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02 200 optimax does not start

Old 06-13-2020, 09:35 AM
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Question 02 200 optimax does not start

First, I would like to say thank to all the guys that have responded to opti issues in the past; I have looked over quite a few of them in trying to solve this issue.

For some time the motor had been hard starting, I would need to open the throttle to get it going. Once it got going; it would run all day. Now it does not want to start. I have the proper battery, charged and tested it for voltage. I even tried jumper cables just to provide extra for cranking. I checked for spark, #6 plug is not firing. I swapped the plug and it would not fire in the other coil. I will replace the set now, but I do not think that is THE problem just not helpful. I tried a 6 gallon tank with fresh gas. I also replaced the fuel lines just to the motor and primer bulb, rebuilt the mechanical fuel pump and checked to see that both the fuel pump and the high pressure pump run. VST tank is clean. "Newish" fuel filter too. I took the air line off the fuel rail and cranked the motor there seems to be good air supply from the air pump. I do not have a fuel pressure gauge but there is always fuel at the valve. Weird thing is I have no air pressure after cranking. I put 80lbs, of air into the valve and crank the motor and it just goes away. I also left it sit with the air in it and it seems to hold pressure. Unfortunately I do not have a gauge set, but I was figuring that maybe there was enough to see why it would not run and not why it is running poorly.
Removed tracker valve it did not seem to be brittle, torn, degraded, or dirty. however, it is the original part.
An update. I went out just to see that it was holding air pressure. I put air to it but i forgot to put the airline back on from the compressor to the fuel rail. When I put air to it I got what seemed like gas blow up through the open on top of the fuel rail. I would not say good gas because it could have been sitting in there for months.

Last edited by Cyrust; 06-13-2020 at 10:07 AM.
Old 06-13-2020, 02:07 PM
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You need to see what air pressure you are getting when cranking, sound like your compressor may be toast
Old 06-17-2020, 06:47 AM
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I changed the plugs and got it "started," I had to open the throttle some to get it started and to keep it from dying right away but after a few minutes it will run with no throttle with a shake. Fuel pressure is still an unknown (I don't have a fuel pressure gauge) but I used my tire pressure gauge on the air rail and I have 90lbs. From what I have been reading that is too high. Another thing when I put air to the valve to check for leaks I did not hear any but I read that if I put more than 80lbs, in the air regulator would open and you would hear the air escape, So, I put in 83lb. and heard air bleed off, Sounds odd that you could have 90lbs, running but I don't know how the different valves work.
Old 06-18-2020, 06:12 PM
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You really need to get a fuel pressure gauge and check fuel psi. What are rpms at idle? Consistent or dropping?
Old 06-19-2020, 11:43 AM
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After it gets going and I can back off the throttle the RPMs are consistent no drops or surging, but there is a miss. I changed the plugs and pulled them about 30 minutes later and one plug was still clean. Since this boat has been sitting more than anything I figured it would be a good idea to have the injectors inspected and cleaned. I could see some trash on the screens and the one that was not firing has some corrosion on the tip. Most likely from setting too long when I had some ethanol gas in it some time ago. After the injectors get back I think I may need to invest into the gauges. Its not like there is any good available help close by.
Old 06-27-2020, 08:46 AM
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Finally got my injectors back. It will start without an open throttle an will idle. It still takes too many revolutions for an "Optimax" to start up. Big thing is I got two loaner fuel pressure testers(unfortunately they were not liquid filled). On start up I was at the 10 psi difference about 82 air and what seemed like 92 fuel. I gave it some throttle and the air remained constant but the fuel pressure increased and remained hgh. I clamped the air dump line and the air pressure spiked. However when I clamped the fuel return line the fuel pressure maxed the 100psi gauge and stayed there even after unclamping the line. I may still have two issues; one a starting issue and the other a fuel pressure issue?
Old 07-02-2020, 10:25 AM
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I have an issue that I just can not seem to find any advice on. After having the fuel injectors serviced, just replacing the port fuel rail with a new one and replacing the tracker valve the motor will run stronger than it has in some time. Each change has brought an improvement.

