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Merc 9.8 thunderbolt to phelon mag conversion

jake11

New member
Good morning, folks. I have 2 old mercs in the garage. 1 is a 71 with the phase maker ignition. The motor is in beautiful shape has great compression and the LU is super solid. The other is a 69 with phelon mag ignition and is missing the LU. Compression is decent. I think the two cylinders are within 3 or 4 psi of one another.
The motor with the PM ignition is repeatedly popping one of the ignition coils(3 now) and at 50 to 100 a piece its getting old fast. I'm assuming something is going on with the extremely expensive and hard to find stator so I want to swap over to the more reliable and easier to trouble shoot phelon mag system. Some of the parts from the 69 are missing but the majority of it is there and the parts and nuts and bolts needed are cheap. So! Anyone ever done one of these conversions that could give me a run down? I have too many hours, dollars, blood, sweat and tears wrapped up in this motor to give up on it so any help would be greatly appreciated.



 
The crank is the same, but the points cam is NOT. You need to change the top bearing carrier, flywheel, mag plate, etc. You'll also have to adapt the arm that moves the mag plate, but all of this is doable and you'll end up with a really nice running motor.

I've done several of these so feel free to ask if you have any problems.


Jeff
 
Thanks for the response Jeff. I plan to get started on it this weekend. Hopefully it goes well. I have a nice running 54 evinrude 15 but really need this 9.8 for fishing all the lakes around here.

-Jake
 
Yea I changed the impeller right before I got it out for the year. I also greased the splines on the prop shaft(do every time I'm working on anything down there). It was recommended to me when I first got the motor and I've been doing it since.
 
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