T9.9 ELHR - cranks fine, won't start - electrical cut-offs?

[Rolf@YOP]

hi all

'93 Yamaha T9.9ELHR 4-stroke
running fine couple months ago, last time I started her
she's always started instantly

but now acting like lanyard cut-off is engaged: cranks fine, won't fire
- no spark I can see at plugs
- fuel is good
- tranny definitely in neutral

definitely seems like some electrical cut-off is engaged - only two I know about are *neutral* and *lanyard*

I found that lanyard switch *does* have a broken neck (thread section is separated from plastic body
didn't seem to affect function, but I removed the switch, and disassembled anyway

there are 2 contacts in there, bridged by a spring-loaded 'washer'
the contacts are *jumped* in the normal *no-start* position
inserting the lanyard key *disconnects* the 2 terminals
disconnecting them lets the engine fire
so removing the front section, leaving the 2 terminals bare, should let the engine fire
but it doesn't

just to check, I tried jumping the 2 terminals
of course, no fire

she's always started easy
I did remove the fuel pump to check diaphragms, all fine, reassembled, don't think I did anything wrong
definitely getting fuel before and after the pump, even just with prime bulb (I checked)

fuse is fine

is there any way to jump power to the distributor or plugs, safely, so I can verify engine runs?
then work my way backward to see what's shorted

again, she cranks strong, and normally fires right up
thanks for any thoughts

Rolf in MA

[rodbolt17]

at the CDI, disconnect the white wire.
now test for spark. if it sparks fix the kill circuit.
the Nuetral start circuit has NOTHING to do with engine spark.

if it still wont spark test the charge coil and pulser coil outputs.
if they test ok then test CDI output.

[Rolf@YOP]

OK:

good news = we have spark

bad news = fuel pump
need a new one
ordered, on its way

meanwhile: I am concerned about debris downstream
is there any kind of filter or screen between fuel pump and carburetor (please please please)?
or am I going to have to teardown carb to make sure?

I have several days before pump gets here, just want to make sure all fuel pathways are clear, so it's bolt-and-go

links to carb rebuild DIY? thanks!

[TownsendsFJR1300]

Are you missing pieces of the fuel pump?

The carb is fairly simple and most times can be pulled apart W/O a kit;

1993 T9.9ELHR Yamaha Outboard CARBURETOR Diagram and Parts

At the least, remove the float bowl drain bolt and prime fuel thru the carb. Try to catch what comes out looking for any debris.

If fuel doesn't come out easily, you could have some crap AHEAD of the float needle. Simply pulling the float/needle out will allow access to clean it..

[Rolf@YOP]

excellent, thanks so much, Scott
there was one small piece of the plastic body of the fuel pump that broke ff - was concerned about any little bits of plastic making their way forward to the carb
will follow your suggestions - thanks again

[TownsendsFJR1300]

Please post back what you find...

Oh, and flush again when assembled with the primer bulb and the drain screw out..
Good luck..