200 Yamaha OX66...RPM loss at WOT

big_b16

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I've been testing this thing for a couple weeks now and have yet to find a solution. The engine is a VX200TLRA. With Rodbolt's help, I found I've got a 2003 block. As the title states, I've gone from running 5200-5400 RPMs at WOT down to 4500RPMs. Sometimes it'll get up to around 5000RPM before coming back down other times it'll get up to 4500 and stay there regardless of throttle inputs. I've tested the fuel pressure on the water and it remained 35psi from engine start all the way up to 5000RPM and back down to 4500RPM. I have replaced the VST filter as well as the pressure regulator screen...both had debris on them originally. I also tested the high pressure in the driveway at idle and used a vacuum gauge to test whether or not the fuel pressure regulator would lower pressure when pulling a vacuum. The fuel pressure decreased down to around 30psi as I pulled about 30kPa (~8" Hg) of vacuum. According to the manual I've got, this is expected. I replaced all 3 lift pumps (not 100% they're good...I tested the vacuum on them dry but that isn't worth much since the seals weren't wet). Not sure of another way to test them. I've pulled the O2 sensor, cleaned, replaced all gaskets and o-rings. Tested the O2 sensor and it will fluctuate between 0.3 - 0.6VDC with the engine over 140F. I tested it at idle according to Seloc. I'm not sure which way to proceed. I did check the TPS and it is good (adjusted a small amount, now at 0.51VDC at throttle closed). I did a link and sync in the process. The only thing I've altered a bit is the throttle linkage. When I had the hotfoot set up before, even when I got to WOT, the throttle valves would not be close to fully open. I lowered the stopper so the roller would just hump the steep part of the armature and get to the top side (it's set up so that the distance thrown on the cable will only minimally alter the throttle valves when it gets to that part). Thanks for any thoughts or ideas.
 

sunbird 18

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Re: 200 Yamaha OX66...RPM loss at WOT

If your rail pressure is at 35 constantly, you can eliminate any fuel component before the rail. Did you check the little screens on the fuel injectors to make sure that they are clean? If they have anything in them, you might want to send you injectors out to get them serviced. Heck, might want to do that just to make sure that they are at optimal performance anyways. If the injectors are fine, it can only be an electrical issue. Check your spark plug caps. is it a gradual loss of rpm or a sundden/cylinder loss drop in rpm?
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

It isn't a sudden loss, but when I'm passing 5000RPM and it goes back down, I can certainly feel the slowing. It isn't like a miss...more like the engine is flooding. Sometimes I can feather the throttle and it may go back up to speed. Last 2 times I ran it, it wouldn't get up to speed, but then on the last run of the night...if I gradually crept up to the WOT, it would hold it for a time. With all the stuff that has been filtered by the 3 filters prior to getting to the injectors...how likely is it that they are fouled? I was wondering if maybe a cylinder shuts itself down at 4500RPMs. I thought I read one of Rodbolt's posts that OX66 engines didn't have those types of setups. When I was replacing the VST filters, I pulled the plugs and they were all fouled pretty good with carbon build up (new this spring). That is also when I pulled the O2 sensor and cleaned it (it was also very dirty). Not sure if that has any association. After running it the last couple times, the plugs weren't fouled. I checked the timing and when warmed up and idling, it's at 4* ATDC.
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

Just pulled all the injectors. The screens were all in pristine condition...no debris whatsoever. Any thoughts?
 

cousinabe

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Re: 200 Yamaha OX66...RPM loss at WOT

check your orange spark plug caps are in spec.
unscrew cap off of coil wire and check resistance across. should be between 4k-6k ohms, anything higher needs replacement.

RPM symptoms will exists under a load.
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

Well, I'm underwhelmed that those ends are connected to the coil wires with a screw. I'd much rather see wires that I can solder in to ensure a good connection. Regardless, they all tested within spec. Is there a test to ensure I'm getting enough spark energy? There isn't a plug that's not firing at all, but maybe there isn't enough energy out of one of the coils when the RPMs get high. Any thoughts on how to test that? I guess I'm now working back to the ECU. Which is apparently only has the coil pack as the in-between piece. I've got a new one on order, maybe I could swap that one from cylinder to cylinder when it comes in next week and see if there is any remedy. Keep any thoughts coming if you think of something else.
 
