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  Yamaha 225 Four-stroke Recall: A fix

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Author Topic:   Yamaha 225 Four-stroke Recall: A fix

fno posted 01-30-2005 12:21 PM ET (US)
For anyone else who might have a problem with the throttle on their Yamaha 225-HP four-stroke not going back to neutral, there is a recall that has been announced by Yamaha. (Probably affects the Mercury 225-HP in black paint version, too.) As of Friday, January 28, 2005, they do not have an expected ship date for the repair kit specified. I decided to take matters into my own hands as I have not had much time to use the boat lately and need it for the "Beercan Island Rendezvous" next month.
The factory fix is to replace the three-arm throttle linkage at the top of the motor, just under the fly wheel and timing belt. The linkage is stiff and does not allow the throttle-body return springs to close it. According to Yamaha the ball ends are binding up (not correct, but I did put a drop of oil on them anyway).
The real culprit is in the balcrank assembly just under the flywheel. This assembly consists of a stamped metal arm with a ball bearing pressed into it, a stud that bolts to the motor for the balcrank to pivot on, and the three rods with ball ends are attached to it. In the recall this whole assembly is replaced including the bolt and washer (a bulb lights up...) .The problem is twofold:
--A: The grease in the ball bearing is dried up.
--B: the washer used to mount the assembly to the motor is too big. The O.D. of the washer can bind on the balcrank I.D. as it is a stamped metal part.
I pressed the bearing out, pried the plastic seals off with a scriber point, then cleaned the old dried up grease out with Gumout Carb Cleaner and compressed air. I re-lubed the bearing with some "good grease" and a drop of 3-in-1 oil, put the seals back on. I had to remove the stud that the bearing is pressed on to accomplish this. I did all my pressing "out" with a brass punch and hammer, the pressing "in" was done with an oridary bench vise. Also, try not to mess up the seals too much.
I tossed the washer and put in a new stainless washer with a slightly smaller outside diameter, also putting some Loktite (blue) on the bolt threads. If anyone wants a copy of the recall notice, let me know, I can fax it to you.
seahorse posted 01-30-2005 01:44 PM ET (US)

I've done a couple of the recall throttle rods already.
The recall bulletin only says to replace the bolt and washer holding the bellcrank since it is a "self-locking" style. I don't doubt that you found a sticky bellcrank bushing, but I haven't seen that yet, though I give it a shot of lube while apart.
You can feel the "stickiness" on each of the ball joint ends on the throttle rods, even a shot of spray didn't help them much. The new improved rods are super smooth acting and they have a "dimple" on a flat area so you can tell the new style from the old.
fno posted 01-30-2005 08:06 PM ET (US)
I did find the rod ends a bit sticky but not to the point of binding up. What got me was the dried up grease inside the bearing. It has been cold here, so that may play into it as well. The throttle problem was not as bad after the motor ran for several hours also, leading me to believe that the grease loosened up a bit.
jimh posted 01-30-2005 08:39 PM ET (US)
If anyone has a copy of the recall notice full text, please email it to me.
handn posted 01-31-2005 11:23 AM ET (US)
Re: 4 stroke Mercury 225 2004 (Yamaha with Mercury 225 black cover). Our 305 Boston Whaler 2004 has 225 4 strokes and we live out of the country and it is impossible for us to utilize dealer service. Could you e-mail us the recall on the throttle problem and/or direct us to the yamaha repair information. We did review the forum information and appreciate additional help and information. Also tried to find the recall information onthe Yamaha site and found nothing. We need help thanks
fno posted 01-31-2005 04:27 PM ET (US)
Jim, I only have a paper copy. I tried to get the same info from the Yamaha website but there was no recall info available. I also tried to turn the paper into a PDF, but that did not work either. The number of the recall is: O2004-010 if anyone has better luck than me.
Joe Kriz posted 01-31-2005 04:33 PM ET (US)
fno,
If you can copy it and send it to me via email, I should be able to convert it to a .pdf...
BlackMax posted 01-31-2005 06:19 PM ET (US)
Reportedly, Yamaha has sold about 30,000 of the F-200/225 engines since their introduction in 2002, including the 4000 sold to Mercury for re-fitting with Mercury cowling components.
kglinz posted 01-31-2005 07:19 PM ET (US)
Do we know that this recall is going the effect the Mercury version of the engine. As I understand it, when the first throttle recall was done, Yamaha just replaced the bushings, but Mercury replaced the entire linkage. The Mercury kit included the shaft, bushings, brackets and arms. My Mercury dealer knows nothing about this recall.

