2006 OptiMax 200 Keeps Destroying Coil Packs

[LukeFishWalker]

My brother has a Jet Boat with the 2006 Mercury OptiMax 200 / 2.5L in it.
He's had to replace over 20 packs in the last year.
And yes, each time he replaces all 6 plugs.
Is there a method of determining why they keep failing?
Is there a method to prevent them from failing?
Is there a recall on the packs?

This vessel is kept indoors in an air conditioned garage.
He's quite frustrated and the mechanic bills are preventing him from " Enjoying " his boat.
He started using a timing light to determine which pack is dead and has cut some of his costs down to repair.
I thought that there was at one time a possible recall on the packs?

Thank You For Your Time & Patience,
Lukus

 

[Faztbullet]

Is it the same pack or both???

 

[LukeFishWalker]

Fastbullet, from what he tells me (He Lives 200 Miles Away) he's changed both
more than 7 times and the port side has been change more often.

I would imagine this is NOT normal and I would imagine it's not the operation
of the vessel that's causing the failures. He's quite the safe operator and doesn't
" Dog " purposely abuse his toys and vehicle. The last time we went to visit
we were riding in this boat and when we'd cross other boats, he would throttle
down to avoid the hopping of the wake(s). He's never pulled any tubes, skiers,
other boats or any method of abusing the boat.

In regards to the propulsion method....Is the jet easier on the motor compared to a prop?

Thanks For Your Time And Patience,
Lukus

 

[Fun Times]

You might also want to try contacting Mercury outboard customer service with your engine serial number to see if they'd be willing to enlighten you of any possibilities of there might be some sort of known problems via possibly a service bulletin number regarding your coil situation. https://www.mercurymarine.com/en/us/...er-assistance/

Don't know if any of these would fall within either your engine serial number or possibly buying old stock coils with issues. While these don't say why the coils failed, it looks like they may know something isn't right somewhere along the line. Maybe provide them the parts number you're buying/installing too.

Service Bulletin - Marine Parts Express
Ignition Coil Problems & Advice in BassCat Boats Forum
Service Bulletin - Marine Parts Express

In order to make the broken links above work, you will have to search online ( 2006 OptiMax 200 Coil Pack service bulletins ) should this link not work for you, http://www.bing.com/search?q=2006%20...E1BB61D099A4C0

To make the next one work, just input online, ( 1.5 Liter OptiMax 0T801000 and above 2.5 Liter OptiMax 1B490866 and ... Service Tip Ignition coil harness service replacement connector P/N 854839T02 can be used ) then open it up.
http://www.bing.com/search?q=%0D%0A%...R&pc=EUPP_DCJB

 

[LukeFishWalker]

Fun Times,
I will forward these to my brother.
Thank You For Your Time And Patience,
Lukus

 

[Faztbullet]

I am leaning toward a grounding issue or bad coil as a inductive kickback will fry a switchbox. Pull the coils off and send to CDI/Rapair and have tested.They have a special unit to test these for this.

 

[sam am I]

First, have your brother put me on his Christmas list...........Second, I'd put my money on something common to both sides, a ground issue like FB says or a stator issue!!