Relay replacement - again

[Saxe Point]

How often do these give out for most motors? My 1996 Johnson 90 seems to require one about every 6 to 9 months. Maybe it's just a bad run of luck, but I am wondering if my experience is typical. Luckily it's an easy and cheap fix (about $20 for one) that I can diagnose and do myself. I paid a mechanic the first time and I'm glad I learned about the problem and how to fix it.

In fact, because of the cost of repairs I am learning to do a lot of basic maintenance and small repairs myself. I got the official Johnson shop manual and a SELOC manual. Along with the internet and YouTube, it's amazing what I am learning to do. I never grew up learning anything mechanical, but I am now and really enjoying it. I'll never be a pro, but I enjoy the challenge and the money I save will be used for those big or complicated repairs that are way beyond me. I imagine most of you guys do other same.

 

[tykkyt e blue]

Check your alternator output voltage when running at speed... I have seen some OMC motors that output 16+volts - you run the risk of burning out just about everything else in the boat too

 

[spring fever]

I agree with blue-blowing a relay is a sympton -not a cause-the output voltage is a good place to start looking. Does that have a voltage regulator as well?

 

[trendsetter]

Which relay is blowing? 96 model Johnson motors are all fully regulated and should never put out more than 14.4v. My guess with limited information is there is a bad ground somewhere.

 

[GLG]

Relay is for the starter
regulator/rectifier is the charging system

some older motors only have a rectifier no regulator.

A 20 dollar part would suggest that it's not a [FONT=Verdana, Arial][FONT=Verdana, Arial]regulator/rectifier.


GLG
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[trendsetter]

The starter uses a solenoid switch so maybe he is talking about that? Also there are trim/tilt relays for power trim..there are relays to run the fuel pump to prime efi motors when the key is turned to on...more information needed!

 

[Saxe Point]

It's the relays for the power trim and tilt that are the problem. Is that caused by excess voltage? I just got a new regulator/rectifier recently and the relays died before this repair as well.

 

[Gunsmith]

If the relay keeps going it would be more to do with the power draw of the trim system. I would look at the wire diameter to and from the relay.