Need Electrical Help for smoked engine wires!!!

[289vjohnson]

Just thought I would tap the e-brains of this forum and see if someone has any ideas? I have a 1990 Stratos 289V/FS with a 1990 Evinrude XP 200 V6. Yesterday it ran fine...did notice that it didn't quite have the topend that it normally has, however it was the FIRST trip of the season and so just gave it to the "haven't run it in a while" theory. However, when I stopped in a no wake zone and then finally stopped to fish, my motor was POURING smoke out from under the case. I feared my motor was on fire, so very cautiously (armed with fire extinguisher‚) I removed the case to find tons of smoke coming out from under a thick plastic cover about 5" x7" on the top rear part of the motor kind of behind the flywheel. The funny thing was that the motor was running pretty much fine, never missed a beat. Did notice the tach wasn't working, but that is not uncommon for my boat...but maybe this thing has been on the blink and I have neglected? Anyway...a mech buddy of mine suggested that it was the voltage regulator. I am going to take some pics and send to him for verification. But after talking to several people on the water yesterday...they all had had the SAME thing happen to them. Very bizarre!

Any input? And if it *is* the VR, then where would a guy get a reasonable deal on one?

Take care,

Scott

[SEAHORSE]

Chances are you have wing nuts on the battery terminals and can move the cables with a counterclockwise tug. For many many years the factory has said to use lockwashers and hex-nuts tightened with a wrench.

Most likely the voltage regulator blew a diode due to voltage spikes from intermittent battery connections. That built up heat internally and started to melt the plastic potting around the electronics. The heat "rose" and also affected the power pack. All this time the alternator is pumping 35 amps into the regulator getting it hotter and hotter. If your motor had an overheat or a running too warm problem, or not enough water in the block, it could not help to cool the fins on the regulator.

You will probably need a new stator, regulator, pack, and possibly a timer base due to the damage.

Sorry to be the bearer of bad tidings, but if you had wingnuts on the battery, even sometime in the past, or a reversed polarity situation, that person is responsible for your misfortune.


Didn't the tach quit or the voltmeter show abnormalities before the smoke got out of the electrical components?

[289vjohnson]

Man I wasn't expecting all that...but you may be right. How would one determine the failure of each of the components, if possible?

Wingnuts...yes.

The motor, as stated, was running normally. The tach, has always been intermittent, actually.
I had glances at the voltmeter while going down the lake, and all seemed normal...but I cannot honestly tell you what the reading was as it was smoking before I turned it off.

Is there a way to attach photos to posts on this board?

TIA,

Scott

[RUSTY63]

When you want to add a photo the photo first has to be hosted on the web, like in shutter fly, then you copy the URL and click on the mountain icon at the top of the page (top of the post page), click between the "][" and paste you URL, you can test this in the testing forum.

[SEAHORSE]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 289vjohnson &raquo;</TD></TR><TR><TD CLASS="quote">

Wingnuts...yes.

The motor, as stated, was running normally. The tach, has always been intermittent, actually.
</TD></TR></TABLE>


I have never seen a burned regulator that did not have wing nuts on the battery.

Your intermittent tach was probably trying to tell you something!

You are not alone, the Merc 40 amp charging system had many many fires and failures also.

[289vjohnson]

So how do you KNOW (not YOU) but how would anybody tell IF ALL THOSE things you mentioned, which probably total $1000 would be fried? I am trying to get photos up as I type.

ST

[SEAHORSE]

Smoke most likely came from a burned thru spot on top of the regulator and you will see if the underside of the powerpack has been damged by heat. (very likely)

The stator copper coils will probably be black or discolored and the black insulation around the other coils will show melting, drip marks, and quite often pools of plastic on top of the cylinder block, sometimes freezing up the rotating timer base. Check the integrity of the magnets on the flywheel too.

The timer base must be checked both visually and with a meter per the service manual. Check the rubber Amphenol connectors for damage also.

Photos are OK but most of us in the business have seen many of these same problems due to folks not following factory procedures. It may not have been you personally, but whoever worked on the boat in the past.

[rudetech1]

Marine batteries shouldn't come with wing nuts. Even the RV guys have problems here. Wing nuts cause generator problems, isolator problems, and others. Another little known problem is the use of wing nuts on the troll motor. Sure can shorten the life of a good troll motor with wing nuts. Use NO WING NUTS. I made my battery distributor bring me a case of ss hex nuts for our batteries, he couldn't get the factory to ship with hex nuts. Get this, hex nuts are cheaper and easier to make!!!

[289vjohnson]

Interesting! Thanks for all the great information and I sure have learned a valuable lesson here! No wing nuts for me...EVER. ;-)

I have found, so far, that my voltage regulator is cooked. The top of it literally melted on the right side and smoked some wires, although the wires look kinda bad...the integrity of them on the CDI box are still good, as are the alternator coils, showing no evidence of being hot. Soooo, my mechanic buddy is hoping it is just the voltage regulator at a mere $209.21 OMC/OEM so far. Am scrolling along, looking for discount marine parts suppliers for OMC/OEM if anyone knows of any reputable ones around?

ST

[289vjohnson]

Am told that the Power Pack isn't shot *if* the motor will start. So I am hoping to get my rectifier by the end of the week and *maybe* squeak past this tragedy with just having to replace it. OH and gonna get 5 sets of SS washers and nuts. 3 for the bassboat and 2 for the ski boat. Had no friggin' idea of its importance.

Will update PRN

ST

[rudetech1]

You learn fast!!! Wish the battery companies would!!