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Author Topic:   1999 Mercury 200-HP OptiMax Problems

mfclapp posted 09-13-2009 02:23 PM ET (US)
I kinda figure it's easier to ask you guys for help than to keep guessing. Here's the problem. Last fall I developed a sudden health problem and the boat and motor were stored inside until now with fuel in all the places where it had been when I turned it off before the heart problem. It was running fine when backed into storage by a friend.
We pulled it out 9/11/09 and refilled the fuel tank (approximately 40 gallons in an 80 gallon tank. Charged up the batteries. Pumped up the primer bulb turned it on and let the beep do it's job and cranked it over to start it. Nothing! Cranked over strong but no start.
Figured it might be a low pressure electric pump problem and sure enough when we tested it it was stuck. Freed it up ( cleaned out the old fuel that had set up in it) and now it pumps fine. Checked the high pressure pump output located on top of the vapor separator tank ( took the hose off where the hose for the rails connect ) with the engine cranking over and no fuel / no pressure.
I kinda figured if it ain't pumping no fuel into the high pressure fuel hose then she ain't gonna crank.
Am I right or wrong? Where do I go from here? Thanks in advance and all help will be genuinely appreciated!
Milt
contender posted 09-13-2009 03:07 PM ET (US)
Remove the cowling and air clearner, Shoot a shot of quick start in the air intake while some one is turning the engine over. If it fires it just the fuel not getting past the injection/carbs, if it does not you have and electrical problem, make sure you have your water connected in case it starts, Good luck
mfclapp posted 09-13-2009 07:29 PM ET (US)
We cleaned the low pressure and high pressure pumps and flushed out the rails and injectors by pressurising and activating each out of cylinder with cleaner. Reconnected all and re-flushed with fresh fuel and pumps working. Also flushed out the oil system (all of it including remote tank)installed clear oil supply line to motor tank and recharged the system. Sure was nice to see the oil pumping through the clear tank line. (no second guessing about oil flow).
Pumped up the primer bulb and she fired up within 2 seconds.
Ran it through the RPM range (not exceeding 3000) for a few minutes then let it idle on the muff for 10 minutes watching the still attached rail pressure gauge and the water flow. (no problems)
Kicked it up to 1000 rpm and ran for 15 minutes same results.
Purrs like a kitten and roars like a lion now!!!
Tight Lines
Milt
Greg Hiller posted 09-15-2009 04:14 PM ET (US)
Nice work! I have a 2000 200 OPTI that has been outstanding. In the late fall here in upstate New York I run a brew of Marvel Mystery Oil, Stabil and gas. I put the mix in a container larger than the motor mounted fuel filter and run the engine at idle until just about all the mixture is gone. The engine will smoke just a little when the MMO burns. I have done this since the engine was new and have not had any spring starting problems.

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Author	Topic: 1999 Mercury 200-HP OptiMax Problems
mfclapp	posted 09-13-2009 02:23 PM ET (US) I kinda figure it's easier to ask you guys for help than to keep guessing. Here's the problem. Last fall I developed a sudden health problem and the boat and motor were stored inside until now with fuel in all the places where it had been when I turned it off before the heart problem. It was running fine when backed into storage by a friend. We pulled it out 9/11/09 and refilled the fuel tank (approximately 40 gallons in an 80 gallon tank. Charged up the batteries. Pumped up the primer bulb turned it on and let the beep do it's job and cranked it over to start it. Nothing! Cranked over strong but no start. Figured it might be a low pressure electric pump problem and sure enough when we tested it it was stuck. Freed it up ( cleaned out the old fuel that had set up in it) and now it pumps fine. Checked the high pressure pump output located on top of the vapor separator tank ( took the hose off where the hose for the rails connect ) with the engine cranking over and no fuel / no pressure. I kinda figured if it ain't pumping no fuel into the high pressure fuel hose then she ain't gonna crank. Am I right or wrong? Where do I go from here? Thanks in advance and all help will be genuinely appreciated! Milt
contender	posted 09-13-2009 03:07 PM ET (US) Remove the cowling and air clearner, Shoot a shot of quick start in the air intake while some one is turning the engine over. If it fires it just the fuel not getting past the injection/carbs, if it does not you have and electrical problem, make sure you have your water connected in case it starts, Good luck
mfclapp	posted 09-13-2009 07:29 PM ET (US) We cleaned the low pressure and high pressure pumps and flushed out the rails and injectors by pressurising and activating each out of cylinder with cleaner. Reconnected all and re-flushed with fresh fuel and pumps working. Also flushed out the oil system (all of it including remote tank)installed clear oil supply line to motor tank and recharged the system. Sure was nice to see the oil pumping through the clear tank line. (no second guessing about oil flow). Pumped up the primer bulb and she fired up within 2 seconds. Ran it through the RPM range (not exceeding 3000) for a few minutes then let it idle on the muff for 10 minutes watching the still attached rail pressure gauge and the water flow. (no problems) Kicked it up to 1000 rpm and ran for 15 minutes same results. Purrs like a kitten and roars like a lion now!!! Tight Lines Milt
Greg Hiller	posted 09-15-2009 04:14 PM ET (US) Nice work! I have a 2000 200 OPTI that has been outstanding. In the late fall here in upstate New York I run a brew of Marvel Mystery Oil, Stabil and gas. I put the mix in a container larger than the motor mounted fuel filter and run the engine at idle until just about all the mixture is gone. The engine will smoke just a little when the MMO burns. I have done this since the engine was new and have not had any spring starting problems.