Ongoing 8.1 HO issue not reaching max rpm one engine

Pony Racer

Member
Aug 13, 2015
167
Ct
Boat Info
2005 Sea Ray 390 Sundancer
Engines
Twin 8.1 S-HO 496's, v-drives
Let start from the beginning. (This will be long)
2016 purchased The boat. The previous owner had all the props and shaft trued up. Silky smooth. He also had an issue with the Cool fuel Module on the port motor had injectors cleaned only on that motor.
when I go the boat bot motor max rpm 4900+ rpms. Over the coarse of a few months the starboard motor started running richer at idle and had a “skip” around 1100 rpms and wouldn’t get past 4600 rpms which I thought was a dinged prop because I lightly bumped a sandbar while idling through an area. My mechanic assured me it wasn’t the prop or running gear but the injectors are clogged as he worked on the boat for previous owner. Checked injectors and there were plugged bad. Pulled cleaned injectors. Roughness went away. Boom back up to 4900+ both motors.
Slowly over the next 2 years the issue came back but was worse on starboard side.
Beginning of last season both engine barely made it to 4500 rpms. 1100 rpm vibrations. Etc. I pulled out both Cool fuel modules and replaced them with the latest ones available. Ran the boat for about 5-10 hours to push anything in the lines to the injectors and the had nothing engine injectors cleaned and rebuilt. Both engines shot up to 4800+ rpms. Smooth as they can be and ran great. Until about 3 weeks later. The starboard motor started to loose top end rpms. By the end of the year it wouldn’t get past 4600. Over winter I checked all the plugs everything looks normal. No issues with plug wires. Etc. now the starboard engine won’t push past 4300. Jumps right up to 4300 with no issues with 3/4 throttle , push the throttle past that one motor won’t go past 4300. The port one shoots up to about 4700 (the other motor is dragging it down)My mechanic said it’s my running gear or growth under the boat. And wants me to haul the boat and drop over $4000 to pull props and shafts retrue everything. Diver under boat said bottom clean no dings in props shafts for what he can tell spin true and no movement in cutlass.

I believe there is something wrong with that motor. Flame arrestors are clean Plates are opening to full. Fuel burn is normal for rpms.
No codes!!!!!

what else can I check.
This is aggravating it’s not the running gear or dirty bottom.
 
Check your fuel pressure at 4300. "no issues with plug wires" ? what exactly does that mean? Did you ohm test them all? If original, toss em.
 
Check your fuel pressure at 4300. "no issues with plug wires" ? what exactly does that mean? Did you ohm test them all? If original, toss em.

No issues with plug wires mean they are not the problem. They are not cracked , all are plugged in and test accordingly when ohmed out

modules came with brand new regulators.
The only thing I havnt tested is fuel pressure since the new modules were put in. Prior to putting them in all pressures were normal. even with clogged injectors.
The computer kept pulling timing. (Again this was prior to modules being replaced)
 
Sound like you have the Rinda software. Have you checked all the values between the 2 engines? Sometimes there can be an issue without setting a code. For the most part, no code means a fuel problem.
Compression test ?
 
Sound like you have the Rinda software. Have you checked all the values between the 2 engines? Sometimes there can be an issue without setting a code. For the most part, no code means a fuel problem.
Compression test ?

it’s an 05 390 Sundancer. So what ever is in mercruiser software.
 
So every other time it wouldn’t reach rated WOT, cleaning the injectors fixed it.

Did you Consider having them cleaned again??
 
So every other time it wouldn’t reach rated WOT, cleaning the injectors fixed it.

Did you Consider having them cleaned again??


The only reason they were cleaned and rebuilt was because of the delamination issue in the cool fuel modules. Upgraded those modules. And had the injectors cleaned AFTER new modules put in. There shouldn’t be any reason to clean/rebuild them. The filters are clean. Plus every time they were plugged or had an issue at 1100ish rpms the engine would run real rough and you can smell the engines running rich at idle.
 
Did you clean the fuel rails after replacing the cool fuel modules and injectors, meaning pulling them off, flushing them with solvent, blowing them out, etc. if not, my money is on clogged injector again.
 
The only reason they were cleaned and rebuilt was because of the delamination issue in the cool fuel modules. Upgraded those modules. And had the injectors cleaned AFTER new modules put in. There shouldn’t be any reason to clean/rebuild them. The filters are clean. Plus every time they were plugged or had an issue at 1100ish rpms the engine would run real rough and you can smell the engines running rich at idle.

Ok. But keep in mind that the paint issue occurs downstream or after the fuel filters. Just because the filters are clean doesn’t mean that There isn’t an issue further down the line.

I know that resolving an issue like yours can be aggravating, just be open to any possibility.
 
Ok. But keep in mind that the paint issue occurs downstream or after the fuel filters. Just because the filters are clean doesn’t mean that There isn’t an issue further down the line.

I know that resolving an issue like yours can be aggravating, just be open to any possibility.



you’re correct. I’m just trying to abound another $800 in removing and rebuilding one motor injectors. In the past we pulled them out lightly tapped them onto a paper towel and the paint was literally falling out.
 
Did you clean the fuel rails after replacing the cool fuel modules and injectors, meaning pulling them off, flushing them with solvent, blowing them out, etc. if not, my money is on clogged injector again.

yes they were flushed out.
Modules went in. Ran for several hours. when injectors went back in my mechanic said he flushed the rails prior to putting any injectors on the rail.
 
yes they were flushed out.
Modules went in. Ran for several hours. when injectors went back in my mechanic said he flushed the rails prior to putting any injectors on the rail.


Did this get resolved? I’m having similar issues.
 

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