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I just purchased a new (2003 model year) Yamaha 250 HPDI to install on a 79 Mako 23 with a sealed transom and bracket. When I mentioned this to a friend recently, who knows a lot about boats, he said "you know there have been problems with the 250 HPDI". It was news to me. Anyone out there heard of any issues with the 2003 250's?
mobydoc, As a new poster you are probably unfamiliar with the "Find" feature on this board. Click on it, put in "250 HPDI" and you will find numerous threads on this topic. Bottom line is many 250 HPDI had over oiling/plug fouling/stalling problems. The good news is Yamaha has issued a tech bulletin that includes many updates. Take the motor back to your dealer and ask that these updates be done and you should be fine. Those that I know of that have had it done (and had problems before) report that the problems appear to have been corrected.
My 250 hpdi was perfect for the first 240 hours, but then started fouling plugs. I had the first three updates done (not the new one that has new plugs) and it has been 100% for the past 35 hours (275 total).
There are now 4 service advisories (some might be called recalls) for the 2003 250HPDI. All are apparently related to overoiling/fouling spark plugs. They are (1) oil linkage rod replacement, (2) voltage regulator replacement, (3) coils replacement. The 4th was just announced via letters to owners in the last 30 days. It includes new/different spark plugs, new oil pump, new ECM (chip) and a case of Yamalube. I've had the first 3 mods on my engine and am waiting for parts for the 4th. Until recently, I've had plug fouling problems...nothing that would cause me to be towed in, but engine shake at low rpms and noticeable carbon on the plugs. With a recent tweak of the oil adjustment linkage, I am finally up to 50:1 fuelil ratio (I have been in the high 30's to low 40's) and have not noticed any engine shake at all in 30 hours of running. The 4th service advisory supposedly updates the 2003 engines with the technology developed for the 2004 engines which (hopefully) is the final cure for over-oiling. I'll have the 4th modification when the parts are available but I am not sure now if I really need it since the fuelil ratio has improved so much. Having had to replace the spark plugs 3 times in 100 hours was certainly annoying, but the engine has certainly been reliable in that it has not left me anywhere, although some folks with this engine have had fouling so bad they had to be towed.
Depending on when your engine was manufactured, you may already have some of the updates. Your dealer should be able to check with Yamaha using your serial number and determine which updates have already been done.
I,ve got three of the 2003 250 HPDI motors and they have fixed the problem from what I have seen. I wouldn't worry about buying one if I were you. Bbogue is correct about the initial problems though there were some bugs. I was told that this latest fix is a complete change out of the oil injection unit.
Our ski team has 3 VMax 225's with the same issues, and one of them has been updated and sounds like a different motor after the oil pump/ECU upgrade was done. Seems smoother in general. Not sure which part of the upgrade was the most important, I think the hotter plugs helped alot.
Talked to a Yamaha tech this week, he said they had some oil pump problems but changed them out to the same pump as the 225 4stroke and there good to go.
I took delivery of a 2004 250hpdi in July and recently rec'd the recall notice for the oil pump and plug replacement so the issue was not resolved for all 2004 model year motors. I only have 24 hours on the motor, but it uses a lot of oil and misses after running at trolling speeds. My dealer is still waiting on parts. Hope this takes care of the 250hpdi issues.
Had all of the recal work done, motor runs strong through entire rpm range, oil cunsumption is much better fuel burn as well. Have not fouled the new type of plug, and the free case of oil will go far. The motor has always been reliable, never left us to use a paddle to get home, even managed to get the boat on plane with four fouled plugs 15 miles off. Runs even stronger now.
Prior to the recalls we fouled a few set of plugs over 400 hours and 8 months. Not really a big deal, though inconvenient. We were never stranded and didn't need a paddle as Tiara4300 suggested. The motors, even with fouled plugs would run about 4100 rpms, enough to get us home from the Bahamas with one motor fouled at about 38 mph.
Since the update our oil consumption has decreased dramatically and we have had 80 trouble free hours.
I have about 50 hours on my 250HPDI since the recall service which consisted of a new oil injection unit and a change in the spark plugs. So far it's been running great, even with a lot of trolling hours this fall.
I have about 50 hours now on my 03 250HPDI since the 4th service advisory (new, hotter plugs, new ECM, new oil pump). I can't say that I see any fuel economy gains, but my oil usage is way down. I average over 60:1 fuelil ratio on offshore trips of over 160 miles, combined running and trolling. No signs of fouled plugs and she spins up readily to max rpms.
I pulled my boat last week and had them check the plugs. I put 55 hours on my HPDI after the latest recall with the new plugs, ECM and Oil Pump. 4 plugs looked perfect the bottom 2 looked pretty bad. I noticed no hiccups while running. I notified my dealer and am waiting for a response from Yamaha.
Tiara 4300, thanks for that display of total ignorance. I will never fear posting and looking stupid again.
I have a pair of 2003 250's that have never missed a beat, failed to start, or left me stranded. I have 294 hours on them and have traveled thousands of miles without the slightest problem. To bad for you I'm offshore spending my kids inheritance while you're still tied to the dock...
One man in his life plays many parts. There is no armour against fate...
yamaha 250 hpdi reliability 
il ratio (I have been in the high 30's to low 40's) and have not noticed any engine shake at all in 30 hours of running. The 4th service advisory supposedly updates the 2003 engines with the technology developed for the 2004 engines which (hopefully) is the final cure for over-oiling. I'll have the 4th modification when the parts are available but I am not sure now if I really need it since the fuel
