How do I use a spark tester to diagnose an Evinrude 60 E-TEC?

Connect an adjustable air-gap spark tester between each spark-plug lead and a clean engine earth, then crank the engine and compare the cylinders at the test gap specified for your model year. Keep every disconnected plug lead connected to an earthed tester; a successful test confirms ignition output but does not prove that the spark plugs work under compression.

Check the tester and battery

Identify your tester before starting. An adjustable tester has two exposed electrodes and a screw or sliding adjustment; an inline indicator usually has a small enclosed lamp and fits between the lead and plug. Use the adjustable type to check whether the ignition can jump a specified gap. A flashing inline indicator alone cannot establish adequate ignition output.

Read the engine model number from its identification plate before selecting the gap. The usual Evinrude 60 E-TEC is a two-cylinder engine, but follow the workshop procedure for the actual model and year.

• Check that the battery is charged, its terminals are tight and the starter turns the engine briskly. Around 12.6 to 12.8 V at rest is typical for a fully charged conventional lead-acid battery, but resting voltage alone does not prove starting performance.
• Put the control in neutral and fit the emergency-stop lanyard in its normal running position. Removing it prevents the ignition test from working.
• Inspect the plug leads, boots and coil connections for corrosion, cracks, loose terminals and signs of electrical tracking.

Work in a well-ventilated area clear of petrol vapour. Keep hands away from the tester and flywheel while cranking, and switch the ignition off before moving connections.

Connect the spark tester

A two-channel adjustable tester lets you check both cylinders together. With a single-channel tool, you also need a suitable earthed termination for the other disconnected lead. Never leave it hanging loose during cranking.

1. Turn the ignition off and remove the cowling.
2. Leave the spark plugs fitted. Pull off their boots by gripping the boots themselves, not the cables.
3. Connect each plug lead securely to its tester terminal. Some boots need the tester's proper threaded-terminal adaptor for reliable contact.
4. Attach the tester earth lead to clean, unpainted engine metal, preferably a sound engine earth point. Painted brackets and rubber-mounted components can give misleading results.
5. Secure the tester where you can see it without reaching across moving parts.
6. Set the electrode gap to the ignition-test specification in the matching workshop manual.