200 HPDI Yamaha Rebuild a SUCCESS!
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Thread: 200 HPDI Yamaha Rebuild a SUCCESS!

  1. #1
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    200 HPDI Yamaha Rebuild a SUCCESS!

    My #4 cylinder blew a hole in the top of my piston on Lake Austin back in Sept. *See original post with pics in this section. *After several months of turning wrenches on weekends and traveling around the world on business I was finally able to set out on Lake Austin today for the (re)maiden voyage. *I did 3 hrs of break-in on the new piston running it at varied speeds from 1500 rpm, to 3000 rpm, and then to 3/4 throttle in 1 hr intervals. *I happy to report she ran GREAT and never missed a beat the whole time out. All of the dash gauges reported everything running as expected. *My laptop confirmed all systems were running fine as well using the Yamaha diagnostic tool connected to the ECU on the motor and the USB port on my laptop.
    What a relief! *I'm proud to have this project under my belt and successful. *Now I can get back to fishing and hanging out with all the ABF crew again!

    PS. *I spent less than $800 on parts including a $300 fuel injector (not a typo, $300 for one (1) injector!!). * *South Austin Marine wanted $5k+ for the rebuild or $7k for a new powerhead * *No thanks.

    -Rich
    RO likes this.

  2. #2
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Rich, I know you didn't put that thing back together stock! Did you add some extra ponies back there?

  3. #3
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Congratulations for a job well done. A lot of satisfaction when your able to do it yourself. Cheers!!!
    "There is only one thing wrong with a fishing day--its staggering brevity. If a man spent all his days fishing, life would seem to be a swift dream." Zane Grey

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  5. #4
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    As always it's a blast teaming up with you. But it's even better to hear that you got your sled back in action.

    Good job bro. See you on the water!

  6. #5
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Juke,

    Haha, you know me too well! I looked hard at upgrading the TB, reeds, and exhaust when I did the rebuild. *From what I could find, these upgrades do best on the 3.1L HPDI 200. *Mine is the 2.6L which is already power optimized to deliver 200 HP. *The 3.1L 200 is "de tuned" from the factory so to speak so adding these upgrades is worth it on the top end. *I chose to go the stock route and save a few grand since I probably wouldn't see the return.

    -Rich

  7. #6
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Rude & BassTrack,

    Thanks guys! It was a fun project doing the rebuild. I learned a lot about outboard motors in the process.

    Thanks, Rude, for the back seat during the recent HHJ Finale and FOM Open! It's always a lot of fishing fishing on Team Rude518.

    -Rich

  8. #7
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Congrats Rich!

    You saved a ton of $$$$. How many hours of labor do you think you spent? Since you were so successfull, I may try rebuilding mine the next time it blows.

    Chris
    poncho703 likes this.

  9. #8
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Rich, that is impressive, congrats man!


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  10. #9
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Congrats Rich, glad you are back in action, look forward to seeing you on the water! JR

  11. #10
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    Re: 200 HPDI Yamaha Rebuild a SUCCESS!

    Quote Originally Posted by 262F262A2B2B2037450
    How many hours of labor do you think you spent? *
    ~20 hrs. *Of course, I went slow since it was my first outboard rebuild. *I could probably do it in half the time next time. *Keep in mind I've spent 100's of hours turning wrenches on cars and motorcycles. *I also got some good first-timer advice from Swimbait's mechanic friend. I would not recommend this project for a casual mechanic.

    yamahaoutboardparts.com has a lot of good info on their message boards and is a great parts supplier at below retail prices. *They also have good schematic drawings that you can enlarge to see the small details on the various sub assemblies.

    If you're considering a rebuild, give me a call. *I'd be glad to share with you what I learned and the options I considered.

    Swimbait, thanks again for letting me borrow your Clymer's manual. *I ordered one from their website and should receive it soon. *Let me know when and where and I will gladly return your manual and buy you lunch.

    -Rich

 

 
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