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2003 HPDI 250 wont go above 4200 rpms

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2003 HPDI 250 wont go above 4200 rpms

Old 10-02-2018, 02:13 PM
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Default 2003 HPDI 250 wont go above 4200 rpms

Hey guys,
Im new to the hull truth so bare with me
I have a 1982 Mako woth a 2003 yamaha 250 hpdi
ive been having this issue since i bought this boat i thought it was a fuel problem but after changing the PLUGS (NGK R), WATER SEPARATOR(10 micron), FUEL PICK UP, VST filter , INLINE filter, CANISTER filter, and LOWER PUMPS im dealing with the same issue (i even used a separate gas tank to rule out a couple things still having the same issue)
Boat runs great at idle an in gear up to 4200rpms wen pushing down on the throttle to reach higher rpms..
1. The rpms stay the same
2. After 2 mins or so The motor will buck an wanna stole out.

someone please help me out im motor savy an know how to work a wrench soo i plan on doing the work myself (just cant seem to figure these hpdi’s out) just tryna save some dough before loosin hope an buying a 4stroke
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Old 10-02-2018, 02:33 PM
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Have you checked to make sure that the boat isn't over-propped? What is the hull weight like, any chance of water intrusion? Is the prop in good condition? Have you done a compression test?
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Old 10-02-2018, 02:37 PM
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Do a search and you will find many tutorials on big block Hpdi's and dealing with their many issues. Buy the yds software on eBay because without it you are throwing away money on parts. I have a 250 hpdi and thought I had bad plugs or wires, then got the software and it showed me the shift position switch was bad. Good luck.
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Old 10-02-2018, 02:45 PM
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Originally Posted by Aliboy View Post
Have you checked to make sure that the boat isn't over-propped? What is the hull weight like, any chance of water intrusion? Is the prop in good condition? Have you done a compression test?
Ive acually just noticed after pulling up the access to my sending unit and pickup some dampness looks like water got in prop was just sharpened an cleaned up i dont know the pitch on it soo ill have to do more research on that
would that cause the motor to surge an not produce higher rpms ? Even in neutral the motor wont exceed 4200..
also didnt do a compression test gotta get on that
thankyouu
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Old 10-02-2018, 02:47 PM
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Originally Posted by JupSC View Post
Do a search and you will find many tutorials on big block Hpdi's and dealing with their many issues. Buy the yds software on eBay because without it you are throwing away money on parts. I have a 250 hpdi and thought I had bad plugs or wires, then got the software and it showed me the shift position switch was bad. Good luck.
shift position sensor is on its way was gunna tackle that next after reading other threads
im gunna look more into this software
anychance u can post up the ebay link ?

Thankyouu
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Old 10-02-2018, 03:39 PM
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Originally Posted by 82mako250hpdi View Post


Ive acually just noticed after pulling up the access to my sending unit and pickup some dampness looks like water got in prop was just sharpened an cleaned up i dont know the pitch on it soo ill have to do more research on that
would that cause the motor to surge an not produce higher rpms ? Even in neutral the motor wont exceed 4200..
also didnt do a compression test gotta get on that
thankyouu
I don't know the details but I think that engine has a rpm limiting function when in neutral. That might explain the 4200. There is also a shoft position switch on that engine that cuts out 2 cylinders at idle. If that had failed you might be only running on 4 cylinders when you power up. Is the boat living on the water or trailered? If trailered, when was the hull last cleaned?
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Old 10-02-2018, 04:09 PM
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Originally Posted by Aliboy View Post
I don't know the details but I think that engine has a rpm limiting function when in neutral. That might explain the 4200. There is also a shoft position switch on that engine that cuts out 2 cylinders at idle. If that had failed you might be only running on 4 cylinders when you power up. Is the boat living on the water or trailered? If trailered, when was the hull last cleaned?
your right it does run on 4 cylinders at idle but i had a mechanic hook it up in a computer an do the TPS scan an everything was working properly as for hull it was on blocks for the last 3 years i just dropped her in clean 2 months ago
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Old 10-02-2018, 04:28 PM
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Old 10-02-2018, 04:39 PM
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So the 4200 in neutral may just be the protection system. Are you getting the exact same max rpms when running WOT? I found an old post from years back where someone with a similar issue eventually tracked it to a broken exhaust tuner. The other thing you haven't had checked yet are your injectors.
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Old 10-03-2018, 06:32 AM
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Originally Posted by Aliboy View Post
So the 4200 in neutral may just be the protection system. Are you getting the exact same max rpms when running WOT? I found an old post from years back where someone with a similar issue eventually tracked it to a broken exhaust tuner. The other thing you haven't had checked yet are your injectors.
WOT i get 4200 4300 when in neutral i get the same..
boats docked as of right now is there any test i can do to find out is exhaust tuners bad? or do i have to haul it ? An im gunna clean injectors an do shift position switch within the next couple days

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Old 10-03-2018, 07:28 AM
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Had a similar problem on an 04 200. If your getting 4200 RPMS I sought it's the neutral switch. You would not be able to get on plane with two cylinders down. Sounds like one cylinder not firing. Mine did this and after changing plugs and swapping coils with no luck we found the culprit. Frayed wires on the lower starboard side where a big bundle of them were rubbing against the cowling. Get an online spark tester and check fire on each cylinder. Top port and middle starboard are the cylinders controlled by the switch on my engine. If one is firing in gear it's not the switch. Now before we found it my mechanic thought it may be a bad pulser. But you'll need the software to check that.
Ricky
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Old 10-03-2018, 01:12 PM
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Originally Posted by 82mako250hpdi View Post


