Oil warning alarm malfunction?

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Bel-Ami

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Hi All, I am new to the forum. Could somebody please help diagnose a problem with a 1999 Yamaha 130 BETO two-stroke-cycle outboard engine 205 hours on the clock. After fitting fuel pump kit, plugs, new oil filters, new thermostats, new primer bulb and new fuel filter and fresh oil, it runs like a dream. I can troll without any problems or I can go to full throttle and it goes like a demon. But, if I go to full throttle, after 4 seconds, the oil warning buzzer sounds, the motor goes into limp mode and the three indicators on the dash gauge flash, signifying that the engine oil tank is low.
I stopped immediately and checked the oil level in both engine oil tank and the motor mounted tank only to find it was full to the maximum mark on the tank. The remote tank had about 8 litres of oil in it. The motor heat felt normal and there was no overheat indication. I went back to the jetty, removed the engine oil tank, cleaned it out, (no dirt in the filter), refitted the oil tank and checked the oil pump operation. It fills the engine tank to the mark and switches off. If I remove the sensor unit from the tank, it works correctly and sounds the buzzer at the low point. It idles fine and gets out of the hole in about 2 secs, but if I go to full throttle, after about 4 seconds, the oil indicators flash and it goes into to limp mode.

The strange thing is that this only occurs if I exceed 4100 rpm. If if run it under 4000 rpm it will go fine all day but the problem remains! Could this be something in the electrics? According to the manual, all three oil bars will flash indicating that the remote tank has oil but the main (engine) tank is low on oil. I have driven with the cowling off and monitored oil level. It maintains the oil level in the engine tank at the maximum mark on the tank. The motor runs at a normal temp and the thermostats are new. Water pressure release valve opens at 18psi at high revs. The battery is fully charged. Charging output at 1500 rpm is 14.8 volts DC.

Sorry to be so long winded but I'm stumped! Any advice would be much appreciated. :?
 
Check the filter downstream of the remote tank, you may be getting a 'flow' alarm instead of quantity. You may be getting sufficient flow to keep the sensor passive at lower rpms, but not when you push it up ... :wink:
 
Curmudgeon said:
Check the filter downstream of the remote tank, you may be getting a 'flow' alarm instead of quantity. You may be getting sufficient flow to keep the sensor passive at lower rpms, but not when you push it up ... :wink:
Click to expand...

Concur. It's a small filter that is usually under the remote oil tank. Used to cost about $11.
 
Hi Curmugeon and Ocnsir,
Thank you so much for your erudite reply. I have changed that little oil filter under the remote tank, but the problem is still there! Where would I find the flow sensor? Any other suggestions?
Thanks again, :?
Bel-Ami
 
That alarm will only occur when the ECU thinks the main tank is empty. Since you say there is oil, then the ECU is getting a wrong signal. When the tank is full, that signal overides the empty signal but when you run at speed and load, you use more oil and I suspect the sensor is dropping a bit below 'FULL'. That is normal but the low oil signal is not. So..
Yo either have a bad connector/harness issue or the tank sensor (main engine oil tank) is bad. It can be checked with an ohmeter. Also check that it's float is sliding up and down easily but I don't think the float ring is the issue.

On the connector of the sensor, there are 4 wires, The black is the common, The high level is black to Blue/white.
The mid level signal is black to Blue/green and the low level signal is black to Blue/red.
Connect an ohmeter to the black and one of the other wires, one at a time,
Slide the float all the way up and down and you should see the continuity change.
If all that checks out, you need to look at the connectors and motor harnesses nect ( a real pain)
 
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Hi Seasick.
Thank you so much for your knowledgeable reply. Tonight I am going to check out all the wiring and harnesses on the boat and also the sensor as you mentioned. I will let you know the results on the forum. Thanks again for your valuable input. :)
 
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Hi Seasick and the Guys,
Thank you so much for the assistance and advice! I think I may have found the problem! I checked the remote oil tank sender unit along with the main engine tank sender and all the other harnesses and connections using an ohm meter. All checked out OK until I got to the remote oil tank sensor unit.
This little gadget was intermittent! I have since replaced it and all looks fine! :) The proof test will be when I head out onto the lake for a test run, but I am convinced that this was where the problem lay.
Thanks again for the assistance and knowledgeable input.
Regards,
Dennis (Bel-Ami) (The name of my Grady!) :D
 
I may have learned something new here. The signals from the remote tank indicates low level or 'empty'. That normally causes a status change on the display but not an alarm or safe mode.As far as I understand it, only a low oil signal from the main tank on the motor will cause the alarm and safe mode operation. So am I convinced that you found the problem? Not yet:) but if the issue goes away, I really have learned a new twist to the Yami precision oiling system.
Good luck and please let us know how the test goes.
 
