SuzukiSavage.com - Electrical Smoke

greenmonster

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Electrical Smoke
05/01/17 at 12:19:19

Hello All,

This fall my bike was running just fine. I wanted to repaint as some of the paint had gotten road chipped. That went fine. Paint turned out well.

While I was pulling stuff apart I figured I would retorque my head bolts. One of the guys who was giving me a hand got a little over zealous and pulled the pin out of the decompression solenoid. I put it back in without a lot of trouble. Is there something that I may have missed doing that?

When I got it all back together, the battery was low and wouldn't turn it over. I figured that wasn't too bad, I had taken it off the charger a couple months ago so no big deal. I hooked it up to a trickle charger over the weekend and thought that would be the end of it.
When I checked this morning, everything looked good. Readings on the battery were where they should be.

I tried to fire it up and it would crank but didn't want to catch. I tried a few more times and just as I was going to stop trying it started to crank on its own. I was not touching the start button. Then smoke started coming from under the seat. I disconnected the battery and took the seat off. The positive going from the battery to the starter solenoid has melted all of the insulation off.

Any thoughts?

-Eric

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verslagen1

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Re: Electrical Smoke
Reply #1 - 05/01/17 at 12:44:13

greenmonster wrote on 05/01/17 at 12:19:19:

pulled the pin out of the decompression solenoid. I put it back in without a lot of trouble. Is there something that I may have missed doing that?

When I got it all back together, the battery was low and wouldn't turn it over.

I tried to fire it up and it would crank but didn't want to catch. I tried a few more times and just as I was going to stop trying it started to crank on its own. I was not touching the start button. Then smoke started coming from under the seat. I disconnected the battery and took the seat off. The positive going from the battery to the starter solenoid has melted all of the insulation off.

Pin connecting the cable? I don't see an electrical issue with that.

Red Flag.

Waving red flag with flares.

Did you check the water?
You really cooked that didn't you.
You shouldn't be running the starter for more than a minute max.
And then you should let it cool for 10-15 minutes.
You'll burn up the starter, the magnets will dislodge and your hair will fall out.
A tired bat will spin the starter just fine, but if you don't have at least 10v it won't ever start.
the CDI just shuts down.

So, now you need new bat leads, maybe a new bat.

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greenmonster

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Re: Electrical Smoke
Reply #2 - 05/01/17 at 12:53:27

My decomp cable is hooked up. I don't think it has anything to do with the smoke. Just wanted to give out any and all info.

I was not running the starter longer than 6 seconds at a time. With 10-15 second intervals between retries.

I did not check the water levels. I have never had a problem with water levels on sealed batteries before, but hey, there's a first time for everything. I'll check them during lunch.

If I do need a new battery, anyone know how many CCA we need for these bikes? I saw some pretty sweet little lithium options last time I was in Battery World.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Electrical Smoke Reply #3 - 05/01/17 at 13:05:15 If it's sealed bat, then no need to check water... idk. I think the stock bat is about 270 cca. Was the engine turning? and not stalled? The cable should not be melting otherwise.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Electrical Smoke Reply #4 - 05/01/17 at 13:11:02 Nobody retorques the head unless they pulled it.
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greenmonster

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Re: Electrical Smoke
Reply #5 - 05/01/17 at 13:49:51

JOG, I retorqued cause I fixed the plug leak and checked my rockers for wear.

Vers, The engine was indeed turning. I am wondering if the wire that I used to replace my battery lead with was not rated for the Starting Amp draw. I have used that wire on Kawasaki 850 V twin engines, but I'm pretty sure that they don't pull the same amp draw as our big single. I have replaced the lead now and I am waiting to see if my battery will charge. Otherwise I have some spares sitting around the shop that I can test with.
After work I will hook it up and see if I melt again or if it was just a bad wire. Cheesy

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Electrical Smoke Reply #6 - 05/01/17 at 15:28:02 Kawasaki 850 V twin engines, but I'm pretty sure See what the CCA requirements are. I'd expect the 850 takes fewer amps. The ground should be a clue.
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greenmonster

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Re: Electrical Smoke
Reply #7 - 05/01/17 at 17:28:33

So my battery charged back up just fine. I hooked it back up and hit the starter button and got a solid "click" from the solenoid.

And that was it.

The voltage on my battery dropped from 12.8 to 12.6 and while I had the button engaged and then went back to 12.8 when I let go. Same result on another car battery.

I took the starter out and it spins well. I opened it up and there was no sign of damage, not even smell.

Is there a way to test my solenoid?

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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: Electrical Smoke Reply #8 - 05/01/17 at 18:04:36 Now that the shop is quiet, I can also hear my decompression solenoid clicking.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Electrical Smoke Reply #9 - 05/01/17 at 19:11:57 the bat is dead
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greenmonster

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Re: Electrical Smoke
Reply #10 - 05/01/17 at 19:25:09

I'm at home now so I can't test it. I really hope that's all it is, but if the battery is dead, why would it read 12.8 and then 12.6 when I push the starter? It went back to 12.8 after I released the starter button.

It's driving me up the wall, the weather is finally turning and I put a ton of hours into the prep and painting, just to be foiled by this.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Electrical Smoke Reply #11 - 05/01/17 at 19:38:20 Sorry, made a snap decision from not enough info. So all you hear is 2 clicks, 1 from the decomp, then 1 from the relay?
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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: Electrical Smoke Reply #12 - 05/01/17 at 20:23:45 Actually, I hear them in the reverse order. The relay then the decomp. I don't know if the order matters or not. Just trying to be thorough. Thanks for your help
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Electrical Smoke Reply #13 - 05/01/17 at 22:04:46 bend over to the left, you should be able to see the decomp going 1st. if it's not going 1st, or is not adjusted right the starter can stall. that'll cause the starter to use more amps and burn up your cables.
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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: Electrical Smoke Reply #14 - 05/02/17 at 07:42:32 How do I go about adjusting it to go first? It is definitely going second right now. I put my hand on it and can feel that it is clicking over after the relay clicks.
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