2004 GTI LE RFI bogging stalling after 5-10 min X2

[Tiggo]

I have the same Ski and love it. It sounds like you have 2 problems. Electrical and fuel. The rectifiers when bad will let the ski run at about idle or slightly faster but don't usually shut off the ski. It just goes into a limp mode. Also, the voltage on mine goes up to about 13.5 when cruising around. It needs to recharge the battery. If yours only goes to 12.44 then that is a problem. OSD's rectifiers are still Chinese and they may have gotten a bad batch. I find it hard to believe that both stators went bad. Did you test them? My other thought is your fuel pump and filters. Do the pumps come on when key is plug in (5 secs)? Check the fuel pressure. Pull the pump and replace the filters. It they sat while you rebuilt the motors, perhaps they gummed up. Keep us posted on the fix.

 

[Tiggo]

One more thought is the fuel injectors. Are they spraying correctly? If needed, pull the fuel rail and inspect the injectors. I bought a cheap fuel injector tester on Amazon and have sprayed fuel injector cleaner through them and the difference afterwards is noticeable. If dirty or slightly clogged, it could cause your situation. Fuel starvation.

 

[NIL8er]

I have the same Ski and love it. It sounds like you have 2 problems. Electrical and fuel. The rectifiers when bad will let the ski run at about idle or slightly faster but don't usually shut off the ski. It just goes into a limp mode. Also, the voltage on mine goes up to about 13.5 when cruising around. It needs to recharge the battery. If yours only goes to 12.44 then that is a problem. OSD's rectifiers are still Chinese and they may have gotten a bad batch. I find it hard to believe that both stators went bad. Did you test them? My other thought is your fuel pump and filters. Do the pumps come on when key is plug in (5 secs)? Check the fuel pressure. Pull the pump and replace the filters. It they sat while you rebuilt the motors, perhaps they gummed up. Keep us posted on the fix.

It doesn't shut off like key removal but like stalls from lack of fuel. If it's the fuel pump or filters then why would it run great for 5-10 min then start bogging and stall then in 10 min run fine again? But I know anything is possible. The stator checks out but as someone said can still not be working. I guess I'll get another new rectifier.

 

[NIL8er]

One more thought is the fuel injectors. Are they spraying correctly? If needed, pull the fuel rail and inspect the injectors. I bought a cheap fuel injector tester on Amazon and have sprayed fuel injector cleaner through them and the difference afterwards is noticeable. If dirty or slightly clogged, it could cause your situation. Fuel starvation.

FI Work good. I cleaned and tested.

 

[NIL8er]

It doesn't shut off like key removal but like stalls from lack of fuel. If it's the fuel pump or filters then why would it run great for 5-10 min then start bogging and stall then in 10 min run fine again? But I know anything is possible. The stator checks out but as someone said can still not be working. I guess I'll get another new rectifier.

Actually I think if filters are crumbling the injectors could be getting clogged after a few minutes them when off the sediment can clear or settle then get stirred up again when running

 

[Tiggo]

Add an inline fuel pressure tester and watch it while you ride. I've seen a YouTuber do it ( I think https://www.youtube.com/c/SeadooRefurb). Maybe the initial fuel pump starts up fine when cold and provides enough fuel and pressure but then slowly dies and can't keep up. The pump is just worn out. Seems crazy that both are doing the same thing. Almost seems like after your rebuilt both engines and reassembled that you missed a step on both skis. Very strange on both at same time. Do they shut off when zero throttle once they begin to bog? Seems like they should just return to idle. NOT totally shut off.

 

[Tiggo]

Actually I think if filters are crumbling the injectors could be getting clogged after a few minutes them when off the sediment can clear or settle then get stirred up again when running

Could be, especially if it's very small bits. Pull the pumps and look inside. Is it dirty in there? Crap floating around? Worth a shot. I have a new pump but waiting till fall to install. Not a fun job. Remove your glove box to get a good view. Just be careful and don't break the three clips. Expensive plastic.

 

[NIL8er]

I have the same Ski and love it. It sounds like you have 2 problems. Electrical and fuel. The rectifiers when bad will let the ski run at about idle or slightly faster but don't usually shut off the ski. It just goes into a limp mode. Also, the voltage on mine goes up to about 13.5 when cruising around. It needs to recharge the battery. If yours only goes to 12.44 then that is a problem. OSD's rectifiers are still Chinese and they may have gotten a bad batch. I find it hard to believe that both stators went bad. Did you test them? My other thought is your fuel pump and filters. Do the pumps come on when key is plug in (5 secs)? Check the fuel pressure. Pull the pump and replace the filters. It they sat while you rebuilt the motors, perhaps they gummed up. Keep us posted on the fix.

