Electrical Smoke from near the Rectifier

[bese6197]

1988 Evinrude 28hp spl on a 1987 Fisher Marsh Hawk 3V

Had a 'moment' when I hooked up my batteries for the first time this year. I had a pop and sizzle from the area near the rectifier. After removing the power, I noticed the red lead (from the power side of the starter solenoid according to my wiring diagram) between the distribution block and the rectifier is melted in a couple spots and looks burnt. I looked at the rest of the wiring and found no issues that would indicate a short. I did several repairs last fall (new fuel lines, rebuilt fuel pump, rebuilt carb) I triple checked the wiring of the solenoid to make sure everything is as its supposed to be and I didn't screw anything up making my repairs. Any ideas what might cause this? I cannot put power to the motor to troubleshoot and risk any more damage or fire. The only thing I have done different than normal is hooked up the motor to my trolling/accessories battery, since my cranking battery was dead and wouldn't take a charge. Is the rectifier shorted to ground? How can I verify? Are there going to be other casualties?

 

[jonesg]

Re: Electrical Smoke from near the Rectifier

Sounds like something Primary is backward nonetheless.
I would suspect the trolling battery terminals are opposite configuration from your starting battery.
I wouldn't install a new rect' until I find the problem.

 

[bese6197]

Re: Electrical Smoke from near the Rectifier

Thanks for the reply. I will remove/recheck the wiring at the battery again tonight and see if that eliminates the issue.

 

[bese6197]

Re: Electrical Smoke from near the Rectifier

Well it ended up being the starter solenoid + being to close to the starter -. Man these are right on top of each other in this engine and if the solenoid is rotated just so, they will arc. I suspect my starter solenoid clamp is a little loose and finally allowed it to rotate and touch the ground. I have rotated the starter solenoid back and 'insulated' the positive side with some electrical tape temporarily. I think I'll look for a rubber boot like is on the other side of the solenoid to prevent any future issues. The short didn't seem to damage anything thankfully. On to the next spring job.