Mercury V6 XR2 - Does this Stator looks bad?

Superjetjim

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I'm having some really random running issues with my 93 XR2 Merc, it'll idle fine on the hose and picks up cleanly out of the water. As soon as you launch it, it looses power within a few seconds, to the point it wont even idle or start. Pull it out of the water for a few mins and she fires right back up, until you repeat the process.

I've gone through the motor and done the following:
  • Carbs stripped, cleaned and reassembled
  • New OEM switch boxes
  • New coils, leads and plugs
  • Compression check (130 PSI all pots)
  • Done a static OHMS test on the stator and pickup as per shops manual (I don't have a DVA meter to test the full functionality of the Stator though)
I've just pulled the flywheel to inspect the stator and found this. Doesn't look great, right? The areas that are rusty seem to have separated slightly. Also the area on the outside of the Stator in this location, has started rubbing against the inside of the flywheel - perhaps this signifies rust and bad things occurring inside the Stator?
 

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alldodge

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I'm having some really random running issues with my 93 XR2 Merc, it'll idle fine on the hose and picks up cleanly out of the water. As soon as you launch it, it looses power within a few seconds, to the point it wont even idle or start. Pull it out of the water for a few mins and she fires right back up, until you repeat the process.

Stator doesn't look bad to me, but I'm no expert. Don't see how putting it in the water causes the issue when it runs fine on a hose or in a bucket. If it was overheat issue it would take longer than that

Hey @racerone , @Texasmark maybe others have any ideas?
 

racerone

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Does spark jump a gap of at least 3/8" , yes or no ?----Load tested the battery?----Inspected / tested the starter motor?
 

Faztbullet

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Aftermarket stator and someone stripped 3 mounting bolts amd replaced with metric ones. Also a 93 should have a 40 amp stator , yours shown is a 16amp, if you are running a 40 amp flywheel it will overload the switchboxes and rectifier
 

Dukedog

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Oct 6, 2009
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agree with fast... something jus don't look right??? buy it used?.. acoupla more pics would verify?.. jus powerhead.. both sides and rear..

merc didn't build a '93 XR2.....
 

Texasmark

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Stator doesn't look bad to me, but I'm no expert. Don't see how putting it in the water causes the issue when it runs fine on a hose or in a bucket. If it was overheat issue it would take longer than that

Hey @racerone , @Texasmark maybe others have any ideas?
Thanks for the compliment. Sorry sir but I never had an issue with issues associated with the flywheel or the functions therein.
 

Superjetjim

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Hi chaps, just checking back in on this one.

The stator was toast, I replaced it with a new CDI Electronics 16A one.

Also did the same with the pickup, went CDI again.

Pics attached of the flywheel I have
1770143089531.jpeg

Also the Rectifier failed some of the tests in the shop manual and the separate Regulator was missing altogether... I've just ordered a combined Merc Reg/Rec and will install that. Sounds like I've been sold a bag of old broken parts on this motor. Compression is good at 125PSI in all pots though, which is something.

Here is the serial number of my motor 1770144446202.jpeg
 
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Superjetjim

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I'll be water testing again this weekend (attempt number 11)!
I've also bypassed the built in boat tank, in favour of a proven external outboard tank and primer bulb to alleviate the tank being an issue.
Will report back if all sorted.
 

Dukedog

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thats a painted light weight.. you must have tha high performance XR2.. mount for tha hi perf. lite weght cowl also... thats a completely different story.......... not many of those left, especially here in tha states............

got my attention now.. what boat is it on?.. pictures?
 

Superjetjim

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thats a painted light weight.. you must have tha high performance XR2.. mount for tha hi perf. lite weght cowl also... thats a completely different story.......... not many of those left, especially here in tha states............

got my attention now.. what boat is it on?.. pictures?
Here's some pics of the motor :)
View attachment 1770226403885.jpeg

View attachment 1770226437246.jpeg

View attachment 1770226583521.jpeg

Its on a Phantom 18 race boat, hoping she goes well once sorted..
 

