Rewiring an old motor

[Gunslingertom]

OK, I have a 62 Evinrude Lark IV, 40 hp with electric shift and it needs completely rewired.
The old wiring is in very poor condition, but it's good enough to use as a reference for a new harness and if all else fails, I do have the diagram from the manual.
Before I take this on, I need to find out if a new harness is available. If not, where can I get the rubber covering for the wires? Also, are new voltage regulators still available and where?
Thanks, Tom

 

[F_R]

Re: Rewiring an old motor

Voltage regulator was part number 377001, superceded by 381538. Still available from Evinrude/Johnson dealers. Be careful of the temptation to use a look-alike automotive regulator. The outboard ones are set to 10 amps max charge rate.

Good luck on the cable.

 

[Gunslingertom]

Re: Rewiring an old motor

Good luck? That doesn't sound good. Is it that complicated?
Thanks for the heads-up on the VR though.

 

[F_R]

Re: Rewiring an old motor

No, I just don't have the answer to your question.

 

[tashasdaddy]

Re: Rewiring an old motor

harness and lower wiring, possible at tcoutboard.com or seawaymarine.com

 

[tashasdaddy]

Re: Rewiring an old motor

sorry sea-way.com

 

[Gunslingertom]

Re: Rewiring an old motor

Well I checked the price of a voltage regulator and it's a hundred bucks. I won't pay that just because it's for a marine application.
So why won't an automotive regulator work? What's the big deal about the 10 amp charge rate? What about a regulator from an old tractor?
Maybe mine is good. How do you test one.
I just figured that since I am going to completely rewire, I'd go ahead with a new voltage regulator too. But at that price, I think not.

 

[F_R]

Re: Rewiring an old motor

You test one by whether it works or not. If it doesn't work, the service manual explains how to troubleshoot the charging system to isolate the problem.

Trying to pull more than 10 amps charge may overheat or burn out the generator. Yes, the regulators are adjustable. Back to the book again. Come to think of it, I'm not sure the service manual tells how to adjust it....I'd have to check on that. There are a few of us old f*rts around that still remember how to service a DC charging circuit, but we are disappearing fast.

 

[Gunslingertom]

Re: Rewiring an old motor

but we are disappearing fast.

That sucks too. I hope someday to achieve "old fart" status. I also hope that there are still youngsters that appreciate the wisdom and experience of old timers. I sure do.
So thanks for the help so far.....................but it still doesn't solve my problem.

 

[Gunslingertom]

Re: Rewiring an old motor

So any other ideas for a regulator? I saw a post where someone used a regulator from a 62 Chevy PU, but I think his OB used an alternator. Would that make a difference?

 

[F_R]

Re: Rewiring an old motor

I have no idea what the chevy has, but to answer your question, it absolutely DOES make a difference whether it is a DC (generator) or AC (alternator) charging system. Two entirely different worlds.

 

[Gunslingertom]

Re: Rewiring an old motor

I know the difference. But output is still DC. My question is, does the voltage regulator care rather it's regulating DC volts from either an alternator or a generator.
BTW, 1963 was the first year for an alternator in a GM car.
Sorry to beat this to death, but I think 100 bucks is insane for something as simple as a mechanical regulator, when one for a passenger car is 12 bucks.
Yesterday when I called my local Evinrude dealer for a price, during my choking he told me that if it floats or flies, be prepared to pay big. That spoke volumes to me.

 

[jameskb2]

Re: Rewiring an old motor

Well,

So far, from my education, I've found that SOME automotive parts will work hee and there, and SOME small engine parts will work here and there!

You can buy a "universal" AC / DC voltage regulator / rectifier for about 20 bucks. They are typically used on small engines found in riding lawn mowers. They are sealed units, rated for 10 to 15 amps most often. I got one from a guy I know that works on lawn and garden equipment.

Many parts are interchangeable from various outboards. Sometimes a little backyard engineering is required to mount it. Outboards have things "crammed" in there to make everything fit compact. For instance, my 60 horse Johnson and 100 horse Johnson (3 cyl and v4 cyl) have interchangeable charging components. The stator and regulator are the same. Years are 70 and 71.

So, with some effort, you can figure out and make things work. BUY A MANUAL for your engine. It's the first best thing to have to figure out wiring and basic operation. (Including charging system type and rating) You really do need to know if that's an AC system or DC system.

JK

 

[Gunslingertom]

Re: Rewiring an old motor

I have the manual. I know my old Lark IV has a generator. Through some late night research, I also know that an external regulator from a 63 or newer GM won't work with a generator. But, I'm thinking that a pre-63 regulator might work. I haven't thought about the lawn and garden angle yet. Thanks.
I used to mess with these old DC systems when I was a kid. My first car was a 54 Chevy Belair and my first tractor was a 53 Ford NAA, both of which I still own, and both where 6 volt, possitive ground systems. And both have been changed over to modern internally regulated GM alternators. If this was an old I/O, I'd do the same thing. Unfortunately, I see no way to make that happen here.
I'm completely new to this boating thing and that's why I'm here. Maybe when I've got this one in tip-top shape, I'll be able to offer something useful to a newbe that's in the same position as I am now.
I really appreciate the help so far. Just hopefully someone finds this post that has had my same problem.

 

[F_R]

Re: Rewiring an old motor

Of course I am not familiar with all car regulators. But a general answer is that DC generators take a different sort of regulator than AC alternators. If you want to play around and experiment with it, go ahead.

The correct regulator for your motor contains 3 units: A voltage regulator, A current regulator, and a Cut-out relay. The first two are obvious as to function, and the 3rd one disconnects the generator from the battery when it is running too slow to charge.

 

[Gunslingertom]

Re: Rewiring an old motor

I think I'll pass on the AC deal. But I am going to check out old tractor regulators. These are sealed units and some are rated at 10 amps.

 

[ezeke]

Re: Rewiring an old motor

The regulators list as Autolite Voltage regulaltors in the VBO4201 series. Someone may have the cross reference for you. The OEM compatible ones are 380250, 377001, 381538, 383609,

 

[Gunslingertom]

Re: Rewiring an old motor

Well, I found a replacement voltage regulator for 35 bucks. And I found 1 inch, thick walled heat shrink tubing in 6 foot lengths that should work for wire loom. So now it's on to other things.
Are crimp connectors sufficient?
Is the fuse block still available? If so, where? Mine is in pretty rough shape.
Thanks

 

[okintex]

Re: Rewiring an old motor

I remember a million years ago I had the same problem on a motor. I went to the helpfull people at NAPA and told them what I needed and the looked through the books and found the regulator with the specs I needed. Might give it a try. Just tell them what voltage coming in and what output you want and they can usually find one that will do it for you. The one I installed was a automobile regulator and it worked.

Goor luck

 

[Gunslingertom]

Re: Rewiring an old motor

I have all my wire now it's time to get started. But I would like you experts to look at a few photos and let me know what you think.

Here you can see some of the damage I have to fix. But there is that little black box to the left of the solenoid. The 10ga. green wire from the bat terminal on the voltage regulator goes to this box, then from there it goes to the ammeter. Does anyone know what this is? It's not in my shop manual or my parts manual.
I should let you know that the voltage regulator is not the stock unit. I was thinking that this little box is some kind of step-down deal to get the charge rate down. But I really don't have a clue.

Here is a good pic of the terminal block. Does anyone know if this is still available anywhere? Or do I need to try to clean this one up?

Here is the whole cobbled up mess.

Continued.........