1989 sea ray 100 hp outboard battery not charging

[richsbca]

I'm working with a 1989 Sea Ray 100 hp outboard which I think is just a Mercury.

My battery doesn't seem to be charging, yet my tach seems to be working. I have done an ohm test across the 2 yellow wires connecting to the top of my rectifier and I get like .7 reading which I think is good... Im assuming that the charge voltagge for the battery comes form the red wire that goes to the start solenoid?? Here I get 12.5 v or the voltage of the battery with the engine load on it. when I shut the engine off the voltage goes to 12.8v is this a stator voltage regulator, or rectifier?

 

[Dave1027]

Re: 1989 sea ray 100 hp outboard battery not charging

Put a new battery on it before anything else.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Put a new battery on it before anything else.

battery is good. It cranks the engine over very strong and will run the boat for hours, but it's not charging in the boat. When engine is reved to about 1500 rpm I get no voltage change whatso ever with batt connected to boat. When I shut off engine voltage of battery jumps to 12.8v from about 12.5. This is it's normal voltage not connected. I noticed that only 1 wire is hooked to positive terminal and it looks like the main battery cable to the starter solenoid. SHould there be another wire that charges? I don't think so...

 

[sschefer]

Re: 1989 sea ray 100 hp outboard battery not charging

Disconnect the red wire comming from the rectifier, start the engine and check the voltage. You should have around 13.5 volts but it could be as much as 17-18v when you rev the engine (don't exceed 2000 RPM in neutral).

Now take the tach grey wire off the yellow that it's on and put it on the other yellow. If it still works then you have some A/C voltage and you would naturally have something at the red also. If you didn't have any voltage at the red and the tach worked on both yellows then replace the rectifier. If the tach didn't work on the other yellow then replace the stator.

If you have good voltage at the red then check all your battery cables and if they're good take the battery in and have it tested. If it's no good then replace it. Normal life on a battery in a boat is about 2 years. Some go forever but that's a rule of thumb that I follow and I aint got stuck yet.

 

[emckelvy]

Re: 1989 sea ray 100 hp outboard battery not charging

I don't have the specs in front of me for that stator's alternator coils resistance, but generally speaking a lower resistance on those windings is what you're looking for.

With the (2) yellow stator leads disconnected from the rectifier and hooked up to your meter, move the flywheel by hand 1/4-1/2 turn or so. Be sure the ign is off and plug wires pulled. When you move the flywheel, even just a bit, you should see some sort of deflection/change in your meter readings. This is merely a practical demonstration that the stator is producing voltage.

Replace the rectifier and don't ever run a motor with the red lead on the rectifier disconnected.

If the rectifier is shot the tach won't run regardless of which yellow wire the tach is hooked to.

Do Not exceed 1500 rpm with any motor in neutral out of the water unless you eventually would like to be introduced to the engine internals in a bad way.........

 

[sschefer]

Re: 1989 sea ray 100 hp outboard battery not charging

I don't have the specs in front of me for that stator's alternator coils resistance, but generally speaking a lower resistance on those windings is what you're looking for.

With the (2) yellow stator leads disconnected from the rectifier and hooked up to your meter, move the flywheel by hand 1/4-1/2 turn or so. Be sure the ign is off and plug wires pulled. When you move the flywheel, even just a bit, you should see some sort of deflection/change in your meter readings. This is merely a practical demonstration that the stator is producing voltage.

Replace the rectifier and don't ever run a motor with the red lead on the rectifier disconnected.

If the rectifier is shot the tach won't run regardless of which yellow wire the tach is hooked to.

Do Not exceed 1500 rpm with any motor in neutral out of the water unless you eventually would like to be introduced to the engine internals in a bad way.........

