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2001 Evinrude 250 HP FFI Problems

Rob B

Moderator
Staff member
Most of you know from another thread I started having problems with the Evinrude motor. I finally got the diagnostic software to run tests and pull a report from the onboard computer. Without running the software I've narrowed it down to two or three areas where OMC has had problems with the motor. The problem: motor would shut off while cruising for no apparent reason, crank up run for a while shut off again. Now the motor will fire but not crank. I've checked the fuel pressure on the fuel rail which is 20 PSI and holds, according to the manual this is the correct pressure. I don't have any leaks that I could find all the fuel connections are tight.

This is from another website and I'm having the same problems along with an answer:

1999 Evinrude Ficht (Boat: Stratos 21SS Extreme)
Model# E225FPLEEO
Hours Approx. 250-300
Bought New in 1999

Work Done:
ECM was replaced the 2nd or 3rd year I owned the boat along with some other recall issues.
New Lower Unit - October 2009
New fuel filter/Separator once a year. I use 3 oz of ring free with every fill up (93 octane)
Plugs - replaced July 2009 and cleaned this year.
Starting Battery - Brand New
Engine has always run great. Idles smooth and most of the time starts right up. The lake I fish is relatively small approx. 8.5 sq miles so I don’t do a lot of long runs. Mostly running the engine for 5 to 10 minutes from spot to spot.
Recently I have been experiencing two problems.
Problem #1
I live in CT and have had the boat out approximately 10 times this year. In the morning the engine fires right up with a turn of the key. It has never required the fuel bulb to be pumped or the key to be pushed in for choke. I turn the key and that’s it. I usually tie the boat to the dock and leave it running to warm up for about 5 minutes while I park the truck across the street.
Typically I will run 5 or 10 minutes to my first fishing spot and fish the area for 1 to 2 hours. When I get ready to fire the engine and run to my second spot I will have difficulties starting the engine. This has happened the last 4 times in a row (always the 2nd time I start the engine) that I have had the boat out and 3 or 4 times before that.
When I turn the key I can hear the fuel pump turn on. The guage lights will all flash one at a time as it cycles through the starting sequence with one long beep and the engine will turn over but won’t fire up. Eventually I will get it to start but it requires cranking the engine up to 10 times. It gets to the point where I almost dont think it is going to start and i'm ready to give up and start making my way back to ramp with the trolling motor. I’ve tried pumping the fuel bulb, wiggling the ignition key, wiggling the throttle lever, push on the gas peddle a few times and push the key in for choke and raise and lower the engine. I don't know if any of this helps but not knowing what else to do this has become my normal procedure. This goes on for about 10 minutes and then it just fires right up without sputtering or stalling. On average I will fish 7 to 10 more spots and the engine will fire right up almost instantly for the rest of the day.
Yesterday I went out in the morning and the engine started right up as usual. Was hard to start moving from my 1st to 2nd spot and started fine the rest of the day. I fished until about noon, went home took a nap and returned to the lake at 5pm for a few more hours. The engine fired right up the 2nd half of the day every time I moved to a new spot (about 5).
The first time I had difficulties starting it this year I went out and bought a new starting battery but this didn’t help.
Problem #2
I don’t know if this is related to Problem #1
One time this year and about 6 times last year the engine will just shut off when I’m running at about ½ to ¾ throttle. It doesn’t hesitate or sputter like it is running out of gas but just totally shuts off like someone pulled the kill switch. The 6 or so times it has happened I lower the engine back down. Turn the key to the off position and then back on and it fires right back up. I had the boat out close to 100 times last year and this issue started to occur towards the end of the year. I would say in the last 40 or so trip this has happened 6 or so times. I did notice that it seems to happen during the first run of the day. No check engine lights come on or warning buzzers with either of these two problems. Battery cables are clean and the connections are tight. Everything appears to look ok under the cowl with no loose wires or fuel smell.



I have resolved an issue with those symptoms that was caused by the PDP (Power Distribution Panel)! Shut down on acceleration and eventually began to not start after idling several times before the start of a tournament. What has happened is that you have solder fatigue or a cold solder joint.
If you are handy with a soldering iron you can remove the PDP and remove the back and clean up the joints. Also DFI Technologies will repair them or you can purchase new. I was able to repair the connections and it is working fine now!

This may or may not be my problem but it's a start. I'll know more when I start troubleshooting.
 
