See below (from 7/14)
1991 Suzuki DT25C. Was backing the boat (16' Starcraft) to retrieve fishing line snag, saw that I might wrap fishing line around prop, placed in neutral and raised motor out of water. Was still running and noticed smoke from lower end. Found that the jumper wires from the clamp had burned! Touched the two ends together and saw spark/arc. Stopped the motor and before I could disconnect the battery, saw smoke from the tiller arm pivot. Disconnected battery and discovered the throttle cables had overheated and fused. Could not operate throttle so had to use trolling motor to return (5 miles, very slow!)
When replacing cables, saw that one had rubbed lower engine case. Checked all connections, grounds, wiring and battery cables. Saw no indication of shorts or damage. Checked battery, showed good. Test ran motor with Mickey Mouse ears and looked for indication of jumper wire overheat -- no problems. Ran motor in lake, worked great, but found the lowest jumper wire burned again. Replaced wire, tested charging system -- shows 13.5 - 14 volts, no spikes. I do get battery voltage showing at jumper wire (engine off) when connecting voltmeter from engine ground to jumper wire terminal. I cleaned anode area (anode is perfect), and am wondering if voltage should show at jumper wire.
I have many years experience with small engines (chain saws, lawn mowers, etc) but am a little lost on this outboard. I have factory service manual and have traced all wiring. The battery and wiring are all isolated from the hull and show no shorts or contact with it. Any ideas?
Since this issue, I have replaced the throttle cables, checked all cables and wiring for continuity and shorts (non found) replaced the battery cables from the front mounted battery to juction block on transom. Did find that the positive cable was being pinched between the hull and the wood flooring. This must have been intermittent as testing showed no continuity between cable and hull.
Test ran motor and found no issues. Put in lake and after 1/2 hour running the bonding wire burned again and one throttle cable melted.
My thoughts: bad battery?, fried regulator?, or should I just buy a new motor! This on runs great and I did get it back to shore by discconnecting the battery and pull starting.
1991 Suzuki DT25C. Was backing the boat (16' Starcraft) to retrieve fishing line snag, saw that I might wrap fishing line around prop, placed in neutral and raised motor out of water. Was still running and noticed smoke from lower end. Found that the jumper wires from the clamp had burned! Touched the two ends together and saw spark/arc. Stopped the motor and before I could disconnect the battery, saw smoke from the tiller arm pivot. Disconnected battery and discovered the throttle cables had overheated and fused. Could not operate throttle so had to use trolling motor to return (5 miles, very slow!)
When replacing cables, saw that one had rubbed lower engine case. Checked all connections, grounds, wiring and battery cables. Saw no indication of shorts or damage. Checked battery, showed good. Test ran motor with Mickey Mouse ears and looked for indication of jumper wire overheat -- no problems. Ran motor in lake, worked great, but found the lowest jumper wire burned again. Replaced wire, tested charging system -- shows 13.5 - 14 volts, no spikes. I do get battery voltage showing at jumper wire (engine off) when connecting voltmeter from engine ground to jumper wire terminal. I cleaned anode area (anode is perfect), and am wondering if voltage should show at jumper wire.
I have many years experience with small engines (chain saws, lawn mowers, etc) but am a little lost on this outboard. I have factory service manual and have traced all wiring. The battery and wiring are all isolated from the hull and show no shorts or contact with it. Any ideas?
Since this issue, I have replaced the throttle cables, checked all cables and wiring for continuity and shorts (non found) replaced the battery cables from the front mounted battery to juction block on transom. Did find that the positive cable was being pinched between the hull and the wood flooring. This must have been intermittent as testing showed no continuity between cable and hull.
Test ran motor and found no issues. Put in lake and after 1/2 hour running the bonding wire burned again and one throttle cable melted.
My thoughts: bad battery?, fried regulator?, or should I just buy a new motor! This on runs great and I did get it back to shore by discconnecting the battery and pull starting.