Yamaha 2 Stroke Oil Pump Replacement DIY

This Video will show how to replace a Yamaha 2 stroke outboard auxiliary oil pump as well as change the auxiliary oil filter. the video then shows how to test the system to make sure it is operating correctly.
Oil Pump Part Number: 6E5-81900-01

[@JuanRodriguez-xd3hl]

I would like to tell you that your video was extremely helpful and I was able to change out my oil pump and filter and now my engine is working and running smoothly. Thanks brother! 👍🏻✊🏻

[@ReelTeaseFishing]

Juan Thank you so much for the positive comment! Glad it helped you get back on the water. Cheers 🤙🏽

[@harrispilton6693]

thank you for awesome video bub!

[@ReelTeaseFishing]

Glad you liked it!

[@gregdanneffel9064]

It's my understanding you have to be careful pulling the float out of the engine mounted oil tank so that the screen doesn't lift out. There is a foam seal on the bottom of the screen that can fall off or shift and when you push it back in it can cause problems - may even stop flow of oil to the engine. I always drain the engine oil tank before pulling the level sensor out just to be safe.

[@Fireship1]

Nice job!

[@ReelTeaseFishing]

Thank you!

[@martinkoche4375]

Thank you

[@wilmarbarrick3194]

If the float switch on the engine mounted tank was low enough to set the alarm when the key was turned on, it should also have automatically started to transfer oil from the remote tank. If it didn't and you needed to toggle the switch, there is a fault in the CDI box. You should also check the tilt switch that prevents filling when the engine is tilted and well as the quantity indicator float in the remote tank.

[@ReelTeaseFishing]

All very good information! Thank you for that post In my case, I new the pump was shot when I put my hand on it, almost burned my hand how hot that thing was.

[@rolandwillis892]

In my case, the remote tank pump failed so the signal and voltage was there but wouldn't operate the pump. Thus the need for and unconventional approach with the drink can fill method for the onboard tank.

[@adamh.971]

Great video..

[@rolandwillis892]

Mine recently failed on a fishing trip. The alarm sounded and I checked the onboard oil tank which was low. I tested the emergency fill switch with no oil flow into the tank. I have BoatUS but I didn't use the service because I have many years of experience in the electronic, electrical and mechanical fields. I didn't have spare oil in a small container so I cut the top out of a soda can, cleaned it, removed the remote oil tank and poured some oil into the can and used it fill the onboard tank to the full level and returned without problem. I now carry an extra quart of oil for just such a problem. I checked the electrial control voltage at the remote tank connector (Brown wire + and blue wire -) 12VDC by using the onboard tank switch, which was good. I then removed the pump/motor and bench tested it. It was intermittent and noisy so I decided to check the price of a new one. Wow, $180. I decided to troubleshot the pump/motor. The pump is a simple gear type which shouldn't fail so I removed the motor cover carefully so as not to lose the brush springs and found the permanent magnets were loose, not broken. I cleaned, reinstalled the magnets with super glue. Carefully reassembled the motor and it works like new. If you do this please remember the pump has to be primed with oil to work properly.

[@ReelTeaseFishing]

Awesome comment! Glad you had the knowledge to get yourself back to the dock. Those pumps are simple little pumps but love to fail when your out on the water. Glad you fixed it and thank you for sharing. While you are at it make sure to change the inline filter. That little filter clogs and strains the pump.

[@aaronroy9825]

How exactly do you prime the pump?

[@rolandwillis892]

@@aaronroy9825 After the repair, I reinstalled the remote tank, filled it with oil, turned on the switch at the control, removed the fill hose from the onboard tank and held the onboard tank prime switch on until the oil poured out of the hose. I reinstall the hose and filled the onboard tank with oil to the proper level. NOTE: have a small cup or equivalent to catch the oil from the hose.

[@aaronroy9825]

@@rolandwillis892 thank you, I had recently replaced my pump, but out on the water the alarm sounded, and the emergency switch at the motor wasn’t pulling in oil anymore.

[@davidthompson1234]

Bro thanks

[@ReelTeaseFishing]

Glad you found our video helpful! Thanks for watching 🤙🏽

[@josesantana561]

Thanks for the video. You don’t need to bleed the oil system?

[@ReelTeaseFishing]

In the last step where you run the manual switch to get oil to the small tank on the outboard is basically bleeding the system.

