6-20
Indmar Marine Engines
WIRING
If during maintenance or inspection, it becomes neces-
sary to move or reposition any of the engine’s wiring or
wire harnesses, verify that wiring is returned to its origi-
nal position, and that all harnesses are routed correctly.
If a wiring clip or retainer breaks, replace it immediately.
Wiring is specifically routed to eliminate problems related
to engine heat and spray, immersion in liquids, or contact
with rotating assemblies. Electrical problems can result if
wiring is moved from its original position and is not prop-
erly repositioned.
Charging System Maintenance / Guidelines
Adhering to the following procedures and guidelines will
ensure proper operation of your battery charging system.
Watch out for:
1. REVERSE BATTERY POLARITY: When reconnecting
the battery after winter storage, it is easy to accidental-
ly reverse the battery leads and connect positive to
negative and negative to positive. This generally
results in a large arc at the battery terminals and fail-
ure of the diodes and/or regulator in the alternator as
well as other components in the electrical system of
the engine or boat that are polarity sensitive such as
ignition modules, ECMs, stereos, etc. For several com-
ponents to fail at the same time, the failures are gener-
ally due to some external influence such as reversed
battery leads or reversed jumper leads. These types of
failures are not covered by Indmar’s Limited Warranty.
2. POOR CONNECTIONS: When there is a defective
connection between the battery and alternator, charg-
ing current will be forced to find an alternate route to
flow out toward the battery. A defective connection
may be caused by corrosion or an open circuit from a
break in several battery cable strands or simply a
loose connection. The alternate route that current
finds usually leads to excessive current flow, causing
the diodes in the alternator to overheat and fail. It is
critical that all electrical connections are clean and
tight.
3. POSITIVE CIRCUIT FAULTS: A bad connection or
open circuit between the alternator output terminal
and the positive battery terminal will force the charg-
ing current to follow a parallel route through the diode
trio and out of the alternator. This heavier than normal
current flows though the diodes and will cause them
to overheat and fail. Consequently, if you have
replaced an alternator because of bad diodes, and the
replacement fails for the same reason, there is likely a
bad connection between the alternator BAT (B+) ter-
minal and the positive side of the battery circuit. Have
your dealer do a voltage drop test to check the entire
circuit. Also, never remove a battery cable when the
engine is running. This will cause the diodes to over-
heat and fail. Never use the alternator to bring an
undercharged battery to a fully charged condition. The
excessive current draw can overheat the diodes and
cause them to fail.
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