91 johnson 40 horse melted wire coming from starter solenoid to relay

[rjrobin2002]

I have a 91 johnson that started running bad when it ran out of gas. I got gas for it and it would only idle after restarting, if I gave it any gas it would start running real bad. My thought was it sucked up trash in the carb, but I have brand new tanks, fuel lines, and a in-line fuel filter. I pulled the motor cover and found a MELTED WIRE COMING FROM THE STARTER SOLENOID, TO A RELAY ON THE RIGHT SIDE OF THE MOTOR, TO A SCREW ON A BLOCK THAT HAS 7 OR 8 SCREWS WITH MULTIPLE WIRES ON IT. Any idea what would cause these wires to melt from what I have said. It will still run, but only idle, and it idles good.

 

[Rscardina]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

the reason a wire melts is usally due to a bad connection or high amperage draw or one of the compenents going bad or some kind of backfeeding.

just guessing, but Your starter solenoid may be on its way out. Hopefully it didnt damage too much...the fact that the starter solenoid has other wires going through it makes it hard to tell what exactly caused the issue..

If its not toasted completely, i would change the wire all the way back to the power pack (black box with all the wires). Make sure all of your conenctions are good and clean...and then see what you get.

If you get the manual for your engine you can see all of the components on that circuit and may be able to narrow it down.

Given your issues with the engine running you may want to verify that you dont have feul issues, carbs etc...could have jets partially clogged etc..or when she is running she is shorting somewhere and cutting out...you wont know till you sniff around..

 

[rjrobin2002]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

What about the melted wire that goes from the power pack the other direction into the relay? That makes me think its something more than just a bad starter solenoid.

 

[Rscardina]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

What about the melted wire that goes from the power pack the other direction into the relay? That makes me think its something more than just a bad starter solenoid.

It may be..but since the starter solenoid acts as a junction to some degree..you cant rule out that there isn't resistance or other issues there..

If you have two wires burnt..both going to and from the solenoid and pwerpack..it would appear that the solenoid is a good starting point..

I cant say 100% without seeing it..maybe you take a picture of it an post it here??..would certaily help see what you are seeing..

But again..replacing wires that are bad with like wire and insulating factors will at least give you a chance to clean that up and start fresh with troubleshooting

p

 

[jtexas]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

[edited]
sorry, disregard what I typed before (if you read it)...could that be your power trim relay?

 

[rjrobin2002]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

The relay is on the right side of the motor close to the primer solenoid, there are 2 of the relays and it has several wires coming from it. And since you mentioned the power trim relay, my trim had quit working. I was assuming it was the crappy toggle switch that I have had problems with, but you may be on to something. I am color blind so I will have to wait for my dad to come over before I can give you anydetails on wire color.
So now I guess there is the possibility that the trim shorted and melted some wires. Possible a carb issue even though I have a fresh fuel system is all new and clean. I will get back with ya'll.

 

[rjrobin2002]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

Here are some pictures. I found that one of the melted wires is from the hot post on the starter solenoid that runs around the backof the motor towards the trim relays, another melted wire is from one of the trim relays, and there are 2 melted wires on a block that multiple wires connect to. The wires completly melted into and are no longer connected. The starter is still working properly and I can hear the trim relay slicking when I move the toggle switch up or down. Any idea what happen to cause all of the carnage?

 

[jtexas]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

Is there more than one trim switch on the boat? maybe one on the transom, maybe one up front by the trolling motor? Switch gets wet, shorts out...

 

[rjrobin2002]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

There is a trim switch on the shifter and on the motor. The wires are not melted on motor toggle and I have not looked at the toggle on the shifter.

 

[jtexas]

Re: 91 johnson 40 horse melted wire coming from starter solenoid to relay

no, I mean, if the switch shorts, then the relay is on all the time. if the motor is already down, and it's the down relay, then the motor will draw a lot more current than usual for an extended period of time -- enough to heat the wires to the point of melting the insulation. This will all happen between the 12V feed, the relay, and the motor, but not the switch. The reason for the relay, is so you don't have all that much current flowing through the switch; the switch wiring doesn't need to be as fat, and it's safer for the operator.

Test the switch with a continuity tester...but if it shorted due to getting wet, it might test ok now that its dry. If this seems feasible, consider opening the switches up to inspect for corrosion.