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Author Topic:   2001 Mercury OptiMax 150-HP Cuts Out
Storf posted 05-03-2007 03:27 PM ET (US)   Profile for Storf   Send Email to Storf  
My 2001 Mercury OptiMax 150-HP motor cuts out at any time at a different range of RPM between 2,000 and 5,000. It is almost like the ignition just switches off. After it cuts out I can start her up with out any problem and sometimes go for about 15 minutes before it happens again. Sometimes happens straight away as I throttle up. No horns going off or any signs on the SmartCraft gauges telling me what is going on. [Seeks] idea what the cause of this problem could be.
Royboy posted 05-03-2007 09:18 PM ET (US)     Profile for Royboy  Send Email to Royboy     
Fuel or spark are the two choices (compression can be ruled out). How old is your fuel filter? What about the priming bulb? I'm guessing fuel first only because spark us usually all or nothing. The fuel supply, however, is prone to getting stopped up.


sosmerc posted 05-03-2007 10:25 PM ET (US)     Profile for sosmerc  Send Email to sosmerc     
I think you need to look very carefully at all electrical connections. You may be losing connection somewhere. Don't forget the main engine harness connection. Perhaps there is corrosion inside that plug. If that engine were in my shop, I would try running it on a separate keyswitch and harness to eliminate boat related wiring problems. If the problem were still there, I would then check EVERY electrical connection on the engine to ensure good continuity. I should mention that, prior to doing anything, I would put the engine on my DDT to see if ANY fault codes have been stored by the engine computer...thus saving valuable troubleshooting time.
jimh posted 05-03-2007 10:47 PM ET (US)     Profile for jimh  Send Email to jimh     
If an engine just cuts out like someone threw a switch, it is a good indication of an electrical problem. Fuel problems usually are not so dramatically on and off in their characteristics.
phatwhaler posted 05-04-2007 01:19 AM ET (US)     Profile for phatwhaler  Send Email to phatwhaler     
I had a similar problem with my 150 Mercury EFI. It would just stop for no apparent reason, but would restart every time. Turned out to be bad voltage regulators. The bad regulators were allowing the engine to make over 16 volts, which would cause the ECM to shut down to protect itself. My Mercury factory service manual clearly states that my ECM should self protect itself.

As for wiring, the already mentioned advice sounds good. You might want to pull the main engine harness apart and carefully spread the pins in an effort to make a good connection. (I did this with success on a friends boat once.)

I know that you have a Opti but it's worth a look.

pw out.

Storf posted 05-04-2007 04:00 AM ET (US)     Profile for Storf  Send Email to Storf     
Thanks for all your advice guys,will have a look at what you recommended,i have put a DDT on and the only fault is recording is number 4(Fuel level hi) but have bin told this only shows up because the theres no fuel sender connected to the smart gauges?
sosmerc posted 05-04-2007 10:47 AM ET (US)     Profile for sosmerc  Send Email to sosmerc     
That's correct, if certain sensors are not hooked up or being used, the DDT will show this as an's not a problem.
Check your main harness plug for corrosion, and carefully clean the pins as previously sugguested.
Storf posted 05-04-2007 11:39 AM ET (US)     Profile for Storf  Send Email to Storf     
Manged to fix the problem,turned out to be dirty or loose connection on the main wiring harness,discovered this by using a different wiring harness and control box,this seemed to clear up the problem?!I then cleaned the pins and opened them up a bit more on the original harness and reconnected it......since then i havnt had a problem!!
So hopefully that should be it!!Thanks to everyone for there advice,another lesson learnt in the world of Outboard mechanics!
duckear posted 05-11-2007 01:52 PM ET (US)     Profile for duckear  Send Email to duckear 200HP 01 does the same thing!!

Never have been able to figure it out, neither can my mechanic. Problem with mine is that is happens so erratically. Three times in one afternoon, and perfect for two months.

Go figure.

Glad yours seems to be fixed.

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