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Help with electrical issue (almost fire) 1998 225

MetrwoWestMA

New member
Hi Everyone,

2nd year boater here, but definitely good at car, motorcycle and engine (and electrical) repair... Boat is 1998 21.5 AcquaSport Ecplorer 225.

We had the boat out and all was running fine, but I noticed the gas gauge was acting weird / intermittent, and RPM gauge was not operating.

About 2 hours into our adventure and luckily on a calm day, the engine gradually looses power and dies.

Then I notice continuing smoke, and electrical smell coming out of the vent at the back of the motor...so I kill the battery switch and eventually the smoke dies down (before I told the family to abandon ship :))

The starter is already on my replacement list.

The pictures tell the rest of the story, so it looks like I will need a Power Pack (found this): https://bpi.ebasicpower.com/shop/in...th=1264_1383_1402_1385_1417&products_id=19433

And probably have to replace or fix a bunch of wires / connectors...

Here are my questions:
1) Is there some other issue I should know about that would cause all this. I will resistance check everything and have the service manual.
2) For the starter should I get lightly used OEM or $79. eBay chepo?
3) Are their replacement wiring kits in case I have to replace a lot or should I just manually replace as a go (I would use solder, new connectors, and waterproof shrink wrap?

Any other thoughts for a marine newbie?

Many Thanks in Advance,

MW

P.S. Located in Falmouth, MA, and boat is on a trailer, mostly used in ocean.

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OP Here with more pictures -- it looks like the entire base thing that the power pack is connected to and much of the wiring needs to be replaced, so this is getting uglier...

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Your rect/regulator failed and caused this. Also pretty common issue with these engines when equipped with loose battery connections, or battery switched while running. Battery switch must be a make before break type.
 
I see now that all the parts are available here on MarineEngine.com, and the guides re terrific!

The OEM and CDI Electronics parts are similar in price, which are generally preferred?
 
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