Voltage regulator fire on Merc outboard

[cobraarvey]

Our 15' Whaler has a 2003 40HP 2 stroke hanging on the back. This past weekend my son complained that the motor would not start. I checked, and got the engine running, but needed the fast idle to keep it going. Pulled off the cowl and saw that there had been a fire under the cowl The voltage regulator was melted and had blown out in the center. There were melted wires around the regulator, melted insulation/sound padding under the cowl, and black soot over everything.

Took the motor to my Merc mechanic, and he confirmed the regulator had blown. Claimed he has seen it three times before. Said it was lucky the fire put itself out. Parts will be over $500, and labor will be several hundred dollars

I just recently installed an EXIDE AGM battery on the boat. Asked the mechanic if this may have caused the problem, and he did not feel that would have contributed to the regulator blowing. Anyone have a problem with regulator catching fire? Makes me wonder if I want my kids running this motor, which to be honest has not been the most reliable considering its age and amount of use it gets. This is my third major repair on a motor with less than 200HRS.

[Glen E]

I'd be talking to merc at 920-929 -5000

have your ser # ready...

[cobraarvey]

Thanks Glen. I'll give it a try. Since it was a 2003, I didn't know if I had a leg to stand on. But a phone call certainly can't hurt. As you know, I take care of my boats/motors. And the Merc has been meticulously cared for, especially since my kids are using the boat on their own.

[ChuckDSlayer]

had same thing happen on my 2004 40 2 stroke. It was a few months out of warranty but they took care of parts and half labor. I didnt mind Merc or my dealer stepping up to the plate.

[thefermanator]

I have read several times in the past that this is not uncommon with MERCS with deep cycle batteries on them. Haven't ever seen it first hand, but have of several others doing this same exact thing.

[cobraarvey]

Just got off the phone with customer service at Merc. Nice young lady by the name of Sarah checked and there has been a recall on the voltage regulator. (I purchased the Whaler off a friend, and did not file paperwork, so they would not have been able to notify me). They instructed me to have my authorized Merc tech contact them and they will work out the details. If I receive re-imbursement like Chuck I would be extremely pleased. I'll keep you posted.

Also, lesson learned for all you guys who purchased a used boat or motor. Register with the manufacturer, so that you can be notified of a possible recall.

Thanks again to Glen E. for the suggestion.