2002 Honda 225 will not go past 3000 RPM

[frogdriver]

After years of trouble free use, cranked up for a return from an offshore trip and motor would not accelerate beyond 3,000 RPM. No alarms or warning lights appeared. Spoke with other owners and a mech they thought I may have a fuel problem. Changed the fuel water separator on the boat and drained about a gallon out of the tank. Checked and found no evidence of water in the fuel. Changed the inline fuel filter and dumped the motor mounted fuel water separator. Still no evidence of dirty fuel or water in the system. Did a test run and motor still has same problem. The mech mentioned a high pressure fuel filter to check. I followed the fuel line but could not find it. (Not sure where it is located) Looks like I will have to remove the cowling to get to it and I was running out of time. I am capable of doing most service type maintenance (oil, lube & filter changes) but I lack the experience to tackle internal stuff. (timing etc.) The Honda dealer is backed up 3 weeks so I was trying to troubleshoot myself. Someone mentioned checking and changing the plugs. How difficult is this on the motor? Not afraid to tackle it but I do not want to damage the engine through ignorance. Would appreciate any advice on this problem.

 

[Zig123]

Re: 2002 Honda 225 will not go past 3000 RPM



I just did a complete fuel-system releated build on my 1999 BF130. It has a newer recalled fuel system which I believe is similar to yours. Mine did not run before I did the overhaul. Took it out for the first time this weekend, ran like a champ! parts = about a grand (included injectors) - sweat labor $0.

I did speak with a honda mechanic that told me that he has seen the insulator screen in the high pressure fuel pump clogged on numerous occassions. If it's fuel related, then I'd suggest changing this out + the high pressure fuel filter itself.

Above shows where the high pressure fuel pump is and the filter, at least on my 130.

I had to take off the VST (3 bolts + disconnected hoses). 2 or three screws for the high pressure fuel pump cover. Take these out and remove. Note that there are two wires for the pump itself. These remain connected! Pull the cover off slowly, exposing the pump. Take the pump out. Now, you'll be able to see the plastic insulator (the screen is at the bottom). This is a bear. I took a pair of needle nose pliers and pulled/ripped it out. It's gonna break, not a big deal, new one on the way anyway.

Look at the screen on the bottom. Likely clogged.

Make sure your take before, during, and after pics. Order all O-rings too. You might want to order a new o-ring for the high pressure fuel pump drain screw as well. +, o-ring for the high pressure fuel filter.

Took me about 2 hrs to pull it apart off the motor; about 4 days for the parts to come; and another 2 hrs to put it all back together. I'm not a mechanic, and this didn't scare me.

Good luck, let me/us now how this turns out.

 

[banana winds]

Re: 2002 Honda 225 will not go past 3000 RPM

Hey Zig 123

You don't happen to recall the part number for the insulator screen for the Honda 130 ?
I'm having the exact same problem and have replaced the high speed fuel filter. But still a problem. Dealer said to get the injectors cleaned and failing that pull the boat off the mooring, lump it 20 miles to his shop with a 2 week minumum turnaround.(Ugh).

He never mentioned the insulator screen though and I'd like to try that first. If I get the part number I cam order it for this weekend.

Thanks.

 

[frogdriver]

Re: 2002 Honda 225 will not go past 3000 RPM

Zig, Appreciate the your efforts and the picture. Looking at the picture, I believe the high pressure pump on the 225 is on the other side. The 225 has a cartridge type fuel filter and a motor mounted fuel water separator where your high pressure pump is. Good idea with the before, during and after photos. Did not think about that. I will use when I tear into the project. After examining my fuel samples, I am not completely convinced fuel is the culprit but it I will go after the high pressure filter just to eliminate it as a cause. Thanks again for your time and effort on my behalf.
Frog

 

[gss036]

Re: 2002 Honda 225 will not go past 3000 RPM

Some Honda owners are finding a whitish powder mixture in the filters, are seeing any like that? So far, my 225 is running great. Good luck on the fix, be sure to post here so we all know what is going on.

 

[Zig123]

Re: 2002 Honda 225 will not go past 3000 RPM

Hey Zig 123

You don't happen to recall the part number for the insulator screen for the Honda 130 ?
I'm having the exact same problem and have replaced the high speed fuel filter. But still a problem. Dealer said to get the injectors cleaned and failing that pull the boat off the mooring, lump it 20 miles to his shop with a 2 week minumum turnaround.(Ugh).

He never mentioned the insulator screen though and I'd like to try that first. If I get the part number I cam order it for this weekend.

Thanks.

11-16718-ZW5-003 was the insulator part. You'll need the o-ring for it (at the bottom of the insulator) + a couple of others (I recall two more around the prump/housing, for 3 total). There's a good site for ordering stuff w/diagrams - I'm hesitant to throw it out here, they're likely competors to here (although I didn't find the specific parts here....).

