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  1. #1
    Bass Banger MWeb's Avatar
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    DIY: POPPET VALVE REPLACEMENT **Photos with Instructions**

    This is a Poppet Valve Replacement on a 2004 150hp OX66 EFI........

    Replacing Parts: Spring, Valve and Gasket

    Yamaha Part Numbers: 6G5-12416-00-00, 90501-16M11-00, 6G5-11382-A1-00

    The location of the Poppet Valve is on the back of the engine, between the cylinder banks down on the bottom on the engine below the Wire Loom.

    Parts you need to remove is the Wire Loom Cover (black cover on the back of the engine) Photo 1:




    The 4 screws you will remove will be black like these:




    Remove this cover:




    Next remove the wire loom screws:




    The 4 screws look like these:




    Now slide the wire loom up (orange arrows show the direction, the green arrow points at the poppet valve location)




    Here is the location of the poppet Valve Location right under the wire loom once you slide it up:




    Remove the two screws and you will see the spring:




    Remove the spring and OLD poppet valve: (here is a photo of the old poppet valve and spring setup)




    Now replace with the NEW poppet valve and spring setup (the mushroom side goes IN towards the motor and the internal rubber grommet):




    The eastiest way I found to do this by myself was to keep the wire loom raised at all times, put the new style mushroom head in towards the motor, put the gasket on the back piece and then put the back end of the spring in the cover and then by hand angle the spring into the back of the mushroom head in the motor and push forward a little, check to see the poppet valve and spring are all alined properly on each side.



    Now once that is aligned and in, you need to slide both screws in on each side and make sure the gasket is lined up on the back cover and try to thread one of the screws in a quarter of the way and then the next. Once again make sure everything is aligned properly. Then tighten the screws halfway side to side and do not tighten one screw all the way and go to the other side, keeping the gasket aligned properly.


    The end result is the motor pissing lazer beams:


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  3. Member
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    #2

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    Awesome wait till you see your water pressure gauge smile at you when your at WOT.

  4. NC Bass Club/Yamaha Motors Moderator BuzzB8's Avatar
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    #3

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    FYI...if you remove the two bolts with the number "9" on them, you can remove the black wrapped looms out of your way to get a better stab at the poppet cover bolts.

    Good pictures.

  5. Member
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    #4

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    Great job, thanks.......

  6. Member
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    #5

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (TomzRanger)

    This is great needs to be pined


    Stratos 285XL
    Yamaha VMax 150
    USAF 1968-1989


  7. Will fish for food! headhigh's Avatar
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    #6

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (Stratos Steve)

    <table width="90%" cellspacing=0 cellpadding=0 align=center><tr><td>Quote, originally posted by Stratos Steve &raquo;</td></tr><tr><td class="quote">This is great needs to be pined

    </td></tr></table>

    Absolutely!

    Brian Skeens

    2015 Bass Cat Margay
    2015 Mercury 150 4 stroke
    8" Slidemaster
    25p Tempest Plus

  8. Bass Banger MWeb's Avatar
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    #7
    Thanks guys, I saw the old photos were the size of my finger nail and the thread seemd outdated but still had good info, I thought these photos and instructions would help more though.

    Btw, The old poppet and spring had crud on it and in the chamber there was crud, this was a replacement that was needed a while ago.

    Hopefully this helps everyone........ :)

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    #8

    Re: (MWeb)

    Someone stated this before and it helped me dramatically but I'll repeat it. Once your ready to put the cover assembly back on use a wooden dowel cut to size from the cover to the lower cowling and wedge it in to hold the cover while you put the bolts in. It acts as another set of hands.

  10. Member Texas Larry's Avatar
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    #9

    Re: (wamma)

    Here is a picture of some of the tools I found have made this operation much easier on my HPDI.

    The flex extension and the nutdriver socket came with a drill bit set - it makes it much easier to get to the bolts than with your fingers. The other is a length of 1/4" dowell that I cut to length. It fits in the indention on the poppet valve housing, and then I wedge it against the inside of the engine housing. It holds the spring in until I get the bolts through the gasket and get them started. As stated above you need to insure the poppet valve is aligned properly before you tighten it down or it will not seal and you won't have the water pressure you need.


