1998 200 EFI Merc NO SPARK & NO FUEL

[Wakestocker]

1998 200 EFI Mercury won't start:
No Spark & No Fuel
(I'm not a tech & new to site, hope this is the right forum)

OLD PROBLEM: motor stalled out at low RPM
Since I've owned the boat in '06, the only issue I've had is debris stuck in the fuel pump, until now...
(emptied tank completely, replaced all fuel lines, installed inline fuel filter, replaced fuel pump & seemed to fix my stalling issue)

Here's a list of new parts that mechanics have installed while troubleshooting the above issue:
stator
fuel pump
plugs
battery
gas tank pick up
gas line

NEW PROBLEM: motor won't start
Cold start has never given us problems until now.
It appears I have no spark & no fuel in any cylinders.

My thoughts:
Could a faulty neutral safety switch or throttle position sensor prevent the motor from operating?
I think I found both sensors using the wiring schematics, disconnected the ECU wiring harness (was a bit loose), inspected pins inside the harness (no rust, dielectric grease seems to be working).

Other observations: (not sure if they're relevant)

• The fuel filters & fuel pump are clear of debris
• The battery seems to have lots of cranking amps (12.9V) as the starter engages & turns the motor over.
• I can see fuel moving through the inline fuel filter upstream from the fuel pump.
• The EFI pressure was inside the acceptable range (I forget the PSI but could test again)
• The fuel in the fuel filter cylinder looks good (no water)
• Previous owner bypassed the kill toggle switch on the dashboard
• The horn no longer works & trim gauge is off by 30 degrees
• (strange how these electrical issues happened right around the same time I started having problems)
• Before today, the boat would start even IF it was in gear
• Throttle is very loose (finding neutral can be tricky)
• Both new & old problems only appeared later in the day, after idling through a channel for 15minutes (temperature climbed a bit above 1/2), mooring while we shopped & returned to boat only to discover these issues)
• Both new & old problems only appeared while on less then 1/4 tank of gas
• I just started running the cheaper Merc EFI oil (non synthetic) & noticed the exhaust while in idle seems to have a whiter colour & has increased in amount.

You can probably tell that my experience working on outboards is very limited. I wouldn't mind some advice before I take it back to the mechanic.

Thanks for any help you can offer.
-russ

[flabum1017]

could be a shorted dead-man switch (lanyard switch) or shorted key switch. The black/yellow stripe is the kill wire for the ignition.....

[Wakestocker]

could be a shorted dead-man switch (lanyard switch) or shorted key switch. The black/yellow stripe is the kill wire for the ignition.....

Thanks Flabum1017 but I think my kill wire is working ok. When it disconnects I lose all power to the starter.

I'm really at a loss with my new motor issue. How could it run so well all day, then after a long idle into town it acts up? Temperature was a bit warmer then 1/2

If it was a shorted key switch, would I still get power to my starter?

[TEXAS20225]

check the in line fuse on top of the the switch box plate

[Dave Strong]

No spark or fuel on a EFI sounds like no power on the ign, purple wire. Bobbie could be right also with the inline fuse, didn't think the would crank if that was popped??

Dave

[Wakestocker]

Thanks TEXAS & Dave, I'll check the in line fuse & ignition wire.

-russ

[Wakestocker]

In line fuse above switch box is good. Not sure how to test purple ignition wire?

-russ

[Dave Strong]

Hard to explain, but should be a terminal block with 4? Purple wires and 2 or 3 tan/blue wire going to it. Check for 12Volts on the purple wire with the ign switch in the run position. No batt voltage on the purple wire look at the ign switch or the engine harness conector,8 pin connector from the controls between the starter and switch boxs. Sorry I know where to go and what look for, but to tell someone is snother thing.

Dave.

[PanRonnie]

online manual very handy
check the ignition section
http://boatinfo.no/lib/mercury/manua...25-jet.html#/0

[Wakestocker]

Hard to explain, but should be a terminal block with 4? Purple wires and 2 or 3 tan/blue wire going to it. Check for 12Volts on the purple wire with the ign switch in the run position. No batt voltage on the purple wire look at the ign switch or the engine harness conector,8 pin connector from the controls between the starter and switch boxs. Sorry I know where to go and what look for, but to tell someone is snother thing.

Dave.

Thanks Dave.
Yes, I have 12.0 V to the purple ign wire @ that terminal.

[Dave Strong]

Does the fuel pump run when the key is turned to on?

Dave

[Wakestocker]

Dave, just came back after a day away & the elec fuel pump is no longer turning on. The only variable changed is a loose wiring harness into the ECM needed reseeding again. I can't seem to get the elec fuel pump back on line.

+ Voltage test on the elect pump is 12.8V which I think is acceptable when the key is OFF

-russ

[Dave Strong]

Disconnect the - wire on the fuel pump and run a jumper wire from the - side of the pump to ground if the pump runs you have a ECU or wire harness issue. If it wont run the fuel pump is your issue on the fuel side.

Dave

[Wakestocker]

Disconnect the - wire on the fuel pump and run a jumper wire from the - side of the pump to ground if the pump runs you have a ECU or wire harness issue. If it wont run the fuel pump is your issue on the fuel side.

Dave

Dave,
I reseeded the ECU wire harness again prompting the electric fuel pump to work again.
I think I have a good pin connection inside the wire harness now, but still no engine start.
I think I'll tape the harness together now that the pump is working & work down the troubleshooting flowchart.
What do you suggest I test next?
Thanks,
-russ

[Dave Strong]

Got a spark tester?

Dave