150 hp excessive sparking at the battery

[LoveMySwitzer2]

I have a 75th anniversary 150 hp Evinrude (1985). The last time I took it out my son smelled some burning when we came in. The next day the battery was dead. I charged it and got the spark show. I put the battery in my camper and it seemed to work okay. I had a friend make sure I was hooking the terminals up correctly. I checked the regualtor/rectifier and did not see any burnt wires. I put an ohm meter across the starter solenoid and it read complete conductivity from post to post. I welcome some ideas on my troubleshooting endeavor. Thanks.

 

[rickdb1boat]

Re: 150 hp excessive sparking at the battery

You have a short somewhere in the wiring. Start looking everywhere for frayed wiring that could have shorted to ground, starting with the motor. Don't hook the battery back up until you find it. Which 2 terminals did you Ohm out on the selenoid?

 

[LoveMySwitzer2]

Re: 150 hp excessive sparking at the battery

I hooked up to the top and bottom of the solenoid (the in from the battery and the out to the starter). I tried pulling apart most of the wire connectors one by on the engine to find the possible short with no luck, figuring I could at least get an idea of where to look?

 

[Lubosleftboot]

Re: 150 hp excessive sparking at the battery

You should also check the thick wire on the bottom of the starter motor as these are often neglected and the sheathing can breakdown causing a short between the starter and the power head.

 

[rickdb1boat]

Re: 150 hp excessive sparking at the battery

Selonoid should not show continuity at those terminals without the key in the start position with the battery connected. Disconnect the wires(Small) at the selonoid and Ohm it out again(Large terminal)...Post results..

 

[LoveMySwitzer2]

Re: 150 hp excessive sparking at the battery

When I pulled the 2 small wires off I still had continuity. I then pulled all of the wires off and the solenoid alone did not show continuity. I determined that one lead was the source of the continuity. It lead to the regualtor/rectifier. I was able to pull contiutiy across this on 2 of the 4 output wires. The two wires that went to terminals number 4 & 5 did not show continuity, while the other 2 wires (one to post 6 and the other to another cylindrical part with a red lever), did show continuity through the regulator/rectifier. I think I am getting closer to the issue, thanks in advance for more ideas to continue the search...