Rough Running When Warm - Coils Hitting Flywheel - Pics!

[monkeypop]

Bear with me here guys, I know this is a long read but I am in desperate need of some free advice. I'm not all that savvy with engine repair but I need to get this fixed myself because I am dirt broke and need my boat for work.

Last winter my 1989 40 horse evinrude started cutting out after running for long periods of time. As the weather got warmer the situation got worse and it barely runs at all anymore. Runs fine for a few minutes when first started but very quickly starts cutting out. I also noticed a strange high pitched grinding noise coming from the flywheel.. it even makes this noise when I turn the flywheel by hand.

After replacing the spark plugs and coil pack with no results I researched online and decided it sounds like a defective stator. Before ordering a new one I wanted to pull the flywheel to take a look. Well, I just pulled the flywheel and the magnets inside the wheel are worn as are the coils on the stator. There is no sign of the coils overheating that I can see. The entire stator assembly has a lot of free play in it, not sure if that is normal or not.

Below are some pics, dont know if this will help you guys or not but I figured it best to include pictures. Any advice would be a big help.

Magnets inside flywheel
http://imgs.inkfrog.com/pix/kingofquartz/100_7635.JPG
http://imgs.inkfrog.com/pix/kingofquartz/100_7637.JPG

Stator assembly
http://imgs.inkfrog.com/pix/kingofquartz/100_7638.JPG
http://imgs.inkfrog.com/pix/kingofquartz/100_7643.JPG

Close up of coil contacts
http://imgs.inkfrog.com/pix/kingofquartz/100_7639.JPG
http://imgs.inkfrog.com/pix/kingofquartz/100_7641.JPG

 

[clanton]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Just fixed one of these, not as bad as yours.

The stator plate has a brass bushing that wears. You can replace the stator plate, or have machine shop make new bushing.

I took a center punch and punched the bushing in 3 rows around inside the bushing, swelled the bushing prefect fit.

Knurling would be better if you can find a tool.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Just fixed one of these, not as bad as yours.

The stator plate has a brass bushing that wears. You can replace the stator plate, or have machine shop make new bushing.

I took a center punch and punched the bushing in 3 rows around inside the bushing, swelled the bushing prefect fit.

Knurling would be better if you can find a tool.

Interesting, I noticed a lot of what looks like brass dust resting on the stator plate. Is this bushing visible? Should I replace just the plate or also the stator itself?

 

[boobie]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

After you get the slop out of the mag plate corrected ( new one or machine shop repaired ), You may have a bad power pack, #583984 or a bad charge coil #583485. Or some broken wires under the mag plate.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

After you get the slop out of the mag plate corrected ( new one or machine shop repaired ), You may have a bad power pack, #583984 or a bad charge coil #583485. Or some broken wires under the mag plate.

Thank you for the advice. The power pack was the first thing I replaced but I suppose it could have gone bad from being run while getting bad signals from the stator. Anyone have a item number for the bushing? Cant seem to find it in the parts diagrams.

 

[clanton]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Can not buy the bushing, have to buy the plate. Take the plate off and measure the clearance, should be almost 0.

 

[boobie]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Also don't forget about the broken wires. Seen that happen on some of those mtrs.

 

[clanton]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

You could also use a speedy sleeve from NAPA or a bearing supply house. Sleeve will fit on bearing housing will take up .001-002 of clearence.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Can not buy the bushing, have to buy the plate. Take the plate off and measure the clearance, should be almost 0.

Edited: I took it apart and got my answer.

The bushing is almost completely worn through, is not worn evenly and has burrs hanging off the bottom. I ran my finger around the crankshaft and literally had 1/4 inch of brass colored dust collect on my finger. I measured and the part the bushing fits around measures 2.066 and the bushing measures 2.092. I'm amazed its been running for this long.

Also don't forget about the broken wires. Seen that happen on some of those mtrs.

Many of the wires are pinched and someone has already repaired a wire with the insulation worn off using electrical tape. Thinking I should just go ahead and buy a entire new stator assembly instead of just the plate to avoid problems in the future.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Having some trouble locating the plate assembly in online parts lists. My engine model number is TE40ELCEC and the number stamped on the plate I have is 583643. I searched for the part using my model number and it came up with part number 583285 but the sites all say the part is "obsolete" and not available???

Wondering why I am getting a different part number.. and its not available.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Bump for help locating the part. Prefer to buy a new plate rather than a used one with a bushing thats already worn.

 

[clanton]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

I checked on a speedy sleeve, they will take up about .011, not enough.

 

[Haffiman]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Another of the disastrous UFI powerpack systems. The best you can do is to see if you may find an older version armateur plate with external power pack, then convert the whole system. Luckily they went back to the old system on the latest models. Should be lots of old 80's lying around where you may salvage the system from.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

I checked on a speedy sleeve, they will take up about .011, not enough.

Thanks for checking. Even if it would take up the slack I'm not sure it would work very well because the bushing is worn in a oblong shape with more material missing from one side than the other.

Going to call some parts stores tomorrow to see if I can find a new one, keeping my fingers crossed. There is lots of used ones on ebay but whats the point in buying one thats already worn.

 

[monkeypop]

Re: Rough Running When Warm - Coils Hitting Flywheel - Pics!

Wanted to come back and say thank you to everyone who posted. Thanks to you good people taking the time to post in my thread my boat is now up and running again without paying a repair man!