2002 Mercury 200hp Outboard

[MGoral]

Wondering if anyone has come across this issue. When I have the throttle of my outboard at a certain spot, my motor stalls and sounds like its getting to much fuel. Runs fine at idle and at WOT but stalls about at half throttle. Is there a adjustment that needs to be made to the throttle cable? Maybe a carb adjustment? Has anyone seen this before?

 

[j_martin]

Re: 2002 Mercury 200hp Outboard

There is a whole set of linkage and timing adjustments that interact with each other. There is a procedure for each engine to properly set those items we refer to as link-n-sync.

Of course the basics need to be in place first. Good mechanical condition (compression), electronics in good shape, etc.

There is no silver bullet. Mechanics that think there is tend to fuddle up engines.

 

[MGoral]

Re: 2002 Mercury 200hp Outboard

Thanks for your help j_martin I will attempt this next week!

I was able to find the carb adjustments in my manual

Here is the information incase anyone needs it

Remove the air box cover from the powerhead both for access and so you can peer into the throttle bores to check shutter positions.


Loosen the 3 carburetor synchronization screws (there is on 1 the linkage for each carburetor) to allow the shutter plates to fully close.


Position the throttle lever so the idle stop screw is against the idle stop, then move the roller arm until the roller itself LIGHTLY touches the throttle cam. In this position, use the idle stop screw to adjust the position of the throttle lever so that the mark on the throttle cam aligns with the center of the roller.


Keeping the roller aligned with the mark on the throttle lever, retighten the 3 carburetor synchronization screws.


Move the throttle lever and check to be sure the shutter plates on all 3 carburetors open and close simultaneously. Repeat this portion of the adjustment if any shutter plate lags.


Next check and adjust the WOT position. Move the throttle lever to WOT. Make sure the carburetor shutters are fully open at wide open throttle and check to be sure the throttle shutters do not act as throttle stops. Use a feeler gauge and check for 0.010-0.015 in. (0.25mm-0.38mm), clearance between the throttle shaft arm and the stop. If necessary, use the WOT stop screw to obtain proper clearance, then tighten the locknut to hold the adjustment.


There are often multiple marks on the link arms for the oil pumps used by Mercury motors. Where there are multiple marks on the arm of a pump used on these models be sure to align the mark positioned furthest CLOCKWISE away from the link ball stud with the mark on the pump body.


Return the throttle linkage to the idle position, then check and adjust the carburetor-to-oil pump synchronization. With the throttle linkage in the idle position the alignment mark on the oil pump link arm should be aligned with the casting mark on the oil pump body. If the mark is not aligned, disconnect the linkage rod from the oil pump lever. Screw the rod end (in or out, as necessary) to align the mark on the oil pump body with the mark on the lever. Connect the rod end back onto the oil pump lever.