[@FrankVansickle-lo5hu]

I have replaced the pump by following instructions in this video. I can't get oil to be sucked up into the pump. I have direct wired it to my battery for testing purposes. I can feel air vacuum when the pump is on. But when I submerge the intake hose in oil it blows bubbles instead of sucking oil. Everything is installed currently with the arrows pointing in the correct direction. Do I need to somehow prime the pump with oil? My next step is to submerge the entire pump in oil to see I can get it to suck in oil. Maybe the one remaining hose I have on the return side has a crack in it? I guess I will hav veto test that next. Thanks for the video. It was very helpful. 2002- 150 hp Yamaha 2-Stroke

[@ReelTeaseFishing]

That is pretty weird. It shouldn’t be blowing air in reverse. Maybe try just for diagnostic purposes reversing the hoses and see if it pumps correctly. I’m thinking the impeller or internals are reversed on this unit. Might be a factory defect if this is the case. These pumps are pretty straight forward and don’t require much prime if at all.

[@igfishing13]

So happy i found yiur channel ,for twenty year i was a inboard guy i now got my first boat with a yamaha 225 outboard 2004. I need your help bro , i did not know i have to mix the fuel with oil , i put in 20 gallon of fuel without mixing it with oil, please help me out thsnks , new subscriber

[@ReelTeaseFishing]

Is your outboard premixed? Meaning your oil tanks have been eliminated? Also your outboard a two stroke correct? This info will help me help you.

[@igfishing13]

Thanks for getting back , like I said am just learning about these outboards, the motor is a 2002 yahama 225 ox66 , I don't think I need to mix the oil , I watch your videos on how to change the oil filter and oil pump , I will just change mine soon , can you do a video how to fog the motor for the winter , and how to drain the water from the motor to avoid freezing thanks.

[@ReelTeaseFishing]

@@igfishing13 Thank you for the kind words! now in the winter is a great time to tackle some of these maintenance projects. I live in south Florida and don't deal with freezing temps. unfortunately I don't feel comfortable giving out any info on winterizing as I don't do it. Here on KZbin there is some great videos with great advice. I definitely recommend you treat the gas with a stabilizer. Best of luck and thanks for all the support.

[@danniermatos98]

Hey my friend i have a quetion where didt the pump inject the oil to the vst or striaight to the cylinders ? I need to know i have one similar and i dont know

[@ReelTeaseFishing]

It all depends on what outboard you have. Fuel injected Yamahas usually send the oil to the VST. Carbed Yamahas send the oil to the carbs or the reeds. Follow the oil outlet hose on the oil tank mounted on the outboard and see where it leads to.

[@gregpopp4847]

What was the "thing" that flowed out of the line when you disconnected the filter ? Looked like a solid piece of plastic or something.

[@ReelTeaseFishing]

just re looked at it and it does seem to have some kind of debris in the line. I have no idea what that was. glad it was trapped on that side of the filter.

[@kevinmckuin2507]

Do you order your parts online just wached your video and figured out why my alarm is going off no oil but am wondering where to order part from??

[@ReelTeaseFishing]

If you don’t have a Yamaha dealer, most boating hardware shops are. You can order from boats.net PartsVu.con or CrowleyMarine.com Amazon even has many parts shipped by Yamaha

[@JerseyBoysJourney]

Hi CARLOS how are you doing,,, I have a Yamaha 150 2 stroke 2005 , The oil tank by the motor does not get filled up by the main tank and the alarm comes on because it gets low,, I move the primer switch and I can hear the pump working But maybe it doesn’t get filled up automatically,,,, maybe I’m thinking is something block in the oil coming through by the filter or the hoses,,, or maybe something electronic,,,, I was wondering if I can get a little help on that thank you,

[@ReelTeaseFishing]

Have you replaced the online oil filter on the main tank near the oil pump? It’s notorious for getting clogged and is usually the cause of slow oil fill or no oil to the tank on the engine. Let me know and we can go from there

[@JerseyBoysJourney]

@@ReelTeaseFishing Thank you brother I will try that tomorrow and I’ll let you know how it goes I really appreciated your answer thank you

[@ReelTeaseFishing]

@@JerseyBoysJourney if it doesn’t solve it, please get back and we will keep troubleshooting. Make sure the key is in the on position when you try to get the oil to fill. Won’t work unless key is in on position 👍🏽

[@JerseyBoysJourney]

@@ReelTeaseFishing I will thank you so much buddy

[@JerseyBoysJourney]

@@ReelTeaseFishing Hey CARLOS how you doing,, I took out the tank and clean all the hoses and filter and I prime it and everything is flowing with the switch next to the tank in the motor ,,, hopefully it does it automatically when I’m using the boat next time,, Alice we go to the next step ,, thank you brother will keep in touch to let you know how it goes 👍🏻👍🏻

[@danaymiranda77]

We have a Yamaha 200 ox66 same issue we replace both floating sensor , pump and filter and still no pump oil to the motor tank , can you please tell what is the CDI Box? This is made me crazy 😠

[@ReelTeaseFishing]

If you replaced all this and still not pumping, I would suggest make sure you are getting power to the pump. You may have a corroded wire or corroded harness connection.

