115 Regulator Overheating

[Freezebear]

Has anyone else had problems with the regulator failing on 4Stroke motors. My buddy's motor is a '02 115HP and first one failed and was replaced with new one. This one overheated and stopped charging but after cooling down, started working again. Battery is perfect condition and there are no heavy electrical loads on the system. We disconnected all wires to regulator after it overheated and ran back across the lake with no power on the regulator and when we pulled the boat out the water and checked the regulator it was HOT HOT! Stupid Yamaha mounts the thing right against the block and we think this is what is causing it to overheat. No problems with motor either. He installed a 12V DC fan on the heatsink of the regulator with a 1-amp fuse to help cool the thing. We also had another idea to run a water line from the pee-water and make a heat exchanger out of 3/16" copper tubing and run through the fins of the regulator for maximum cooling, but will see how fan works first.

 

[new2obrepair]

Re: 115 Regulator Overheating

As an electrician by trade, I'd say move it to a cooler location, extend wires if neccessary, must be well grounded in new location, which can be a wire mounted on old location, and run to new one if a good ground is not available. Last you need heat sink compound to put between the regulator and the heatsink to maximize the heat conduction. Good luck.

 

[rodbolt]

Re: 115 Regulator Overheating

mmmm most of those were water cooled but maybe not that model. I know they had some fuel cooler problems some years back. talk it over with your yamaha dealer and see if any tech bullitens appear on YDS or parts smart.<br /> good luck and keep posting

 

[Freezebear]

Re: 115 Regulator Overheating

RodBolt,<br />You mean the regulators were water cooled on some models? How did they do it? Maybe we are on to something here that will work.

 

[Vitamin Sea]

Re: 115 Regulator Overheating

check your wiring for shorts and all accessories also i have had a bad battery internally short and go through two regulators in two weeks but had no sign of problems sitting at trailer or dock battery would short when boat was pounding or if it was a bumpy ride also clean all battery connection remove wing nuts and use bolts and lock washers. that regulator get hot when its over-worked. if you dont have a voltage meter get one it will help you identify your problem when it begins to occur also to protect from fire and ruining regulator and stator I recommend installing a 30 circuit breaker on the + input this will break when the short occurs for protection

 

[Freezebear]

Re: 115 Regulator Overheating

Correction to original post. This motor is a '01 model not a '02 model as posted.