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My son while on the inter-coastal called stating his engine just quit running. Further investigation found no electrical power, voltmeter at 0, motor would not lift. He "fiddled with" the battery connections and one was actually so hot that he burned his finger. After switching batteries engine started and he continued on. Several minutes later it did exactly the same thing. "Jiggled" battery cables and motor started again. Any thoughts?
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Sounds like there needs to be a serious inspection of the battery cables. The hot cable at the terminal end indicates a poor connection and subsequent arcing. Lift any insulation where the cable is crimped or soldered to the terminal and make sure that is free of corrosion. Clean the battery terminal and the cable terminals really good, including the nut that secures the cable to the battery stud. That's where to start. If that doesn't solve the problem, then further inspection will be required, moving on up the wire feeling the insulation for any tell-tale signs of deeper corrosion. Also, if the battery cables run anywhere near other wires or bundles, such as the positive or negative bus, it's possible that one of them were moved while jiggling the battery cable, so a problem may also lie there. All in all, it shouldn't be too hard to find the problem, since you probably have the general area pinned down.
One other point. Your son's DF150 has a "sub-battery cable," a smaller gauge white wire, that should also be connected to the positive terminal of the battery. Also check the integrity of this wire. It is an important wire for the reliabilty of the electronics on the motor.
Let us know what and how your son does.Mike -
If the battery terminal was hot (not the wire) it is simply a bad/dirty connection, do not be fooled by looking at it, you need to remove the terminal, clean it properly, and the battery post, and refit it nice and tight.Comment
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Thanks guys, my son took it to a suzuki repair shop today... let you know what happensComment
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