2.5 200 merc. Staying in guardian

[Varmint]

'03 model,rebuilt in our shop andd has run perfect for 2 seasons,.015 bored on all 6 completely machined and assembled from bare block up. Has 140 hours of perfect run time . It is smartcraft enabled. Took for testing props on a bass boat. Made 2 runs and she was able to turn a 27p chopper srx to 5600 rpm,limiter is set at 6050 from factory,went out with smaller prop and she went limp and wouldnt go over 2k. Found oil injection check valve on pulse side was done. Motor bottle was empty of oil. Replaced check valve and all good,primed and ran fine. Back to lake,same think,rev to limit in neutral and in gear 2k,but run/start perfect. Put on mercury ddt,no faults/cofes in memory. Except only 20% power available,set it back to 100% power available and back to lake. Same thing,fire right up into gear and run perfect,but wont go over 2k. Pull hood and do cold compression check with throttle open. 140 psi on all 6,dead on perfect ,plugs all nice tan color with plenty of oil evident,cant find any bad grounds bent pins. Showing no codes or faults. Any ideas fella's ? I put a new set of plugs in anyhow,and did a spark test,all good and all coil packs test strong.

[Varmint]

And she has a freshly assembled 4 hole cle with bob's cone and new impeller etc. 10psi at idle 20+ on plane,running a bit deep,it isn't overheating at all.,it is mounted on a ridgeback mid with a 2.5 2 pc. Adapter plate and a 2.5 200 tuner.

[Euroski]

does it have shift interrupt switch as if so is it working?

[Varmint]

No it actually has an older merc flush side box circa early 90's,that has no horn,i have a brand new 8 pin harness in my paramount with warning horn,and 14 pin adapter to run my 250 pro xs,so i was gonna switch the harness' so i have the 8 pin on the 2.5 with warning horn,and put the 14 pin harness back with the 250.

[Varmint]

does it have shift interrupt switch as if so is it working?aren't those only on sterndrives ?

[Euroski]

aren't those only on sterndrives ?

My 300xs has one and if in "N" will only rev to 1900rpm

[Varmint]

well that's not the problem,this one will hit the limiter in N,stays at 2k in gear,my 250 pro xs is the same.except it runs great,in gear.

[XstreamVking]

Check to see if there is a bad interrupter on the shift slide on the motor. Blue and black wires. Opti's have them and will give the same symptoms.

[tlwjkw]

aren't those only on sterndrives ?

it should have one... mounts on anchor bracket... shifter and/or harness has nothing ta do with it....

[Varmint]

Check to see if there is a bad interrupter on the shift slide on the motor. Blue and black wires. Opti's have them and will give the same symptoms.
Oh ok makes sense,will do,it kinda is an opti,with the motorola electrics oil inj. And downdraft intake

[XstreamVking]

You can test by jumping the two wires together.

[CircleHook]

"this one will hit the limiter in N"
Reving to limiter - what maybe 6K - in neutral ?? I thought that was a serious bad idea-
or am I missing / mis-understanding what "reving to limiter" means ??

[Varmint]

"this one will hit the limiter in N"
Reving to limiter - what maybe 6K - in neutral ?? I thought that was a serious bad idea-
or am I missing / mis-understanding what "reving to limiter" means ??i said it will rev to the limiter in N,means it will act normal in N and rev way past the 1900rpm it shuts down at in gear,,doesn't mean I did /do rev it that high. the limiter is set at 6050.,,:)

[Varmint]

You can test by jumping the two wires together.tks. can it be bypassed if it is faulty ? or need to be replaced ? I have the same motor on a shelf blowed up that i can borrow from.tks. !!

[XstreamVking]

Yep, ran one of my opti's around with it bypassed for a long time. Just keeps you from revving too high in neutral. Eventually replaced it....

[Greg G]

2003 200 EFI model, rebuilt in our shop and has 140 hours of perfect run time and is smartcraft enabled. Found oil injection check valve on pulse side was done. Motor bottle was empty of oil. Replaced check valve and all good, primed it and ran fine at idle. Put on mercury DDT, no faults in memory except only 20% power available. Pulled hood and did cold compression, 140 psi on all 6. Plugs are all nice tan color and all coil packs test strong. Any ideas fella's?

Just to get a little more info on a couple of items. First, are you saying that once you went into limp mode, that caused you take the cowl off after idling back to the ramp and you noticed for the first time that the oil reservoir tank attached to the motor was COMPLETELY empty of oil? Or was it at half full?

[Varmint]

Ya but does it fix the low rpm in gear issue as well ?won't go over 2k

[Varmint]

Just to get a little more info on a couple of items. First, are you saying that once you went into limp mode, that caused you take the cowl off after idling back to the ramp and you noticed for the first time that the oil reservoir tank attached to the motor was COMPLETELY empty of oil? Or was it at half full?completely empty,the check valve on the pulse side screwed up,wouldn't let the pump know to feed the motor tank from the 3 gallon res. Changed the valve back at shop,then put ddt on it,gave no faults but said it had only 20% power avail. Set it back to 100% and same thing,no power in gear,but run normal and sounds healthy

[Greg G]

Very strange. As a Smartcraft capable 2003 the minute the oil in the engine mounted tank dropped below half you would at least have shown a fault code in the DDT for low oil and yet you have zero codes. Does the boat itself have an SCM100 gauge on the dash?

[Varmint]

Very strange. As a Smartcraft capable 2003 the minute the oil in the engine mounted tank dropped below half you would at least have shown a fault code in the DDT for low oil and yet you have zero codes. Does the boat itself have an SCM100 gauge on the dash?shoulda chucked a code,we just bypassed my boat ignition with a shop harness and ddt hooked up,but we think the 1 year old battery was maybe the culprit. So tossed in a new one after old barely passed the load test fired her up and immediately she ran like a beast compared to before,only had her in a test tank,but it had huge throttle response in gear,no warning horns or beeps and 10 psi WP at 1000 rpm in gear,thru a coned cle freshly assembled.even with old battery fully charged she ran night/day with a fresh new batt. No codes and ecm says she has 100 % power available. Next up is a test blast in the river with some real world resistance,see how she acts. Tks fella's for all the advice,you guys are great . Happy and Safe 4th to everybody and their families.