HELP!! Engine no start, throws check light with no cranking (07 model 206 with ZR6)

[Donbayers]

Hi gang. Hope the collective experience here can help.

Bottom line: enter start code (everything powers up on dash), hit start button, I hear fuel pump buzz for about 5 seconds then stop, then check engine light comes on. pushing start button again nothing happens i.e. engine never cranks.

Details:

Got boat out of winter slumber.
Put brand new battery in it.
connected water and it started right up
warmed up engine to change oil and filter
shut off, drained oil, changed filter. etc.
Then upon restart the above happened
Engine has 700 hrs on it.

Something is causing a fault code to trigger that then prevents cranking of the engine! Any ideas what this could be and how I can go about testing things?

I read here some posts about fuel pump relay... but if relay was not working then the pump wouldn't turn on in the first place...? Under normal operating conditions I don't recall hearing or waiting on the fuel pump before hitting the start button.

Please know that the boat is new to me just since Sept 2019 and I've only had it out once.

Thank you for any help

PS. I have all the owners manuals and documents for the boat including full service history (it was a one-owner and only serviced at the dealer) but these references don't help much.

[Neptune442]

Bad shift cable?

[NautiqueJeff]

Why do you think it is causing a fault code? How do you know that? Have you hooked it up to a DIACOM?

The check engine light would normally be on when the ignition is on, but the engine isn't running. The only things that trigger the check engine light are low oil pressure or high engine temperature. Before the engine starts, the oil pressure would be low, so the light would be on.

It sounds to me more like a possible keypad issue, or maybe a starter or starter relay failure or a neutral safety switch failure. Do you get a click or anything when you hit start?

[Donbayers]

OK! That could be the case! What if it thinks it's in gear. It absolutely would not allow the engine to crank.

I wonder how I could test that theory? There must be a sensor or something mechanical that would do that.

PS. When I was running it before the oil change I had the shift lever button pushed so that I could work the throttle independently. I shut the engine down in that condition.
When I went to restart it was still in that position. When it through the light I immediately recognized that position and put the throttle back in the neutral position and the button popped back. But that did not change anything. I would think that you could operate the starter with the throttle level engaged and tranny disengaged....but perhaps it is set up to completely lock you out of a start up condition unless you are in a full neutral level position???

[NautiqueJeff]

I think the most telling thing will be to know if you hear a click when you hit start. If so, it is likely a starter relay issue (or possibly the starter itself). If not, it is probably a sensor, like the Neutral Safety Switch, or possibly the keypad (but I doubt it).

[Donbayers]

Why do you think it is causing a fault code? How do you know that? Have you hooked it up to a DIACOM?

The check engine light would normally be on when the ignition is on, but the engine isn't running. The only things that trigger the check engine light are low oil pressure or high engine temperature. Before the engine starts, the oil pressure would be low, so the light would be on.

It sounds to me more like a possible keypad issue, or maybe a starter or starter relay failure or a neutral safety switch failure. Do you get a click or anything when you hit start?

OK, Thanks for the reply. "fault code" was just my way of saying the check engine light is on. Your explanation helps a lot. Appreciate it.

I get no click or noise of any kind when I hit start button. I think you're on to something with a safety switch failure or starter relay.

[Donbayers]

One small detail I forgot....

the check engine light does a slow blink not a constant "on". If that means anything to anyone

[Donbayers]

I think the most telling thing will be to know if you hear a click when you hit start. If so, it is likely a starter relay issue (or possibly the starter itself). If not, it is probably a sensor, like the Neutral Safety Switch, or possibly the keypad (but I doubt it).

OK, I tried to test the neutral switch by putting the two wires on the same side (did that for both sides). It didn't change anything. Again, I get NO click or sound from the starter.

What should I check next

Thanks for any help

PS. everything else on the boat powers up and is functioning normal

[CincinnatiCC]

Have you tried the safety switch? Under the throttle on the side wall on my 2008 206. I would see if that is on and seated properly. If so, may have to check the wires behind the switch.

[Donbayers]

Have you tried the safety switch? Under the throttle on the side wall on my 2008 206. I would see if that is on and seated properly. If so, may have to check the wires behind the switch.

I tried (cycled) it a number of times. No difference. Thank you for the reply

[Lakejackson]

Confirm the battery is charged and all connections are secure. My 2011 had a cracked battery terminal. Did you try the mechanical safety switch? They will not allow the boat to crank if not in neutral. Sometimes these are out of alignment.


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[Donbayers]

Confirm the battery is charged and all connections are secure. My 2011 had a cracked battery terminal. Did you try the mechanical safety switch? They will not allow the boat to crank if not in neutral. Sometimes these are out of alignment.


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Thanks. I'll certainly check the connection at the starter end. I just put a new batt in and cleaned all those connections.

Can you tell me more about this "mechanical" switch. Where is it at and how to check it?

Regards

[NautiqueJeff]

At this point, I would use a screwdriver to momentarily connect the two large posts on the starter relay and see if the engine turns over. Put the code in the boat and turn the ignition on (so that the check engine light is lit). Be sure the screwdriver handle is insulated or you'll get a good zap! If the engine cranks, the starter relay is likely bad.

[Lakejackson]

Hopefully I can explain this correctly. I believe there is a safety switch inside the shift mechanism. When the shift lever is in neutral the switch is activated to allow the boat to start. If the mechanism is out of alignment it will not push the switch and allow it to start. On My 2004 sometimes I had to pull back slightly on the shift lever to get it to start. With the lever in neutral move the lever forward and back (without putting the boat in gear) and try to start. I think Jeff’s suggestion above bypasses all this circuitry. Good luck.


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[Donbayers]

At this point, I would use a screwdriver to momentarily connect the two large posts on the starter relay and see if the engine turns over. Put the code in the boat and turn the ignition on (so that the check engine light is lit). Be sure the screwdriver handle is insulated or you'll get a good zap! If the engine cranks, the starter relay is likely bad.

OK, Status update. I remove the power wires from the top pole (stud) on the starter and the bottom stud with wire going into the starter. Cleaned them to ensure a good connection. NO CHANGE.

I then momentarily connected the two poles. The starter winded but did not engage the engine. Just spin and spin. Did this a number of times. I was expecting for the starter to engage the engine and crank....???

So, I'm still back at square one. There is SOMETHING preventing the starter from cranking at the start button.. Grrrr