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Old 10-23-2013, 10:41 PM
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macattack macattack is offline
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Boat: 2005 MasterCraft PS197 TT, #31/100, MCX 5.7L
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2003 Excalibur, 5.7L, engine sporadically dies at idle

Ref my ski buddy’s 2003 5.7L PCM Excalibur engine, 1670 hrs, mechanical throttle linkage, normal mx accomplished annually.

The boat is used 4-5 times a week; normally, 3 ski sets each time out. It is kept outside on a lift. The past month or so, the engine will either not start for the first set of the day or dies while idling during the ski sets (no sputtering, just quits); does this whether the engine is hot or cold. The engine will turn over strong, but absolutely no indication of a start. Let it sit for a while, crank it several times, then it will finally start.

The only other problem which may or may not be related is the engine will also go in reduction/limp mode while pulling up a skier. We pull the throttle back to idle, pull up the skier again and it works fine. This happens maybe once every 2-3 weeks for past several months.

The engine runs great except for these sporadic problems…the “die at idle” problem may happen once a week or every other day…no consistency.

We initially thought it was the kill switch going bad; took it out and spliced the wires together. That “cure” only lasted a few days. Next we noticed the butterfly plate in the throttle body had some carbon build up. We sprayed it thoroughly with carb cleaner and it seemed to fix the idle/die issue for about a week. Now we are back to the engine just sporadically quitting; again, only at idle. We also drained a bottle worth of fuel from the fuel canister/filter, no water.

Appreciate any thoughts…tks, mac
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Last edited by macattack; 10-24-2013 at 12:05 PM. Reason: added engine type, PCM
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Old 10-25-2013, 10:24 AM
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Bump...anything? tks, mac
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Old 10-25-2013, 10:38 AM
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I would guess it is an IAC problem on the idle, but have no knowledge of the PCM Excalibur.
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Old 10-25-2013, 11:15 AM
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IAC is a good possibility, but always start with the basics. Spark plugs.......
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  #5  
Old 10-25-2013, 12:45 PM
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Check fuel pressure and spark first next time it won't start. Could be a bad pump or failing ignition module
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Old 10-25-2013, 04:28 PM
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mikeg205 mikeg205 is offline
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What maintence has been done to ignition and fuel delivery system?
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Old 10-25-2013, 06:41 PM
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@tablerocker, I believe the Excalibur is just a 5.7 L Chevy engine; agree, it could be an IAC issue

@mrMC & mikeg205, accomplished the following mx at the beginning of the summer...new plugs, distributor cap/rotor, fuel filter, cleaned metal air filter, oil changed every 50hrs

@rossterman, had fuel at the schrader valve during the last time it died, not sure where the ignition module is located; you would think it would either work or not, but not sure on this one?

I found a parts manual on this boat and discoverd there is a IAC and throttle position sensor on the throttle body; since the engine seemed to last longer between dying episodes when we sprayed carb cleaner in the throttle body, will explore further cleaning the areas where these sensors are located.

Will also check fuel pressure at the rail the next time it happens...

Keep the ideas coming! tks, mac
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Old 10-25-2013, 08:23 PM
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Which fuel pump does this craft have? - In tank? may be same issue a number of folks had here. Show some pics of motor - Distributor cap - so module most likely at base of distributor. May be worth throwing on a diagnostic computer to see what readings are - fuel injection right? throttle body or MPI?
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