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TOPIC: 40 amp regulator failure

40 amp regulator failure 2 years 4 months ago #126596

Anyone else experience this failure?
1990 200v6
This is the second regulator failure for this Merc.
This one was almost the end of the story for the Merc & boat.

The solution appears to be installing a new stator with (2) separate sets of 20 amp charging coils - (4) yellow wires rather than just (2), and obviously a replacement regulator kit.

So far,...So good,...Fingers crossed in the Mercury Magic Shop.
doc F
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Re:40 amp regulator failure 2 years 4 months ago #126633

A friend just replaced the regulator/rectifier on his 2002 Merc 115. Not as dramatic damage as you've posted, but failure nevertheless. There was heat damage to the bullet connectors from the rectifier to the engine's wiring harness. He determined that a bad ground wire between the engine and the battery was the culprit.
best,
Larry

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Re:40 amp regulator failure 2 years 4 months ago #126658

  • Robby321
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sailor58 wrote:

A friend just replaced the regulator/rectifier on his 2002 Merc 115. Not as dramatic damage as you've posted, but failure nevertheless. There was heat damage to the bullet connectors from the rectifier to the engine's wiring harness. He determined that a bad ground wire between the engine and the battery was the culprit.
best,
Larry



Agree, and Doc? Good chance stator going south.

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Re:40 amp regulator failure 2 years 4 months ago #126738

The stator still ohm'd out fine & still provided correct DVA readings.
All the grounds and bullet connectors appeared to be fine.
All the grounds were clean too.
Originally this 40 amp stator had a water cooled regulator.
The CDI/e replacement regulator (the blue one that is fried) did not have the water cooling aspect.
The replacement kit, a CDI/e stator, 174-9610K2, with two separate 20amp charging coils, (4 yellow wires) and a CDI/e regulator kit, 194-8736K1, seems to have resolved the problem. For the moment anyway.
doc

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