FUEL INJECTION / IGNITION / EXHAUST SYSTEMS
5.40
2004 Four Stroke PWC Service Manual
Troubleshooting -- Engine Lacks Performance, RPM Limits
Indicated Problem Suspected Problem Solution
Engine RPM will not rise with throttle flipper
movement.
No reaction to throttle input. PPU not work-
ing or connected. ETB not learned.
Check ETB and PPU wiring harness con-
nections.
Perform ECU reset procedure by inserting
lanyard, then disconnecting main relay. Re-
connect main relay and wait at least one
minute. ECU will re--learn ETB.
Use diagnostic software to inspect throttle
position function and accuracy.
Replace PPU or ETB.
Engine idle RPM above 1600 RPM. Air leak at manifold or after ETB assembly . Verify all hose connections at throttle body
and air intake manifold.
Verify ETB is mounted securely to manifold.
Verify drain plug, sensors, and banjo fittings
are installed securely on intake manifold.
Engine RPM limited to 1800 ± 50 AND
CHECK ENGINE MIL light is ON.
ECUisinLIMPHOMEMODE. Use diagnostic software to find any trouble
codes associated with ETB, or PPU compo-
nents.
Check ETB and PPU wiring harness con-
nections.
Replace PPU or ETB.
Engine RPM limited to 2000 ± 50 and WA-
TER TEMPERATURE WARNING indicator
is ON.
Exhaust manifold thermoswitch is detecting
a water temperature of 60_C or higher.
DO NOT RUN WATERCRAFT FOR MORE
THAN 30 SECONDS!
Check all freshwater hose connections.
Verify there are no kinks or cuts on any of
the hoses.
Check pump assembly for weeds or foreign
material.
Flush the freshwater cooling circuit using
flush kit.
Engine RPM limited to 2000 ± 200 and WA-
TER TEMPERATURE WARNING indicator
is ON after watercraft has re--started after
sitting off of five to ten minutes.
(Will only occur on models with ECUs using
Level 5 software.)
Exhaust manifold thermoswitch is detecting
a water temperature of 60_C or higher.
Condition caused by heat soak within ex-
haust manifold.
Full power will return once freshwater circuit
fills and cools exhaust manifold.
Engine RPM limited to 3000 ± 50 and the
WATER TEMPERATURE WARNING indi-
cator is ON.
Engine cooling circuit is too hot. Internal
engine temperature at or above 87_C.
DO NOT RUN WATERCRAFT FOR MORE
THAN 30 SECONDS!
Check the engine coolant level and test
condition of coolant boil over protection us-
ing coolant hydrometer.
check the engine cooling system circuit for
leaks, plugs, etc.
Perform a cooling system pressure--leak
test.
Perform a cylinder compression test.
Verify there is no oil in the coolant, or cool-
ant in the oil.
Engine RPM is limited to 3400 ± 50 RPM
with NO WARNING INDICATORS ON.
Reverse or ESP mode RPM limit. Engine
runs fine between idle speed and 3400
RPM.
Verify reverse gate is in the UP position.
Check reverse switch wiring harness con-
nections.
Test reverse switch for proper operation.
Test the ESP system.
Check ESP wiring harness connections.
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