95 Merc 200 XRI

[abritton77]

I am going to try this again. I tried to post this earlier and guess I did something wrong because I cant find it now. If you guys see 2 post, I am sorry. I am having a problem with a boat that I recently bought. It is a 95 Ranger 461 with a jack plate. To me it seems like it never has the power it should and with 2 grown men and full livewells it wont hardly com out of the hole. It seems like it bogs when you give it throttle and I believe is missing some. It seems to run ok when it is first started until you run it a while and kill it. Then it when you try to restart it will sneeze a little and be kinda hard to start. It then seems to bog at that time when you give it throttle. Today on the way back to the ramp it started missing and bogged completely down until it came off plane. I had to idle back with it missing pretty bad. I thought it had blown up but when I got it home it fired right up and idled good until I killed it. I checked the compression and all cylinders were above 120. All plugs were also firing. I replaced the plugs a couple days ago and it didn't make a difference. I have also checked the timing according to the manual and it looks as it should, but I have not confirmed that the detonation control module is allowing it to completely advance. One thing that I just found out is that maybe I dont have the right plugs. It had ngk-bu8h and thats what I put back in it. I just saw a website that the 200 XRI should have ngk-buz8h. From what I can tell the buz8h will not cause interference. I am wondering if it may be somthing like the stator heating up and not working properly. I talked to a local mechaninc and he said he didnt want to mess with it and that he thought if it were a fuel issue it should have blown up by now. I have lots of experience on cardurated v-8s but am new to 2 strokes. I also am an electrician by trade and know how to use a meter. I have also done allot of searching on here but never see a post where sombody has said that there problem is solved. any help would be appreciated and if I fix it I will post back.

 

[rodbolt]

Re: 95 Merc 200 XRI

is this a carbed motor or EFI my 95 200 is EFI but they also made a carbed version as well.

when was the last time the lift pump was checked and the carbs cleaned.
a weak fuel lift pump will give that indication.
so will dirty carbs.
if its EFI check the filters for the vapor seperator and the lift pump.

 

[abritton77]

Re: 95 Merc 200 XRI

It is a efi

 

[abritton77]

Re: 95 Merc 200 XRI

Well I found a minor problem today but that didnt fix it. I took it back to the lake just to see and it fired right up and idled fine but bogs when you give it throttle. I thought if I hadint fixed it that it may do ok since it had cooled off. I guess I will start looking at the fuel system next. Today I checked the hose that pressurizes the oil tank and the TPS. Both seemed fine.

 

[madgadget]

Re: 95 Merc 200 XRI

can you run the engine in the dark and see if you have any flash over on the plugs from the covers to the engine? I had this with mine I have fixed it but have yet to test it.

 

[Bill Kilgore]

Re: 95 Merc 200 XRI

I guess I will start looking at the fuel system next.

I am not a mechanic. I do not know if any of the following will help your situation out or not, but I have done the following to my '93 model 200 EFI. I did the following because the last gas station I knew of to not use ethanol, now has ethanol in it fuel.

• Checked o-rings on "gas caps" of the fuel tanks.
• Replaced 2 "fuel withdrawal assemblies" in 2006. Googled "pickup tubes" and got all kinds of different stuff
• Replaced all rubber hose from on board fuel tanks to the outboard with Gates brand fuel hose that, according to a parts house website, 'Approved for use with leaded and unleaded gasoline, diesel and gasoline blends of ethanol (E85), methanol and ethers (up to the legal limits allowed by the EPA).'
• Inside the motor, I replace all rubber hose with the same brand hose until I got to the output side of the electric fuel pump. There I used rubber hose the was rated for fuel injection (Goodyear Brand)
• A fellow on this site, j martin, touted the use of TYGON fuel hose so that is what I used to replace all the rubber tubing in my bleed system. (I found the TYGON at a chainsaw shop here locally)
• At this point I think I have all the rubber components that were from 1993, replaced with rubber that will hold up to the mess they are putting in our fuel nowadays.

I also replace frequently:

Water separator filters (one in boat one on engine)

A little less frequently:

• Part# 857005A1 DIAPHRAGM KIT for the low pressure fuel pump.
• Check and clean the filter that is after the VST and before the high pressure fuel pump. It is inside the "U" shaped 7/16" ID fuel line. part# 823501
• Check and clean the final filter part# 150282

Not near as frequently:

Change out filter in the bleed system part# 8M0042285

All the above part#s are from Crowley marines website
I do not know if any of this will help, it is just my two cents.

