Ground Cable Hot

[Stevehay]

I have replaced my main ground cable running from the battery to the engine case on a 2002 Seadoo Gtx 4 Tec as the old cable was getting red hot and in bad condition, went for a run today for about 1 1/2 hours and the new cable insulation is melting at points, I did not use an original Seadoo cable but used what I thought was a heavy duty cable.

Can anyone say what current this cable would have running through it to get so hot, I cleaned all the connections/terminals, upon inspection of the 2 smaller ground cables coonected to the battery they are both black inside the cable.

If someone can help I would be greatful.

I also blew a seal on the propulsion shaft but its going to a local workshop for that.

 

[Dr Honda]

It shouldn't be getting that hot.

If you have high resistance in the cable for some reason, it would get hot... but if there are no other problems... run a second ground to a different part of the engine. Using 2 cables will share the load, and should keep it from melting the casing.

 

[05GTXSC]

Sorry to go against you Doc but if I where him I would want to find out why there is that much current going though a ground wire. If all the production 4-tec's have no issue then why should he? I have never heard of this problem but I would use a current meter and trace back where that power is coming from could it be a bad regulator? Or maybe something in the computer?

 

[Stevehay]

Hot ground

Thank you for your replies, I will run a second ground but what could be the cause of this as my concern is that there must be a lying fault somewhere?
I have replaced the regulator/rectifier, I would think there must be a direct short somewhere or could this be the result of bad ground connections.
I have purchased a better quality/rated ground cable today which i will connect and check to see how many amps are present in this cable with the motor running.
The really strange thing is that the engine runs with no faults at all,just an intermitant fuel pump fault that i have checked out to be a faulty connection.

Your comments are welcomed

 

[Dennis]

Battery Ground Cable

Something really strange going on because the only reason the ski has a large ground cable and positive cable is for when the starter is engaged. It's the only thing that can draw that many amps.
Are you sure it's not heat from the exhaust manifold causing the insulation to bubble up?

DAWG

 

[Dr Honda]

Sorry to go against you Doc but if I where him I would want to find out why there is that much current going though a ground wire.

:agree:

I totally agree. I was just offering a band-aide

The root of the problem needs figured out, and fixed.

 

[Bills86e]

Maybe his starter is running?

 

[Stevehay]

Hot ground

Guys, thanks for your replies.
The exhaust system does have a problem and is being repaired tomorrow, I still think there is an electrical fault I am sure the starter is not running but could there be a possible short in the starter causing this.
I did a static test on the stator last night and I have 0.6ohms between each phase and no resistance to ground so this is fine.
I will keep you updated, I am sure it is something obvious but I cannot see it at the moment.
Thanks