Lewmar Pro-Sport Motor Replacement

[Robert]

Our windlass failed to deploy the other day on our 2025 R23. The windlass has only been used several times and we are freshwater boaters. Trouble shooting with Lewmar technical support we confirmed the contactor is functioning properly. 13 volts at the incoming power terminals and 13 volts leaving the contactor when rocker switch is pressed. This was quite the process going through the dashboard.

Has anyone replaced the motor on a Pro-Sport windlass? Is this something we can perform? It appears the motor wiring terminations are embedded and the wiring below the windlass will require splicing for a motor replacement.

I did observe moisture inside the motor housing and minor corrosion around the perimeter of the motor. Lewmar indicated lack of use could have led to the premature failure of the motor. Lewmar also recommended a thin bead of 4200 be applied on the housings when reassembled.

Any guidance would be appreciated.
Thanks
Bob

 

[sgeary]

Confirm the wiring to the motor is properly attached. If the chain has ever stacked to the motor, it may have affected the wiring. The wires can even look attached properly, but make sure they are tightened. This happened to us and we suspected the motor had failed, but it was a loose wire at the motor. Worth a check before buying a new motor.

 

[NorthernFocus]

Our windlass failed to deploy the other day on our 2025 R23. The windlass has only been used several times and we are freshwater boaters. Trouble shooting with Lewmar technical support we confirmed the contactor is functioning properly. 13 volts at the incoming power terminals and 13 volts leaving the contactor when rocker switch is pressed. This was quite the process going through the dashboard.

Has anyone replaced the motor on a Pro-Sport windlass? Is this something we can perform? It appears the motor wiring terminations are embedded and the wiring below the windlass will require splicing for a motor replacement.

I did observe moisture inside the motor housing and minor corrosion around the perimeter of the motor. Lewmar indicated lack of use could have led to the premature failure of the motor. Lewmar also recommended a thin bead of 4200 be applied on the housings when reassembled.

Any guidance would be appreciated.
Thanks
Bob

I've replaced the motor and had to do a couple of other repairs. If you've got basic mechanical skills and can splice the wires it's doable. Water in Lewmar windlasses is a fact of life. People think they leak but no matter how well you seal them they will still get condensation inside the windlass simply due to day/night cooling cycle. When you reassemble it you should coat all of the gears generously with grease. Also don't seal the split line along the bottom so that condensation can drain out.

 

[4umfreak]

I'd suggest a custom sunbrella cover if you can manage it! That should help with condensation and keep some rain out.

I need to do maintenance on my lewmar but keep it covered when no in use.

 

[Robert]

Thanks for the comments. I will give it a go. We might have to look into the Sunbrella cover. I have seen some post on here about Fluid Film for corrosion protection. Perhaps spraying inside the motor housing when reassembling?

 

[4umfreak]

Thanks for the comments. I will give it a go. We might have to look into the Sunbrella cover. I have seen some post on here about Fluid Film for corrosion protection. Perhaps spraying inside the motor housing when reassembling?

Never heard of it! Goes to look...

 

[Tows in the sand]

I've replaced the motor and had to do a couple of other repairs. If you've got basic mechanical skills and can splice the wires it's doable. Water in Lewmar windlasses is a fact of life. People think they leak but no matter how well you seal them they will still get condensation inside the windlass simply due to day/night cooling cycle. When you reassemble it you should coat all of the gears generously with grease. Also don't seal the split line along the bottom so that condensation can drain out.

Just did mine on our 2025 R25. Like Dan said, it's doable but not all that fun. A mirror helps. I removed ALL of the electrical tape and snipped the wires at the connectors. Make sure you use the heat shrink type connectors on it. Lewmar should warrenty the motor and ship it to you for free.

 

[Robert]

Just did mine on our 2025 R25. Like Dan said, it's doable but not all that fun. A mirror helps. I removed ALL of the electrical tape and snipped the wires at the connectors. Make sure you use the heat shrink type connectors on it. Lewmar should warrenty the motor and ship it to you for free.

Thanks Pam & Phil. I'm getting ready to order the new motor. Do you know of any cause for the motor failure or was it lack of use as suggested by Lewmar?

 

[localboy808]

I rebuilt ours on our C-Dory two years ago. Ours is a Lewmar Pro Series. New motor and all seals etc. Pretty basic. I did a lot of extra sealing with Life Seal because the motor had rusted out. This included where the motor wires entered the housing and the two housing halves, depending on model year. Ours is ~20 years old and a "gen 1" so there's no seal located there and water enters. I recommend replacing all the shaft seals too, since you will have it all apart.

A good protective spray is BoeShield created by Boeing. It dries to a waxy film and does not adversely affect wiring, electrical connectors, plastic, even rubber. Greats stuff. I go to town with it all over my outboard engine under the cowling.