Here�s the situation, I have a 1990 Merc 150 XR4. It has been a great motor but it is giving me some headaches as of late. I (or someone who knows what they are doing) have made many updates including: new voltage regulator, stator, updated the charging system, plugs, fuel filter, head gasket, starter rebuilt etc. Two weeks ago the motor was bogging down getting onto plane. So I purchased some Yamaha Ring Free and did the shock treatment. I ran it hard and solved that problem (I still plan on using the Merc Power Tune someday soon). Yesterday at the lake I went to start the motor and the starter would not engage the fly wheel (I think that�s what it is called). It was not every crank but almost every other crank it would not engage. Well it finally started. As I am making my morning run (about 6-7 miles from the ramp) I notice my volt meter is not registering the volts it normally does at WOT. In fact, it is draining power (approx 10-11 volts). I get to my spot and fish for about 2 hours and go to start the motor and the starter will not engage at all. I was able to lift the starter gear up with pliers to "catch" the fly wheel, but by that time my cranking battery was dead. Switched the batteries and got back to the ramp. OK that was the history. Here�s my questions.

What would cause my volt meter not to register the correct WOT voltage?

Is my starter shot or can the spring inside the starter be shot?

Please Help (Sorry for the long draw out explanation)

Brad

Voltage regulator is shot.

Try lubing the shaft on the starter, sounds like it's sticking. LPS or WD40 will do it.

Thanks for the reply Pat. The voltage regulator is less than 2 years old. Is it common for these things to go out so fast? Could there be a bigger problem causing the regulator to go out?

Brad