Yamaha 200HP HPDI fuel pump rebuild or replace??

Yamaha HPDI 200 hp fuel pumps replacement. Pulse pumps replacement with new pumps. Removal and installation.

[@sfllife03]

Thank you for showing us how the gasket goes onto the fuel pump. You were the only fuel pump video that actually sits there and shows which way the gasket glaze on there. Thank you.

[@apackwestbound5946]

Well done video thank you. Anybody who replaces his low pressure fuel pumps every other year or so as PREVENTATIVE maintenance is EXACTLY the kind of person I want to buy a used boat/engine-car-whatever from. Very impressive! I'll bet you have zero or close to zero reliability problems on all of your equipment! Very cool!

[@robertjackson7590]

The factory pumps use rubber that don't like ethanol if left very long. I pulled the diaphragm pumps and blocked them off, installed an electric fuel pump on board. A switch that allows me to pump the fuel out to winterize, drain the VST and your done. Bad fuel is the biggest issue with boats. Racor 10 micron on the suction side before the Holley pump, then 2 EFI in line filters(12 micron) upstream that are 7 bucks a piece, replace every couple of years. Replaced the 70 dollar OE filter with one as well, I can replace both for 14 dollars from any parts store. If you look in a troubleshooting manual and for all the symptoms of different problems point to the same part, it's a design flaw and should be looked at to upgrade. For liability reasons I can see why they didn't want the fuel pump on board.

[@TrophyFish]

I have that exact same motor and its bogging and then wont start at all. I was going to look at the fuel pumps next so THANK YOU for this video.

[@florida4funshinechannel998]

Thank you. Check your plugs for fouled plugs. I have had the same situation and had 2 fouled plugs. Since in idle it only runs with four cylinders out of the six .., if 2 of the 4 are fouled. Well...you get it. Let me know. Thanks and good luck.

[@TrophyFish]

@@florida4funshinechannel998 I got 2 low pressure fuel pumps, the fuel pump in the VST and the diagnostic cable and software. Also got clear fuel line material and some starter fluid to see what happens. The plugs were replaced within the last 2 weeks so I highly suspect a fuel issue, but I'll check the plugs to see if something fouled since they were installed. Thanks for the advice.

[@gcuervogold]

Excellent vid. You wouldn't happen to have a vid changing out the hi pressure pump in the vst and servicing it in general? My 04 VMAX won't go over 45-4700rpms. A diagnostic confirmed low fuel pressure.

[@billrodriguez4671]

Excellent video and great instructions!! I have exactly the same engine and suspect its the identical problem you described!!-- You saved me hundreds of $ Muchas gracias!!😀

[@florida4funshinechannel998]

Glad to help. Check out the other HPDI videos if you can. Take care.

[@danieldabal1300]

Thank you , very useful video. Good man

[@florida4funshinechannel998]

Glad you liked it!

[@jaredzeno]

what are the symptoms of bad pumps? My hpdi cut out when I throttle up almost like i'm turning the key off then back on and I am also starting to foul out spark plugs. It goes away when i change out the plugs but then will start again after I put a few hours on them?

[@andrewvillanueva4222]

Awesome job

[@florida4funshinechannel998]

Thanks. Thank you for watching. More videos soon.

[@Grady252]

I would highly recommend using the yamaha zip ties for the fuel lines. They are curved and also are highest quality. I have too many of the white or clear types, even the black one's break after some time .Also some stretch more with heat and don't seal properly.

[@florida4funshinechannel998]

Agree@

[@florida4funshinechannel998]

Great point. Will be doing it. Thanks

[@braynmoreno6194]

Great video! Can you please provide the part numbers of the gas pumps? The first one can be see it but not the second one. Thanks!

[@florida4funshinechannel998]

Same part # for both. Thank you for watching.

[@MrSchultej]

Great video. I have a 2003 200 HPDI which runs great at low RPMs below 2200 and great above 3800. The motor will surge in between, never dies just surges. I have replaced the VST filter and the mid range filter. Would one of the two low pressure pumps cause what I am seeing?

