Stator Wiring Problem

[j442w30]

Ok I posted about a month ago when I found burned wires that connect the stator to the rectifier on my 1993 Mercury 40 hp outboard. After looking at the wiring some more I think that I have the wrong stator. According to the wiring diagram in my service manual I should have a 6 wire stator and right now my stator only has 4 wires, 2 of which go to this box and then connect to the switchbox. Because I only have a 4 wire stator there are 2 open posts on my switchbox. I should mention that the engine runs fine but I am concerned about the burned wires and high voltage doing damage to the electrical system

Heres a picture of the two burned yellow wires, last winter I had to replace the rectifier because the plastic around the terminals had melted a little bit.

I removed the stator and found that of the 4 wires total, there are 2 yellow wires that go to the rectifier and a green and a green/white that go to this box thing which has blue and blue/white on the other end which go to the switch box. I took the serial numbers off this stator and cross referenced them on the CDI site and supposedly this stator goes to a OMC engine.

Heres a picture of the stator and box, does anyone know what this black box is?

Now here is the page from my service manual that shows how it should be with the six wire stator.

Now I assume I have the wrong stator, should I ditch what I have now and get the six wire stator? Will this fix the burnt wire problem? My engine has the rectifier setup, not the voltage regular, does anyone know what stator is correct for my engine? I've been looking around and I think I found the right one, its CDI part # 174-5454 K1. Can anyone confirm this?

Sorry about the long post but this really confused me.

Thanks

 

[Laddies]

Re: Stator Wiring Problem

Yes the 174-5454-K1 is the stator for your engine, what you have is part of a red stator kit for a mercury engine I can't tell from the picture what it is for sure, I think that they all come with a regulator. I can't tell you for sure as we don't use the junk stators that merc builds.

 

[jdshort98]

Re: Stator Wiring Problem

I don't have a parts manual in front of me to tell you if you have the correct part number, but I can answer your question about the black box. The old black colored stator you removed produced a much lower voltage output than that new red one. The black module you have is a voltage reduction. The reason for the additional ground wire it has is to bleed off the additional voltage the red stator produces. Without it, the red stator would take out your switch box. As far as the two additional terminals on your switch box, if you bought the stator new, it should have come with some black caps to thread onto the empty studs to prevent and problems. The stator should have come with a new diagram to replace the one you have in your manual, to explain which studs to attach the green wires to.

Good luck!

 

[j442w30]

Re: Stator Wiring Problem

I don't have a parts manual in front of me to tell you if you have the correct part number, but I can answer your question about the black box. The old black colored stator you removed produced a much lower voltage output than that new red one. The black module you have is a voltage reduction. The reason for the additional ground wire it has is to bleed off the additional voltage the red stator produces. Without it, the red stator would take out your switch box. As far as the two additional terminals on your switch box, if you bought the stator new, it should have come with some black caps to thread onto the empty studs to prevent and problems. The stator should have come with a new diagram to replace the one you have in your manual, to explain which studs to attach the green wires to.

Good luck!

Thanks for the quick response Laddies and jdshort98

I figured the black box was some kind of regulator but I think it has stopped working because of the burnt wires and melted rectifier. I am just going to replace it with the 6 wire version so that should fix the problem.

One other question

Now if I get the 6 wire stator and it doesn't come with a regulator am I risking frying the switchbox?

 

[Laddies]

Re: Stator Wiring Problem

No that stator is the standard stator for that engine and won't hurt the switch box, however the old stator with the burned up regulator may have

 

[achris]

Re: Stator Wiring Problem

Within your new stator are 2 completely separate windings. One winding is the charging circuit and goes to the rectifier, they are the 2 yellow leads. The other winding is the power for the switch box. The original stator had a low speed winding and a high speed winding. The low speed was the blue wires and the high speed was the red wires. The new stator has only one (the green wires) that go to the thin black box you have in the second picture. The output from that box are blue and go to the terminals on the switch box that the original blue wires went to.

Chris............

 

[j_martin]

Re: Stator Wiring Problem

The overheated connector on the yellow wires is pretty normal. anything over 5 amps is a lot to ask for a "bullet" connector, especially in potentially wet conditions. The burn doesn't hurt anything except the connector.

Your present stator, hooked up the way it is, should be fine. Put a CDI rectifier in it instead of the Merc/Mex junk.

hope it helps
John