So I bought a boat........

[bobleeswagger]

And my wallet keeps getting thinner! 96 Bass Tracker with a 97 Tracker 40hp 2cyl. wont start. Found fried rectifier/regulator. This was a basket case so not sure if it was fried when I got it or I somehow killed it. I am a great shot after all... Looks to be old damage not positive.
The question is what commonly kills the regulator. Just random failure? I did have the key on for hours testing and tracing the wiring as I rebuilt everything. It was basically the hull to start with. Just want to make sure I don't kill a new one if I have the key switched on motor off. (KOEO) The big main 7or 8 pin harness plug on the left side of the motor seems to have a problem. Move it and the 12v battery power dies. I tried zip tying it and that seems to fix it but I don't like it at all. I am looking into that to find a real fix. The radio is connected to the key switch so the key would be on to have the radio on. (and I did ) That could be a problem if this would overheat the Reg just having the radio on.
I thought about a toggle switch to run the radio power. Any suggestions?
Anyone have experience with the 4 wire reg? Will the 5 wire work? Same part number - (815279-4) for both. It has a ground wire that the 4 wire don't have. Any benefit to the 5 wire?
I assume you must have the 4 wire thought I would ask.
Thanks for your help in advance!


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[Nordin]

I do not know why the rectifier/regulator failed.
As it is a combo, there is a rectifier inside and a regulator.
The regulator is basically a zener diod that opens up (starts to lead) when reached the zener voltage and it is connected to ground and the rectifier is a single wave rectifier with a diod bridge.
I would suggest you to connect the radio to an own feed from the battery with a fuse and a switch or you use the switch that is in the radio.
You should newer have to have the ignition in ON position to use the radio.

 

[bobleeswagger]

Thanks for that input Nordin!
After further review this was old damage so it had nothing to do with the key being on, it was already fried. I agree with you, after I wired it up per the radio instructions I thought that was a bad idea. I have an extra toggle straight from battery so I will dive back into the wiring and fix this! I ordered the 4 wire just to make sure I had the correct one. Stupid to have the same part number for 2 different configurations. Everything I touch on this project seems to bite me!!!

 

[Jiggz]

Most likely that was miswired before causing the rectifier burnout. Although, there are times a rectifier will fail but mostly it never shows any burnt signs like in this one. Directly connecting the radio to the battery through a toggle switch is not a bad idea. Although, this can cause unintended consequence of draining the battery if the radio is accidentally left on. Most wiring is through the "I" terminal of ignition switch and then a toggle switch in series. Meaning the radio cannot be turned on without the key in "On" position but can also be turned on and off with a toggle switch. Note the rect/reg only rectifies and regulates the output from the stator alternator output and not with the battery usage. Meaning any power being used from the battery does not flow through the rect/reg.

 

[jerryjerry05]

You sure there's not another wire in the battery area? Lots of boats have a power lead for the accessories.
One guy calls and says he needs to get his boat rewired as the previous owner messed up the wiring. The PO had added about 200 foot of wiring trying to get power to the radio/depth finder. He changed the battery and didn't rebook the hot lead, turns out that it fell down under the battery box and the salt water/corrosion ate the connector. Look around????

 

[bobleeswagger]

Hey jerryjery05,
Thanks for the reply! Yes, there was a separate batt wire to the panel with a toggle on it. Because I did not see this thing come apart I followed the instructions on the marine radio that came with the boat. Again, this was only the hull and motor when I started. My ignition switch only has run and start, no acc position. So not a good option at all! I was trying to not have a hot lead that could be left on and run the batt down. I have went ahead and put the "on" wire for the radio in the toggle switch powered wire. Maybe a small LED to indicate that switch is on to help prevent leaving it on! I got the new regulator yesterday and that went in without any issues. New plugs and a fresh tank of gas. I fired it up and it runs great! That was the first time I ever heard it run! Getting pretty excited to get it on the water!
Thanks to all that replied! This is a great resource for info and help!!!!