Optional Battery Charging System Regulator Test (9 Ampere ) 1. Check battery voltage at Description battery with engine running. The battery charging system components are the sta- 2. If battery voltage is above 14.5 volts, replace volt- tor, , and battery. (gener- age regulator. Check condition of battery as over- ated in stator alternator coils) flows to the rectifier, charging may have damaged battery. which changes the alternating current to direct cur- 3. If battery voltage is below 14.5 volts, charge bat- rent for charging the battery. tery; refer to “Charging a Discharged Battery”, MODELS EQUIPPED WITH RECTIFIER preceding. If battery can NOT be satisfactorily charged, replace battery. 4. If battery accepts a satisfactory charge, check a battery voltage while cranking engine; refer to “Charging a Discharged Battery”, preceding. If cranking voltage is not acceptable, replace bat- tery. b 5. If cranking voltage is acceptable, disconnect end of RED (located between rectifier (+) terminal and starter solenoid) from rectifier. Secure RED wire (from ) to rectifier (+) termi- nal with hex nut. c 6. Connect RED (+) ammeter lead to (+) terminal of rectifier and BLACK (–) ammeter lead to RED wire a - Stator (disconnected in last step). b - Rectifier c - Battery IMPORTANT: For accurate test results the voltage at battery with engine running, in next step, must MODELS EQUIPPED WITH REGULATOR be 13.5 volts or less. It may be necessary to oper- ate electrical accessories to drop voltage to 13.5 a volts or less.

7. Run engine at 3000 RPM. b 8. Meter should read between 7 - 9 amperes. 9. If meter reads 7 - 9 amperes, this indicates the charging system is functioning properly and the battery is being discharged because the amper- age draw on the system is greater than the amper- age output of the system. c NOTE: With engine running at the following RPM’S, the ammeter should indicate the following approxi- mate amperes: RPM AMPERES IDLE 1 1000 4 a - Stator b - Regulator 2000 8 c - Battery 3000 9 The charging system may be damaged by: 1) re- 10. If the meter reads less than 7 amperes, test the versed battery cables, 2) running the engine with bat- stator; refer to “Standard Stator (Alternator Coils) tery cables disconnected and stator leads connected Amperes Output”, following. If stator tests OK, re- to rectifier, and 3) an open circuit, such as a broken place voltage regulator. wire or loose connection.

2B-4 ELECTRICAL AND IGNITION 90-13645--2 495 Battery Charging System 2. Use an ohmmeter and perform the following test. Troubleshooting IMPORTANT: If stator is mounted on engine, black stator lead (if provided) must be grounded to pow- A fault in the battery charging system usually will erhead when testing. cause the battery to become undercharged. Check battery electrolyte level, and charge battery. See 3. Replace stator if readings are outside ranges “Electrolyte Level”, and “Charging a Discharged shown. Battery”. Scale Resistance If battery will NOT accept a satisfactory charge, re- Test Leads Reading (Ohms) place battery. (x ) If battery accepts a satisfactory charge, determine 9 AMPERE STATOR the cause of the charging system problem as follows. Between YELLOW .6 – 1.1* .6 – 1.1* 1. Check for correct battery polarity [RED cable to stator leads (R x 1) positive (+) battery terminal]. If polarity was incor- Between either No No rect, check for damaged rectifier. See “Rectifier YELLOW stator lead Continuity Continuity Test”, following. and engine ground** (R x 1000) 2. Check for loose or corroded battery connections. 16 AMPERE STATOR Between YELLOW .17 – .19 3. Visually inspect wiring between stator and battery .17 – .19 for cuts, chafing; and disconnected, loose or cor- stator leads (R x 1) roded connection. Between either No No YELLOW stator lead Continuity 4. Excessive electrical load (from too many acces- Continuity and engine ground** (R x 1000) sories) will cause battery to run down. 24 AMPERE STATOR If visual inspection determines that battery connec- Between YELLOW .05 – .15 tions and wiring are OK, perform the following stator .05 – .15 and rectifier tests. stator leads (R x 1) Between either No No Stator Ohms Test YELLOW stator lead Continuity Continuity (Alternator Coils Only) and engine ground** (R x 1000) NOTE: Stator can be tested without removing from * DC resistance of these windings generally is less engine. than 1.5 ohms. If a reading (resembling a short) is 1. Disconnect both YELLOW (stator leads) from ter- obtained, this would be acceptable. minals on rectifier (or terminal block). ** If stator is removed from engine, connect test lead to black stator lead, if provided. 4. If meter readings are other than specified, replace stator.