Last edited:

cousinabe

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Re: 200 Yamaha OX66...RPM loss at WOT

link and synch done with the throttle linkage disconnected? same for the TPS adjustment? linkage must be disconnected.

Still sounds like a fuel or TPS issue.
Does pumping the primer ball help your situation?

You can T in a vacuum gauge between the lower lp pump and engine mounted filter. make sure you are getting between 1-4" Hg. More and you have a restriction from that point to the tank, less you are sucking air or lp pump needs attention.

Not sure about that hot-foot setup you have, but the butterflies should be fully opened at WOT.
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

I didn't disconnect the linkage for the throttle when adjusting the TPS. I'll do that this afternoon. Can the HP fuel pump get enough pressure if there is a restriction downstream? Do I check the vacuum at the problem RPM or at idle on the muffs?
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

Should the throttle arm have the roller all the way to the end of the slot when at WOT? Or should I just eyeball the throttle valves?
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

T-d in a vacuum gauge...holding 3.5"Hg between the check valve and the low pressure pumps. I'll have to wait until tomorrow night to re-do the link and sync with the throttle cable disconnected. Fire off any other thoughts if you can think of any. Thanks again for your help.
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

Re-did the link & sync with the top throttle linkage disconnected. Will it matter if the TPS is w/in spec with the linkage disconnected then out of spec with it re-connected (based on idle screw opening a hair)? My throttle arm was bent a little (the one that connects all the throttle valves) but it was that way when it was running fine a few weeks ago. What I find odd is when cycling the throttle to verify the TPS limits, the #2 fuel injector makes some noise when the throttles open about 1/8 (actually only when #1 opens). Is this normal? Maybe that injector is screwing up? Any thoughts? I wonder if any of you guys have seen this before?
 

cousinabe

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Re: 200 Yamaha OX66...RPM loss at WOT

i would check that VST screen again. Your VST pressure should not drop below 35psi.
Check for debris again.
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

It doesn't. The rail pressure is a constant 35psi. The only time it dropped is when I pulled a vacuum on the regulator (which it's supposed to do). Any ideas on the injector?
 

cousinabe

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Re: 200 Yamaha OX66...RPM loss at WOT

as part of your link and synch, did you do the throttle valve pick-up timing adjustments?
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

Yep...they were pretty good, but I just did them over from scratch. I ran it today...it did stumble one time but the rest of the day I could get it up to 5200-5400 RPMs. The engine maxes RPMs before the throttle plates are fully open since I've got a bit more throttle movement left...I guess I could increase the pitch on the prop...but that'll have to wait for another day. I've got the idle sitting at about 600RPM when in gear at idle and every now and again it'll stall when I start it after sitting and fishing for a while. I repumped the primer bulb and it didn't seem to help much. If I feather the throttle, it'll get up and go. Maybe I'll set the idle RPM up a bit more. I forgot, to keep these from smoking at start you should trim the motor up a bit...correct?
Rodbolt...if you're reading this thread...what do you think about that injector buzzing when opening the throttle? Is this normal ops?
 

PBJohn

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Re: 200 Yamaha OX66...RPM loss at WOT

The injectors will buzz at two diffrent throttle settings. I have a 250 and this is considered normal. I would recheck the O2 sensor at speed. It may show good at idle but at higher RPM it may be going full rich. If your smoking alot that's another indication the O2 may be bad.
 

big_b16

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Re: 200 Yamaha OX66...RPM loss at WOT

A bit harder to test O2 sensor at speed without the test harness. How much are those harnesses?
 

PBJohn

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Re: 200 Yamaha OX66...RPM loss at WOT

Paper clips work just as well just take the time to secure everything and have an extra body to help. If it helps I'm on my fourth O2 in ten years. I can get them to work after cleaning but usually not for long.
 

rodbolt

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Re: 200 Yamaha OX66...RPM loss at WOT

actually if you open the throttle with key on engine off very very slowly they normally wont buzz at all, rapidly and the all fire and thats the buzzing noise your hearing.
at about 3/4 throttle with no engine run signal the ECU goes into a flood clear stage and shuts the injectors off.
the trim up for smoking at start up is strictly for 4 strokes and the engines need to be trimmed up at shut down.
OX66 smokes at start up
carefully follow ALL the steps in the manual for link and sync.
dont skip a step.
 
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