After winter and launching the boat its engine BF225 (2003/about 530 hours) worked normally in the beginning for a single ride of 22 km (13,6 miles). Then suddenly right from the fly engine turned off, just like pulling off mistakenly emergency switch. No warning lights or beeps. Start motor ran, but motor did not start. Had to tow the boat back and carry it to local repair shop. Even after 2 days in harbor before taking off water for the repair shop the engine did not start - only start motor was running and releasing some petrol into water line presumably from exhaust pipe. Also then checked fuses, changed spark plugs, cleaned electrical connectors with contact cleaner.
In repair shop they did not have fault code reader available. Anyway they investigated that injection pump was operating when supplying it power by bypassing the start key turn position one (relay control). They made the engine to start by bypassing the relay control of start key position one by supplying injection pump power connecting it power right after one of the 10A fuse. Thus now when turning key into start position right away (not using key position one) the motor starts ok. Also boat side fuel filter was changed.
Then test ride with above change made the engine ran fine first but exactly after about the same 13,6 miles again speed was reduced to minimum. Again without warning lights and beeps. This time engine did not die but stayed on running very rough when increased rpms. Engine was stopped and started after about half an hour rest. After that it ran roughly when increasing over about 2000-3000 rpm but was managed to ride it for about 12,5 miles back to harbor. Also while tried to increase rpms over about 3000 to got rough run also manually pumped the fuel and noticed manual pump was quite normally full (no vacuum). Also tried to release fuel filling cap but no vacuum noticed there either.
Next steps thought:
* changing fuel filters (low and high pressure) with O-rings (not changed last 10 years/less than 100 hours)
* run engine with remote gasoline tank bypassing boat's integral tank to exclude boat side fuel line issues
What else suggested/recommended?
In repair shop they did not have fault code reader available. Anyway they investigated that injection pump was operating when supplying it power by bypassing the start key turn position one (relay control). They made the engine to start by bypassing the relay control of start key position one by supplying injection pump power connecting it power right after one of the 10A fuse. Thus now when turning key into start position right away (not using key position one) the motor starts ok. Also boat side fuel filter was changed.
Then test ride with above change made the engine ran fine first but exactly after about the same 13,6 miles again speed was reduced to minimum. Again without warning lights and beeps. This time engine did not die but stayed on running very rough when increased rpms. Engine was stopped and started after about half an hour rest. After that it ran roughly when increasing over about 2000-3000 rpm but was managed to ride it for about 12,5 miles back to harbor. Also while tried to increase rpms over about 3000 to got rough run also manually pumped the fuel and noticed manual pump was quite normally full (no vacuum). Also tried to release fuel filling cap but no vacuum noticed there either.
Next steps thought:
* changing fuel filters (low and high pressure) with O-rings (not changed last 10 years/less than 100 hours)
* run engine with remote gasoline tank bypassing boat's integral tank to exclude boat side fuel line issues
What else suggested/recommended?