This one has me stumped**Updated**

NathanY

Commander
Joined
Mar 16, 2002
Messages
2,408
The motor:
1994 Johnson 88SPL (90hp without VRO)

The problem:
Battery going dead

I had the battery tested, it tested good but it kept going dead. I would charge it up, it would last about two or three fishing trips, and it would go dead. I thought the rectifier was bad, so I talked to two or three mechanics and they all told me that if the rectifier was bad that the tach would not work, that the tach on that motor runs off of battery pulses not spark pulses. They also told me to look for a possible short or battery draw from somewhere running the battery down. I am an expert when it come to 12v and 24v wiring, its part of what I do for a living, so if there was a short or some electrical draw somewhere I would have found it. I didnt find anything. I had the battery tested several times and was told it was good. I did a load test at my shop and the battery was good, but the consensus from all the mechanics that I talked to said that if the tach is working that the rectifier is good. So I just went ahead and bought a new battery. Still having the same problem. First trip out, now problems what so ever. Second trip out, battery went dead. I run a Lowrance fish finder and it has a voltage sensor in it. I use it since my boat doesnt have a volt guage. When the battery is fully charged, it reads 12.4+ volts. I have that ff run straight to the battery with an inline fuse so that I could get the most accurate reading. When I am running down the lake, the voltage should go up with the rpm's of the motor, but it doesnt. It stays about the same as if the motor is idling, which makes me think the rectifier is weak or bad, but the tach still works and is accurate because it was tested. Anyway, this one has me stumped. I've tested everything I can think of, traced wires, cut power to everything, and still the battery goes dead after a couple of trips.
 
Joined
Oct 28, 2010
Messages
923
Re: This one has me stumped

Re: This one has me stumped

Have you checked stator charge output? Put your multimeter on the battery post/reading? With the engie off put amp clamp on battery cable to see if their is a constant draw.
 

dew2

Senior Chief Petty Officer
Joined
May 6, 2010
Messages
674
Re: This one has me stumped

Re: This one has me stumped

I guess you know there is batt drain,where? is the problem, have you thought of each time you start the motor disconnect the + batt cable, Kinda of a hassel but it will after time let you know if the batt. is draining without the motor hooked up.If accessories run off the batt stick in a shutoff switch between the batt and starter.
 

NathanY

Commander
Joined
Mar 16, 2002
Messages
2,408
Re: This one has me stumped

Re: This one has me stumped

I guess you know there is batt drain,where? is the problem, have you thought of each time you start the motor disconnect the + batt cable, Kinda of a hassel but it will after time let you know if the batt. is draining without the motor hooked up.If accessories run off the batt stick in a shutoff switch between the batt and starter.

You can not pull the battery cable off with the motor running. That will fry the power pack.
 

NathanY

Commander
Joined
Mar 16, 2002
Messages
2,408
Re: This one has me stumped

Re: This one has me stumped

Also, when the key is off, and all the switches are off, there is no draw on the battery. I have checked all that. There are no shorts anywhere in the boat, no vampire electronics, no power draw anywhere. This problem is in the motor somewhere. Either the rectifier is bad or there is another electrical problem in the motor somewhere. I just dont know where. But I do know that there is no wiring problems in the boat.
 

tx1961whaler

Vice Admiral
Joined
May 31, 2008
Messages
5,197
Re: This one has me stumped

Re: This one has me stumped

If the battery voltage is not going up when the engine is running, then the charging system is not working. The 88 has only a rectifier on it, so it is easy to test.
 

NathanY

Commander
Joined
Mar 16, 2002
Messages
2,408
Re: This one has me stumped **Updated**

Re: This one has me stumped **Updated**

If the battery voltage is not going up when the engine is running, then the charging system is not working. The 88 has only a rectifier on it, so it is easy to test.

Ok, so how do you test it?
 

tx1961whaler

Vice Admiral
Joined
May 31, 2008
Messages
5,197
Re: This one has me stumped

Re: This one has me stumped

From Joe:


(Small Rectifier Description & Location)
(J. Reeves)

On most 2,3,4,6 cylinder engines, the small rectifier is located on the starboard (right) side of the engine just in front of the engines electrical wiring strip. There are a few older V4 engines that have the wiring strip on the rear portion of the engine and the rectifier would be located just under that terminal strip. The smaller horsepower engines usually have the rectifier located on the starboard side of the powerhead close to the carburetor area.

