150 hpdi hp pump,2003 Z150TRXB

[03cobia21]

Anyone know what Flagship marine does to rebuild these pumps, I have taken my cover off and removed the screens and still runs the same, starts bogging down bad above 1900rpm, new plugs fouled real quick just water testing engine.
Changed gas in tank, changed water seperator and have been testing with remote tank.
changed vst filter, bowl filter, medium pressure filter, have 50 psi at all times.
So looking at many forums I seen many threads on these pumps, so I took my cover off and removed screens, put back together and water tested no improvement. Will start and idle ok but bogg when throttle up to 1900rpm.
So my dilema, pull pump and send out, or buy new since I have 950hrs on motor. Also should I pull injectors at same time and send out with pump.
I did try to back probe pump sensor but no matter what combination on the 3 pins I either got 5V or 4.5 volts, from prevois threads I should get between 2.8and 3.2 volts, wil this sensor cause the problem?

[03cobia21]

I put the boat in the water and tested it in gear,

[03cobia21]

more info
the boat was tested in the water and in gear for low pressure and high pressure readings.
also compressions checked good
new plugs,etc
guess realquestion is send out with injectors,I here injectors dont like to come out
or buy new pump since high hours 950 and recheck before sending injectors out

[rodbolt17]

myself I would buy a diagnostic test lamp,about 80 dollars, and verify fuel rail sensor issues before trying to remove the injectors.
if you see code 25 you know you have a sensor/pressure issue.
IF the swift position switch has failed OR become unplugged the engine will start but WILL remain in the partial cylinder operation mode.
means above about 1700 the engine only sparks 2 cylinders.
some saltwater use engines I have had to remove the head and drive the injectors out with a small socket and a hammer.
check fuel pressure sensor reference voltage,5 V orange to black, sensor feed back is pink to black.
check feed back voltage with key on engine off.
then start the engine and check again.
if the sensor fails or becomes unplugged the signal is locked at 725 PSI, ign control is normal,idle is normal and top speed can be reached.

[03cobia21]

right now, I have the pump off and notice some contamination in the fuel rail from the outlet side of pump over to the HP pressure regulator # 28. Just small black specks in a depression from the milling of the rail. Also noticed the pump has a outlet valve where fuel reurns to vst. So with this found going to try and clean everything out including Hp pressure regulator put back together, check throttle switch and recheck fuel pressure before pulling injectors and sending pump out.

Rodbolt, I am assuming the regulator bypass fuel back to vst to control fuel pressure but I noticed those return lines are also hooked up to a cylender assembly on the forward side of pump and the outlet valve wich is # 27 in the parts list. So regulating fuel pressure is a combination with some redundency I suspect so not to overpressurize system. There is alot more to these pumps then the filters.

[seahorse5]

There is alot more to these pumps then the filters.

BINGO !

That is why they charge hundreds of dollars to rebuild them back to new specs.

[03cobia21]

Seahorse you sound like you know what they do the pumps, do they come back with a overhaul tag on them with warranty. Why don't you give us some details on the parts changed and testing, does it include the TESTING AND OVERHAUL OF regulator, the drive section? what moving parts are inside,does it have a releif valve etc

$600 BUCKS THATS 60 HOURS LABOR AT $100
GIVE US A BREAKDOWN AND DON'T HIDE THE MARKUP

[99yam40]

I am sure Seahorse does not rebuild them, you may need to contact the people that do to get the info you are looking for

[03cobia21]

I realize that, its just extremly frustating, just look at all the post's on all the forums for these pumps. These pumps are definetly not rocket science. And I relize the business side and the liability but You will find out more from the average joe with pics and trial and error than from a tech that went to school and wont even give a description and operation of the pump, besides what you can read on popular mechanics magazine. I have been to many, many aircraft schools and they dont teach from the remove and replace manual, they provide simplied schematics and flow diagrams and the training manual is just that a training manual. Any body out there willing to step up.

[rodbolt17]

dude you either dont get it or cannot read.
yamaha SPECIFICALLY says DO NOT dissasemble the pump as most parts are NOT offered by yamaha.
the pumps are made by Mitsubishi and apperantly they dont sell many component parts to yamaha.
I have NO clue what Flagship does.
would it be to hard to properly test the rail pressure .
oh mighty aircraft dude, I hope you never wing it when working outside the manual on any airplane near me.
no this is not rocket science, its a simple wobble plate type pump that steps up a 50 PSI feed to a 725 PSI feed.
the average dude cant fix a diaphram pulse pump correctly much less a wobble plate type pump.
however this pump was used on some european and asian stuff outside the marine industry.
yes I have done a handful, even made 2 into 1 once.
dont like it wont write on a workorder that I ever touched it and its 3 times my normal labor rate.
dunno about the airplane side but in MY industry if I dissasemble that pump,after the FACTORY service manual SPECIFICALLY says not to, AND any thing happens.
how would you assume THAT court case is gonna go?????
I carry a 2 million general liabilty policy,has another 1 million as an umbrella.
however there is a negligence clause .
I actually wonder how long YOUR boss would keep you under his insurance if he knew you were making OFF manual repairs to aircraft parts????

[Aleutianwest]

Seahorse you sound like you know what they do the pumps, do they come back with a overhaul tag on them with warranty. Why don't you give us some details on the parts changed and testing, does it include the TESTING AND OVERHAUL OF regulator, the drive section? what moving parts are inside,does it have a releif valve etc

$600 BUCKS THATS 60 HOURS LABOR AT $100
GIVE US A BREAKDOWN AND DON'T HIDE THE MARKUP

Thats 6 hrs labor at 100

[rodbolt17]

as far as markup?
dunno.
why do some of the inline yamaha fuel filters cost 180 dollars?
why does the new EPA approved fuel line/primer buld kit cost 120 dollars.
why does just the fuel primer bulb for the FV8 motors cost 120 bucks?
I am a tech, the price isnt determined by myself,my service manager now the owner.
its mostly cause no other vendor makes it.
I did machine aircraft parts for Boeing,General Dynamics and lockheed for a few years, I can tell you why some of those parts cost ay more than cutting pipe threads at ACE hardware.

[seahorse5]

Seahorse you sound like you know what they do the pumps, do they come back with a overhaul tag on them with warranty. Why don't you give us some details on the parts changed and testing, does it include the TESTING AND OVERHAUL OF regulator, the drive section? what moving parts are inside,does it have a releif valve etc

$600 BUCKS THATS 60 HOURS LABOR AT $100
GIVE US A BREAKDOWN AND DON'T HIDE THE MARKUP

What grades did you get in math class ?



Here is the Yamaha phone number and the source of all knowledge if you know how to work the system. 1-866-894-1626 Knock yourself out.