Starter wire issue

[pursuit2460]

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]

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

 

[pursuit2460]

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

Mine is different. I have the Bat cable to starter post. Orange and solid red on same terminal crimp connected to 90amp fuse. Yellow/red to terminal closet to engine. Orange wire goes to alt. Solid red goes to 50amp push fuse. Opposite side of 50amp push fuse is a red/purple strip wire. My alt has a 2 wire plug. One is red and the other is purple. Both run into the main harness. At the main harness plug, in the engine bay, I see a purple and a purple/white stripe that runs to my center console. This boat was a single owner and all original from what I was told. I have owned the boat for about 6 years and never an issue till now that the main bat power nut came loose on the starter.

 

[pursuit2460]

Well, I hooked eveyback up as I took it off. Now I get power to my key and can crank it. But now it won't start. You can see that there is no fuel coming out and getting the TBI blades. I will check tomorrow with starting fluid. If it doesn't crank up, then I believe my ECM is fried. The 3 fuses are good. I will check a few things but I think my ECM might have fried. Any suggestions on what to look at would be appreciated. Thanks

 

[Fun Times]

Well, I hooked eveyback up as I took it off. Now I get power to my key and can crank it. But now it won't start. You can see that there is no fuel coming out and getting the TBI blades. I will check tomorrow with starting fluid. If it doesn't crank up, then I believe my ECM is fried. The 3 fuses are good. I will check a few things but I think my ECM might have fried. Any suggestions on what to look at would be appreciated. Thanks

You'll need to know if you're getting spark out the coil and to the spark plugs...Do you happen to see if the RPM gauge is moving any when you crank the engine over to start? Own a timing light to bring to the boat with you for testing?

May have hurt the sensor under the distributor cap and rotor item 6 and if so, you'll need a new rotor number 5 while in there, https://www.mercruiserparts.com/bam/subassemblydetail/44283391/28169703

Are you getting the 2 second prime "sounds" from the fuel pump / ignition/fuel pump relays at first key up?

Genuine Mercury Marine parts, large inventory, fast shipping. 5.7L EFI GM 350 V-8 1999-2001 0L325977 THRU 0M299999

5.7L EFI GM 350 V-8 1999-2001 0L325977 THRU 0M299999

www.mercruiserparts.com

 

[alldodge]

Orange and solid red on same terminal crimp connected to 90amp fuse.

Many are installed this way because the Red wire terminal is not large enough to connect direct to starter post. In Merc documentation it list Red as Bat power unfused and Red/Purple Bat power fused

Check the voltage on the other side of the 50 amp breaker