Dukedog

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thats a very nice piece for its age!.. . its probably tha easiest merc V6 ta work on and will live forever if taken care... even still has tha cle on it! if your boat is a lite weight it won't disappoint.. jus keep in mind that even though it comes from tha high performance side n all dolled up, its still justa 2.0 motor.. its about tha same performance wise as a 200 production motor...

not familiar with tha boat.. Austrailian/British, somewhere else???.. looks like its gonna be a fun (handful) ride???.. not much of a pad... ya may need ta bring ya "chine-walk" skills up ta date!
 
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Superjetjim

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thats a very nice piece for its age!.. . its probably tha easiest merc V6 ta work on and will live forever if taken care... even still has tha cle on it! if your boat is a lite weight it won't disappoint.. jus keep in mind that even though it comes from tha high performance side n all dolled up, its still justa 2.0 motor.. its about tha same performance wise as a 200 production motor...

not familiar with tha boat.. Austrailian/British, somewhere else???.. looks like its gonna be a fun (handful) ride???.. not much of a pad... ya may need ta bring ya "chine-walk" skills up ta date!
OK so managed to water test it again just now, still wont pick up in the water, as soon as its in the water and the offshore mid exhaust is under water it bogs. If its out of the water (trimmed up) it picks up under load. On the hose its no problem, revs crisp and clean on all six.
It looks like some kind of back pressure or water related issue. Updated list up things I've replaced and done below:
  • Carbs stripped, cleaned and reassembled
  • New OEM switch boxes
  • New coils, leads and plugs
  • Compression check (130 PSI all pots)
  • New CDI Stator
  • New CDI Pickup
  • New Impeller and water pump
  • External electric fuel pump has solid 6PSI on gauge
  • Bypassed boat tank to outboard tank to alleviate that side
Any other ideas please, I'm all out, short of pulling the powerhead and looking at the water passages? Could someone who built this up, have used the wrong gasket on the powerhead to exhaust extension plate, causing these backpressure symptoms when in the water? I've never seen this engine run before (other than on the hose on collection)

Other symptoms it has no cooling water coming out of the pisser unless its revving (has new impeller and housing) - but there is stacks of water coming out of the prop hub.. All spark plugs are super clean, like brand new, even after running on the house for a few mins. Maybe steam from water getting somewhere it shouldn't is cleaning them?

1770381401065.png
 
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racerone

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When it is on a hose or trimmed out of the water there is NO LOAD on the prop.-----It will bark and roar on 3 of 6 cylinders.------Checked reed valves ?----Perhaps pistons are not installed correctly ??
 
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Chris1956

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A lot of V6 Mercs do not have a telltale until the thermostats open. On a flusher, that may never happen at idle.

Does that motor have an idle relief tube, exiting the lower cowling at the rear? Is it connected on both ends? If it leaks, exhaust will get sucked into the carbs, killing the power.
 

Superjetjim

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When it is on a hose or trimmed out of the water there is NO LOAD on the prop.-----It will bark and roar on 3 of 6 cylinders.------Checked reed valves ?----Perhaps pistons are not installed correctly ??
Its on the trailer, partially submerged, with prop in the water, but offshore mid clear of the water. Runs under load like that. Big rooster..

Good shout on the reeds, not checked those, that said there is no blow back through the carbs.
 

Superjetjim

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A lot of V6 Mercs do not have a telltale until the thermostats open. On a flusher, that may never happen at idle.

Does that motor have an idle relief tube, exiting the lower cowling at the rear? Is it connected on both ends? If it leaks, exhaust will get sucked into the carbs, killing the power.
Thanks Chris, this is the XR2 race motor which doesn't have any thermostats or poppet valve.

I cant find an idle relief valve on the parts schematic for my motor - can you see it?
 

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