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98 Johnson Fast Strike j115glecm ignition devils

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Bjsmith919

Regular Contributor
So I thought I'd figured out why I wasn't getting spark to my port side cylinders but now I'm being told that what I found wouldn't cause that issue. Coil on stator with brown wires coming out is melted, black goo running out everywhere. I have done every ignition test the manual says do, replaced every ignition part except for the stator and rectifier down to the key switch, brand new battery kept on a tender but they all say no. Tell me it's a bad shift switch but was also told V4 don't have shift switches plus I read the shift switch interrupts starboard side not port side. One guy said that if the stator was bad it wouldn't just pick the 2 port cylinders, spark would be erratic on all 4. Another guy told me I screwed up the optical sensor because I installed it outside in the sunlight. Can anyone tell me what's right and what's wrong? I just don't want to throw another $500 at something that's not going to fix my problem. Screenshot_20220414-085541_Gallery.jpg
 
No shift switch on the V-4 models.----No the optical sensor is not destroyed by sunlight !!!----Replacing parts based on poor testing technique / bad advice will cost you a lot of money!------Have you taken ohm readings on the stator windings ?----Taken peak voltage readings while cranking ?----You installed a new powerpack ?
 
New power pack, ignition coils, wires, plugs, battery, key switch, cleaned every ground I could find. My dva adapter won't be in until Saturday so I did the cdi ohm test on the stator. Orange to Orange I get 55.4 ohms and brown to brown I get nothing. Can't remember the color lines on them but cdi says I should have a reading of 750-850 on brown to brown but I get nothing, get nothing when I test brown to coil on stator as well. I figured out the hard way throwing money at it isn't going to fix it unless I get lucky that's why I want to be 100% before I spend another $500 and still have the same problem
 
No reading on the brown wires is a concern.----Check for a break in the brown wire.----Or an issue with pins / plugin connecter.
 
racerone said:
No reading on the brown wires is a concern.----Check for a break in the brown wire.----Or an issue with pins / plugin connecter.
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No breaks in wire, plugs all look good. Hoping to have remedied the problem. Called up cdi and the tech had me do a few tests with just my multimeter since my dva still isn't here. Was nice enough to stay on the phone and walk me through the tests and unless he's just trying to oversell the problem we found was my rectifier blew a diode causing the stator to overheat by current backflowing into the stator which melted the power coil on the stator. There is alot of black goo on the bottom of the coil the brown wires come out of and directly underneath so to correct the problem it's gonna cost $800 instead of $500. He did tell me to wait if I could on ordering until my dva come in to get true voltage readings but said he would bet his life those two parts is where my problem is.
 
racerone said:
What is your total investment coming to on this ignition issue ??
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Before the stator I'm between 700-800. That's with ignition parts and specialty tools I've bought. Plus one throttle cable I got reamed for at the local marine repair shop I paid $120 for and could have got it online for $50
 
But my dva finally came in yesterday and the stator is 100% bad on the power side. Really probably both sides, the charge side came out just a little under spec with the dva but ohm test was dead on. Power side # was way low and ohm test showed 0
 
Kept everything. Now that I have a dva adapter I can do some real tests before I chunk anything. Now I'm like a kid waiting for Christmas waiting for my stator.
 
Back to square 1. Installed new stator and still no fire on 2 and 4. I'm at a loss, gonna go thru everything again, 3rd time. It acted worse after I put new stator on than it did with old stator. Took forever to crank, would crank on 1st bump of key with old stator and now cuts off as soon as I put it in gear. There is something I have to be missing.
 
I could go and take flywheels off some motors here.----But not going to.-----Take your flywheel off see if there are magnets.---If there are some then see if magnets are loose or cracked.
 
I have never seen magnet damage effect 2 cylinders...Most likely talking to Clark at CDI which lost that bet on what parts was bad. If a CDI pack, check connections as they are bad about not being fully inserted in connector and if CDI pack it may be 'new" but defective out of box.
 
racerone said:
I could go and take flywheels off some motors here.----But not going to.-----Take your flywheel off see if there are magnets.---If there are some then see if magnets are loose or cracked.
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All magnets are there and look fine. Flywheel looks brand new. No idea about strength, it takes a puller to raise and lower it into position with it wanting to pull to one side or the other. Will upload a pic after work. Did another dva test on it and power coil test read 37 volts, ohm test read 48 ohms, charge coil reads nothing while cranking but jumps to 290 then slowly comes down after trying to crank and reads zero between two brown wires on ohm test
 
faztbullet said:
I have never seen magnet damage effect 2 cylinders...Most likely talking to Clark at CDI which lost that bet on what parts was bad. If a CDI pack, check connections as they are bad about not being fully inserted in connector and if CDI pack it may be 'new" but defective out of box.
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Everything ignition wise is CDI except for plugs and key ignition
 
This is old stator and housing. I cleaned all the melted plastic out but would that varnish cause any problems? Didn't really clean it. Did clean the screws good before installing new oneScreenshot_20220421-084408_Gallery.jpg
 
Talked to Clark at CDI. After giving him the output numbers I have to send it back in for them to check it. Hopefully this won't take long.
 
faztbullet said:
I have never seen magnet damage effect 2 cylinders...Most likely talking to Clark at CDI which lost that bet on what parts was bad. If a CDI pack, check connections as they are bad about not being fully inserted in connector and if CDI pack it may be 'new" but defective out of box.
Click to expand...

Clark is who I spoke with earlier. Tried telling me it was impossible for it to be bad, wished I could believe him. After a little back and forth he finally give me a return authorization number to have their guys check it out, so hopefully will have time tomorrow to get it off and back to them
 
Thank you for the help racerone and faztbullet. Got it figured out and as I stated earlier it was sodimple I need my head checked for not thinking of it myself. A Facebook friend recommended I run a 1/4 20 tap thru the bolt holes that the stator mount to to clean them good. Did it and blew them out with air and put everything back together. BAM, fire on all 4 cylinders. Holes were not letting the stator get a good ground. Still have some work to do, thinking I need to reset my timing. Now that it's firing on all 4 it won't stay running unless I give it a small amount of throttle. Run smooth when only firing on starboard side so thinking I need to reset the timing with the johnnyrude easy timer or a carb adjustment. Once again thanks for the help on all the threads I've posted. Hopefully will be able to figure the rest out without hassling you guys, but I wouldn't bet on it
 
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