2003 Mercury 40 hp EFI 3 cylinder. Voltage Regulator melt down

RandyJ

Master Chief Petty Officer
Joined
Jun 13, 2002
Messages
808
I can't tell what really happened but I just caught it right on time. I pulled the cowl off to check oil with the intent to change oil and filter. I heard a fizzle... looked at wiring harness to voltage regulator. The yellow wires got hot and melted the outer black cover. It looks like the blue wire to the oil pressure switch was squeezed tightly in between the two fittings on the fuel pump and may have shorted. all the wires at the voltage regulator melted and the side of the regulator against the block totally melted out. My question is whether I have to worry about anything else such as a stator or what do you suggest I do to prevent this happening again? Everything will be safely routed and I'll put heat shrink on the naked part of wire to the oil sender. I'm not sure how to figure out if something else caused this to overheat. I sure don't want to take that gamble.
 
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