Smoking on start up (electrical)

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pgp29646

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Hope to get some direction... 86 M1009 - never have had any starting issues. Today on the third start up of the day, when turning the key after waiting for the wait light to go out - nothing. Tried again and a light click on the passenger side and then smoke - smelled electrical - lasted for 10 seconds then stopped. Felt the battery cables from the batteries down as far as I could the they were not hot to the touch. I did not get to go under the truck as it is in a big puddle and I couldn't get wet at the time. I have not done the doghead relay - I know, I know - its on the list. Still 24v starting system, new batteries this spring and again I have never had any starting issues before. What should I be looking for when I get it home? Thanks in advance for your insight/advice!
 

nyoffroad

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Sounds like you let the magic smoke out of the starter, once it's out you can't put it back just replace with a new or rebuilt starter.
 

Curtisje

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I smelled smoke during starting a few weeks ago. That was the last time that starter worked for me.

I agree with nyoffroad. Time for a new or rebuilt starter.
 

MarcusOReallyus

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Yep. Check all of your fusible links, first. Can't hurt to test the starter, but it's sure not time to start buying parts.
 

pgp29646

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Thanks for the feedback!! I’ll start checking fuses tomorrow. If I can find a way to get all the smoke back into the starter I’ll let you know!
 

firefox

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Just checking. You do realize that fuseable links are not the same as fuses and are not found in the fuse box. Not being a wiseass, just trying to help.
 

pgp29646

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No offence taken Firefox - I had to look it up!
So I found one of the fuse links that had fried, replaced the link and hooked the batteries back up and tried to start it up and the starter kicked in and would not stop cranking even with the key out of the ignition. Luckily I didn't have the batteries hooked up that tightly (on purpose) and was able to disconnect and shut it down. So my question - obviously the starter relay is trashed - is there anything else I need to look for after doing the doghead relay? Could the starter solenoid be shot as well?
 
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Curtisje

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I installed a push button under the steering wheel and by passed the relay when it quit on me. Wired it right into the relay wires so I can install a new relay later if I want to.


20190915_134721.jpg
 
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firefox

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My guess is that once you do the doghead mod, you will be good to go. Others may chime in with more suggestions. Let us know how things work out. Make sure you fully charge your batteries, since that run on start will have really drained your batteries.
 

pgp29646

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Ok so I did the dog head and still once I turn the key, it continues to cycle and I have to pull the battery cables to get it to stop. What’s next? Are there any fuse links that are hidden? I can’t find one that is blown. Time to pull the starter? Thanks for the feedback!
 

Tinstar

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New starter solenoid should fix the issue.
Its still trying to crank because it’s welded itself internally.
Cheap fix.
 
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MarcusOReallyus

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Yep.

As to the fusible links, there are a handful coming off the 12v port (diamond shaped terminal) above the GP relay, and a few coming off the 24v buss over on the passenger side.
 

firefox

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When mounting the new starter, be sure not to forget the strap and bolt that secures the end of the starter to the truck. Also get a NEW proper set of mounting bolts that are to spec.
 

pgp29646

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Been traveling and will get time this weekend to mount the new starter. The one I removed was fried. Is it necessary to use new bolts?
 

rspring

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This exact same thing happened to me this morning. Guess I need to figure out the dog head mod. Do I need a 24V solenoid? Thanks
 
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