Well, I finally got to troubleshoot the charging system on my outboard today (yesterday was yard work:).
My first phase of troubleshooting started with disconnecting all the battery terminals from the battery. I then started locating all my engine grounds. I then removed each bolt and ring connectors and used a dremel tool with wire wheel, to removed all the corrosion from the ring connectors (both sides), block boss and bolts. I did this for all the grounding points on the engine block.
My second phase of troubleshooting started with removing all the wiring harness wire ties (all ring terminals connected at this point to respective component) and getting the old electrical tape removed that was wrapped by the PO, cleaned all the sticky off the wires. I then separated all the wires and checked the insulation along the length of each wire looking for any dry rotted insulation, nicks in the insulation that could cause a short and found none.
My third phase of troubleshooting started with checking all the electrical components ring terminal (that have those) for any signs of looseness and corrosion. I went first to the electrical terminal block and started at the top removing the ring terminal from the component wires, and using wire wheel to clean the ring terminals and mounting plate. I did this for each terminal and also check for any looseness of the wire connected to the ring terminals. I then reconnected all them.
My forth phase of troubleshooting started with the starter solenoid. I removed the first locking nut (it was snug but over tighten) and removed the wire ring terminals and checked for any corrosion on the ring terminals and there was some, so I wire brushed it off of both sides and checked the ring connectors for looseness and the were all tight.
I then started to remove the 2nd locking nut and it was loose...and there were 2 wire ring connectors under that locking nut- The 1st ring terminal being Bat + and the 2nd ring terminal came from the Rectifier/Regulator (I thought maybe I just found my charging issue--keeping fingers crossed!) so I check them both for corrosion and wire brushed them off and the ring terminals were tight to the wires. I then reconnected all of them
My fifth phase of troubleshooting started with taking a voltage reading on the battery and it was @ 12.78 V. I then reconnecting the battery cables to the battery terminal with nuts (not wing nuts) . I then put my plug in the container that I use to test run the outboard in and filled the container with water. I went to the fuel line primer bulb and pushed fuel into the carbs until the primer bulb was firm. I went to connect the kill clamp inserted the key into the switch and turned it to start the engine...she fired right up and was pumping water strongly. I then took a reading of the battery Voltage and it was at 12.78 so I let the engine run for 5 minutes at about 1500 rpms (my rpm gauge doesn't work so I went by ear on that) I checked the battery voltage again for the 2nd time engine running and to my surprise (my fingers were crossed) and I got 13.1 V I then continued to let the engine run for another 10m and rechecked the battery voltage for the 3rd time and I got 13.88 Wow I think I fixed it !!!!??
Now I believe the charging system is fixed at the moment and the overheating issue I had a while back is fixed..I ran the engine at idle today for a total of 40m and no issues with battery voltage or overheating.
I feel now some what confident that I'm ready to go for a lake test...but before I do I will put new spark plugs in and run the engine a few times more.
I do appreciate all the input and advice from you folks.. I will update this thread again if things don't work out, however I'm thinking positive on this one