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  1. #1
    ThrottleOut's Avatar
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    EMM Repair Longevity - Calling those who have had DFI repair an EMM!

    So now that I've got a ski that is fuel injected I've been doing a bit of reading on common problems and failures with EMM's. It seems there are several common problems among the fuel injected skis.


    • EMM - Low injector voltage while cranking
    • TPS - Common failure point - may bench-test ok but engine vibrations can cause it to read sporadically
    • Start Solenoid - If it is black with a metal base it will fail so replace it, if it is brown with metal base it is the improved design so use with caution - the ideal solution is to replace with the all black SkiDoo (Yep, using parts from the dark side... BRP)
    • Fuel pressure regulator - In-tank regulator can fall-out of place causing low fuel pressure. It seems the easiest/best solution is to use the Kawi regulator in the return line. To test, check fuel pressure at the schrader valve in the return line while cranking (should be ~20-23 psi).
    • Water Injection Solenoid (2-Cylinder Only) - These are known to fail and can be safely removed and a resistor put in place so the EMM does not throw a trouble code. The water lines can be removed/capped and the fitting on the exhaust pipe should be capped.

    Aside from the obvious engine and compression check these seem to be the most common problems from what I've read. The links in K447's signature have some excellent information as well (where I got most of this info ).

    Since it seems like the EMM is the most costly repair I wanted to see if we could pull some information together for what is the 'best' way to fix these. Since DFI offers a repair service and it seems many have used them in the past with good results I wanted to see if some people who have had their EMM repaired could post some information on the date of repair, results (what they found, fixed, couldn't repair, etc) and if the repaired EMM is still working.

    So if you've had an EMM repaired, fill out the following:

    What ski did you have? Did you purchase it non-running?
    What were the symptoms and what was the mode of failure?
    Did DFI repair the unit?
    If so, when was the EMM repaired?
    What did DFI mark as repaired?
    Is the repaired EMM Still Working?
    Any other info?
    Last edited by ThrottleOut; 01-16-2013 at 10:27 AM.


  2. #2
    PWC Addict lilman573's Avatar
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    Good idea.

    Great thread.

    -What Ski do you have?
    2002 Virage i

    -What were the symptoms and what was the mode of failure?
    The ski would only start and stay running sometimes. If the battery was fresh off the charger, it would be fine for the day. If it wasn't it was a crap shoot. Soemtimes it would start, run extremely rough and then cut out. Sometimes it would run extremely rough for a minute or so and then settle out and run fine for the rest of the day. There was a few times it was running extremely well and then died in the middle of the bay.

    -Did DFI repair the unit?
    Yes
    -If so, when was the EMM repaired?
    Last year, I will have to look up my invoice on this one.

    -What did DFI mark as repaired?
    Replaced C89, upgrade EMM, passed functional test.
    Battery voltage regulation - 14v
    Injector voltage regulation - 40v
    Charge current @1700 - 35a

    -Is the repaired EMM Still Working?
    Yes
    -Any other info?
    My ski had 3 out of the 4 of those common failures. TPS, EMM, and starter solenoid. Actually saying this out loud, I am going to buy the in line pressure regulator right now to have on hand......

    My thread is here:
    http://www.greenhulk.net/forums/showthread.php?t=117338
    Last edited by lilman573; 01-25-2013 at 06:19 PM.

  3. #3
    jackofalltrades's Avatar
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    What ski did you have? 2002 Genesis I
    Did you purchase it non-running? Yes
    What were the symptoms and what was the mode of failure? Backfiring
    Did DFI repair the unit? Yes
    If so, when was the EMM repaired? Late 2010
    What did DFI mark as repaired? Capacitor that supplies the 5 volts to the memory side of the EMM
    Is the repaired EMM Still Working? Yes
    Any other info? Also replaced TPS because of a rough idle issue.

    Cheers

  4. #4
    PWC Addict lilman573's Avatar
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    Re: EMM Repair Longevity - Calling those who have had DFI repair an EMM!

    Forgot to say, I have the report they sent if you want me to post or pm it to you.

  5. #5
    I'm addicted to Polaris PWC ghostinstallations's Avatar
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    Post it please

  6. #6
    ThrottleOut's Avatar
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    Quote Originally Posted by lilman573 View Post
    Forgot to say, I have the report they sent if you want me to post or pm it to you.
    Quote Originally Posted by ghostinstallations View Post
    Post it please
    If you could post it that would be awesome. The more information we can bring together in one thread the better.

  7. #7
    PWC Addict lilman573's Avatar
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    Re: EMM Repair Longevity - Calling those who have had DFI repair an EMM!

    Sorry guys. I got a few pm's about this so here you go! Like I said, not too much to see.
    Click image for larger version. 

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    Last edited by lilman573; 02-08-2013 at 07:08 PM.

  8. #8
    Thanks, for everyone wondering where C89 actually is inside the ECU, it's on the backside of the I/O board which is the board with the 40 pin connector.
    Here's a photo of that capacitor so you can see the silk screened lettering C89
    Click image for larger version. 

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    I've also put together an album of photos as I've been taking the ECU apart, the ski has a non-running problem and backfiring on turning over so I suspect C89 to be the issue. I'll try and keep everyone updated on any progress I make.

    Gallery of EMM photos

  9. +1 by:


  10. #9
    Click avatar for tech links/info, donation request K447's Avatar
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    I suspect that there is more than one revision of the internal circuit boards used in these EMM.

    Do not assume that other EMM versions have the exact same numbering for the same parts. They might be the same PCB location codes and components, or not.

    Thank you for documenting your EMM repair process. I am sure this info will be useful to others.

  11. #10

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    OK,
    I got the EMM back and got it installed. The ski starts and runs, but I have not had it back in the water.
    The repair cost was their flat rate of $600.00 plus.
    They reported the 6 volt (I think) rectifier was bad. This is the power for all the engine sensors (?)
    They also reported that the EMM had, at some point, over heated.
    Hope to get a test run in a few weeks.

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