Thought I'd share an odd hiccup with my machine. Had the machine for four years or so, and initially, I had a weak battery, I get a new one. A year later, I noticed the hot lead to solenoid was wiggling out of the crimp-on connector (below red rubber boot in pic). I re-crimp, and all is good. Yet, every once in a while, I'd get a click, click, no start. I'd hook up jumper cables and fire it up. A couple of days ago, I got a partially starter engagement, then click. And the light on panel was indicating a dead battery. Voltmeter said 12.6V...not great, but not bad.
I'm like no way, it is virtually a new battery. I pull the terminals all around, clean and re-install. Still the same...click, click, or partial starter turn, then click. I was thinking it was my crimping job of the hot line connector to solenoid. As I was figuring out how to really meld the wire to connector I noticed the ah-ha moment. The hot lead has a plastic shield from battery to solenoid, except the last 4 inches. In those last four inches, it gently sits on the starter and attaches to the solenoid. Well, after 4000hrs, I guess the vibrations of the machine had worn through the hot lead sheathing, and it was shorting on the starter when I tried to start it. Amazed no fuses blew or battery meltdown.
I pulled on the plastic shielding, as there was some slack, and was able to cover the 'hot' spot (also wrapped the hot spot in tape). Then taped everything together and voila, it fires up without hesitation.
What really rankles me, is I probably fried the first battery and was well on my way to frying the second battery before I discovered the problem, as it wasn't visible (underside of cable). That hot cable has a very thick jacket on it, yet it managed rub off over all these years.
![Name: 20151125_151426 (Large) short.jpg
Views: 56
Size: 58.1 KB]()
I should see about attaching a non-conductive clamp to wire and bolting it to black bracket in pic....one day. Or maybe an old garden hose...
I'm like no way, it is virtually a new battery. I pull the terminals all around, clean and re-install. Still the same...click, click, or partial starter turn, then click. I was thinking it was my crimping job of the hot line connector to solenoid. As I was figuring out how to really meld the wire to connector I noticed the ah-ha moment. The hot lead has a plastic shield from battery to solenoid, except the last 4 inches. In those last four inches, it gently sits on the starter and attaches to the solenoid. Well, after 4000hrs, I guess the vibrations of the machine had worn through the hot lead sheathing, and it was shorting on the starter when I tried to start it. Amazed no fuses blew or battery meltdown.
I pulled on the plastic shielding, as there was some slack, and was able to cover the 'hot' spot (also wrapped the hot spot in tape). Then taped everything together and voila, it fires up without hesitation.
What really rankles me, is I probably fried the first battery and was well on my way to frying the second battery before I discovered the problem, as it wasn't visible (underside of cable). That hot cable has a very thick jacket on it, yet it managed rub off over all these years.
I should see about attaching a non-conductive clamp to wire and bolting it to black bracket in pic....one day. Or maybe an old garden hose...