07 SV211 ZR6 dying while under way

[sfjakey]

Any ideas? Just started happening this weekend. only 215 hours on boat. Ran great for about 2-3 hours, then died suddenly mid pull. Started back up and ran good for a while then died again. Yesterday, tried to ski again, ran good for about an hour, then died after hitting a wake hard, I figure some sort of electrical short. Continue on, then it dies on flat water 10 minutes later. One more easy restart, then it dies and won't start for about 5 minutes, starts finally and I run for home, dead again. Trouble starting again, then I get it going and idle back 5-7 minutes no issues. Dealer just serviced the fuel filter among other things at about 200 hours, but I doubt that had anything to do with this. Again, its a 2007 ZR6 in a SV211 Team. Thanks for any input.

[sodbuster88]

Maybe fuel pump. Might need dealer to do a fuel pressure check.

[AirTool]

Note: another gremlin is the fuel pump relay. There are two relays....one for each pump.

http://www.nautiqueparts.com/relaypc...dfuelpump.aspx

[AirTool]

I assume you never lose power to the dash and when it "won't start" it is still happily "cranking"

[sodbuster88]

Airtool, you sure about two? In the 2007 zr6, there may only be one fuel pump relay (found right next to the ignition relay inside the power distribution box on top of the engine). FUEL PUMP RELAY: Controlled by the ECM (Pin 84). When it is energized, the fuel pumps will run. At initial Key ON, the ECM will energize the relay for 2-4 seconds to prime the fuel system. Once the ECM recognizes the Crank Position Sensor signal the fuel pumps will remain on while the engine is running or until Key OFF.

Troubleshoot wiring between relay socket pin 85 and ECM pin 84. Troubleshoot relay socket wiring for any shorts to ground or power, broken, pushed, or shorted pins. Replace Fuel Pump Relay

Or an easier way is to swap the ignition and fuel pump relays and see if it makes a difference.

Ref: http://www.pleasurecraft.com/manuals/PCM-ECM-07.pdf

[sodbuster88]

Also, this is where having a good look at the wiring in the CKS and CMS circuits is a good idea....sort of where I was heading on Nauti's boat. Problem is...there should be a code thrown if there were a problem with either of these two sensors and we don't have a DIACOM or other simple plug in code flasher. In the case of Nauti's boat, there's a blinking check engine light. Sfjakey...what about your check engine light?

[sodbuster88]

Another note...the dealer tells us that they rarely find codes logged at all because in their experience, 90% of failures of this type or nature (boat dies, or hard starts, etc...) are fuel pump or relay related. In the case of Nauti's boat, there was no fuel pressure...so they replaced fuel pump. This fixed the pressure issue, but boat still dies... Would think if you can rule out pump and relay,and all connections are good...then ignition module? (but what are the codes?)..haha

[AirTool]

Airtool, you sure about two? In the 2007 zr6,

5.7 yes....zr6....not sure.

[sfjakey]

Yes boat still cranks after it dies. I also tried the ignition/ fuel pump relay switch and it did not fix the problem when it wouldn't start for an extended time, so I can rule the relay out. It seems odd to me that a fuel pump would go bad in this manner. I know on my Volvo Penta 5.7, when the fuel pump went bad, it just died. THis random, intermittent failing really has me thinking something electrical, which is a much worse, and costly scenario.

[CradGen2]

Also you might want to check the lanyrd swtich. Seems to solved a couple problems lately. Thanks

[sfjakey]

Good idea, I'll take it out and wire it straight through.

[s_kelley2000]

Also you might want to check the lanyrd swtich. Seems to solved a couple problems lately. Thanks

I was just going to suggest the same thing. The terminals on the back of that switch have been known to be pretty bad and can cause loose connections. Also the plastic on the lanyard itself can get weak from sun exposure and no longer hold the button in all the way. Both of those issues could be intermittent. If there is any play between the lanyard and the button try to stick a coin or something in there to tighten it up and/or get a new one from Nautiqueparts.com. If the lanyard is not on or a loose connection makes it seem like it is not on then the motor will crank all day but the fuel pumps will not power up. The week plastic on the lanyard stumped me for a good two hours at the dock last year.

[sfjakey]

Put a fuel pressure gauge on it and read 60 psi constant before starting and while while running. Bypassed the deadman switch, so hopefully that is the problem. I'll know more and update on thursday or friday.