Evinrude Charging Problem

[Steve22]

Hi, I have a 1989 Evinrude 60HP Outboard. I replaced the battery earlier this season but I think I have a charging problem. I only get 12 volts at the battery when the engine's running. Should it put out over 13 volts like a car?
I hear many issues are with the rectifier. Where's the rectifier located? how do I recognize it? how can I test it?

Thanks!!

 

[Joe Reeves]

Re: Evinrude Charging Problem

(Small Rectifier Description & Location)
(J. Reeves)

On most 2,3,4,6 cylinder engines, the small rectifier is located on the starboard (right) side of the engine just in front of the engines electrical wiring strip. There are a few older V4 engines that have the wiring strip on the rear portion of the engine and the rectifier would be located just under that terminal strip. The smaller horsepower engines usually have the rectifier located on the starboard side of the powerhead close to the carburetor area.

The rectifier appears to be a round object approximately one inch (1") in diameter and also about one inch (1") high. The base of it is sort of triangular in appearance and is attached to the engine with two (2) screws/bolts..... usually one screw/bolt is larger than the other. The rectifier, depending on which one your engine uses, will have either:

One Red wire, one Yellow wire, and one Yellow/Gray wire, or One Red wire, and two Yellow wires.

Note that either of the above rectifiers could have a fourth wire which would be Yellow/Blue

Thousands of parts in my remaining stock. Not able to list them all. Let me know what you need and I'll look it up for you. Visit my eBay auction at:

http://shop.ebay.com/Joe_OMC32/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1
********************
(Small Rectifier Test)
(J. Reeves)

Remove the rectifier wires from the terminal block. Using a ohm meter, connect the black lead of the ohm meter to the rectifier base (ground), then one by one, connect the red lead of the ohm meter to the yellow, yellow/gray, then the red wire (some rectifiers may also have a fourth yellow/blue wire. If so connect to that also). Now, reverse the ohm meter leads and check those same wires again. You should get a reading in one direction, and none at all in the other direction.

Now, connect the black lead of the ohm meter to the red wire. One by one, connect the red lead of the ohm meter to the yellow, yellow/gray, and if present, the yellow/blue wire. Then reverse the leads, checking the wires again. Once more, you should get a reading in one direction and none in the other.

Note that the reading obtained from the red rectifier wire will be lower then what is obtained from the other wires.

Any deviation from the "Reading", "No Reading" as above indicates a faulty rectifier. Note that a rectifier will not tolerate reverse polarity. Simply touching the battery with the cables in the reverse order or hooking up a battery charger backwards will blow the diodes in the rectifier assy immediately.

Thousands of parts in my remaining stock. Not able to list them all. Let me know what you need and I'll look it up for you. Visit my eBay auction at:

http://shop.ebay.com/Joe_OMC32/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

 

[Steve22]

Re: Evinrude Charging Problem

Thanks Joe!!, I'll check the rectifier tonight.

Can you tell me the part # for a new one? Can I buy one from you? Price?

 

[Vic.S]

Re: Evinrude Charging Problem

Your rectifier is the round non regulated type that Joe describes . It is only the three wire type .... no yellow blue wire.

You have checked that the volts measured at the battery does not rise once the engine is running at a good speed.

However 12 volts is pretty low and indicates that the battery is in need of charging.

Charge it before going any further.
It should read at least 12.6 volts, preferably 12.7, or even a tad more, after resting for 12 hours with no charge or discharge.

Now with a properly charged battery check what sort of reading you get between ground and the red wire from the rectifier. As the revs increase you should see the volts rise well above the battery volts. You need at least 13.8 volts to give any reasonable charging.

If you dont see this then either the rectifier is blown or the stator coil is defective.

Disconnect the rectifier and check it following Joes method BUT if you use a digital meter use one with a diode test setting. Analog meters are OK but digital ones may not work for diode testing on the ohms ranges.

You can also check the stator coil. You should see a fairly low resistance, couple of ohms perhaps, between the yellow and yellow gray wires coming from it.

Connecting the battery with reversed polarity is a good way of blowing rectifiers so take care when you have fitted a new one.

 

[Steve22]

Re: Evinrude Charging Problem

All very helpful info. thanks!!

I'm not sure if my meter has a diode test setting, I'll check it tonight. I must admit I'm not meter expert, generally I use my meter for simple AC/DC voltage and/or continuity. I'll have to experiment with ohms.

I really appreciate your advise.

 

[Vic.S]

Re: Evinrude Charging Problem

The trouble I think with the ohms ranges is that they don't apply a high enough voltage to make the diodes conduct in the forward direction... so you are likely to get a "no reading" even when you should get a reading.

I think my little cheap multimeter will work on its highest ohms range, but it has a diode test setting anyway.

 

[Steve22]

Re: Evinrude Charging Problem

Hi,
I removed the rectifier and the back side was all melted, so I at least need a new rectifier.
The lower screw of the rectifier has a funky design, it threads thru an assembly then two wires attach (with eyelets) and a nut on the back side completely out of sight! I never would have realized this until the nut slide down from behind the asssembly. I have to remove the assembly to be able to see and reattach the wires and the nut, I digress.

My question is, You mention the staor coil. How can I ID the stator coil and test??

Thanks!!

 

[Joe Reeves]

Re: Evinrude Charging Problem

The stator is under the flywheel. A visual check to see if anything is leaking from it, dripping down on the powerhead will do for now. I say this due to the fact that the engine starts and apparently runs okay..... just a charging problem (rectifier).

The ohm readings, testing the rectifier....... you're not concerned about the actual reading, the concern is getting a reading or not. Do the test and let us know what you find. If needed, we'll get into the stator thing later.

 

[Steve22]

Re: Evinrude Charging Problem

Excellent, it sounds like all I need then is the rectifier.

Just curous about the stator, do I have to remove the flywheel in order to see anything dripping on the powerhead? I ask because I don't have a socket large enough along with a puller to remove the flywheel.

I really appreciate your expertise!!

 

[Joe Reeves]

Re: Evinrude Charging Problem

Looking under the flywheel with a good flashlight will do it.

 

[Vic.S]

Re: Evinrude Charging Problem

You could also check the stator coil for continuity.

You should get a low, but measurable, resistance with an ohms meter.

 

[Steve22]

Re: Evinrude Charging Problem

This message goes out to Joe Reeves and Vic.S.

I can't thank you guys enough for your help with my charging problem. I replaced the rectifer and it's now appears to be charging OK.

The details you guys provided were very helpful.

Thanks Very Much!!

Steve