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2002 SeaDoo GTI 4Tec ECU

Riverrats2

New Member
I have a 2002 with 30 hours on it in pristine condition. Problem is it has consistent miss fire at all speeds. I have narrowed my diagnosis down to ECU failure. I have sent the ECU to two separate places with a not repairable diagnosis. No codes, or any other problem. I am unable to locate a new UCU. Are there any suggestions on what I can do? Is there a newer ECU that could be compatible? Awesome PWC that I cannot use.
 
I exchanged spark plugs, spark plug coils, injectors and fuel supply pressure and quality, checked all looms for continuity and that leaves the ecu. Verified twice that it is faulty. Unless something else is also failed. The remarks were that the ecu could not maintain 5 volts.
 
You said in your first post "misfires at all speeds." So, that means it runs, but misfires; which cylinder is misfiring? The ignition is a simple ground-side switched COP system. It's very easy to see if the ECM is providing coil control.
 
Glad you have asked. All cylinders misfire. I installed a separate plug, grounded it, and ran the engine. I could visually see spark, and then not and then the engine would eventually stall. I tried this method on each cylinder with the same results. Basically, no cylinder is at fault it varies between the three. What was I performing incorrectly?
 
Well, you have to remember that the ECU needs inputs to control ignition timing. Inputs to the ECU include crankshaft position, and camshaft position sensors (to name just two). Some engines require cam and crank sensor inputs to run; the 1503 only needs the crankshaft position, but if the signal is missing or erratic, it will prevent proper ignition timing.

Here's an example of a faulty crankshaft position sensor signal on a 2017 GTR 230; the engine ran, but it ran like crap ... like it was misfiring.

CPS (faulty) Sep 23.JPG

Here's the signal after the sensor was replaced. Notice the slope rising at the gap in the reluctor wheel. Now go back to the previous picture and look at the falling slope. See the difference?

Crankshaft 11 Sep (new sensor).JPG
Typically, once ignition coil driver in the ECU is fried, it's fried for good ... they don't heal themselves. On the crankshaft sensor, I've seen these sensors produce signals that "come and go" especially when they get hot ... when they start to fault, they do so when they get hot.

The problem with the older 2002 engine is the crank sensor requires you to pull the PTO cover, so that means an engine pull. On new engines the sensor can be removed without pulling the PTO cover.

One last thought, the BRP instructions for testing the crankshaft position sensor are woefully inadequate! In the BRP version, you use a multi-meter, but a multi-meter isn't fast enough to see the whole wave form; without the wave form, it's impossible to properly analyze the signal.
 
Very interesting. I have no support from Sea doo, they tell me there is nothing you can do. The part is no longer available. If you were me, what would you do. I have a PWC that is in spectacular condition, that is not functioning.
 
In my experience the on-board diagnostic system in the Ski (especially for a 2002) would fail do diagnose a faulty crank sensor. I don't have any experience with BUDS; my Can Doo can only read if there is a fault, it can't show a crank sensor waveform; you need a lab scope to see that. In the case of my 2017 GTR 230, when I scrolled through modes in the information center, it did show a fault for the crankshaft sensor, but it cleared after cycling power. I found the faulty sensor after connecting my scope.

Riverrats2, back to your question. Where are you located? Any good automotive diagnostic guy can connect a lab scope to your crankshaft sensor and catch a sample wave form for analysis. I would not even bother looking for an ECU until I verified you have a good crank sensor signal. Both of the sample wave forms above were captured by simply cranking the ski over in the clear-flood crank mode. (holding the throttle wide open while you crank it over.)
 
I am in rural MS, and finding a automotive shop with a lab scope, will be very challenging, but why would two shops condemn the ECU? I sent the ecu by itself to each of the two labs, caramo, and jjsfuntoys. I would assume if they both performed their diagnostic tests properly, they would have reported a functioning ECU.
 
As Reacher would say ... "Assumptions can kill." LOL. It is possible you do have a bad ECU, no doubt if the ECU is not producing a proper 5V reference voltage that is a problem. From a diagnostic standpoint, I would want to check all the ECU inputs and outputs in the SKI before I even send the ECU out for testing because if you have a faulty input, output, or short to ground, you could cook the replacement ECU. If you do have a short to ground, that could have been what caused your ECU failure. You said you checked the wiring for continuity, but did you check for shorts to ground or shorts to power? I'm in Pensacola, so IM me if you want to discuss further.
 
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