Snowmobile Ski Doo REV SERIES (2004 year). Manual - part 51

Section 05 2–TEC ENGINE MANAGEMENT
Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

The ECM may generate several fault codes per-
taining to the TPS. Refer to SYSTEM FAULT
CODES in DIAGNOSTIC PROCEDURES section
for more information.

Wear Test

While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.

Using the vehicle communication kit (VCK) with
the B.U.D.S. software, use the Throttle Opening
display under Monitoring.

Slowly and regularly depress the throttle. Ob-
serve the needle movement. It must change
gradually and regularly as you move the throttle.
If the needle “sticks”, bounces, suddenly drops
or if any discrepancy between the throttle move-
ment and the needle movement is noticed, it
indicates a worn TPS that needs to be replaced.

Voltage Test

Check the voltage output from ECM to the desired
throttle position sensor.

A32C9SA

TPS

Disconnect plug connector from throttle position
sensor. To unlock connector, insert a small screw-
driver between the folded tab. To see the con-
nector pin-out and its pin numbers, temporarily re-
move the connector shield joining the harness.

Install the tether cord cap, turn OFF engine cut-out
switch and push START/RER button momentarily
to activate the ECM.

Connect a voltmeter between pin 1 and 2 in the
wiring harness.

Voltage should be 5 V.

Check the continuity between pin 3 on wiring har-
ness TPS connector and pin 24 on wiring harness
ECM connector.

If tests are good, replace the TPS.

If voltage tests are not good, continue to check
the resistance of the rest of the TPS circuit.

Resistance Test

Reconnect the TPS.

Disconnect the connector DA from the ECM.

R1503motr191A

Using a multimeter, check resistance value be-
tween terminal DA-25 and DA-39.

The resistance should be 1600 - 2400

in any

throttle position.

Check the resistance between terminal DA-24 and
terminal DA-39 with the throttle plate in idle posi-
tion.

The resistance should be approximately 1000

Check the resistance between terminal DA-24
and terminal DA-39 with the throttle plate in wide
open position.

The resistance should be 2500

Check the resistance between terminal DA-24 and
DA-25 with throttle plate in idle position.

The resistance should be 2500

Now check the resistance with the throttle plate
in wide open position.

The resistance should be approximately 1000

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Section 05 2–TEC ENGINE MANAGEMENT

Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

NOTE: When measuring between pins DA-24 and
DA-39, resistance value increases while depress-
ing throttle lever. When measuring between pins
DA-24 and DA-25, resistance value decreases
while depressing throttle lever. The resistance
value should change smoothly and proportionally
to the throttle movement. Otherwise, replace
TPS.

If resistance values are correct, try a new ECM.
Refer to ECM REPLACEMENT procedures else-
where in this section.

NOTE: Check if wiring harness shows any signs
of scoring prior to replace the ECM.

If resistance values are incorrect, repair connector
or replace the wiring harness between ECM con-
nector and the TPS.

Replacement

Remove the throttle body as described above.

Loosen two screws retaining the TPS.

Remove TPS.

A32C9RB

THROTTLE BODY
1. Throttle position sensor (TPS)
2. Screws

Install the new TPS.

Apply Loctite 243 on the TPS retaining screws,
then torque to 3 N•m (27 lbf•in).

Reinstall remaining removed parts.

Proceed with the Closed Throttle Reset. See be-
low.

Closed Throttle Reset

NOTE: This operation performs a reset of the val-
ues in the ECM.

This reset is very important. The setting of the
TPS will determine the basic parameters for all
fuel mapping and several ECM calculations in idle
speed control of the engine.

NOTE: Reset must be done each time the throttle
position sensor (TPS) is loosened or removed or
throttle body or ECM is replaced.

CAUTION: An improperly set TPS may lead to
poor engine performance.

Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment.

Unscrew idle speed screw until the throttle body
plate stop lever rest against its zero position stop-
per screw (capped screw). If necessary, loosen
the throttle cable. Open throttle approximately
one quarter then quickly release. Repeat 2 - 3
times to settle throttle plate.

Push the Reset button in the Setting section of
B.U.D.S.

The following message will be displayed:

Make sure the idle screw is not in contact with the
throttle stopper. Click OK to continue.

Follow instructions and click OK.

