dt40 melted my battery cables

[buildman]

Hi Folks;

I've read all the FAQ's about starters and I couldn't find this situation, shucks, I'm old, I may have missed something somewhere, but I tried .

I've just installed a used flywheel and starter on my 1994 Suzuki manual pull start engine. From the beginning the starter was turning sluggishly, it would turn slowly at first and then pick up speed until the engine would start. Today my son and I were starting the engine and it didn't start at first and my son just helt the switch down on the stater and the next thing we new the battery cables we hot and melting, the battery is new.

To give you the whole story I did not change out the stator that was on the engine because to me the wiring looks the same, would this cause a problem? This motor only has about 50 hours on it and the stator on the engine still looks brand new. I did purchase a used stator with the flywheel, should I have changed that out when I installed the flywheel?

Thanks in advance for any help.

James

 

[99yam40]

Re: dt40 melted my battery cables

Sounds like your motor is binding and too hard to turn over, the starter motor has a problem and is binding , or your cable connections are bad or possible too small of cables

 

[buildman]

Re: dt40 melted my battery cables

Sounds like your motor is binding and too hard to turn over, the starter motor has a problem and is binding , or your cable connections are bad or possible too small of cables

Hi and thanks for resonding;

I went this morning and had a larger set of custom cables made for the engine, I went up a size and had all the connections reemed out to the exack size of each connection and installed, the starter is finally doing as it should. The used stater I purchased came with a set of cables that was just too small, this part of the problem seems to be fixed.

I still need an answer to the stator issue in the original post.

Thanks a bunch

James

 

[99yam40]

Re: dt40 melted my battery cables

Check to see if it has a rectifier/ regulator to change the pulsing A C voltage into DC and regulate it to about 12-14 volts. Your manual should have steps for testing

 

[buildman]

Re: dt40 melted my battery cables

Check to see if it has a rectifier/ regulator to change the pulsing A C voltage into DC and regulate it to about 12-14 volts. Your manual should have steps for testing

Yes there is a rectifier and I'll look at the manual, I installed the rectifier when I installed the starter and flywheel, as aforementioned I didn't change out the stator because the used electric start one I purchased look exactly the same as the one on my manual start engine, oh the confusion!

I had to call the Suzuki dealer in New Orleans today, I needed to order a kit to rebuild the carburetor, these are good folks at this dealership so I asked to speak to their mechanic and I quizzed him about the differences in the stators on the manual start engines and the electric start type. He looked at the wiring diagrams and advised me to change out the charging coil and I should be good to go, does that sound about right to you folks?

Thanks