'92 Merc 90hp overcharging issue.... I think it's fixed!

[jpollman]

Just thought I'd give you all an update on the charging problem I've been having with my '92 Merc. (I thought it was a '91 but I did some checking and found that it's actually a '92) After all of the overcharging issues and non-functioning replacement regulators I went ahead and replaced the entire charging system with an OEM red stator kit and new OEM regulator. It cost about $400 which is more than the aftermarket CDI components but the bad experience I had with the CDI stuff makes it well worth the extra cost.

I went out yesterday afternoon and picked up the new parts and got home and installed them. It wasn't that tough and I spent a little extra time inspecting and cleaning all of the ground connections because some of them looked a little suspect. After finishing the installation and rechecking everything I put the muffs on and fired her up. I'm happy to report that it appears to be functioning properly. I ran it for over twenty minutes and varied the RPM's and it's putting out between 14.2 and 14.4V so I think I've finally got the problem solved. I've got to work Saturday morning but as long as the weather cooperates, I'm planning on a good shakedown cruise early Sunday morning.

Thanks again for all the responses I had on my previous posts concerning this problem. Your input is greatly appreciated.

See ya on the water!

John

 

[Texasmark]

Re: '92 Merc 90hp overcharging issue.... I think it's fixed!

Glad you went the extra mile John and obviously it paid off. The voltages you measure are perfect.

Mark

 

[jpollman]

Re: '92 Merc 90hp overcharging issue.... I think it's fixed!

Great news!

I launched at about 5:30 a.m. on Sunday morning. I was out for six hours and the boat was running for a good deal of that time. I ran around the lake for a while from place to place just stopping here and there to fish for a while. The boat performed perfectly and the charging system worked just as it should. Never got above about 14.2V and not a single alarm in the entire six hours. At this point I believe that the overheat alarm I was getting before may have been caused by the overcharging condition. I may be wrong but I think that by the stator pushing almost 17V through the alarm system that something was going nuts and setting it off. Now that I have the charging system working as it should the alarm problem has gone away to. I've got plenty of water coming out the tell tale and she's running great.

Thanks again for all the input folks. This is an awesome resource!

Take care and CYA on the water.

John