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'96 Evinrude 48SPL - Melty Charge Coil and Sensor Assemblies

T

TimNLB

New member
Hello! I have a '96 48SPL that lost spark last year. I ended up replacing the rectifier, Power Pack, and spark plug coil assembly (I needed it for vacation and just wanted it to work). It ended up being the key switch :mad:

It ran fine for the rest of the season (maybe 15 hours). Went to get it going this year for the first time. It backfired once, and then...no spark. I popped off the flywheel and saw that Sensor and Coil Assemblies had black melty ooze that had run down. Also, there was a strange almost gold looking dust on many of the parts. I'm going to replace the Sensor and Coil Assemblies, and probably the stator while I'm under there. Has anybody else had weird dust under the flywheel? There's a bit of lateral play on the plate, is the bearing underneath a wear item? I couldn't find any info on replacing it in the factory manual. I just don't want to smoke newly replaced parts. Thanks for your time!

I'll try to post pictures.

https://drive.google.com/open?id=0B-DRPSbcyD1tcWxscllGZU1xQkk

https://drive.google.com/open?id=0B-DRPSbcyD1taW9ld0ZwZEtSR1E

https://drive.google.com/open?id=0B-DRPSbcyD1tRTVvbjB2MTZuREU

https://drive.google.com/open?id=0B-DRPSbcyD1tb0hvd0I2Qm5YZk0

https://drive.google.com/open?id=0B-DRPSbcyD1tc29uQm9GWEl5Z1k
 
Update! I replaced both the Charge Coil and Sensor Coil Assemblies (both had signs of melted casing. Some of which had made some contact with the flywheel magnets). Before putting it all back together, I'd noticed some lateral play on the ignition plate. Ordered up a new "bearing" (it's plastic) for it to ride on, and that seemed to tighten it up. Boom! Spark. Back in the game!
 
Will do! I changed the impeller about 4 years ago. It doesn't get a ton of use. The stream is still pretty strong, and i usually temp check with my fingers on the thermostat...good to the touch for about 5 seconds and then it's a bit much. Sometimes I'll run it in very shallow streams at a high trim (tilt?), so I'll keep an eye on that. I was lucky enough to grab a new, open box, charge coil (oem discontinued!) on eBay for $15. Did the trick! I love this engine, but I've dumped so much into parts on it, it's getting a bit ridiculous.

Thanks for your input!
 
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