Mercury 200 OptiMax Jet Drive Service Manual page 93

Ignition
Cause
2.0 Low air pressure in rail
2.1 Low fuel pressure in rail
2.2 Abnormally high friction in engine
2.3 Air in fuel system/lines
2.4 TPS malfunction
2.5 Remote control to engine harness connection is
poor
Cause
3.1 Low air pressure in rail (less than 79 ± 2 psi while
running)
3.2 Fouled spark plug
3.3 Failed direct injector
3.4 Failed fuel injector
3.5 Bad coil/weak spark
3.6 Flywheel misaligned during installation
Cause
4.1 Broken fuel pressure regulator or tracker
diaphragm
4.2 Fuel leak
4.3 Tracker valve spring missing
4.4 Improper setup
Cause
5.1 Fouled spark plug
5.2 Low air pressure in rail
5.3 Throttle incorrectly adjusted
5.4 Bad coil/weak spark
5.5 TPS malfunction
Page 2A-12
2. Engine Cranks, Starts, and Stalls
Refer to 1.2.
Refer to 1.3 and 1.4.
Check for scuffed piston or other sources of high friction.
Refer to 1.3.
Crank and start engine several times to purge.
Check motion of throttle arm.
Stop nuts should contact block at idle and WOT.
Check TPS setup.
Clean and inspect male and female connectors.
3. Engine Idle is Rough
Refer to 1.2.
Replace spark plug:
‑ If carbon bridges electrode gap or if it is completely black.
‑ If it is not firing and is wet with fuel.
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston.
‑ Wrong spark plug.
Refer to specifications for ohm test.
Refer to specifications for ohm test.
Refer to specifications for ohm test.
Remove flywheel and inspect.
4. Engine Idles Fast (RPM > 700) or Surges
Measure fuel pressure.
Remove and inspect diaphragms (a special tool is required for assembly).
Check for fuel entering induction manifold or air compressor inlet.
Fuel pump diaphragm leaking and/or vapor separator tank is flooding.
Inspect tracker valve for proper assembly.
Check throttle cable and cam roller adjustment.
5. Engine Runs Rough Below 3000 RPM
Refer to 3.2.
Refer to 1.2.
Check throttle cam setup on induction manifold.
Inspect linkage and roller.
If throttle plate stop screws have been tampered with, contact Mercury
Marine Service Department for correct adjustment procedures.
Refer to 3.5.
Refer to 2.4.
Action
Action
Action
Action
90-8M0050731 MAY 2011