I have a 2001 Johnson 90hp and I just got the optical ignition system replaced (along with the eye and the stator) due to the engine just randomly completely dying at times as if I just turned the key off. I also just got the water pump replaced along with a new tachometer. I ran the boat yesterday, and it did not randomly die at all....BUT, it did still do something that it was doing prior to getting it worked on. While running the boat on plane (around 3500-4000 rpm or even higher) at random times a cylinder will cut out with no associated overheat horn or overheat light (Is this called SAFE mode??). So my question: What causes my engine to go into this "SAFE" mode...even though I do not have a "hot" light or an associated horn??
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one cylinder cuts out underway
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If it is going into a safe mode, with no codes, then possibly a bad shift switch/neutral switch kicking in and out?
If it isn't a ”safe” mode, then I might think a plug (cheapest first/ even if new) might be missing/ shorting, similar to a spark leak from a coil wire, or something along that area. Can you tell which cylinder is dropping out? Is it the same cylinder?
Does this happen at all speeds (idle too)? Does it happen on muffs?
If happens at lower RPMs (like when flushing on muffs), can remove Cowling/cover and run at night on muffs, to see if there is a spark leak around plugs, or wires, or coils?
Good luck, post back if you find anything?
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