'99 OX66 complete fuel system "flush out"

[seahorse5]

Re: '99 OX66 complete fuel system "flush out"

Check with a large machine shop in your area. There is a "tap burner" that will take care of your hardened steel easy-out.

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Thanks,<br /><br />Is this portable? can (they) cone to me?

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

hello<br /> most tap burners are not portable. I ran one for years at a shop in Cleburne TX.<br /> if the welder is good its not hard. weld a washer and a nut to it. the designe of it is just a water jaket. any scarring can be repaired with epoxy if they are not super gouges. I would call some welding shops. and call the machine shops. wont hurt to ask. we weld them out all the time here in the salt pond. steel rod wont stick to aluminium.<br /> but just think of the lesson ya learened <br /> easy outs that the automotive world uses are a teat on a boar hog here in the salt outboard world .<br /> next time use a quality drill bit. I love the bullet point ones. use the tap drill size or the next smaller for anything less than 3/8ths (10mm) dia bolts and drill it and tap it. helicoil it if you miss a bit.but never ever use easy outs . they swell the bolt in the hole and then snap off. let us know what ya find<br /> but its no worries<br /> its still fixable just gonna cost a bit more. look at the post about autherized dealers in the merc forum

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Was able to get the easy out removed by shattering it with a carbide scribe, redrilled the hole with a bigger drill and used a larger, square "snap-on" extractor and got the screw out!!<br />Whew! I will never do that again!<br /><br />Anybody ever replaced the impeller and thermostat on one of these? ('99 Yamaha 225 OX66)<br /><br />Thanks,

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

uep<br /> maybe once I did. why ?

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Thought it might be a good idea with along with all of the other work. Does the Yamaha manual give a pretty good description of the process?<br />Any tips?

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

nope<br /> it sucks<br /> do a search on this forum. I gave a complete step by step procedure. its rather long but includes all tools and tips. I think it was for someone with a 95 v4 but its the same procedure except the 250 has no speedometer tube.<br /> if you cannot find it I can do it again but it will take a day or so.

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Thanks,<br /><br />I found the link on the impeller replacement.<br /><br />I greatly appreciate the help you and others have provided. Had this help not been available as a resource, it would have greatly influenced my decision to purchase these motors.<br /><br />I am purchasing new bolts for the water jacket plate. BTW: what is the torque spec for these bolts?<br /><br />thanks!

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

dont keep many service manuals at home. but its not much<br /> 50 or 60 INCH pounds.<br /> on that motor its just a plate. coat the screws with PST sealent or other teflon pipe dope and install them. plain water proof grease will work as well.

 

[John from Madison CT]

Re: '99 OX66 complete fuel system "flush out"

I once had a small leak on the water jacket gasket on my '98 250hp Ox66. I got out 23 of the 25 bolts, then the last 2 snapped. I had to drill 'em both out, and it wasn't fun.<br /><br />Anyway, word to the wise on Lower unit removal, I had the Yamaha manual and they still MISSED a bolt that is there to be removed. It's NOT the one under the trim tab either, but under the cav. plate and kinda hidden and recessed.

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

its there<br /> when you look at the section that describes the bolts, bolt torque and bolt dressing with the exploded view it shows the bolt and the quantity. its just not clear. but yes its bit a few people. that bolt is used on the V6 4 stroke and all 3.1 and 3.3 blocks.

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Finished the fuel and cooling system service on this engine. Engine wont start. Seems the H.P. fuel pump is not running no juice to the pump. Aditionally the oil transfer switch on the engine does not work either. Are these on the same circuit? Relay?<br />Any ideas?<br /><br />Regards,<br /><br />Steve

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

are all other engine circuits working? trim,start and such? are you sure you properly plugged in any removed connectors at the bottom of the ECU after the grommet change? by oil transfer switch, are you refering to the manual toggle switch?

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Thanks for the reply. Yes I marked and reconnected all connectors at the bottom of the ECU. The oil transfer manual toggle switch on the engine is the one that does not work. I just remembered that I have the electrical lead unplugged at the remote oil tank. But as for the High pressue FI pump, could it be a relay of some sort? Trim, start, and all other circuits are working.<br /><br />Tks,<br /><br />sstarnes

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

hello<br /> if I make it to work today I'll have a look. I think there is a fuse for the pump. I cant remember if there is a relay. if there is a relay it will be under the electronics panel but I dont think there is a dedicated fuel pump relay. test for 12v on the pump red wire to ground with the key on engine off. the blue wire is toggled to ground inside the ECU. that ground is normally open with key on engine off. thats how the pump run for 5 sec at key on works.the big resistor just above the airbox drops voltage so the 2 speed pump mode can run. test continuity of the resistor. cant remember the wire colors but ya cant miss it. has a caution tag on it. check all the fuses in the fuse holder assy.

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Thanks in advance for the help!<br /><br />sstarnes

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

Turned the key over to start and could hear the HP FI pump run for the 5 seconds. but still no start. Resistor OK, Getting good fire, just no fuel to the clys.

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

test the high pressure rail for pressure.

 

[sstarnes]

Re: '99 OX66 complete fuel system "flush out"

What is the best process to do so?

 

[rodbolt]

Re: '99 OX66 complete fuel system "flush out"

use a EFI high pressure tester on the schrader valve on top of the VST.<br /> you can buy one at napa for 60 or so. you may be able to rent one at some places. if it does not have 35 psi on the rail it may or may not run. wont run at all below about 20 psior will run very poorly. with the key on engine off, test for 12v on all the injector yellow/red wires as well. they are hot all the time if the key is on. the circuit is completed inside the ECU.