2011 Nautique 200 Won't Start

[bruce.hartman.96]

Hi all, I'm a newbie here, I’m hoping that someone out there can help with a perplexing ignition problem. I have a key actuated ignition that does not activate the starter relay, but it is an intermittent problem, most of the time it is broken. I have chased this the best way I can without a schematic. First of all, does anyone have a good one, all the ones I’ve searched for are not detailed enough.

So back to the problem, I’ve checked and done the following…

1. Replace the ignition switch.
2. Replaced the PME relay under the dash.
3. Hard bypassed the lanyard switch.
4. Hard bypassed the neutral lockout.
5. Validated operation and contact closures of the starter relay.
6. Validated operation of the ignition relay, rolled it with the fuel pump relay since they are the same.
7. Checked the voltages on Starter Relay, appears I’m not getting a ground to activate, 12v appears on one side of the relay coil.

The problem seems vibration induced, but I can’t recreate it by shaking harnesses or reseating connectors. An example of what I’m talking about, boat died at the dock, towed it to the launch ramp, pulled it out and drove back to my garage about ¼ mile away, the darn thing started! The next day, hooked a hose to the boat, started it, ran it for 15 minutes, towed it 200 yards to the gas pump, it died again.

Need some ideas on where to check other voltage points, I think it is a continuity problem or does the ECM come into play for the starter circuit?

I appreciate any help!

Bruce

[mzimmer75]

I had a 1997 SN that had some intermittent start problems. The first time it was the neutral safety switch on the transmission. The second time it was the emergency cutoff switch. Your post indicates that you've bypassed both.
When it doesn't start, does the starter engage but no start, or is there absolutely nothing happening when you turn the key?

[bruce.hartman.96]

Thanks for your input. The starter solenoid is controlled by the Starter Relay which does not operate when I turn the key, so dead with no click. I pulled the relay and applied 12v to it and it works just fine, contacts and all. So I suspect somewhere between the kill switch and the starter relay there is an open. Uggh!

[HollywoodBall]

Are your battery connections clean and tight?


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[bruce.hartman.96]

Thanks! Yeah my battery clamps are good, tight and clean. One thing I haven't checked is the ground connection to the block, I'll be doing that tomorrow. Just got my hands on a wiring diagram, hopefully that will help.

[skinautique]

Thanks! Yeah my battery clamps are good, tight and clean. One thing I haven't checked is the ground connection to the block, I'll be doing that tomorrow. Just got my hands on a wiring diagram, hopefully that will help.

Did you figure this out? Having a very similar issue with a ZR409 (2011 200) right now.

[bruce.hartman.96]

Yes, I got it figured out. It was the ECM . If your Starter Relay is not activating, check pin 89 of the ECM to pin 85 of the starter relay for continuity. BTW it passes though the neutral lock out. If you need an ECM, marinepartssource.com has good deal, on other stuff too.

[skinautique]

Thanks for this info and the website link. I've ordered a new ignition and starter relay to rule those out first. Hoping it's not the ECM. Glad you got yours resolved!

[bruce.hartman.96]

NP, another thing to try is to strap 5 & 7 together on the 8 pin connector (right rear of motor), then apply 12v. That should fire your starter, if it does, your problem is on the helm side of the boat. Good luck.

[skinautique]

Thanks for that info too. It's a strange one and it's been narrowed down to the throttle position. Really hoping it's not the throttle position sensor but we'll see. Sometimes it starts, other times it doesn't and when it does, it's after messing around with the throttle.