The rectifier appears to be a round object approximately one inch (1") in diameter and also about one inch (1") high. The base of it is sort of triangular in appearance and is attached to the engine with two (2) screws/bolts..... usually one screw/bolt is larger than the other. The rectifier, depending on which one your engine uses, will have either:

One Red wire, one Yellow wire, and one Yellow/Gray wire, or One Red wire, and two Yellow wires.

Note that either of the above rectifiers could have a fourth wire which would be Yellow/Blue

********************
(Small Rectifier Test)
(J. Reeves)

Remove the rectifier wires from the terminal block. Using a ohm meter, connect the black lead of the ohm meter to the rectifier base (ground), then one by one, connect the red lead of the ohm meter to the yellow, yellow/gray, then the red wire (some rectifiers may also have a fourth yellow/blue wire. If so connect to that also). Now, reverse the ohm meter leads and check those same wires again. You should get a reading in one direction, and none at all in the other direction.

Now, connect the black lead of the ohm meter to the red wire. One by one, connect the red lead of the ohm meter to the yellow, yellow/gray, and if present, the yellow/blue wire. Then reverse the leads, checking the wires again. Once more, you should get a reading in one direction and none in the other.

Note that the reading obtained from the red rectifier wire will be lower then what is obtained from the other wires.

Any deviation from the "Reading", "No Reading" as above indicates a faulty rectifier. Note that a rectifier will not tolerate reverse polarity. Simply touching the battery with the cables in the reverse order or hooking up a battery charger backwards will blow the diodes in the rectifier assy immediately.
 

NathanY

Commander
Joined
Mar 16, 2002
Messages
2,408
Re: This one has me stumped

Re: This one has me stumped

Didnt have to test the rectifier. When I pulled it off to test it, I found that the potting in the back had melted and was running down the block and formed a small puddle in the lower cowl pan. I ordered a new one from iboats, for $34 including shipping, and everything is now golden.

You can see where it had melted in the lower part of the picture. There is a hole that goes all the way in, but you cant see it very well in the picture.
rectifier.jpg
 

Joe Reeves

Supreme Mariner
Joined
Feb 24, 2002
Messages
13,262
Re: This one has me stumped

Re: This one has me stumped

Very strange for that small rectifer to melt down like that UNLESS you have a high output stator (35amp) which is unlikely on a 88hp model. Being somewhat loose, a retaining bolt not tightened securely, would do it also.

The battery test you mentioned, load test etc..... I've had batteries with bad cells tested at various stores and had them tell me the battery was okay. They put a small charge in the battery then performed that load test with their "state of the art" equipment. Each time I told them to get a hydrometer and check the individual cells which they did and a cell would show up as being bad. Have you run across this at any time?
 

NathanY

Commander
Joined
Mar 16, 2002
Messages
2,408
Re: This one has me stumped

Re: This one has me stumped

No, I havent run across any bad cells on my batteries. I have an old school tester that uses a heating element, I think those are better personally because you are putting a real load on the battery not a "simulated" load like on the new testers. I have had several batteries test good with computer type testers only to fail when I put the a real load on them. The shop has a hydrometer that we use for checking the dump truck batteries. With four batteries running parallel it makes it faster to just pop the top and go across the cells rather than unhooking all the batteries and load testing them all. Winter is real hard on truck batteries.

Just for the heck of it, I sit here and picked all the potting out of that rectifier. There are two yellow wires with buttons on the ends soldered inside the case. Then there is a small plate soldered on one top of the buttons with a red wire going to it. I removed the little plate to expose the little buttons, one of them was burnt. Dont know if it shorted out, but thats what it looked like. Could have happened when I hooked up a battery charger one time or maybe the battery was hooked up backwards at some point by mistake, who knows. The motor is 17 years old.
 

hidef

Lieutenant
Joined
Aug 22, 2009
Messages
1,465
Re: This one has me stumped

Re: This one has me stumped

I have seen all kinds of mysterious things happen to electronic items over the years. I have been an Electronics tech for 35 years so I have seen it all. Some times a part will fail for no known reason, usually there was an issue in the manufacturing process but whatever the cause at least you found it.
 
Top