Mercury 200 ProMax Troubleshooting
| Engine Model: Mercury Pro Max 200 Hp |
| Engine Type: 2-stroke 6-cylinder gasoline outboard engine |
| Total Displacement: 153 cu.in (2507 cc) |
| Rated Engine Power: 200 Hp (149.1 kW) at 6500 rpm |
| Fuel System: Electronic fuel injection (EFI) |
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| Engine starts hard or will not start |
No gasoline in tank - Add fuel.
Low-quality gasoline - Use quality gasoline.
Dirt and debris in fuel system - Remove debris and dirt.
Spark plug wire is disconnected or loose - Inspect spark plug wiring connection, change or repair.
Spark plug is damaged - Change spark plug.
Fuel filter is plugged - Fuel filter needs changing.
Fuel lines are clogged - Fuel lines need to be cleaned.
Drained or faulty battery - Battery needs to be recharged or replaced.
Wiring harness connections are damaged - Check wiring harness connections.
Ignition system malfunction - Check ignition system components and change if necessary.
Defective pulse fuel pump - Install new pulse fuel pump.
Electric fuel pump failure - Install new electric fuel pump.
Electronic control modul failure - Replace ECM.
| Engine starts but then stalls |
Damaged spark plug - Spark plug need to be replaced.
Defective ignition coil - Install a new ignition coil.
Defective pulse fuel pump - Replace pulse fuel pump.
Restrictions in fuel system - Clean fuel system.
Dirty final fuel filter - Replace fuel filter.
Damaged electric fuel pump - Install new electric fuel pump.
Ignition system failure - Inspect ignition system and change failed components.
Clogged or defective fuel pump - Clean or change fuel pump.
Fuel lines are dirty - Fuel lines must be clean.
Clogged fuel filter - Replace or clean fuel filter.
Engine overloaded - Load reducing is recommended.
Wrong ignition timing - Ignition timing needs to be adjusted correctly.
Defective thermostat - Change thermostat.
Water pump failure - Water pump need to be replaced.
Stale gasoline - Use proper gasoline.
Engine overloaded - Load reducing required.
Wrong adjustment of low idle speed - Correct the settings.
Fuel pump is clogged or faulty - Check fuel pump and change if required.
Crankshaft or main bearings wear - Need to install new components.
Worn piston rings or cylinder bore - Replace faulty components.
Dirty or damaged fuel pump - Service or change fuel pump.
Defective ignition - Inspect ignition system and change faulty parts.
Worn powerhead components - Replace defective components.
Failed switch box, stator, or coil - Change faulty components.
Compression is insufficient - Normalize compression.
Fuel delivery problem - Check fuel system.
Manifold is leaking - Leak must be repaired.
Vapor separator is flooded - Normalize vapor separator functions.
| Excessive fuel consumption |
Loose or defective spark plug - Re-tighten or replace spark plug.
Worn piston, rings, or sleeve - Change faulty components.
Engine overloaded - Load reducing is recommended.
Clogged or damaged fuel injectors - Inspect fuel injectors and change as required.
| Engine vibrates excessively |
Propeller bent or damaged - Have propeller repaired or replaced.
Damaged propeller shaft - Replace propeller shaft.
Weeds in the propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten bolt.
Damaged or loose steering pivot - Tighten or replace.
Propeller bent or damaged - Have propeller repaired or replaced.
Propeller shaft malfunction - Replace propeller shaft.
Weeds in the propeller - Remove and clean propeller.
Engine mounting bolt is not tightened - Tighten the bolt as required.
| Trim motor runs but system does not move |
Low oil level - Check and refill oil.
Defective pump assembly - Test pump and replace if necessary.
Manual release valve leaking - Close the valve fully or replace it.
Motor or pump driveshaft faulty - Replace defective component.
| Trim cannot be fully up or down |
Defective pump assembly - Replace pump.
Tilt ram piston ball is displaced - Service or repair.
Tilt ram piston O-ring is worn - Change O-ring.
Not enough oil - Check and refill oil.
Lower check valve not seating in port side trim ram - Secure valve properly.
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