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Mercury XRI 200 Troubleshooting

Engine Model: Mercury XRI 200 Hp
Engine Type: 2-cycle 6-cylinder gasoline outboard engine
Total Displacement: 153 (2507 cc)
Rated Engine Power: 200 Hp (149.1 kW) at 5800 rpm
Fuel System: Electronic fuel injection (EFI)


Engine starts up hard or won't start

Empty fuel tank - Fill it up.
Improper fuel grade - Use quality gasoline.
Air in fuel tank - Bleed fuel tank.
Spark plug wiring connection is defective - Inspect spark plug wiring connection, change or repair.
Defective spark plug - Install new spark plug.
Fuel filter is dirty - Replace fuel filter.
Fuel lines are dirty - Clean fuel lines.
Drained or faulty battery - Recharge or replace battery.
Damaged wiring harness connections - Check wiring harness connections.
Ignition system is damaged - Change defective parts.
Pulse fuel pump is defective - Replace pulse fuel pump.
Faulty electric fuel pump - Change electric fuel pump.
Electronic control modul failure - Install new ECM.

Engine starts and then shuts off

Damaged spark plug - Spark plug need to be replaced.
Ignition coil is faulty - Ignition coil should be replaced.
Faulty pulse fuel pump - Pulse fuel pump need to be replaced.
Fuel system is dirty - Service fuel system.
Plugged final fuel filter - Replace fuel filter.
Faulty electric fuel pump - Change electric fuel pump as required.

Unstable engine running

Defective ignition - Check ignition and replace faulty components.
Fuel pump is dirty or defective - Check fuel pump and replace if necessary.
Dirty fuel lines - Clean fuel lines.
Fuel filter is clogged - Change fuel filter.

Engine is overheated

Engine is under excessive load - Reduce the load.
Wrong ignition timing - Set the ignition timing properly.
Faulty thermostat - Change thermostat as required.
Defective water pump - Install new water pump.

Engine noises or knocks

Stale gasoline - Change gasoline.
Excessive engine load - Reduce engine load.
Incorrect low idle setting - Adjustment required.
Dirty or damaged fuel pump - Check fuel pump and change if required.
Main bearings or crankshaft failure - Replace crankshaft or bearings.
Damaged cylinder bore or piston rings - Change defective parts.

Engine power is too low

Dirty or defective fuel pump - Service or replace fuel pump.
Defective ignition - Check ignition and replace faulty components.
Damaged powerhead components - Replace defective parts.
Failed switch box, stator, or coil - Replace damaged components.
Bad compression - Normalize compression.
Fuel supply problem - Check and repair.
Manifold is leaking - Repair leaks.
Vapor separator is flooded - Check and correct malfunction.

Engine using too much gasoline

Loose or defective spark plug - Replace or tighten spark plug.
Worn rings, piston, or sleeve - Replace faulty components as required.
Engine overloaded - Reduce load.
Fuel injectors are defective or dirty - Service or change fuel injectors.

Trim motor runs but system does not move

Insufficient oil - Need to add the oil.
Damaged pump assembly - Check pump and replace if necessary.
Manual shut-off valve leaks - Close the valve fully or replace it.
Pump driveshaft or motor damaged - Replace defective component.

Trim cannot be fully up or down

Pump assembly is damaged - Change pump.
Tilt ram piston ball is in wrong position - Service or repair.
Tilt ram piston O-ring damaged - Change O-ring.
Oil level is low - Checking oil level and add if necessary.
Lower check valve not seating in port side trim ram - Secure valve properly.