2004 Evinrude 250 - No oil light mystery!

[littledutch]

You have to follow this story close as there are a lot interesting turns of events, one issue leads to a fix, uncovers another problem then a fix etc...

I have a 2004 250HP Saltwater Edition. Several weeks ago running about 5400-5500 RPM in moderate/smooth water my motor had a hiccup, the buzzer and no oil light came on and it went into safety mode. Meaning, wouldn't run over 1000 RPM's. Heard a humming coming from the motor so took the cover off and to my surprise the starter was still engaged/spinning. Cut the battery, starter stopped and did a visual inspection. Plenty of oil in the reservoir tank and bulb was primed. Checked the gas bulb and there was no prime. Turned battery back on, starter automatically engaged and cranked the engine and stayed engaged. Flipped the ignition switch to right as to crank it sending a current to the solenoid and then starter disengaged. Took to the shop. Results, solenoid was bad/sticking thus causing the starter to stay engaged. Ignition switch was fine. Gas hand pump bulb was bad. Oil pump was fine but safety mode turned on when the oil pump fuse had blown. (we think it was due to the solenoid issue and starter drawing voltage while running or something to that effect)

Anyway, did a full service on the motor. Water pump, new temp gauges the entire works. Did a compression check for Sh**s and Giggles, Got a new solenoid, new batteries and double checked fuses and stocked up on the goods, just in case.

All was running good no problems, no buzzers. Took her out to Indian Pass for vacation and then a few scalloping trips after that.

This pass Sunday went scalloping. Run out was good. The low oil light came on but that was because it was literally low on oil in the reservoir. Filled her up, all was fine. Anchored up and then my GPS and Radio went dead in front of my eyes and wouldn't turn on. CB however still had power??? Few minutes later I tried them, GPS and Radio came back on. Very strange I thought. Motor was off the entire time. Finished the fun day, headed back in, 5400-5500 RPM in the St Marks, all was running smooth and then just out of the blue the no oil light came on i throttled her down and turned her off. No hiccups this time, the starter was not engaged and the gas was primed. Checked the oil pump fuse just to be sure and it was fine. All of the fuses were A-OK. Turned her back on and she was in safety mode. One minute later no oil light went off and she came out of safety mode as if nothing ever happened. Ran fine rest of the way in but I only did 5000 RPM's.


My first thoughts were:
1. Maybe electrical wiring problem, related to why the GPS and Radio shut off?
2. Maybe the sending unit on the reservoir was going bad?
3. Maybe the sending unit on the reservoir was experiencing the same electrical problem as the GPS/Radio?
4. Bubble in the sending unit from the low oil earlier? Was a little rough out, did some bouncing before low oil warning came on.

Any thoughts?

[ELGIN]

Welcome to the BBC.

Model and Serial number Please?

Do you have wing nuts holding the battery cables to the battery?

I would suggest you look at the back of the battery switch to see if the wires are tight.

You will most likely need to replace the oil injector.

[ChampioNman]

And if you don't believe him then you are in trouble. Da man knows his chit!

[littledutch]

Thanks for the welcome!

Model: E250FPZSRM
Serial: 05044477

Wingnuts are on both batteries. Also, both batteries are less than 2 months old.

I will check the battery switch.

I've never had to replace an injector but I know where and what it is. Any special requirements? Or should I have a dealer handle it?

[littledutch]

What does the ZSRM stand for on my model?

[SEAHORSE]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by littledutch &raquo;</TD></TR><TR><TD CLASS="quote">Thanks for the welcome!

Model: E250FPZSRM
Serial: 05044477

Wingnuts are on both batteries. Also, both batteries are less than 2 months old.

I will check the battery switch.

I've never had to replace an injector but I know where and what it is. Any special requirements? Or should I have a dealer handle it?


What does the ZSRM stand for on my model?
</TD></TR></TABLE>


First, get rid of wing nuts and use stainless steel lock nuts tightened with a wrench. Be sure to sand or wire brush the terminals and the battery cables until they are SHINEY!

Remove battery switch and SHINE the cables on that and tighten the nuts securely.

Blowing an oil injector fuse is sometimes a problem inside the EMM, so if it happens again and the injector tests OK, send the EMM in for repair or factory exchange.

Remove the plastic 2 wire connector from the oil pressure sensor and see if oil is in it. Sometimes the sensor will leak internally and the oil migrates down the wires to the connector and can short them out, giving a false NO OIL alarm.

With your electronics going dead, there may be a loose or bad connection in the wiring going up to the console. Pay particular attention to the ground wires.

E250FPZSRM means an Evinrude 250 F(FICHT) PZ(xxl shaft) SR (2004) M (production code)

[littledutch]

Ok. I am sure glad you guys are here to help. I will do as you suggest and respond ASAP.

Great Forum.