02 SJ starting problem

[Don 79 TA]

need some help here. went out today, launched from the doc, started and ran fine.
get to the spot, turn it off.
tweaked her throttle out on her ski.
we go to start, and i hit my start button. i get like a sound from the electrical box, kind of like a buzzing relay or something.
the started doesn't engage. pumps work, so it's not a battery issue.

i open the hood hit the button and again noise from the electrical box.

i do it again, sounds like the starter engages once, then a puff of smoke from the exhaust manifold/starter area.

did the starter fry?
no i get nothing, so is a fues or relay now blown?
i have the factory B pipe on. does all of that have to come out to remove the starter? and the manifold too?

where and how should i start troubleshooting?
thanks

ruined the day thats for sure

 

[Matt_E]

Pulling the headpipe and chamber should be enough to pull the starter.
What battery are you using?

 

[D-Roc]

i just pulled my starter without removing the bpipe in my square, my bendix must have stuck last weekend before i changed it and spun my starter, gave out this weekend, change the fuse in the ebox to get some more smoke happening,

 

[SUPERTUNE]

The first thing to do is add a new ground cable (go to auto parts store and get something temp for like for $10) add on to the neg. terminal and go to head bolt or a intake bolt on the engine directly, charge, change, or use new battery, next disconnect the red/brown 2 wire connector that goes to start/stop switch and jump with like needlenose pliers on the box side to see if start switch is not giving a good connection, if still no go, pull out elec. case and open up and remove the main lead to starter and jump to the main terminal from the battery to see if the relay is bad, if still not cranking, check starter lead and starter...Make sure you remove plugs and add some oil in cylinders until you get ski started.

 

[Don 79 TA]

Pulling the headpipe and chamber should be enough to pull the starter.
What battery are you using?

Oddesy battery, i know it's good
you can smell something not so good near the exhaust pipe.
i am going to pull that fuse out to check that out too

reason i suspected the starter is is that it's 4 years old and has been cranking high compression motors over. could also be the salt water environment too

 

[Don 79 TA]

The first thing to do is add a new ground cable (go to auto parts store and get something temp for like for $10) add on to the neg. terminal and go to head bolt or a intake bolt on the engine directly, charge, change, or use new battery, next disconnect the red/brown 2 wire connector that goes to start/stop switch and jump with like needlenose pliers on the box side to see if start switch is not giving a good connection, if still no go, pull out elec. case and open up and remove the main lead to starter and jump to the main terminal from the battery to see if the relay is bad, if still not cranking, check starter lead and starter...Make sure you remove plugs and add some oil in cylinders until you get ski started.

Tune.....
You ARE the man......
broken ground cable. i was feeling underneath, pulled the loose cable, looked at it, traced it to the bat, used a jumper cable from neg bat. to the cyl head, and she fired right off......

I can't believe that
so what i will do is try to get a new ground cable, and ground it to the cylinder head. I'm not sure if they cable is totally rusted inside, i snipped about 4" off, it seems ok, but has some sort of chalkish type of residue that looks rust color.
where does the ground cable usually go to on these skis?
bedplate?
can i also run another cable as a ground cable and ground it to somewhere else as well?
i just need to see what threading size that exhaust bolt area is, to see if i can find a bolt to fit in there. i hope i can

i was able to run it and flush it, that was a major concern

 

[D-Roc]

i run my ground to one of the bolts that holds on the starter motor and that is it, not sure if you need one on somewhere else.

 

[keefer]

If you are going to replace the ground cable, I suggest that you buy a new one from Yamaha or get one from JSS. If you want to make your own then buy one off the shelf from any auto parts or supply house that is the same guage and length as the original. Usually the ends are crimped and will only work for a while especially if you ride in salt water. While you are at it get some new tin coated terminal ends and solder them on. The solder will wick up into the conductor and partially melt the plastic to help seal the wire.. This will make them last alot longer. I have made up several and they are working well.

BTW, it is best to attach the ground wire at the top starter bolt. It will work attached to the head, but if it is at the starter the high current for starting has less potential for resistive loss the closer it is to the starter motor.

 

[Don 79 TA]

ok, i was going to try to avoid pulling everything apart to get near the starter, but if that's the best location, then i'll do it

I'll order a new cable today

 

[Don 79 TA]

ok i pulled the end off the starter and removed that bolt
i am going to get some tin ends to use.
i can work on it at work in the lab and get a good seal on the ends

looks like salt water culprit and vibration broke it
thats ok, i can fix it

can i use the power cables that i have left over from doing her amp install in her car?
i think it was 4 6 or 8 gauge, i can't remember, looked like nice cable, just want to make sure there isn't a special cable that i would need.


thanks again for everyone's help on this, greatly appreciated

 

[keefer]

I don't remember the exact guage, but you can just compare it to what you had and figure it out. There is nothing special about it, just a ground wire. You will probably have to use a small butane or propane torch to get enough heat into the joint to solder it. Get some big rosin core solder and get to it. It is a bitch to remove / attach to the top starter bolt but it can be done. I did it on my blaster earlier this year. Work a while cuss a little and work some more.:banghead: :biggrin:

 

[Don 79 TA]

i went to west marine, bought a 4 guage made up cable
fit's perfect
tinned and sealed
wasn't that expensive either
put everything together and BAM fired right up

so that outta work for this season