KNOCK SENSOR Keeps Breaking!! ADVICE APPRECIATED!

[Cojo005]

I am looking for some help with a reoccurring problem. I have a 2011 210 with the twin 1.5's. I had it winterized by the dealer after an awesome summer last year. The dealer replaced both timing chains as part of a recall at the beginning of this season. The very first trip out the Starboard engine kept flashing Chk Engine when the Rpm was between 5000-6000 range.
Got it in & the knock sensor was faulty. They replaced it & I took it back out. Guess what; Codes again on same engine!! Back to dealer we go & ; the knock sensor is faulty: AGAIN!! The Senior tech said he has no idea what is causing the sensor to go faulty. "maybe bad 1 from factory?!?" I wonder why the first one crapped out?
Is it possible they screwed something up when they replaced the timing chains? The tech said No; but doubtful he would admit it if they did!!
They said it was fine to run as it is until the new one comes in. I am new to this jet boat game & I would rather put my gas money in the boat, rather than in trips to & from the dealer!
Gettin Frustrated!!!
Anyone have any advice???

 

[Cojo005]

Can anyone offer any help or advice?
I have had this problem since last summer. We have replaced 3 knock sensors, wiring harness, lake tested with Engineers on line, & replaced the dash gauge. Still codes between 5000-6000rpm on right engine only. Both engines run to 7250 rpm w.o.t.
Dealer is getting frustrated also. I just made a complaint with seadoo customer service. They are looking into my service history. This will be the 7th time in for the same problem. It's a warranty issue that occurred on original warranty. I still have 2 yrs warranty left.

I asked for a new boat swap; Apparently Not Going to Happen! How about replacing both engines? I dont want 1 new & 1 with 52 hrs on it if that is even an option. Dont think I am being unreasonable to ask for this at this point.

BRP said they are committed to fixing the problem. That's great; but when? The guy said he would look into some compensation for all my trouble & fuel for the multiple trips to the dealer/lake. I wonder what that means! I am trying to line up a meeting/call with the area sales rep to see what can be one.
I HAD ENOUGH!

 

[Coastiejoe]

First thing I would do at this point is swap the sensors. See if the code comes back. If so, is it on the same engine it was or did it move. If it moved, you probably have some sort of a bad batch of sensors from BRP. If it comes back and it is on the same engine,, then I would guess some sort of a wire or module issue. I say this as, you KNOW the sensor was fine and good to go on the other engine with no codes...

At least this will help you isolate the direction you need to head in...

 

[Cojo005]

Thanks for input! I forgot to mention that the 3rd visit was to swap the ECM's but the code stayed with the engine. There were a bad batch of sensors early last summer, but they have replaced it several times and apparently have a good one in now. The latest knock sensors shows good, but still getting dash code.
Always on Starboard engine.

 

[Coastiejoe]

Thanks for input! I forgot to mention that the 3rd visit was to swap the ECM's but the code stayed with the engine. There were a bad batch of sensors early last summer, but they have replaced it several times and apparently have a good one in now. The latest knock sensors shows good, but still getting dash code.
Always on Starboard engine.

Swapping the ECM would not have solved in in my opinion as that was not an issue until after the knock sensor replacement.

Ok, so after the swap you still have a code on the STBD engine, What is the code?

 

[Cojo005]

I forget the original code #'s. The dealers said the initial code was the knock sensor. Now there is no code stored when the check engine light comes on; just the annoying beeping, & the CHK STARBOARD ENGINE rolling across the screen.
The dealer has followed all instructions from BRP. I assume they would have looked at all possibilities. Still no clue as to the cause of the problem.
At this point; I am wondering what is reasonable for me to expect from the dealer or BRP. 6-7 times for same issue = Lemon in my mind.
- New boat? - Money back? - New Engines? I think I have a case for some kind of compensation.

The boat ran fine the first season!

 

[smc0922]

I wonder if its something simple like a bad ground.... But if they did a harness they should have found it.

 

[Cojo005]

Dealer called; wants to drain tank of Reg 87 gas, and refill with 91 premium. I ran last summer about 15 hrs on premium gas with no chk engine lights. The grade of gas shouldn't matter as it has twin 155 hp engines. This all seem to start right after the timing chains were replaced (Warranty Recall). I asked the dealer if this could be all tied together with the timing; knock code at 5000-6000 rpm; & being able to run premium (sometimes) but not regular gas. He checked with BRP who said it wasn't likely.
I think this is the path they are looking down now. I suggested replacing the timing chain last summer after the 2nd knock sensor replacement. Instead we switched ECM's from side to side; replaced wiring harness; another knock sensor; then dash gauges.

 

[Cojo005]

Changed injectors & lake tested with mechanic. Coded as usual. Dealer sent data to BRP for review. Engine specs looked fine. They installed a new update to "de-sensitize" the knock sensor. They said this should do it. It's fixed!
NOPE! I took it out couple of nights ago & it is THE SAME!
We will get it fixed they say. My dealer is doing what they can. BRP has no idea what is causing this. Next trip in will be the 9th time since May 2012.
When is BRP going to man up, admit they can't fix this thing & give me my money back! They can play with it on their time.
I am wondering if a lawyer could help at this point. There must be some law that protects a customer. There has to be a reasonable expected time for a repair when it's the same problem.
I HAVE ****ING HAD ENOUGH!!

 

[Coastiejoe]

It is nice that the dealer is really trying to help out. But,,, I would be super frustrated at this point...

You will never get your past back. I hate losing my summers as it is, if it was at the cause of another that would simply make it worse..

 

[Cojo005]

FINALLY FIXED - WE HOPE
BRP Engineers been working on this thing since last summer. After examining all the engine data from the last couple of lake tests; they determined that:
After the timing chains were replaced last summer under the recall, the right engine started running so smooth that it did not detect any "knock". This is apparently what caused the system to code. It was looking for an electrical problem, not a knock sensor malfunction. They sent a new computer code to fix the issue. I have ran it for 3 hrs since, with no codes or problems.
Hopefully we are done with this issue!!! The dealer & BRP did work together to get the issue resolved. It just got extremely frustrating for me & the many many trips I had to make back with it.