2002 Mercury 200 EFI 2 Stroke RPM Loss at WOT

trophypro2302

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Hello All,

Currently my baby is running a little below spec. She runs, starts and idles great until I need to open her up. A 2002 Mercury 200 EFI 2 Stroke should run at about 5000-5500 RPM at WOT. The way she sits, she will run at about 4200 RPM at WOT under load. If i put her in neutral, she will rev to spec. I have cleaned and replaced spark plugs and she runs better and increases RPM at WOT, but after a little while its back to 4200 RPM. In some cases i have come back from offshore fishing trips and she wont even plane out. Once again, i clean the plugs, and tried a little mercury quickleen and she runs good for bit then back to the same thing. The merc is bolted to a 2302 Trophy Pro and has a 15 3/4" x 15 pitch mercury mirage prop. This is the stock prop size, so i dont believe that she is over propped. I have replaced the following, some to try and correct the problem, some just as routine maintenance:

-Spark plug wires
-Spark Plugs
-Primer bulb and lines
-Water fuel separator filter and housing
-Impeller
-Thermostats

I plan on doing a couple more things before i take it to the dealer. It seems like there is excessive oil on the plugs when i clean them. I am starting to suspect it is "pulse pump" that draws the fuel from the tank. Sometimes the primer bulb isnt exactly as hard as it should be. If I let the boat sit for a week or so, the primer bulb is soft and i have to pump it to get hard again before i start it. I have tested the fuel pressure in the VST and its at 40 psi, where I think it should be. I am starting to think that those check valves are bad and the pistons on the down stroke are forcing the fuel pressure back towards the tank. I am pretty mechanically inclined and feel like i can fix whatever the issue is myself, my problem has been the diagnosis of the problem. Has anyone experienced these symptoms and come up with a solution? I feel like I should just take it to the dealer before i replace everything. It might be cheaper.

Thanks in advance.
 

alldodge

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I have cleaned and replaced spark plugs and she runs better and increases RPM at WOT, but after a little while its back to 4200 RPM. In some cases i have come back from offshore fishing trips and she wont even plane out. Once again, i clean the plugs, and tried a little mercury quickleen and she runs good for bit then back to the same thing

Sounds to me like your getting to much oil and/or fuel. Clean plugs runs great for a bit then they need cleaned again
 

trophypro2302

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Thanks for your response AllDodge. I agree with you, I am defintely getting too much oil. I imagine the oil and fuel mix at some point in the VST after being drawn by the pulse pump. Could it be that i am getting the correct amount of oil but not enough fuel? It seems like there is definitely more 2 stroke oil on the plugs (plugs have a dark gummy substance on them). I am thinking that if its more rich with oil than fuel, The mixture of the two wouldn't ignite correctly. The motor would run, just not efficiently.
 

trophypro2302

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I would also like to add, even with new plugs it runs better but not 100%, so i know there is more to the problem.
 

alldodge

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Not a guru on OB, but if you get to much of gas or oil the performance will suffer. Also believe your motor is direct oil injection so the oil is not mixed with gas in the VST.
 

trophypro2302

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I have the EFI version, not the optimax DFI version. The EFI version injects fuel into the intake manifold where DFI is injected directly into the cylinder. You are correct, it does not mix in the VST like i stated before. I just found in the manual that the fuel delivered from the water separator by the crankcase mounted pulse fuel pump. The amount of fuel allowed to enter the vapor separator is controlled by a needle / seat and float assembly in the vapor separator. I am thinking that my problem lies somewhere in here or even in the fuel rail or injectors.
 
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