250XS issues

[todd250]

I got a buddy with a 2003 250xs on a Bullet 21 XDC. This morning he went to the lake and when he started getting on plane the motor just cut out real bad and died. He said the motor started right back up and did the same thing, but then it got harder to start. I took his fuel filter off and emptied it out and unplugged alot of different connections and reconnected to insure good contact on everything and checked the fuses. We took it back to the lake and it did the same thing. The motor ran good about a month ago when it was used last. Probaly that good ethanol in the expensive fuel we buy now. I have never heard of this problem on any of the XS engines before, so any help would be appreciated.

Thanks Michael

[EuropeanAM]

Check the basics:

1. Load test battery to confirm 800 CCA or higher capacity MINIMUM.
Make sure connections are CLEAN, and WRENCH TIGHT. A bad battery, or
low battery voltage/capacity CAN AND WILL CAUSE THIS PROBLEM.

2. Spark test

3. Compression test

4. Look for fuel delivery restriction- primer bulb, filters, lines, anti-siphon valve,
pulse fuel pump problem, or low pressure fuel pump giving problems.

Also, a check of air/fuel pressures would be a good "early check". Low or no air pressure also accounts for low or no fuel pressure...

[todd250]

Don, I took the battery out of my boat and tried it and it did the samething. I have a 250XS also and the battery is the blue top optima. He is going to take it to the shop this week and let them figure it out. I really appreciate your quick response.

Thanks Michael

[todd250]

Well the high pressure fuel pump was the problem. The mechanic was running the motor on the hose and he felt of the pump and it was hot. The computer did not show any problems, so he got lucky by feeling the pump. The fuel pump was kind of expensive, but the motor was useless without it.

[EuropeanAM]

+1 That's the value of a good tech!

Many a "failing" fuel pump have been "eventually" found because they were "hot to the touch".

Just for future reference... any fuel pump that exceeds 120 degrees (F) while engine is running should be "questioned". Easy to check them with a small infrared or laser temp gun.