Clunking noise in Gear at Idle in HPDI's

[TexasCub]

Since I bought this boat I was immediately made aware of this sporatic gear backlash clunking sound that is heard when you put the motor (2005 200 HPDI)in gear and just putt around (like leaving the ramp area) under no extra throttle. The noise goes away immediately once you raise the rpms with the throttle even a little bit. Using the search function on here there are dozens of posts about this noise and even one guy recorded it and has the sound so it can be easily heard. Is this just something normal that I have to live with? If it is normal then I am okay with it, would love to hear other guys that have this noise chime in to make me feel better.

[Rich Z]

Sounds like you need to turn up idle rpm a little.

[TexasCub]

Idle is well within spec, I dont want to turn it up or I'll be chewing up some gears.

[Rich Z]

I guess you will have to live with it. Ear plugs will help.

[TexasCub]

I can live with it just seems that there has been so many posts on this topic that maybe someone found a fix. So far these are the things that have been suggested per the search feature

1. Turn up the idle
2. Check and adjust Cowl latches
3. Make sure white spacer and metal cover on drive shaft under water pump housing installed while pulling up on driveshaft
4. Switch to an Aluminum prop
5. Check jackplate center bolt for tightness
6. Check prop nut for tightness


So far none of those reccomendations fixed the noise for anyone as fas as i can tell from other posters that have this noise. To me it sounds identical to my Merc 250 XS with the metal hub though they did come out with snubbers you could put on the hub to quiet it down. Just hard to believe there isnt a fix for this especially since it doesnt just affect the 200 but lots of guys with the 225's have complained about it too.....

[Rich Z]

"The noise goes away immediately once you raise the rpms with the throttle even a little bit."

So, I suppose that turning up 50 rpm won’t help? The rpm varies with how cold or hot the motor is or how deep the motor is in the water. If you trim it up it will idle easier and higher and the opposite goes if you trim it all the way down. Nothing is written in stone as far as the service manual goes. Heck, your tac maybe off by a little bit. Believe me, it won’t hurt anything to try unless you just don’t want to know if it will work or not. As far as the gears are concerned; you are not shifting the gears. They always stay engaged with the pinion gear. Only the clutch dogs reverse the direction of the prop shaft. If you ever had a LU apart you would know there’s nothing to worry about.

[TexasCub]

Thats a good explanation Rich, I'll try it! I was just scared to make the gear engagement too harsh by turning up the idle.

[hawgherder]

Pull on the prop and check the end play then check the drain plug magnet for chunks of metal before doing anything.

[TexasCub]

Already did that, I changed out the gear oil and there was nothing to be concerned with on the drain plug. You can pull out on the prop just a wee bit in and out

[tzx200]

its normal guys mine is a 2005 and does the same thing since i bought it. clunks into gear and runs rougher than normal at idel because of the 4 cylinders. make sure your Lower Unit has fresh oil, change your water fule seprator and if you dont have one install it now, change your fuel filters and replace your low presuure fuel pumps if they are leaking and the filter above the fuel canister.

then run it like you stole it........

[sktrbtr]

I have not experienced this myself but have read that on a water pump install if you dont pull up on the shaft when you put the stainless steel crush ring down on the impellar housing that you can get a knocking noise at idle. Have you had a pump installed recently? Hope this helps.

[TexasCub]

That reccomendation has been attempted and made no difference. I am thinking this is just an inherit sound on some year models. I had a 2004 Yamaha F225 4 stroke on a center console that made the exact same sound under the exact same conditions.

[rtinplnc]

Do you have a hotfoot installed with this boat? If so, I was told that if you just put it in gear without pushing the hand gear lever al the way down it would skip like that. I had it happen with me on one of my first trips out. I called my dealer from the water and he walked me through it. I've never had it happen since. So, I suggest you try pushing the gear lever all the way down when at idle if you have a hotfoot installed and see if it goes away, mine did.

Hope this helps.

[leethefishking]

I just did a water pump install on my HPDI and did not pull up on drive shaft while installing ring and I have no clunking noise. Should I be concerned and redoo the pump or is it fine the way it is.

[TexasCub]

I didnt have any play to speak of that would allow me to pull up on the driveshaft when I changed mine out. I wouldnt worry about it.

[bassfinder1]

What you are hearing is prop rattle. If you are running a yammy prop remove it and replace the washers. Yamaha has a new 2 piece washer system now that is just for this problem. The prop will feel tight but at idle the thrust washer actually is rotating a little bit. I have had more people bring their boats to me for this problem, replace the washers and fixed. Hope this helps

[TexasCub]

Part numbers????

[Charlie206]

99999-03848-00

[TexasCub]

What kind of spacer is this that cost $120?

[TexasCub]

Oh it appears to be a 2 piece thrust washer.