Starter wire issue

pursuit2460

Petty Officer 2nd Class
Joined
Aug 24, 2004
Messages
190
Took the boat out over the weekend. When I was getting to my destination the boat just suddenly stopped. Got it towed back in and back home no issues. Started feeling around the starter and I felt some burnt wires. Took off the riser and the manifold and sure enough the main positive cable was loose which I guess created enough heat to burn out the 90 amp fuse. Now correct me if the wiring was hooked up correctly. 90 amp fuse, burnt, had a orange and red wire connected together to the small terminal on the fuse and was the first on the main terminal. Then on top of that was the main power from the battery and a 2nd wire that runs to the trim/tilt unit. A yellow/red stripe wire to the terminal closet to the block. The other small terminal, opposite side of the yellow/red stripe wire, had nothing connected to it. I also found a negative wire that goes connected to the back of the alternator was just about completely broken. I did notice when going out today that the charging voltage was a bit high around 15.7 to 16 volts, but eventually settled down to 14.5. I ordered a new fuse and want to make sure that the way I took it off is the same way that I need to reinstall it. I'm hoping that the ECM didn't get fried because of the overvoltage and the loose wires. 2000 5.7 TBI L635326
 

alldodge

Moderator
Staff member
Joined
Mar 8, 2009
Messages
44,023
2000 5.7 TBI L635326
charging voltage was a bit high around 15.7 to 16 volts
Voltage goes higher than 14.5V because the ALT sense (purple) wire is not connected or making a bad connection.

The Bat cable Red and Red/Purple wire gets connected directly to the starter post. The Orange wire goes to the ALT and gets connected to the 90 amp fuse. Yellow/Red connects to terminal closest to the block. The other terminal is only used with Carb motors
 
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