You can ohm out the injectors too - mine were close to 14 ohms, spec's were <12.3 or near there.

Zig, Appreciate the your efforts and the picture. Looking at the picture, I believe the high pressure pump on the 225 is on the other side. The 225 has a cartridge type fuel filter and a motor mounted fuel water separator where your high pressure pump is. Good idea with the before, during and after photos. Did not think about that. I will use when I tear into the project. After examining my fuel samples, I am not completely convinced fuel is the culprit but it I will go after the high pressure filter just to eliminate it as a cause. Thanks again for your time and effort on my behalf.
Frog

Frog, one thing I should have said is that the mechanic I spoke with said that the bad insulators he saw many times were on the 225, not the 130. My high pressure fuel pump fits into the insulator itself. I assume that yours likely does as well (checked on-line diagram, and it appears to be the case).

Some Honda owners are finding a whitish powder mixture in the filters, are seeing any like that? So far, my 225 is running great. Good luck on the fix, be sure to post here so we all know what is going on.

I didn't see any powdery looking stuff in/on insulator or high pressure fuel filter, only varnish on the insulator screen. The boat had been sitting for quite some time - I guess this should have been expected.

Good luck. Apprecaite a reply to see how you made out.

 

[frogdriver]

Re: 2002 Honda 225 will not go past 3000 RPM

Gentlemen, Great news! On the advice of a local mechanic, changed the plugs out this weekend and it ran like a brand new motor. Feel a little foolish for not doing this earlier but they (the plugs) were not due yet. Thanks for all the replies and help. Frog

 

[banana winds]

Re: 2002 Honda 225 will not go past 3000 RPM

Unfortunately for me I'm not having good luck. Had the injectors cleaned, calibrated and balanced ( 2 were stuck and the other 2 were dirty, all were out of spec on pressure), replaced the injector screen which was clogged, but still can't go above 2500 RPM.

I know on Johnsons and Yamis if you blow a powerpak, it limits you to low RPMs ( 3000-3500). I'm wondering if that's what's happening here.

I believe Honda calls their powerpak a ECM. Anyone ever replace one?

 

[Zig123]

Re: 2002 Honda 225 will not go past 3000 RPM

BW - not familair myself with the ECM/power pack. Is yours a 130?

Stupid question, but did you replace the plugs?

Great news frog - I read a post somewhere else on the web about a similar situation. It doesn't seem sensible, but guess it works. I'll have to keep an eye on my plugs as well....

 

[banana winds]

Re: 2002 Honda 225 will not go past 3000 RPM

I replaced the plugs, racor water separator, both filters on the 130 and drained the tank when I found the water.

Then I went to the injectors, screen, etc.

But that said I'm buying another set tonite just for chucks and giggles to see what happens.

ECM is the brain of the ignition system and controls air and fuel mix, temp sensors, etc. In OMCs if this goes it shuts down the high speed limiting you to about 3000RPM.

 

[dummyman]

Re: 2002 Honda 225 will not go past 3000 RPM

Hi,
If yours is a single bf 225, would you please have a check at your throttle cables, while the remote at full throttle ensure that the linkage arm is pulled max till the stopper. your ECM does not seem faulty if faulty it gives a continious beep.

Regards

 

[JAMIEJBRANDT]

Re: 2002 Honda 225 will not go past 3000 RPM

hello ALL I HAVE THE SAME PROBLEM WITH MY 2004 225 i REPLACED THE LOW PRESSURE FUEL PUMP AND THE HIGH PRESSURE PUMP ALL FILTERS AND THE MESH FILTER AS WELL
I DID NOTICE THAT THE FILTER BULB THAT THE GAS GOES DOWN IN IT AND THEN I PUMP IT UP TO FILL IT AND THEN IT GOES DOWN EVEN IF IT IS FILLED IT STILL BOGS DOWN
IT SEEMS LIKE ITS GETTING AIR
I HAVE CHECKED ALL HOSES AND EVEN WENT DIRECT TO ANOTHER GAS SUPPLY STILL IS THE SAME
ANYONE HAVE ANY HELP
JAMIEJBRANDT@YAHOO.COM

 

[JAMIEJBRANDT]

Re: 2002 Honda 225 will not go past 3000 RPM

Eeeeeeeeeeee

 

[hondon]

Re: 2002 Honda 225 will not go past 3000 RPM

The main question here is ,what is that high pressure fuel pressure at the point of failure.That should be around 40 psi and stay there .Sadly Honda has made that measurment difficult to do on this engine in the real world as you need to remove the bottom cowls to accomplish it.