Wire hot to the touch

[Dman223]

I was tracing down a wiring issue on my 2017 Z1 with my fuel pump and noticed this connector gets very hot after starting the boat. After only a few minutes it gets almost too hot to touch. You can see the discoloration of the wire in question. Anyone know if this is normal? The wire just comes off the main harness then into the fuse block looking thing and back out to a Y split wire to the fuel pump connector.

[isaac]

If no wiring modifications have been done……

I assume resistance has built up in the connector. I would do my best to clean the contacts, ensure a good mechanical connection is being made between the male and female ends. I would inspect the insulation to make sure it isn’t brittle or otherwise damaged. Reassemble, and monitor.

For me, a major clue is if the discoloration is adjacent to the connector (indicating the connector as the heat source), rather than along the entire wire (suggesting an overload).

[Dman223]

If no wiring modifications have been done……

I assume resistance has built up in the connector. I would do my best to clean the contacts, ensure a good mechanical connection is being made between the male and female ends. I would inspect the insulation to make sure it isn’t brittle or otherwise damaged. Reassemble, and monitor.

For me, a major clue is if the discoloration is adjacent to the connector (indicating the connector as the heat source), rather than along the entire wire (suggesting an overload).

thank you, this sounds right, only the connector was hot and wire after it but not before it. It looks clean, but I’m going to put some dielectric grease inside.