[@ReelTeaseFishing]

CDI box on an outboard will deliver power to your spark plugs.

[@wilmarbarrick3194]

The CDI box is the engine computer. While it does control the voltage to the spark plugs it does a lot more including turning the alarms on (like an overheat or low oil) as well as turning the transfer oil pump in the remote tank on from float on the engine tank.

[@ReelTeaseFishing]

@@wilmarbarrick3194 yes you are correct. The computer can be bad an fail to send signal.

[@tsi87supr60]

If my aux. Tank comes out of the hull. It's getting drained out, completely disassembled, cleaned out of all old oil, all new lines, new filter, new pump. The main tank and both sensors should be cleaned also.

[@ReelTeaseFishing]

If you are doing that much, might as well clean the engine side tank and sensors too. It’s a good idea.

[@davidsonpeguero2760]

Carlos where in Florida are you?

[@ReelTeaseFishing]

South Florida 👍🏽

[@davidsonpeguero2760]

I’m in Tampa. So this weekend my reserve tank was full. Was running and boom oil alarm goes on. I pull to nearest island and check my fill on the engine and it was just at the bottom line. I hit my emergency switch nothing. But I let it sit and it was full again and got me home No problem. Should I buy all these parts and replace them?!

[@ReelTeaseFishing]

@@davidsonpeguero2760 that sounds like your in-line oil filter located on the back of the aux oil tank is clogged. Basically when running the clog doesn’t allow the oil to fill fast enough and it will slowly consume more than you can replace unless you slow or stop for a few minutes. We have a video on that in-line filter

[@ReelTeaseFishing]

@@davidsonpeguero2760 sounds like the pump is doing fine, I’d just replace the in-line filter 👍🏽

[@davidsonpeguero2760]

@@ReelTeaseFishing awesome I’ll get that ordered now and appreciate that!!

[@carlospadilla9576]

Question: can my oil pump be going bad. I run my boat and runs fine then about 20 to 30 min the oil tank on the motor is not getting filled. I go slow for about 30 min then runs and repeats any ideas

[@ReelTeaseFishing]

Hi Carlos, thank you for watching and messaging me. With the symptoms you are describing I’d bet it’s the small white in-line filter located on the auxiliary tank by the oiling motor. This filter when clogged will slow the rate at which the oil pump can fill the tank in the outboard. Usually the sign is exactly as you describe If that doesn’t fix it I’d look for kinks in the oil line from tank to your outboard. I’d also look for corrosion at the contacts and clean them with a wire brush. These oil pumps usually either run 100% or completely die. Yours is running so I’d suspect it’s not the oil pump

[@carlospadilla9576]

@@ReelTeaseFishing I will switch it out and thank you for the quick response

[@ReelTeaseFishing]

@@carlospadilla9576 no problem, let me know if that was it. Best of luck

[@carlospadilla9576]

@@ReelTeaseFishing will do thank you

[@carlospadilla9576]

Hey Carlos I changed the filter but it did the same. Now question how can I tell if it is oil or over heating alarm can you tell. Well I was cruising at 20 mph no alarm but when I was going faster at 45 mph the alarm came on so I think it’s oil not fill fast enough should I Changed pump an all lines and when I stop and Cruz At 20 mph I have no alarm

[@georgeanddaddecker7563]

Why not replace the stiff oil hose?

[@ReelTeaseFishing]

Those hoses are ment to be stiff like that because they hold the shape of the tank. They fit a cutout on the backside of tank

[@georgeanddaddecker7563]

@@ReelTeaseFishingThey are meant to be stiff?

[@ReelTeaseFishing]

@@georgeanddaddecker7563 they are ment to be pre shaped. If the hose is stiff in the sense of pliability then I’d change them out. Stiff as in brittle is no good, stiff as in pre shaped hose is normal