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mercury 525EFI backfiring loss of power

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Old 03-28-2022, 05:37 AM
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Default mercury 525EFI backfiring loss of power

Hello Everyone,
I hae read through different related posts of what could cause my 525EFI with approx 104hrs suffer from backfiring.
both Mechical and Electrical Fuel pump have been changed.
Spark Plugs changed,

Engine runs normal for a few minutes then starts backfiring and will run on 950/1100rpms only as soon as i puch the throttle it chokes... high smell of unburned gas,
can hear the exhaust on portside not exhausting normally... like if engine was running on fewer cylinders...

Any help is highly appreciated.
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Old 03-28-2022, 06:05 AM
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Start with the basics:
#1 fuel psi test
#2 compression test
#3 scan for codes


Last edited by SB; 03-28-2022 at 06:07 AM.
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Old 03-28-2022, 07:51 AM
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A friend of mine had this exact problem on his 500EFIs. He changed and checked EVERYTHING and still no results. Turned out to be that his ground wire for the engine was loose. It would break contact intermittently while underway causing the same symptoms you describe. Might be something to check.
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Old 03-28-2022, 08:21 AM
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Sounds like a ground issue or a header sprung a leak . Once she heats up the crack opens up and aqua puts out the fire .
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Old 03-28-2022, 06:13 PM
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Possibly a bad coil pack. Has the engine been scanned for codes?? Without being scanned, you are just guessing.
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Old 03-29-2022, 04:01 PM
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Recently had same issue on my 525s, changed mechanical fuel pump, filters, etc. Still no pressure at the rail.

Problem ended up being fuel line from tank to mechanical fuel pump. Inner lining was separated and clogging fuel flow like a clogged artery.

After changing fuel line, my 525s never sounded so healthy and smooth running since Ive owned her. They are thirsty engines!
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Old 03-29-2022, 04:18 PM
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Roughly……
500hp .500 bsfc (hp/lb/hr ) fuel is 6lb/gal
500 X .5 = 250lb
250/6 = 42gal/hr. Yum yum. I need more fuel.
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Old 03-29-2022, 04:32 PM
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So when initial start up when cold it seems normal until it heats up after a few minutes. Then smell unburned fuel? I’d start adding additional grounds… one at a time. Perhaps the heat is causing an unwanted expansion of ground bolt etc.
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Old 03-29-2022, 04:36 PM
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Originally Posted by getrdunn
So when initial start up when cold it seems normal until it heats up after a few minutes.
Sounds like a typical magneto issue with sleds huh ? Lol.
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Old 03-29-2022, 05:21 PM
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IAC might be choking it to run fat
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