Old SJ electrical problem - won't stop starting. HELP!

Evaun

Evaun

Location
San Antonio
okay guys so I have done many searches but Google still has not brought me an answer....so here I am. I apologize if this has been covered in another topic, but I have not found it so your help is greatly appreciated.

I bought a 91 Superjet from this dude about 3 months ago. It's old, been run in saltwater most it's life, and just old.

It has been running fairly decent for the past 10 hours. I changed out the battery this morning and attempted to start it.
After hitting the start button, the engine WOULD NOT STOP STARTING! Pulling out the kill switch did absolutely nothing! Sparks began flying from the positive batter terminal as I frantically tried to unscrew the battery lead from the battery. Pulling the lead was the only thing that stopped the started from engaging.

My first thought is that the solenoid or relay has gone bad, but I just changed the thing out not less than 1 month ago!

Everything was melting hot. The battery terminals has parts of the top melted and the terminal screws were outrageously hot.

And yes, I did check the battery voltage. It read 12.75 volts

Any ideas? Any response is greatly appreciated! Please help me not kill myself trying to fix this myself.

Thanks guys!
 
augustaf

augustaf

Location
central florida
I noted you changed out the solenoid recently, was that a used one or an aftermarket solenoid?. That seems to be the problem: the contacts are sufficiently bad/ burnt , they stick together and wont release. If the solenoid is operated with a weak battery, the starter may draw a lot more amps since the voltage will be lower, that could cause this failure. Solenoid cannot be repaired satisfactorily, needs R&R.
 
Evaun

Evaun

Location
San Antonio
Thanks for the super quick reply Augustaf!

It was a brand new relay I purchased on eBay actually. Aftermarket.

I was having some trouble starting my ski the other day and did run the battery down pretty low. I see what you're saying. My best option would be to go with a brand new solenoid, correct?
 
Evaun

Evaun

Location
San Antonio
Definitely pricey from Yamaha. Upwards of 75 bucks for the relay.

eBay is where I got mine.

Oh well. Now I know.

Thank you kindly for the help! It is greatly appreciated!
 
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