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Old 10-09-2017, 05:43 AM   #1 (permalink)
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Default Suzuki Samurai electrical problems

I am restoring a 1986 Samurai, and have it stripped down for painting. Last night, I needed to start it to move it, and the battery was nearly flat. Took it out, and charged it overnight. It is a new battery, by the way.
This morning, put the battery back in, and tried to fit the terminals. Sparks ! And there is a small cable from the terminal which goes back into the loom, which has a spade terminal connector just before it goes back into the loom, which started to get hot, and smoke.
I dieconnected it pretty promptly!
What I would like to know, is what does this csble connect to?
And secondly....what the heck shorted itself out during the night, when all I did was remove and charge the battery??
Help please!
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Old 10-09-2017, 09:56 AM   #2 (permalink)
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That wire is the main supply for everything but the starter motor. The short lead coming from positive terminal is a fuse link and is designed to burn up before the main loom gets damaged in a short circuit. Just about every other circuit has its own fuse so it's largely protecting the cable to the fusebox and alternator.
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Old 10-09-2017, 11:32 AM   #3 (permalink)
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More fuselink info here Suzuki Club UK ? View topic - Fuselink info
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Old 10-09-2017, 01:45 PM   #4 (permalink)
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Are you sure you connected + to +, and - to -?

... Philip
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Old 10-09-2017, 02:22 PM   #5 (permalink)
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Aquanaut was thinking the same as I was.
If you put the battery back in correctly then there should be no problems
Seems like you may have reversed the polarity??
That would mean several fuses and fusible links were blown
Radio and dash lights may be out also.

Check your fuses .. all of them.
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Old 10-09-2017, 10:59 PM   #6 (permalink)
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Thank you all for your prompt and kind replies.
No, the battery cannot be connected the wrong way round, because the cables are too short to allow that.But I still went out to check I am wondering if there is a live cable which as become disconnected and grounding out somewhere...I can't think of anything else...unless some rodent decided to get under the dashboard and chew a few wires
This really is ridiculous! Nobody went near it overnight...I even began to wonder if I connected the charger up back to front, and reversed polarity of the battery D
I will go back to bed, and take another closer look in daylight...but i checked the engine bay for a cable touching the chassis, but nothing...next have a look under the dashboard...I will post any results.Thanks again!
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Old 10-10-2017, 10:23 AM   #7 (permalink)
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Expensive mistake. In the dark, flat battery...connected it to the charger...reversed polarity. Blew radio, alternator, and lord knows what else. At my age, I should have known better. Getting old and senile.
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Old 10-10-2017, 10:25 AM   #8 (permalink)
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And a brand new battery.
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Old 10-10-2017, 02:13 PM   #9 (permalink)
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Quote:
Originally Posted by Nick Cann View Post
Expensive mistake. In the dark, flat battery...connected it to the charger...reversed polarity. Blew radio, alternator, and lord knows what else. At my age, I should have known better. Getting old and senile.
Guess it might have been better to wait for the daylight to do this work.
Anyway, check all fuses and fusible links.
If radio fuse is blown then be careful. Radio may be shorted out??
Also check headlights.

I wish you luck in getting it back up and running again!!!
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Old 10-10-2017, 04:19 PM   #10 (permalink)
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Yeah....familiarity breeds etc.
The radio burnt out, but it was a 1986 tape deck...so who cares? alternator is fine, and all fuses intact...but headights are disconnected, so can't check them.
I decided to drain the battery, using a 12 volt motor used for starting RC plane engines. Slow drain, until empty. Put the battery back on charge, CORRECTLY CONNECTED this time been charging for 12 hours, and registers 13.8 volts. Maybe because it is new, and I drained it slowly ( 3 hours) until empty, I might have saved that too. The ignition light goes out when it should, and ciesn't come back on at all.
Fingers crossed!
Now, I have to source some Stromberg carbs and manifold, to replace these ridiculously complicated original ones.
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