2.5 merc 200 rebuild and conversion from EFI to carb - running but couple of issues

[CircleHook]

2.5 '96 200 came to me in as box of parts- down on #2 and #4- appeared crank oil gear failure- Bored .15 over on 2 & 4 and put it back together. Running - 1 hour time- compression numbers good so far.
First issue is spark weak and irregular on 1 piston when running (#3) others vary from very strong to ok- 3/8" gap jump- Coil? stator? trigger, pack? I have several extras of each.

Second issue- wiring diagram for 200 carb and EFI of this age shows NO shift switch- what prevents in gear starting? I put one on it- which did not work correctly- when I shift into gear with it running it jumps about 500 to 1000 rpms- shift it back I into neutral and RPMs drop back to normal idle. ?? Also when shift into gear (switch closed - Switch is open when at neutral) motor still turns over and has spark - presumably would start in gear-:eek: I did not actually test to see if it would start- it had spark-

I installed idle stabilizer which shares the white/black circuit with the shift switch, connection thur both packs with a jumper. So idler stabilizer and shift switch are on same circuit . The XR6, MAG III and 175 are shown this way on diagrams. I did NOT re-install warning module as oiler is removed, and did not install detonation module.
Throttle position sensor not present- part of old EFI I suppose.

Yeah I Know a bunch of ya'll pefer EFI- but not everybody does...

Thanks

[TEXAS20225]

you shoulda tossed the idle stabilizer with the rest of that stuff starting in gears prevention wires are yellow red stripe in shifter or close to it , you only did two holes and left the rest :eek::nonod: i guess after rebuilding several hundred of these things i aint crazy bout going back into same mota in a short while, the switch that is on the throttle is called a throttle interrupter switch it monetarily kills the motor when shifting into gear , i toss it also when im cleaning one up

[TEXAS20225]

and yes i hate carbs with a passion its easier to pop one on carbs then it is with EFI

[90 5.0]

Does your block have bleed fittings in it?

[TEXAS20225]

he said it was a 996 efi 200 i never saw one with them unless it was a 225 pmax or other unpainted hipo stuff( 260,280,300 drag)

[90 5.0]

he said it was a 996 efi 200 i never saw one with them unless it was a 225 pmax or other unpainted hipo stuff( 260,280,300 drag)

I have one promax that has them and one without.

I was curious to if other efi blocks had bleed fittings that were capped. I have no idea why one of my promax blocks has them?

i wonder if it was slated to be a 245 carb and merc put steel sleeves in it and sent it out the door as a pm??

[tlwjkw]

I have one promax that has them and one without.

I was curious to if other efi blocks had bleed fittings that were capped. I have no idea why one of my promax blocks has them?

i wonder if it was slated to be a 245 carb and merc put steel sleeves in it and sent it out the door as a pm??

all production efi blocks have 'em... which is what i think bobby meant.... they probably don't know if tha thing is gonna end up as a carb motor or efi motor when its produced, so lets just make it "bi" and cap 'em on tha efi's.... even tha 150 and 200 PM blocks since they are just "naked" production blocks... so one of you PM blocks is a 150 or 200 block............

doubt it was a 245 changed ta PM cause of tha oiler. they wouldn't machine it or swap front halves....... least not at merc.

[CircleHook]

Ok - remove shift switch, remove the idle stabilizer. Confirm shifter has start in gear prevention.
Any suggestions on weak irregular spark? thanks-

[CircleHook]

http://i67.tinypic.com/1611dt3.jpg

[CircleHook]

Yes- capped- I used 200 carb bleed hose map and installed bleed lines.

[90 5.0]

all production efi blocks have 'em... which is what i think bobby meant.... they probably don't know if tha thing is gonna end up as a carb motor or efi motor when its produced, so lets just make it "bi" and cap 'em on tha efi's.... even tha 150 and 200 PM blocks since they are just "naked" production blocks... so one of you PM blocks is a 150 or 200 block............ doubt it was a 245 changed ta PM cause of tha oiler. they wouldn't machine it or swap front halves....... least not at merc. Yes the one that has the capped bleed fittings is a 200 PM block, I had thought previously 225 and 200 pm blocks were the same but i am finding lots of differences. I thought previously only difference was 5 vs 7 peddle and ecu. I had heard port timing was different but sleeve part numbers for the two appear to be the same???

[TEXAS20225]

225 has rod slots 200 does not, sleeves are the exact same, however champher on the ports is much larger on 225 to speed up that charge or raising it up which ever you prefer, there is also some better clean up on slag from casting i just built my 13th 225 promax last week it aint fired yep there was a couple things different on this 99 model versus earlier models but basicly not too much different since i bought my first one new in 1995 on a red Bullet :D

[CircleHook]

Any thoughts on weak irregular spark one cylinder?
Figured to start with coil, then stator and trigger, packs last swap out-

THANKS !!

[TEXAS20225]

if its running dont worry about it i have done plenty of "wonder why its doing that thinking" like pulling plug wires off while running and noted not hardly any noticeable change in the way its running but when on the water it runs good, but if ist firing then not firing it may be a switch box ,take all the plugs out and ty wrap them together in a bundle for each side ground them then turn it over with starter see which one its skipping, change that box (best to change both) but if your a economy boater do what ever it takes to get it going ,

[bigshrimpin]

all production efi blocks have 'em... .

My 240 sportjet block O ring doesn't have bleeds :(

[tlwjkw]

its nota regular 150/200 production block... closer ta tha PM family and painted.....

[Steve Pope]

Shift switch is actually a 3 degree advance system to help stop engine stalling when shifting into gear with large pitch props.Thats why engine rpm increased when out of neutral. As for the different quality of spark, disconnect the stop circuit wires from the switch boxes(black with yellow tracer) and recheck spark. You will need to choke engine in order to stop it when stop circuit disconnected

[CircleHook]

Shift switch is actually a 3 degree advance system to help stop engine stalling when shifting into gear with large pitch props.Thats why engine rpm increased when out of neutral. As for the different quality of spark, disconnect the stop circuit wires from the switch boxes(black with yellow tracer) and recheck spark. You will need to choke engine in order to stop it when stop circuit disconnected

Replaced coil on weak spark- jumps 3/4" now- OUCH- Removed all stuff except packs and coils- sound great on hose - smooth and will idle way down - like 400 rpms - should get it on a boat and to water today. Thanks Guys