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Tan, I have a 1988 70hp Merc, S/N 0B276244, with high voltage…

Tan, I have a 1988 70hp...

Tan,
I have a 1988 70hp Merc, S/N 0B276244, with high voltage problems. I have (quite literally) cooked three rectifiers. I brought it in for repairs when the top cylinder stopped working and they replaced the switch box and the rectifier. My question has to do with the stator (that they said tested fine). I have not pulled the flywheel to see what stator is on there, but the wires coming out are green/white and white/green along with the yellows. I expected to see red and blue. Is it possible someone before me installed the wrong stator?
The primary symptom (other than fried rectifiers) is very high voltage - over 18v measured at the battery - at 2,000 RPM. The voltage seems manageable at idle and low RPMs. I'm looking at the CDI(###) ###-#### ***** stator. The engine has a rectifier only, no regulator, which leads me to believe it is supposed to be 9 amps. The switch box that was replaced has part number(###) ###-####
I'd rather not guess what to replace next.
Thanks.

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Answered in 16 minutes by:

8/11/2014

Marine Mechanic: Tan, MerCruiser Certified Technician replied 8 years ago

Tan, MerCruiser Certified Technician

Category: Boat

Satisfied Customers: 11,507

Experience: 40 yrs. experience with complete engine repairs both inboard/outboard and MerCruiser Certified Technician.

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Hello. My name is ***** ***** I will be assisting you today.

Ok your engine calls for a regulator 12082A 1. Is there a part number on the stator? They used 2 different stators. The one with the red blue and the one with the green/white and white green. These are for the ignition system. The yellow wires are for the charging circuit. Thses are not related to each other. You have charge coils for the ignition and charging coils for the charging system. They are 2 independant systems. The only thing they have in common is they are put together in the assembly called stator.

Does this mak sense?

Customer reply replied 8 years ago

There is no regulator installed and I don't recall seeing a location where it would have been located. I'm not sure it ever had one. That is why I assumed it was a 9 amp version rather than the 16 amp.

I can't see the stator part number without pulling the flywheel. However, the two different stator options, 8778A10 and 9710A12, both have the red/blue combination for the ignition. I understand the charging circuit is different, but information from CDI literature indicated that the stators with green/white combination of wires charge differently. Is this not the case? They clearly state that the stators with green/white should NOT be used as replacements for either 8778 or 9710 stators, one of which belongs in my engine.

The parts information I referenced came from the Mercury site and from the maintenance manual I have. Am I looking at incorrect information?

Marine Mechanic: Tan, MerCruiser Certified Technician replied 8 years ago

Well lets look at it this way the rectifiers must be wrong as they keep blowing and can't handle the voltage. So what does that leave us a voltage regulator. Your engine is a 1988 so who knows what has been done to the system.

All the merc 3 cylinders fir that model year show a voltahge regulator # ***** Now they also show a rectifier. I think they have been installing the wrong part. Diagram of 70 (3 CYL.) Mercury Outboard 0B240451 THRU 0C221999 Electrical Components Diagram and Parts

The 8778 stator isn't available through Merc anymore.

Customer reply replied 8 years ago

The rectifiers that have been blowing are the parts listed for this engine. There is a note in the service manual regarding the regulator; only the 16-amp motors came equipped with one. The 9-amp motors came with rectifiers only. That note does not appear on the Boats.net site.

The CDI replacement stator for the 8778 is(###) ###-#### ***** (w/ red/blue ignition) and there is a note that it can be used with a rectifier only.

The CDI replacement stator for the 9710 is(###) ###-#### ***** (w/ red/blue ignition) and there is a note that it MUST be used with a regulator.

The CDI stator(###) ###-#### ***** is a 9-amp stator with the white/green ignition wires. The note on this one is not to use it as a replacement for 8778.

The CDI stator(###) ###-#### ***** is a 16-amp stator with the white/green ignition wires. Same note applies here - not to be used as a replacement for the 9710.

I agree with your observation that, given the age, who knows what has been done to the system.

Could it be the case that the wrong part that is installed now is not the rectifier, but the stator with the green/white wires? What stator with those wires could properly be installed in this motor assuming the only two options are 8778 or 9710 and their replacements?

Marine Mechanic: Tan, MerCruiser Certified Technician replied 8 years ago

The switch box 332-778 will work with either stator. . Now you must have the higher output stator as the rectifiers can't handle the higher voltage. This is the purpose of the voltage regulator to handle the higher voltage.

The stator you should have is 9710A14 and the regulator 12082A 1. Now as for what you have now I have no idea as it could be anything. This is the reason I need the part number on the stator to tell you which regulator or rectifier you need for your system.

Post back with questions.

Customer reply replied 8 years ago

After doing some research online last night, I came across this 9 amp to 16 amp conversion kit: Stator Kt-3Cyl16A, Mercury - Mercruiser###-##-####-5. This would explain how the green/white and white/green wires showed up.

There is surprisingly little information available about this kit. I could not find a wiring diagram or an explanation of the parts involved. One site did say there was an inline regulator but not which part that was.

Now, given that I have a new(###) ###-####switch box and a new rectifier, could I just install the CDI(###) ###-#### ***** stator and revert the entire system back to 9 amps?

Marine Mechanic: Tan, MerCruiser Certified Technician replied 8 years ago

Yes that is the correct replacement from CDI . The Merc p/n this replaces which is the original stator is(###) ###-####17. This is the stator that uses the rectifier p/n 62351A 1.

It seems that someone in the past has installed the wrong parts on your motor.

Tan, MerCruiser Certified Technician

Category: Boat

Satisfied Customers: 11,507

Experience: 40 yrs. experience with complete engine repairs both inboard/outboard and MerCruiser Certified Technician.

Verified

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