Rectifier-regulator 4 wire, can I use a 5 or 6 wire???

[Force39]

Hi, I have a 1995 Force 70hp outboard. I read open (2.8 megohms) across the 2 yellow wires from the regulator/rectifier. Believe it to be bad since it won't charge the battery. Stator ohms looked good. Mine ( 815279-2 ) has 4 wires, 2 yellows a red and a gray. Can I use a 5 or 6 wire reg/rect to replace it? Do I just tape up the extra wires?? Thanks!

 

[Redbarron%%]

Many rectifier/regulators are available and might work for you.
I have used one that was a three phase (three wire to the stator) and used two of them.
This worked for me and actually had a better regulator that limited the voltage better than the one for the force that I had and had a large heat sink that dissipated heat better.
Many are MOSFET that work better. BUT you may have a problem with just how much current they can draw from the stator and might cause you a problem with that, I can't be certain about that issue.
I did use one off a motorcycle and it worked, but I did replace it and the engine seemed to run smoother, but I would have to try that again to be able to say for sure.
Will one work? Yes it will you will be only using 1/3 of the rectifiers in the unit and they will regulate the output as well.

 

[kumoparris]

Hi, I have a 1995 Force 70hp outboard. I read open (2.8 megohms) across the 2 yellow wires from the regulator/rectifier. Believe it to be bad since it won't charge the battery. Stator ohms looked good. Mine ( 815279-2 ) has 4 wires, 2 yellows a red and a gray. Can I use a 5 or 6 wire reg/rect to replace it? Do I just tape up the extra wires?? Thanks!

I am in the same situation. In my research, the replacement for mine is a fine wire. Hoping to see more replies.

 

[kumoparris]

I am in the same situation. In my research, the replacement for mine is a fine wire. Hoping to see more replies.

That should have been a five wire.

 

[Redbarron%%]

OK the gray wire to the tach can be just tapped into one of the yellow (?) wires that provides the AC power to the rectifier/regulator. so this takes care of 3 of the wires ( 2 yellow and one gray ) One black ground and a red power out. for a total of 5. The sixth wire on the 3 phase regulator would be another power input to the rectifier bridge.
So - 3 power wires from the stator
ground.
Power out
Probably no tach wire
There may be several other wires and you need to look up the application they are made for to be sure how to hook them up.
MOSFET are the new standard. I think that MOSFET rectifier/ regulators are now made to fit the old Force/Merc.

 

[jerryjerry05]

Why not get the right one??

 

[Redbarron%%]

Why not get the right one??

There is that.
He asked if he could use something different and maybe he can.
Sometimes you install different problems when you use something other that the correct unit.
I think that the MOSFET unit used may have caused a little problem with my Sport Jet 90, but I would have to try it again before I am certain.

 

[Force39]

Many rectifier/regulators are available and might work for you.
I have used one that was a three phase (three wire to the stator) and used two of them.
This worked for me and actually had a better regulator that limited the voltage better than the one for the force that I had and had a large heat sink that dissipated heat better.
Many are MOSFET that work better. BUT you may have a problem with just how much current they can draw from the stator and might cause you a problem with that, I can't be certain about that issue.
I did use one off a motorcycle and it worked, but I did replace it and the engine seemed to run smoother, but I would have to try that again to be able to say for sure.
Will one work? Yes it will you will be only using 1/3 of the rectifiers in the unit and they will regulate the output as well.

I believe the red wire is going to the positive of the battery. I just don't understand when there are 2 red wires?? If a 5 or 6 wire one would work, they are about $25. I did find a 4 wire one, but it is $150. Thanks for the help, much appreciated!

 

[Force39]

That should have been a five wire.

So your is a 4 wire, but the replacement is 5 wire? I have seen some 5 wire ones with one being the ground. I'm guessing it would work. Mine the case is the ground. If the replacement one isn't case grounded, we might have to ground that 5th black wire.

