Hi, I’m new to this forum and have been scouring this forum and the service manual for help with this problem. Thank you in advance for what you’ve contributed and for helping with my issue described in this post.
I recently repowered my 20ft Whaler with a rebuilt 2006 225hp Optimax on a 17p prop. I’ve had trouble getting the mechanic who rebuilt this for me to diagnose the problem and to honor his warranty. His DDT scan sees the occurrence of this “over rev” fault but says everything is normal after he replaced the TPS. He also claimed to have tested the boat in a lake, but I know is not true (lack of gas use and increase of engine hours). With him dodging my calls, I’ve taken it upon myself to repair and hope to get some advice here.
I am intermittently going into Guardian mode, a few times per trip, four total trips so far. The occurrence seems random and is not readily reproducible. I get a long 4 second beep and a check engine light. After slowing down, it goes away and I can then resume as if nothing happened. I don’t have smartcraft, but Vesselview mobile tells me error code 2011-23, “Guardian, A particular state or condition exists, Engine guardian is active, Power will be limited to prevent engine damage, Reduce engine speed.” I get no other relevant faults. My voltage ranges from 13.5V to 14.5V. Water temperature is around 120F, as reported by Vesselview.
For various reasons, here’s what I’ve done so far to fix this outboard:
1. New alternator. Mechanic gave me motor with a broken one...
2. New Optima blue top D31M, 900CCA. New 20ft 1/0AWG cable runs to help with cranking/staring issues.
3. New TPS (although old one was probably fine), measured 0.5V to 4.7V at idle to WOT.
4. New key switch control harness. Old one was spliced into the factory Evinrude harness and I had intermittent connectivity on the purple ignition wire.
5. Outboard oil tank is full and switch measures closed.
I’m a bit lost on what to look at next, short of taking it to a dealer. I do plan to look at the shift position switch next. Any ideas or suggestions?
Edit (5/3/21):
1. Engine Serial Number: 1B242084
2. Year/Make/Model: 2006 Mercury Opitmax 225XL
3. Prop you are Running: 17P Mirage Plus, 44mph @ 5200RPM (boat is a 20' Boston Whaler Ventura, ~4000 lbs. loaded)
4. Current Maximum RPM: 5200
5. Idle and WOT Water Pressure Readings: Unknown, not sure how to get this info
6. Smartcraft or Analog Instruments?: Analog, with VesselView Mobile