Title: Melted Engine Harness on a Mercury 225 Opti Max

Customer Complaint: Engine has started to run poorly. After removing the engine cowling I found melted wires.

Boat Make: Robola

Engine Make: Mercury Marine

Engine Model: 225 Opti Max

Engine Year: 2010

Prop:  21 P

WOT Speed:  50 MPH

WOT RPM: 6000 RPM

Diagnosis: After discovering the melted engine harness, we preformed and compression test and a cylinder leak down test on all cylinders to verify there was no internal damage. At this time we investigated potential causes for this particular failure. After not finding any specific problems leading to this failure it was determined that an electrical short was the cause. It was verified that this is not a typical known failure for this particular outboard motor rather an isolated issue.

Repair: Replaced complete engine harness assembly,  along with fuel rails, Direct Injectors, Fuel injectors, Ignition coils, spark plugs, compressor air filter, and fuse assembly.

Lake Test: No issues found after replacing all the necessary parts, the boat passed the lake test.

Parts Required For Repair:

• Engine Harness- P/N 892971T05
• Fuel Rail Assem- P/N 8M0055703
• Ignition Coil- P/N 8M0077473
• Injector Air Kit- P/N 8M6001743
• Washer Assem- P/N 828694A1
• Air Filter- P/N 880084T01
• Harness Fuse- P/N 878231A6

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