 

[Force39]

There is that.
He asked if he could use something different and maybe he can.
Sometimes you install different problems when you use something other that the correct unit.
I think that the MOSFET unit used may have caused a little problem with my Sport Jet 90, but I would have to try it again before I am certain.

Update, got a new 5 wire rectifier/regulator. Ohms check across the yellow wires is 3 megohms?? The one I suspected bad was 2.8 megohms. I had notes saying it should be around 90 ohms?? Bad notes?? Does anyone know what ohms a good one should show?? Thanks

 

[Redbarron%%]

CDI has troubleshooting information for most outboards available on line.

https://www.cdielectronics.com/wp-content/uploads/2013/02/CDI%20Troubleshooting%20Guide%20-%202012.pdf

 

[Force39]

CDI has troubleshooting information for most outboards available on line.

https://www.cdielectronics.com/wp-content/uploads/2013/02/CDI%20Troubleshooting%20Guide%20-%202012.pdf

Good troubleshooting guide! Thanks Redbarron!

 

[Nordin]

As the rectifire/regulator contains a diod bridge (1, or 3 phase) and 1, or 2 zener diods it is hard to measure resistance to check if it is bad or not.
It is depending on which test lead you connect to which terminal at the rectifire/regulator.
The diod brigde rectifies the AC current into DC current and the zener diod grounds out the voltage when it reach the zener voltage (zener diods has different zener voltage when it starts to open the gate and ground out the voltage. In this application it should be about 14-16V).
If you have a a VOM with diod measurement you can try to check with that.
The diod bridge should have about 0,6VDC in one way and infinity in the other way. (switching positive and negative test leads).

 

[Force39]

Thanks to all for your help! I did the diode check on the new rectifier/regulator and saw the change when the test leads were swapped. Did the same check at the boat on my rec/reg and did not see any change when leads were swapped. Installed the new rec/reg and now seeing 13.6vdc at the battery terminals increasing to 14.5 vdc as I revved the motor. Also, mine had been a 4 wire and the new one was a 5. Only difference was a ground wire which I didn't need since mine is case/frame grounded. Just taped it up. Here's a link to the one that I bought. Thanks again Gang!!

Commercial navigation Replacement for Regulator Rectifier Voltage Mercury Mariner Outboard 5 Wires 25 to 250 HP Replace 815279-1 815279-2 815279-3 815279-4 815279-5 65W-81960-00-00 65W-81960-10-00
Sold by: Commercial navigation
Return eligible through Oct 3, 2021
$23.90
Condition: New

 

[Redbarron%%]

Ground the black wire anyway as corrosion might build up over time. Find a likely ground screw, preferably where other grounds are connected.

 

[rk970]

4 wire regulator grounds through the case
5 wire has a dedicated ground wire
6 wire has a "sense" for voltage that can be connected to the battery (or fuse bus bar) directly or combined with the red charge wire.
Otherwise they all will function just fine.

 

[beepx2]

Thanks to all for your help! I did the diode check on the new rectifier/regulator and saw the change when the test leads were swapped. Did the same check at the boat on my rec/reg and did not see any change when leads were swapped. Installed the new rec/reg and now seeing 13.6vdc at the battery terminals increasing to 14.5 vdc as I revved the motor. Also, mine had been a 4 wire and the new one was a 5. Only difference was a ground wire which I didn't need since mine is case/frame grounded. Just taped it up. Here's a link to the one that I bought. Thanks again Gang!!

Commercial navigation Replacement for Regulator Rectifier Voltage Mercury Mariner Outboard 5 Wires 25 to 250 HP Replace 815279-1 815279-2 815279-3 815279-4 815279-5 65W-81960-00-00 65W-81960-10-00
Sold by: Commercial navigation
Return eligible through Oct 3, 2021
$23.90
Condition: New

Thank you SO much for posting this. I've spend an hour trying to research and figure this out, 5, 6 wire, etc. I just ordered one of the above. Good on ya!