90-13645--2 495 ELECTRICAL AND IGNITION 2B-5 9. With engine running at the indicated RPM’s, the Standard Stator (Alternator Coils) ammeter should indicate the following approxi- 9 Amperes Output mate amperes: IMPORTANT: Rectifier must be functioning prop- RPM AMPERES erly for accurate test results to be obtained. IDLE 2 1000 10 1. If engine is equipped with a voltage regulator, 2000 17 disconnect voltage regulator leads at rectifier; 3000 18 reinstall hex nut on rectifier terminal that has 10. If ammeter indicates approximately 18 amperes yellow stator lead. at 3000 RPM, this indicates the charging system 2. Remove red wire from (+) terminal of rectifier. is functioning properly and the battery is being 3. Connect RED (+) ammeter lead to rectifier (+) termi- discharged because the amperage draw on the nal and BLACK (–) ammeter lead to red rectifier system is greater than the amperage output of the wire. system. 4. Run engine at 3000 RPM. 11. If ammeter reads less than 18 amperes, test the stator; refer to “Stator Ohms Test (Alternator Coils 5. Meter should read 7 - 9 amperes; if not, replace Only)” [18 Ampere Stator], preceding. If stator stator. tests OK, replace voltage regulator/rectifier. 16 Amp Alternator System Test c (LARGE FINNED VOLTAGE REGULATOR/RECTIFIER) 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5 volts, replace volt- age regulator/rectifier. Check condition of battery as overcharging may have damaged battery. 3. If battery voltage is below 14.5 volts, charge bat- b tery; refer to “Charging a Discharged Battery”, d a 21619 preceding. If battery can NOT be satisfactorily charged, replace battery. a - Voltage Regulator/Rectifier c - Center Terminal b - RED Harness Wire d - RED Sense Lead 4. If battery accepts a satisfactory charge, check battery voltage while cranking engine; refer to NOTE: If one or more of the 3 terminals on the termi- “Charging a Discharged Battery”, preceding. If nal block are shorted to ground, the battery charging cranking voltage is not acceptable, replace battery. system output will be reduced. 5. If cranking voltage is acceptable, disconnect RED a harness wire from center terminal. 6. Secure RED wire (d) on terminal (c) using hex nut. 7. Connect RED (+) ammeter lead to terminal (c) and BLACK (–) ammeter lead to RED harness wire (b). 8. Secure away from flywheel. IMPORTANT: For accurate test results the voltage at battery with engine running, in next step, must be 13.5 volts or less. It may be necessary to oper- ate electrical accessories to drop voltage to 13.5 volts or less.

26001 a - Terminal Block

2B-6 ELECTRICAL AND IGNITION 90-13645--2 495 16 Ampere Alternator System Test Optional 24 Amp Alternator System Test (SMALL VOLTAGE REGULATOR/RECTIFIER) (LARGE FINNED VOLTAGE REGULATOR/RECTIFIER) 1. Check battery voltage at battery with engine run- ning. 1. Check battery voltage at battery with engine running. 2. If battery voltage is above 14.5 volts, replace volt- age regulator/rectifier. Check condition of battery 2. If battery voltage is above 14.5 volts, replace volt- as overcharging may damage battery. age regulator/rectifier (a). Check condition of bat- 3. If battery voltage is below 14.5 volts, charge bat- tery as overcharging may have damaged battery. tery; refer to “Charging a Discharged Battery”, 3. If battery voltage is below 14.5 volts, charge bat- preceding. If battery can NOT be satisfactorily tery; refer to “Charging a Discharged Battery”, charged, replace battery. preceding. If battery can NOT be satisfactorily 4. If battery accepts a satisfactory charge, check charged, replace battery. battery voltage while cranking engine; refer to 4. If battery accepts a satisfactory charge, check “Charging a Discharged Battery”, preceding. If battery voltage while cranking engine; refer to cranking voltage is not acceptable, replace battery. “Charging a Discharged Battery”, preceding. If 5. If cranking voltage is acceptable, disconnect larg- cranking voltage is not acceptable, replace battery. er diameter Red wire from STARTER SOLENOID 5. If cranking voltage is acceptable, disconnect RED terminal. harness wire (b) from terminal (c). 6. Remove smaller diameter RED wire (SENSE 6. Secure RED wire (d) on terminal (c) using hex nut. LEAD) from STARTER SOLENOID terminal and 7. Connect RED (+) ammeter lead to terminal (c) connect to the POSITIVE (+) terminal of a 9 VOLT and BLACK (–) ammeter lead to RED harness battery. Ground the NEGATIVE (–) ter- wire (b). minal of the 9 VOLT battery to the engine. 8. Secure wires away from flywheel. 7. Connect RED (+) ammeter lead to larger diameter RED wire, and BLACK (–) ammeter lead to POS- IMPORTANT: For accurate test results the voltage ITIVE terminal on STARTER SOLENOID. at battery with engine running, in next step, must be 13.5 volts or less. It may be necessary to oper- 8. Secure wires away from flywheel. ate electrical accessories to drop voltage to 13.5 9. With engine running at the indicated RPM’s, the volts or less. ammeter should indicate the following approxi- 9. Run engine at 3000 RPM. mate amperes: 10. Meter should read 20 or more amperes. RPM AMPERES IDLE 2 11. If meter reads 20 or more amperes, this indicates 1000 10 the charging system is functioning properly and 2000 17 the battery is being discharged because the am- 3000 18 perage draw on the system is greater than the am- perage output of the system. 10. A reading of 18 amperes at 3000 RPM indicates the charging system is functioning properly. The 12. If meter reads less than 20 amperes, test the sta- battery is discharging due to the amperage draw tor; refer to “Optional 24 Amp Stator (Alternator on the system is greater than the amperage out- Coils) Amperes Output”, following. If stator tests put of the engine charging system. OK, replace voltage regulator rectifier (a). 11. If ammeter reads less than 18 amperes, test the b c a stator; refer to “Stator Ohms Test (Alternator Coils Only)”, [18 Ampere Stator], preceding. If stator tests OK, replace voltage regulator/rectifier.

