Yamaha 2002 150 HPDI Twins

[fec]

This will be kind of a long post so I can explain all that has happened with these engines.<br />Problems first started in mid summer 03 with the engines missing out coming home from offshore one day, thought it was possible bad fuel so changed filters and problems seemed to go away. Then noticed port engine was idling rough but still ran okay at WOT. Did a decarb job late summer useing Seafoam and still no help. Also running Seafoam in fuel in lieu of Ring Free. Boat was up for winter and so last week took it to what I thought was a reputable dealer to do the 100 hr service, I received a call from the dealer saying the plugs were fouled and that it was due to the batteries needing to be bigger, mentioned something about Yamaha tech bulletin saying they need at least 1000 MCA. Well the batteries that are on the the boat were 1000 MCA (3 onboard two starting one house)which I had just check fluid levels on and load tested two days before and they were good and they are less than two years old. I decided after the dealer quoted me over 1000.00 dollars to change the water pumps, lower unit oil and plugs that I would do this myself.<br />I do also have the factory service manuals on these engines and also spent 15 years of my life turning wrenches. I got the water pumps changed, the oil replaced,two new racor fuel/water seperator filter assemblies, the spark plugs put in,and two new 1000 MCA batteries. Cranked the engines out of the water with earmuff flushers on them and they still have a very erractic idle, bounce between 600-800 RPM. I pulled both O2 sensors and cleaned out the plunger and housing which did show some signs of carbon build up but not bad. Restarted engines and still have an erractic idle. Have spoke with Yamaha Customer Relations but all they could do was post a complaint against the dealer. Have spoke with another dealer in area and he has the computer program to check out the engines so I am trying to schedule appointment to do this where I can be present when they run the program. Does anybody have any other suggestions on where to look for what might be causing these engines to idle so erractic. Also does anyone no how to contact a factory service rep for Yamaha? I have read the stories on these site and do not want to blow one or both up offshore fishing with my wife and kids. I also have some questions on the Yamaha gauges but will wait on that till I get this issue resolved.

 

[rodbolt]

Re: Yamaha 2002 150 HPDI Twins

hello<br /> welcome to DFI. FICT, OPTIPOP< and HPDI. all like to foul plugs. dont belive the 1000 amp battery BULL shoot scam. its hog pookey. the spec is like 512 CCA minimum. 875 will work well. plug fouling has been a major issue with these motors. we found by cleaning the O2 sensors every 75 hours we can keep some of it down. I have never seen the tech bulliten you refer too. ask them to please give you the yamaha bulliten number so I can look it up. there are some updates availible for your engine. make sure the oil links are correctly adjusted as are the TPS voltages. the thermostats can get stuck open with debris and cause the engine to overcool and foul them faster. the O2 sensor needs to be removed from the holder to clean it proerly. that motor sounds blown up on muffs. its normal. it surges like a thourobred on steroids on a flush muff. and dont let them tell you to rev the engines in nuetral to clear the cylinders either. that motor idles on 4 cylinders in nuetral. above about 1500 in nuetral it shuts off two more and only runs on two. so its a rough idleing beast on a flusher. keep spare plugs. ask the techs how to access the water pressure relife valve. we have seen some problems caused by the filter between the VST and the high pressure pump. that filter is about 190 dollars<br /> also the filter in the VST its about 90 dollars and the gasket is about 28 dollars. careful with the computer, it usually only shows ya whats not broke. if you spend a lot of time in the 1200to 1700 rpm trolling carry spare plugs, there is no cure. but dont fall for the standard battery aint big enuff scam. I have a customer that finally but in a pair of 1300 CCA marine diesel starting batteries and it still fouled plugs.<br /> good luck and keep posting but be aware most techs know nothing of the yammi's. ask to see the certyificate that they attended fuel systems and electrical systems schools. I got mine

 

[rodbolt]

