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2000 Johnson 200 Stator issues

Old 06-02-2016, 11:20 AM
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Default 2000 Johnson 200 Stator issues

Hello all, I have a 2000 Johnson 200 Ocean Pro that has been burning up the power coil side of the stators. I have been working with CDI who has been great about replacing parts, however this is driving me crazy. The power pack, regulator and stator are all new, I ran the boat yesterday for about an hour and you can already see the power coil turning brown. This is longer then the three before it, I would run the boat in the driveway on the hose for 15-20 mins and the power coil would be burning up to point of seeing smoke come from the flywheel after I shut it down. I have been through all of the battery connections and only run one flooded cell Interstate Marine battery. I have also checked the engine wiring to see if anything is grounding out, and it checks out.
Anyone have any ideas of what to look at next?
Thanks for the help
Old 06-02-2016, 12:37 PM
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Maybe a bad connection to the batteries or wiring that is shorting to ground somewhere. Could also be a bad battery with an internal short that's causing a huge current draw from the stator / rectifier / regulator.
Old 06-02-2016, 01:31 PM
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Thanks for the reply
The battery is brand new (not that a new one can't be bad), I have also checked the battery cables and the engine wiring harness to ground with the key both on and off.
Old 06-02-2016, 01:41 PM
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Monitor the power coil voltage with a DVA meter while the motor is running. You do mean the power coil and not the charge coils or the alternator windings, right?

Check your motor cover to make sure the sound deadening liner is not falling down on the flywheel and blocking the cooling air flow.

Are you using the standard CDI ignition components or the special digital ignition system by CDI?

What is your engine model number ?
Old 06-02-2016, 02:06 PM
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Yes, I am talking about the power coil that feeds the power pack with an orange and orange/black wires. The liner is good and in place, I am using standard CDI components.
Model number J200VXSSS

When all this started back in Jan. the motor was smoking like burning oil ( I run mixed fuel with a non VRO pump) and hard to start with the quick start not functioning. The power coil was putting out 8 volts DVA with an OHM reading of 30.
Old 06-02-2016, 03:49 PM
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Originally Posted by cthuman1 View Post

Yes, I am talking about the power coil that feeds the power pack with an orange and orange/black wires.

The power coil was putting out 8 volts DVA with an OHM reading of 30.




power coil should be 93-103 ohms and 11-22 Volts running according to CDI troubleshooting book for their products
Old 06-02-2016, 04:51 PM
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Yes I am aware of the CDI trouble shooting guide. I replaced that stator and have been through 3 others, I have sent power packs and stator back to CDI and they have sent new ones. CDI has said the power pack was fine however I burned up another stator send everything back and repeat. I have also been though 3 regulators all with different issues. First one no tach, second overcharging up 18 volts after 3000 rpm, third one did nothing no tach no charging. The forth seems to be working fine 13.5 volts at idle a needle over 14 at WOT tach works as well.
I am beginning to think the issue might be with their parts.
Old 06-05-2016, 07:47 AM
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Bump, anyone else have any ideas?
Thanks
Old 06-05-2016, 09:23 AM
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Originally Posted by cthuman1 View Post
Yes I am aware of the CDI trouble shooting guide. I replaced that stator and have been through 3 others, I have sent power packs and stator back to CDI and they have sent new ones. CDI has said the power pack was fine however I burned up another stator send everything back and repeat. I have also been though 3 regulators all with different issues. First one no tach, second overcharging up 18 volts after 3000 rpm, third one did nothing no tach no charging. The forth seems to be working fine 13.5 volts at idle a needle over 14 at WOT tach works as well.
I am beginning to think the issue might be with their parts.
Awhile back my dad ordered a power pack from CDI as we had one cylinder not firing. We did all the voltage and ohm testing and things tested fine according to the CDI troubleshooting guide but still had the one cylinder not firing. Sent it back and they tested it and said it was good. Still had the same issue. Called them and they sent another one which we had a certified mechanic install and we still had the same issue. The mechanic grabbed an OEM power pack and the cylinder fired immediately. We called CDI to see about a refund and they would not do it. Just our experience so thought I would share it.

Thanks,

Caleb
Old 06-05-2016, 09:32 AM
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I have heard they are outsourcing a lot of components , which I think has brought the quality down. Very frustrating!
Old 10-17-2016, 07:07 AM
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Any update I am having the same issue

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