Alternator issue - I think?

[scisgr8]

Mercury 200 HP Saltwater EFI - 2002 Model
First noticed the batteries going dead - dual batteries. Purchased a new battery hooked up ran for a couple of hours and dead.

Started troubleshooting and unhooked battery switch and hooked to a fully charged battery. Motor starts up runs fine, when I dismount from battery, it shuts off.

Called a boat parts store and they looked up alternator and said it was $575. Mentioned it looked like a car alternator and had a belt. That makes me question maybe I don't have a bad alternator that the belt may have popped.

I'm a novice here and any advice appreciated. I don't have a ratchet nut big enough to fit the lock nut on top of the flywheel. is this a standard size. went and purchased a 1" nut and it seems a tad loose and won't grab the nut tight - maybe need a 15/16? nut.

Any other advice on what to look for what to replace and where to find an alternator that doesn't run $575. Sorry gang, times or tough and I'm trying to do what I can on my own without damaging anything.

 

[j_martin]

Re: Alternator issue - I think?

The nut is 15/16", but you may not need to take it off. If you do need to pull the flywheel, you need a flywheel puller that threads into the flywheel.

First, I would recommend you get the manufacturer's maintenance manual for your engine. Then you would understand that the alternator is built into the stator, and the rectifier/voltage regulator, maybe multiple, are external to the flywheel.

For now, find the yellow wires coming out of the flywheel, count them, and tell us where they go, and we can help you troubleshoot it.

Pictures help a lot.

hope it helps
John

 

[sschefer]

Re: Alternator issue - I think?

John, I think those motors used the Nippon Mini alternator and it hangs off the back. They hung them off the side on the Opti's because of the fuel rails in the back. Carb motors still had the stator/charging coils under the flywheel.

 

[j_martin]

Re: Alternator issue - I think?

John, I think those motors used the Nippon Mini alternator and it hangs off the back. They hung them off the side on the Opti's because of the fuel rails in the back. Carb motors still had the stator/charging coils under the flywheel.

He didn't say opti, or DFI, he said EFI. So what is it?

 

[scisgr8]

Re: Alternator issue - I think?

It is an EFI, not an Opti

200 HP Saltwater EFI. I will check the yellow wires this afternoon and try and take some pics and upload. Thanks for the advice thus far.

 

[sschefer]

Re: Alternator issue - I think?

He didn't say opti, or DFI, he said EFI. So what is it?

Some EFI's in those years had the mini alternators also. These were the ones that dropped off the back. Opti's are DFI.

 

[Faztbullet]

Re: Alternator issue - I think?

Only the 3.0 liters have belt alternators....

 

[scisgr8]

Re: Alternator issue - I think?

Ok I double checked everything and purchased the manual for the motor which is very helpful....
The motor is a 2001 model and does not have a belt or alternator (I don't think) it appears it generates power from the stator. One thing I found is I think my starter ignition switch may be bad. I noticed that the starter motor would continuously run after the motor started and would run. It also wanted to continuously run even when the key was in the off position so that could be the answer of why my batteries were running dead that when my motor was running the starter motor continued to as well. I'm going to replace the switch and kill switch, try that and troubleshoot, i'll post once this has been completed.

 

[Faztbullet]

Re: Alternator issue - I think?

Replace the solenoid as I see more of these failed than ignition switches....

 

[sschefer]

Re: Alternator issue - I think?

Only the 3.0 liters have belt alternators....

Well, actually the 2002, 150/175/200 EFI (2.5L) motors had them too.

Crowley Parts list - http://www.crowleymarine.com/mercury-outboard/parts/6996_50.cfm

Boats.net Parts List - http://www.boats.net/parts/search/M.../1B227000 & Up/Flywheel-Alternator/parts.html

 

[Faztbullet]

Re: Alternator issue - I think?

Quote:
Originally Posted by Faztbullet
Only the 3.0 liters have belt alternators....

Well, actually the 2002, 150/175/200 EFI (2.5L) motors had them too.

Crowley Parts list - http://www.crowleymarine.com/mercury...ts/6996_50.cfm

Boats.net Parts List - http://www.boats.net/parts/search/Me...tor/parts.html

Well I should have been a little clearer, the late model 2.5 (2002) in serial number range OT40905xx and up do have them but earlier serial #'s use a stator. The 2003(OT59903xx)thru 2007 also have them as do the 200 EFI 3.0 liters.. my bad..

 

[scisgr8]

Re: Alternator issue - I think?

It definetely was not the switch, it's been replaced and still have the same problem. I'm going to start investigating the solenoid as suggested and go from there. It's starting to look like I"m going to have to bite the bullet and take it into someone who knows how to trouble shoot this.

I'm just broke these days and don't have any spare cash. I mean living from one paycheck to the next and always borrowing from the next paycheck just to make ends meet.

 

[j_martin]

Re: Alternator issue - I think?

Why don't you quit throwing parts at it until you have diagnosed the problem.

Disconnect the wires from the small terminals on the solenoid. Hook up the battery. If the starter spins, the solenoid is stuck. If it doesn't, troubleshoot the starting switch circuit.

hope it helps
John