Another message will appear to ask you to per-
form a ECU tracking shut down to save the
changes into the ECU permanent memory.

Remove the tether cord cap from the DESS post
and wait until the message disappears before rein-
serting the tether cord cap.

Re-power up the ECM by pushing the START/RER
button momentarily.

The throttle opening displayed in B.U.D.S. should
be 0.00 (0.05 maximum).

If TPS is not within the allowed range while reset-
ting the Closed Throttle, the ECM will generate a
fault code and will not accept the setting.

Now, the idle speed screw has to be adjusted.
To do this, screw in the idle speed screw until
B.U.D.S. throttle opening displays value as per fol-
lowing table.

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Section 05 2–TEC ENGINE MANAGEMENT
Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

VALUE

ENGINE TYPE

AT SEA LEVEL

ABOVE 1800 m

(6000 ft)

593 SDI

3.9°

4.1°

If throttle cable has been loosen during the proce-
dure, adjust a throttle cable.

Start engine and make sure it operates normally
through its full engine RPM range. If fault codes
appear, refer to SYSTEM FAULT CODES in the DI-
AGNOSTIC PROCEDURES section for more infor-
mation.

CRANKSHAFT POSITION
SENSOR (CPS)

NOTE: The CPS is the trigger coil used for forward
and reverse.

A32C9UA

1. CPS connector

NOTE: Take into account that a CPS fault can be
triggered by missing encoder wheel teeth. First
check fault codes then check the teeth condition
if necessary. See below.

Disconnect CPS wiring harness connector. Probe
terminals coming from CPS while cranking engine.
Voltage should be within 1-2 Vac. Otherwise, in-
spect wiring and replace CPS if wiring is good.

Resistance Test

Disconnect the CPS plug connector from the
wiring harness and check the resistance of the
sensor itself.

The resistance should be between 190

and

300

Otherwise, replace the CPS.

If resistance tests good, reconnect the CPS and
disconnect the connector DA on the ECM.

R1503motr182A

Using a multimeter, recheck resistance value be-
tween terminals 5 and 19.

If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.

NOTE: Check if wiring harness shows any signs
of scoring prior to replace the ECM.

If resistance value is incorrect, repair the connec-
tors or replace the wiring harness between ECM
connector and the CPS.

Replacement

Disconnect connectors and remove the rewind
starter, then the magneto flywheel.

Refer to

MAGNETO SYSTEM.

Remove CPS.

A32C9VA

1. CPS inside crankcase

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Section 05 2–TEC ENGINE MANAGEMENT

Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

When installing new CPS apply Loctite 5910 be-
tween CPS and crankcase.

Torque to 8 N•m (71 lbf•in).

Reinstall remaining removed parts.

AIR TEMPERATURE SENSOR
(ATS)

A33I0IA

1. Air temperature sensor (ATS)

Resistance Test

Disconnect the plug connector from the ATS and
check the resistance of the sensor itself.

Refer to TEMPERATURE SENSOR TABLE at the
beginning of this section to find the corresponding
resistance value for this sensor temperature.

If out of specification, replace the sensor.

If resistance tests good, reconnect the ATS and
disconnect the connector DA on the ECM.

R1503motr186A

Using a multimeter, recheck resistance value be-
tween terminals 7 and 21.

If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.

NOTE: Check if wiring harness shows any signs
of scoring prior to replace the ECM.

If resistance value is incorrect, repair the connec-
tors or replace the wiring harness between ECM
connector and the ATS.

Replacement

Disconnect the connector of the ATS.

Pull the ATS out of the air intake silencer.

Follow this procedure to install the ATS.

First, install the ATS rubber ring.

NOTE: If the rubber ring is installed on ATS sensor,
remove it before ATS installing.

Spray soapy water on ring. Install ring on air intake
silencer then push the sensor in place. Reconnect
it.

COOLANT TEMPERATURE
SENSOR (CTS)

Resistance Test

Disconnect the plug connector from the CTS and
check the resistance of the sensor itself.

A32C9WA

The resistance between pin 1 and 2 is used for
temperature gauge.

Refer to TEMPERATURE SENSOR TABLE at the
beginning of this section to find the corresponding
resistance value for this sensor temperature.

If out of specification, replace the sensor.

The resistance between pin 3 and 4 is used for
ECM.

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