what will happen if.... ( stator question)

what would happen if the two yellow wires coming from my stator on my 76 merc 1150 inline touch each other, they are old and all the plastic coating has crumbled off. is there a way to recover them without having to buy a new stator?

Re: what will happen if.... ( stator question)

Mike, It the stator wires short together, they may ruin the stator. Clams had posted a method whereby you splice new wires onto the stator where it emerges from the plastic molding. I have added it here!<br /><br />From Clams Casino To repair rotted out Stators<br />I've fixed 100 of those, here's what you do:<br />Get two new wires of the same length and guage. Cut off the old wires leaving 1/2 to 3/4 inch of bare nubs sticking up. <br /><br />Here comes the fun part. <br /><br />CLEAN the nubs using a light sandpaper stroking the wires straight out form the stator, be gentle and try to breal as FEW strands as possible. Let the strands fan out so yo ucan get most of the green stuff.<br /><br />When most of the wire is clean, "re-twiddle" them back to 2 separate wires. Make SURE they are separate, angle them both away from center a bit.<br /><br />Now bare 1/2" of your new wire and use two single strands of new wire to TIE the new one to the "outboard" side of the old one. Then solder generously. Repeat for other wire.<br /><br />Let it cool and drop on 2 inches of shring sleeve right all the way to the plastic, then add the ring connector to the other end.<br /><br />When both are done, verify they are totally separate and wrap a piece of electrical tape arounf the plactic to make a "form" and fill that with potting compound or even black silicone seal.

Re: what will happen if.... ( stator question)

Mike,<br /><br />The stator on your engine only produces about 5 or 6 amps. If they did touch, very little would happen. The reasoning behind this is that if you have a low batery on the system then the stator is at maximum output anyway. Whether it's drawing max current to charge the battery or just feeding to itself, max current is max current.<br /><br />Best thing is to fix them as the other 'Chris' says. Or you could just slide a bit of heat-shrink tubing over each of them and shrink it down. <br /><br />Chris..........

Re: what will happen if.... ( stator question)

You can repair the insulation with shrink tubing. You'll have to crimp new connectors on the ends, but it'll work. You can get that stuff most anyplace that sells wiring stuff like a hardware store or auto parts store. Just snip off the connectors, slide the tubing over whatever is left, heat it with whatever works, and crimp on a new pair of eyes.