Sorry for the lengthy post. Wanted to make sure I got all of the facts in here. Thanks for taking the time to read it.
Had a problem earlier this year that indicated the diaphram pump was bad. Engine would idle great, run great at WOT, stutter and die at load -> 2K RPMs. When it died, the primer bulb would be compltely flat. Replaced the primer bulb, same problem. Replaced the diaphram pump and problem solved. It appeared anyway. Not sure if what I’m seeing now was the actual problem or a new one.
Started the engine yesterday. Idled very rough. RPMs would swing between 500 and 800; normal is ~700. I let it idle while I loaded the boat and finally it evened out. Pulled off the dock, started to load the engine, started running rough and then died. Checked the primer bulb and it was firm. Took several rounds of squeezing the bulb and trying to start before the engine caught.
Went to WOT, Floscan showed 25 gph which is normal coming out of the hole. Engine is a 200 'Rude. Usually settles back to around 20 gph once on plane. Pulled the throttle back to 4500 RPM and Floscan continued to read 25 gph - should have been in the 12 - 15 range. After about a mile or 2 it settled into the approrpiate range.
Stopped to catch some menhaden, engine idled fine. Pushed the engine up to ~1K RPMs. Floscan showed 0 gph, should have been .5 - 1 gph. Engine ran rough and died. Primer bulb was firm. Couple of rounds of squeezing the bulb and starting the engine and everything was normal again. By the way, once I do this, the engine will run just fine at 1-2K RPMs and the Floscan will show the correct gph.
Made two other stops and the same scenario played out.
Working from the engine back to the tank the components are: lift pump, fuel line, primer bulb, floscan sensor, racor, fuel line, tank. I’ve replaced everything from the lift pump back to - but not including - the floscan sensor. I also replaced the racor. All hoses are double-clamped and clamps are tight.
Per Floscan, a high sen