Need your Help PLEASE! Blowing Starter Fuse 20A

[Gusolah]

This has progressively gotten worse over the last couple of months. When you hit the start button, the 20A Starter Fuse blows and boat will not start. I can replace the fuse several times and finally the boat will start and run, however it did kill on me about two hours into riding and when i went to restart it blew another fuse. I put a spare 40A in and it started so i went back to the dock not wanted to risk getting stranded. After getting boat on trailer i stopped and tried to start again and it blew the 40A.
Any ideas where to start troubleshooting this issue, very frustrating.
2017 G23 XR7 550

Thank you for your help!
Gus

[Gusolah]

This has progressively gotten worse over the last couple of months. When you hit the start button, the 20A Starter Fuse blows and boat will not start. I can replace the fuse several times and finally the boat will start and run, however it did kill on me about two hours into riding and when i went to restart it blew another fuse. I put a spare 40A in and it started so i went back to the dock not wanted to risk getting stranded. After getting boat on trailer i stopped and tried to start again and it blew the 40A.
Any ideas where to start troubleshooting this issue, very frustrating.
2017 G23 XR7 550

Thank you for your help!
Gus

[Rednucleus]

Fuses are there to protect components. If 20a is the rated fuse and you replace it with 40a, you risk damaging other expensive components, or causing a fire. The fact that you blew the 40 as well is pretty scary. Sorry for the rant. Time for some proper electrical sleuthing before you use your boat again. I'm sure others here will point you in the right direction. Do you have a multimeter?

[bturner]

Does it do it while in acc mode? If it's only when the starter starts to kick in I would look very closely at the cable going to the starter and work back from there. You could have a cable that has rubbed through (or close to it) and is shoring to ground at the starter or somewhere between where that cable attaches and the battery.

If you don't see anything with the cable, the highest drawing device in the starting circuit would be the starter. Pull the starter and have it checked to see if the starter has a short.

As Red states above, blowing a 40A fuse is = to a direct short on a very large cable. As someone that has had a boat burn while on it, my advice would be to stop playing games and figure out what going on before you burn the boat to the waterline and quite possibly get someone hurt bad.

[gary s]

"two hours into riding and when i went to restart it blew another fuse. I put a spare 40A in and it started so i went back to the dock" I don't think there is any need to keep busting his chops putting in a 40 to get home - he here asking for help, he knows it uses a 20 he knows a 40 is wrong. Any of you would do the same rather than being stranded

[mikenbike211]

Check the plastic base and ALL terminals on fuse block on top of the engine. Pull ever fuse and relay and look at the terminals closly. Make sure none are melted. Then check all major power and engine ground connections. Sounds like a connection issue to me.

[Scooter G]

The demons of electrical problems and the countless hours spent. Add a little moisture to the environment and the real fun begins. Proud of you for not using a paper clip in lieu of a fuse, lol. Disconnect your batteries and clean and check all your connections at the starter as the crew mentioned, work backwards from there. Clean up the batteries and cables while you have them off, just good practice. I have seen the bendix in the starter go bad (in automotive) and will start frying fuses. After cleaning up the connections and a thorough visual inspection, if you are still blowing fuses (20 amp), might be time to pull the starter for a bench test.
Seems I saw something on PN a while back on a G throwing fuses, might have to do a little hunt...

If you have a clamp amp meter, not that expensive on the Amazon, you may be able check the amperage draw at the starter hot wire to help narrow things down. For too long I thought the clamp on my meter was so that I could clip to something whilst I took readings, comes in handy in more ways than one, live & learn.

Edit: The other post I was trying to recall was a no start problem on a '15 G, not a fuse blower. There are several posts on other platforms that mention either a starter wire/ignition wire (not the 12v cable from the battery) problem, or a bad starter short. Let us know, you are a year newer than me, so I'll be paying close attention.

[Gusolah]

Thank you for all the advice and what to try.

[Boats Bros]

Are you the original owner of the boat? The previous owner could have done some shady electrical repairs and not told you about them. But I’m leaning towards the starter as most are.

[BasaltRMK]

bturner - that picture will haunt me!

- bob

[bturner]

That day is still with me. Great story over beers though!

[Gusolah]

Ok here is an update.....
Traced all the wires and they were all ok. All the bases of the fuses were good as well. I pulled the started and had it bench tested and the solenoid was bad and the starter was dragging. Installed a new starter and so far the problem with the fuse blowing has been solved.

[bturner]

At the risk of telling you something you may already know then getting put on blast for mentioning it, did you ensure the replacement starter was a marine rated starter? There is a difference. Both will work but the automotive version, while typically cheaper, doesn't include a spark arrestor device.

[Scooter G]

Good to know, seems like the starter was the general consensus, but not a bad idea to check and clean connections along the path.
Ditto with bturner, seasoned veteran in the fire sale department.
How much do starters run price wise these days, and was it any easy straight forward R&R or did you find the box on some old cuss words you haven't used in a while?

[Gusolah]

Yes used a marine grade certified starter Model 6793N. $145 from a local shop. It was pretty easy to replace, just a tight spot to get in.