Keypad Ignition Problem

[txleach]

My boat has an intermittent issue.

2006 SN196 LE
PCM 330 Excalibur
Gateway Control Box deleted.
PME box analog gauges added.
ZO Conversion with current version & single puck
AGM battery confirmed good, sits on intelligent solar charger / trickle charger when not in use

Keypad configured with No passkey used to start the boat.

Normal startup process and behavior:
Action: Turn selector toggle switch on right side from ALL OFF to ALL ON.
Result: ZO display comes on for a bit. If no other action is taken, the display will go blank.
Action: Press Start button on keypad once.
Result: Analog gauges move and show a reading. ZO Display comes back on and stays on.
Action: Press and Hold keypad Start button while starter runs until motor fires up.
Result: All gauges read correctly and engine is running, ZO is on and ready to be used.

Symptom #1:
Action: Turn selector toggle switch on right side from ALL OFF to ALL ON.
Result: ZO display comes on for a bit. If no other action is taken, the display will go blank.
Action: Press Start button on keypad once.
Result: Analog gauges move and show a reading. ZO Display comes back on and stays on.
Action: Press and Hold keypad Start button
Result: All dash gauges shut off and starter does not engage.
Repeated attempts have same result
Turn toggle switch off then on again.
Now everything works as it should.

Symptom #2:
Action: Turn selector toggle switch on right side from ALL OFF to ALL ON.
Result: ZO display does not come on
Action: Press Start button on keypad once.
Result: Analog gauges twitch ZO Display comes on briefly then goes off.
Action: Press and Hold keypad Start button
Result: All dash gauges stay off and starter does not engage.
Repeated attempts cause the keypad to display the left 5 accessory button lights on even though none have been pressed
Turn toggle switch off then on again.
No change.

Theories:
1) Keypad is failing - I have taken it out, cleaned all contacts, inspected for any signs of loss of seal (none found). Works sometimes but not others.
2) Toggle switch is failing - I have taken it out, cleaned the contacts, and reinstalled. I do not know it this is an issue, but likely not.
3) PME module has an issue - Possibly the local dealership could diagnose. Does anyone know how to inspect the PME to see what model/version/etc. it is and how to see if it has a diagnostic port?
4) A relay to the ignition is failing - I can't find a user-serviceable relay. It sounds like it may be internal to the PME.

If anyone has any ideas on how to determine root cause so that I don't just buy suspect parts which really weren't the true problem, I welcome your insights and advice.

Regards,
Todd

[txleach]

Update: I wiggled/reseated most connections in the helm. I cleaned and verified connections on the back of the toggle. After all that, it would start each time. So possibly I have resolved the issue, despite not knowing exactly which of these actions did the trick.

[Jonny Quest]

I feel your pain. I just replaced the keypad on my 2003 Ski Nautique. The symptoms I was having were not similar. Boat running. Everything working properly. Perfect Pass (StarGazer) engaged, Then, if I pressed the Heater switch on the keypad, everything would completely shut down. No gauges, no engine, no PP, nothing. I then would have to toggle the switch from ALL ON to ALL OFF to ALL ON again. Then the engine could be started and everything appeared to be working normally again. If the PP was NOT engaged, the Heater switch functioned normally. With PP engaged, depressing the Heater switch would again cause everything to completely shut down.

So...I coughed up $367 for a new keypad. Everything now works as it should. No issues with any accessory -- even if PP is engaged or not. Your mileage may vary.

JQ

[NautiqueJeff]

Typically when power drops out when attempting to start the engine, the voltage is dropping below the minimum and shuts the system down. When this has happened to my boats, it has sometimes been that the battery cables are corroded, sometimes up under the rubber coating. How do your battery cables look? How about the connections at your battery switch (if you have one)?

Could certainly be the toggle switch. Those are cheap and easy to replace.

Also, just FYI, on a boat that new I don't think you have to hold the start button until the engine starts. You can just press it and release it and the engine will start.

[MN Ryan]

Also, just FYI, on a boat that new I don't think you have to hold the start button until the engine starts. You can just press it and release it and the engine will start.

NautiqueJeff On an '06? I am 99.9% certain I have to hold the start button down to crank it on my '07.

[NautiqueJeff]

Not sure what year that started. Next time you're out, try it and let me know.

[MN Ryan]

Will do. It'll be about 6 months...

[NautiqueJeff]

Yeah, I thought about that after I made that post.

[txleach]

Update: I wiggled/reseated most connections in the helm. I cleaned and verified connections on the back of the toggle. After all that, it would start each time. So possibly I have resolved the issue, despite not knowing exactly which of these actions did the trick.

[txleach]

Also, just FYI, on a boat that new I don't think you have to hold the start button until the engine starts. You can just press it and release it and the engine will start.

On this 2006, if you short press the Start button the starter just fires for a second or less. The start button must be held to keep the starter running until the engine fires.

[NautiqueJeff]

It must have been later when that started then. Sorry for the confusion.