Re: Onto a new learning curve…CD ignition

[Don]

Unfortunately, ANYTHING is possible. Generally speaking, the sensor and charge coil are simple/reliable parts that rarely fail. Their failure mode is usually caused by be being hit by the flywheel magnets due to a sloppy mag plate or loose hardware flopping around under the flywheel. Flywheel magnets are rarely a problem, except on larger engines with glued in magnets.
CD ignition spark should be able to jump a 1/2" gap, 3/4-1" might be stretching it a bit.
Again, my best advice is to start with the simple stuff. Don’t do the "it looks it" check on grounds, use a good analog ohm meter that shows low resistance readings clearly. Just because a ground "looks bad", doesn’t mean it is, the same goes for a ground connection that "looks good". It is always nice to find an actual problem/cause by checking the grounds before ripping them apart to clean them. Those pesky amphenol connections can cause problems as well. Bent pins, pins/sockets partially pushed out, corrosion all can create nightmares. Be sure to eliminate that stop circuit completely as well. Those push on primary leads can cause problems in salt water as well. Be sure to pull the connections, clean the terminals, crimp them down stlightly for a good tight fit, and apply a little grease to the primary terminal on the coils. Chafed/melted leads, along with sloppy repairs are another big problem.
Once you have exhausted the simple stuff, you will need the proper test equipment.
You will have to spend the bucks on the amphenol tools, now way around that. Stevens makes some nice terminal extenders for the coils and amphenol terminals to make resistance and voltage tests easier.
You will need one of the peak reading voltmeters as well, your coil tester will need an "amplifier" from stevens to check the CD coils. There is a little adapter, called the PL-88 that is needed to check pack output on newer engines also.
Finally, polarity and voltages have changed over the years, so improper meter set up prior to testing can lead to confusion and headaches. Use the proper OMC manual to avoid confusion. And, it is best to check every component during repairs to avoid repeat pack failures due to marginal parts/grounds/faulty stop circuits.