Power Pack 225 Johnson Venom

[BoatingCop]

I'm trying to figure out a problem for a friend of mine. About a year ago, he took his bass boat, with a 1994 (I think that's the right year) 225 Johnson Venom, to the shop to get the lower unit fixed. He then recived a call from the shop, who told my friend that there were wire melted on the top of the engine, and told him that the engine did not run. The shop told him it was the power pack, and it would be $1000.00 more to fix that. The boat was running before he took it to the shop, the reason I know is because I was riding on it. That's besides the point though. My friend also noticed something that looked like molasses, that was dripping down the engine. He also noticed that there were many wires were burnt, but didn't know where the power pack was (he's no mechanic nor am I). I guess it could be melted wire.

Anyways, my main question is, how hard is it to replace the power pack on one of these engines? Pics of the power pack on the engine would be helpful, as I have never dealt with a problem like this. What are the steps to changing it? Thanks a lot!

Eric

 

[jonesg]

Re: Power Pack 225 Johnson Venom

First order the factory manual
www.kencook.com

inspect the stator, often melted plastic tar drips down from the stator under the flywheel.

powerpack is a very simple swap out but it sounds like theres some other issue ,maybe overheating or shorting.

 

[tashasdaddy]

Re: Power Pack 225 Johnson Venom

agree^^

 

[Dhadley]

Re: Power Pack 225 Johnson Venom

If the wires are burned the reg/rect probably caught on fire. If the tach was working the last time you ran the boat the fire happened after you shut it off. If the tach wasn't working, the wires were burning then. Many times the wires on the pp & stator get fried too. Look inside the hood.

 

[BoatingCop]

Re: Power Pack 225 Johnson Venom

The model number on the engine reads as follows: J225STLERK. The serial number reads as follows: G 03642551. What is the best service manual to get, because I see any of them, and a lot for a pretty penny. Any help is appreiciated as I have never tackled this sort of job before. I'm seeing two different boxes, one of which bolts to the top of the block and is made of plastic. The other is directly below the plastic box and almost looks as if it is integrated into the metal. The last item I described is the one that is burnt. Thanks in advance for the help.

Eric

 

[ezeke]

Re: Power Pack 225 Johnson Venom

That is a 1994 model number. The best manual would be a OMC factory service manual. You will probably fiind the best pricing on Ebay, new or used, but you can buy them direct from the distributer, Ken Cook.

This link will give you an idea of what to look for: http://cgi.ebay.com/ebaymotors/1994...10234927636QQptZMotorsQ5fManualsQ5fLiterature

or, http://cgi.ebay.com/ebaymotors/1994....c0.m245&_trkparms=72:727|65:12|39:1|240:1318

As Dhadley anticipated, what burned was your water cooled regulated rectifier.

 

[jonesg]

Re: Power Pack 225 Johnson Venom

It won't cost anywhere near $1000 if you spend $50 for the factory manual.

 

[Fl_Richard]

Re: Power Pack 225 Johnson Venom

To answer your question directly. A power pack will cost from $250-$350 depending on where you get it abd they are super simple to replace. The stator and rectifier may also have problems from your description.

IF the shop is replacing all of them it's probably not too far out of line.

 

[Dhadley]

Re: Power Pack 225 Johnson Venom

The regulator / rectifier is what you're seeing that's bolted into the block. It's water cooled so the underside has to be in the water jacket. That will have to be replaced most likely. If the fire wasn't too bad the pack wires might be able to be repaired. Just depends on what you find when you take it off.

You'll need to figure out what caused the fire or it'll happen again. The most commoncause is the block isn't filling with water (air trapped at the top) and the reg/rec can't cool properly in air. There are vent passages in the block, those need to be checked. You might think about installing another vent at the top of the block to give the air somewhere to escape.