2010 SAN 230 Electrical trouble: Start/Run Relay Popping

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  • mattmcg94
    • Sep 2018
    • 2

    • Toronto

    • 2010 SAN 230

    2010 SAN 230 Electrical trouble: Start/Run Relay Popping

    Hi All,

    Here's the situation and apologies for the longwinded post but would really appreciate any help!

    Possibly trivial details:: Installed new speakers in the boat a couple weeks ago. Pretty simple, plug and play for the most part. Kept 1 stock amp running 4 JL m650 in boat, replaced 1 Polk amp with a JL M700/5 running 2 JL M880 on tower and 10" JL Sub. Ran new 4ga wire for the JL Amp; Positive connected straight to battery w/ 60A fuse, negative was on negative battery post of battery originally but then moved to the engine stud where the starter and port grounding buss connect to the block. I also ran a small jumper wire from amp on JL ground to the factory "post" under observers seat-- this is where the 8ga jumper to the Polk amp connects, along with the 6ga ground that runs to...who knows, I cant remember if it connects to port grounding buss or goes back to the engine.

    After first day, the boat ran like normal speakers worked great. At the end of our day we went to empty the ballast, and when we hit the starboard ballast drain the speakers made a "POP", and all the switches on the keypad no longer worked. what was on, stayed on, what was off stayed off. Got back to the dock, turned the boat off via the toggle under the throttle ("STOP" wouldn't work), and then flipped the battery disconnect. Turned everything back on and it ran like normal. Took it out of the water that day, dropped it in a couple days later for 10 min to see if everything worked and it did, no problem.

    A few days after that, we were driving away from the launch, and as soon as we turned the stereo on the boat just died, and I could see it was the start/run breaker under the steering wheel that was popped. I could press it back in, but as soon as I hit "START" it would pop again. I disconnected the amps and port side grounding buss (which has courtesy lights, 12v plugs, P-blst, and stereo ground) from the grounding stud on the engine, after about 45 minutes, the boat restarted.

    Got it to dock, and the port courtesy lights were doing a slow flash, even though they were not grounded to anything, and the courtesy light switch was off. I disconnected all the grounds from the port ground buss and taped them up, boat ran like normal all day.

    Decided to play around in the driveway, got everything hooked back up, the courtesy lights were no longer flashing, and all the speakers worked fine hooked up as per original.

    Launched it the next day, had the stereo head unit turned off, hit start, and pop goes the breaker. Wouldn't even start. Disconnected everything and got it going again, except this time I disconnected the amps, and also disconnected the "stereo" ground from the ground buss thinking this is the problem. Courtesy lights worked as per normal, just no music obviously. Boat ran fine allllll day, it randomly died when my brother in law was driving and I was surfing, but started back up without having to reset any breakers. He said he didn't hit stop, or hit the tether, but the jury is out on this one... .

    Does anyone have a clue as to where to start, what this could be? PME? Linc system? Keypad? Bad starter? Short in the head unit or old amp? Random ground wire short somewhere? I've farted around with this so much, I'm at my wits end almost but don't know what to try next.
  • scottb7
    1,000 Post Club Member
    • Aug 2011
    • 2198

    • Carson City, Nevada

    • 2014 G21 (Current) 2008 SANTE 210

    #2
    Yeah, my buddy had that same boat and we found a shorted wire in engine compartment by the little fuse box...similar symptoms...Little bit of electrical tape, and done...but we could easily see the short...try maybe looking for it...good luck...hopefully nothing serious. Trace the wires from the little fuse box...

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