d 21619 90-13645--2 495 ELECTRICAL AND IGNITION 2B-7 Tachometer Terminal Block (Design 1) DESCRIPTION ALT YEL Contains a which blocks high voltage AC GREY pulses (180 VAC) coming from the stator and allows low voltage DC pulses (20-30 VDC) to pass through TACH ALT YEL to be counted by the tachometer. This terminal block (with diode) is only used with large, finned type regu- lators. This block is BLACK in color. WARNING HIGH VOLTAGE is present at the tachometer block’s stator side terminals, while the outboard 50644 is running. To avoid electrical shock, physical Tachometer Terminal Block (Design 2) contact should not be made on these terminals or ANY IGNITION RELATED COMPONENT WHILE DESCRIPTION THE OUTBOARD IS RUNNING. This block is a junction point for stator and tachometer IMPORTANT: The following ohm test is used to de- signal wiring. It contains no electrical components. termine the proper functioning of the diode lo- This block is LIGHT GREY in color and is to be used cated in the tachometer block. If the diode is ONLY with small, non-finned voltage regulators. No OPEN (NO CONTINUITY IN EITHER DIRECTION), test is required for this terminal block. the tachometer will be inoperative. Tachometer Terminal Block TESTING TACHOMETER TERMINAL BLOCK (Design 1 and 2) (DESIGN 1) REMOVAL With outboard NOT running, remove all leads from block. Using an ohmmeter, test block as shown, fol- 1. Remove two YELLOW alternator wires from lowing. Continuity should be observed on the ohm- block. meter with the needle swinging in only ONE direction. 2. Remove GREY tachometer wire from block. NO CONTINUITY should be observed when test leads are reversed. If CONTINUITY is observed in 3. Remove two attaching screws and remove diode BOTH directions or NO CONTINUITY is observed in block. either direction when leads are reversed, diode is de- INSTALLATION fective and MUST BE REPLACED. 1. Secure diode block to powerhead with two NOTE: There is only one diode located in the tachom- screws. Torque screws to 30 lb. in. (3.4 N m). eter block. It may be located either between the cen- ter (TACH) terminal and the top (ALT) terminal or be- 2. Attach two YELLOW wires to “ALT YEL” tween the center (TACH) terminal and the lower (ALT) terminals. terminal. 3. Attach GREY wire to “GREY TACH” terminal.

ALT YEL GREY

TACH

ALT YEL

50644

2B-8 ELECTRICAL AND IGNITION 90-13645--2 495 3 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW

h

b

g c f

d e

50405 a - Stator e - To Remote Control Harness b - Terminal Block f - 20 Ampere c - ToTachometer g - To Battery d - Voltage Regulator/Rectifier h - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-9 3 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW

h BLK YEL YEL

b BLK

RED GRY RED RED RED

g BLK

f c YEL YEL GRY

d e GRY YEL YEL RED RED

51000 a - Stator e - To Remote Control Harness b - Terminal Block f - 20 Ampere Fuse c - ToTachometer g - Battery (+) Positive Terminal d - Votage Regulator/Rectifier h - Starter Solenoid

