95 200 Mariner EFI stator ?

[JDS723]

My motor was running good sometimes, but sometimes it would only give me 3500 rpms so I bought a used stator from a guy on here. I put it on and connected all the wires, but my question is, does it matter which yellow wires connect to what? I noticed 2 of the wires are long and 2 are short so I connected the long wires off the stator to the short wires off the regulators and the short wires off the stator to the long wires off the regulators. I ran the boat and it would just bog down at 1500 rpms with the new stator.

[EuropeanAM]

Have you tested the stator to confirm it's GOOD via the testing guidelines in the OEM Service Manual?

The yellow leads (charging circuit leads) should be PAIRED... one set goes to one voltage regulator, the other set goes to the OTHER voltage regulator.

Leads coming off the regulators themselves are actually (or should be) the same length.

Also, inspect the REGULATORS, and their bullet connectors for signs of burnt spots, browned/blackened/burnt connectors (especially on the RED or YELLOW WIRES).

If any of the above are noted- replace BOTH regulators (NEW, OEM units ONLY)... and any damaged bullet connectors.

BTW.... a Spark Test would also be a good idea.

[JDS723]

Both regulators are brand new, both switchboxes are brand new, ECU was recently rebuilt, good compression, good spark, but the motor will run great sometimes and then just cut out and only give me 3200-3500 rpms sometimes. The only electrical part left is the stator. I havent tested either stator, but I will.

[basspastor]

When I had the EFI on mine (changed to carbs.) it would do same thing...adjusted the TPS and it would run fine ...... Just saying???????????????

[JDS723]

Ok Don, I know you always recommend only OEM parts, but I have read that the CDI Stator can run a little hotter than the OEM part, and that the stator getting hot could be why it is dropping a whole bank. Is there any truth to this?

[EuropeanAM]

I don't use that particular stator (brand)... so it wouldn't be fair to comment.

Regardless of brand, IF the stator is overheating, there should be some form of "visible evidence" (eventually). Darkened or leaking windings, burnt spots, etc.

BTW... I notice you haven't mentioned the TRIGGER. Don't overlook it... and when testing, keep in mind that the trigger MOVES (and it's harness flexes) as throttle is applied (resistance tests should be done while throttle is moved from idle to WOT and back).

[JDS723]

Yea I havent messed with the trigger at all. I will test it to see if anything is going on there. Thanks for the heads up.

The bullet connectors from the stator to the regulators arent burnt through the plastic or anything, but it does look as if they have burnt a little. I recently replaced both regulators and switchboxes, so once I get this stator on and check the trigger Im bound to figure out this ghost!

[JDS723]

Ok, I put on the new stator and it ran great first time out. Ran good again yesterday for awhile, but then the problem came back! It bogs at 3000 rpms and shakes really bad when WOT, if I back off to 2500 rpms the shaking stops. That makes a new stator, regulators, switchboxes, wiring harness, diaphram pump, and rebuilt ECU and problme still exists. It seems as if when I put on a new part it fixes it for a trip or two then it comes right back. Also, yesterday the alarm went off, which has to be overheat because I premix. I looked and notice the exhaust hose wasnt lined up with the hole in the back of the motor so I pulled the hose through. Maybe the exhaust was spitting back into the motor causing it to overheat? The water pump in fairly new and it is peeing just fine. I will get the trigger tested. Any other suggestions?

[EuropeanAM]

On the hose situation.... would have to see a picture.

Stator.... still recommend testing. It's the only component you've NOT replaced.

Water pump being fairly new does not mean that it's "fairly good". Anytime cooling system problems develop- ALWAYS, ALWAYS start at the SOURCE: The Water Pump.

Keep in mind- you may need to go back and TEST components you've already replaced. Don't fall into the "I've already replaced that" trap.... "New does NOT NECESSARILY = Good".

[JDS723]

I have replaced the stator and the problem still exists. Everything tests good. I do need to put in a new water pump kit, but other than that every electrical part on the motor test as good. Could my temp sensor be the culprit?

[EuropeanAM]

Temp sensor unlikely. It could cause running condition problems- but unlikely to result in what you're experiencing.

We talked about the TRIGGER earlier. Precisely what have you done in regards to TESTING the trigger?