2004 Seadoo sportster issues

[donphantasmo]

I'm hoping you're wrong, even though I think you're right..

I don't want to mess with it, but I need to figure it out... Well, Off to ebay I go for pricing :-(

 

[donphantasmo]

OK. So, I'm going to have to bite the bullet and buy the wiring harness. I looked at sea-doo parts, and they say that my harness is part number 204470773. I look on Ebay, and they have none. But, when I type seadoo sportster 4tech wiring harness, they all say that part number 420664054 fits. About 5 or 6 come up.

So, I cross reference that part number, and it shows a 2003, and a bunch of other 4tech jet skis. I'm confused.

Does anyone know if 420664054 will work? you guys will have a lot more experience then I will...

 

[Sportster-2001-951C-Stock]

I'd forgotten if you had found damage in your existing harness. I'd look for corrosion and/or abrasion/burning. It's not too uncommon to find a harness rubbing against a bracket or something causing intermittent problems (in general, not necessarily seadoo 4-tec). I've found this before several times, that and internal wires broken due to stress.

Perhaps [MENTION=41828]Minnetonka4me[/MENTION] can source a harness for you, he's well respected for providing good quality used freshwater parts.

I doubt an IACV would limit WOT RPM, most likely the engine controller wouldn't be able to control idle speed.

 

[Sportster-2001-951C-Stock]

An idea that might help pinpoint this issue: Some diagnostics analyzers have what's called a "wiggle test", which repeatedly actuates the electro-mechanical devices back and forth so the technician can confirm they are working.

Not sure if candoo has this feature but if it does, you might try using that "wiggle test" to confirm operation of the IACV and wiggle the harness and connectors while it's being actuated back and forth.

Or perhaps this, from the service manual:
P0505
"Possible cause:
Damaged actuator, damaged circuit wires, damaged connector or damaged ECM output pins.
Service action:
Check for approximately 50 ohms between pins A and D and also between pins B and C of the idle bypass valve.
Check for damaged circuit wires.
Check for approximately 50 ohms between pins A-36 and A-35 and also between pins A-37 and A-38.
Check for damaged connector, damaged ECM output pins or ECM failure."

http://www.sea-doo.net/specifications/4-tec-diagnostic-procedures.pdf

 

[donphantasmo]

I haven't checked for resistance yet. I think that's my next thing. But, also the other code that's showing is p0353. So, that's 2 things connected to the wiring harness. I already swapped 2 and 3 ignition coils. The codes are still the same.

I think it's more harness related. I'm not sure if that 420664054 will work instead of the 204470773 harness. Like I said, the 204470773 isn't showing up anywhere but Seadoo retailors. It's 660 bucks. The other one is under 200 because it's on E-bay...

 

[donphantasmo]

An idea that might help pinpoint this issue: Some diagnostics analyzers have what's called a "wiggle test", which repeatedly actuates the electro-mechanical devices back and forth so the technician can confirm they are working.

Not sure if candoo has this feature but if it does, you might try using that "wiggle test" to confirm operation of the IACV and wiggle the harness and connectors while it's being actuated back and forth.

Or perhaps this, from the service manual:
P0505
"Possible cause:
Damaged actuator, damaged circuit wires, damaged connector or damaged ECM output pins.
Service action:
Check for approximately 50 ohms between pins A and D and also between pins B and C of the idle bypass valve.
Check for damaged circuit wires.
Check for approximately 50 ohms between pins A-36 and A-35 and also between pins A-37 and A-38.
Check for damaged connector, damaged ECM output pins or ECM failure."

http://www.sea-doo.net/specifications/4-tec-diagnostic-procedures.pdf

And Sportster-2001, I thank you for your reply.

I have done that thing "activate" before. I think everything works, with the exception of #2 spark (or something like that). That's why I still think it might be the harness.
I hope it's not, because of the cash I'd have to spend. But I need to get it fixed, and this is the best time to fix it.

I just need to figure out if the cheaper "used" wiring harness works or not...

 

[Sportster-2001-951C-Stock]

If everything works in "activate" then try wiggling the harness around while in that mode, could be a flaky connector or chafed wire? Tap around with a screwdriver handle as well as wiggle the harness.

If the actuator is working most of the time than a lose connection can cause a fault while the ski seems to run fine otherwise (such as maintains idle speed), eventually the lose connection will get worse and isle speed control will be noticeably lost. But meanwhile that pintle moving in and out controls idle air thus speed, and as long as it's not completely in or completely out but near normal operation range the idle speed will seem normal.

Once idle speed gets out of range then you should also get an "idle speed out of range" fault as well, I'd expect. I have to explain I don't know the 4-tec very well at all, this is just speaking from experience with other fuel injection closed-loop systems.

I'm gonna guess the codes have something in common, will look up P0353 and see what that is. It's gonna be easier to repair the harness than replace it, I'm thinking.

Also, someone else mentioned they were experiencing intermittent issues with fuel injectors not firing and traced them to the fuse holder box... Might be a weak point to check out. They replaced the fuse box I think, and the problem disappeared. Seems that might be a common problem on 4-tecs?

So, (and this is just a guess) maybe some power or a ground for the IACV and whatever P0353 relates to, comes from the fuse box?

 

[donphantasmo]

Hmm... Yet another thing to look at. The fuse box.. Great. Well, the harness is on it's way. I'll look at the fuse box, as well...

 

[donphantasmo]

So, finally got the time to put in the wiring harness... GUESS WHAT!!!

Same ol' issues.

IACV and #2 coil.

I guess I'm going to check that IACV I got from E-bay to make sure it's good. If It reads good, I guess ECU is my next thing. I pray it's not!!!

 

[Sportster-2001-951C-Stock]

Yeah, harness problems would've been too easy.