Kemp Lindsey
kglinz posted 01-31-2005 07:25 PM ET (US)
fno
I don't if this url will work, but are you speaking of item 26.... http://www.mercurypartsexpress.com/PartsExpress/ProductSelection/ServiceParts/PartSelectionframeSet.asp
Barry posted 01-31-2005 08:41 PM ET (US)
Yamaha: http://www.uscgboating.org/recalls/recalls_detail.aspx?id=030149T
Mercury: http://www.uscgboating.org/recalls/recalls_detail.aspx?id=030176T
fno posted 02-01-2005 12:16 AM ET (US)
Barry, the links you posted are for another recall issue. This got fixed on my 2004 motor just before I picked it up in March last year. It's basically old news. The one I have posted is the latest problem, and may or may not be the real reason behind the 2003 recalls.
fno posted 02-01-2005 12:20 AM ET (US)
Klingz, your Merc dealer doesn't know about it because Mercury has not announced it yet. Only Yamaha has. When my dealer pressed Merc about it, they acknowledged that there will be a recall just as soon as some parts are available. My delaer said he would put the Yamaha parts on if they become available sooner.
Steve Leone posted 02-01-2005 12:39 AM ET (US)
I have a friend with a Mercury 115 4 stroke, 2004 yr model. It has the same problem. He brought it back twice and it still is not fixed. He gave up and just is "living" with it. I wonder if these new parts may help him? Steve
Barry posted 02-01-2005 07:11 AM ET (US)
http://www.uscgboating.org/recalls/recalls_detail.aspx?id=050003T
kglinz posted 02-01-2005 10:32 AM ET (US)
At least, from the CG Recall, we learn that Yamaha has 34,158 effected motors. Thats a bunch of motors.
seahorse posted 02-01-2005 05:12 PM ET (US)
According to NMMA, only around 29000 V6 4-strokes were sold and in customer hands. The remaining number are powerheads and units not sold.
Figure 30,000 sold since the first model year when they came out in '01. Now we are in '05, so that averages about 7500 per year of both right and left hand rotation F225's and F200's. Compared to the car business, that's only a few days production. The marine business is not that big.
fno posted 02-01-2005 08:00 PM ET (US)
Thanks for the updated info, Barry. This is the one that mine and it looks like a lot of others are subject to.

