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  1. #1
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    2006 Optimax 225 - fuel in air rail

    2006 Mercury Optimax 225- had a poor idle problem, found fuel in air rail, replaced both the tracker valve diaphram and fuel pressure regulator diaphram. Motor ran great for a few trips.... then after running all day and back to ramp... motor would not start (but, good place for motor to quit!). Anyway, pushed the schrader valve on the air rail and fuel squirted out. Thoughts? Could a bad injector oring cause fuel to get in air rail? Ideas on how to test?

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    Low pressure on air side could let fuel into air side? I would think that inj o-ring would flood cylinder. Is plug wet? BTW I am not a tech, just a shade tree mech. But I do have 3 of these 225's. And have done the inj's and rails.

    83 V-King, 96 Mariner, 200 hp ff block 2.5 w/a 28p choppa
    We gotta clean this liberal mess up, VOTE TRUMP TO MAGA!
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    Bad injector o-ring, stuck open fuel injector, stuck closed direct injector, tracker valve, fuel pressure regulator.

    EDIT: If you can get it to idle, check the air/fuel pressures too.
    Last edited by InjectorService; 12-18-2020 at 03:01 PM.


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    Heres an example of a fuel injector o-ring leak. This is viewed from the air injector side. Its pretty plain to see here, as the fuel was full of crap and rust too. But definately not a spot to ignore.



    www.InjectorService.com
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  5. #5
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    Thanks everyone for your responses. I had time to tear into the motor this weekend. Pulled the fuel rails and cleaned the injectors, replace o rings and screens on the fuel injectors.... checked both the fuel regulator diaphragm and track valve diaphragm (previously replaced). Found another torn tracker valve diaphragm. This seems to be the cause of the fuel in the air injection system again. Thoughts on why multiple failures of tracker valve diaphragm??? I'm ordering another new diaphragm and will check air and fuel pressures once engine is running again. I'm think there must be an extreme pressure differential between the air and fuel systems... either the fuel pressure relief is not working properly or the air compressor cannot produce enough PSI to maintain the 10 psi pressure differential at the tracker valve.???? thoughts?

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    You are on the right track in my opinion. you should be at 80psi and 90 psi, if either of those are way off you will have this problem. I've seen a bad belt cause exactly what you are saying because it didn't have enough air pressure. It had like 55psi, enough to run, but there was always fuel in the air till that belt was changed.
    8' Yellow Jacket - 25 hp Mariner
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    Best way to be sure though is put a gauge on both those schraders and verify your psi
    8' Yellow Jacket - 25 hp Mariner
    1984 Hst VKing - 15" Bridgeport EFI
    1990 Collins Mirage - 15" 260
    22' Aquasport - 150 SeaPro Fourstroke

    25 hp Merc that runs on ACETONE
    25 hp Merc with dry side pipe
    25 hp Merc with 11" mid and 2.42:1 gears


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    Installed a new tracker valve diaphragm this weekend, engine fired right up. Gauges on air and fuel.... air 80 psi, fuel 90. Did the pinch test on air and fuel return/exhaust lines, air went to over 100 psi and fuel to about 140 psi. I have heard that others have had to replace multiple tracker valve diaphragms...with the thought that the diaphragms were old (sitting on shelf too long)....???? Not sure why diaphragm would have failed again. thoughts??

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    I ran a dose of quick clean thru my "2010" 225 opti. The tracker and the fuel pressure failed soon after. I don't know if the chemicals got the rubber, or it was just a coincidence, or a bad run of rubber. Replaced all 3 with the purple ones. Had tan ones. I also have an 05 225 opti that still has the original rubber in it. Have used the quick clean but maybe just not as strong? Also have a 01 200 opti with original rubber?

    83 V-King, 96 Mariner, 200 hp ff block 2.5 w/a 28p choppa
    We gotta clean this liberal mess up, VOTE TRUMP TO MAGA!
    Rebuild thread:
    http://www.screamandfly.com/showthre...-it&highlight=
    http://www.screamandfly.com/showthre...cs.&highlight=
    Videos

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    If they backfire while an air injector is open it can blow the tracker out.

    EDIT: Also what color was the tracker you put in the first time?


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  11. #11
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    all were purple diaphragms

  12. #12
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    Thanks to everyone responding to this post it makes it much easier to try to diagnose with the various thoughts.... I very much appreciate your help and comments.

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