replaced rectifier and it still is not charging.

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Pokertrampp

Petty Officer 1st Class
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Sep 17, 2009
Messages
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Re: replaced rectifier and it still is not charging.

What are the chances that the new stator was faulty???? Just not sure what to check next.......
 
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wilde1j

Vice Admiral
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Apr 15, 2002
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5,964
Re: replaced rectifier and it still is not charging.

Extremely unlikely ... CDI makes good stuff.
 
7

71 seascow

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Jul 12, 2010
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Re: replaced rectifier and it still is not charging.

hey guys, sounds like i have the same issue with my motor. its a 1994 120hp v4, my tach cuts out intermitantly all day long. i put a voltmeter right at the battery an its seems i get 12.6volts at idle and when i up the throttle it jumped to 13.8v then back to 12.6 and the tach was still reading?? i've never had any problems with the battery its starts fast and strong every time and the volt gauge never drops below 12v but i suspect the regulator is the culprit. i bypassed the grey wire right from the reg unit up to tach and it is the same issue, the tach is new. does this sound like i could be on the right track?
 
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mamm7215

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Messages
184
Re: replaced rectifier and it still is not charging.

Really sounds like a broken wire/corrosion issue. If components are good, not much else it can be...
 
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Pokertrampp

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Re: replaced rectifier and it still is not charging.

71 seascow said:
hey guys, sounds like i have the same issue with my motor. its a 1994 120hp v4, my tach cuts out intermitantly all day long. i put a voltmeter right at the battery an its seems i get 12.6volts at idle and when i up the throttle it jumped to 13.8v then back to 12.6 and the tach was still reading?? i've never had any problems with the battery its starts fast and strong every time and the volt gauge never drops below 12v but i suspect the regulator is the culprit. i bypassed the grey wire right from the reg unit up to tach and it is the same issue, the tach is new. does this sound like i could be on the right track?
Click to expand...

This sounds nothing like the issue being discussed... You may get a better response if you start a new thread.
 
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Pokertrampp

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Re: replaced rectifier and it still is not charging.

mamm7215 said:
Really sounds like a broken wire/corrosion issue. If components are good, not much else it can be...
Click to expand...

I am thinking the same thing, but have yet to find a broken wire/corrosion issue... But I am still looking. I feel it is staring me in the face and I just don?t see it.
 
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mamm7215

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Re: replaced rectifier and it still is not charging.

The problem may be it's staring at you from behind the wire coating. Corrosion will creep several inches up the inside of the pvc wire coating over time so even if you clean the connectors or ring terminals, no signal/current will pass if it's corroded too far up or even broken. Again, with the motor running and the red rectifier wire disconnected from the terminal strip, do you get ANY voltage on that red wire? If so, you likely need to replace the red wire from the terminal strip to the starter solenoid...or work back through the little rubber connectors that connect the rectifier to the stator. If you have 12-13ish volts at the rectifier running, you're almost there...
 
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Pokertrampp

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Re: replaced rectifier and it still is not charging.

The red wire is connected to the far portside terminal on the terminal block (Terminal #1), which has a red wire going to a harness then that red wire goes to the hot post on the solenoid so it is always hot (12v) that is how I found it when I started working on this. Would this make a difference if it went straight to the solenoid? I verified the 12 volts with a meter, The voltage is the same whether the motor is running or not.

I can tell you that the engine has a constant "Pop" type mis throughout the rpm range, and at times (mostly at any rpm above idle) it will act like someone reached in and turned the key off and back on again real fast. it is strange, and I have not been able to do anything to make it happen, but when it does happen if it causes the engine to stall it takes a very long time to restart. I was convinced it was an electical/Ignition issue but i am unsure at this point if it is electrical or fuel related.

I thought the 2 problems may have been related because neither issue changes no matter what I have done, but now I have no idea.

I am aware the corrosion can be hidden under insulation but I do not know where to start looking, I am considering buying a new harness but I feel that may just be a waste of time and money as well. I guess I just need a starting point......
 
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mamm7215

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Re: replaced rectifier and it still is not charging.

Pokertrampp said:
The red wire is connected to the far portside terminal on the terminal block (Terminal #1), which has a red wire going to a harness then that red wire goes to the hot post on the solenoid so it is always hot (12v) that is how I found it when I started working on this.
Click to expand...

Right but what I meant was disconnect the rectifier red lead from the terminal strip on the starboard side (on my 81 90hp anyways) so the red rectifier lead is just hanging in air. Run motor and measure voltage. The rectifier is taking the AC from the stator and converting it to DC (12-14 volts depending on rpm) and feeding that back into the system parallel to the battery (why it connects to the red/battery lead on the solenoid) to charge the system. That's why if you have 12v on the red lead by itself, the rectifier IS working, onto other troubleshooting. What you just said above also may indicate a faulty iginition switch. Or bad/broken connection with the safety lanyard switch. That's the black/yellow wire in the control box. With no safety lanyard pushed in, the switch is made and the wire is grounded, grounding the whole system, killing the engine. Off position on the keyswitch does the same thing. Intermittent fault on this will give you the same symptoms you describe. You can test by snipping the wire going into the safety switch (leave enough to splice later if you want this feature again). You could also just get another keyswitch, which is what I would tend to do. But that's me. It's only money, I'll just go make more...

