What makes a power pack go bad?

[Raymorgan]

I have a 2001 johnson ocean pro 115 that I had to replace the power pack for the third time. Is this normal? It took my mechanic only 3 months to figure it out.

 

[HighTrim]

Re: What makes a power pack go bad?

Not normal at all no.

Ill assume he checked the black/yellow kill wire at the pack, to ensure that there is no voltage being applied to it? That is a usual cause of their failure.

 

[HighTrim]

Re: What makes a power pack go bad?

...either that or the PP was not faulty at all, and the mechanic was simply throwing a part at it.

What exactly was the issue?

 

[Raymorgan]

Re: What makes a power pack go bad?

The first two were replaced in the first couple years i had the motor, so the last one was working for 5 years or so. When i brought it to the shop earlier this year, it was losing fuel prime, not using much oil, and the oil alarm was sounding when running at idle for a couple of minutes. Also, on the test run before i brought it in, it ran fine (besides the previously mentioned problems) until i ran at about 5000 rpms, then it started to bust up. It was almost like it was going into slow mode. It would idle fine, but when trying to get up on plane it would sputter real bad.

The mechanic removed the oil injection, put on a new fuel pump, cleaned the carbs, etc. Compression was good and equal all around. That fixed the fuel prime and alarm issues, but it would still would sputter once i started running faster.

Then he replaced vapor separator, and it was still acting up, even before i went full throttle. Finally he replaced the pack and optical sensor and it ran great for 2 hours yesterday.

The symptoms were similar to when i repaced the pack before except that this time it wouldnt always act up.

 

[clanton]

Re: What makes a power pack go bad?

2000/???? had a lot of pack and sensor problems. It seems that a lot of techs donot own a meter, and never check the packs or coils. The coils arc thru the insultation to the metal plate between the pack and coils. You can see the burnt spot on the coil and plate. Stator output should be check for proper output, voltage could be too low or high. Dealer special tool for checking the sensor cannot always id a bad sensor.

 

[Raymorgan]

Re: What makes a power pack go bad?

He says that he replaced the stator as well (before replacing the pack). This last pack lasted 5 years or so , so hopefully its not getting extra voltage