Hello all- I have a 1977 Mercury OB on my 2-battery Oday 25 that was not charging the house battery too well. I finally got around to looking at the wiring and found it was totally shot. Upon removing the pull and flywheel, I found that both of the entire lighting stator wires were cracked, and useless. They don't make the part anymore so I was stuck. I used Mototool with a cutting blade to carefully cut into the sealer where the windings met the wire, then soldered a new piece of high temperature wire onto the winding end. Made sure it was all packed down in there, then used JB Weld to seal it all back up again. It's doable! The high temp wire was $6 for three 18-inch pieces ; it is used for electric stove gas igniters so I figure it can handle 12 volts. I can't test it until Spring, but am happy!
Mercury 9.9 lighting stator rebuild.
- Thread starter Ritdog
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