[@florida4funshinechannel998]

Hello. I am no expert...but a surge usually ( for Me) indicates fuel starvation. Most likely. It is the high pressure fuel pump. Does your fuel bulb remain hard or does it soften at high rpms.? It sound to me that the engine is asking for fuel at that 2200-3800 rpm range and it is not getting it and finally it gets it and runs above 3800 rpms. Other test will help ie. fuel pressure test, in line fuel filter, dirty injector/s,. But..Having said that...fuel restriction at some point. Check hoses for leaks. Hope this helps..please keep us informed

[@MrSchultej]

@@florida4funshinechannel998 Thanks. I replaced all the filters, so my next move is going to replace the low pressure fuel pumps like shown in the video. I agree that it looks and acts like a fuel starvation issue. I would need to have someone look in the bilge to see if the primer ball is collapsing while running.

[@JohnColeman-ul5rj]

I wonder if you could delete these low pressure pumps like you can on the 066 with an electric fuel pump and block off plates?

[@florida4funshinechannel998]

I do not know. Never have done it and cannot recommend it it either way. Thanks for watching and commenting.

[@rickyenriquez7102]

Hi was hoping for some help? My hpdi is bogging out at higher RPMS I’m guessing high pressure fuel pump but don’t know where its located? Any tips? Thank so much!

[@florida4funshinechannel998]

Hello. The VST is the location of your pump. But...before you go there, check your fuel hoses for any obstruction, kinks or broken/cracked. The grey fuel hoses tend to flatten and obstruct fuel flow. Try pumping the bulb when this happens to see if pump is weak. Fuel pressure test is also recommended. Please comment and share what you found and how you fixed it. Thanks and good luck

[@chadpipkin840]

Good morning just pick up a 2003 Yamaha 200 hpdi .took it out for the firs time . When shifting into reverse it would go into reverse but would not rev up to move boat .have tou ever had this problem with your motor. Thanks

[@florida4funshinechannel998]

Check for cavitation and proper prop pitch. Please update. Thank you

[@chadpipkin840]

@@florida4funshinechannel998 I think o have found the problem with reverse adjusted the cables at the remote I now have throttle in reverse on the hose have not water tested at this time will update when I do . Thanks for your reply.

[@florida4funshinechannel998]

Awesome!

[@damonmeeking164]

Hi I'm rebuilding a 250 hpdi in the UK I want to run it on a fuel oil mix as is lost oil to 1 and 2 . What do you think is the best answer to the oil problem the hpdi has?

[@florida4funshinechannel998]

Hello. Need to check the feeds to those cylinders for oil following the oil pump hoses. There could be broken, disconnected, daqmaged

[@billwilson1506]

Do you grease the seal before reassemble?

[@florida4funshinechannel998]

I do not. Thanks

[@captlucky2320]

Probly don't want to use those plyers on those harness connectors thats how they break also may not want to pull on the wires on those same harness ends that's how they get pulled out and shorted which cause running issues which can have you throwing parts at a problem

[@florida4funshinechannel998]

Great points. Thanks

[@michaelh7527]

Always going to have someone pointing out that you didn't do something by the book 😂😂 As someone who is mechanically inclined, you just learn how to do things without breaking them. You learn by feel on how much pressure can be applied before breaking something, etc. Nothing he did was alarming.

[@badkarma2202]

if you intend or anyone else to work on your engine the sharp tail of the tie will cut you up. Use pliers and twist the tail off. Or a fine cutter and flush cut. Seen to many people get stitches because of ties.

[@florida4funshinechannel998]

Thank you. Great advise.

[@rainergimenez4022]

How do you know if you have a VST issue or a fuel pump issue. What should I look for?

[@florida4funshinechannel998]

Hello Rainer. You have a fuel pump and a filter inside the VST. What is the motor doing or not doing? Is it at low rpms or high rpms? With HPDI or outboards in general, there is a process I use to determine where the problem is. Is it compression? Is it fuel? Is it electrical? Most problems are related to one of these items or at least related in one way or another to these items. compression, fuel, electrical.

