Voltage Regulator/Rectifier Problem??

[Heeler43]

I have a 2001 Mercury 60 HP Bigfoot. It is new to me. The first time out this year the motor ran great for 25 minutes and then died. It would not restart. The next morning the motor started on the first try. The tachometer was not workng and the volt meter did not go above 12 volts even at WOT. I suspect the Volt Reg/Rect. Is there a test I can do to make sure?? Thanks for the help!!

 

[JB]

Re: Voltage Regulator/Rectifier Problem??

I think that your problem is engine electrical, Heeler.<br /><br />I will move this to Mercury Troubles.<br /><br />Good luck.

 

[rickdb1boat]

Re: Voltage Regulator/Rectifier Problem??

I doubt it's your rectifier/regulator causing the original running problem. These only charge your battery and unless your battery was very marginal when you went out, it should run on a fully charged battery longer than that. Start it up at home on the muffs and point a hair dryer at suspect parts and see if it dies right away or soon and you've found your problem.. It does sound like the rectifier/regulator also needs replacing, along with whatever else is wrong. Those motors need all the juice they can get... You have already proved that by no Tach reading and the voltmeter reading not changing when running, that the rectifier is bad.

 

[Heeler43]

Re: Voltage Regulator/Rectifier Problem??

Thanks for the input. I will do that tonight and post the results. I too agree that I may have more than one problem. The first items I will heat are the coils and go from there.

 

[BillP]

Re: Voltage Regulator/Rectifier Problem??

I have an older 50hp 4 stroke Mariner (Merc/Yamaha)and the main harness connector wasn't making good contact when I bought the motor new. It was similar to your problem...stop, not start, start ok, tach, voltage, etc. I fixed it by enlarging the hollow male pins to get better contact. The connector is mounted on the engine block, round in shape and maybe 1.5" dia. It's a 2 minute job to check and another 5 to spread the pins.

 

[Heeler43]

Re: Voltage Regulator/Rectifier Problem??

I discovered 2 yellow wires running from the stator to the rectifier were making contact with the motor. The heat had burned the connectors and I suppose shorted out these 2 wires. I cut out the bad connectors and replaced. The voltage regulator/rectifier and the tach now function properly, however, when I had the boat out tonight Cylinder #2 only fired intermittantly. I could remove the spark plug wire and see no spark. When the boat felt like all 3 cylinders were firing, I could remove the spark plug wire on #2 and see and hear current. Could the burned out wires from the stator have damaged the coil to cylinder #2?? What else could be causing this problem. It did not appear to heat related as sometimes cylinder #2 did not work initially but then worked after a few minutes. It would fire OK for several minutes and then stop again. Any help would be greatly appreciated!!

 

[99tango]

Re: Voltage Regulator/Rectifier Problem??

You are going to need a service manual for the following tests. If you do not have a service manual maybe you can find some info here... http://outboardparts.com/mercury/troubleshooting/troubleshooting11.htm <br /><br />The 1st thing you could do is to swap one of the ignition coils out with the one that was not firing and see if the new one still doesn't fire. If it does not fire just like the old one then obviously the old coil is fine and you need to check the following:<br /><br />Check the stator, trigger, and switchbox (if it has a switchbox).<br />I have only been able to find how to test the switchbox in my service manual but I own a 1999 175 sport jet so my info is different than yours. I had the regulator go out in my boat a few months back and it took out the stator with it...that is common.<br />Try here for parts.... http://www.mercruiserparts.com/selectModels2.asp?type_id=MAR <br /><br />Also try http://www.seilermarine.com/rapair/mercury.htm <br /> <br />The newest part numbers on the trigger is 854512T<br />The newest p/n on the stator is 398-832075A21 for electric start and 398-832074A11 for manual start.<br /><br />I know a salvage yard here in St. Petersburg, FL that has just about everything in stock. Of course the parts are all used but VERY good priced. I bought 2 switchboxes for $65 each that normally cost $189 each new. You can email me at joe "at" tcc.us. If I use the @ symbol I will get spammed so I used "at" in place of @.

 

[Heeler43]

Re: Voltage Regulator/Rectifier Problem??

99Tango,<br />I was in the process of trying to switch the coils around and noticed that the wiring harness to coil #2 did not appear to be making a connection on the black wire (ground I assume) so I pushed the female part out and squeezed together a little with plyers and reconnected the wiring harness to coil #2. I then started the motor and pulled #2 plug wire off and it was firing. I have not had a chance to put back in the water to see if it fires continually or not. I do plan on trying some of the other checks you recommended as well. Thanks for the help. I will post what I find out.

 

[99tango]

Re: Voltage Regulator/Rectifier Problem??

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