Mercury Outboard Stator Test | Mercury Outboard Regulator Rectifier Test | Boats.net

Our Mercury outboard charging system has some issues. See how to test the stator on an outboard along with a regulator rectifier test in this video from Boats.net.
We’ve been working on the powerhead on our Mercury Tracker 40 2-stroke, and now we’re taking a closer look at the charging system. Specifically, we’re trying to diagnose why we have burned up connections between our stator and our regulator rectifier.
In this situation, it makes sense to perform a stator test and a regulator rectifier test first. If both components are okay, we can eliminate them as the issue and just replace the connectors. But this is a unique testing situation because both the stator and regulator rectifier are off the powerhead and we can’t run the powerhead to perform any of the tests.
We’ll start with the stator and look for shorts and make sure it’s in good shape. Then, we’ll move to the regulator rectifier and perform a diode test to make sure it’s okay.
After that, we’ll get to work replacing the connections using Mercury OEM outboard parts. Here’s what we used:
Get the female side insulator here: www.boats.net/...
Male insulator: www.boats.net/...
Mercury terminal kit: www.boats.net/...
VIDEO HIGHLIGHTS:
Stator test - 1:40
Regulator Rectifier test - 6:00
Replacing the connections - 6:40
Find Mercury outboard parts here:
www.boats.net/...
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In the video we’re working with a 2002 Mercury Tracker 40 2-stroke outboard motor, but you may have similar steps for your Mercury outboard. If you’re not sure whether these steps apply to your motor, leave a comment and we’ll get back to you.
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[@gonefreediving8958]

Brilliant! Thank you. Help me with trouble shooting my regulator, which was shot un the end. Replaced and now all good and charging again.

[@samfusco8158]

John Tally ..Best in the business! Always great videos!

[@hoonicav]

Hello from Scotland, love the content, literally everything I’ve done on my 1999 Mercury 40 2 cylinder 2 stroke has been from you, first boat and motor, the motor has been serviced by myself and is running well for age but my Rev counter has went from running, to only running over 3k and now doesn’t show revs at all, it’s a new Mercury Rev counter too, I have noticed the fish finder only shows 12v when running too, I would have thought it would show more running, any help much appreciated, as I’ve heard you say running tests on this engine on a few of your videos

[@antanasronkauskas5920]

98 year mercury 60 hp 4 stroke elpt, voltage regulator (vires. Yellow, yellow, red, black, grey), where need connect grey vire?

[@mauriciomartins9297]

Thanks for the vídeo 🇧🇷

[@Letstieoneon3194]

I have a 2004 Mercury 150 OptiMax showing an overcharge code will these test tell me the problem?

[@jimhughes8242]

John I want to know how to test my 1970 ,9.8 outboard stator, it says reverse connection but what does that mean,do you have a video of this. It was rebuilt and was supportively ok.

[@JimNobles-gv4ky]

Your meter is creating voltage to test???

[@ShellMacPherson]

Need help to test Stator for Merc 60HP EFI 4stroke stator has only 2 yellow wire. What is resistance value (ohm) to test for?

[@dutchpoacher1]

I just checked that on my 60hp efi and found 0.5

[@patricklogan3678]

How can I find the regulator on a 2006 optimax?

[@baysinfisher6094]

Is there a way to test the switch boxes on my 1988 blackmax 150 xr4 having problems cant get motor to go over 6mph at full throttle any tips would help thanks

[@RN67POST]

Check for spark on all 6 plugs! If you’re good your switch boxes and coils may be fine , after your motor reaches 2000 rpm it sends power from different coils in your stator . You need a DVR meter to test stator out put ! Blue wires at top of switch boxes power low speed red high speed! I had one blue wire not powering one box. That causes one box 3 cylinders not to fire! CDI electronics has great trouble shooting charts! I have the same motor as you. And there part corrected my problem! Also have a conversion kit for the water cooled regulator that burned out my stator. Very Expensive Parts !

[@irishmike519]

Just got my 2001 Mercury 40hp 2 stroke back from my local service center. Brought it in because I found oil in the fuel. It sat for over two years without running. I had then check the oil injection and get it started. They got it started, said the oil injection system was working, and it needed new plugs. Good so far, but they said the regulator was melted and it would cost approximately $600 to replace, because the parts are hard to find and they’re expensive. What other issues should I check into?

[@steven33068]

dont expect John to answer. Never gonna happen.

[@RichSingleton-sv2tw]

He said 1.9 volts was in range mine is reading 2.4 volts does that mean it's defective?

[@RichSingleton-sv2tw]

Sorry. He was testing one of the yellow wires to the ground and getting 1.9 he said he wanted 1.5. I'm getting 2.4

[@hl1aup672]

Green and green/white line resistance same as well?

[@steven33068]

as usual his videos leave many open questions, but dont expect these guys to EVER answer the comments.