Rut-row...new probelm Help Please

[Lockon]

Well after talking on the phone with another member, Scott Starr (scstarr) about my reed replacement and injector clean project, he was telling me how he had an electrical fire once on his motor from an faulty voltage regulator...it burned up is entire wiring harness Well I decided to inspect mine and here is what I , I am hoping I can just replace the bullet connectors








It does not appear to have burnt any of the adjacent wires, only the bullet connector and the sheathing around the connector. I also does not seem to be affecting the performance, but it can not be good

What do I do Mr. Don?????????????? If it matters I did not disassemble anything yet, but I could read the voltage regulators and they say "CDI" on them....aftermarket?? did someone have an issue at one time??

[EuropeanAM]

If these regulators say "CDI" on them, they have indeed been replaced with an "aftermarket" regulator.

Personally, I strongly recommend the OEM Units (Part# 883072T). These regulators have been improved (repeatedly) over the years, and now have REDUNDANT ground paths (ground path is very critical, as one of the regulator's functions is to discharge excess current to ground SAFELY, to prevent overcharging).

Bullet connectors that are damaged SHOULD be replaced. Connections must be ABSOLUTELY clean... especially those on the RED or YELLOW wires.

I would recommend addressing this before running the engine again... as you're already aware of the potential of a "thermal event" (and no, that's not what Smokey the Bear called them).

Sherm @ Sherm's Marine (or I) would be more than happy to assist you with replacement regulators, and/or replacement Bullet Connectors.

Email or Phone are the BEST means of contacting the Parts Department(s).

[rolloman]

i Just took a look at my wires and the yellow bullet connectors look the same way. A couple have melted the plastic. I have a battery maintaner that is connected at all times to the starting battery. When I get home I plug it in to the AC power to top off the starting battery. Could it be the cause of the wires burning since it stays connected to the batttery when running the outboard?
I also run 2 hds and 2 LSS boxes all the tiime.

[EuropeanAM]

<table width="90%" cellspacing=0 cellpadding=0 align=center><tr><td>Quote, originally posted by rolloman &raquo;</td></tr><tr><td class="quote">i Just took a look at my wires and the yellow bullet connectors look the same way. A couple have melted the plastic. I have a battery maintaner that is connected at all times to the starting battery. When I get home I plug it in to the AC power to top off the starting battery. Could it be the cause of the wires burning since it stays connected to the batttery when running the outboard?
I also run 2 hds and 2 LSS boxes all the tiime.</td></tr></table>

Unlikely. MUCH more likely is that you have a WEAK battery, improperly rated battery (considering the engine's needs AND your above accessories), poor battery connections, OR are simply running the battery down too low before restarting the engine (while out fishing).

Comments above regarding regulators would also apply in your case.

[rolloman]

Thanks, Don. I do tend to not run very far due to the price of fuel. When I first installed those electronics I was running the battery down and not giving the outboard enough time I'm sure to recharge. That's why I added the battery maintaner. Since then I have not had any issues at all and the battery is strong all day while fishing. I'm assuming it happened prior to adding the maintainer.
I will still check the battery specs and change the affected bullet connectors. The regulators are OEM. Does this sound reasonable?

[Lockon]

I am also baffled as to why some of my connectors are burnt. It could be from running the battery down at a Tx last year in Texas and having to start the motor off the trolling motor batteries, It could be a weak battery (old and never load tested). What I did find interesting is I have aftermarket voltage regulators made by a company called "CDI." Doing a little research I found this about their regulators: "DO NOT USE A MAINTAINENCE FREE, AGM OR DRY CELL BATTERY WITH THIS TYPE REGULATOR/RECTIFIER!!!", which I was using a maintenance free battery. I will be switching back to an OEM regulator in the near future.

[rolloman]

The connector is the weakest link in the line. I'm gonna replace my bullet connectors with gold plated versions and just keep my eye on them. I don't think I'll see any problems again now that I hook up my onboard battery charger and maintainer until I go fishing again. I bet were not the only 2 people with this problem I'm sure. Good luck with your fixes.

[EuropeanAM]

<table width="90%" cellspacing=0 cellpadding=0 align=center><tr><td>Quote, originally posted by Lockon &raquo;</td></tr><tr><td class="quote">I am also baffled as to why some of my connectors are burnt. It could be from running the battery down at a Tx last year in Texas and having to start the motor off the trolling motor batteries, It could be a weak battery (old and never load tested). What I did find interesting is I have aftermarket voltage regulators made by a company called "CDI." Doing a little research I found this about their regulators: "DO NOT USE A MAINTAINENCE FREE, AGM OR DRY CELL BATTERY WITH THIS TYPE REGULATOR/RECTIFIER!!!", which I was using a maintenance free battery. I will be switching back to an OEM regulator in the near future. </td></tr></table>

Maintenance-Free, and Deep Cycle batteries are NOT recommended with ANY of the Mercury Engines.

AGM... that's normally NOT a problem, however.

[rolloman]

I ordered gold plated bullet connectors, but until they come I snipped out all of the burnt bullets and soldered the two wires back together. Coated with dialectric grease and double heat shrunk the connection. I was afraid to run the boat as bad as some of them were burnt. Ended up fixing all 4 of the yellow wires and 2 of the red wires. Being and ex electronics tech this repair was not that difficult until the gold plated bullets come in. Be sure to disconnect the battery connections before doing any repairs.