Yamaha 200 OX66 Cooling System Maintenance

In this video we change the thermostats, the poppet valve, water pump and fuel filter on a 1999 Yamaha 200 OX66 Fuel Injected 2-Stroke.

[@justintime3944]

Just watched your video, probably one of the better ones I have seen. You get to the point, show the parts needed. My only comment was that some of the video was out of focus, no biggie, and when you showed some of the parts and part numbers, you were out of the range of the camera. I have the exact motor so this was a huge help and encouragement for me to try some of this maintenance myself. Can you do one on the fuel and oil pumps? Have you done any other maintenance videos on this outboard? Thanks Jim….. 😊. Keep em coming….. 😊

[@turningwrenches9524]

I just did the tilt and trim seals, but with my schedule right now it’s just easier not to film. When it comes to the fuel pumps… I have never replaced my low pressure fuel pumps. I also do not pump my home before starting which from what I have been told makes those pumps go bad faster. Thanks for watching!

[@aprendiendoconsamuelcarran9682]

Hi 👋 I am a fishing man and I like you videos brother 👍👍👍

[@turningwrenches9524]

Thank you! I will be making more this winter. Too busy in the summer to be able to spend time in the Garage. Thanks for watching.

[@gregeconomeier1476]

I have the same system in my SX150TRXA. I do almost exactly what you do. I pull the thermostats and flush annually for about 2 hours with salt away or similar products and pull the heads and clean the water passages every 500 hours. The engine has been very reliable and so for so good! BTW, I also do the garden hose flush EVERY time I use the engine.

[@turningwrenches9524]

When I first got it, it looked like it had never been done, once it was done it lives up to the bulletproof name for sure! Thanks for watching!

[@raulhumbertomoriel7238]

Excelent!

[@timothyvanvickle117]

I could swear i saw that cover with the lip come off with the lip towards the left side and then saw you install it to the right

[@turningwrenches9524]

Cover? Where at in the video? Time stamp?

[@drifter9425]

The grommet in case for poppet valve is the one to change if corrosion pushed on it that will create a tight hanging up poppet valve

[@turningwrenches9524]

I did end up changing the grommet, spring and piston…no issues since so it was probably my problem last year as well. Thanks for the heads up!

[@drifter9425]

@@turningwrenches9524 I got a dealer mechanic friend who's super good and swore the popped never goes bad But my ox66 200 it was overheating at low speeds only that was the problem I found after changing thermostats and impeller and removing heads to sandblast passages Got another ox66 225 someone traded in with a low end overheat after dealer did heads thermostat and pump I bought it for 1500 and it looks new under cover so I'm hoping it's the poppet valve on it as well Then gonna swap the 200 for 225 18ft McKee Pulse 200 running 54 @ 5400

[@turningwrenches9524]

@@drifter9425 that will scoot along pretty quick on that hull.

[@georgedrager-bluewaterdreamer]

That’s good I have a 2011 150 hp yamy How do you check oil injection system I would like to see that

[@turningwrenches9524]

Good idea. I will look at doing a video on that. I’ve only been stranded one time. And it was due to the oil pump not pumping from the reservoir tank into the motor mounted smaller tank. It would run for a few minutes and then go into limp mode

[@WranglerRunner1]

Thanks for the video. I just purchased a 99' Pursuit Kodiak with the same year Yamaha 200 OX66. Powerhead was rebuilt a while back. How many hours on yours? I've heard good things about them in terms of reliability and longevity.

[@turningwrenches9524]

I’m not sure how many hours on mine… pretty sure it’s less than 1000… And from what I have seen it lives up to the bullet proof name. It’s basically a carburetor with fuel injection on the front side like a throttle body, So it starts easy and runs well with a lot of power. I also run non-ethanol gas to avoid any problems. Thanks for watching!

[@WranglerRunner1]

@@turningwrenches9524 great to hear; thanks for the feedback. Subscribed!

[@user-ul9qq5ew2q]

It didn’t look like you took the little rubber gasket off the old fuel filter and reinstall it into the top of your new one. Maybe u did, but u didn’t show it. Also, you didn’t grease anything on your water pump replacement. Those new gasket pins, the Woodruff key, housing bolt threads, shift shaft or the top of the shaft itself, at a minimum.

[@davidkelly5041]

Do you know if there are any engine block anodes that need to be replaced?

[@turningwrenches9524]

When I did a total water jacket clean out, I replaced all of my engine anodes. Cleaning the water jacket was easier than I expected it to be and the result was great. No over heating since.

[@davidkelly5041]

Where are the anodes? I can’t find them!? Thanks!!

[@jimmisfyl5841]

My friend we never grease the impeller

[@jimmisfyl5841]

The lubricant of the impeller is water

[@turningwrenches9524]

I was only applying the grease… To make it easy to install the impeller. Is that not the correct way?

[@jimmisfyl5841]

If you put grease the oil reduce the life of the impeller some manufacturers they noticed this in tha service manual....

[@jimmisfyl5841]

Many years before it was acceptable

[@jimmisfyl5841]

But they change it

[@turningwrenches9524]

@@jimmisfyl5841 Thanks for the heads up!

[@jimmisfyl5841]

Is made from natural latex

[@TOC1616]

You forgot the small o ring that goes on top of the fuel filter, it's the size of a dime

[@turningwrenches9524]

There is not one on the parts listing. Post a link?

[@TOC1616]

@@turningwrenches9524 65l-24564 is the part number. My Yamaha dealer sells it with the filter, the small o ring that goes on the top of the filter and the gasket that goes on the bowl.

[@turningwrenches9524]

Yamaha started or switched to that o-ring for the 2001 and up year models. The 1999 and 2000 model use the large o-ring like I used. The part you listed is in the parts diagrams for 2001 and up. That was a head scratcher for a minute. Thanks for watching!

[@ChrisWrightDVM]

Thanks for the vid!!! I just did both thermostats... and my poppit (PRV) valve. My motor, 2001 250hp ox66 SX250TURZ, also has a "thermosensor". Only ONE, on the STARBOARD side, directly next to the thermostat, I have a thermosensor sticking straight up w/ an electrical connection. Online, yamaha OEM parts lists this as a "thermosensor"... but my manual calls this an "engine cooling water temperature sensor". First off, do you do maintenance on these, cleaning or replacing? And second, what's the purpose? If the thermostats are both measuring the temperature of the water, then what is the thermosensor doing? Any insight is appreciated... thanks.

[@turningwrenches9524]

The thermosensor is there to tell the engine control computer when to alarm from an overheat condition and go into limp mode. Limp mode is where your engine computer limits the rpms to 2000. I am not sure they can be cleaned, but I have verified them electronically by heating up the sensor with a blow dryer and seeing if the sensor will break continuity…or make continuity if it is a normally open sensor.(can’t remember)

[@georgedrager-bluewaterdreamer]

Oh yea I forgot to mention the outboard mechanics here where I live are useless couldn’t care less but holes so I’ve learned how to do things myself I’ve had spark plugs fall out shift not going into forwards bent water pipe engine blowing up pay for full water pump kit get just impeller the list goes on and they look at you like your the biggest asshole when you tell them to fix it

[@turningwrenches9524]

They must also work for congress:)