2019 X-Star Ballast Fill Alternator Replacement

[Wakejunkie]

Ok thought so. I was making sure people understand that the pulley will help get the 95 amps at lower rpm but won’t gain any extra amps.

As far as the electrical system comments. Yes it might produce more heat. I wonder if you could spin the air filter 180 so the sensor would be at opposite side of alternator then. You do need bigger charge cable to battery. Maybe program ecu to not give rpm warning for fast fill boats. Also if you have the 170 amp alternator and the boat only needs 130 for stuff at that moment that’s all it will draw. The extra amps don’t go anywhere. I know I’m drawing equal to or more than 95 amps now when boat is running, 3 amps on, 3 ballast pumps because the voltage drops which means the batteries are suppling the extra amps not covered by the alternator.

[Mystic3D]

Ok thought so. I was making sure people understand that the pulley will help get the 95 amps at lower rpm but won’t gain any extra amps.

As far as the electrical system comments. Yes it might produce more heat. I wonder if you could spin the air filter 180 so the sensor would be at opposite side of alternator then. You do need bigger charge cable to battery. Maybe program ecu to not give rpm warning for fast fill boats. Also if you have the 170 amp alternator and the boat only needs 130 for stuff at that moment that’s all it will draw. The extra amps don’t go anywhere. I know I’m drawing equal to or more than 95 amps now when boat is running, 3 amps on, 3 ballast pumps because the voltage drops which means the batteries are suppling the extra amps not covered by the alternator.

100% - The alternator design on a higher output alternator is completely different, Stator windings, Rectifiers are all different. Without question it will produce more heat.
if you see a voltage drop when filling ballast then the alternator is not keeping up with the pumps, and that current is coming from the batteries.

The kit from ilmor Gen 5 Alternator Upgrade Kit PART # 50H-0205 what really has me curious the ECU cable and it's function. everything else seems straightforward.

[FourFourty]

100% - The alternator design on a higher output alternator is completely different, Stator windings, Rectifiers are all different. Without question it will produce more heat.
if you see a voltage drop when filling ballast then the alternator is not keeping up with the pumps, and that current is coming from the batteries.

The kit from ilmor Gen 5 Alternator Upgrade Kit PART # 50H-0205 what really has me curious the ECU cable and it's function. everything else seems straightforward.

ECU cable?? I’ve put a couple of them in, and there wasn’t any “ecu cable”. Just the alternator, a different belt, and a larger charge back wire.

[Mystic3D]

ECU cable?? I’ve put a couple of them in, and there wasn’t any “ecu cable”. Just the alternator, a different belt, and a larger charge back wire.

Thanks as always, the ECU Cable was what Ilmor told me was included as I was questioning what was included due to the $1,800 price.
https://mcpartsdepot.com/products/ge...bb1d1fdd&_ss=r
https://www.ilmor.com/product/3790/2...or-upgrade-kit

I think I could live with $1,000, but knowing what an alternator+batt cable+belt costs, I can't bring myself to do $1,800

I might not be the sharpest tool in the shed, but...

[Wakejunkie]

Yup agreed the bigger ones are different. I think this can be done for $600 with buying $500 alternator direct from mech man. Maybe you could take stock one to send in as a core and save money. I think that’s all that is needed to do the swap on the 5000 (5.7) motor.

[jackpine]

Does anyone know what the dealer charges for the for the MPI version of the Illmor alternator upgrade kit?

https://www.ilmor.com/product/3789/1...or-upgrade-kit


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[Wakejunkie]

I believe I’ve found an alternative to the mech man alternator and expensive kit from mastercraft. At $1800 it was just too pricey for me. You can buy the mech man 170 amp directly from them here for $500

https://www.mechman.com/high-output-...10DN-10SI-12SI

Or this 150 amp alternator from Amazon made for an indmar.

https://www.amazon.com/dp/B07QF9HBJK...H7Y1AET421GTSM

You will need new charge and ground cables as the stocks are 6 gauge (on my 5000 5.7 motor). You need a red cable 42” long with 5/16” ring lugs on either end. Also a black cable 39” long with 3/8” one end and 1/4” other end.

https://www.batterycablesusa.com/2-g...able-with-ends

Tools needed for the job are the following:
10mm socket
13mm-15mm socket
13mm wrench
15mm wrench
17mm socket
3/8” ratchet
1/2” breaker bar

Use the breaker bar with 14mm socket to move tensioner pulley and drop belt off alternator. Remove 13mm bolt and 15mm bolt/nut. Free alternator and remove positive 13mm positive cable nut and 10mm ground cable nut. Remove 15mm nuts off positive post near transmission and 17/15mm nuts off ground post slightly lower than positive post. Fish out old wires and feed new then reconnect everything. Note this detail is for the 5000 (5.7) motors. It might be slightly different for 5.3 and 6.2.

[Mystic3D]

I believe I’ve found an alternative to the mech man alternator and expensive kit from mastercraft. At $1800 it was just too pricey for me. You can buy the mech man 170 amp directly from them here for $500

Thanks for this!
Which alternator did you go with?(amazon or Mechman?)

[Wakejunkie]

Thanks for this!
Which alternator did you go with?(amazon or Mechman?)

I went with the one off Amazon. It has a year warranty so figured it was worth the try. Most of these components don’t fail often. Worst case you have a spare as the original that comes off and wiring is upgraded.

[mallees]

Do the newer boats (2020) come with the bigger alternator? I'm still waiting for the fast fill pumps to come back into stock, but when the do arrive, I'll have 5 pumps running to fill ballast.

[MCOR]

Yes. 2020 has the 180amp alternator.

[mallees]

Awesome, thanks.

[Wakejunkie]

Did some testing with new alternator. Stock 95 amp read 11.8 volts at idle and 13 at 1800 rpm and new 150 amp read 13.2 at idle and 14.5 at 1100 rpm with all pumps running.

[Mystic3D]

Putting a bit of caution out there for those thinking of going this route. I ordered the Mechman Alternator. Mechman warned me the pulley offset might be off so they included a few pulley shims in case it was off. Using a Dial Indicator in a vise comparing the stock 95 amp alternator as a reference to the back mounting holes on the alternator, I measured it. It is .168" or 4.26mm in too far in towards the alternator. This is too much to shim as the threads on the pulley are not that long.
So will call mechman tomorrow. The problem here is if the belt is not straight, it will slip and wear abnormally.

[Wakejunkie]

Putting a bit of caution out there for those thinking of going this route. I ordered the Mechman Alternator. Mechman warned me the pulley offset might be off so they included a few pulley shims in case it was off. Using a Dial Indicator in a vise comparing the stock 95 amp alternator as a reference to the back mounting holes on the alternator, I measured it. It is .168" or 4.26mm in too far in towards the alternator. This is too much to shim as the threads on the pulley are not that long.
So will call mechman tomorrow. The problem here is if the belt is not straight, it will slip and wear abnormally.

Man that sucks especially for the price for that alternator! Are you sure there isn’t enough threads to get that 5/32~? It looks like you would have enough threads for it. The nut needs to be flush with stud for full thread engagement.