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  #1  
Old 01-31-2015, 01:30 PM
Mako19's Avatar
Mako19 Mako19 is offline
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Default Suzuki 4-stroke 140 hp burnt wiring harness help

I know there are some boat mechanics on here that have been very helpful in the past to some posters with motor problems so I wanted to see if anyone had any advice for this one:

I am helping a friend try to fix his 140 hp 4 Stroke Suzuki motor. I think it is around a 2001 model.

The motor had not given him any problems until the last trip he took.
When he started the motor is started as usual and after about 5 minutes of idling he heard an alarm. Not sure hat alarm was for. Checked all fluids everything good, no more alarms, so continued on with trip. Around 4 hours of starting and stopping while fishing.

Killed motor at boat launch and backed-up trailer. Motor would not start back up to load onto trailer. No beep when key turned on, no trim, and no power anywhere else. Only thing on was gauge lights on console.

Pulled cawlin and noticed wires from wiring harness melted together (pictures attached). No fuses found burned or anything else wrong. Verified that there was still power at started on motor.

Our game plan as of now is to cut out the burnt section of wires on harness and then see what we have.

Any suggestions or experience are greatly apppreciated.

A very helpful friend, BGizzle, stated that the wire insulation may have just rotted and caused a short which caused the heat to melt the wires together. If this is the case then cutting out the bad section of the wires should do the trick.

My main concerns are:

The wires melting together like that could have fried computer or other devices.

Cutting the bad sections out and hooking it back up to battery will cause even more damage.

Thank you in advance for any input.
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  #2  
Old 01-31-2015, 03:21 PM
mallard mallard is offline
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The rusted spot on the engine is the problem. Pretty common issue in the early Suzuki 4 strike. The bolt rusts out over time. Then starts allowing exhaust into the cowling. Eventually melts the wiring harness. Need to get a welder to patch the hole then fix harness. I used south side welding.
Or you can replace the entire engine holder but it's pretty expensive.
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  #3  
Old 01-31-2015, 04:05 PM
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Mako19 Mako19 is offline
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Quote:
Originally Posted by mallard View Post
The rusted spot on the engine is the problem. Pretty common issue in the early Suzuki 4 strike. The bolt rusts out over time. Then starts allowing exhaust into the cowling. Eventually melts the wiring harness. Need to get a welder to patch the hole then fix harness. I used south side welding.
Or you can replace the entire engine holder but it's pretty expensive.
Thanks for the reply Mallard!

You are right, I read your post and now we can see that there is a hole in the engine holder.

When this happened to your motor did anything else get fried or did just patching the hole and fixing the wires get the motor running again?
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  #4  
Old 01-31-2015, 04:43 PM
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wishin i was fishin wishin i was fishin is offline
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As far as the electrical portion, you wil have to patch and see what happens. if it was an exhaust leak you may be fine.

if you are around Lafayette area, and need help with the wiring repair, Holla.
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  #5  
Old 02-01-2015, 01:32 PM
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keakar keakar is offline
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the most common things to get fried by shorted wires will be your rectifier and your ECM.

since it didn't blow the fuses then if you are lucky both parts should still be fine.

in my experience the ecm can withstand a few more "oops" moments then the rectifier so test the rectifier for shorts and that the diodes all work ok. even if its not shorted it may not charge the battery correctly if the diodes are blown.

Suzuki must use low grade aluminum because they all have these corrosion and rust issues even though this one is a steel plug.
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  #6  
Old 02-02-2015, 04:04 PM
mallard mallard is offline
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My wiring harness was fine. Caught it before it melted. Just patched the hole.
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