2000 Mercury 200 EFI regulator meltdown

[Kzaker]

I posted in electric forum then figured I’d probinly get more specific answers here so:

I have the above motor (SN: OT153942). The charging has never worked since I owned the motor (last year). I haven’t needed to additional charge but want to get it fixed. The battery, when charged is just over 12v and I get no additional voltage when running at any RPM. I found one of the rectifiers is melted a bit and was going to swap it out but figured I’d ask the collective of experts here if there is anything additional I should do OR, swap them out and see if the problem is fixed. I’m also buying a lead acid battery to replace the AGM that the previous owner had installed (which may have caused the problem to begin with). I thought I had read that Mercury had new rectifiers to replace the old design and they solved many of these problems- anyone know anything about this? I’ve also read that both should be changed at the same time. I will continue to research this for myself but it never hurts to ask someone (you guys) who have been here before.

i see part number listed as: 883072T2 (x2)

thanks for taking the time to read this, I appreciate any input/advice in advance!
Regards,
Karl

[JOE54]

yes replace both and check stator for burnt windings and correct batt

[EuropeanAM]

+1

Also inspect connectors for any burnt, browned, blackened areas- replace ANY suspect connectors.

Two new-style regulators at the same time, OEM Mercury/Quicksilver only.

Make sure you have a wet-cell CRANKING battery (only ONE battery connected to engine cables). Engine cables on battery FIRST, remaining lugs Largest to Smallest. Finish off connections with a stainless Locknut (do not use wing-nuts).

[Kzaker]

I am ordering 2 new regulators tonight. One has a hole blown through the insulation so I’m going to assume that’s at least the start of any repair if it isn’t the extent of the damage. I see some listings for these oem units come with a fuse: any idea what that’s about? I seem to recall reading a recommendation to install inline fuses when updating regulators but can’t find any more information.. any help would be great!

Regards,
Karl

[JOE54]

your wire harness has fuses for these regs ,the rear mounted regs (updated) now come with fuses for protection, your takes a diff part num than those, please use oem and follow above suggestions you should be fine from there

[Kzaker]

When I looked up the SN, I came up with this part: 883072T2 (apologies)<EDIT- Please read the Forum Announcements. We do not support parts purchased from Ebay.>

Ill know for sure when they arrive. Your saying that I DO have fuses? I looked under the cowl and didn’t see anything. I’ll look online for additional information since I’m not particularly fond of continuing to ask questions but for the cost of those; I’d rather be 100% sure

Regards

[JOE54]

follow red wires one should go to fuse holder , 20amp atc mini

[Kzaker]

I believe I found it now in the schematic.. was looking at a 1999 diagram and it wasn’t there( or at least that I could see). I’ll check motor when I get home for the location of the fuses.

does anyone know for sure if the manual I should be using is 90-878079?
Regards,
Karl

[EuropeanAM]

878079R01 is the correct manual.

Please take a moment to review the Forum Announcements... hoping you didn't order parts through the bay.

[Kzaker]

Sorry, no, I ordered elsewhere but that was a quick reference to the same part number when I put it in the google search bar. But I did make sure that I ordered NEW OEM parts. And thank you SO much for your helpful support. I’m really hoping these are the entire problem, both upper and lower fuses were blown also. I may be back to ask some questions about the exterior color of my spark plugs though- one side looks like it may have been hotter than the other for some reason. I’m replacing them and will shoot it with a thermal gun next time in out testing on the water.

Regards,
Karl

[JOE54]

99 had rear mounted regs non fused