Typically I will run 5 or 10 minutes to my first fishing spot and fish the area for 1 to 2 hours.
Insert fishin mota joke here:poke:

All joking aside, I hope this is the problem and its just a bad joint that can be fixed easily. This is one of the reasons I like the old stuff better, the electronics and me just don't see eye to eye and I get outsmarted real quick:thumb:
 
Insert fishin mota joke here:poke:

All joking aside, I hope this is the problem and its just a bad joint that can be fixed easily. This is one of the reasons I like the old stuff better, the electronics and me just don't see eye to eye and I get outsmarted real quick:thumb:

Damn fish n mota!!! :brickwall: I'm with you on the old stuff, those I can fix without taking it to the dealer. I hoping it's an easy, inexpensive fix.:)
 
Good luck Robbie, can't wait to see what you end up with!

The problem with my 2003 carbed 150 was the computer. At some point the temperature of the ECU would hit some magic number and a cold solder joint or bad component would cause the motor to shut down at any rpm without warning. Motor would fire but not start. Wait a few days, then she'd run OK for a 'while' then die again. I got lucky and the motor still had a month of warranty left, so the $1500 ECU plus labor was free.
I kept my trolling motor in the ski locker after that experience.............
 
Tomorrow I hope to have some kind of news, whether it's good or bad. I've loaded the new software on my laptop, so I'll post the results. Thanks for the kind words and encouragement, I need it.:thumb:
 
hopefully it will be a soldering issue. find an old school computer guru that knows his way around a soldering iron and you will be good to go.
 
I just ran a diagnostic software test, it shows that I have water in the fuel which is code 37 for Envinrude. So does this mean the motor will not fire because the sensor is detecting water in the fuel if so how do you repair it? The total run hrs for the engine is 34:32:25 for a 2001 Evinrude. I got to figure out how to post the pdf print out.
 
weedo and I figured you still have fuel issues. Hopefully that's all it is!

Takes FOREVER to get all the crud out of a system! You're gonna have to purge everything from the tank to all the fuel lines on the engine. Do you have a water seperator fuel filter inline before the engine? I can't remember.

Once all the fuel is purged (be careful!) you'll want to run a good brand of gas (like Shell, where they add extra fuel injection cleaners) AND use the new Sta-Bil that's rated for alcohol.
 
weedo and I figured you still have fuel issues. Hopefully that's all it is!

Takes FOREVER to get all the crud out of a system! You're gonna have to purge everything from the tank to all the fuel lines on the engine. Do you have a water seperator fuel filter inline before the engine? I can't remember.

Once all the fuel is purged (be careful!) you'll want to run a good brand of gas (like Shell, where they add extra fuel injection cleaners) AND use the new Sta-Bil that's rated for alcohol.

I've got a water seperator fuel filter just after the tank and before the engine. I had been filling up at the Hess station around the corner from me and the last couple of times I filled up at the Texaco station. I didn't have these problems until the last two fill ups @ Texaco station. I added stabilizer as well. So i'll need to remove all the gas and start over?
 
Robbie,does the ecu retard the ignition if it detects bad fuel? Except for some gas....this might be a cheap fix for you!
 
Well looks like I'll be taking the boat to a dealer.:brickwall: I've got fresh gas, new prime bulb, new filters, Sta-Bil. I've checked every fuse on the motor according to the manual. I did find out the reason the prime bulb would never get hard, the water separator unit was clogged up. So I disconnected that and attached the hose straight to the tank. The bulb stays hard now. I've also pulled the suction tube out of the tank and it's clear. The motor will crank and run for about two minutes and shut off. I'm frustrated now, spending close to $100.00 in gas, filters and other misc stuff and still nothing. Damn fish n mota!!!!​
 
Sorry to hear that CM. I'll keep my fingers crossed and hope they don't bend you over too bad. I'm looking forward to seeing some videos of your Enforcer when it's 100%
 
Could it be a bad water sensor throwing the code and shutting the mota down?

Good question. But I replaced that along with the filter on the motor. The sensor is mounted on the top of the filter. I can't imagine a engine with only 34 hrs of run time has a bad fuel pump or fuel lifter pump. Something is causing the motor to shut down, just don't know what it is.:brickwall:
 
I've had a couple of friends that...

had the same issues and it was the computer heating up and breaking down. Cools off and runs.
They replaced them w/rebuilt units and corrected their issues.
Hope this helps.
Gary
 
Robbie, have you tried running the engine with a little 3 or 5 gallon tank hooked directly to the engine? Bypass every bit of your fuel delivery system and see what happens.
 
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