WOT i get 4200 4300 when in neutral i get the same..
boats docked as of right now is there any test i can do to find out is exhaust tuners bad? or do i have to haul it ? An im gunna clean injectors an do shift position switch within the next couple days

Tuner needs to be checked with the leg off. It is probably the least likely of the options though so I would look at all the stuff you can on the water first.
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Old 10-03-2018, 05:31 PM
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Originally Posted by going2fast View Post
Had a similar problem on an 04 200. If your getting 4200 RPMS I sought it's the neutral switch. You would not be able to get on plane with two cylinders down. Sounds like one cylinder not firing. Mine did this and after changing plugs and swapping coils with no luck we found the culprit. Frayed wires on the lower starboard side where a big bundle of them were rubbing against the cowling. Get an online spark tester and check fire on each cylinder. Top port and middle starboard are the cylinders controlled by the switch on my engine. If one is firing in gear it's not the switch. Now before we found it my mechanic thought it may be a bad pulser. But you'll need the software to check that.
Ricky
i had a mechanic hook up his laptop to my motor an he said my motor running great.. compression good, spark good , TPS good. Just doesnt make sense wen i know this motor is capable to be running at 5500 rpms can my injectors be clogged an cause restriction? Can it be the high pressure pump? While my mechanic was at the boat we didnt get to go for a sea trial to check high pressure to see if pressure drops at WOT but wats confusing me is that i run WOT (4200rpms) an if i try to push it any further the rpms stay the same an the motor will surge within Minutes like its starving for fuel ?
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Old 10-03-2018, 05:36 PM
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Originally Posted by Aliboy View Post
Tuner needs to be checked with the leg off. It is probably the least likely of the options though so I would look at all the stuff you can on the water first.
gunna keep that in mind wen i do pull the boat this season
ill respond to thread if ur wondering if the problem gets resolved..

thankyou
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Old 10-03-2018, 06:04 PM
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Your motor is not running great if its only getting 4200 RPMs. Curios to know where you are you located? I just went thru this: ATTN: YAM EXPERTS: Is this an OX66 or HPDI? Why different props for same HP rating?

I finally unbolted the motor an replaced it with a 1995 carb'd yam motor, As you will read in the above post I did just about everything recommended online with no results, just out all the money in Yamaha parts.

It aggravates me when people say things like "get a new motor" because that not always an option for everyone, but in this case due to the age of that motor and the price of the repairs I would start looking for a good deal on something different and less complicated. For example if you need the high pressure pump repaired I understand there are only three places in the country who can rebuild it and it cost $800+. The VST is 700 for JUST the pump, not the tank. That specific part must be OEM yamaha or you it will likely fail.

Chris
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Old 10-03-2018, 07:19 PM
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google mystery filters on HPDI, I found all the basket filters and O rings online for under 30 bucks and spent an hour and a half replacing them, solving the problem. post back back after researching!
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Old 10-03-2018, 07:57 PM
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Originally Posted by nevets View Post
google mystery filters on HPDI, I found all the basket filters and O rings online for under 30 bucks and spent an hour and a half replacing them, solving the problem. post back back after researching!
I wanna change out those mystery filters located on the high pressure but my boats in the water an i dnt have a trailer is this job possible while being at the dock or should i not even attempt this ?
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Old 10-03-2018, 08:01 PM
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[QUOTE=HydraSport2000;11870053]Your motor is not running great if its only getting 4200 RPMs. Curios to know where you are you located? I just went thru i finally unbolted the motor an replaced it with a 1995 carb'd yam motor, As you will read in the above post I did just about everything recommended online with no results, just out all the money in Yamaha parts.

It aggravates me when people say things like "get a new motor" because that not always an option for everyone, but in this case due to the age of that motor and the price of the repairs I would start looking for a good deal on something different and less complicated. For example if you need the high pressure pump repaired I understand there are only three places in the country who can rebuild it and it cost $800+. The VST is 700 for JUST the pump, not the tank. That specific part must be OEM yamaha or you it will likely fail.

Chris[/QUOTE

Im located on long island NY
im gunna have my mechanic come with his computer an do a test on the HP to soo how its doing the VST hold 50psi steady
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Old 10-04-2018, 03:35 AM
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[QUOTE=82mako250hpdi;11870399]
Originally Posted by HydraSport2000 View Post
Your motor is not running great if its only getting 4200 RPMs. Curios to know where you are you located? I just went thru i finally unbolted the motor an replaced it with a 1995 carb'd yam motor, As you will read in the above post I did just about everything recommended online with no results, just out all the money in Yamaha parts.

It aggravates me when people say things like "get a new motor" because that not always an option for everyone, but in this case due to the age of that motor and the price of the repairs I would start looking for a good deal on something different and less complicated. For example if you need the high pressure pump repaired I understand there are only three places in the country who can rebuild it and it cost $800+. The VST is 700 for JUST the pump, not the tank. That specific part must be OEM yamaha or you it will likely fail.

Chris[/QUOTE

Im located on long island NY
im gunna have my mechanic come with his computer an do a test on the HP to soo how its doing the VST hold 50psi steady

Using the right diagnostic equipment these engines are fairly straight forward to trouble shoot. The cheap fuel pumps on ebay work well. I have used them with good results several times and the high pressure fuel pumps are very reliable. You should never need to send it out. You really need to check fuel rail pressure then vst pressure at speed. When my Tuner fell apart the engine sounded a little different and lacked power across the rpm range. It barely made it onto a plane but once it did I could make it to about 4000+/-. It would definitely be helpful to know what prop you're running.
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