I continue to have problems with the Stator on a 1995 Johnson 200HP, Got the boat about 4 years ago and previous owner stated that the Stator, Power Pack, and timing advance had been replaced because of unknown issue. Ran boat a few times and because of a loose fuel line all the oil was sucked out of the reservior, limped home but scorched a cylinder in the process. Tore engine down to have it rebuilt and noticed that the Stator had an issue as well. The winding that has the orange wires that connect to the power pack was burned and it was loose on the winding. So I replaced the stator while rebuilding the motor. Boat ran approx 10 times and was putting it up for the season and decided to change the plugs and just check the boat out. Noticed that the Stator was burned again in the same place. Contacted CDI who replaced the Stator under warranty, but they didn't have any suggestions of what may be the cause. Also looked at the flywheel magnets and found one magnet was a little loose and one had a crack so both magnets were replaced. Took out the boat about 2 weeks ago and had some problems with it not staying cranked at idle and hole shot was bad. Back in the shop she goes and once again the Stator has signs of problems on the winding with the orange wires. Order a new Stator, Power Pack and Regulator/Rectifier, install all those components and decided to rebuild the carbs while she was down. found some trash in one and a stuck float on another. Put it all back together and set the timing, and carb jets per the manual. Took it out for a test run and it runs better now than it ever has. After getting it back home I noticed that the tie wrap that is wrapped around the winding on the same orange wire has gotten so hot it melted off. Looked on CDI troubleshooting guide and realized that the OEM spark plugs are not right and have a set ordered along with new wires, but what could be overheating or causing the coil that feeds the power pack to fail. Any help or suggestions would be greatly appreciated...