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Hi Seasick,
Another possibility was that when I removed and dismantled the battery cut-off switch, it had corrosion in it and I'm sure this was also causing low voltage to add to the problem.
I'll let you know what the test results are on the lake.
Thanks again!
Dennis. :)
 
Hi there Seasick, Curmugeon and Ocnsir,
Guys, I just wanted to say a massive thank you to you and the guys on the forum, for your most valued advice on the Grady forum.
It is so gratifying to know that there are folks that are so willing to spend time assisting fellow boaters. – THANK YOU!
I finally found the problem with the oil warning system on my Yam 130!
After following your good advice, I changed the battery connectors for new ones and checked all the harnesses and wiring.

I used an ohm meter to check the two oil tank sender units. The remote tank unit was intermittent, so I replaced it with a new one but the problem persisted.

Seasick, after reading through your comments again on the forum, I went to look again, and one thing I hadn’t checked was the battery isolator switch, (I installed it a long time ago as a safety measure). :-| I took it out and dismantled it, (a sealed unit), and PRESTO! Lots of corrosion resulting in a very bad electrical conducting item! :goodjob

I bought a new one for $7.00, installed it, making sure of the connections. I then headed out onto the lake and EUREKA! My Yamaha is back to her old self, going well, with no more problems! Oil lights back to normal, pump working OK! :dance :praise

Thank you all so very much. :D
Dennis.
Krugersdorp - South Africa. :arrow:
 
My 1991 yami 175 on my 190 tournament is not filing the engine mounted oil tank. The manual switch on the back of the motor does fill the engine tank from the remote tank. I replaced the sending unit in the engine tank and cleaned the filter in the remote tank. Still getting the alarm. All 3 lights on my gauge have been on for a long time but i have just started getting the alarm. Could it be the sending unit in the remote tank? could it be a voltage issue?

Thanks
Walt
 
Hi There Walt,
I had a problem with the oil warning system on my '99 Yam 130 BETOL.
My problem was a bad connection in the electrical system.
One thing I hadn't checked was the battery isolator switch, (I installed it a long time ago as a safety measure).
I took it out and dismantled it, (a sealed unit), and found lots of corrosion resulting in a very bad electrical connection.

Normally, all three lights would illuminate/bars flash if the remote tank has oil and the main tank is low on oil.
A disconnected main oil harness will also cause this condition.
3 bars flashing means the oil control module sees SW# closed, shorted to ground or the module is bad.
The oil control monitors both engine tank level and remote tank level.
Engine and remote levels ok, = far right bar or green lamp.
Remote tank low, = centre bar or yellow lamp.
Engine tank low = far left bar or red lamp.

Engine tank low, SW3 closed and remote level OK, SWB closed, you get 3 bars flashing, audible alarm, RPM reduction and the transfer pump runs for 180 seconds or until SW1 (top switch in the engine tank) closes.
If all is working and battery voltage is in range at Wide Open Throttle, then suspect an oil control module failure.

All the switches can be monitored with a multi-meter while running, as can battery voltage. Also check your battery cable connections at both ends. Clean them thoroughly and then reattach.
Your motor is consuming more power which is resulting in a voltage drop within the oil control system. This low voltage can cause the conditions that you reported. Bad battery cables and connections can cause low voltage resulting in the symtoms you are experiencing.
Good luck, and let us know how you get on. :)
Dennis.
 
Thanks Dennis,
I will troubleshoot my voltage. I do occasionally get the flashing battery icon on my gauge even when at cruising speed... My gauge has been flashing all 3 oil lights for over. Year, but I never had the oil transfer issue til recently. I was told it could be a bad ECM if the engine tank and remote tank control units Check out ok. When you refer to your electrical switch, you are referring to the perko type battery switch, right?

Thanks
Walt
 
Hi Walt,
Yes, the switch I'm using is a common battery isolator switch, similar to the Perco. It sounds almost like you have the same as the problem I had. - After changing the isolator switch and replacing the battery connections, the problem was solved. (I also checked all harnesses and electrical connections).
I was told by a Yamaha expert that any bad connections or dirty battery contacts will cause havoc with the electrics, and specifically the oil level monitoring system.
I somehow doubt that it could be your ECM. - Try the above and see what happens. :)
Regards,
Dennis.
 
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