Super Jet Keep burning wires...HELP

[lilracer94]

Wires keep burning up on my superjet. The plastic coating does not melt, just the wire inside turns black and loses conductivity. I have had to re-wire my bilge pump 2 times in 4 months because it has stopped working (maby bad bilge switch?). The wires are not corroded, and I only get about 8 rides out of the ski before I have to re-wire.The bilge pump still works after i re-wire it. Now after taking my start/stop switch off, I noticed the brown wire is also starting to burn inside the plastic (only the brown wire). The brown wire is progressively burning from the connection off the e-box towards the start/stop switch. It was burned about 1/2 the way to the start/stop switch. Does anybody know what would cause the wires to burn like this?

 

[OCD Solutions]

Sounds like a high resistance short to ground. What size fuse are you running?

 

[lilracer94]

I was running the 1100 GPH Rule bilge pump with a 10 amp fuse (calls for a 5 amp, thought I put a 5 amp in until I took it out to check yesterday). I got 2 500 GPH Rule pumps and will be putting a 5 amp fuse for both combined (calls for 2.5 amp fuse for each). I am also putting a new cable for my ground to flywheel cover.

 

[lilracer94]

The bilge pump that I was running was an auto, off, on type. The "on" stopped working until I rewired it. Could it be that it stalled and was drawing too much power? Anyone....Please

 

[augustaf]

I think there is more than one issue. The copper of the brown wire of the start/stop switch is turning black because of the corrosive components of saltwater, yes it can penetrate the insulation eventually (might take a few years). This is why "marine grade" wire is tin coated. You obviously had water leak into your bilge switch causing it to fail. - salt water is somewhat electrically conductive which can cause the pump to draw some power continuously if the switch has thus been compromised.

 

[227]

I'm an amatuer electrician at best but its been my experience that burning wires are usually the result of a poor ground. I'd start by first disconnecting all your grounds, cleaning the terminal ends AND the bolts they attach too until they're shiny and re-connect them and cover them with die-electric grease. Even if its not your problem you can't go wrong with good grounds