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cooked stator and or wiring harness

J

Jhanratt

Regular Contributor
2000 125 Mercury 125 elpto 2 stroke. Ran great last year. First run this year the tach went flaky. Then it refused to idle.
I opened the cowl and the wiring harness from the stator to the voltage regulator is cooked.
Do I solder,and heatshrink and replace the harness and try to run it?
Do I pull the flywheel and replace the stator and heatshrink the wiring harness??
I own the service manual so I could test the stator as per the manual but I figured somebody here would save me the time.
Photos are attached in the files.

Thank You!!!
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Thank you. That might track. The batteries were weak coming out of storage. I did charge them before going out.

What is my best repair option? New stator or just solder and heat shrink?

I'm pretty solid with a soldering iron and heat gun.
digital gauge on the boat said 14.1V
analog gauge on the boat said 12v but they have never agreed!
 
IMO that is evidence of a poor connection at the connector plugs. Excessive resistance results in an increase of temperature at the connector point. Not uncommon at all.

I would cut, splice, solder and hardwire new connectors.
 
Thank you!
I pulled the flywheel and stator. I’ve started to solder and heat shrink new wires in but I ran out of the really good dual wall adhesive lined 4:1 so I’m down for the night.

It looks likely that the stator is ok.
Since my time is free I’ll give it a shot first.
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It lives!!!

I finished my solder and heat shrink this morning with some new pieces of wire patched in to replace the burned wire.
I load tested both batteries. The passed as a 1000CCA but I think they are more like 700CCA.
12.3 volts after the load test and before starting.
14.5 volts after running 10 minutes on the hose in my driveway.
All wires were cool to the touch.
I also had to plastic weld the oil tank due to heat damage from from the burned wires. I sanded it smooth and melted in some plastic from a 5 gallon bucket using a soldering iron and flat tip.
A test run on the lake is in order but it looks like an overheated connection which is bizarre because I filled all of the connections with Di-electric grease when I bought it. I've owned it about 22 of it's 26 years.
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Thank you for the advice!!!
This was a bit sobering for me because I trust this boat more than I should! Its a 2000 2002FF Trophy and I've been off shore with it.
It might be time to upgrade but there is comfort in knowing you boat and it's maintenance history well!
 
My Mercury 175 EFI showed the same type of indications. Fortunately I caught it before much damage happened.

Good report. Good job. Thanks for the feedback.

I suspect those connections will now outlive the motor.
 
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