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  #1  
Old 05-16-2015, 05:22 PM
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reidcc reidcc is offline
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Default 2166- Burning Ign Terminal wires

Hi All-

Have a 2003 Model 2166 giving me some fits.
It died while cutting yesterday. It will crank, it will Fire, and then die.
Looked at Fuel, spark, carb Solenoid, and started pulling on wiring.

While tugging on the relay behind dash- I could hear and feel the clicking while ignition on. Watched some of wiring while tugging and could see movement on terminals on Ignition Switch.

I got it to crank and fire and stay lit, and could see the Red wire terminal was glowing with a bit of spark, so I just shut it down. I pulled the switch, and marked which color each terminal mated with, and all Terminals were wrapped with electrical tape, but some seemed to be melted and/or corroded.

The Solid Red seemed somewhat corroded and melted housing. I think either the blue or yellow might have been somewhat bubbled as well. If I look at the back of Switch itself- other than being dirty- it seems ok, as all lugs attached seem to be tight.

My question is what would cause the melting/burning?

I found a replacement switch, and looks like I'd have to add a couple of new terminals to wiring and probably find some better heat shrink to protect wires.

All I want to do is get it running- as I've had it for sale and missed a sale last night because it died.

Thx
Chris
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  #2  
Old 05-16-2015, 06:00 PM
R Bedell R Bedell is offline
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Hot wires = "High Resistance" connection.

Anything that is discolored is TOAST. Cut out any/all bad wires, and terminal ends. If the Ignition Switch has discolored terminals......replace it.

Bottom line. Get everything back to good wire, terminal ends and switching devices.
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Old 05-16-2015, 06:45 PM
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reidcc reidcc is offline
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Thank You Roland
I was going to replace the switch anyway- its cheap.
I was just unsure of something else to cause the wire issue.

I've attached pic of rear of switch. The Red Wire connected on the left middle lug.

Chris
Quote:
Originally Posted by R Bedell View Post
Hot wires = "High Resistance" connection.

Anything that is discolored is TOAST. Cut out any/all bad wires, and terminal ends. If the Ignition Switch has discolored terminals......replace it.

Bottom line. Get everything back to good wire, terminal ends and switching devices.
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File Type: jpg switch.jpg (25.3 KB, 57 views)
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  #4  
Old 05-16-2015, 07:45 PM
R Bedell R Bedell is offline
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That switch is Well Done Toast....

High resistance is usually caused by "loose terminals" When you cut out the bad stuff, make sure the new wire and terminals connect.....TIGHT
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CC Models: 100, 105, 1450, 782, (2) 784, & 2072

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Old 05-16-2015, 09:56 PM
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I'm all over it! Hopefully I can get the switch sometime this week and put back together.

Thank You!!!
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Old 05-17-2015, 09:10 AM
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Quote:
Originally Posted by reidcc View Post

I'm all over it! Hopefully I can get the switch sometime this week and put back together.

Thank You!!!
Seems like a few weeks ago someone posted a plastic connector number for the switch--- thinking it was a delphi connector.
think you have to provide the wire ends tho'
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Old 05-17-2015, 09:12 AM
R Bedell R Bedell is offline
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Quote:
Seems like a few weeks ago someone posted a plastic connector number for the switch--- thinking it was a delphi connector
YUP....that was for a 1450.
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Old 05-23-2015, 12:20 PM
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Well I did not have a chance to get the switch- but I did clean it up quite nicely, and added new terminals to all wiring. It starts and runs quite nicely now- and I just sold the machine.

I am curious if the initial connection was done through a plastic housed connector though. I did have an issue some years ago and a southern NH dealer who shall remain nameless charged me an obscene amount of $$$ to supposedly replace a relay and a fuse. The terminals were just covered with electrical tape and that was all. I am sure as a part of their "troubleshooting" it was messed with.

Now I can take the cash and buy my triple bagger for my 2544.

Thx
Chris
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