1986 Merc 90 i6 - stator replacement labor

[jeff_smith_0423]

Gents,

Recently lost spark on 1-3-5. Diagnosed as bad switch box. Replaced switchbox and questionable rectifier. Still no spark on 1-3-5. Engine will start and once i give it gas, 1-3-5 kick in.

So, i'm thinking that my stator is bad. I'm handy, but i don't have the tools or a source for them to pull the flywheel. How many hours labor should I expect to have the stator replaced?

Thanks in advance. This forum has saved me quite a bit of time and money so far.

 

[micbaca]

Re: 1986 Merc 90 i6 - stator replacement labor

I just pulled my own flywheel. It is really simple and you don't need expensive tools. Put your boat in gear and jamb your prop (like you're removing the prop). Crank the nut off the flywheel. Go to napa and buy a universal steering wheel puller (for small fly wheels) for $20. Some motors have a bunch of bolts that you simply unscrew (i.e. no puller needed).

The key is don't bend your flywheel, otherwise you are screwed. Whatever you do, don't use a "jaw" puller because it will definitaly bend it.

Good luck.

 

[jeff_smith_0423]

Re: 1986 Merc 90 i6 - stator replacement labor

I'm getting close to attempting it. I don't know if others have opinions but jamming up the prop to get leverage sounds dangerous to me. Seems like without really securing the flywheel with a proper strap, i'm putting 100-120 lb/ft of torque on the internal engine parts and crank bearings. Sounds like a costly screwup.

The steering wheel puller does sound like a good cheap idea though.

All of this to replace a part that should take about 15 minutes. Also, since the flywheel has a keyway and can only go back on one way, will a complete link and sync be required after the work is done? Right now, the timing is spot on. Seems like i won't be messing with anything mechanical when removing the flywheel. The only thing i can see changing is if the stator output is slightly different than this one was when originally tuned.

 

[woody66912]

Re: 1986 Merc 90 i6 - stator replacement labor

jeff please put some kind of holding strap on flywheel . swaping ele parts can get costly most dealers can knock this out 1.5 hours thats with a voltage output test .

 

[j_martin]

Re: 1986 Merc 90 i6 - stator replacement labor

The proper way to pull a Mercury flywheel is with a Mercury flywheel puller, which screws into the big threaded hole in the middle of the hub. The steering wheel puller is a fair second choice, but I've seen some come off quite hard. A jaw puller will ruin the flex plate before it even begins to move the hub.

Stator replacement shouldn't affect anything in timing. (theoretically). You just need to remember that Murhpy's law supercedes all other natural law.

hope it helps
John

 

[jeff_smith_0423]

Re: 1986 Merc 90 i6 - stator replacement labor

1.5 hours sounds about right to me. I'm not just "throwing parts" at this motor. The switchbox was confirmed bad - some of the potting had blown out and was melting. Couldn't run the motor in that shape to do a voltage test to begin with. Biggest problem is that none of the shops I've contacted will work on anything more than 10 years old. I had one guy literally tell me "Just buy a new four stroke, these motors aren't worth working on". There is one salvage yard who does work on older motors at a decent labor rate, but they don't give estimates before they start, and the last time i had control cables and a water pump put in, I was charged for 4.5 hours of labor.

 

[CharlieB]

Re: 1986 Merc 90 i6 - stator replacement labor

Since there is NO RETURN ON ELECTRICAL PARTS and the fact that many of them are getting quite pricey, me thinks that it may be wise to test and PROVE what part(s) are bad, BEFORE spending money needlessly.

Rapair/CDI has an excellent Ignition Troubleshooting Guide, along with a DVA Meter that will save you many hours and a lot of $$$$$$$

Get it, use it.

You may have a weak low rpm winding in the stator, wouldn't you like to know BEFORE you buy one?

 

[jeff_smith_0423]

Re: 1986 Merc 90 i6 - stator replacement labor

I certainly appreciate the concern for my wallet, but regardless, this stator is going to be replaced. The switchbox leads are still pilable and intact, but the rectifier leads are crumbling. No amount of liquid vinyl and electrical tape are going to save them for any length of time. Since i plan on using this nearly immaculate, low hours motor on another hull next season, it's going to get treated right.

I'll keep the 1.5 hour estimate in my head when shopping around. If any of the other pros on the board have other opinions, I'd love to hear 'em.

 

[bchoate]

Re: 1986 Merc 90 i6 - stator replacement labor

I certainly appreciate the concern for my wallet, but regardless, this stator is going to be replaced. The switchbox leads are still pilable and intact, but the rectifier leads are crumbling. No amount of liquid vinyl and electrical tape are going to save them for any length of time. Since i plan on using this nearly immaculate, low hours motor on another hull next season, it's going to get treated right.

I'll keep the 1.5 hour estimate in my head when shopping around. If any of the other pros on the board have other opinions, I'd love to hear 'em.

1.5 hours is about the norm for this job concidering the "retesting that a mechanic would do just to make sure this is the problem.
If you dont have the tools its better to take it to a reputable dealer for repair as the proper tools would cost more than the labor involved.

 

[jeff_smith_0423]

Re: 1986 Merc 90 i6 - stator replacement labor

Got the stator swapped out on my own and that took care of the problem. Now i only have one minor issue. My tach quit working. Was working earlier with the bad stator. When i turn on my master power switch, the tach pegs back down to zero as it used to, but nothing else happens.

Getting close to the water..

Thanks all.

 

[CraigC]

Re: 1986 Merc 90 i6 - stator replacement labor

Ok, for your tach - if it worked fine before you changed the stator and doesn't work now I would start by making sure all of the connections are clean, and double-tripple check that you wired everything correctly. If the connections are clean, tight, and correct, and it still doesn't work, I'd try sweeping the selector switch on the back of the tach a few times, then put it back where you found it. Together those things should take care of the problem...should, being the key word!
If should isn't good enough and it doesn't work....well, it could just be a coincidence that the tach went bad now...anything can happen I suppose. Thats all I can come up with, someone else might have some more info for you though.

 

[jeff_smith_0423]

Re: 1986 Merc 90 i6 - stator replacement labor

Yep. that was the plan. Double checked and reconnected all of the rectifier connections and tested, with the same result. Figured it couldn't hurt to put the old rectifier in and voila, everything back to normal. Ran the motor at about 2000 rpms and saw 12.56 volts at the battery, so I think it's charging. Battery read 12.45 before i started the motor.

Still need to replace the tach as it pegs out at 2800 rpms and will not go beyond that. I have a spare sitting around here someplace.