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My friend has a 2001 Sport Nautique with the GT40. Last year, he went to start it, and it would blew the fuse up by the battery. It would repeatedly blow the fuse when trying to diagnose it. I ended up creating a jumper wire and running it to the starter solenoid, and then the boat would start and work fine. I started digging into the wiring at the starter relay, but when I started moving the wire harnesses around, the problem fixed itself. Even messing with the wires as much as I could, I couldn't get the problem to happen again. I left him the jumper wire with directions to use that if it acted up again.
Fast forward to this last weekend, and it acted up again. It blew the fuse, but this time, the jumper wouldn't work. The starter relay would make one click and that's it. I then unhooked the positive battery cable from the starter relay and hooked it directly to the starter, which made the jumper work again. I then unhooked the 3 red cables from the starter relay that all go to the same terminal (battery, starter, and the 60 amp breaker supply), and bolted them together, hanging out by themselves. Jumper still worked. I was getting ready to blame the relay, but I ended up hooking everything back up normal and I jiggled the wires around. Magically, the boat is fixed again. I was moving/pulling on the brown, purple, and purple/red wires off the relay. I couldn't get it to act up again, no matter how much I pulled on the wires or moved them around. I have the wiring diagrams, but they don't make sense to me. It shows the purple going to EEC relay, but I can't find that. The purple wire goes into a large harness bundle/loom that loops around to the front of the engine, but I can't find where it comes back out. There are 2 relays next to the ECM, but I think that's the ECA and fuel pump relay. I unhooked both of those, and the engine still cranks. Last year I did replace the wire that goes from the neutral switch to the starter relay, mainly because it was easy to replace. I'm assuming there is a short somewhere. Any ideas where to look, or where the purple and brown wires go?
Fast forward to this last weekend, and it acted up again. It blew the fuse, but this time, the jumper wouldn't work. The starter relay would make one click and that's it. I then unhooked the positive battery cable from the starter relay and hooked it directly to the starter, which made the jumper work again. I then unhooked the 3 red cables from the starter relay that all go to the same terminal (battery, starter, and the 60 amp breaker supply), and bolted them together, hanging out by themselves. Jumper still worked. I was getting ready to blame the relay, but I ended up hooking everything back up normal and I jiggled the wires around. Magically, the boat is fixed again. I was moving/pulling on the brown, purple, and purple/red wires off the relay. I couldn't get it to act up again, no matter how much I pulled on the wires or moved them around. I have the wiring diagrams, but they don't make sense to me. It shows the purple going to EEC relay, but I can't find that. The purple wire goes into a large harness bundle/loom that loops around to the front of the engine, but I can't find where it comes back out. There are 2 relays next to the ECM, but I think that's the ECA and fuel pump relay. I unhooked both of those, and the engine still cranks. Last year I did replace the wire that goes from the neutral switch to the starter relay, mainly because it was easy to replace. I'm assuming there is a short somewhere. Any ideas where to look, or where the purple and brown wires go?
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