Burned wires?

[j442w30]

I've got a 1993 40hp Mercury (Serial - OD152581) and I think my voltage regulator is shot. Last year I had to replace the rectifier because some of the plastic around the terminals had melted slightly. I took a look at the engine this weekend and I noticed the two yellow wires that come down from the stator were slightly burned at the bullet connectors. Also when I was running the boat this summer I thought the voltage meter was showing higher than normal voltage.

So my guess is a bad voltage regulator. But in my electrical box I see the oil module, the rectifier, the switch box, the starter solenoid, the coils and the power trim relays but not the voltage regulator. There is a rectangular box with three wires behind the switch box and I'm not totally sure what it is. It doesn't really look like the voltage regulator in the parts diagram on Mercury Parts Express.

Anybody got any ideas?

Thanks

 

[Laddies]

Re: Burned wires?

Your regulator is combined with the rectifier if it has 5 wires a straight rectifier has only 1 red,2 yellow and 1 gray wire have you made sure the connections are clean and tight at the plugs

 

[j442w30]

Re: Burned wires?

I looked at the parts diagram on Mercury Parts Express and it describes the 5 wire regulator as "design 2." I do not think I have this unless it is buried underneath the power trim relays. I have the straight rectifier with the 2 yellow, 1 gray, and I think a red wire. What else regulates the voltage?

I will not be able to take a look at the engine for a week or two so I was just trying to get some ideas. When I go home hopefully I can snap some pictures so I can help you guys out a bit.

Thanks Laddies

 

[Laddies]

Re: Burned wires?

With a rectifier system the only thing that controls voltage is the battery, meaning capacity,amount of charge and condition of the connections. So if the system is working at WOT most will put out 16 to 18 volts on a small capacity battery whats why you hear people talking about converting to a regulator as the system is spiking the accessories on the boat

 

[j442w30]

Re: Burned wires?

The battery is an automotive starting battery with I'm guessing a pretty good capacity. It came out of my Dad's Land Cruiser, its less than a year old. The connections seemed good and tight all season, the battery cables could use some work though, I'll start with that.

Is it hard to convert to a voltage regulator setup? My main concern is the burned wires and possible damage to other electrical components.