Are you serious.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Rectifiers good, how do I know? Cause I replaced it and it still isnt' charging the battery. Seems like im getting at least voltage for the engine to run... how do I know? Cause, like an idiot, I didn't have the battery wires clamped and they had falled off the battery terminal while the engine was runing and the engine kept running. Hooked the battery cables back up and still no differen't. could this be a voltage regulator? Tach seems to be working fine.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

This issue continues to dog me! Not a big deal cause I have so far been just using it for short lake trips to my local lake and the battery can handle the laod for the day fine.... However I don't like the idea of the battery not getting charged at all during use. Engine seems to run fine once started even without battery as stated above. Got the merc manual for this 89' 100hp outboard and it showes a voltage regulator but I really doubt this unit has a voltage regulator.

Can anyone tell me where the V-regulator is and if it even has one?

 

[CharlieB]

Re: 1989 sea ray 100 hp outboard battery not charging

I didn't have the battery wires clamped and they had falled off the battery terminal while the engine was runing and the engine kept running. Hooked the battery cables back up and still no differen't.

Ignition system and charging system or TWO TOTALLY SEPARATE electrical systems. Yes each has coils on the same stator FRAME, but nowhere are ANY wires common, other than a common ground.

You can remove the battery completely and still pull-start your motor, with a big enough rope and a REALLY BIG arm!

A faulty battery connection can smoke a new rectifier in about a heartbeat.

Remove the rectifier and test each yellow to the red terminal with your Ohm meter, reverse the meter leads and retest again. You should have continuity in only ONE direction, none in the other.

Replace the rectifier,(again) if there is NO continuity on any of your tests.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Ignition system and charging system or TWO TOTALLY SEPARATE electrical systems. Yes each has coils on the same stator FRAME, but nowhere are ANY wires common, other than a common ground.

You can remove the battery completely and still pull-start your motor, with a big enough rope and a REALLY BIG arm!

A faulty battery connection can smoke a new rectifier in about a heartbeat.

Remove the rectifier and test each yellow to the red terminal with your Ohm meter, reverse the meter leads and retest again. You should have continuity in only ONE direction, none in the other.

Replace the rectifier,(again) if there is NO continuity on any of your tests.

Thanks Charlie!

My thinking was that the fact that the engine keeps running when the battery is disconnected would indicate the stator is doing it's job and outputing electrical current, hence should be charging the battery as well. Guess I could be wrong since the battery isn't charging, but I suspect something else is going on here. And yes I realize that the battery's main function isn't to provide electricity to run the ignition system, but more for running the starter and providing power for accessories when the engine isn't running.

At any rate, I have clean connections to the battery, and I've done the standard rectifier diode test and that seems good voltage only flows in 1 diirection (I have at least 2 others that are good as well).

I found a couple of postings talking about the early mercury charging systems having no voltage regulator and only having a rectifier. And they were known for destroying batteries with overcharge. It seems that I have one of these types of charging systems. I think the battery voltage has something to do with if it's sends current to the battery, or not. Just trying to learn exactly how that system works since the manual I bought doesn't seem to cover it, but only has the voltage regulator equipted systems. Ohhh welp!

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Thanks Charlie!

My thinking was that the fact that the engine keeps running when the battery is disconnected would indicate the stator is doing it's job and outputing electrical current, hence should be charging the battery as well. Guess I could be wrong since the battery isn't charging, but I suspect something else is going on here. And yes I realize that the battery's main function isn't to provide electricity to run the ignition system, but more for running the starter and providing power for accessories when the engine isn't running.

At any rate, I have clean connections to the battery, and I've done the standard rectifier diode test and that seems good voltage only flows in 1 diirection (I have at least 2 others that are good as well).

I found a couple of postings talking about the early mercury charging systems having no voltage regulator and only having a rectifier. And they were known for destroying batteries with overcharge. It seems that I have one of these types of charging systems. I think the battery voltage has something to do with if it's sends current to the battery, or not. Just trying to learn exactly how that system works since the manual I bought doesn't seem to cover it, but only has the voltage regulator equipted systems. Ohhh welp!

Looks like I may be replacing the stator next...

 

[CharlieB]

Re: 1989 sea ray 100 hp outboard battery not charging

Never give up and start throwing parts on, there is NO RETURN on electrical parts.

Testing to prove the fault is the most cost effective method of repair.

