Dead Stator?

[curtiscapk]

I put this in my rebuild thread too, but the end of last summer the toon would just die no sputter nothing just pffft. AFter 5 minutes or so start back up...It would do it one day and not the next. On Labor day weekend it did it twice at the end of the day. Didn't go out again and when I winterized it, she started for about 30 seconds and died. Now it doesn't start at all, no spark in any cylinder. I found all four of my wires coming from the stator look burnt.

I am assuming it is the stator... I just ordered on of ebay for 125 so it could get here by Thursday

what do you guys think? and how the hell do you get the crank nut off!?

[BobG]

I put this in my rebuild thread too, but the end of last summer the toon would just die no sputter nothing just pffft. AFter 5 minutes or so start back up...It would do it one day and not the next. On Labor day weekend it did it twice at the end of the day. Didn't go out again and when I winterized it, she started for about 30 seconds and died. Now it doesn't start at all, no spark in any cylinder. I found all four of my wires coming from the stator look burnt.

I am assuming it is the stator... I just ordered on of ebay for 125 so it could get here by Thursday

what do you guys think? and how the hell do you get the crank nut off!?

That doesn't make sense to me. The stator is part of the alternator. If the alternator was not putting out, the battery would still run the sparkplugs. If the alternator was out, your battery would eventually die. Is it? I see four wires. Does your engine happen to have four plugs? Does it have a "coil on plug" setup?

[curtiscapk]

no alternator on a 2 stroke.... The stator creates spark, and charges at the same time....so I have read.

[badmoonrising]

Did you try replacing the burnt connectors ? I'm more familiar with Evinrude/Johnson of that year but the flywheel nut is a bear to remove. I used an impact gun and flywheel holder.

Burnt connectors usually means water got in and corroded them. Replace them with heat shrink connectors...

[curtiscapk]

I didn't replace connectors pretty sure it is the stator ...what I didn't show was one of the wires had rubbed through on the block you could barely see bare wire. I would assume when it died the couple times before it was making contact and shorting out? Then it just got smoked. The 94 stators I have read had a habit of going out on their own. I do need a puller but from what I have read harmonic balancer pullers can usually do the job and I can "borrow" one from Advanced auto. Instead of paying 50 bucks for the merc puller that I will use once. There is a way to check wether stator is bad, but didn't have my volt meter down there so I am running blind... If it isn't the stator you may not hear from me again as I will have been forced to walk the plank from the admiral....

The nut just got put in last year for my rebuild so hopefully it shouldn't be too bad. I have read to wrap the flywheel with a nylon strap and secure to frame when trying to turn the nut. Then special puller to get flywheel off.
I will keep you updated...

[badmoonrising]

Yeah, grounding out will fry it quick. That also explains the fried connectors.

[MH Hawker]

It depends on the hp and ignition system but most 2 strokes have 2 separate windings one makes the voltage that goes to a CDI box for the ignition and one for charging and lights. it may be combined on the newer or higher hp motors. The motor i have now is the newest I have ever owned lol its a 1996.

[jrolin1]

I had a similar problem including the burned connectors on my 2005 90hp mercury. I replaced the stator but it did not fix the problem. Fun doing that. It turned out it was my voltage regulator which is far easier to replace. My problem was caused by my battery shifting and pulling the ground wire loose momentarily.

[curtiscapk]

Crap I was wondering the samething.... I guess I better get one of those if I can before Friday.... and then sell whichever the problem isn't.....BOAT

[curtiscapk]

Stator received and Regulator coming today....wish me luck!

[jrolin1]

Good luck!

[cwag911]

Good Luck.

[curtiscapk]

Well Good news and bad news........
The cover works awesome!! Lots of heavy rain last week and no pooling and carpet was dry!

I am still frustrated so going with condensed version.

I started unhooking the REgulator and noticed two of its wires were melted together... Damn these barrell connectors suck!
I hooked up the new Regulator first since it was the easiest. Still won't fire. AFter 3 hours I got the Stator replaced air impact is a must for removing the flywheel!!! and a ratchet strap around the flywheel to keep it from spinning. We even had to use the impact on the puller bolt.... I was very careful on this one to make sure nothing was bending etc... ONce stator replaced still wouldn't fire! I spent the next hour looking for any disconnected wires and wouldn't you know I found one unhooked. Still wouldn't start... At this point started looking at the console wiring and damn two wires hanging from the ignition switch... I know I unhooked them all without labeling!!! I go over to the old console and look at the where they could have been hooked up. Well there is no kill switch on this model but at the very bottom corner of the controller hidden by the throttle is an off\run switch....Really 4 years and I had never seen this before! I got it pulled from the old controller and wired to ignition switch. Still wouldn't start. Went over to my Bro's place just pissed. Sent my SIL to get me some brews and my bro came back with me and said smells like massive gas have you cleaned the plugs??? So we clean the plugs let them dry and she fires up!! Put it on the hose and she ran like a champ for 15 minutes. Forward, reverse, fast throttle, slow throttle, Tilt works great alright! I call the admiral to make the call to everyone She is running come on down for the weekend. I turned it off and decided to figure out why the tach has been reading 7k from the time I hooked up the console on the boat. I look for loose wires at the tach and couldn't find any. Try to start it and nothing. After 30 minutes ignition switch won't do anything not even a click. I make the call to tell everyone forget about the weekend. The tilt and trim gets its power from the ig switch and now it doesn't work. It will if I bypass the hot with an accessory wire.. I use my dc tester and all the hot wires to switch now read ground and ground reads ground, only one thats hot is the tach wire in the ig switch. Shit! With the burn marks inside the switch case I am guessing it is the switch if not the only thing left is the switch box 250 bucks! I will start with the 30 dollar switch. I know at this point we should take it in, but with my step daughter getting married money is a little tight... I can't get back down till the end of June now. Needless to say frustration has set in!

[MPosey519]

Check that 20 AMP fuse, that did me in for ignition and trim for a couple hours before I thought about it.

[curtiscapk]

Already did that..... I have power at the motor. Can tilt and trim from switch on the side of the motor. Just no power from ignition switch back.