2006 Glastron GX 205 - 20-amp fuse at ignition keeps blowing

[Karri]

Getting boat ready for the first time out on the water this season. Batteries are healthy (checked using multi-meter on the posts), blower and other accessories work. However, when turning the key, nothing happens. Gauges don't work, no clicking. After a day of research, we found a 20-amp fuse near the ignition switch blown. This is a different fuse than the assortment of fuses nearby labeled for each accessory.

We replaced the 20-amp fuse, turned the key to the first position of "ON" (not "START") and fuse blows. From what we read from this forum and elsewhere, we assumed a short in an accessory. So, we removed every single accessory fuse in the nearby fuse box with the plan of slowly adding back until the fuse pops. Unfortunately, even w/all accessory fuses removed, it still blew. We are now not sure next steps.

I have to admit I wonder if we hooked up the batteries in the back incorrectly even though my husband and son labeled them when they removed them last fall. The tricky part is they added a custom stereo with a second battery, so the wiring is a bit tricky. Also, there is a circuit breaker related to the stereo near the batteries with a yellow reset lever, so tomorrow I think we should try tripping that to disconnect and then try again. Or is it possible the ignition switch is bad?

We have a multimeter and I picked up a circuit tester tonight, so will also search online for additional advice on how to test the electrical.

We are hoping to go boating Saturday for the holiday so decided I'd see if someone on this group might have some great suggestions. Thank you very much.

 

[briangcc]

IF it were me, I'd disconnect the stereo/amp/whatnot. Get it back to basics with a single battery and stock wiring. Now replace the fuse and try the key. Does the fuse blow?

If it doesn't blow, there's something crossed in the wiring of the stereo and its time to start tracing wires.

If it does blow, you need to trace wiring and see where something went awry but at least you removed the stereo from the mix as its disconnected completely.

 

[Karri]

IF it were me, I'd disconnect the stereo/amp/whatnot. Get it back to basics with a single battery and stock wiring. Now replace the fuse and try the key. Does the fuse blow?

If it doesn't blow, there's something crossed in the wiring of the stereo and its time to start tracing wires.

If it does blow, you need to trace wiring and see where something went awry but at least you removed the stereo from the mix as its disconnected completely.

I love this idea, however since we didn't install the stereo system, battery and battery switch, we aren't sure how to do this. So many wires! If you have any advice on how to bypass this easily, I'd love to hear. I think I read we could disconnect the battery and run a jumper wire to the ignition panel but have to read more. Thanks for your help so far. This afternoon is going to be a busy one trying to figure this out. Worst case we take it on our vacation and first stop is a boat repair center...

 

[jimmbo]

I love this idea, however since we didn't install the stereo system, battery and battery switch, we aren't sure how to do this. So many wires! If you have any advice on how to bypass this easily, I'd love to hear. I think I read we could disconnect the battery and run a jumper wire to the ignition panel but have to read more. Thanks for your help so far. This afternoon is going to be a busy one trying to figure this out. Worst case we take it on our vacation and first stop is a boat repair center...

And I will guess all the wires the Stereo Installers added were all the same Colour?
Who did the Stereo Install, and did they provide any info, as in a Wiring Diagram?
Are both Batteries installed with the proper Polarity? If one isn't, and the Battery switch gets set to 'Both', it will get very interesting in a Hurry.

As mentioned earlier, isolating/restoring the Original System, is the first step.

 

[Karri]

And I will guess all the wires the Stereo Installers added were all the same Colour?
Who did the Stereo Install, and did they provide any info, as in a Wiring Diagram?
Are both Batteries installed with the proper Polarity? If one isn't, and the Battery switch gets set to 'Both', it will get very interesting in a Hurry.

As mentioned earlier, isolating/restoring the Original System, is the first step.

Car Toys did the install so maybe that wasn't a great idea. We've tried the switch with all three settings (#1, both, #2). Hopefully we can figure out how to test with original. Stay tuned.

 

[Karri]

Update from our testing. Using the circuit tester, every accessory fuse under the dash works fine (light comes on).

Testing the 4 wires at the ignition, the battery input (B), triggered the light, but the other three didn't do so.

For the heck of it, we bought a new ignition switch, wired it, but same issue

Any suggestions what we do next? How can the "A" (accessory gauges), "S" (solenoid) or "I" (we think ignition) all not work?

 

[jimmbo]

Inspect the wire(s) of the circuit that the blown Fuse feeds. I suspect a Pinched or Chafed wire.

 

[briangcc]

Radio (headunit) - it's a modern unit right? More than likely has a large plug with several wires running into it. Gonna be power, speakers, amp, etc. Either pulls out of the Radio (headunit) OR there's a pigtail with a matching plug coming out. Disconnect.

Amp - there's gonna be (3) wires you're interested in. Should be a large 4g wire going to battery ground. Gonna be another 4g wire going to battery positive (better be fused too). Going to be a 3rd wire, probably blue, coming from the Radio (headunit) that turns the amp on when the Radio gets turned on. Disconnect all 3.

My hunch is that someone crossed a wire while installing said system.

Replace the blown 20A fuse and try the key again. It blows, move onto the battery switch. Without knowing what said "installer" did, you really do need to dig in and start tracing wires to see what was done.

**This assumes that the boat was working normally before said system was installed.