"09" 250 HPDI melted exhaust tuner

[SMG]

Went to have my 100 hour service done and my service tech calls me and says the exhaust tuner was melted. Asked me if my motor was runnin rough? I never had a clue, had it out the day before and it ran like always. anyone run into this before and what causes this? Tech says they have replaced a few already. Sounds like a big job and im glad its under warranty. Whats all involved in changing this out and how much would it cost if out of warranty?

[Rich Z]

New tunner and some gaskets plus a bunch of labor. Complete removal of powerhead and mid section. I’m guessing on price $800 +.

[Carlos H]

What causes it to melt besides it getting too hot?????

[SMG]

No one seems to know what causes it. At least thats what I gather so far.

[toledo freak]

have never had yamaha not cover this, several that i have done have had loose and missing tuner bolts causing improper water flow through the tuner

[SMG]

Well thats good news I guess. I just dont want it happening out of warranty. I wish I could find some pics of this tuner! Any websites w/ pics?

[toledo freak]

i have had it covered even out of warranty, yamaha is awesome

[SMG]

I wonder if I could get away with putting on Hydro-Tecs Mega exhaust tuner? Any benefits or suggestions? Since they are gonna tear it down anyway, I wonder if it would be worth it? Probably void the warranty though.

[hooken203]

Older mercs had a problem with this when the holes around the tuner would get plugged with small stones and cut off the water flow to the tuner. If you are thinking about a performance tuner now is sure the time to do it.

[stratoveros]

SMG I just purchased a Hydro Tec 5300 Tuner for my 09 250 HPDI and ended up trading for a SHO. I am going to return the tuner to Hydro Tec for credit, but if your interested in it I will take $220 TYD. At that price you will save $25-30. As far as warranty it will be as good as your dealer if he will stand behind you it wont be an issue . Hyrdo Tec told me it does not void Yamaha warranty installing their tuner. If interested you can e-mail me at deyockel@scottsboro.org

[rid 05 198]

Melted tuner but it ran fine???

[SMG]

Thanks stratoveros but Yamaha has sent the replacment already. Yea it ran fine, had it up to 72 mph on GPS the day before on Fork. Made a mile trip down the lake and fished a bit and made the run back. No signs of trouble.