200 Hpdi fuel troubles - The Hull Truth

m680pjh · 09-12-2009, 11:58 AM

I was recently asked to repair a 2006 Yamaha 200 hpdi. Following investigation I found the engine to be bogging down and starving itself for fuel. I read some of the posts on this site as inspiration as this was a new engine to me and I feel it is only fair to share my results to help someone else in bother.
I started by cleaning and changing all the filters including the vst filter/ guaze and checking all fuel lines. Waste of time.

Cleaned the injectors. Waste of time.

All pressure checks etc pointing to high pressure pump. Using the Yamaha software I monitored the fuel pressure and found it disappearing under any load.I bit the bullet and pulled the front cover off the high pressure pump and found two small guaze filters inside. I removed these by threading in a screw and found one to be partially blocked. I cleaned these using high pressure air and rebuilt the pump.
I put the boat in and it ran like a dream.

To remove and clean these two filters you need no special tools and once the covers are out of the way it takes only twenty minutes. There are no gaskets needed and it might save you lots of trouble and worst of all a failed engine. I will certainly be cleaning them on any engine which I will be servicing from now on.
I hope this post helps someone and better still saves someone from the unnecessary and costly removal of the high pressure pump for the sake of twenty minutes and an airline.

DinoGucci · 09-12-2009, 12:12 PM

You are the MAN!

viogator · 09-12-2009, 12:19 PM

Thanks for the post. Could be quite helpful for me and others in the future!

Sea Hawk · 09-12-2009, 04:07 PM

Gringoooooo where are you?

actionc · 09-12-2009, 04:25 PM

thanks for the info

triumphrick · 09-12-2009, 04:51 PM

Quote:

Originally Posted by Sea Hawk

Gringoooooo where are you?

BW23 · 09-14-2009, 07:21 AM

Well done ! Any pics of the location of these filters ?

Thanks !

m680pjh · 09-14-2009, 07:38 AM

None really needed. Just look at your hp pump and you will see the manifold with the two pipes going to the injector rails. Remove them and the manifold is held on by four bolts two 10mm head and two 12/13mm head. Remove this manifold (it will be stiff) and look into the two large ports and you will see the filters. Remove using a screw (but gently or they will get damaged) and clean. Simple.

Gringo · 09-17-2009, 04:05 PM

when you say a screw, you mean like a pointy thing that could poke a hole in a screen, or a small bolt with a blunt end?

m680pjh · 09-18-2009, 03:45 AM

Small bolt with a blunt end. It just looks like a small hole with a o-ring around it. take a picture of yours with the cover off if you like and I will mark it.

billatstarbrite · 09-18-2009, 06:50 AM

Great post - thanks for the info. You will save a lot of people a lot of grief.

MAGNUS · 09-18-2009, 07:37 AM

Thanks for the info!

diazhome · 02-08-2010, 03:21 PM

m680pjh: Many thanks for the info! I've spent lots of time debuging fuel problems in my 300HPDI's and like Gringo now I consider myself an "expert" and have all the tools of the trade (YDS, fuel pressure gauges, etc.). I removed the tiny guaze filters (the 300HPDI has 4 of those!) but unfortunately broke one that was very tight. Do you happen to know a) if they can be purchased somewhere, or b) what would happen if I run the motor without those tiny filter?

Thanks in advance for your insight!

lostsinker · 02-09-2010, 11:27 AM

Quote:

Originally Posted by diazhome

m680pjh: Many thanks for the info! I've spent lots of time debuging fuel problems in my 300HPDI's and like Gringo now I consider myself an "expert" and have all the tools of the trade (YDS, fuel pressure gauges, etc.). I removed the tiny guaze filters (the 300HPDI has 4 of those!) but unfortunately broke one that was very tight. Do you happen to know a) if they can be purchased somewhere, or b) what would happen if I run the motor without those tiny filter?

Thanks in advance for your insight!

In theory, as long as there is no contamination (particulates) in the fuel, you wouldn't need the filter. This is the real world and crap can get in there. Without the filter, you risk clogging your injectors and that will cost a lot more than the filters to repair.

keylargodude · 02-09-2010, 07:19 PM

One more time....pls for the hearing impaired.

Where are these filters? In the VST ?

Andrew134 · 02-09-2010, 07:40 PM

Great Info. Thanks for taking the time!

LOVEBOAT · 02-09-2010, 07:57 PM

really could use some pictures. I would love to see what and where these are.

dward51 · 02-09-2010, 09:13 PM

Quote:

Originally Posted by LOVEBOAT

really could use some pictures. I would love to see what and where these are.

I second the request for some photos. I've looked over the exploded diagrams for my 2001 200HPDI and can't find anything that looks close to what he is describing. On the other hand, he has a 2006 so the design may be different.

I just don't want to tear into the motor not knowing exactly where these little buggers are supposed to be (or worse, if my model does not even have them).

SSFoam · 02-10-2010, 06:08 AM

I had one of my motors was running sluggish and figured out it was plugs
The plugs looked fine and all of them fired when I held them to the block
I was told no matter what the plugs look like throw them out and get new ones every 100 hrs
I am going to look for them filters on mine and If I find them I will post some pics
(I assume the 300s are set up the same as the 200s)

diazhome · 02-10-2010, 04:52 PM

For details, diagrams, and pictures you should read the thread titled "300HPDI with water in cylinders". The thread is quite long, so if you'd rather get to the point then start reading at post #446 (pg 23) of that thread. Lot's of good info and details!