[@rainergimenez4022]

@@florida4funshinechannel998 The engine is running pretty good. It likes to foul the plugs with extended idling anything over 1/2 hour. Starts running fine when I take off with full throttle although sluggish getting there for about a minute or so. That could be the nature of the beast though. I will ck the O2 sensor and clean it. It's never been done since it was bought in 2003. I guess I should ask the question a different way about the fuel pumps. What is the purposes of the VST vs the two smaller pumps mounted inside of the VST? I'm guessing the two smaller pumps draw the fuel up from the fuel tank and then the VST boosts the pressure up to feed the injectors. Is that correct?

[@florida4funshinechannel998]

@@rainergimenez4022 Low pressure delivery for low rpms and high pressure delivery for higher rpms. Are you using ring free? Perhaps you need to decarb the engine. I have a video on cleaning the O2sensor. Is your engine a HPDI?

[@rainergimenez4022]

@@florida4funshinechannel998 It's a 2003 200 HPDI and I watched your video on O2 cleaning. The engine gets used extensively (we dive every week sometimes multiple days). It get's a regular lower unit oil change and every filter replaced included the $140 one on top the motor every 100 hrs. It's just never had the poppet valve cleaned or replaced or the O2 sensor cleaned or replaced.

[@florida4funshinechannel998]

@@rainergimenez4022 Okay. Sounds like you have it well maintained. These engines tend to foul plugs. Try using fully synthetic 2 stroke oil and that will help with the fouling plugs. Otherwise, it sounds like you have it under control. Stay safe my friend!

[@richscott2952]

I have twin 225 four stroke Yamaha‘s left motor will not go higher than 4300 RPM runs nice and smooth below 4300 that but at just in gear kind of like Surging

[@florida4funshinechannel998]

Hello. I would check fuel ( fuel pressure). I would check filters and battery cables and finally the the shift position switch. Comment when yiu fix it to help others

[@richscott2952]

I forgot to mention when you bring it up to 4300 RPM it starts to break up could be those little screens in the motor by each of the injectors or possibly the injectors I will go through what you first recommended , thanks for your help

[@florida4funshinechannel998]

@@richscott2952 Those "Little screens" are known as "Mystery Filters" in Yamaha HPDI, not sure on 4 stroke engines. I am not confident that they would cause what you are mentioning. I am a firm believer in tackling them last if all else fails. I would also suggest checking the gas for water or adding an additive to the gas if you have old gas in the tank. Even draining the gas and putting a fresh tank of REC. non-ethanol. As an addition, check all your hoses for possible leak. You might be getting air in the fuel lines or have a block vent.

[@juantelocomio]

Hello Why did you change them? What was the problem?

[@florida4funshinechannel998]

Hello. I had no specific problem. These pumps were original and they work with a rubber diaphragm that becomes weak and can break with time. This was preventive maintenance. I recommend changing them at least every 1 to 2 years of use.

[@catallaxy2000]

I replaced mine after I had one fail (i.e., membrane failed)... Symptoms were loss of RPM and hesitation at cruise... This is a consequence of the lifter pumps not being able to keep fuel supplied to the VST and high pressure fuel pump... No sense in rebuilding these - they're only about $35 each to replace...

[@robertjackson7590]

@@catallaxy2000 Ethanol is a problem with rubber components and can fail these pump diaphragms prematurely. I'm getting rid of mine for this reason and installing a Holley Blue electric pump with a regulator. Totally bypass both pumps. Install some block plates and forget about them. Install a Racor primary filter with a 2 Micron element between the tank and the pump and not have to worry about these guys. Might research the Racor on The Hull Truth. Some say it stopped all of their problems with fuel filters on the HPDI. Many more threads like this; www.thehulltruth.com/boating-forum/1011491-hpdi-racor-help-please.html The objective of the 2 micron is to keep the 10 micron filters downstream from needing to be changed since the spin on in the boat is so much easier to get to. You can install a warning light on the suction side to show the filters getting too full of debris.

[@yunierperez8987]

You didnt show how to put gasket

[@florida4funshinechannel998]

Hello. I did not rebuild them , I replace them with new ones. The Gasket can be replaced with a kit to rebuild them and they go on the same way that they are removed. Not difficult or complicated. Look how you removed the old one and put the new ones the same way. Hope this helps. Thanks.