Re: Yamaha 2002 150 HPDI Twins

wow<br /> I cant type tonight. I am talking with 3 people and typing. its not working. please read through my many typo's <br />good luck and keep posting

 

[fec]

Re: Yamaha 2002 150 HPDI Twins

Thanks Rodbolt for the info, the second dealer I went seems a little more knowlageable on the updates. While I was there getting the water pump kits he went on the computer and search for all tech bulletins on the 150 HPDI and only found one and that was something about idle adjustment. No one has said anything about oil injection arm adjustments or anything else. Can you fill me in on this a little more. Also noticed while running the engines on the flush out muffs that the engine never would get warm in regards to water temp coming out of the telltale spray, I had run them at idle and up to 2000 rpm for about 10 mins each. the block however did warm up to touch. Do you think that running out of the water with no back pressure will have anything to do with the rough idle? Also I have yamaha guages and on the Tachs at the bottom is a an oil icon and a water temp icon, under the water temp one the bar flashs continously is this normal, on the oil icon there is just a bar, should this have like 3 different symbols under it depending on the level in the oil tank. Can you tell me anyting in this regard, one shop told be the blinking bar on water was normal and another said that it not. One last thing do you know how to get in touch with a Yamaha tech service person or they strickly offlimits except to the dealers?<br />thank again for the help.

 

[rodbolt]

Re: Yamaha 2002 150 HPDI Twins

hello<br />factory tech reps.<br /> they are offlimits.<br /> I could tell ya but then I would have to quit work.<br />the HPDI motors are ragged on the muffs<br /> period. we wont discuss that any more. <br /> the link and sync on this motor is critical.<br /> half the techs I deal with cant do it right. most here are of the varity of, if it runs at all it runs well and if it made it back its super duper.<br /> the tell tale water will ALWAYS be cold. if its ever warm your suffering a melt down.the temp bar should not flash period. its bad<br /> try removing and resetting the DIP switches in the tachs. some one may have set them incorrectly or they are just not making good contact. also check the filter on your engine. if the little red ring is floating it indicates water in the fuel filter.anytime you take your motor to get any service look for the school participation certs, there are 6 areas. all six should have a gold bar. mine does. dont run the motor past idle on the flusher and dont run it past 1000 in nuetral. at 2000 in nuetral its only running on 2 cylinders but still oiling on all. its just not good.get yourself the manual. none of the link and sync is hard. its detailed and you yeally need to know why certain things are done in certain ways. <br /> good luck and keep posting

 

[fec]

Re: Yamaha 2002 150 HPDI Twins

Hey rodbolt just wanted to give you an update on the 150's HPDI, after a frustrating weekend of trying to figure out why than ran so rough out of the water I finally gave up this weekend and just put it in the water to test run, Miracles never quit because they ran fantastic and both idle great. all I had to do was adjust the idle speed they were a little low at 600rpm, I guess these things need the backpressure to smooth out. Top RPM was 5400 RPM and top speed was 46 MPH. Never saw that before now. Also pulled the plugs on the tach and found that the 3rd dip switch on both were set wrong, pushed it to the down position and it now shows the oil level in the tank and the water temp bar quit flashing. Do you think I still need to set the sync and link. Also I do have the Yamaha service manuals.

 

[rodbolt]

Re: Yamaha 2002 150 HPDI Twins

hello<br /> glad to hear ya got it sorted out. 600 is about where they seem to idle. to set the TPS uou need the test harness. by moving the idle screw you alter the TPS voltage setting. it needs to be checked. the tech manual may not have the updated version of the setting procedure. anyway if it idles about 700 or so in gear in the water your fine. I told you that motor sounds blown up while on the flusher. the 200 and 250's are noit as bad.<br /> I have not heard a 300 yet but we have a pair to install soon. they guy says his o3 225 four strokes dont have enough so as soon as he can get them he is upgrading to a pair of z300's. if it were me i would keep the f225's but oh well. if ya got it spend it <br /> good luck and keep posting