2B-10 ELECTRICAL AND IGNITION 90-13645--2 495 4 Cylinder 16 and 24 Ampere Battery Charging Wiring Diagram IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW h

b

g c f

d e

50406 a - Stator e - To Remote Control Harness b - Terminal Block f - 20 Ampere Fuse c - ToTachometer g - Battery (+) Positive Terminal d - Voltage Regulator/Rectifier h - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-11 4 Cylinder 16 Ampere Battery Charging Wiring Diagram (with Small Voltage Regulator/Rectifier) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW

h YEL YEL

b

RED GRY

RED g RED RED

GRY c f YEL YEL

d e GRY YEL YEL RED RED

51001 a - Stator e - To Remote Control Harness b - Terminal Block f - 20 Ampere Fuse c - ToTachometer g - Battery (+) Positive Terminal d - Voltage Regulator/Rectifier h - Starter Solenoid

2B-12 ELECTRICAL AND IGNITION 90-13645--2 495 3 Cylinder Battery Charging Diagram with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW j

b

c

i Move Red Lead From Start Solenoid to Position Shown h d g

Start e Battery User Supplied Red Lead (10 Gauge Minimum Diameter with Protective Abrasive Sleeve Installed) Move Lead From Red Stud to Position Shown

Screw Size f #10-16x3/8” P/N 10-62568

50403 a - Stator f - Auxiliary Battery b - Terminal Block g - Start Battery c - To Tachometer h - To Remote Control Harness d - Voltage Regulator/Rectifier i - 20 Ampere Fuse e - Battery Isolator j - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-13 3 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW j YEL YEL BLK

b BLK

RED GRY

RED BLK RED

Small GRY c Red YEL i (Sense)Lead YEL

RED h B1 d A RED g B2 GRY YEL YEL RED e Large Red RED (Output) Lead

f

51051 a - Stator f - Auxiliary Battery b - Terminal Block g - Start Battery c - To Tachometer h - To Remote Control Harness d - Voltage Regulator/Rectifier i - 20 Ampere Fuse e - Battery Isolator j - Starter Solenoid

2B-14 ELECTRICAL AND IGNITION 90-13645--2 495 4 Cylinder Battery Charging Diagram with Battery Isolator IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED j YEL DYELLOW

b

c

i Move Red Lead From Start Solenoid to h Position Shown d

g e User Supplied Red Lead (10 Gauge Minimum Diameter with Protective Abrasive Sleeve Move Lead From Red Installed) Stud to Position Shown

Screw Size f #10-16x3/8” P/N 10-62568

50404 a - Stator f - Auxiliary Battery b - Terminal Block g - Start Battery c - To Tachometer h - To Remote Control Harness d - Voltage Regulator/Rectifier i - 20 Ampere Fuse e - Battery Isolator j - Starter Solenoid

90-13645--2 495 ELECTRICAL AND IGNITION 2B-15 4 Cylinder Battery Charging Diagram with Battery Isolator (Small Voltage Regulator) IMPORTANT: After electrical connections are made, coat all terminal connections using Quick- silver Liquid Neoprene (92-25711), to avoid corro- sion.

a

BLK DBLACK BLU DBLUE GRY DGRAY RED DRED YEL DYELLOW

j YEL YEL

b

RED GRY

RED RED

c Small GRY

i Red (Sense) YEL Lead YEL RED h B1 A RED d g B2 GRY YEL YEL e Large Red RED (Output) Lead RED

f

51050 a - Stator f - Auxiliary Battery b - Terminal Block g - Start Battery c - To Tachometer h - To Remote Control Harness d - Voltage Regulator/Rectifier i - 20 Ampere Fuse e - Battery Isolator j - Starter Solenoid

2B-16 ELECTRICAL AND IGNITION 90-13645--2 495 Rectifier Test d a c WARNING Disconnect battery leads from battery before b testing rectifier. f NOTE: Rectifier can be tested without removing from engine. e 1. Disconnect all wires from terminals on rectifier. 2. Use an ohmmeter (R x 1000 scale) and perform 07300 the following test. Refer to illustration for rectifier a - Terminal d - Stator Terminals terminal identification. b - Terminal e - Positive Terminal c - Terminal f - Ground

Rectifier Test

Connect RED meter lead to ground, BLACK lead alternately to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated. Connect BLACK meter lead to ground, Connect BLACK meter lead to ground, RED lead alternately to terminals “a” RED lead alternately to terminals “a” and “c”. and “c”.

No Continuity Indicated. Continuity Indicated. Connect BLACK meter lead to terminal “b”, Replace Rectifier. RED lead alternately to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated. Connect BLACK meter lead to terminal “b”, Replace Rectifier. RED lead alternately to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated. Connect RED meter lead to terminal “b”, Replace Rectifier. BLACK lead alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated. Connect RED meter lead to terminal “b”, Replace Rectifier. BLACK lead alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated. No Continuity Indicated. Continuity Indicated. Rectifier tests OK. Replace Rectifier. Replace Rectifier. Rectifier tests OK.

90-13645--2 495 ELECTRICAL AND IGNITION 2B-17