Stator Wires sheared

BB63QM

Seaman
Joined
Aug 4, 2023
Messages
71
My Merc 850 (70’s) had a wire shear off at the stator and the other stator wire or nearly off and old. The wires come from the rectifier and disappear into a grommet buried in black stuff at the alternator stator under the flywheel.

The new stator wires (yellow with stripe) from the rectifier are MUCH narrower gauge and have a slot connector (as of supposed to be screwed in).

Is there a fix short of replacement?

On the distributor, I had a similar situation, which I remedied by marrying the severed wire and based with a brass nail and finished with solder.

Any advice and/or is there a better way to deal with the issue?
 

BB63QM

Seaman
Joined
Aug 4, 2023
Messages
71
The stator in my backup motor isn’t much better. Not sheared off, but corroded and brittle.

Replacement stators from CDI don’t have all the black shielding…could I cut into that to get a better bite in the wires for a tap?

Cheapest replacement is $100…most $200-400…just looking to save a few bucks if I can…unless I shouldn’t.
 

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BWR1953

Admiral
Joined
Jan 23, 2009
Messages
6,328
I had the same thing on my '85 Merc 50. I just paid the price and bought a new stator from CDI. Worth it. :cool:
 
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