94 Merc 200 xri dies after short run

I have a 94 Merc 200 xri on a 95 PII. Recently it began shutting down after a short run. While running there were no issues, ran great. After about 3 - 5 mins it acted as though it was running out of gas. I can restart but it will die. Then will not restart. I can let sit for a few days and it will repeat the above actions. I replaced water separator filter with no results. I'm thinking it may be the electronic fuel pump overheating and shutting down. Any thoughts or direction is appreciated

This topic has 7 replies, 4 voices, and was last updated 2 years, 3 months ago by Bass Cat Boats.

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September 8, 2023 at 8:56 am #719082

basshooker57
Participant

I have a 94 Merc 200 xri on a 95 PII. Recently it began shutting down after a short run. While running there were no issues, ran great. After about 3 – 5 mins it acted as though it was running out of gas. I can restart but it will die. Then will not restart. I can let sit for a few days and it will repeat the above actions. I replaced water separator filter with no results. I’m thinking it may be the electronic fuel pump overheating and shutting down. Any thoughts or direction is appreciated

September 10, 2023 at 10:34 am #719182

SimonP
Participant

I had the same situation on my 95 Merc 200EFI. A possibility is the Fuel drivers in the ECU are going out. After a while it won’t restart. Means Replace ECU or rebuild it.

September 10, 2023 at 11:57 am #719183

apdriver
Participant

Might be a fuel delivery issue. You can run it on an external tank to see and rule it out.

September 11, 2023 at 7:02 am #719198

basshooker57
Participant

I ran the primer bulb straight to the port tank since I didn’t have an external tank available. It did the exact same things. I will try to use an external tank before I explore the ECM issue. I had ECM rebuild about 5 yrs ago.

September 11, 2023 at 12:48 pm #719199

apdriver
Participant

External tank and all new hose and bulb through rigging hose to wherever your current fuel hose hooks into motor under cowl. Not sure on a 94 motor. This bypasses and replaces any fuel delivery problems up to your motor.

September 21, 2023 at 11:34 am #719437

basshooker57
Participant

Today I rigged up an external tank. Motor ran great. Never died, stuttered, or hesitated. Ran several laps around a small lake. Got up to 66mph. Came back home and removed what I thought was the anti-siphon valve but no valve, just fitting for fuel hose. I ordered new tank control valve from BassCat today. I will also replace all fuel and fill hoses. Hope this solves my problem!

September 21, 2023 at 8:15 pm #719448

apdriver
Participant

That’s good news. Sounds like you found it.

September 30, 2023 at 8:16 pm #719698

Bass Cat Boats
Keymaster

It’s going to likely be ethanol and degrading hose related. The fuel primer bulb and engine lines from the tank to engine will need replaced. Also the bleed lines on the engine deteriorate.

Fuel lines on the actual boat are all ethanol resistant and you should likely never have to replace those.
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