I don't know if any of this would have any effect on the charging system, but you could have more than 1 problem here as well.

edit: I retracted my advice to remove black/yellow from keyswitch as it would remove ability to shut off motor from switch. To test this I would likely just get another switch.
 
RobbyA

RobbyA

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Jun 5, 2010
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Re: replaced rectifier and it still is not charging.

I have exactly the same thing going on here! No tach and motor misses.
 
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mamm7215

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Apr 28, 2010
Messages
184
Re: replaced rectifier and it still is not charging.

You need an OEM manual for starters. Then search this forum for "tach" and you'll find a good week's reading. No tach can be stator, tach, wiring. Motor missing can be stator, timer base, fuel/carb issues, battery, wiring/connectors, sync out, etc...again, a search on "motor missing" will get you started...
 
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clemsonfor

Lieutenant Junior Grade
Joined
Sep 19, 2005
Messages
1,011
Re: replaced rectifier and it still is not charging.

Pokertrampp said:
The red wire is connected to the far portside terminal on the terminal block (Terminal #1), which has a red wire going to a harness then that red wire goes to the hot post on the solenoid so it is always hot (12v) that is how I found it when I started working on this. Would this make a difference if it went straight to the solenoid? I verified the 12 volts with a meter, The voltage is the same whether the motor is running or not.

I can tell you that the engine has a constant "Pop" type mis throughout the rpm range, and at times (mostly at any rpm above idle) it will act like someone reached in and turned the key off and back on again real fast. it is strange, and I have not been able to do anything to make it happen, but when it does happen if it causes the engine to stall it takes a very long time to restart. I was convinced it was an electical/Ignition issue but i am unsure at this point if it is electrical or fuel related.

I thought the 2 problems may have been related because neither issue changes no matter what I have done, but now I have no idea.

I am aware the corrosion can be hidden under insulation but I do not know where to start looking, I am considering buying a new harness but I feel that may just be a waste of time and money as well. I guess I just need a starting point......
Click to expand...

i did not think my harness was bad till i cut on wire to replace a terminal and started stripping the wire and it was rotted, cut another and it was to . The New harness from CDI was some of the best $100 i spent. It also corrected the coke that was disconnected by someone b/c the wiere was not known by previous owner or it was rotted i cant remember, i use to have to manually choke it to start it.
 
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Pokertrampp

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279
Re: replaced rectifier and it still is not charging.

Well I found a slightly corroded wire on the power pack, it is the black ground wire coming out of the pack. I was going to splice a new piece of wire to it but the corrosion goes all the way to the pack if not into it it is hard to tell. so... I am wondering if this could be the cause of my mis, so far it is the only thing I have found that looks out of place. I dont really want to just start changing parts just to see how much money I can dump into it. :confused:
 
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Pokertrampp

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Messages
279
Re: replaced rectifier and it still is not charging.

Is there an easy way to check the harness (without removing it), to see if that is in fact the problem?
 
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Pokertrampp

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Re: replaced rectifier and it still is not charging.

I spoke to a mechanic a a local marine shop, and he swears both problem sre caused by a bad power pack. does anyone agree. I mentioned that I was informed that the charging system was not part of the power pack and he disagreed. also, I mentioned doing the test previously mentioned, taking the red wire off and look at voltage and if I understood correctly, he said the red wire is where the rectifier gets its power not sends the increased voltage, but I may have misunderstood that part.
 
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lmuss53

Lieutenant Junior Grade
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Sep 9, 2008
Messages
1,227
Re: replaced rectifier and it still is not charging.

pokertrampp check your PM's, I cant help with your troubleshooting but I may be able to buy some of your extra parts to help fix my problems. Look at the top of the page right under the ad for the PM clicky.

I don't have the book in front of me but I think the red wire from rec. to solenoid carries the charge back to the battery.
 
Vic.S

Vic.S

Rear Admiral
Joined
May 4, 2004
Messages
4,718
Re: replaced rectifier and it still is not charging.

The red wire is the DC output from the rectifier

The yellow wires are the AC input the rectifier
 
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Pokertrampp

Petty Officer 1st Class
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Sep 17, 2009
Messages
279
Re: replaced rectifier and it still is not charging.

Any thoughts on whether or not the power pack could be the cause? I don?t want to spend $200+ if the consensus is that it could not be the problem? I will post some pics of the problem wire tonight if possible.
 
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