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1987 sea ray 165 alternator conversion kit

L

lrl930

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"have a 1987 searay w a 165 me

"have a 1987 searay w a 165 mercruiser made the brackets myself and bought a 3 wire alternator to put on myself. boat runs but only gettin 5 to 7 volts to coil, can anyone tell me how to rewire this so it works? alternator works well chargin round 13.5 volts on guage but mustve missed something on rewiring the coil"
 
"It is working properly, the r

"It is working properly, the resistance wire or ballast resistor is reducing the voltage."
 
How many volts on the end of t

How many volts on the end of the resistance wire measured to ground when it's disconnected from the coil?
 
"resistance wire gives 12.25 v

"resistance wire gives 12.25 volts when removed and electric choke is disconnected. 11.5 when choke is reconected, 5.0 when reattached to coil and 4.5 when 3 wire alternator wire is run to pos side of coil sound right or too low? maybe i need a straight jumper wire right from ignition switch or not? boat did run but coil went bad after one yr of this setup, coincidendce or wired wrong? thnks for all the help larry"
 
"update forgot to mention that

"update forgot to mention that those readings were w key on and boat not runnin, got it started now and at idle is runn in 11.9 volts,sounds like i may need some starter work, anyone kno where i can buy brushes to fit a 165 merc starter?"
 
"Lawrence:

Is the battery f

"Lawrence:

Is the battery fairly new and fully charged? If the battery is not sealed, get a simple battery tester w/5 balls in it--not an antifreeze tester. Test each cell w/it; if one or more cells shows a substantial difference from the other cells; replace the battery.

Measure the voltage at the fully charged battery for reference. Test the voltage on the choke wire; it should be the same less 0.02 volts. If the voltage drop is more than 0.02 volts, there is a corroded wire in the circuit.

The resistance wire can increase its resistance over time. It should only drop the voltage to the coil to 8 to 9 volts. Since yours is dropping more voltage I would replace it.

The 3 wire alternator should have an 8 ga. output (orange) wire to the starter where the battery wire attaches. The sensing (red/purple) wire should be connected to the engine circuit breaker on the side opposite of the red wire. The excitation wire is the main purple wire.

Due to the age of the wiring, many of the wires will be coated w/black corrosion. If you find it, clean the wire w/sand paper by running it between you fingers.

I would try to get a new engine wire harness and replace the wires not included with it. Solder each "heat shrink" connector after crimping it and shrink the tubing. That is what I did to my 1987 4.3L."
 
"well as for the brushes find

"well as for the brushes find a local electric motor repair place, they can help. typically they do starters, alts, generators, altenators, hydraulic pump motors etc.."
 
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