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Bench testing Rectifier 94 225...

O

oldschoolnc

Contributing Member
Ok, here is what I have done. Disconnected all wires to rectifier, set my meter to diode test, connected one yel wire to red wire nothing one way, reversed probes, 683ohms that way. Same thing but opposite in regards to pos. neg. probe placement,with yel/gry to red. Nothing one way, 685ohm with probes switched. CDI guide says thats a good test. Anything else I can test? Tach did work before dissambly,(just flywheel off) and motor ran normal. just no charge. I do not have access to a dva peak v meter to test stator but think it is at fault.... I am about to order one...Is there a ballpark resistance for the charge coils on the stator that I can check? No signs of overheated coils or melting coils on stator, however some of the coils seem very loosely wound... ANY HELP OR SUGGESTIONS WILL BE APPRECIATED!! sorry if I posted this here b4 I just want to be sure as possible b4 I spend $274 THANKS AGAIN.:confused: Oops, I tried to edit and somehow double posted.... my bad...:eek:
 
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I am guessing that is a 3 wire rectifier, 2 yellow and a red? It doesn't sound like you are doing a complete test. How about each yellow to ground & reverse leads.
 
Thanks, I'll check that this morning. It is actually a 6 wire, yel, yel/gry, red, blk ,gry ,purp. I'll also check to make sure pwr is going to purp, with key on....
 
It is recommended you replace the rectifier with a new stator. A bad battery or faulty wiring is the normal cause of stator failure. It can snowball and cause power pack failure as well spend the dime and get the dva and confirm all is well before putting into service.
 
Do you have a volt meter on the dash? If not install one so you can monitor voltage real time. A good fishfinder/chart plotter will tell you batteryvoltage.
 
As per your statement pertaining to the rectifier's wiring of post #3 containing wires colored "6 wire, yellow, yellow/gray, red, black ,gray ,purple" (two gray wires?... Typo?). Anyhow, the engine being a 225hp, that would no doubt be a water cooled Voltage Regulator/Rectifier combination.

OMC's instructions on testing the unit, back when that expensive water cooled thing came into being, was so drawn out, loaded with this and that as far as I'm concerned, including load a test (On the engine only). There was no bench testing procedure ( If one existed in later years, I'm unaware of it).

It appears that you're trying to test that complex unit as one would test the smaller 3 or 4 wire rectifier... don't waste your time... can't be done.

You say in your initial post that the tachometer did work before disassembly... BUT... did it work properly?

The tachometer operates off of the charging system. If the tachometer operates perfectly, exactly as it should with no discrepancies, jumping around, false readings, cutting in and out... that is an indication that the charging system is functional. Always possible though that something new has surfaced that none of us has encountered, but unlikely.

You indicate that the stator is not melting down... dripping anything sticky looking on the powerhead... BUT... it's always possible that it could be failing and not putting out the proper AC voltage to the regulator/rectifier unit. There are voltage and ohm tests to be made of the stator but having retired in 1991, I don't have the book. Other members would have that information..
 
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Thanks Everyone! Joe the tach worked normally and accurately, I tried two. One of the yel wires has a gry stripe, that was what I was indicating. I'm thinking it is like what you posted in that last paragraph.... Faztbullet.. Thats the page I tested off of, I didn't include in my post that the ground side tested as normal... Wish I could find out what the STATOR CHARGING CIRCUIT RESISTANCE is supposed to be? I'm on a low budget, So its drop the $85 for an analog DVA meter, or replace the Stator? All CDI bench tests indicate rectifier is OK..... Decisions, Decisions... lol. I Do have an onboard v meter thanks, kimcrwbr1, And got my water pressure issue resolved. Thanks Faztbullet! Wish I had the funds to replace stator, rectifier, and get a DVA meter... Maybe I'll try "Go Fund Me" Haha! THANKS AGAIN!!
 
What everyone doesn't quite understand is this is 3 separate parts in one unit. The tach circuit,the rectification circuit and the regulator circuit. It can still test ok and be bad as the 12V accessory may not be turning it on internally. Ohm the yellow stator wires and should read close to 0.00-0.004 between the 2 and no reading to housing for each one.
 
Thanks for responding faztbullet. It is an all in one unit. The rectifier I tested per. the cdi page tested ok diode wise, Tach lead tested right at 10,000 ohm per spec. Tach has always worked normal..... just no charge. checked purple 12v supply to unit got batt voltage. However when I checked the 2 yel to case, one at a time, I got 16k on one and 8k on the other, cdi spec is "should be in the m ohm range" also yel to red should be very very high 25m, Mine was much lower. So I replaced the rectifier unit with new cdi..... Ran it just a couple seconds, Same thing, I was afraid I damaged the new one so performed the test listed above and all were in spec. I should have bought the dva meter kit...... lesson learned. I'll be checking the stator resistance first light.... even if it checks ok i'm gonna take it to the local mech, he said if i have it opened up and bring my lwp adapter he will measure the dva voltage for $10! wish i would have known this to start with.... Thanks for the numbers, and your help!! I hope the stator shows a problem, otherwise I will be pulling my hair out..... like kimcrwbr1 said, probably better to replace both anyway. I'll start saving.... lol
 
Thanks. Found stator yellows shorted to ground with no resistance!! duh, I hate i missed that until now..... original rectifier is bad.. Glad I didn't damage new one, It is a cdi 193-4641, as shown on this site, has purple and a gray wire, as well as the red and two yellows,one w/gray stripe. Thanks for your Help/Advice! Come on Spring!
 
That odd as CDI went away with the purple wire years ago as unit went to a sense circuit . I know the Serria has no wire either. Maybe they (CDI)changed it back in last several years as I have just about quit using their products do to quality and warranty issues....
 
Yeah after looking at the other rectifiers I see what you mean..... Should I get a CDI Stator? I Thought CDI had a descent rep. Thanks again....
 
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