• This site contains eBay affiliate links for which Sea-Doo Forum may be compensated.

02 Utopia M2 240 EFI No Power above 4500 rpm, then no real power bottom end.

Status
Not open for further replies.

6MISFITZ

New Member
We had some performance issues with the 02 Utopia 185 we bought last summer that were all delt with by a complete tune up of, new spark plugs, new gas, port cylinder head temp sensor, water seperator and fuel filter. With the engine running properly, the feel of all 240 HP was more than I expected and the noticeable DROP in fuel consumption was welcome side benefit as I no longer needed anywhere close to full throttle to maintain a comfortable cruise speed.

Forward to this year and all was well until late June. I was losing top end - nothing over 4500 rpm and needed full throttle just to come up on plane. I tested my port side cylinder head temp sensor and from the Merc book I had - and incorrectly failed my sensor. (Found a small amount of water getting past the expansion chamber gasket while checking the engine running in the driveway at the same time, you know that gut feeling???).

Installed a new expansion chamber gasket and a temp sensor and full performance surged back intermittently for about 2-3 minutes on the next river trial. And then full throttle would not even get me on plane. Barely any power anywhere depsite where the throttle was.

Cylinder compression checks came back between 124 - 128psi
Dealer had a different Mercury Jet book than mine and said temp sensor ohms reading was fine.

Checked the TPS as that was the next item in the book and it initially looked good.

So I headed to the dealer who has a Digital Diagnostic Terminal and it ran through its software and throttle position sensor failed. Oh my goodness, $730 Canadian or $ 601.75 at the American dealer for something that looks like it should be, maybe $40 ... at the high end!

I saw them on ebay (new in package for a bit less but then overnight shipping & brokerage to Ontario, possible warranty issues), so gave my dealer the go ahead. Part has to come from USA warehouse, 1 week for delivery to my dealer.

Won't print what my dear wife said.

Mike.
 
The early TPS units are crazy expensive. I found a spare to keep around. BUT, the TPS doesn't normally cause issues at full throttle since it only trims the fuel at low RPM's. TPS issues normally show up as hard starting, won't idle, and smoke.


With the power loss you are describing... I would be more inclined to think you lost spark on a couple cyl's.


SO.... knowing that... do not let your dealer keep your old TPS !!!!
 
You know that gut feeling I mentioned earlier, call it gut rot now because that was not the news I was looking for Tony.
Thank you for the heads up on the old part but that does describe a rough idle and the smoke.

Very small chance that the boat will be ready next Saturday if the TPS arrives in Canada from USA Friday afternoon, so will report back with a water test as soon as we get it.

Mike.
 
Sorry about that... but you should have come here before letting a dealer swap parts. We are here to save you $$.
 
The 90-884822 M2 book that came with the boat was invaluable in figuring out why the reverse bucket was jambing in the up position and gave me wiring diagrams to identify and repair the running light wires, the running lights, blower switch wires, finding the correct wire for the water sensor on the water seperator and failing a good temp sensor.
Perhaps one of the reasons the previous owner cut the buzzer wires just under the dash?

Book shows 5 pins on the coils & coil plugs but mine only have 4!
Not able to get any ohms readings or test it like it showed.

The readings I got on the TPS sitting quietly in my driveway did not match the readings the DDT got while running in the water at different throttle settings.

Also idling the M2 on the water hose on the trailer was perfect but in the water, another story.
The year on the book fits the boat, but not the engine serial # range, so it was frustrating trying to follow the printed instructions that did not match parts.

Will have to look for the proper manual before I call the dealer next time,
Mike.
 
Post a picture of your engine please. OR, at least post the engine serial number. With the price you said the TPS was... that would indicate an early version of the 240. If that's the case... you have the wrong manual. The early 240 manual is 90-877837
 
I apologize, thought I had done that already and thank you for the correct book #.

Engine serial # OE397584

Mike.
 
Yep... that's an "early" or pre-2001-1/2 engine. And yes... that's a crazy expensive TPS.
 
Nope. The one for the Jag was close... and would physically fit... but it still wasn't right. Also, since I closed my shop, I'm not able to machine adaptors for anything else.
 
Nope. The one for the Jag was close... and would physically fit... but it still wasn't right. Also, since I closed my shop, I'm not able to machine adaptors for anything else.


Darn. I read that thread with enthusiasm as I thought you were on to something. Maybe there is still something out there but we need someone else with your skill set to continue the effort.
 
Darn. I read that thread with enthusiasm as I thought you were on to something. Maybe there is still something out there but we need someone else with your skill set to continue the effort.

I'm very sure there is something out in this world that uses this same TPS. Like I said before... the Jag one will physically fit, but it's the wrong potential.

The problem is... it's so obscure, that even if we find another unit... it's still going to be expensive. I guess the easier way to have this work is to tap the old mercury "Racing" ECU, to see if we could change the parameters of the engine. Heck... for the $500... it's almost worth making a megasquirt work.


My real suggestion to EVERYONE WITH AN EARLY 240 EFI is to keep your eye on eBay. DO NOT BUY A USED TPS... but watch for the even older TPS from the outboard. (Late 80's to 90's) It's the same TPS, but the plug is different. Most people don't know it's the same, and they go cheap. I've seen them go for $10 to $50 over the last few years. Just swap the plug, and you are ready to go.



OR.............


If you even come across a good, complete newer 240... buy it... swap it into your boat... and then sell your older engine. If you do it right, you will break even, and then all the parts are cheaper, and you get all the cool smartcraft controls too.
 
Last edited by a moderator:
What is considered early 240 EFI? Are the 2003 ones expensive as well?

The boat year doesn't mater. I've seen 2003's with the older engine. Basically... S/N less than OE406400.

The TPS on the newer engine is only $120 or so. The older one is $500.
 
yeah from a previous post, I am pretty sure I have the newer engine in my 2003. However I do like innovative thinking which is why the TPS project you started caught my attention.
 
Was really hoping to have the boat back last weekend in time for Thunder on the Niagara but finally back from dealer today after new TPS installed.

Dealer did an in water demo for me in their 10 acre fresh water pond and it started first time, very steady idle with much less smoke and ran perfect for that demo ride.

Pulled the boat home and put it in the Niagara. It stumbled at idle and stalled once after I fired it up, however once we were away from the dock the boat ran very well. Why would the idle change like that?
May have to turn up idle in the future but what a difference this pain in the pocket book part made!!!

Mike.
 
TPS is not cheap with Seadoos. I know very little about the Merce, but With a new TPS it isn't unrealistic that other adjustments such as the idle would need some attention.


Sent from my iPhone using Tapatalk
 
Idle was set by dealer after they installed it and was flawless in its operation in their pond but something about the river water our boat did not like or did not not adjust well to.

Does water temperature make a difference? Pond 80 degrees and Niagara river 72 according to Humminbird.

Mike.
 
Yes and no. The temp sensor will give the brain information and make adjustment based on temp. With carb items not as much as with injected.


Sent from my iPhone using Tapatalk
 
Status
Not open for further replies.
Back
Top