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2019 X-Star Ballast Fill Alternator Replacement

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  • mallees
    replied
    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.

    Leave a comment:


  • Wakejunkie
    replied
    Originally posted by Mystic3D View Post
    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.

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  • Mystic3D
    replied
    Originally posted by Wakejunkie View Post
    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?)

    Leave a comment:


  • Wakejunkie
    replied
    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.

    Leave a comment:


  • jackpine
    replied
    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


    Sent from my iPhone using Tapatalk

    Leave a comment:


  • Wakejunkie
    replied
    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.

    Leave a comment:


  • Mystic3D
    replied
    Originally posted by FourFourty View Post
    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...
    Last edited by Mystic3D; 06-26-2021, 12:47 PM.

    Leave a comment:


  • FourFourty
    replied
    Originally posted by Mystic3D View Post
    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.

    Leave a comment:


  • Mystic3D
    replied
    Originally posted by Wakejunkie View Post
    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.

    Leave a comment:


  • Wakejunkie
    replied
    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.

    Leave a comment:


  • LD50
    replied
    No, I don't believe it's possible that spinning the alternator faster with the smaller pulley allows it to produce a higher amperage. It should only allow it to produce peak amperage at a lower engine rpm. I only brought the point up because the fact that this pulley only appears to be used on boats with the 2:1 trans ratio. I'm unaware of all the factors that play into this choice, and there could be more than just spinning the alternator faster at a lower engine rpm. Just thought it would be useful information for someone to have that's also looking to swap an alternator on a boat with the same ratio transmission.

    Leave a comment:


  • jackpine
    replied
    If this is true that the smaller pulley provides increased output, is possible to just purchase the pulley?

    This all brings into question the safety or necessity for recalibration of the ECU, rotation of the intake sensor & swapping battery cables?

    I suppose doubling the output is going to put more of a strain on the electrical system & generate more heat. You’d think better alternator output would be help with the additional draw down on the batteries.

    It sure would be nice not to have to wait for pumps to finish before putting her into drive, raising the RPMs and freaking out the crew due to the low voltage alarms.


    Sent from my iPhone using Tapatalk

    Leave a comment:


  • Wakejunkie
    replied
    So are you saying the smaller pulley makes it output more amps to 170? I know a smaller pulley spins them faster so it doesn’t take more revs to get same amps at idle but not sure it would almost double the output power.

    Leave a comment:


  • LD50
    replied
    Something I didn't know until I did a lot of searching for a replacement alternator for my Xstar is that the factory alternators for motors with the 2:1 transmission have a smaller pulley on them. Other than that, the part numbers on the casings themselves all seem to match up and it appears to be the exact same unit. I picked up the standard 95 amp replacement and swapped pulleys. All works as it should.

    https://parts.ilmor.com/?post_type=product&s=alternator

    Leave a comment:


  • Wakejunkie
    replied
    2019 X-Star Ballast Fill Alternator Replacement

    Originally posted by Mystic3D View Post
    That makes a lot of sense, there is a low voltage alarm on mine, and it's Fast Fill
    Do you run into the same low voltage issues on non-fast fill?
    if you get more info, let us know, I would be inclined to do it for $500-$600.

    Here is the Maine Mechman - Not sure about bolt pattern and pulley size, will need to take a look when I get the boat back
    https://www.mechman.com/high-output-...10DN-10SI-12SI

    I haven’t seen any alarm yet. I think the fast fill boats have a rpm warning too. Mine doesn’t have that one but I’m sure a low voltage just hasn’t gotten low enough to trigger it. I do have some bigger ballast pumps installed and they drop the voltage when on so I’m looking into this alternator to pickup the voltage and amperage for what I need. The system will only use what it needs nothing else so I’m not sure why there would be any ecu stuff besides removing warnings.

    I reviewed my 5000 (5.7) engine picture and the alternator is down low away from filter and opposite side of sensor. I don’t see it being any issue. I’m guessing with your star it’s either 6.2 or 7.4 which would be different than mine.

    Leave a comment:

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