 

[abritton77]

Re: 95 Merc 200 XRI

I didnt think about the fuel lines. They could have broken down and plugged every thing up.

 

[abritton77]

Re: 95 Merc 200 XRI

Well I checked the fuel pressure today it it was ok while the boat was idling with the muffs. Could it be not firing properly under load? I also checked the final fuel filter and it looked ok but I went ahead and cleaned it. I think that I will take it to the lake and try to check the fuel pressure with it under a load.

 

[abritton77]

Re: 95 Merc 200 XRI

Well I have figured out that injectors 3 and 6 are not spraying any gas. I am looking through the manual now to see if I can figure out why. I am guessing it is electrical but I assume they could be completely plugged. I know the switch boxes have something to do with the firing, but the respective plugs are definitely getting spark.

 

[abritton77]

Re: 95 Merc 200 XRI

Well its the injectors. The 2 that are not putting out check out to be open and the ones that are check just as the manual says they should. Any body know what an injector should cost and where I can get a good deal.

 

[abritton77]

Re: 95 Merc 200 XRI

Well I thought I would post how I figured all of this out.
1. I checked the compression and every thing was ok.
2. I checked the fuel pressure and it was ok.
3. I confirmed that all the plugs would at least light up a timing light.
4. I started the motor and I removed the plug wires 1 at a time to see if the rpms would change. I found that it didnt matter if 3 or 6 were hooked up. Use insulated pliers for this.
5. I bought a spark gap tester at autozone and hooked it up to the 2 cylinders in question. I set the gap to about 1/4'' and found that both cylinders were firing.
and the spark looked just as good as the cylinders that were working fine.
6. At this point I should have disconnected the fuel injector harness and checked the injectors with an ohm meter like the manuel says, but I missed that. This would have told me that I had a bad connection or bad fuel injector.
7. Instead of doing 6, I intended to take the cover off of the throttle body housing but didnt realize that that was going to take the whole thing loose. Since I already had it loose I pulled it out enough to so that I could see if the injectors were spraying fuel. Before turning the key on I grouded everything just as it was before. I had my wife turn the motor over and sure enough 2 injectors were not putting out. They turned out to be 3 and 6. Problem found.
8. At this point I completed step six and found out that I had 2 open injector circuits.
9. Now I had to take out the fuel rail so that I could take out the suspect injectors and find out if they were bad or if I had a wiring problem. Turned out that the #3 and #6 injectors were bad. The good injectors would read about 3 ohms and the bad ones were open.

Hope this will help somebody. I will post back when I replace the injectors and hopefully fix the problem.

 

[Faztbullet]

Re: 95 Merc 200 XRI

Send them to Tony @ Brucatosvs.com and have him check and clean them and he can give yur best deal on a injector...

 

[abritton77]

Re: 95 Merc 200 XRI

Well I replaced the 2 injectors last night and took the boat out this morning. It ran like a top.

 

[Bill Kilgore]

Re: 95 Merc 200 XRI

Good news. You did real well reporting tests, remedies, etc. in this thread. I think it will be a very useful thread in the future.

 

[abritton77]

Re: 95 Merc 200 XRI

I took the boat out today and did some fishing. I cant believe how much power this thing has now. I did lots of running around with a full tank of gas and both live wells full and 3 people in the boat. It will run all the way up to the 5800 rpm rev limiter without a problem. I need a bigger prop know I guess.

One thing worth mentioning, If you are going to crank the motor over with the throttle body loose, you need to disable the ignition. I would think that you could pull the kill switch but I am not sure if the injectors would fire. I would try that first. I cranked my motor 2 times to check the injectors and the second time it fired up and revved up for a split second to no telling what rpm. Scared the crap out of me and my dog. I also believe that you are at great risk for fire doing this so have a fire extinguisher handy and do not have an ignition source nearby. It only takes a couple revolutions of the motor to see if you have a problem. Just use cation and do not crank it any more than you have to.

 

[crappiehuntr]

Re: 95 Merc 200 XRI

great news, great post