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: https://www.boats.net/product/mercury...

Male insulator: https://www.boats.net/product/mercury...

Mercury terminal kit: https://www.boats.net/product/mercury...

VIDEO HIGHLIGHTS:
Stator test - 1:40
Regulator Rectifier test - 6:00
Replacing the connections - 6:40

Find Mercury outboard parts here:
https://www.boats.net/catalog/mercury...

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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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