2004 Yamaha 200 hpdi cutting off randomly

[finbox]

I have twin 2004 200 hpdi's and the port motor cuts off randomly.

It first i thought it was fuel so I REPLACED the VST filter, the $80 metal filter and the racor filter, and the filter in the clear plastic bowl on the motor, still cuts out.

With YDS hooked up when it cuts off it looses communication with the laptop.

All stats on the YDS when it is running are in spec.

When it cuts out if you turn the key to crank it will not start, but if you turn the key to the left and turn it off (the motor is already off) and back to start it cranks and runs fine every time.

Cleaned the plugs (not that dirty)

Cleaned and tightend ALL battery connections/grounds

Swapped Batteries

Idles and WOT are fine.

When it shuts off the 3 bars for the oil level flash and it beeps...???

I have swapped both the injector relay and the ECM relay and the motor oil tank level sensors with the GOOD starboard motor but have not tested it yet.

Any ideals?

Thanks

Finbox

 

[rodbolt]

Re: 2004 Yamaha 200 hpdi cutting off randomly

check the keyswitch,harness and main relay.
when communication is lost it means the 12V or the ground at the connector was lost.

 

[finbox]

Re: 2004 Yamaha 200 hpdi cutting off randomly

I tried swapped the key switches, checked all connections by the switches and under the cowl all are very clean

Where is the main relay? Is that the ECM relay?

Thanks for your help

 

[Bob Gale]

Re: 2004 Yamaha 200 hpdi cutting off randomly

Rodbolt as always is right on. Had a similar experience with my 150 HPDI. Turned out to be a flaky kill switch.

 

[finbox]

Re: 2004 Yamaha 200 hpdi cutting off randomly

I have one kill switch for both motors, the starboard motor never cuts off... I will check/swap the connections on the kill switch