Boating How-To’s - Yamaha 200 HPDI doesn't get over 4400 WOT, Bogs down

Ok guy's need your help here

Replaced both LP fuel pumps, VST filter, cleaned VST chamber, HP fuel filters, LP fuel filters, spent $300.00 in parts within the past week, and the problem is better, but not 100%. Also replaced all the fuel lines from tank to water separator, separator to motor with new 3/8 fuel lines. Also changed the water separator to a Racor 2 Micron separator

When going onto plane, I full throttle it, and it bogs down, till it catches, the RPM's jump up, and she shoot outta the hole

Once on plane, 3600 RPM, we ran an hour up & down the river no problems, from 2800 RPM to 4,400 RPM

After 4,400-4,600 RPM it doesn't go anymore, full throttle should be 5,500 RPM

Dirty Injectors maybe? Can I clean them myself ? filter in the HP pump?

I don't know where to go from here

If you've changed racor filter, onboard paper filter, canister filter, and the vst filter, the next in line are the filters in the HP pump. The big blocks have 4 basket filters in the pump, not sure about the 200s. Next after that would be the basket filters for the injectors - each injector has one. While you're at it in there, you might as well clean/test injectors.

Sure sounds like a fuel delivery issue, and those basket filters are probably the culprit.

yeh 10/4, maybe sending the injectors out to here for cleaning , so they can tell me if I have a bad injector also:

http://injector-rehab.com/shop/Dynamic-Cleaning.html

These are the basket filters for the HP right?

http://injector-rehab.com/shop/Bosch-Universal-Filter-Basket.html

Should I change the filters for the injectors before sending them in for cleaning, or after?

I didn't know the injectors had the basket filters in them as well

Yep, those are them.

I would first change the basket filters in the pump. It's a pretty strait fwd job with the pictorial on here. Then run the boat and see what happens. If that doesn't solve your problems, then go to the injector filters and injector testing/cleaning. All of these filters are 2 micron, so once you have this issue worked out, your 2 mic racor should keep the rest of the system clean.

10/4, thanks, I pulled the fuel injectors also, I have 4 out now, the last two on the bottom are stuck in their pretty good, I'm working on getting them out, but their not coming out

Next I'll do the HP pump filters , then everythings done on the fuel side :)

Pics of the fuel injectors, yuk!

3 were frozen, had to use a vise grips around them, and W-D 40 to get them out

I think I got to them, theirs only 1 of them I belive ?

fltekdiver did this just happen all of a sudden? I am running into the same problem on my port engine. It "womp womps" and then will jump up to 2800 rpms (target rpm) drops down to 9/1200 it fluctuates across the board. Troubleshooting my own problem.

fltekdiver, looks like there's 3 basket filters there - the little holes inside the big holes I would think would both have one. Then the other big hole (the one on the left) looks like it still has the fitting in it...the filter would be behind that fitting.

BUT, I'm not sure about any of this, I did my 250s but I don't know what the 200s have. I'm only guessing based on what I saw w/ my 250s. Search through RocknReeln's thread and see if there are any 200 owners that chimed in - I think I remember that there were, and I think I remember them saying there were less filters than in the 250/300 pump. But I would be surprised if there was only 1 filter in there.

How were the injector filters?

Yes, since the past 2 weekends. I have 420 hours on the motor approx, 3 weekends ago we were 38 miles off shore, with no issues. The next weekend we were 32 miles off shore, and coming home, It would get off planes, bog down to 1800 RPM's, stay like that till it catched, the RPM's would jump up, and we would be on plane for a few miles, and it would fall off again

I since did the VST filter, HP filter, LP filter, new LP fuel pumps, new fuel lines from the tank to seperator/motor

It got allot better, now at 3,600 RPM, I can run it all day, problem I have now is, I can't get over 4,400 RPM, or when I full throttle the boat to get on plane, it bogs down, for about 15 seconds, then catches, the RPM's jump up, and she gets right on plane

I'm sending the injectors out for cleaning, since their 9 years old, and 400+ hours and also changed the mystery basket filters in the HP pump :)

fltekdiver, looks like there's 3 basket filters there - the little holes inside the big holes I would think would both have one. Then the other big hole (the one on the left) looks like it still has the fitting in it...the filter would be behind that fitting.

BUT, I'm not sure about any of this, I did my 250s but I don't know what the 200s have. I'm only guessing based on what I saw w/ my 250s. Search through RocknReeln's thread and see if there are any 200 owners that chimed in - I think I remember that there were, and I think I remember them saying there were less filters than in the 250/300 pump. But I would be surprised if there was only 1 filter in there.

How were the injector filters?

I removed the fitting, nothing behind it. I found a thread on a 200 owner, and he said their was one basket filter , so I'm crossing my fingers theirs only one

Scroll up 3 post and see the pics of the injectors i posted :grin:

Now sure on the injector filters, as I'm sending them out to be cleaned, I should check one or two so I know though, good idea

There are 2 of them...look at this thread:

http://www.thehulltruth.com/boating-forum/348431-hpdi-mystery-filters-part-ii-5.html

Go to post 94. He has the same pic you posted, but missed one. The poster in post 96 describes the location of the one he missed.

There are 2 of them...look at this thread:

http://www.thehulltruth.com/boating-forum/348431-hpdi-mystery-filters-part-ii-5.html

Go to post 94. He has the same pic you posted, but missed one. The poster in post 96 describes the location of the one he missed.

Perfect, Thanks ! I'll change it out also

There was no " basket ", just a brass ring on the one I pulled out, maybe the whole thing disolved over the years?

Changed the basket filters, sent the injectors out for cleaning, still not running smooth

Im lost now, did the VST, HP/LP fuel filters, injectors, basket filters, the basket filter I never found, just the brass O oring that it connects to, I'm wondering when I stuck the screw all the way into it, if I pushed that basket filter furthur back into the HP, cause its worse now then before

OK, so you have replaced the boat mounted racor, the engine mounted fuel/water separator in the clear bowl, the metal mid pressure $80 canister filter, the vst filter and gasket, and the micro filters in the high pressure pump. You have also replaced the two low pressure diaphragm pumps. If you have done all of these filters, there are no more to do. Other things to look at would be primer ball, a leak at a fuel hose allowing air to enter the system, plugs, wires (although it doesn't sound like a miss...), computer or sensor.

This thread has some good info on troubleshooting and isolating the problem... http://www.thehulltruth.com/boating-forum/441990-help-hpdi-rpm-problem.html

Just a follow up, VST had 50 lbs of pressure when running, changed all the fuel lines prior, changed the plugs, and turned out to be a bad injector. Had a mechanic find it on his laptop, and he couldn't fire it from the laptop

Got the new injector in, and the others cleaned, went out for the bay test, and WOT was 5,200 RPM's, and the boat ran like a bat outta hell !

OMG, I'm gald this is over

Thank you once again for your help guys, its really appreciated !

So how many filters on a 2002 200 HPDI including HP pump AND injectors?

One in each injector so total of 6 their, plus two on HP side

Maybe I missed it but didn't you send in the injectors for cleaning? Don't they test them.?