Continuos Alarm then no alarm then loss of power

Swetzel

Recruit
Joined
May 20, 2012
Messages
3
Hi Everyone,
I just received my boat back from a local mechanic which repaired my faulty voltage regulator.
My charging system is working great and I also installed a battery switch and a second battery myself.
My new problem is that I have a Merc 60 4 stroke bigfoot pushing a 21ft Pontoon and I have read that WOT (~5200 RPM) is ok, however, now I am getting a continuous alarm and I slow down and the alarm goes off, then if I power back up to 3500-5000 RPM it sounds the same alarm. So knowing this, I ran at about 3500 on a run for about 15 min and then idle in a no wake zone then the engine seems it went into safe mode and would run rough then kill.

Upon checking engine for any obvious things, I noticed the fuel filter retains very little fuel in it, I pump the bulb and it fills a lil, and while running with the cover off (~3000 RPMs) the fuel is almost gone in the filter until pumping bulb while running and then it goes down again.
The engine doesnt shut down when there is a small amount in the filter (ever) even with about 1/16" showing.
In cold start the filter shows fuel and bubbles at dock with engine cover off, water splashes while under power and I dont want to mess anything else up so Im not sure what its doing under power.
note - the bulb sometimes gets hard and sometime doesnt.

I ran it at about 2000 RPMs for about 2 hours under power and no problem with cover off. (at night)
I ran it at about 2000 RPMs for about 15 min under power (cover on) yesterday at mid-day and no alarm but engine started dropping RPMs, safe mode??? - I took the cover off and was able to return to camp without any issues.

I ran it home to trailer for about 60 min ride at 3000 RPMs with cover off and full load on barge and no problems at all.:confused::confused::confused:

I am considering changing fuel filter (or cleaning the current one?) and thermastat (ECT?) and new gas cap my self.
The fuel line from tank to engine including bulb is new from previous owner and receipt from shop he gave me.

Any and all suggestions welcome...
Thanks!
 
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