2004 206 - horn not working, odd one - need suggestions!

[Speedy]

Yup that's the one. Just be sure to install it with the horn pointed downward so that condensation does not puddle inside of it with no way to drain.


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[SilentSeven]

OK - finally...yes finally...figured out my horn problem.

The TL;DR is that the main wiring harness bundle from the PCM box has no strain relief....and the bundle is heavy and pulls downward straining the PCM connection point and thus 'disconnecting' the horn. The fix was to lift the wire bundle slightly and install a home made bundle support / strain relief.

The issue of no strain relief on the main bundle could be the source of other electrical issues. For example, I also have a problem where my PP resets if do a hard wake crossing and I'm 99% sure due to this problem. IMO, this is a design miss by Nautique...over time the banging of waves is going to cause stress on the PCM connection ultimately leading to odd electrical problems.

How I figured this out was as follows. Had the lower kick panel out and was diagnosing the horn circuit with a meter. Circuit all tested fine and the horn worked. Reinstalled kick panel and - oops - horn stopped working. Wat?? Pulled the panel...started working. Rinse and repeat. This lead me to conclude there was strain issue somewhere as installing the kick panel really mashes a bunch of stuff behind the dash - my panel has two heater outlets, is jammed against the heater fan unit, holds the large PCM box, mounts a speaker and also holds the PP stargazer box and associated harness. Looking closely, I noticed the orange horn circuit wire was exposed at the top of the bundle at the PCM connection....and when I wiggled the bundle, the horn circuit would work / not work.