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2004 Honda BF255 not charging batteries

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Seachaser

Regular Contributor
Ok, I had my engine worked on by Honda tech, he replaced my leaky shift seal and that problem was fixed. But since he worked in that area my batteries are not charging. When he left we only ran it for <10 minutes at the dock and I did not have any electronics on.

I'd like to know the best way to troubleshoot this.

I did a visual inspection of the connectors and nothing appeared to be "Not Secured". I wiggle the connections to see if the it would vary the voltage nothing.

The motor starts and runs fine, just not charging. See photo of when he replaced my Shift seal, he had to peal back the associated cabling harness and unplug various connections.

I have two independent batteries on an A/B switch and select to run them independently, neither one appears to be charging when the motor is running.

IMG_20160908_104453reduced.jpg


If I remove the connection to the alternator (remove the load) to measure the output, will this create a problem since there will be no load on it?
 
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Found that alternator fuse no. 5 (10 amp) is blowing. Need to find out why.





[QUOTES=Seachaser;552948]Ok, I had my engine worked on by Honda tech, he replaced my leaky shift seal and that problem was fixed. But since he worked in that area my batteries are not charging. When he left we only ran it for <10 minutes at the dock and I did not have any electronics on.

I'd like to know the best way to troubleshoot this.

I did a visual inspection of the connectors and nothing appeared to be "Not Secured". I wiggle the connections to see if the it would vary the voltage nothing.

The motor starts and runs fine, just not charging. See photo of when he replaced my Shift seal, he had to peal back the associated cabling harness and unplug various connections.

I have two independent batteries on an A/B switch and select to run them independently, neither one appears to be charging when the motor is running.

View attachment 14195


If I remove the connection to the alternator (remove the load) to measure the output, will this create a problem since there will be no load on it?[/QUOTE] you
 
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Re: 2004 Honda BF255 not charging batteries, Blown #5 10a fuse

Using my Honda Marine shop alternator troubleshooting step, determined a good connection between ACG Side 4p connector pin 3 (alternator) to ECM Connector A pin 23.

IMG_20160910_163454.jpg IMG_20160910_163348reduceb.jpg

I don't like the next step: to substitute a known good ECM and recheck................

Not like a have an extra one just hanging around.
 
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Unlikely it's the ECM. You're on a bug hunt for a short somewhere. I took a quick look at pages 2-20 & 2-21 in my shop manual to see what feeds off of fuse #5. Based on that, the first place I would look is the four-prong red service connector. The mechanics likely had to screw around with that a lot when they replaced the shift rod seal.
 
Thanks when I get back there I'll look more into that red service connector. And yes to gain access to the shift seal assy., the tech did disconnect most of that cabling (see prior photo) and removed the bracket assy. then pealed tie wrapped it off to the right side of the motor.

This morning I measured resistance with the Fuse #5 removed, The top of the fuse terminal read 200 ohms to ground and the bottom of the fuse terminal read 4 ohms (essentially grounded) to ground. I'll try to investigate from the circuit if that sounds correct.

IMG_20160911_093915reducedb.JPG


Another note: Besides fuse #5 blowing, all the others #1 to #7 visually looked good (not Blown).


But I'd agree there's got to be a short to ground somewhere...........
 
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You essentially have the list of potential path for the short.

To make it easier, get a 12 v test light and connect it to the fuse holder in place of the fuse.

Carefully put paperclips in the slots, then use small jumper wires to wire up the light.

Turn on the key switch ....do not start the engine.

The test light should light up.

Then go to each of the items listed and disconnect them, one at a time. When the light goes out, that connected device will be the area of the cause.

I say, area of the cause, it could be the part (like the alternator's regulator) or it could be messed up pins in the connector or a short in the wiring harness.

If that does not give you direction, after you turn off the key switch, take the 14 pin (big round connector) apart from the plug and check for any corrosion on the pins. Also check the 6 pin connector near the 14 pin connector, that is also connected to the wiring harness at the engine going to the helm.

Most of the connectors are easily reachable.

Hope that gives you some direction.


Mike
 
That light bulb trick was brilliant, I have photos coming. What I found was the jumper light bulb will not lit (not shorted) when the "Fuse Box to PGM-FI main relay connector" is disconnected.

Still have not found the root cause, I need to research where this is located and do further testing.
 
Seachaser. Look in your manual. Don't have mine available at the moment but I thought the power to that fuse and many of the others came from the main relay. I'll confirm when I can get back to my manual
 
Chawk is correct. Disconnect the mian relay, the power goes away.

The same will happen if you disconnect the 14 pin connector.....That will turn off the main relay. That is why I only said to check the pins.

If you do not have any luck with the light trick, the you will have to track each circuit with an ohm meter. Look for smashed wires behind mounting brackets that may have been removed during the previous repair.

Mike
 
Problem solved!

The last tech who worked on the shift seal issue crossed up two cables directly above it.

When I have time I'll provide pictures.
 
Problem solved: The last tech that replaced the shift seal mistakenly reversed two cables causing the blown fuse. Remember, you can't always assume these guys are doing the right thing. Take many before and after photos.
 
It was the blue connector and the black connector, right there in front, behind the black cover. Usually you can't cross cables in that harness, but not these two. When I have time I'll post pics.
 
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