VERIFY BATTERY IS FULLY CHARGED
INSERT LANYARD INTO STOP SWITCH.
DOES THE ELECTRICAL SYSTEM
POWER UP?
YES NO
MOVE THROTTLE FLIPPER FROM
CLOSED TO OPEN. DOES ETB
THROTTLE PLATE MOVE WITH FLIP-
PER?
YES NO
CONNECT DIGITAL WRENCHt SOFT-
WARE TO ECU. ARE THE FOLLOWING
SPECIFICATIONS TRUE?
PPU POSITION SENSOR 1 & 2 OPER-
ATING VOLTAGES
ETB THROTTLE POSITION SENSOR 1 &
2OPERATING VOL TAGES
YES NO
MONITOR OPERATING VOLTAGE S A S
THROTTLEFLIPPER IS MOVED FROM
CLOSED TO OPEN POSITIONS. DO
THE VOLTAGES MOVE SMOOTHLY
WITHOUT DIPPING OR JUMPING
AHEAD?
YES NO
LOCATE PPU AND ETB WIRING HAR-
NESSESS. VISUALLY INSPECT ALL
WIRES AND CONNECTIONS. “WIGGLE”
HARNESS CONNECTIONS.
PROBLEM(S) FOUND?
YES NO
VISUALLY INSPECT THE ETB AND PPU
COMPONENTS FOR PHYSICAL DAM-
AGE. INSPECT ETB MOUNTING SUR-
FACE FORGASKET INTEGRITY.
DAMAGE FOUND?
YES NO
VISUALLY INSPECT THE ETB AND PPU
COMPONENTS FOR PHYSICAL DAM-
AGE. INSPECT ETB MOUNTING SUR-
FACE FORGASKET INTEGRITY.
DAMAGE FOUND?
YES NO
POOR PERFORMANCE OR RUNABIL-
ITY ISSUE CANNOT BE ATTRIBUTED
TO PPU OR ETB COMPONENTS OR
FUNCTIONS.
TROUBLESHOOTINGENDED.
TROUBLESHOOT START/STOP SWITCH,
MAIN RELAY, ECU, AND ASSOCIATED
WIRING HARNESSESS AND CONNEC-
TIONS.
VERIFY SIFB IS NOT IN “SLEEP” MODE.”
PERFORM ETB LEARNING PROCEDURE PROCESS.
CHECK ALL PPU AND ETB WIRING HARNESSESS AND CONNECTIONS.
CONNECT DIGITAL WRENCHt SOFTWARETOECU. VERIFY ETB LEARNING PROCEDURE
DISPLAYS “TRUE”.
VERIFY ETB THROTTLE PLATE IS NOT OBSTRUCTED BY FOREIGN MATERIAL.
REPAIR ANY BROKEN CONNECTION
VERIFY COMPONENTS ARE RECEIVING
5VdcREFERENCE SIGNAL FROM ECU
REPLACE COMPONENT THAT IS OUT
OF SPECIFICATION.
VERIFY COMPONENTS ARE RECEIVING
5VdcREFERENCE SIGNAL FROM ECU.
REPLACE COMPONENT THAT IS OUT
OF SPECIFICATION.
REPAIR OR REPLACE AFFECTED WIR-
ING HARNESS OR CONNECTOR.
REPLACE ETB GASKET IF DAMAGED.
REPLACE ANY COMPONENT THAT IS
MECHANICALLY DAMAGED.
FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
5.30
2004 Four Stroke PWC Service Manual
Electronic Throttle Body (ETB) / Pedal Position Unit (PPU) -- Troubleshooting
TheETB and PPU components are integral to the engine management system. To perform any troubleshooting
procedures, the ECU must be connected to the Digital Wrencht diagnostic software.
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