Smoke from engine- maybe stator- need help please...

[GreggBrightwell]

So I bought a 1986 Stratos, with an Evinrude xp150, a few months ago. I bought it for a song, knowing the motor wasn't right. I've replaced lots of parts- thermostats, rebuilt fuel pump side of VRO, six new check valves for the manifold, one new power pack, set timing via Reeves, new plugs and wires, rebuilt all three carbs. After several iterations of taking it to the lake, and not being able to get it over 1800 rpm in gear, I found I was losing spark on a cylinder. Replaced that side power pack, and finally got it going great yesterday. Water pressure seemed real good at idle, and at power. I took off down the water, making big circles near the ramp just in case. This boat flies! I saw 55+ on the gps, and wasn't even WOT. I was trying to ease into WOT, and find the sweet spot on the trim, when it started cutting back on the rpm a bit. I looked back, and something sounded wrong so I pulled it back to idle, and shut it down. Noticed some smoke coming from under cowling, so i took the top off. Definitely smelled electrical, and was smoking pretty good. Would not restart. (would barely turn over, actually) I have a rocket of a trolling motor, so that got me back to the trailer. After a little while, the engine cranked fine/normal but wouldn't fire a lick. It seems to me, that I might have cooked my stator. I don't think I overheated the motor itself, as I am pretty well certain that the water circ was still good at speed, ( it was hard to hang on with the rough water) I have new thermostats in it, and i do have the SLOW feature. The lower unit seems fine, good rotation, good shifting, properly serviced, etc. I'm still right side up enough on this boat to buy a stator if I have to, but I don't want to spend a fortune on a 30 year old motor. What do you guys think? Sorry for the long post, but wanted to give all the details I could to help with the troubleshooting.

 

[GreggBrightwell]

Just as an addition, I just went out the boat, put it on the hose, and it started right up. I think I am still on the right track with the stator. Seems its "breaking down" under load/heat?

Any other possibilities? It WAS positively charging the battery yesterday. I put my digital Fluke on the batter before and after start. I did notice close to 15 volts trying to charge the battery at 2500 rpm or so, which seems too high or a regulated voltage. Wish stators weren't so dang expensive.

Thanks for your advice,

Gregg

 

[emdsapmgr]

You did not hear an overheat hot horn? When a powerhead gets really overheated (smoke is an indicator) the pistons can swell inside the powerhead. If they get hot enough, they will expand so much they lock up in the cylinders. When that happens, the starter won't crank the engine. Once it cools off a little, the starter may be able to crank the engine. This is a rather catastrophic occurrence, if it is an overheat. One of two more times like this and the piston/rings may need to be replaced.
You may want to pull the heads and look at the position of the rubber water deflectors (one for each piston) in the water jackets. Your model does have a regulator. Should charge up to 13.5 normally. It can get higher if you have a loose connection at the stator or at the battery.

 

[GreggBrightwell]

No horn, unfortunately. Guess I should pull the heads and check cylinders/piston/rings? I have a ring compressor, and I imagine head gaskets aren't that high. I'd like to see the inside of the cylinders anyway. But, I still believe this is electrical, and a stator. Thanks though, i sure hope it is NOT an overheat.

GB

 

[emdsapmgr]

Just one thing about your stator. It's the huge 35 amp, air cooled stator. Puts out huge current. If some of the electrical connections are not tight or are corroded, the stator has trouble dissipating it's current. That can overheat the stator, causing the smoke, and can even cause a fire. Pays to be extra-cautious with this electrical system.