Both skis were under water without being properly dealt with as you can see in pic of one of the engines, at some point so I wouldn't be surprised if the statues were bad

 

[Tiggo]

Both skis were under water without being properly dealt with as you can see in pic of one of the engines, at some point so I wouldn't be surprised if the statues were bad

Oh... I missed that part. Didn't see any pics or mention of being underwater in this thread. If they were dunked then an electrical issue i.e. corrosion could cause all kinds of problems unrelated to the engines.

 

[BGS]

Rather than look for new problems I would try to fix the KNOWN problem, low voltage.
I would check DC Current & AC Voltage to isolate.

 

[NIL8er]

Could be, especially if it's very small bits. Pull the pumps and look inside. Is it dirty in there? Crap floating around? Worth a shot. I have a new pump but waiting till fall to install. Not a fun job. Remove your glove box to get a good view. Just be careful and don't break the three clips. Expensive plastic.

I've pulled the pumps and cleaned tanks. Filters looked good so didn't replace against better judgment.

 

[NIL8er]

Add an inline fuel pressure tester and watch it while you ride. I've seen a YouTuber do it ( I think https://www.youtube.com/c/SeadooRefurb). Maybe the initial fuel pump starts up fine when cold and provides enough fuel and pressure but then slowly dies and can't keep up. The pump is just worn out. Seems crazy that both are doing the same thing. Almost seems like after your rebuilt both engines and reassembled that you missed a step on both skis. Very strange on both at same time. Do they shut off when zero throttle once they begin to bog? Seems like they should just return to idle. NOT totally shut off.

I'll do this next. If fuel pump is bad can it be a larger draw and causing low voltage readings?

 

[NIL8er]

Oh... I missed that part. Didn't see any pics or mention of being underwater in this thread. If they were dunked then an electrical issue i.e. corrosion could cause all kinds of problems unrelated to the engines.

I checked all contact points and even cleaned off stator but it still needs replacement to be sure.

Oh... I missed that part. Didn't see any pics or mention of being underwater in this thread. If they were dunked then an electrical issue i.e. corrosion could cause all kinds of problems unrelated to the engines.

previously submerged. Since then rebuilt motors starters etc. stators have not been replaced but looked good no rust corrosion , check out ok but appears system isn't charging up to par

 

[NIL8er]

whats a good stator manufacturer for these units

anyone, or does anyone have OEM one to sell

 

[NIL8er]

fuel filters and canister had a lot of junk cleaned them out and still same issue. Plug gaps were .03 instead of .018.. i dont think this is the main problem but ill run it today and see.

 

[NIL8er]

new fuel pump new filters new rectifier ew battery.
what do you think about this

after running for about 5 min, begins to bog as it has been, but when it begins to bog i spray gas into intake(remember its an RFI) and it'll keep running--- so i know its not electrical or at least ignition side of electrical(still could be electrical that controls fuel delivery) anyway what do you make of this.

im going to make fuel pressure tests set up now. any other thoughts?

 

[NIL8er]

so apparently these have to have a quarter tank of gas for the fuel pump to be able to deliver fuel.. im suspicious of the rubber top oring in the tube that the spring goes on bec if i push down on the top it doesnt spring back like its stuck. seems like it shouild go back up .. Or is that normal. possibly the oring swelled and is hindering that motion??I added gas and the thing runs great and without stalling or bogging on the hose. to the water to morrow to see if it holds up .

 

[NIL8er]

ran good for 10 min, then runs erratically , doesn't stall, much different than before, not bogging just erratic rpm despite throttle position, ran enough to get to dock.. no matter how much i press throttle it'll only jump between 900ish and 2400ish rpm. i guess i start at the beginning.

 

[NIL8er]

getting bad cps codes

 

[NIL8er]

cps had short replaced it
stator VAC within normal limits


today on water after about 10 min fuel pressure drops from steady 60psi to 20 ans wont run but to limp to dock.
battery was 12.9- 13,2 even when fuel pressure dropped.
its a new fuel pump. i dont think injectors are stuck open ( no excess gas in the cylinders).
time for a fuel regulator.