Can stranded copper wire replace old original stator wires?

[FishermanRich]

Would it be acceptable to either butt splice or solder and shrink wrap new 16 Gauge stranded pig tails onto the 4" of good stator wires?<br /><br />On a 84 115HP IL6 #06478920 there seems to be a problem with the wires from the stator to the switch boxes. When moved it is obvious from the voltage test (from red/wht to ground when cranking) that something is either broken or shorted as voltage peak levels change dramatically at times. As a side note... the wire from stator to the rectifier has cracked, dried out & broken insulation for about 3" at the rectifier which shows that at least this wire from the stator was toasty. The wires coming from Stator are good for at least 4 inches so it seems they all could be cut back to get rid of the bad and replaced with good. <br /><br />Also the green wires from the switch boxes to the ignition coils are also cracked and shedding pieces - can they be repaced with standard 16 gauge wire - THHN 90 degree C. grade wire.<br /><br />Also, would shorting of these cause the switch boxes to become bad?<br /><br />Also, What would cause this much heat in this area or is bad insulation something that is a known problem for the year engine?

 

[ronmold]

Re: Can stranded copper wire replace old original stator wires?

Plastic gets old, sounds like time to get new stator. With wires that old stator death isn't far behind. Get a red open coil after-market unit rather than a factory replacment. They last longer.

 

[clanton]

Re: Can stranded copper wire replace old original stator wires?

I would think the thhn wire would be too stiff. I would use marine grade stranded wire, or automotive wire. The thhn is for pulling thru conduit right?

 

[ossola]

Re: Can stranded copper wire replace old original stator wires?

DasBoot,<br />Whats the name of the aftermarket stator you mentioned and where can one find it? Thanks.

 

[ronmold]

Re: Can stranded copper wire replace old original stator wires?

from RAPAIR.COM lots of aftermarket Merc ign./elec parts which from what I hear (and now know first hand) are better and cheaper than factory. Merc pots their stator windings in black epoxy, the red ones are open windings and just coated w/ red varnish. This keeps them much cooler! rapair only sells through dealers, I got my stuff from seilermarine.com

 

[FishermanRich]

Re: Can stranded copper wire replace old original stator wires?

I ordered a replacement Stator as recommended.<br />I was getting wacky readings each time I moved a wire - I'm thinking the wires were pinched / broken / pulled or shorted at the stator where they exit/enter the unit.<br /><br />Any suggestions on getting the flywheel off? Should I rent a puller from the auto parts store?<br />-- the manual I have doesn't offer any help or even mention how to do this replacement.<br /><br />The THHN is also MTW wire that I used for replacing the bad wires that go from the switch boxes to the ignition coils. Also being rated MTW (machine tool wire - I think) it is more flexable then straight THHN.

 

[ronmold]

Re: Can stranded copper wire replace old original stator wires?

Oh ya the flywheel, you must get a merc puller that screws into the flywheel hub. about $70 from merc. You can take the bolts off around the hub to remove the stator but DON'T! It will unbalance the flywheel because you can't get it back on exactly as it was when it was balanced. Take it to a merc mechanic and have them pop it off.

 

[andrewkafp]

Re: Can stranded copper wire replace old original stator wires?

I know you've decided to replace the stator, but you can do as you suggested by cutting back and joining with same amp wire (Auto is fine).<br />Tinned is better (For corrosion)<br /><br />I did it on my trigger and re-covered the loom with that rubber self-sealing stretch tape..<br /> http://www.myfishingpictures.com/watermark.php?file=527/1413wire-med.jpg <br />Works a treat and was a result of feedback from some of the more senior members here on iboats..