Engine Sputter when Accelerating to Higher Speeds on our 2006 RXT

[Mast High]

PWC Muscle recently rebuilt our supercharger. Although we never had a chance to run the machine flat out the first time back in the water, the machine seemed to run fine. Unfortunately, the next time we took it out, the engine now sputters when moving from medium to a higher speed. In fact, it simply wont obtain any kind of high speed at all. Could this issue be related to the supercharger?

The only other factor we can think of may involve the fact we did capsize the machine the first time back on the water. Surprisingly, the engine compartment did take in a couple gallons of water. As a safeguard, we drained all the water as soon we got out of the water and installed new spark plugs. Unfortunately, the engine still stalls as you accelerate to higher speed.

Anybody have some advice on how to troubleshoot and what steps to take next?

 

[MacSeaDoo]

First start with the hoses to make sure all hoses are fitted and clamps are tight.

Also, you changed the plugs so check to make sure the coils are seated down properly.

Stupid question..when you put in the new plugs did you take off the removable tip to expose the screw tip? Did you also check the gap to .28?

You could have a bad plug, rare but what did you do with the old plugs? What did they look like?

 

[Mast High]

In order to keep the story simple, I see I may not have been clear on the sequence of events... We noticed the engine sputtering before we decided to change the spark plugs. It did seem to idle a little smoother/quieter with the new plugs but we still experience the sputtering as we accelerate out of medium speed. So unfortunately, I don't think it can be the plugs or the new plug installation. I will check the hoses as we did disconnect a number of hoses to pull the supercharger for the rebuild.

Someone else suggested it may be the impeller/wear ring or perhaps the ignition coils. Do you think either of these could cause the sputtering?

 

[Digdog]

Impeller/wear ring will not cause 'sputtering' , maybe you have water in your fuel? Maybe just coincidence but could your intercooler be leaking. When you took the old plugs out what did they look like? You can help diagnose some things this way.

 

[Mast High]

Here's a plug I just replaced. I thought about replacing the gas but gave up on the idea when I did not have a small enough diameter tube to get into into the tank. Perhaps, I should revisit this idea.

Regarding the intercooler, can I assume this is part of the antifreeze system? If so, I have noted that the antifreeze reservoir is full.

 

[Digdog]

No I think your intercooler is okay, it gets fresh water from the jet pump and cools the air coming in, sometimes through improper winterization or just failure they leak water into the intake which can cause problems. When you remove all 3 plugs do they look the same? Maybe a coil is acting up or has a wet connection causing a misfire.

 

[Mast High]

The sputtering issue was the same after I changed the plugs so swapping out the coils may be a good idea.

 

[Digdog]

The sputtering issue was the same after I changed the plugs so swapping out the coils may be a good idea.

 

[MacSeaDoo]

I recently had a low speed stutter. I figured it was a coil so I bought 1 new one and started with cyl1. The plan was to move it if the problem still existed to the next cyl.

Turns out cyl 1 was my culprit as the problem stopped. Also of note the cyl 1 plug looked slightly different so that is why is started with it.

Here in Canada, a new coil is $155 so I didn't want to replace them all only to find out it didn't make a difference.

 

[Jim Brown]

Check your intercooler for water intrusion. The intercooler is a heat exchanger used to cool the intake air, improving intake charge density and removing the heat of compression generated by the supercharger. Over time the intercooler will suffer the effects of corrosion and water will enter the induction system...not good. I just had this issue with my 2011 RXT260. I was experiencing engine surging and was only able to achieve 6000 RPM at WOT. I pulled the intercooler and applied air pressure to one water port while blocking the other off. Also taped plastic over each induction port and secured with tape. When I applied compressed air to the water side the plastic moved outward indicating a leak between the water side of the cooler and the air side. Replaced the intercooler and now she runs fine. Look in the service manual before removing the intercooler as there is a procedure there for checking for water by removing an induction hose, starting the ski and looking for water. Hope this helps.

 

[Mast High]

Very interesting... Unfortunately, I don't understand how the intercooler and supercharger interface with each other. Could I have caused this leak when removing and re-installing the supercharger when we sent it off to be rebuilt?

 

[Mast High]

I also want to share we were able to swap out the fuel and replaced it with high octane, non-ethynyl. Unfortunately, this did not improve the ski performance. I can now, at least, scratch fouled fuel off the list. Looks like we are down to an intercooler leak, a failing coil or the impeller (although I have heard a few skeptical comments regarding this possibility).

 

[Klubba]

On the 215hp the intercooler is integrated into the intake manifold.

This design is pretty bullet proof and has not had any of the issues associated with the 255 and 260hp models.
Also checking for leaks by disconnecting an intake hose is not possible....

here is the 2006 RXT layout, 23 is intercooler

 

[Digdog]

Test for leak by removing the two water hoses, use hoses and a gauge and pressure to 15psi and see if it holds. Use soapy water to check your connections to be sure. This is the same method used in plumbing , automotive testing to say test the system or the heater core.

 

[Mast High]

On the 215hp the intercooler is integrated into the intake manifold.

This design is pretty bullet proof and has not had any of the issues associated with the 255 and 260hp models.
Also checking for leaks by disconnecting an intake hose is not possible....

here is the 2006 RXT layout, 23 is intercooler
View attachment 51879

 

[Mast High]

Test for leak by removing the two water hoses, use hoses and a gauge and pressure to 15psi and see if it holds. Use soapy water to check your connections to be sure. This is the same method used in plumbing , automotive testing to say test the system or the heater core.

Sounds straight forward enough but perhaps a dumb question.... Do I perform this leak test with the intercooler removed from intake manifold?

 

[Digdog]

No you leave it inside to test it.

 

[ski-d00]

Either way works but it's easy to take out, it has just enough room to pull it out without removing anything else. Make sure to mark the location before pulling out. If you take it out and it has a leak, you will normally see water in the bottom of the intake manifold.

 

[Mast High]

Very helpful...thanks!

 

[Copious]

Very interesting... Unfortunately, I don't understand how the intercooler and supercharger interface with each other. Could I have caused this leak when removing and re-installing the supercharger when we sent it off to be rebuilt?

What was said as just did my supercharger last fall and have issues on first big run