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Author Topic:   290 OUTRAGE, Twin 225-HP OptiMax

dr john posted 11-17-2008 03:20 PM ET (US)
I have an unusual problem with the port engine [a Mercury 225-HP OptiMax on a Boston Whaler 290 OUTRAGE] sucking air [into the fuel line] which eventually stalls the engine. I then bleed the air out though the rail only to have the problem recur a short while later. This happens on either tank and I was wondering if the [cause] is at the fuel switch? Anyone, ever have a similar promblem? I also smell fuel but cannot find any leaks. Thank you in advance
jimh posted 11-18-2008 12:14 AM ET (US)
Since this problem only occurs on the PORT engine, the source of the problem has to be some component which is only used on that engine. I don't know how much of your fuel system is in common for both engines. If everything is separate back to the tank pick up, it could be anything in the system that is sucking air. Since the fuel system operates on negative pressure, it is more likely to suck in air than to leak out fuel in any portion of the system upstream of the fuel lift pump.
You could swap the fuel lines to the engines, if that is not a hard task, and that would let you see if the problem is in the engine or in the boat. If the PORT engine continues to suck air, the source of problem is in the engine or some component downstream of the point where you swapped lines. If the problem moves to the STARBOARD engine, the source of the problem is in the boat, upstream of the point where you swapped lines.
handn posted 11-19-2008 12:35 PM ET (US)
I had a similar problem. It turned out to be the fuel bulb. I start with the easy obvious things and graduate to the more difficult things.
You are sucking a lot of air so the problem should be relatively easy to solve.
When your engine stalls, is the fuel bulb still hard with fuel? If so your problem is downstream from the bulb.
If you have good hearing listen for a hiss under cowl.
Check your rubber fuel lines, they deterorate. Then graduate to the fuel tank fittings.
If the problem occurs with either tank, then the problem is downstream from the tanks, possibly at the fuel tank switch.
You will get a fuel smell out the vents when the tanks are full. If the smell continues when the are tanks empty, then it is most likely a fuel leak which may be the same problem as the vacuum leak. Good luck
dr john posted 01-11-2009 03:38 PM ET (US)
Thanks for that info, problem turned out to be the low pressure fuel pump. Gas smell disappeared. Mercury had a backorder on these pumps so others seem to be having this issue.

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Author	Topic: 290 OUTRAGE, Twin 225-HP OptiMax
dr john	posted 11-17-2008 03:20 PM ET (US) I have an unusual problem with the port engine [a Mercury 225-HP OptiMax on a Boston Whaler 290 OUTRAGE] sucking air [into the fuel line] which eventually stalls the engine. I then bleed the air out though the rail only to have the problem recur a short while later. This happens on either tank and I was wondering if the [cause] is at the fuel switch? Anyone, ever have a similar promblem? I also smell fuel but cannot find any leaks. Thank you in advance
jimh	posted 11-18-2008 12:14 AM ET (US) Since this problem only occurs on the PORT engine, the source of the problem has to be some component which is only used on that engine. I don't know how much of your fuel system is in common for both engines. If everything is separate back to the tank pick up, it could be anything in the system that is sucking air. Since the fuel system operates on negative pressure, it is more likely to suck in air than to leak out fuel in any portion of the system upstream of the fuel lift pump. You could swap the fuel lines to the engines, if that is not a hard task, and that would let you see if the problem is in the engine or in the boat. If the PORT engine continues to suck air, the source of problem is in the engine or some component downstream of the point where you swapped lines. If the problem moves to the STARBOARD engine, the source of the problem is in the boat, upstream of the point where you swapped lines.
handn	posted 11-19-2008 12:35 PM ET (US) I had a similar problem. It turned out to be the fuel bulb. I start with the easy obvious things and graduate to the more difficult things. You are sucking a lot of air so the problem should be relatively easy to solve. When your engine stalls, is the fuel bulb still hard with fuel? If so your problem is downstream from the bulb. If you have good hearing listen for a hiss under cowl. Check your rubber fuel lines, they deterorate. Then graduate to the fuel tank fittings. If the problem occurs with either tank, then the problem is downstream from the tanks, possibly at the fuel tank switch. You will get a fuel smell out the vents when the tanks are full. If the smell continues when the are tanks empty, then it is most likely a fuel leak which may be the same problem as the vacuum leak. Good luck
dr john	posted 01-11-2009 03:38 PM ET (US) Thanks for that info, problem turned out to be the low pressure fuel pump. Gas smell disappeared. Mercury had a backorder on these pumps so others seem to be having this issue.