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  1. #1
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    225 HPDI rebuild

    Got a 2004 Yamaha 225 3.3L HPDI with burnt #2. Figured I would do a rebuild thread on this one being you don’t see much info on these, and thought maybe some others would be interested to see what’s on the inside as I did. Cust sent injectors to Brucato, and sure enough #2 injector was toast along with another one. So at least we know the cause of the melt down.
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    It has 3.3661 bores, pistons measure 3.352, 0.009 piston to cylinder wall clearance.
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    Two transfer ports opening at 118 atdc (124 degrees duration) and one large booster port with main port opening same as transfers, with nice angle on top opening at 116 atdc.
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    Exhaust port has compression notch with really large angle on top center of port. Main port open at 97 atdc (166 duration) and including angle opens at 94 atdc (172 duration)

  2. Thanks engineermike thanked for this post
  3. #2
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    Click image for larger version. 

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    Pisons have rounded top and heads have angled squish bands.
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    Metal caged rod bearings and wrist pin bearings. I number bags to keep up what bearings come from what cylinder.
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    Etch numbers in rods and caps to keep them matched up properly and cylinder they came.from

  4. #3
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    Click image for larger version. 

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    Center main bearings
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    Brass oil pump drive gear
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    No obstruction from rod slots
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    Has closed exhaust chest, gonna get some pics and descriptions when get back in shop

  5. #4
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    As I start repair, post some more pics. If anyone wants to see any particular part I don’t post or any info that I may can get just let me know.

  6. #5
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    Cut the chest open

  7. #6
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    Lol, believe me, I’m itching to start tweaking , but I’m gonna for the most part leave this one alone. Gonna try to get some pics of it, may have to wait to once I get her cleaned up so pics will show. Gonna try and use boroscope and get some pics if it’ll show up worth a hoot.

  8. #7
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    Good looking motor

  9. #8
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    I like the quality of it, well built. Way too much junk on top of it that not really caring about. The thing doubles in size and weight with all the junk on it. I’ll get some pics of intake and front half also.

  10. #9
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    Had a quick look at a vmax , 300, 350 I can't remember but a beast of a motor.

  11. #10
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    Subscribed. I ran a pair of 3.3 with hydrotec stage 2 kits for several years. The motors were a solid design but I think they just cheaped out on the engine management. There weren’t enough sensors to reliably accomplish what they were trying to do. That, and something like 12 fuel filters that could clog.

  12. #11
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    Yeah, all the screens and filters was my first thought of possible cause. He had the screens in vst replaced, all other screens cleaned and filters changed last summer at another shop for running bad. That was the beginning of the end, injectors probably should have been checked then, they probably got the varnish and whatever else was in the screen back then, being two tested bad at this time. He also noticed he was down on performance, but was blaming it on a new prop. Any time something changes in way one runs or performance wise, it’s always a good idea to find out why and not just keep running it. This motor could have more than likely been saved by doing so. I’m gonna completely go through the fuel system on this thing, I’ll post pics as I go and try to point out all possible problematic areas.

    There is is a lot I like with the heart of this motor, and can see where it could easily be bumped up to the higher hp models with very little efffort.

  13. #12
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    Has a vibration dampener on the bottom of crank
    Click image for larger version. 

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    Front half and reed plate, angled downward
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    Heads
    Attached Thumbnails Attached Thumbnails 3B360327-4D89-454C-8867-FDD1FA80CFAD.jpg  

  14. #13
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    Exhaust chest, hard to get good detail on pics. But has a flat floor, that is located on the side near cylinders, has pretty steep angled ramps downward(you can see best from mold in pic from cooling side), and with floor being toward the cylinders the pockets are fairy shallow.
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  15. #14
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    Scope

  16. #15
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    Your welcome, I’ll post more pics as we begin building it back up. Tried to get a pic on scope, but it’s magnified too much and all you can see is carbon. I did try to get scope pic of big angle on top of exhaust port
    Click image for larger version. 

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    From what I’m seeing with just 21 degrees blowdown where it counts, and a healthy 124 duration on transfers. The exhaust port is where they are choking the 225 down porting wise compared to the larger 250 and 300 models.
    Cust just contacted me and asked if while it was apart, could we do some things to help it pull off corners . So we may May a few minor changes to it, he wasn’t really willing to pay the cost of some of kits from hydra tech offers. But we gonna see what we can do with these old hands and keep it economical for him

  17. Likes W2F a V-King liked this post
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