  11. Member kk4iz's Avatar
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    #10

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    is the same for a 2006 HPDI 250 ? And what did your water pressure at idle and WOT go form to?


    12 lbs 9 oz caught on 4/28/1975 Lake Eufaula

  12. Bass Banger MWeb's Avatar
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    #11

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (kk4iz)

    <table width="90%" cellspacing=0 cellpadding=0 align=center><tr><td>Quote, originally posted by kk4iz &raquo;</td></tr><tr><td class="quote">is the same for a 2006 HPDI 250 ? And what did your water pressure at idle and WOT go form to? </td></tr></table>

    Why are you giving the roll the eye face.......?

  13. Member kk4iz's Avatar
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    #12

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    Why what does it mean to you??!! hope it didn't offend you. Just was not sure if the HPDI 250 was up dated and how much did it improve the 150.


    12 lbs 9 oz caught on 4/28/1975 Lake Eufaula

  14. Bass Banger MWeb's Avatar
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    #13

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (kk4iz)

    <table width="90%" cellspacing=0 cellpadding=0 align=center><tr><td>Quote, originally posted by kk4iz &raquo;</td></tr><tr><td class="quote">Why what does it mean to you??!! hope it didn't offend you. Just was not sure if the HPDI 250 was up dated and how much did it improve the 150. </td></tr></table>

    What year is your motor? I noticed an immediate difference at idle with the headphones on it, boat doesnt go out for the next tournament in 2 weeks, will report back then.

  15. Member joeyd20i's Avatar
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    #14

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    I just did mine on my 2006 hpdi. After pulling it apart I cleaned out the housing wich didn't seem to be that dirty to me, but after putting the new parts and everything back together saw a huge difference in my water pressure. My h2o gauge was showing 10psi at wot before and now it's 20+ at wot.

  16. Member
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    #15

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (MWeb)

    bump back to top, as I am getting ready to do mine

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    #16

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (dannyp)

    Well after a few curse words I got mine done,, I used some red gasket sealant to hold the gasket in place,, Raining here so plan on doing the fuel filter and water separator tomorrow and hook up to muffs or if nice just drive over to the ramp.

  18. Member briansgi's Avatar
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    #17

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (dannyp)

    My OB is a 250HP 2008 Series 2, how much different is the procedure for doing mine then this illustration that was posted? My water pressure gauge has always read low, around 12 PSI at WOT and zero at idle. I'm wondering if I should check/clean/replace my poppit valve?
    2008 Z520/Yamaha 250



  19. Member
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    #18

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (briansgi)

    Brian, if you are getting 12 WOT this time of year, the poppet most likely does need cleaning. I doubt you need to replace anything, just clean out the sand first and see if that works. Your engine will be no different from the illustration above.

  20. Member SkeeterDD22's Avatar
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    #19

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (Charlie206)

    The poppet is a by-pass. Water pressure will be less when water is bypassing around the valve.
    Reasons for water to bypass:
    1) Running hard, it's bypassing doing it's job.
    2) Weak spring (highly unlikely)
    3) Trash in between the valve face and the seal grommet. (common)
    4) Hard,brittle, bad seal grommet (common)
    5) Very inner tip of factory poppet valve is bottoming out against the motor block (common and overlooked, due to number 4)

    Quick free fix, take it out, clean it up, grind 1/4" off of the inside tip of the poppet valve and replace. Problem solved.
    Better fix, do the same and replace the seal grommet while you're in there.

    Replace everything? Parts are cheap, mushroom style seems to work fine. BUT, If you're going to buy parts, make sure a new seal grommet is 1st on the list.

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    #20

    Re: DIY: POPPET VALVE REPLACEMENT **Photos with Instructions** (SkeeterDD22)

    Put it on the muffs and didnt get any stream,, How long should I run on muffs before a stream??? I replace impeller and poppet,,, Hope I got it back together right

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