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Author	Topic: Yamaha 225 Four-stroke Recall: A fix
fno	posted 01-30-2005 12:21 PM ET (US) For anyone else who might have a problem with the throttle on their Yamaha 225-HP four-stroke not going back to neutral, there is a recall that has been announced by Yamaha. (Probably affects the Mercury 225-HP in black paint version, too.) As of Friday, January 28, 2005, they do not have an expected ship date for the repair kit specified. I decided to take matters into my own hands as I have not had much time to use the boat lately and need it for the "Beercan Island Rendezvous" next month. The factory fix is to replace the three-arm throttle linkage at the top of the motor, just under the fly wheel and timing belt. The linkage is stiff and does not allow the throttle-body return springs to close it. According to Yamaha the ball ends are binding up (not correct, but I did put a drop of oil on them anyway). The real culprit is in the balcrank assembly just under the flywheel. This assembly consists of a stamped metal arm with a ball bearing pressed into it, a stud that bolts to the motor for the balcrank to pivot on, and the three rods with ball ends are attached to it. In the recall this whole assembly is replaced including the bolt and washer (a bulb lights up...) .The problem is twofold: --A: The grease in the ball bearing is dried up. --B: the washer used to mount the assembly to the motor is too big. The O.D. of the washer can bind on the balcrank I.D. as it is a stamped metal part. I pressed the bearing out, pried the plastic seals off with a scriber point, then cleaned the old dried up grease out with Gumout Carb Cleaner and compressed air. I re-lubed the bearing with some "good grease" and a drop of 3-in-1 oil, put the seals back on. I had to remove the stud that the bearing is pressed on to accomplish this. I did all my pressing "out" with a brass punch and hammer, the pressing "in" was done with an oridary bench vise. Also, try not to mess up the seals too much. I tossed the washer and put in a new stainless washer with a slightly smaller outside diameter, also putting some Loktite (blue) on the bolt threads. If anyone wants a copy of the recall notice, let me know, I can fax it to you.
seahorse	posted 01-30-2005 01:44 PM ET (US) I've done a couple of the recall throttle rods already. The recall bulletin only says to replace the bolt and washer holding the bellcrank since it is a "self-locking" style. I don't doubt that you found a sticky bellcrank bushing, but I haven't seen that yet, though I give it a shot of lube while apart. You can feel the "stickiness" on each of the ball joint ends on the throttle rods, even a shot of spray didn't help them much. The new improved rods are super smooth acting and they have a "dimple" on a flat area so you can tell the new style from the old.
fno	posted 01-30-2005 08:06 PM ET (US) I did find the rod ends a bit sticky but not to the point of binding up. What got me was the dried up grease inside the bearing. It has been cold here, so that may play into it as well. The throttle problem was not as bad after the motor ran for several hours also, leading me to believe that the grease loosened up a bit.
jimh	posted 01-30-2005 08:39 PM ET (US) If anyone has a copy of the recall notice full text, please email it to me.
handn	posted 01-31-2005 11:23 AM ET (US) Re: 4 stroke Mercury 225 2004 (Yamaha with Mercury 225 black cover). Our 305 Boston Whaler 2004 has 225 4 strokes and we live out of the country and it is impossible for us to utilize dealer service. Could you e-mail us the recall on the throttle problem and/or direct us to the yamaha repair information. We did review the forum information and appreciate additional help and information. Also tried to find the recall information onthe Yamaha site and found nothing. We need help thanks
fno	posted 01-31-2005 04:27 PM ET (US) Jim, I only have a paper copy. I tried to get the same info from the Yamaha website but there was no recall info available. I also tried to turn the paper into a PDF, but that did not work either. The number of the recall is: O2004-010 if anyone has better luck than me.
Joe Kriz	posted 01-31-2005 04:33 PM ET (US) fno, If you can copy it and send it to me via email, I should be able to convert it to a .pdf...
BlackMax	posted 01-31-2005 06:19 PM ET (US) Reportedly, Yamaha has sold about 30,000 of the F-200/225 engines since their introduction in 2002, including the 4000 sold to Mercury for re-fitting with Mercury cowling components.
kglinz	posted 01-31-2005 07:19 PM ET (US) Do we know that this recall is going the effect the Mercury version of the engine. As I understand it, when the first throttle recall was done, Yamaha just replaced the bushings, but Mercury replaced the entire linkage. The Mercury kit included the shaft, bushings, brackets and arms. My Mercury dealer knows nothing about this recall. Kemp Lindsey
kglinz	posted 01-31-2005 07:25 PM ET (US) fno I don't if this url will work, but are you speaking of item 26.... http://www.mercurypartsexpress.com/PartsExpress/ProductSelection/ServiceParts/PartSelectionframeSet.asp
Barry	posted 01-31-2005 08:41 PM ET (US) Yamaha: http://www.uscgboating.org/recalls/recalls_detail.aspx?id=030149T Mercury: http://www.uscgboating.org/recalls/recalls_detail.aspx?id=030176T
fno	posted 02-01-2005 12:16 AM ET (US) Barry, the links you posted are for another recall issue. This got fixed on my 2004 motor just before I picked it up in March last year. It's basically old news. The one I have posted is the latest problem, and may or may not be the real reason behind the 2003 recalls.
fno	posted 02-01-2005 12:20 AM ET (US) Klingz, your Merc dealer doesn't know about it because Mercury has not announced it yet. Only Yamaha has. When my dealer pressed Merc about it, they acknowledged that there will be a recall just as soon as some parts are available. My delaer said he would put the Yamaha parts on if they become available sooner.
Steve Leone	posted 02-01-2005 12:39 AM ET (US) I have a friend with a Mercury 115 4 stroke, 2004 yr model. It has the same problem. He brought it back twice and it still is not fixed. He gave up and just is "living" with it. I wonder if these new parts may help him? Steve
Barry	posted 02-01-2005 07:11 AM ET (US) http://www.uscgboating.org/recalls/recalls_detail.aspx?id=050003T
kglinz	posted 02-01-2005 10:32 AM ET (US) At least, from the CG Recall, we learn that Yamaha has 34,158 effected motors. Thats a bunch of motors.
seahorse	posted 02-01-2005 05:12 PM ET (US) According to NMMA, only around 29000 V6 4-strokes were sold and in customer hands. The remaining number are powerheads and units not sold. Figure 30,000 sold since the first model year when they came out in '01. Now we are in '05, so that averages about 7500 per year of both right and left hand rotation F225's and F200's. Compared to the car business, that's only a few days production. The marine business is not that big.
fno	posted 02-01-2005 08:00 PM ET (US) Thanks for the updated info, Barry. This is the one that mine and it looks like a lot of others are subject to.