Search results

Nice! Definitely interested to hear how this progresses. So, old original engine (240efi gen2)... replacement engine (240efi gen1) I would attempt, as you are, to convert the gen1 into a gen2 as far as you can. The changes to gen2 are worthy. - Intake manifold (w/ injectors and base reed...

Yes. Both of these are 240efi engines. The non-alternator version is the gen1 (I have this in my boat). The alternator version is the gen2 (your engine). These engines can be swapped... same block... same jet pump. The gen2 has some differences. Alternator, newer different ECU, electric...

Hi. Sorry to hear about your 240efi. Sadly, not uncommon. Do you know the engine in the 185? I'd guess the mercury 210 carb'ed version... but possibly the 200hp Optimax?? The 210 would swap (same block/jet pump as 240efi)... not positive about the Optimax (are those the 3.0L blocks??)...

I concur, new flywheel needed. I had to get a good-used flywheel for my 240 rebuild. Cross-reference the part number to see the other engines (some outboards) that used that same flywheel (and use the part # in fleabay search too).

Hi. On my Challenger 240efi... there are fuses on the engine (beside the starter), fuses behind the helm dash, and fuses as part of the battery shut-off switch. Perhaps you missed the shut-off switch ones? GL.

Same result with a new starter... hmm. I'd be pulling the spark plugs and ensuring the engine is able to crank over smoothly/easily with no compression. If still struggling to crank... possible jet pump issues. Maybe something jammed in there. Or bad-case... jet pump gear failure. Good luck.

Testing TPS The connector to the TPS needs to be connected so the ECU and send the supply voltage to the TPS and we can read the signal/return voltage to determine if the sensor is working proper. Mercury sells a 3-way test connector, but I have used an easier way. Get a couple inch long...

The TPS is on the intake manifold... driver (starboard) side... down low... under/behind the fuel filter. Round shape with two retaining screws and a 3-wire connector.

In lieu of the proper TPS Test Harness... here's how I tested mine. Take a short piece of multi-stranded wire... strip sheathing off... unwind strands... get 3 separate thin strands... at least a couple inches long. Unplug the TPS connector. Put 1 strand in each female connector hole and plug...

The jumping of power off and on... would make me suspicious of the TPS (throttle position sensor). As they start to go bad, they give bad readings to the ECU... to include jumpy readings instead of smooth readings as throttle changes. These bad reading cause the ECU to alter fuel injecting...

Welcome. The Merc 240efi is a 2-stroke, and as such does burn oil along with gas. Smoke is usually most noticeable on cold starts at idle, and should clear up as the engine warms up and at higher speeds. If your engine is running on premix fuel/oil (auto oil pump removed)... then you will...

Yes, the bilge siphon hose... the end with the screen filter, goes down low in the hull where water would be (if present) to be sucked out. Yes, the bilge siphon hose does need to be looped up high in the middle. It goes over the top of my engine. This is important to ensure the hose is above...

The pictured hose is the bilge siphon hose. It sucks water through that filter-end anytime the engine is running in the water. That hose should have a connector in its middle... where it's routed up and over the engine... that connector should have a tiny hole in it to prevent a backflow...

Here's an M2 jetpump (removed from boat) to better illustrate which bolts you are talking about. The RED circled 4 bolts remove the nozzle, steering, reverse bucket. The BLUE circled 4 bolts remove the pump stator, and then you can slide off the wear-ring from around the impeller. All bolts are...

Someone will correct me I hope... but I think only the 2nd-gen 240efi... has the capability to connect with VesselView (updated electronics/ecu). The 1st-gen 240efi (which I have) does not.

I would double-check the throttle linkage and throttle arm adjustments on the new engine. This throttle arm also affects timing (connected to trigger)... which I would also double-check on the new motor. There is also possible jet pump. Impeller-to-wear_ring gap could be causing you to lose...

Possible hot restart issues. I had it with my 240efi. It floods when trying a hot restart and will crank and crank but won't start. Pull plugs... they are wet. In my case I had a few leaking injectors that allowed the fuel pressure to bleed off into the crankcase when engine was shut off. If...

Do you still have oil injection (oil pump)... or have you gone pre-mix? I would test the TPS. It can cause erratic idle and stalling. Also... do you have the 'Throttle Guardian' on your boat? I've read those are problematic and it is recommended to remove them. Get a spark tester and see if...

Look up your part via the Mercury parts website. You'll need to specify which exact engine you have to drill down to the diagrams to find the belt you need. Take the given part # and google it to find sales online. Parts for Mercury Sport Jet

Welcome. Which engine do you have in your Utopia? Is it the 240efi with alternator ... or an Optimax engine with alternator and airpump?