Here is the question: When I went to restart it after running a few minutes, it would not start.. I pushed the air Shrader valve and there was no pressure, When I pinched the air dump line it built up pressure and started up. Why would this thing be dumping air and not starting?
Old 07-02-2020, 06:20 PM
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What is air psi when cranking?
Old 07-02-2020, 06:51 PM
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Take the black plastic cover that is on top of the powerhead off. Stick your finger on the hole the air comes in on the compressor when you crank the motor. If it sucks your finger down the compressor is good if it barely does anything or nothing the compressor is dead. Normally if your compressor is dead your motor wont run cause it needs the compressor to compress the fuel and air through the injectors, no pressure then no fuel through the injectors and no run. You can start a good motor and stick your finger over that hole and it will shut the motor off on a Opti. Normally the only main Opti issues are fuel pumps or air compressor, tracker valve just keeps it from idling. Injectors are hardly ever the problem when it comes to a motor not starting. The older opti fuel hoses can fall apart on the inside when the fuel pump kicks on but it looks fine on the outside. Never ever ever use ethanol gas in a older Opti, you will fight fuel issues till you're blue in the face.

All the stuff youve replaced and I'd be looking at bad fuel hoses or garbage gas thats gelling in your motor when you dont use it. Bad gas sitting just a couple days in your opti can cause it to take a while to start. Those older Optis are the most fuel sensitive motors ever. You could have a weak high pressure pump too, just pull the line off the top of the vst and crank it, fuel should shoot about 5ft in the air. If its not shooting very far your injectors wont get fuel. Could be the screen at the bottom of the fuel pump inside the vst or just a weak pump. To check the other pump on the outside the vst just pull the hose and crank the motor, if fuel pumps out your good. Start with pick up pump first then to high pressure pump. If vst is empty and high pressure pump works but pick up pump doesnt then no run. If the vst is full and pick up pump is dead but high pressure is good motor will start for a minute till all fuel runs out in vst then no more run. If the pick up pump is good but high pressure pump is bad then you will get fuel inside vst and but motor wont run or it put-puts a couple times and keeps shutting off as fast as you keep cranking it, the fuel could actually pump a little out the high pressure pump inlet making you think high pressure is good but its not cause high pressure should shoot 5ft into the air not 1ft.
Old 07-02-2020, 07:52 PM
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Originally Posted by Eightpter View Post
What is air psi when cranking?
When I had the air pressure gauge on it, I could turn the motor over and see the gauge build pressure. On the third stroke it was up at 80psi and started. This issue is starting to look like it is related to heat(not over heating just operating temps); and seems like it will start cold every time. When it is warm it is looking like it is 50/50. When it does not start there is no air pressure at the valve
Old 07-02-2020, 07:58 PM
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Originally Posted by PRO-BLU View Post
Take the black plastic cover that is on top of the powerhead off. Stick your finger on the hole the air comes in on the compressor when you crank the motor..
Oddly, I did it backwards I took the air line off the fuel rail and cranked the motor with my finger over the compressed air line. I am using a portable gas tank with fresh gas, new lines, and primer bulb,
Old 07-03-2020, 06:49 AM
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Right now excluding connections I have 8 openings in the air system. The pressure regulator. the 6 direct injectors, and the air compressor. I don't know how to validate the air compressor and it is too expensive just to swap. I changed the air regulator, but it might be bad out of the box. I was thinking of pulling the line from the compressor to the fuel rail and see if it was pumping out air but then I should not have been able to start the motor by pinching the air dump line. The air regulator should not bleed off any of the air till it exceeds 80psi? Then there are the six direct injectors, I would like to think that one bad one should not keep to compressor from building enough pressure to start the motor.
The variable that is confusing is this seems to be a 50/50 warm start issue. Maybe it needs a water test now. I am going to take it to the water this morning and see what kind of performance it has; that might shed new light on things.

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