Z200 HPDI 2001 no spark

[numbskull]

2001 200 hpdi died while idling (after running at cruise speed for 30+ minutes without a hint of trouble), will spin but won't start, not even a cough. No spark (discovered after changing out all the fuel filters). Kill switch seems OK (no continuity with clip in/continuity with clip out), gauges work, neutral switch tests OK, I changed out the fuse holder after both relays seemed to fail repeated continuity tests as specified in the service manual (though I was skeptical about it), still no luck. Any ideas about something simple? Might it still be the ignition switch? How do I check that? Thanks.

 

[numbskull]

Re: Z200 HPDI 2001 no spark

Well, it doesn't seem to be the ignition switch. I swapped mine over to a friend's boat and it worked fine, but his won't start my boat. My engine will make an occassional single cough when I turn it over if it has been sitting for a while (which sounds like a fuel problem inspite of changing all the reachable filters), but when I test for spark with a cheap spark tester I see nothing. Got any ides where to look next? Thanks.

 

[numbskull]

Re: Z200 HPDI 2001 no spark

Turns out I am way off. The spark tester was faulty. A neighbor, brighter than I, suggested a second test for spark......try to start with a squirt of ether......I did and it ran briefly. So I am back to fuel issues. Since I get fuel easily to the vapor separator by squeezing the bulb, I assume the problem is in there. Couple of questions. If I jump 12 volts directly to the electric pump leads should I hear it run? Could a problem with the pressure regulator or fuel strainer kill an engine suddenly in idle, and keep it from starting, after it ran fine at 3600 rpm? Any ideas on what to check next (while waiting for a pro)?

 

[rodbolt]

Re: Z200 HPDI 2001 no spark

the Z motors are simple but not for the faint hearted. you will ned a fuel rail test guage and a peak reading multimeter. to test the fuel pump a quick easy method is to simply turn the key to on and listen. the pump will run at key on power for about 5 seconds and MUST maintain 50 psi on the medium pressure rail. it can and will run with the high pressure pump belt removed.
you will need a peak reading multi meter to test the injector driver and the ign system, the Z motors use a 12v transistor controled ign system not the altenator driven set up most outboards used for years.
another quck test of the medium pressure pump is with the key on seperate the blue pump wire and take the pump end of it to ground, pump should run. the red7yellow is ,or should be, hot any time the key is on.

 

[numbskull]

Re: Z200 HPDI 2001 no spark

the Z motors are simple but not for the faint hearted. you will ned a fuel rail test guage and a peak reading multimeter. to test the fuel pump a quick easy method is to simply turn the key to on and listen. the pump will run at key on power for about 5 seconds and MUST maintain 50 psi on the medium pressure rail. it can and will run with the high pressure pump belt removed.
you will need a peak reading multi meter to test the injector driver and the ign system, the Z motors use a 12v transistor controled ign system not the altenator driven set up most outboards used for years.
another quck test of the medium pressure pump is with the key on seperate the blue pump wire and take the pump end of it to ground, pump should run. the red7yellow is ,or should be, hot any time the key is on.

Thankyou for your response. It was indeed the fuel pump. I'm back up and running, although a bit chagrined at the $ of the fuel pump, not to mention my own stupidity for buying an unneccessary fuse holder. Live and learn. Thank you again.

 

[rodbolt]

Re: Z200 HPDI 2001 no spark

I forgot to warn ya of the price of a medium pressure pump.
they are a tad pricey. failure is rare though.
I am suprised it failed during operation. normal failure is after extended storage.