Ingnition fuse blows when shifting to neutral. Sea Ray 185

[Sigge]

I have a Sea Ray 185 2007 Mercruiser 3.0 L 135 hp.

I have a problem that started intermittently but occurs more and more often.

When I go from forward to neutral or reverse to neutral the 15 A ignition fuse under the instrument panel blows and the engine stops. When I've replaced the fuse the engine starts and runs perfect until I go into neutral next time and the fuse blows again.

I've also tried to to go neutral with the engine not running but the key on and then the fuse blows as well.

I have a theory that it might be some problem with a shortcut in the neutral safety switch? There are 2 yellow/red cables coming out from the remote control which I guess are connected to the neutral safety switch.
To reach the neutral safety switch I have to dismantle the remote control. I need some hints how to do that without breaking any plastic details and where to find the neutral safety switch inside the remote control box.

Or do someone have another solution I am grateful.

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

The neutral safety switch only controls the starting circuit of the engine, not the ignition.
You can verify if it works or not by disconnecting the yellow/red wires from the switch and hooking the wires together. This would remove the neutral safety switch completely from the system, and you will be able to start the engine in gear.
Then just see if it still blows the fuse.

Has any work been done on the engine lately? Tuneup, timing check or anything?

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Thanks Don for the hint and quick reply. I will try that.

No work has been done to the engine lately

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

The kill switch on the control has wires going to the ignition attached to it (purple wires), might want to make sure they aren't touching something that is moving on the control.

 

[fat fanny]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

After verifying the trouble shooting tip Don gave u if you still need to look at the wires for chaffing modt controls require u to move them into the full forward position and pry the throttle only button out of the handle gently and from there you can see most of the wiring some u are able to remove the bezels around the shifter arm at this point in the dissasembly. Good luck!

 

[tfret]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

You have a short circuit, most likely it is a skinned wire inside the shifter, as fat fanny suggested. I had a similar problem and decided it was a good time to upgrade my control arm. Pull the control arm off and inspect the wires. I bet they are skinned up.

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

You have a short circuit, most likely it is a skinned wire inside the shifter, as fat fanny suggested. I had a similar problem and decided it was a good time to upgrade my control arm. Pull the control arm off and inspect the wires. I bet they are skinned up.

There are no wires under the handle, or in the handle that are in any way connected to the ignition circuit. Only trim and tilt, and that comes from the trim pump through a 10A fuse.

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

After verifying the trouble shooting tip Don gave u if you still need to look at the wires for chaffing modt controls require u to move them into the full forward position and pry the throttle only button out of the handle gently and from there you can see most of the wiring some u are able to remove the bezels around the shifter arm at this point in the dissasembly. Good luck!

Thanks "fat fanny" for the hint.
When you say the "control in full forward", do you mean "in gear" or with the throttle only button pushed before going into full forward?

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

The kill switch on the control has wires going to the ignition attached to it (purple wires), might want to make sure they aren't touching something that is moving on the control.

I've checked the kill switch wires. They are in good order.

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Thanks "fat fanny" for the hint.
When you say the "control in full forward", do you mean "in gear" or with the throttle only button pushed before going into full forward?

Before you start taking the handle off for no reason, go back to the trim pump and remove the 10A fuse from the holder. Your trim will no longer work. Now turn your ignition switch to on and try your trim. Still doesn't work. Now, shift in and out of gear and see if the igition fuse blows. It will. The trim has nothing to do with the ignition, which means there is NOTHING under the handle that can short the ignition, only trim and tilt wiring. So why remove the handle>????? There is nothing to look at under there.
The kill switch is the ONLY thing hooked to the ignition and it's not under the handle.

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Ok, if the kill switch wires are good, here is a very easy test to try next.

New fuse, ignition switch on, engine not running. Go to the engine and activate the shift interrupt switch manually and see if the fuse blows.

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

I've done this test and the fuse blows when going from reverse or forward to neutral, the ignition switch on and engine not running

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

I've done this test and the fuse blows when going from reverse or forward to neutral, the ignition switch on and engine not running

I didn't say shift gears, just go back to the engine and activate the shift interrupt switch and see if the fuse blows. Don't even touch the shifter.

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Ok, if the kill switch wires are good, here is a very easy test to try next.

New fuse, ignition switch on, engine not running. Go to the engine and activate the shift interrupt switch manually and see if the fuse blows.

Hi again Don. Tanks for your effort!

I might was a little bit quick when I interpreted "activate the shift interrupt switch manually" as going from reverse or forward to neutral with the control handle?
When I read your text again I see that you write "go to the engine". Do you mean aft, in the engine compartment?

Or what do you mean by "activate the shift interrupt switch"?

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

I didn't say shift gears, just go back to the engine and activate the shift interrupt switch and see if the fuse blows. Don't even touch the shifter.

Where on the engine do I find the shift interrupt switch?

 

[Don S]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Do you mean aft, in the engine compartment?

Yes, that is normally where you find the engine in an IO boat.

The shift interrupt switch is on the bracket where the shift cables both attach. there is a bracket that actuates the shift interrupt switch, just push it back and forth to activate the shift interrupt switch.

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Yes, that is normally where you find the engine in an IO boat.

The shift interrupt switch is on the bracket where the shift cables both attach. there is a bracket that actuates the shift interrupt switch, just push it back and forth to activate the shift interrupt switch.

View attachment 168157

I'll check that. Thx for your patience with a boat rookie from Sweden ;-)

 

[Sigge]

Re: Ingnition fuse blows when shifting to neutral. Sea Ray 185

Ok, if the kill switch wires are good, here is a very easy test to try next.

New fuse, ignition switch on, engine not running. Go to the engine and activate the shift interrupt switch manually and see if the fuse blows.

Now I've done some testing.

I've had the boat on land the last week so I did the tests on my trailer.

New fuse, ignition switch on, engine not running.
I joggled the shift interrupt switch.
Went from forward/reverse to neutral several times.
The fuse did not blow anytime!

Then I put the boat in the water for a test drive.
Went from forward/reverse to neutral something like 20 times with the engine running.
The fuse did not blow anytime!
Everything worked perfectly normal!

Strange!? But I'm glad that everything works now.

Now it's time for winterization and I keep my fingers crossed that everything will work next spring when I put it in the water.

Thank You Don for the leads.