1995 Sport Jet 90 - No Spark - Black Stator

[calledinsick]

Can someone post the specs/procedures for testing the black stator? Most everything I found on here refers to the red. Same old story, no spark on the 3 plugs. Recently replaced the key switch when it fell apart, then a couple of weeks later I replaced the Rev-Limiter when it stopped working (disconnected black/yellow wire and it started, blowing off the rideplate).

Last Saturday the boat was running great all day, then I went out to start it after sitting for 2 hours and it just cranked. Spark tester showed no spark on any plugs. Could this be the original stator from 1995? After reading all the problems, it seems unlikely.

Thanks!
Brian
www.calledinsick.com

[kend301]

Welcome to IBoats , First of all be sure you have a black stator by the wire colors , 2 aftermarket company's make black looking stators , The "real" black stator will have a red and a blue wire coming from it to the switchbox . Test specs for the 90 hp are as follows :
Set OHM meter to R x 1000 scale
Disconnect blue and red wires from switchbox at the bullet connectors.
Ohm Red to Blue wires , should read 3600 to 4200 OHMs
Ohm Red wire to engine ground , Should read 90 - 140 OHMs

Next test the trigger using white/black as ground , individually ohm the Purple , White and Brown all to the white/black wire , Should read 1100-1400 OHMS on each wire . Post up results and we can go from there

[calledinsick]

My stator has Red, Blue, and 2 Yellow wires.

The Multi-meter only has 200, and 2000 for ranges, so I used 2000 and took the following readings:
Red to Blue = 1415
Red to Ground = 34

Trigger (2000 setting) to White/Black:
Purple = 1220
White = 1231
Brown = 1216

Thanks in advance!

[kend301]

Stator is toast , I will look up the part numbers for you as you will need the adapter to run a red stator . If you can get and post the number of the regulator (where the yellow wires go) you may need to update it also to go to the red stator, But I think CDI still makes a stator that would be a single part replacement if $$ is a factor .

[kend301]

I am going to need your engine serial number 95 was a split electronics year for the 90 hp . Also check the stator harness for a merc part number tag , post it if you find one and Post a pic of stator and the stator wires .

[calledinsick]

Engine Serial: OE112656
Regulator Number: 815279-4 (also had a 3994 below this number)

Cost is always a factor! What is the Cost/Benefit of the Red Stator?

What type of puller will I need for the flywheel?

[kend301]

OK I'll start looking up numbers . Mercury discontinued the black stator in 96 , too many were failing , They went to a red stator that is 16 amps (black was 9 amp) The red stator is still in production , the 9 amp ones are only available aftermarket . And still very prone to failure .

[kend301]

OK here you go , the direct mercury replacement is the 16 amp red stator with an adapter , the kit part number is 832075a5 , it must be this number exactly as you will need the adapter that comes in the kit.
CDI makes a 9 amp stator pn 174-8778k1 that is a direct replacement with no other modifications as does Mallory pn 18-5870
Now CDI also shows a 16 amp stator that will work with the 815279-5 voltage regulator without any adapter or modifications , the part number is 174-9710k1 BUT you need to call CDI to be sure it will work , their number is 866-423-4832

I use a standard steering wheel puller available at any parts store for about $25.00 REMEMBER, NEVER hit the flywheel with a hammer to "loosen" it , you will be buying a flywheel for sure !

[calledinsick]

Coolio. Thanks for the info.

Do you ever really get all the bugs worked out of these engines...or are they constantly requiring repairs? It seems a lot of people have continous problems with the SJ90's.

I hope to find the kit and get it together as soon as possible to be back on the water. I'll let you know how it goes. Are there any tricks to getting it installed correctly or is it pretty straight forward?

Thanks again for all the help!
Brian
www.calledinsick.com

[calledinsick]

Surprisingly, my local shop had the Red Stator Kit 832075A5 IN STOCK!! Picked it up at lunch! Cha-ching!

[kend301]

Cool deal , Just be sure to run the black wire out of the adapter to a good ground . Post up results as I think you should be set for years to come

[calledinsick]

OK, is there a way to keep the crank from turning while loosening the nut on top? The only thing I see is the center crank nut and 3 small holes around it (triangular, for the wheel puller I would guess). I don't want to damage the teeth, but don't see any other way to secure the flywheel while applying torque to the nut.

[dmball]

They do make flywheel holders but they are not necessary if you dont have one. Have someone else there to help you. I used a homemade type "pry bar" and had the helper hold the flywheel against somthing sturdy. Then tighten the forcing bolt on the puller and then lightly strike the top of the forcing bolt with a hammer. Tighten the bolt another turn or two, tap it again and it should come of easy. Usally it pops right off after a light tap with the hammer.

[kend301]

You can get 2 bolts that fir the flywheel puller holes (make sure they are grade 8 ) put them in and put a prybar through the bolts to hold it from turning . As dmball said nothing wrong with tapping the puller center bolt that is touching the flywheel but NEVER hit the flywheel itself .

[calledinsick]

Whew! Impact wrench instead of breaker bar on the crank-nut took it right off. Then a couple of good hits with a hammer on the forcing bolt, crank down forcing bolt, couple more good hits and she popped loose! Yay!

Now I started hooking up the Red Stator Kit, and I notice in the instructions it says: "Only use the new Design Regulators P/N 815279A4". My regulator is 815279-4, but I didn't catch anywhere that I needed to change the regulator. Do I need to track down the 'A' version of the regulator? Ugh!

I've been taking photos of the steps and will post them up shortly.

Thanks,
Brian
www.calledinsick.com

[kend301]

NO .. the regulator you have is fine , the A4 was a conversion kit that really had the A5 regulator but was labeled a4 due ti the kit. Mercury hardly ever put the letters in part numbers they always have been dashes . you have the "a4" regulator on there otherwise I never would have recommended the red stator without one

[calledinsick]

Cool. Thanks.

I've got it back together, took it to the river and put the spark tester on. Cranked and no spark on top or middle cylinder (Didn't bother to check the bottom one). Ugh! Now I guess my diagnostics switch to the red stator specs! Is it time to start over?