Charging system

. - 1. Disconnect the neutral switch alid remove it from the power head. Refer to Chapter Seven for the removal pro- cedure. 2. Calibrate the ohmmeter on the R x 1 scale. Connect the positive meter lead to a green lead of the neutral switch (Figmre 33). Connect the negative meter lead to a good engine ground. Test with the shift control lever in FORWARD, NEUTRAL and REVERSE positions. 3. Repeat Step 2 by connecting the positive meter lead to the other green lead of the ~leutral switch. 4. There should be no continuity- at all times during this test. Replace the neutral switch if continuity is present during any part of the test. 5. Refer to Chapter Seven for the installation procedure.

Manuah Start System

The manual start components include the recoil pulley, spring, drive pawls, drive pawl spring, rope and handle. The most colnmon failure of the system is a frayed or bro- ken rope. Before replacing an apparent locked manual starter, verify that the gearcase and power head are not seized and that the starting lockout mechanism is hnc- tioning properly. Otherwise, refer to Chapter Ten for com- plete repair procedures.

CHARGING SYSTEM

The charging system consists of the flywheel, battery charging coil (Figure 34 and Figure 351, rectifierlregula- tor (Figure 361, wires and :he battery. The charging sys- tem maintains the battery charge after starting the engine and when using onboard accessories. The use of accesso- ries, such as depth finders, stereos and fish finders, place additionai demands on the charging system, and in some cases, the charging system cannot meet the additional de- mand leading to a discharged battery. Check all charging system components if the battery discharges. Determine the total amperage of the onboard accessories and com- pare the total with the charging system output. Remember that the charging system output will be less than the listed maximum if the outboard is consistently operated at low speed. Consider installing an additional battery or a higher capacity battery as a possible solution. Battery maintenance and testing are provided in Chapter Seven.

Engines with a manual starter generally do not use a charging system. Some models have the option of a light- ing coil. The lighting coil is positioned under the flywheel and produces alternating current as the flywheel magnets rotate past it. The current produced by the lighting coil is suitable only for operating lights. Adding a rectifier con- verts the current produced by the lighting coil to direct cuwent. This arrangement allows the cranking battery to charge. Models with electric start use a rectifierlregulator unit. The rectifier portion of this component converts the alternating current produced by the alternator to direct current. The regulator portion of this component senses the voltage at the battery and prevents overcharging.

Troubleshooting the charging system requires the use of a multimeter. Use an analog multimeter when checking for open or closed circuits. To begin the troubleshooting process, verify that the charging system is not operating. Test the charging system components after verifying a charging system fault.

CHAPTER THREE

Charging System Output

1. Connect a voltmeter to the battery and note the battery voltage. 2. Start the engine and note the voltmeter. If the charging system is functioning, battery voltage will increase over that checked with the engine stopped. A voltage equal to or less than the first measurement indicates that a charging system is not functioning; further testing is required.

TROUBLESHOOTING AND TESTPKG

51

0

GCBAWGlNG SYSTEM 45-40 HB MODELS)

1. Exciter coil 2. Pulser (trigger) coil 3. Coil plate assembly

4. Alternator coil

5. Flywheel cover 6. Flywheel

3. A voltage exceeding 14 volts indicates a likely over- charge condition that warrants further testing.

WARNING Stay clear of the pr~opeller shclft 11,hile run- ning an engine on ajlz~slz/test device. As a safety precaution, remove the pr.opeller be- fore running the engine.

C4 UTION Never n~rz an ozitbourd without fir*stprovid- ing cooli~g water Use eitlzer a test tank or j'lush/test device. Remove the propeller be- foi~ nmnirzg the engine. I~zstall a test piao- yeller to run tlie engine in a test tank. NOTE In most, but not all, cases the tachometer does not operate if the char.ging system fails.

4. If a discharge or overcharge is indicated, test all components of the charging system. Many times, both the charging coil and the rectifierlregulator are faulty. Weak, cracked or broken flywheel magnets may cause decreased charging output; however, the same magnets are used to power the ignition system. Problems with magnets in the flywheel will likely also cause ignition problems. 5. Check the resistance or voltage output of the lighting coil, then test the rectifier or rectifierlregulator.

52

Alternator Charging Coil Test

Resistance specifications are provided for all models. When performing the lighting coil resistance test, remem- ber that ambient temperature affects the measured resis- tance. The resistance values are specified in Chapter Seven.

Voltage output specifications are provided in Chapter Seven. Reinember to run the engine at the specified en- gine speed while testing voltage output.

Coil resistance test

1. Disconnect the leads that connect the main wire har- ness to the coil. 2. Connect the ohmmeter between the coil wires. See Figure 37. Note the resistance reading. 3. Compare the resistance to the appropriate table in Chapter Seven. Replace the coil if its resistance is not as specified. See Chapter Seven for removal and installation.

Lightinghatteuy charging coil output test

NOTE All wires nzust renzain connected during a voltage output test. Back-pi,obe the connec- tors using junzper leads as vequired to se- curely attach the voltnzeter to the coviAect termirzals.

1. Connect the negative lead of a peak-reading voltmeter to the white coil wire and the positive meter lead to the yellow coil wire. 2. Start the engine using a testlflush adapter or test tank. Run the engine at the recommended speed specified in the appropriate table in Chapter Seven. 3. Test and/or replace the rectifierlregulator if the output voltage is above the specification. Replace the charging coil if the voltage is below the specification. 4. Refer to Chapter Seven for charging coil and recti- fierlregulator removal and installation.

Rectifier/Regulator Test

Use an ohinmeter to check the rectifierlregulator for open or shorted circuits. Refer to Figure 38 for 8-90 hp models and Figure 39 for 115-140 hp models. Test speci- fications are provided in Table 27 and Table 28 in Chap- ter Seven. 1. Connect the ohmmeter to the terminals specified in Ta- ble 27 or Table 28 in Chapter Seven. Note the meter read- ing at each connection.

CHAPTER THREE

CHARGING SYSTEM

1. Flywheel cover (40-90 hp models) 2. Flywheel (40-90 hp models) 3. Alternator coil (1 15-1 40 hp models) 4. Exciter coil (1 15-1 40 hp models) 5. Exciter coil (40-90 hp models) 6. Alternator coil (40-90 hp models) 7. Coil plate assembly (40-90 hp models) 8. Guide plate (40-90 hp models) 9. Shim (40-90 hp models) 10. Set ring (40-90 hp models)

TROUBLESHOOTING AND TESTING

@ALTERNATOR COIL TEST

1. Alternator coil 2. Coil plate 3. Alternator white lead 4. Alternator yellow lead 5. Rectifier/regulator

53

RECTIFIERIREGULATOR TEST [48-90 HP MODELS)

1. Rectifiedregulator 2. Red leads 3. Yellow lead 4. White lead 5. Black lead

CBECTBFBIERjWEGUkATOR TEST (4 4 5-$40 HP MODELS)

1. Rectifierlregulator 2. BlacWwhite lead 3. BlacWwhite lead 4. BlacWwhite lead 5. Red lead 6. Black lead