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Author Topic:   2003 OptiMax 150 Dies After 15 Minutes

Local_Boy posted 02-26-2014 07:10 PM ET (US)
[This thread moved to REPAIRS/MODS--jimh]
I have a pair of 2003 Mercury OptiMax 150-HP engines on a 2003 Outrage. The last three trips out the port engine dies after operation in the 3,400-RPM engine speed range for over 15 minutes. The engine is totally dead, it has no electric power. No beeping when ignition turned ON. After eight to ten minutes, a beeping will come and engine will start and run normally again. The engine can be run at trolling spped all day with no problems. I have swapped the trim relay with the main power relay, but the swap does not appear to affect the problem. A mechanic suggests the cause is a switch or computer. Reply with ny thoughts you have.
Gary
jcdawg83 posted 02-27-2014 10:07 AM ET (US)
I have a 1999 Ficht 90-HP that had the exact same symptoms. It was the computer. My ECM is water cooled and the water channel that ran through the ECM was completely blocked. I could troll all day with no problem but after about 10 to 15 minutes at 3,500-ROM or higher the engine would die and do absolutely nothing.
I replaced lots of fuel system, ignition parts, and switch parts while I was in denial about the computer being the problem. Eventually, I took the computer off and found the blocked water passage. I knew then that my worst fears were confirmed.
For a while it would restart after cooling down, eventually it died permanently. Check the water flow to the computer if it is water cooled. If it's not, have the computer checked. I would bet that is the problem. Luckily for you, I imagine Mercury still supports a 2003 engine. Bombardier bought Evinrude and no longer supports the Ficht engines.
Local_Boy posted 02-27-2014 02:50 PM ET (US)
Thanks. We switched computers yesterday, but [today] the problem occurred on the same motor. So water cooling the computer may be [the cause of the problem]. I will [check] that next.
Gary
jimh posted 03-07-2014 10:01 AM ET (US)
Loss of electrical function after an engine has been running under load for 15-minutes sounds like it is related to build up of heat. It could be as simple as an interruption in the circuit feeding voltage to the engine from the ignition switch.
I suggest you conduct some basic electrical diagnostics on the engine. The next time the 2003 Mercury OptiMax 150-HP engine shut off completely and shows no sign of having any electrical power, check for the presence of electrical power at important distribution points in the circuit associated with the ignition key switch. Verify you have power at the ignition switch from the engine, and that you have power returned to the engine from the ignition key switch. The description you gave of no response in any way to turning the ignition key to RUN from OFF makes me think this problem could be a very basic problem in electrical power distribution.
phatwhaler posted 03-07-2014 01:54 PM ET (US)
Make sure your voltage regulator is working. Voltage too high may make the computer shut down to preserve itself.
RevengeFamily posted 03-14-2014 06:55 AM ET (US)
My 1999 Mercury Optimax 225 ECM are not water cooled...
I would have thought it may be a fuel cooling problem. The fuel injection system employs a fuel cooler to avoid vapor lock in the fuel injection rails. But you say the engine is electrically dead when this occurs...
Whatever the cause, it does sound electrical. Check the connections on the ignition switch?
Keep us posted,
Norm
jcdawg83 posted 03-14-2014 07:39 AM ET (US)
The totally dead symptom definitely sounds electrical or ECM related. Since you switched ECMs and had the same problem, I am thinking it is electrical, possibly caused by heat buildup of some sort.
My knowledge of electrical issues is only slightly greater than my knowledge of nuclear propulsion, so I will leave this to those who know more than I do.
outragesteve posted 03-15-2014 06:43 PM ET (US)
Check the positive and ground connections from on both the battery and the engine. Loose or poor grounds can cause wholesale loss of electrical power. When the engine dies, does the power trim still function? If it does, the cause of the problem likely is not the battery cabling. Good luck, and let us know!

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Author	Topic: 2003 OptiMax 150 Dies After 15 Minutes
Local_Boy	posted 02-26-2014 07:10 PM ET (US) [This thread moved to REPAIRS/MODS--jimh] I have a pair of 2003 Mercury OptiMax 150-HP engines on a 2003 Outrage. The last three trips out the port engine dies after operation in the 3,400-RPM engine speed range for over 15 minutes. The engine is totally dead, it has no electric power. No beeping when ignition turned ON. After eight to ten minutes, a beeping will come and engine will start and run normally again. The engine can be run at trolling spped all day with no problems. I have swapped the trim relay with the main power relay, but the swap does not appear to affect the problem. A mechanic suggests the cause is a switch or computer. Reply with ny thoughts you have. Gary
jcdawg83	posted 02-27-2014 10:07 AM ET (US) I have a 1999 Ficht 90-HP that had the exact same symptoms. It was the computer. My ECM is water cooled and the water channel that ran through the ECM was completely blocked. I could troll all day with no problem but after about 10 to 15 minutes at 3,500-ROM or higher the engine would die and do absolutely nothing. I replaced lots of fuel system, ignition parts, and switch parts while I was in denial about the computer being the problem. Eventually, I took the computer off and found the blocked water passage. I knew then that my worst fears were confirmed. For a while it would restart after cooling down, eventually it died permanently. Check the water flow to the computer if it is water cooled. If it's not, have the computer checked. I would bet that is the problem. Luckily for you, I imagine Mercury still supports a 2003 engine. Bombardier bought Evinrude and no longer supports the Ficht engines.
Local_Boy	posted 02-27-2014 02:50 PM ET (US) Thanks. We switched computers yesterday, but [today] the problem occurred on the same motor. So water cooling the computer may be [the cause of the problem]. I will [check] that next. Gary
jimh	posted 03-07-2014 10:01 AM ET (US) Loss of electrical function after an engine has been running under load for 15-minutes sounds like it is related to build up of heat. It could be as simple as an interruption in the circuit feeding voltage to the engine from the ignition switch. I suggest you conduct some basic electrical diagnostics on the engine. The next time the 2003 Mercury OptiMax 150-HP engine shut off completely and shows no sign of having any electrical power, check for the presence of electrical power at important distribution points in the circuit associated with the ignition key switch. Verify you have power at the ignition switch from the engine, and that you have power returned to the engine from the ignition key switch. The description you gave of no response in any way to turning the ignition key to RUN from OFF makes me think this problem could be a very basic problem in electrical power distribution.
phatwhaler	posted 03-07-2014 01:54 PM ET (US) Make sure your voltage regulator is working. Voltage too high may make the computer shut down to preserve itself.
RevengeFamily	posted 03-14-2014 06:55 AM ET (US) My 1999 Mercury Optimax 225 ECM are not water cooled... I would have thought it may be a fuel cooling problem. The fuel injection system employs a fuel cooler to avoid vapor lock in the fuel injection rails. But you say the engine is electrically dead when this occurs... Whatever the cause, it does sound electrical. Check the connections on the ignition switch? Keep us posted, Norm
jcdawg83	posted 03-14-2014 07:39 AM ET (US) The totally dead symptom definitely sounds electrical or ECM related. Since you switched ECMs and had the same problem, I am thinking it is electrical, possibly caused by heat buildup of some sort. My knowledge of electrical issues is only slightly greater than my knowledge of nuclear propulsion, so I will leave this to those who know more than I do.
outragesteve	posted 03-15-2014 06:43 PM ET (US) Check the positive and ground connections from on both the battery and the engine. Loose or poor grounds can cause wholesale loss of electrical power. When the engine dies, does the power trim still function? If it does, the cause of the problem likely is not the battery cabling. Good luck, and let us know!