Mercury 200L Troubleshooting
| Engine Model: Mercury 200L |
| Engine Type: 4-stroke 6-cylinder DOHC 24-valve gasoline outboard engine |
| Total Displacement: 209 cu.in (3.4 L) |
| Rated Engine Power: 200 Hp (149 kW) at 5800 rpm |
| Fuel System: Electronic Fuel Injection (EFI) |
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| Engine starts up hard or will not start |
Empty fuel tank - Add gasoline.
Wrong fuel grade - Use quality fuel.
Air in the fuel system - Air bleeding.
Spark plug wire is disconnected or loose - Inspect spark plug wiring connection, change or repair.
Defective spark plug - Spark plug need to be replaced.
Clogged fuel filter - Replace or clean fuel filter.
Worn or defective vapor separator needle valve - Install new needle valve.
Dirt in the fuel lines - Fuel lines need to be cleaned.
Fuel tank air vent restricted or closed - Fuel tank air vent need to be opened or cleaned.
Defective fuel feed pump - Replace or rebuild fuel feed pump.
Choke cable is unadjusted or damaged - Adjust properly or replace the cable.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Valve timing is incorrect - Adjust valve timing as required.
Fuel pressure is low - Inspect fuel system for leaks or inspect low pressure fuel pump.
Dirty or faulty fuel injector - Clean or replace as required.
Fuel regulator is defective - Install new fuel regulator.
ECM is not functioning - Install new ECM.
| Engine starts and stalls immediately |
Spark plug is defective - Install new spark plug.
Damaged or wear vapor separator needle valve - Replace needle valve.
Defective ignition coil - Install a new ignition coil.
Fuel tank air vent clogged or closed - Fuel tank air vent need to be opened or cleaned.
Fuel pump malfunction - Replace or repair fuel pump.
Choke system malfunction - Inspect and replace choke system components.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Wrong valve timing - Adjust valve timing as required.
Loose or worn valve springs - Change valve springs.
Stuck valves - Clean the valves.
Low compression - Check and change damaged parts.
Dirty fuel filter - Fuel filter needs to be replaced.
Fuel injector is faulty or clogged - Clean or replace if necessary.
Engine oil level is low - Fill up the oil to required level.
Defective oil pump - Change oil pump.
Water intake is blocked - Wash or clean as required.
Defective thermostat - Install new thermostat.
Water pump failure - Water pump need to be replaced.
Defective ignition system - Check ignition system and replace faulty parts.
Dirty or defective fuel pump - Inspect fuel pump and change as required.
Damaged or wear vapor separator needle valve - Change vapor separator needle valve.
Fuel lines are dirty - Service fuel lines.
Fuel tank air vent restricted or closed - Open or clean air vent.
Clogged fuel filter - Replace fuel filter.
Intake manifold air leaks - Install new gasket.
Clogged water intake - Wash or clean as required.
Throttle valve and throttle link are defective or worn - Change faulty components.
Clogged or worn fuel injector - Clean or replace if necessary.
Engine overload - Reduce engine load.
Fuel injector or fuel pump is dirty - Clean or replace if necessary.
Bad ignition timing - Ignition timing needs to be set properly.
Damaged thermostat - Install new thermostat.
Water pump failure - Install new water pump.
Propeller selection improperly - Check the propeller size.
Damaged or bent propeller - Have propeller repaired or replaced.
Outboard motor is positioned too low or too high - Position the engine correctly.
Not enough engine oil - Check and refill engine oil.
Damaged oil pump - Replace oil pump.
Clogged water intake - Need to clean or wash.
Incorrect valve setting - Adjust valves as required.
| Abnormal engine noise or knocking |
Low octane fuel - Change gasoline.
Engine is overloaded - Reduce engine load.
Wrong adjustment of low idle speed - Correct idle adjustment.
Fuel pump is clogged or faulty - Clean or replace fuel pump.
Crankshaft or main bearings failure - Have bearings or crankshaft replaced.
Cylinder bore or piston rings are worn - Change defective components.
Fuel lines are dirty - Service fuel lines.
Defective fuel injector - Change fuel injector.
Clogged or damaged fuel pump - Check fuel pump and change if required.
Ignition system failure - Inspect ignition system and change failed components.
Cylinder head gasket is blown - Cylinder-head gasket replacement required.
Powerhead parts are faulty - Defective components need to be replaced.
Stuck or burned valves - Change or service valves.
Incorrect propeller selection - Install correct propeller.
Damaged or bent propeller - Have propeller repaired or replaced.
Motor mounted at incorrect height on transom - Adjust the outboard motor height correctly.
Trim angle is incorrect - Adjust trim angle.
| Engine using too much gasoline |
Fuel injector is clogged or malfunction - Replace or clean if necessary.
Loose or defective spark plug - Re-tighten or change the spark plug.
Worn piston, rings, or sleeve - Replace defective components.
ECU failure - Install new ECU.
Propeller bent or damaged - Replace propeller.
Propeller shaft damaged - Have propeller shaft replaced.
Weeds clogs the propeller - Clean the propeller.
Motor mounting bolt is loose - Tighten the bolt as required.
Damaged or loose steering pivot Tighten correctly or replace.
| Starter motor is not working |
Battery voltage is low - Recharge the battery.
Battery does not hold charge - Service battery or replace it.
Corroded battery terminals or disconnected wires - Check wiring connections and replace or clean terminals.
Starter motor failure - Replace or repair starter.
| Trim motor runs but trim system does not move up or down |
Oil level is low - Fill up oil.
Defective pump assembly - Test pump and change if necessary.
Manual shut-off valve leaks - Valve need to be closed or changed.
Motor or pump driveshaft faulty - Replace defective component.
| Trim does not fully up or down |
Defective pump assembly - Change pump.
Tilt ram piston ball is not positioned correctly - Clean or repair.
Damaged tilt ram piston O-ring - Replace O-ring.
Insufficient oil - Fill up oil.
Lower check valve is not properly secured in port side trim ram - Secure valve properly.
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