DFI Tech

[UnityRacing]

Has anyone *recently* used DFI for EMM repair?
I used them a few yrs back for another ski and had excellent results, but it seems I can't get ahold of them now.

If you have used them, what was the cost to just have them check everything out?


I think I have a bad injector, and i'm afraid the EMM may have taken it out. Ski starts and runs, but sounds like crap. Swapped in another set of injectors, but not their matching computer just to test with. (Running on the hose with the pump removed). Sounded much better. So i'm at the point where I need to know 100% that I am working with a good computer and injectors :/

Oh, if I try to hold throttle at like 1500-2000 it will just rev up. I'm pretty sure I swapped in a new TPS, so I'm thinking maybe because there is no load on the engine?


One other note - anyone deal with the other EMM repair shops that have popped up on ebay??

[K447]

See the recent thread discussing DFI changes, the apparent replacement company MarineComputerSupply.com and the recently appeared Harris with EMMrepair.com

Regarding ebay, Harris is advertising there as the-old-stuff. Not sure if Chet is too.

[FichtEMMRepair.com]

gb

[K447]

... it could be a clogged injector nozzle ...

You mean the poppet valve in the injector tip?
Or the fine mesh screen inside the injector tip assembly?

[UnityRacing]

Does anyone else besides DFI have the means to actually test everything out?
I've been chasing tails with this ski since I started this project in 2007. Now that everything including gelcoat is brand new I keep having issues pop up.

First was the motor wouldnt start. Problem turned out to be a bad MFD. Then it ran for crap. New (second new) TPS installed. Then the rebuilt pump took a crap and ate the bearings after 45 minutes run time. Then the oil system took a dump all over the freshly cleaned hull. It's been sitting after all that for about 2 years. I got fed up with it and started building a Yamaha Exciter 270. Now that i'm tired of that i'm back to this Virage.

Just fixed the oil leak, drained the old gas and dumped 5 gal of fresh 87 in. Charged the battery and could get it to run.
I seem to recall the last time I had it out it was making an odd noise so I babied it back to the dock and parked it.
When I started it up the other day it sounded like hell on wheels. On a hunch I swapped injectors. It sounds better, but i'm not confident its 100%.

My plugs are pretty black, one injector was wet, and even afer the injector swap it takes some cranking to fire up, and most times will stall out after 10-15 seconds. I'll try to take a look at the injector tips and clean them, but I don't think that will be the solution. I'm not a newbie here, just got fried and took a leave of absence

Pretty much at my wits end.

Since the reliability on this is pretty much nil right now, I went and bought an 05 Yamaha FX Cruiser HO. It's nice, but I like the Virage hull better. Its like a low rider on the water and give alot more confidence.

[UnityRacing]

I should probably add - the injectors I swapped in are from a 99. My next move is to try swapping in the 99 EMM also.
Pretty sure the non and the pigtail TPS are electronically identical correct? Just physical differences?
Currently running the 02+ throttle bodies and sensor.

[UnityRacing]

Just got off the phone with Marine Computer Supply.
Not sure if this was covered elsewhere, but the owner used to work for DFI. Left about 3 yrs ago and started his own gig.
Also interesting to note - the Polaris EMM's have NO software updates available. The updates are just for the older outboards.

These guys seem like the real deal. 1 day turn around time, I *think* he said $395 if any repairs are needed, and they will test my EMM for free.
Only downside is he said they don't/can't test injectors. Also said nobody else is that he is aware of.

Thanks K447 for the info there. It used to be DFI was the only gig. Nice to know we have options.

[K447]

I should probably add - the injectors I swapped in are from a 99. My next move is to try swapping in the 99 EMM also.
Pretty sure the non and the pigtail TPS are electronically identical correct? Just physical differences?
Currently running the 02+ throttle bodies and sensor.

The 1999 Polaris Ficht was only sold on the 1999 Genesis FFI and the 1999 version of Ficht is unique. Ficht sold in 2000 to 2004 is different from 1999 Ficht.

In 1999 the Ficht injectors and the EMM were non-compensated. That means each injector had to meet exact flow specifications and be basically perfect. This made the 1999 injectors rather expensive to manufacture and many did not pass flow testing accuracy requirements on the injector manufacturing line. The 1999 Ficht EMM was programmed to match these 'perfect' injectors.

After 1999 Polaris changed to a compensated Ficht fuel injector system. The injectors are still high precision manufactured but minor differences in individual injector flow rates are recorded and mapped. Each injector serial number ends up with a corresponding injector flow map, otherwise known as an injector flow compensation table.

Each Fight EMM for model years after 1999 is loaded with a unique compensation map for each individual fuel injector installed on that engine. The EMM uses the map data to adjust the electrical pulses that drive each injector resulting in the precise amount of fuel being delivered as needed for each cylinder on each power stroke.

I do not know how the 1999 injectors compare to the 2000-2004 injectors in terms of fuel flow mapping.

My suggestion is to never mix 1999 with 2000-2004 injectors or EMM, assume they are not interchangeable.

Since each injector is mapped inside the EMM to a specific cylinder and injector it is important that the injectors be marked and returned to the same cylinders and used with the same EMM. This is what we call a matched set of injectors and Ficht EMM.

[UnityRacing]

I've read all that before, and the reason why I noted that. I may try the 99 EMM in the ski before I ship it out. Its just a PITA to swap as i'm sure you are aware.

I'm just sick of working on this. I know i'm close to being done, but damn all the hours working on it, and i've only logged 3.3 hours since I've owned it
I've probably put an easy 300 hours into working on it, and $6k into it on top of the purchase price itself. I'm in too deep.

[K447]

... I've probably put an easy 300 hours into working on it, and $6k into it on top of the purchase price itself. I'm in too deep.

[UnityRacing]

Call me a fanatic. The truing of the hull and gelcoat ran around $2k alone.

[K447]

Call me a fanatic. The truing of the hull and gelcoat ran around $2k alone.

What model and year is this hull?

[UnityRacing]

2002 Virage TXi. I think. Might have been an 03. Dunno, got it from Retro a few years back as it had much less spider cracking in the top coat.

I had all the chines redone as well as fill all the "beached" rash. Top is red, bottom is black, and the console/hood are black. Pics are on here somewhere.

Yeah, i'm an idiot with a hole in my pocket, but it's the most unique, badass looking, 'new' as can be Virage.

[ThrottleOut]

Does anyone else besides DFI have the means to actually test everything out?

Even DFI doesn't really have the means to fully test an EMM. They bench test it in a ski and basically if it fires up and runs the engine they consider it OK. I had them repair the EMM in my Virage and it started and ran ok out of the water but ran like crap in the water. After lots of hours trying to diagnose the issue they agreed to rebuild another EMM, copy my injector data and send that to me. That was my issue, a bad EMM with an unknown failure.

Only downside is he said they don't/can't test injectors. Also said nobody else is that he is aware of.

While he's unable to test injectors, user ghostinstallations on here offers an injector programming service. He's able to set up an EMM for a different set of injectors.

[UnityRacing]

Sad thing is I wanted FI so I wouldn't have to fool around with carbs, bad gas, and rebuilding / tuning. Here I am 7 years later and its still not right. Should have went the carb route

I have no problems swapping parts around to troubleshoot issues. The problem I have is getting stranded out on the water when something goes wrong. Last time it left me as a sitting duck for over an hour. Thats the main reason I parked it and left it.