Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

[fossildave]

Having trouble this summer with 15 amp ignition fuse blowing (under helm) after about 45 minutes of run time. Engine starts skipping but will run for awhile at low speed (still skipping but not as severe). Once engine starts to skip any attempt to go to full throttle will blow fuse. Can't find any shorted wires but still looking. Removed ignition switch and tested good & reinstalled. After fuse blows first time, any attemptto replace will result in blown fuse as soon as switch is turned to "on" position. Continues to blow fuses till engine cools down (about 15 minutes). Could a bad Ignition Control Module cause the fuse to blow and somehow reset itself after time to cool. The ICM factory mount is on exhaust manifold riser which is a hot area of engine. Would hate to replace an expensive ICM only to find that it's not the problem. Any help or suggestions would be greatly appreciated.

 

[Don S]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Was any new electrical items hooked up to your boat that work only when the key is on?

 

[fossildave]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

I installed a new stereo head unit + amp last summer. Worked fine all summer long 2010. I was thinking along the same line but I think I figured it out today. I found that the violet wire & the red/violet wires that plug into the alternator both had been rubbing against engine. Violet was rubbed half in two. Other one rubbed about 1/3 in two. Paint was rubbed off of engine at wire rub location. Wouldn't this blow ignition fuse? Replaced fuse & turned to "on" position without problem. Will go for sea trial tomorrow. Do you think these wires arcing out on engine would blow ignition fuse (violet wire)??? I believe I have read similar problem behind alternator on this site or one other.

 

[Don S]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Wouldn't this blow ignition fuse?

Sure, but why was it loose and able to rub anything?
You shouldn't be messing with any wiring going to the ignition switch for installing electrical accessories. The ONLY thing that should be on the ignition system is ignition and insturments. There is an accessory panel for accessories.

 

[Pete104]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

There was a "recall" on this subject. About 5-6yrs ago. One of the wires coming off the alt. could possibly chafe on the dipstick tube or between that & ground stud on alt. Notice was sent to all dealers to inspect &/or correct with piece of flex-tube!

 

[fossildave]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Loose and able to rub due to poor wire routing by Mercruiser/Sea Ray. These two wires were never disturbed by anything I've ever done to boat. They should have been routed differently or sleeved from manufacturer. After making necessary wire repairs I routed away from engine rub and tie wrapped to assure they will remain clear of abrasion.

 

[fossildave]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Thanks Pete. I'll check those areas as well.

 

[Don S]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

That service bulletin (2006-02) was for V8 engines only, not the 4.3.
Besides, if it shorted, you would get a fire, it's not fused at all, and would have nothing to do with the fuse at the helm.

One other note, that is supposed to be a 20A fuse, not 15. Look at item #9 in the wiring diagram below

 

[fossildave]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Thanks Don. The wiring diagram in my owner's manual does show 15 amp fuse on ignition circuit @ helm. It is also clearly marked on the fuse block that 15 amp fuse is for that position #2. Not a big deal. My wiring diag. is different than the one you referenced. The only thing I'm concerned about now is that you say the purple and red/purple wires that were arcing on engine could only start fire & not blow ignition fuse. I hope there is a connection between the fuse & the defective wires or I may still have trouble later on. I went out on Lake Keowee yesterday for 4 hours with no problems. Thought my troubles were over, but now I'm not as sure. I will have an electrician look at my wiring diagram today & see if he can make a connection with defective alt. wires & blown fuse.

 

[Don S]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Stick with the 15A fuse shown in your owners manual.

Your fuse blowing was probably due to the purple wire at the alternator touching, the red/purple wire is unfused at the alternator and if shorted to the block at that point is unfused.

 

[Fun Times]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

The only thing I'm concerned about now is that you say the purple and red/purple wires that were arcing on engine could only start fire & not blow ignition fuse. I hope there is a connection between the fuse & the defective wires or I may still have trouble later on. I went out on Lake Keowee yesterday for 4 hours with no problems. Thought my troubles were over, but now I'm not as sure. I will have an electrician look at my wiring diagram today & see if he can make a connection with defective alt. wires & blown fuse.

Your in good shape now. The fire that was mentioned would have been if the orange wire on the back of the alternator was rubbing on anything that could have rubbed through and shorted out, That orange wire is one of the main 12 volt power wires to the 12 volt power system for the engine.

Even though it's not needed on your engine according the service bulletin, Just to be safe, double check that the orange wire coming off the back side of the alternator area is not rubbing on anything sharp and you should be good to go.

 

[fossildave]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

I agree Don. I think and the electrician I discussed with thinks that the purple wire is originally fed through the #2 position (ignition) on fuse block @ helm. Purple wire short from alternator was root cause of fuse blown.

Thanks again for your thoughts & help with this. I will check remaining wiring around engine & sub components to assure all wiring is clear.

I will also consider posting a couple of photos of as found wires when I get a little time & if I can figure out how.

 

[fossildave]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Thanks Fun Times. I think the repairs to the purple & red/purple wires has resolved my ignition fuse blowing but I will be sure orange as well as all others on engine are clear from abrasion.

 

[mkm492]

Re: Blown Ignition Fuse - 2006 Sea Ray 4.3 Litre S/N OW635564

Thanks Fun Times. I think the repairs to the purple & red/purple wires has resolved my ignition fuse blowing but I will be sure orange as well as all others on engine are clear from abrasion.

Thanks so much for this forum and this thread. I fixed my "Blown fuse" quick enough, but never would have chased down the Purple Ignition Wire short without this thread. Here are some pictures so other folks can see where this occurs. Couldn't see the breach in insulation, but ohm meter found it easy.