the attached diagram were missing. I did have the carbon seal which i promptly chipped and the other items in the upper seal.
I replaced the carbon seal and a new quad-ring and installed the missing parts (dang it – I was saving those and that carbon seal for my Johnson rebuild I’m starting this winter).
I then swapped the coils and installed a new Atom module for the lower cylinder and soldered all wiring connections. Then tested with multi-meter.
I also installed new copper core plug wires just to have all new stuff.
could the oil from the upper seal have caused the Atom unit to malfunction and provide week spark?
I wonder where the missing pieces went…I’ve never gone past the magneto plate on this motor.
as part of my diagnosis I also inspected the crankcase drain and found nothing. chased a thin wire through the drain opening and blew it out with compressed air after removing the little copper reeds.
Next thing to do is install new plugs and check for spark.
one other thing I noted: there was a lot of oily residue inside the hose leading to the cut-out switch. More than I’ve noticed previously. The hose was original and showing signs of cracking so I replaced that too. When I test this motor I will disconnect the cut-out switch completely so i can test the rest of the components on their own.
could this be one of my problems since the cut-out switch affects the lower cylinder only??
