2005 Mercury 90 Horse 4 Stroke Hydro Lock Issue???

AUdixie

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May 31, 2020
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Having some issue with my 90 horse Merc. Motor will crank right up, idle fine and will run all day long until I cut it off. I mean it will run great at low RPM's, full throttle or however want to run. If I ever shut it off it will not crank back up. It seems like a fuel delivery issue. I can wait about 30-45 minutes and it will finally crank up, but will idle rough and struggles to get going. It will finally pick up and run great again whether wide open or just putting along. I had some gas from last year still in the tank so I drained it and put fresh gas it. I didn't really think that was the issue, but I just wanted to eliminate it. I have replaced both fuel filters, plugs and all four coil packs and it still does the same thing. The plugs that I took out were dry and didn't seem fouled. They had a white to greyish residue on the electrode, but that seems normal. The crankcase does seem like it is a little over filled, but it doesn't seem to have any gas it in or at least it doesn't smell like it. I just can't figure it out. My next step is to open up the FSM and replace the float switch and high pressure pump. Any ideas? Am I on the right track? Does this sound like a vapor lock issue? Thanks.
 
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alldodge

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Do you mean the motor can be shut down and immediately restated and it won't start, or it sits for a time period and it will not start?
 

AUdixie

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Sorry for the confusion. When it is cold it will start right up and run great until I shut if off. If I shut it off and try to start it back up after only a few minutes it will not start up. I have to wait about 30-45 minutes before I can get it to crank up again. Even then it idles very rough and will hesitate when I open the throttle up. After a few seconds it will finally smooth out and run great again.
 

alldodge

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I would say that's not hydrolock

What is the serial number of the motor?
 

alldodge

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I'm thinking fuel pressure but sorry I have not been able to find out what the pressure should be.
Not finding the serial number at boatinfo or any other place

Hope an OB guy shows up to help
 

AUdixie

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Thanks alldodge. I am thinking the same now. I have read that the high pressure side should be around 40 PSI. I have a pressure gauge that I am going to screw into the valve on the high pressure side and see what it is. For about $200 I can rebuild the FSM with a low and high pressure pump, float switch and seal kit. I may just go ahead and do that
 

mav6759

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I know when I head my 90hp 2 stroke hydro locked, I removed all the spark plugs and turned the engine over a couple of times. Sprayed some carb cleaner in each one of the cylinders and turned it over again without the plugs so it can blow all the oil out of the cylinders. and mine was fine
 
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