It 'could' be a bad charge coil on the stator, but if it is NOT you would have spent a lot of money needlessly.

Test AC Voltage on the 2 yellow wires from the stator, better yet, DVA test these wires, what do you see at idle, and at 2000?

 

[Silvertip]

Re: 1989 sea ray 100 hp outboard battery not charging

You seem to still be confused about what the stator does, what the regulator does and what the rectifier does and moreover, you seem to want to gravitate toward the most expensive part (stator) in this system when it very likely IS NOT the problem. Remember -- the Tach works. It gets its pulses from the ignition side of the stator. Using your manual, test the CHARGING side of the stator and I suspect it is OK. The output of the charging portion of the stator feeds the rectifier. This converts the AC (alternating current) from the stator to DC (direct current) for battery charging. If the engine has a voltage regulator that comes after the rectifier and it's purpose is to regulate the charging system so the battery is not overcharged. Troubleshoot, isolate, and THEN repair. Don't start throwing expensive parts at the engine. There is also a rectifier test procedure in the manual. Check it. Since you ran the engine with the battery cables off, there is a good chance it is bad.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Thanks for talkin some sense into me guys! I'm going to take a closer look at facts of the situation tomorrow. I'll post what i find out.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Hey guys did a few test:
rectifier is good acording to the ohm flow chart test in my manual.

when I run the boat at about 2000 rpm I only get about 2.5 or 3v from the yellow wires connecting to the rectifier. On the + side of the rectifier I get the battery voltage when the engine is running 12.5v.

Also, I did an ohm test between the 2 wires and I get .2... Actually my meter is a Craftsman and it is automatic so it won't show me any numbers ofter the first decimal palce. But it dances between .2 and .1 (Don't worry, I'm getting a new meter tomorrow to do this properly). No continuity between ground and each yellow wire.
What would this point to?

Going to use a new meter and retest, I think my current meter is goofy!

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

doing an ohm test between the 2 yellow wires from the stator will peg my ohm meter as if though I were touching the + - leads together. I think it should be between .17 and .19.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Well I hope someone finds the picture useful anyhow...

 

[CharlieB]

Re: 1989 sea ray 100 hp outboard battery not charging

It is still possible for a charge coil to be bad. Load tests such as DVA testing is much more reliable than Ohms testing.

Fake it.

Disconnect both yellow wires from the regulator/stator.

Grab your trusty test light or any 12 volt light bulb.

rig a couple of jumper wires, connect one to one yellow lead from the stator to ground, rig one jumper from 12 volts/battery to one side of your test light, hold the other side of the test light to the other yellow stator lead.

Does the light come on and stay on?

If no, order a stator.

DO NOT ATTEMPT THIS WITH A TRIGGER, you WILL SMOKE a trigger as they can only withstand (at most) 3 volts.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

It is still possible for a charge coil to be bad. Load tests such as DVA testing is much more reliable than Ohms testing.

Fake it.

Disconnect both yellow wires from the regulator/stator.

Grab your trusty test light or any 12 volt light bulb.

rig a couple of jumper wires, connect one to one yellow lead from the stator to ground, rig one jumper from 12 volts/battery to one side of your test light, hold the other side of the test light to the other yellow stator lead.

Does the light come on and stay on?

If no, order a stator.

DO NOT ATTEMPT THIS WITH A TRIGGER, you WILL SMOKE a trigger as they can only withstand (at most) 3 volts.

Thanks again CharlieB! I will give it a shot by weeks end and report the results.

 

[richsbca]

Re: 1989 sea ray 100 hp outboard battery not charging

Ok light stays on... Could it be that the charging system only works if battery is below say 12v? I've only worked with good batteries so far. This seems to point to the recifier since I get voltage coming in to the rectifier on the AC side and nothing but battery voltage on the positive/battery, or DC side. The rectifier does pass the ohm test outlined in the Mercury manual and I have 2 of them that test good, yet do the exact same thing. Perhaps Sea Ray did something funky with the charging system.... Either way, I'm confused! Thanks for any additional clues