2006 Optimax 200 Problems - Need Help

[115 optimax]

My 115 Opti was doing the same thing.My main fuel line was too long,and when trimming the motor up at WOT the line would slightly pinch causing it to bog out.I felt the fuel primer ball and it would be empty.I shortened the line and zip tied it down,now it works perfect.

[steiny93]

Originally Posted by Papascott

Hook her up to an external tank with fresh fuel. it will determine if is a fuel line / tank issue.

definately sound like a fuel delievery issue; i think Papascott nailed it with the external tank test; that will determine if they issue is with the engine or with the tank/vent/lines

[Waxy]

I'll be water testing with the dealer again this week. First thing to do will be hooking up an aux tank. After that it'll be hooked up to as much diagnostic equipment as possible and the problem recreated to see if it can diagnosed "live".

I'll post the results. I sure hope its as simple as a fuel restriction, because the other options = big $$$$.

Waxy

[LawEtech]

Took my motor to the repair shop. Got it on the computer the mechanic said the only thing he could see was that it might of gotten over heated. The water pump was working but he figured it was not pumping enough water... so we changed that and I took it out and it actually ran for a little bit... but barely got me back in and started to do the same thing.

Start out slow open the throttle... get's too about 4K... and then the motor starts to act like it is not getting fuel or bad fuel and then start too beep and then shuts off.

It is back in the shop. Certainly Mercury should know something about this issue..... mine is a 90HP Optimax Big Tiller.... 2008

[Iowa Farm Boy]

Not saying this is the issue on your boat but there are known issues with the coils on the 2008 Optimax 90hp. You might want ot see if your motor's serial number is suspect.

This is from another post.

"I spoke to Mercury tech support today. He said that the serial number of my motor is listed in the serial number range of those engines that "may" expierence issues with faulty ignition coils. The bullitan says to replace all coils.

Do a search on "Google Optimax Bulliten 2009-26" for a list of motors effected and the corresponding serial numbers.

This bulliten applies to:
40-60 Four Stroke
75-250 Optimax
175, 225-250 Pro XS Optimax "

[mudpuppy]

Originally Posted by Papascott

Hook her up to an external tank with fresh fuel. it will determine if is a fuel line / tank issue.

Exactly. Thats what should have been done from the start. Dealers, don't get me started. I had to go back and edit because I was going on a rampage about dealers just randomly changing parts.

Yes, you probably are running out of money, and for that I feel bad.

[LawEtech]

Thanks for the heads up on this issue. I will check right now. Much appreciated.

K

Originally Posted by Iowa Farm Boy

Not saying this is the issue on your boat but there are known issues with the coils on the 2008 Optimax 90hp. You might want ot see if your motor's serial number is suspect.

This is from another post.

"I spoke to Mercury tech support today. He said that the serial number of my motor is listed in the serial number range of those engines that "may" expierence issues with faulty ignition coils. The bullitan says to replace all coils.

Do a search on "Google Optimax Bulliten 2009-26" for a list of motors effected and the corresponding serial numbers.

This bulliten applies to:
40-60 Four Stroke
75-250 Optimax
175, 225-250 Pro XS Optimax "

[REW]

Waxy,
Just for a quick check, take a 5 gallon fuel tank with a new line and hook it directly to the motor and take the boat for a drive.

See if there is any difference at all.

If the problem has gone away, you have eliminated the motor as an issue.
Then, start at the bottom of the tank, pull the fuel pickup, and replace every fuel line and filter from the bottom of the fuel line pick up to the engine connection.

It likely won't make any difference, but it is a very quick way to be 100% positive that you don't have a fuel tank, fuel hose, filter issue.

REW

[Waxy]

Originally Posted by Papascott

Hook her up to an external tank with fresh fuel. it will determine if is a fuel line / tank issue.

You nailed it. I nailed it too in hindsight, a fuel restriction was the first thing I diagnosed. I replaced the short fuel line and bulb and took the floor up and inspected the tank and pickups, I just wasn't smart enough to do this simple test. After that I convinced myself it couldn't be a restriction because the bulb didn't go soft or collapse.

All that time and money, and it was a restriction somewhere in the main fuel line. I haven't pinpointed the problem yet, but it runs perfectly on the external tank and the kicker fuel line. So the problem is either in the aux/main valve or in the tank at the main pickup. I plan on spending some time going over the fuel system myself to see of I can locate and solve the problem before I take it back to the dealer again.

Thanks for all the help.

Waxy

[SteveJ]

Originally Posted by Waxy

You nailed it. I nailed it too in hindsight, a fuel restriction was the first thing I diagnosed. I replaced the short fuel line and bulb and took the floor up and inspected the tank and pickups, I just wasn't smart enough to do this simple test. After that I convinced myself it couldn't be a restriction because the bulb didn't go soft or collapse.

All that time and money, and it was a restriction somewhere in the main fuel line. I haven't pinpointed the problem yet, but it runs perfectly on the external tank and the kicker fuel line. So the problem is either in the aux/main valve or in the tank at the main pickup. I plan on spending some time going over the fuel system myself to see of I can locate and solve the problem before I take it back to the dealer again.

Thanks for all the help.

Waxy

Sorry you spent the money you already have, but be thankful that there is nothing wrong with the motor. Hopefully it won't be too difficult or expensive to solve now that you know where to look.