1971 Johnson 85 HP not charging

[MWatts9728]

I got a problem that seems a little mysterious to me. I bought the boat 3 years ago knowing it needed work but I needed a cheap fishing boat for a inshore fix. It?s a 1973 crestliner 17? Buccaneer with a 1971 Johnson 85ESL71A 85 horsepower outboard. The motor runs great and can fish all day on as long as both batteries are charged and we head back in after we run down the first. But I?m sick of heading back early. I replaced the old rectifier after seeing AC voltage months ago. Even though I?m getting DC voltage now it?s just running off the batteries. So today I pulled the stator out and bench tested it. According to the manual it works just fine. Tester with infinite resistance between the yellow wire against the metal frame on low ohm scale. Then tested 0.6 ohms between the yellow wire against the yellow with a gray stripe wire on a high ohm scale. I think the rectifier tested okay as well with resistance on each wire in one direction against ground and infinite resistance in the opposite direction. Double checked the wiring against a wiring schematic all the yellow wires meeting on the 1[SUP]st[/SUP] and 2[SUP]nd[/SUP] lugs with a metal jumper tying them together on the distribution block. And all the yellow/gray stripe wires meet on the 3[SUP]rd[/SUP] and 4[SUP]th[/SUP] lugs with a separate metal strap. And the red wiring from the rectifier meets only one other red wire on lug number five I believe. The diode and lead assembly has a green with a purple strip I believe the meets another wire of the same color the the 10[SUP]th[/SUP] lug. We tested that diode the in the same as the rectifier using the green/purple stripe wire as ground. And it showed some continuity in one direction on both wires but none in the opposite direction. I figure its time to ask for help before I start throwing parts.
As I see it there are two likely possibilities that remain: first is one of both The clipper assembly (A voltage regulator I think) is bad. And/or the diode & lead assembly is bad. As this lead doesn?t truly have a ground it can?t be tested in the same manner. But I believe this diode has more to do with the electric shift function as it ultimately ties to the remote for the drive. Do you have any other ideas? Is there something we could have done differently? Is there any way of testing the clipper assembly? And is clipper assembly just a fancy name for a voltage regulator?

 

[racerone]

The clipper is part of the ignition circuit.----It is not a voltage regulator for the charging system.

 

[gm280]

MWatt, seems you have a good idea how your engine works and tested some of the electrical components as well. And that is a good thing seeing how many electrical parts are now obsolete. So make absolutely sure the part you are wanting to change is indeed bad. A great way to help identify those parts being good or bad is to buy the manufacturer's year, HP, model specific shop manual for your engine. That shop manual will cover every part and how to verify good or bad. Well worth the money in my book. They do specify so much about how to test parts that it will surely allow you to determine good parts and bad. Then use the net and EBay for either verified used parts or NOS parts to replace your bad ones. JMHO!

 

[MWatts9728]

Okay now I'm dieing to know. What does the clipper circut do? If it is not involved with the charging system I won't worry about it.
I understand the diode and lead assembly serves a failsafe function for the electric shift preventing it from kicking into drive when the ingnition is shut off.

As for a manual I agree the manufactures books are hands down the best. I've been given a book for a 1968 Evinrude equivlant model, equalivlant horspower. I know its not a perfect senerio but the price was right.

And if the stator tested okay, the rectifier tested okay all my known electrical connections have been cleaned.
1. But it still not charging what would you do?
2. If I get the stator rewrapped can I get it upgrade to produce a few extra amps for a big sceen TV, and perhaps even some central air?
3. Do you think a proper manual is gonna be that different?

 

[tblshur]

I'm going out on a limb here because I'm no expert but my 83 140 clipper was the voltage reg . I disconnected it then my battery would charge but the voltage will sometimes go to 16 v, so I got a combination regulator rectifier $70 bucks from cdi so far it works fine. It looks just like the rectifier . 13volts+ hope this helps :joyous:

 

[MWatts9728]

I ordered the correct manual and the regulator/rectifier this morning. And I'm thinking of rewinding my stator.

 

[racerone]

There was no " clipper circuit " on the 83 models.------The clipper on the motor in question prevents high voltage to the amplifier.----The clipper on the motor in question is NOT part of the charging circuit.