02 200 HPDI can't get on Plane

[mikey11741]

I got a late start to the season to add insult in injury, I can't get on plane. A little history about the motor with 255 hrs on it. 2nd year with boat, last year I've had problems with the needle valve sticking if I let the boat sit for 2 weeks (happy wife, happy wife! goes camping). This season, I slightly sanded the orifice where the needle valve sits and pumped 12 gallons of water from the fuel tank.
I drop the boat in yesterday and take the family for a ride, NOT. As I tried to get on plane, the motor seemed like it was starving for gas. Copy and paste video link from Youtube- https://youtu.be/iVMltvLhiZ0.

I checked fuel separator and clear plastic gas filter under cowl and no water found. Also changed silver filter above VST tank. Connected YDS system and here is the following report. I have indicated places in file where I think I might have a problem.

Note: Diagnosis Record - Cylinders 2 & 3 were off. But =- when I revved in neutral to 1500rpm, cylinders 5 and 6 turned off. Not sure if this is okay or not.

When I did an Active test-cylinder check, cylinder 1 - stalled the engine within 10 seconds of the 20 second test.
Cylinder 2 and 3 are off - No change in rpm.
Cylinder - 4, 5, rpm dropped, but picked up, then eventually stalled motor.
Cylinder - 6, rpm ran fine.


Save date June 10 2017
ECM No.: 68F8591A20

Diagnosis
Code Item Result Condition
22 Atmospheric press sensor Normal
13 Pulser coil Normal
14 Crank position sensor Normal
15 Water temp sensor Normal
18 Throttle position sensor Normal
19 Battery voltage Normal
23 Intake temp sensor Normal
25 Fuel press sensor Normal
26 Injector Normal
27 Water in fuel No
28 Shift position switch Normal
44 Engine stop lanyard switch Off

Diagnosis Record
Total hours of operation 257
Code Item Occurred
26 Injector 256.6
22 Atmospheric press sensor 256.5 - ?
28 Shift position switch 241.6
27 Water in fuel 226.5

Engine Monitor
Monitor Item Result Unit
Engine speed 650 r/min
Fuel pressure (5.0±0.8) 5.03 MPa
Fuel pressure (725±116) 734.92 psi
Atmospheric pressure 1258.6 HPa - ?
Atmospheric pressure 37.3 inHg - ?
Ignition timing BTDC 4 deg
Battery voltage (12-16) 13.11 V
Oxygen sensor voltage (0-1.0) 0.16 V
TPS voltage (0.5-4.5) 0.63 V - ?
Throttle valve opening (0-90) 2.6 deg
Fuel injection duration 1.06 ms
Water temperature (below 90) 34.5 °C
Water temperature (below 194) 94.1 °F
Intake temperature (below 70) 28.5 °C
Intake temperature (below 158) 83.3 °F
Electric oil pump Low
Firing of cylinder #1 Yes
Firing of cylinder #2 No
Firing of cylinder #3 No
Firing of cylinder #4 Yes
Firing of cylinder #5 Yes
Firing of cylinder #6 Yes
Starter switch OFF
Engine stop lanyard switch OFF
Over-rev control release lead OFF
Main switch ON
Shift position switch ON
Water detection switch OFF
Oil level switch (remote tank) ON
Oil level switch1(engine tank) ON
Oil level switch2(engine tank) OFF
Oil level switch3(engine tank) OFF
Water temp switch (over heat) OFF
Dual engine system switch OFF

Data Logger[Engine operating hours according to engine speed]
Engine speed Time[h]
- 1000 r/min 69.2
1000 - 2000 r/min 131.5
2000 - 3000 r/min 17.7
3000 - 4000 r/min 30.3
4000 - 5000 r/min 8.3
5000 - 6000 r/min 0.1
6000 - 7000 r/min 0
Total hours of operation 257

Data Logger[Data comparison graph]
Engine speed[r/min] Fuel pressure (5.0±0.8)[MPa] Battery voltage (12-16)[V] Oxygen sensor voltage (0-1.0)[V] TPS voltage (0.5-4.5)[V] Water temperature (below 90)[°C]
1000 5.11 13.92 0.69 0.84 38
1400 5.14 16.48 0.1 0.94 36.5
700 5.03 14.36 0.11 0.63 38.5
700 5.07 14.65 0.1 0.63 40
1750 4.99 13.04 0.05 1.13 39.5
1500 4.95 16.26 0.09 1.02 38.5
750 5.07 15.38 0.16 0.63 38.5
650 4.99 13.84 0.1 0.63 41.5
750 5.07 13.92 0.11 0.63 42
600 4.99 13.4 0.2 0.63 42
650 5.03 13.77 0.1 0.63 41
650 5.03 12.38 0.6 0.63 26
650 5.07 12.96 0.17 0.63 34

I need help to trouble shoot this, before wife want's boat gone. Happy to trade wife for tech support.

THanks,
Mikey

[99yam40]

what did you do with the gas that was in the tank with the water?
was it E10?

Did you have the tank cleaned?

I was expecting a pressure reading in PSI

with that much water there is probably a need to have the VST ,LP & HP pumps, and injectors serviced.
lots of screens/filters in things

HPDI motors run on the edge of lean to start out with, running a sick motor can damage it quickly.

find a Yamaha shop with a master tech to have a look.

Rodbolt might comment

[mikey11741]

what did you do with the gas that was in the tank with the water?
was it E10?
I disposed of the bad gas.

Did you have the tank cleaned?
No, thought the dry tank was good enough.

I was expecting a pressure reading in PSI
YDS produced the report.

with that much water there is probably a need to have the VST ,LP & HP pumps, and injectors serviced, lots of screens/filters in things.
I serviced the vst tank myself (very handy guy), and filters associated with fuel lines (silver filter ontop of VST, plastic filter under cowl). Was going to wait until this winter to service injector mysterious filters.

HPDI motors run on the edge of lean to start out with, running a sick motor can damage it quickly. I hope Poseidon is on my side with this one. I've only owned it 2yrs now and unaware of prior issues. I'm finding out the hard way.

find a Yamaha shop with a master tech to have a look.
Suffolk County Long Island, NY. I've been told, Accurate Marine Yamaha are the best.

Any additional help is welcome...

Rodbolt might comment

[rodbolt17]

that engine is on a submarine.
look at the baro pressure.

we need a YDS screen shot at the FAILURE RPM and LOAD.
that engine in N runs on 4 cylinders at idle and 2 cyl above about 1200 RPM.
make sure the shift position switch works when shifted into gear.

[boscoe99]

that engine is on a submarine.
look at the baro pressure.

Or supercharger has been installed. A lot of boost pressure at idle. What will it be with the throttle opened up?