Stator internal wiring damaged, SLT700 red engine

[Pineappleslicez]

I got a used SLT 700 last summer from my old boss, he had someone replace the CDI box and the stater couple years back. I was out on the lake last year and it died on me while me and a couple friends were tubing.

I decided last week to tear down the stater as I was getting very goofy readings from all of the wires to the cdi. Finally removing the flywheel today I noticed that the stater wires that go through the back of the housing have been rubbing on the flywheel.



How many guys would agree with me to possibly splice these wires back together?
it would save me $280 and it's definitely possible ,
but my only other question would be is, what method should I use to splice them back together?

[K447]

Remove the stator so you can have a better look at the wires and the damage.

If mostly the wire insulation has been abraded and perhaps a few thin strands of each wire, the fix may be as 'simple' as sleeving heat shrink tubing over each damaged wire. Use adhesive lined heat shrink tubing that will seal to the wire inside, which will keep moisture away from the copper strands inside long term.

[xlint89]

Welcome to the Hulk.

Something doesn't look right. Are you sure you have an SLT 750? That looks more like a domestic (red) engine to me.

I would try splicing the wires back and see what happens before you go purchasing any parts.

I would recommend soldering and heat shrink for a repair.

My only concern may be if the wires shorting out on the flywheel ruined the CDI.

[Pineappleslicez]

Welcome to the Hulk.

Something doesn't look right. Are you sure you have an SLT 750? That looks more like a domestic (red) engine to me.

I would try splicing the wires back and see what happens before you go purchasing any parts.

I would recommend soldering and heat shrink for a repair.

My only concern may be if the wires shorting out on the flywheel ruined the CDI.

Oh yes, I talked to type it and definitely missed that one , it's a slt 700.

I was hoping to avoid pulling the wires from the CDI box and just splicing them inside the ski, ( pushing the wires to the back of the housing, giving me more slack to work with )

I don't think I'd be able to get heat shrink around them. I was thinking, possibly using a rubber coating, almost like a liquid rubber that can be painted on.

I do need to get in there and see the extent of how badly they're burned/wore down. Didn't have time last night

[casey67]

The wires will slide,with some effort,where the wires go through the rubber grommet. The 2 bolts and bracket applies pressure to the grommet to hold the wires in place when assembled.

The aftermarket stators have slack on the wires in the stator housing. That is what caused your issue.

All the wires are color coded, so mixing them up is not an issue. You should remove the stator to get a really good repair,easier to work on. Most heat shrink gets stiff when dried,keep that in mind with the length of the repair. you will need to remove the slack from the wires in the housing- probably do that before removing it.

[Pineappleslicez]

UPDATE:

I pulled the stator out and found 2 of the wires were completely cut in half, and one that was 3/4 of the way cut. We decided to solder them back together adding some marine grade heat shrink back around the solder. Some new wire loom and electrical tape and I think it looks almost like a factory job !

I'll be assembling everything back together tonight so hopefully she runs with no issues