Really, really bad discovery today

[KRS62]

I took my cover off today to fill the motor with oil and discovered this. It appears as if there was a small fire under the cowl. (It's a 2003 Merc 50hp 2 stroke.) I have no idea if this was a random problem and happened the last time I went out or caused by the on-board charger. It looks like it started at the voltage regulator.

The last time I went out in the boat, the main battery died when we were at our duck hunting spot. I went to start it up and it would only crank over a few times. (I hadn't charged the battery fully, but it started fine in the morning and expected it to charge enough on the boat ride out.) To get home, I moved the trolling motor battery back to use it. When I cranked it, the battery sparked and smoked a little at the terminals. I thought the spark might have come from loose connection, but the terminals seemed tight, so I disconnected the accessory wires from the battery just in case. I only had the motor wires connected. It started fine and ran perfectly for the 30 minute boat ride home. Tilt worked fine.

One thought is that I crossed wired it somehow, but I really doubt it. The wires are positioned where it would be hard to do. It didn't spark until I cranked it.

At no point did I ever smell anything in the garage. I was thinking that if there was a charger issue, it would have caused a smell in the garage.

Has anyone experienced this problem? I am obviously concerned that this is going to be a huge bill. I suspect 90% if the wiring in the motor will need to be replaced, the voltage regulator and rev limiter at a minimum.

I plan to take it in tomorrow, but please let me know if you have seen this before and what it took to fix it.

thanks!

KRS

 

[mikethepike]

Re: Really, really bad discovery today

I had the same thing happen to me last fall to the 6 or 7 wires above the postive red boot going to the box (voltage regulator.?) ........I had noticed the battery wasnt charging, so when took the cover off, i discovered it.

I changed all the fuses in the boat , replaced all the bad wiring and now all is well. Mine was burned , but not quite as bad as yours . I have since taken it out on the lake (last week in Lk Erie) and ran the **** out of it . Its seems to be fine and its charging, tac works ...i'm hoping that we fixed it. Otherwise, the mother better burn to a crisp , because i have full coverage.

I did notice all the wires bundled really tight, i dont know if friction wore them and arced to start the electrical fire or not.

 

[dunc333]

Re: Really, really bad discovery today

your rectifer has gone up in flames,there was a safety alert bulliten issued a few years back in australia and probably in usa,check your serial# against the recall bulliten and let us know if your motor was in the list.all merc did in aus was to put a inline fuse between the rectfier and the stator,cheers dunc 333

 

[1nebel0]

Re: Really, really bad discovery today

You can buy the harnesses all day long on Ebay....just need some knowledge and manual..Beats paying our shop rate in California of $125hr.......

 

[Faztbullet]

Re: Really, really bad discovery today

Depending on your deductable I would submit it to insurance company. From the pictures posted you need: internal and remote wiring harness, rev limit module, rect/reg, neg battery cable, possible trim harness and solenoids, starter solenoid, engine cleaning to remove soot, carbs cleaned to remove soot from throats, sound blanket for cowl. Parts and labor are a easy $1500+

 

[KRS62]

Re: Really, really bad discovery today

I don't have insurance on this boat, but maybe I should look into it again? (I had it on my last boat.) I felt that my current boat is probably "not worth" covering. If it would have covered something like this, then I guess it would be! I had no idea that there is a possibility that they would cover repairs. Why would they? Is it the possibility that it was caused due to a possible electrical/charger issue?

KRS

 

[mikethepike]

Re: Really, really bad discovery today

You can buy the harnesses all day long on Ebay....just need some knowledge and manual..Beats paying our shop rate in California of $125hr.......

so what is this harness called a in-line rectifer / rectifier harness. Do you have a link???

 

[RadarRick]

Re: Really, really bad discovery today

KRS, were you able to figure out when this happened? I keep looking at those photos and there must have been some serious smoke & smell. It was fortunate that it didn't ignite the fuel system.

Was there a main battery switch? Would the rectifier spontaneously ignite on its own or was there power to it?

Good luck with repairs or ??

 

[KRS62]

Re: Really, really bad discovery today

KRS, were you able to figure out when this happened? I keep looking at those photos and there must have been some serious smoke & smell. It was fortunate that it didn't ignite the fuel system.

Was there a main battery switch? Would the rectifier spontaneously ignite on its own or was there power to it?

Good luck with repairs or ??

No idea yet. I need to head down to the shop and speak to the mechanic. For a complete repair (like it never happened) I am looking at $1K. He said that if I can live with some parts that just have visual damage, I could save some $$. I will find out tomorrow.

Yes, the fact that NEVER smelled anything leads me to believe it happend while running. Either way, it's strange. I have a battery switch, but it's just that....a switch, not breaker. My biggest fear is to fix it....only to have it happen again!!!