C115TLRR No spark

[shawnglogan]

While trying to fish several months ago, early morning, it would turn over fast (good charged battery), but no spark at any plug. This happened two mornings back to back. Around 11 o'clock both days, the spark some how returned. I checked the kill switch with a Fluke meter. Although it is good, I disconnected the two wires at the key switch, and the white wire on the CDI. Nothing.
I brought the boat home, and pulled the ignition, wiring, removed and cleaned all ground wires, removed and cleaned all screws and terminals on the CDI, etc., and tried to start it, but no spark. I took it to a shop, and plugged in a new complete ignition switch harness. Nothing.
Last night, I started checking continuity, ohms, etc. and after everything checked okay, I removed the blue wire (rev limiter), and bingo! It started. But here's where I'm confused.
According to all these tests, if it runs normally after removing the blue wire, it's the CDI. I was not excited about having to buy a CDI, but relieved that I found the problem.
So, I reconnected the blue wire, and it runs normally. I reconnected the all the kill switch wires, and it runs.
This morning I turned the key, and it runs fine.
I do not trust it. I can see going somewhere miles away with it running, and relive the no spark thing all over again. Can a powerpack work at random?
Help, please.

[boscoe99]

More likely than an intermittent CDI is an intermittent electrical connection. You unplugging and reconnecting the electrical connectors might have fixed your problem without your even knowing it.

Tell us some more about this blue wire that is for the rev limiter. Where does it connect to other than at the CDI?

[shawnglogan]

The blue wire comes from inside CDI unit, and connects to the bottom left terminal. However, I was able to finally diagnose the issue.

With the Blue wire connected, it ran fine for quite some time. I had downloaded a technical pdf from CDI Electronics, and began checking voltages. When I touched one of stator wires with the DVM, the engine died. I restarted it, and tried the test, and it again died. But, when I tried to restart the engine, it would not. I removed the blue wire, and it started. It now will not run with the blue wire connected.

I talked to a mechanic from a marine shop, and he told me that I'd be surprised at how many boats that are running around with the blue wire disconnected, because people didn't want to pay the price for a new CDI.
The problem with running the motor without the blue wire connected is that you cannot kill it with the key. He told me I could mount a toggle switch, and run it off, and flip the switch on when I want to shut the motor off.

I have a new CDI unit coming, and I'm keeping the bad unit in a vacuum sealed bag on the boat for an emergency. Don't think I'll chance it.

[ausnoelm]

I'm more surprised that the "mechanic" knows of any others running with the blue wire disconnected other than yours.....

[boscoe99]

What electrical component does the blue wire connect to? Beyond the terminal that you mention, that is.