Installed PCM 100amp alternator in 95 SS, now boat wont start

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  • workky
    • Nov 2003
    • 120
    • Lake Allatoona

    • Marietta,Ga

    • 1995 SuperSport

    Installed PCM 100amp alternator in 95 SS, now boat wont start

    I installed a 100 amp PCM alternator kit on my 1995 SS. I followed the instructions to a tee and even made a phone call to double check something., Now the boat wont run at all. The fuel pumps are not coming on. I did bypass the relay and applied power to the pumps and got the boat running. I need to know if anyone has ever had the same trouble installing the 100 amp kit from PCM. You do have to change the green wire, run some new wires supplied with the kit.
    Cant seem to figure this thing out, its bothering me quite badly. I've got the PCM manual and going to trouble shoot tomorrow and see if I can figure it out, just didn't know if anyone had the same issues as me with this install.

    Any help would greatly be appreciated, the fuel pumps don't come on for the 2 secs while you put the key to the on position. They don't come on when the engine is turning over as well.
  • Chexi
    1,000 Post Club Member
    • Jan 2025
    • 2119

    • Austin

    • 2000 SAN

    #2
    Originally posted by workky View Post
    I installed a 100 amp PCM alternator kit on my 1995 SS. I followed the instructions to a tee and even made a phone call to double check something., Now the boat wont run at all. The fuel pumps are not coming on. I did bypass the relay and applied power to the pumps and got the boat running. I need to know if anyone has ever had the same trouble installing the 100 amp kit from PCM. You do have to change the green wire, run some new wires supplied with the kit.
    Cant seem to figure this thing out, its bothering me quite badly. I've got the PCM manual and going to trouble shoot tomorrow and see if I can figure it out, just didn't know if anyone had the same issues as me with this install.

    Any help would greatly be appreciated, the fuel pumps don't come on for the 2 secs while you put the key to the on position. They don't come on when the engine is turning over as well.
    Check the lanyard.
    Now
    2000 SAN

    Previously
    1999 Air Nautique
    1996 Tige Pre-2000
    1989 Lowe 24' Pontoon / Johnson 100HP outboard

    Comment

    • workky
      • Nov 2003
      • 120
      • Lake Allatoona

      • Marietta,Ga

      • 1995 SuperSport

      #3
      Originally posted by Chexi View Post
      Check the lanyard.

      I did,even crossed it out for diagnosing.

      No power to fuel pump, relays making funny noise , we are out here now trying to figure it out. Diagnosing fuel pump, relays , ECM. At a loss, getting pissed and getting another beer.

      Comment

      • workky
        • Nov 2003
        • 120
        • Lake Allatoona

        • Marietta,Ga

        • 1995 SuperSport

        #4
        Does anyone have or know where i can get a wiring schematic of the engine wiring harness for a 1995 gt-40. We are really thinking we have a ground issue, but without a schematic it becomes kinda hard to track it down. I have downloaded the PCM manual on nautique fans and the GT-40 manual. They do have limited schematics , im looking for a one page complete wiring of the engine if it exist.

        Thanks

        Comment

        • wake_fun
          1,000 Post Club Member
          • Jul 2003
          • 1330

          • CA

          • 1995 Super Sport

          #5
          I installed mine exactly like the instructions said...........been working perfect for years. The instructions I followed are in my photo album.
          Photo Album
          Ballast Install 1
          Ballast Install 2
          Amp Install
          PPass Install
          Alternator Install

          Comment

          • scottb7
            1,000 Post Club Member
            • Aug 2011
            • 2198

            • Carson City, Nevada

            • 2014 G21 (Current) 2008 SANTE 210

            #6
            You did not say. You said relay making noise. Is there a fuel pump relay? Is it getting power?

            Comment

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