Starter is hot and wires are smoking...

[swamp-fox]

I put back together my '78 90hp Merc. While I was trying to start it I noticed the wires were smoking from the wiring harness inside the motor. It seems the ground that goes to the cowl is getting the hottest. I checked the polarity on the battery and it was right. I had taken the harness out, when I did there was no rotten wires or touching. The only thing I changed was I used the yellow/red wires from the stator to the rectifier. There were heavier ones on there and the yellow/red were taped up in it.
If any thing it might not charge right, but not the ground get hot?

Also the starter is really really hot!! It's working perfect, but I don't think I grinded enough to where I can barley touch it....
Also I used crappy aftermarket carb kit, and they are stuck. No gas is going through the gas tube that goes over the top of the carb...

I think I will be ok after I change the carb kit..but I dont want to burn up anything..Any help will be greatly appriciated!!

 

[recess]

Re: Starter is hot and wires are smoking...

Start with the easy first. Check your positive and especially the ground connections at the starter and relay. Make sure they are clean, clean, clean. I use my Dremel with a wire wheel and polish every connection to remove all corrosion. Clean the posts on the motor connections as well. Sand paper will work in a pinch.
If that shows no difference, then it sounds like either the relay, or the starter. Even though it is turning, the amp draw may be too high and causing the heat.
Also, what gauge wire are you using for your battery to motor connection. I would think 6 guage should be sufficient for a 90. Good luck.

 

[swamp-fox]

Re: Starter is hot and wires are smoking...

I checked everything again. I changed the starter with another that I had. It started up right of the first turn. The wires weren't hot or anything, I noticed it wasn't peeing so I stoped it, started again, gave it a little gas, still wasn't. Then I ran weedeater wire up it to clear anything. Now it won't start again......Doing the same thing wires are getting hot and it won't start....

 

[swamp-fox]

Re: Starter is hot and wires are smoking...

Well lesson learned..Only buy Mercury parts....Changed new starter silenoid with old one. Starting up and running perfect without even a lync n sync yet. Now I have to drop the lower unit and change the water pump.

 

[bobbymatthews]

Re: Starter is hot and wires are smoking...

good video on you tube on how to change your water pump, did it on my 82 merc 90
http://www.youtube.com/watch?v=BiQNhFYFvdQ&NR=1
also another one by a southern guy.

 

[bobbymatthews]

Re: Starter is hot and wires are smoking...

also how can I tell if my starter is burnt out or the relay. I hear only a click on the solenoid. I am having starter problems too.

 

[swamp-fox]

Re: Starter is hot and wires are smoking...

That was a good video. I wish it would have only taken me 10 min...LOL It took me about 2 hours..Thanks

 

[SleekWolf]

Re: Starter is hot and wires are smoking...

also how can I tell if my starter is burnt out or the relay. I hear only a click on the solenoid. I am having starter problems too.

Jump the big leads that come from the battery and go to the starter on the solenoid with the key in run position. Use a screwdriver and hold it across the two terminals (use 2 screwdrivers if one can't touch both). Be careful cuz it may start, and it will cause sparks, so make sure there is NO FUEL OR VAPORS PRESENT! If it cranks the starter is good and your problem is the solenoid or elsewhere in the wiring. If the starter is good, test the yellow lead for 12 volts with key turned to start position. Check the black wire for proper ground. CHECK THAT ALL CONNECTIONS ARE CLEAN AND TIGHT, and battery is fully charged. If these all check out ok, replace the solenoid.

 

[swamp-fox]

Re: Starter is hot and wires are smoking...

Yes bobby I basically did what sleekwolf said. If you have hot battery and can jump the starter and make it engauge then it will probably be the solenoid. Mine seemed like it was feeding +current throught the -ground that was going back to the cowl and battery. That's why it was smoking.