OK I messed it up big time need help!!!!DOC?
 

I really need help. I am replacing the gages in my 01 25OL. I "thought" I had everything labeled well but obviously not. Anyway here is where I am at. I am sure all the sender wires are proper but ran into issues with the purple ignition wire placement or the grounds. Main issue, the fuel pump does not come on when switching the ignition on. I know the kill switch is good and checked the voltages there, all good. I think the issue is with the voltage gage. You would think each gage would have had just a light power, ignition power, sender and ground. No where near the case. My old gages had terminals and the new are the plugs. I attempted to label and keep the same sequence but obviously missed something.

What I need is to know if anyone has been behind the dash and knows the wiring sequence. I am looking to know how the fuel pump gets its signal from the ignition and I think through the kill switch(lanyard). The reason I think it is centered around the volts gage is the number of wires that were going to it. It also had two larger gage ground wires which is puzzling. I am at a loss here, I know how to get ignition power and good groudn to all the gages, no issue but can't figure out why the fuel pump is interlocked with the wiring to the gage panel. Please help.

Also if anyone knows anyone at the old Baja factory who did wiring on the 25OL's I need to talk to them. Thanks. DOC hope you could help here.

Larry

By the way the new gages look great, would really love it if the engine worked

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I sent you an email through OSO. Let me know if you do not receive it.

On gauges I always make it a point to replace only one at a time.

Good luck

DOC thanks will check my account when I get home.

For others this is what I have found so far. Power goes from the ignition switch through the kill. All good there. Then it goes to the gage cluster and other places. I found a purple wire that goes down to the fuse panel (under the helm in a 25OL) with a 20A fuse labeled ignition. I assume this is the line that goes eventually to the fuel pump and the ECM/FI rails. The other purple wires that leave to the gunnel I think are for the hour meeting and fire bottle indicator monitor. My only concern is the purple wire that goes down to the fuse panel isn't any larger than any of the others but with a 20A fuse. Do fuel pumps just use the ignition as an indicator to turn on with main power coming from somewhere else (short of like the 12V input to a stereo amp)? Just want to make sure I am not missing something. Need to get it fixed to be on the water for the J-Ville Poker Run.

Blk -Grounds-General
Blk/Brn -Pump Grounds
Blk/Red -Voltmeter Grounds
Blk/Org -Isolated Accessory Grounds
Blk/Yel -ignition stop
Blk/Grn -Water Level Sender Ground
Blk/Blu -Lighting Grounds
Blk/Gry -Nav Light Grounds
Blk/Wht -Battery Parallel Solenoid
Brown -Pumps-General, Bilge or Sump (Manually Switched)(Also alternator starter to Ign.)
Brn/Red -Pumps, Bilge or Sump
Brn/Org -Power feed to Auto Bilge Switches-Pumps, Fuel/Oil Tranfer or Priming
Brn/Yel -Baitwell or Aerator
Brn/Grn -Fresh Water Pump/Water Maker
Brn/Blu -Head Pump
Brn/Vio -Washdown Pump
Brn/Wht -trim pos sender
Red - Battery Feeds Unprotected
Red/Vio -Misc. Accy. Main Feed Protected (fused) from batt to trim panel.
Pink -Fuel Sender
Org/Blk -Audio System Feed
Org/Brn -Electric Head-Sanitation System
Org/Red -Wiper Port
Orange -Accessories common feed- Dist Panel to Acc switch-Anode Electrode-Mercathode
Org/Yel -Diesel Pre-heat
Org/Grn -Wiper Stbd
Org/Blu -Communications Equipment
Org/Vio -Navigation Equipment
Org/Wht -Wiper Center
Yel/Blk -Choke - Neutral saftey trans mounted
Yel/Red -Start Solenoid(starting circut), Neutral Safety
Yel/Org -Powered Ventilation, Fans
Yellow -Bilge Blowers -(also alternator DC output)
Yel/Wht -Rudder Angle Sender
Grn/Red -Stop Solenoid/Kill Switch
Grn/Yel -AC Grounding
Green -Bonding
Grn/Wht -Engine Trim in and or tilt down
Grn/Org -Engine Independent Trim down
Blu/Blk -Cabin Lights
Blu/Brn -Oil Temp Send
Blu/Red -Cabin or Cockpit Lights Port
Blu/Org -Engine Independent Tilt Up
Blu/Yel -Lighting Circuits to Remote Send
Blu/Grn -Cabin or Cockpit Lights Stbd
Blu -Instrument & General Lighting
Blu/Vio -Courtesy, Boarding Lighting
Blu/Wht -Engine Trim Outand/or Tilt Up
Light Blue -Oil Pressure
Vio/Red -Eng. or Generator B+ from Breaker
Vio/Yel -I/O Trim Up (ballast bypass)
Vio/Grn -I/O Trim Down
Vio -12v Ignition-Generator or Engine
Vio/Wht -Trim "Trailer" switch
Gry/Blk -Mast Light
Gry/Red -Spotlight Remote
Gry/Org -Docking Lights
Gry/Grn -Strobe or Beacon
Gry/Blu -Spreader/Flood Lights
Gry/Vio -Windlass/Winch
Gray -Navigation (running) Lights, Tach. Send
Gry/Wht -Anchor Light
Wht/Brn -Temp. Alarm or Indicator
Wht/Red -Fuel Alarm or Indicator -((Ignition module to Dist.)Mercury Thunderbolt Ignition)
Wht/Org -Fire Alarm or Indicator
Wht/Yel -Air Flow Alarm or Indicator
Wht/Grn -Water Press/Flow Alarm or Indicator - ((Ignition module to Dist.)Mercury Thunderbolt Ignition)
Wht/Blu -Oil Press Alarm or Indicator
Wht/Vio -Voltage Alarm or Indicator
White -General Alarm Usage, Yamaha Kill Switch
Tan - Water Temp sender
Tan/Blu -Warning system sense wire (Audio warning)
Pink -Fuel sender

Holy Crap that is gold. I eventually figured it out, got all the IGN wires on a terminal jumpered across. Traced the wires using a signal generator but still no joy. Went back to checking voltages and where I had it before coming from the kill switch was no more. Cleaned the kill switch terminals, again, cycled the switch a bunch of times and all is good. New dash looks great and am happy, unfortunately took for a drive sucked up some piece of plastic (no longer intake throught the drive) and smoked the raw water pump. Yeah I know I should have a sea strainer but not yet. Anyway, pump repaired and ready for the weekend. Remember if it didn't break all the time it would be called a car not a boat.