8.1. Fuel Injection System. Fuel Injection System - Components Main Components. Internal EMM Sensors. External EMM Sensors

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1 Fuel Injection ystem NOTE: It is unlawful to tamper with any system or function of Polaris DIt model personal watercraft Do not modify any part of the watercraft Doing so may end in a fine and/or imprisonment Fuel Injection ystem - Components Main Components EMM (Engine Management Module) Fuel s Capacitor Flywheel tator (Magneto) Ignition Coils Water Injection olenoid (Virage i) Internal EMM ensors Barometric Pressure ensor EMM Temperature ensor 4 Volt Circuit ensor RPM Limiter ROM Verification External EMM ensors Air Temperature ensor Water Temperature ensor TP (Throttle Position ensor) CP (Crankshaft Position ensor) LOWt Warning ystem (peed Limiting Overheat Warning) The EMM will go into LOWt mode to prevent serious engine and or EMM damage in the following instances: Overheating Engine Cooling ystem Overheating EMM Condition Alternator Output Exceeds 4 Volts When activated, fuel delivery is interrupted, and the EMM will begin a gradual five second drop in engine RPM to a threshold limit of approximately 300 RPM Additionally, the EMM will flash the CHECK ENGINE lamp on the MFI NOTE: The engine will run normally when RPM is under 300 RPM Above 300 RPM, fuel delivery will be interrupted To recover from LOWt mode, two conditions must be satisfied: Failure that initiated LOW must be repaired Engine RPM must be returned to idle LOWt ervice Codes Code -- Alternator 4V Above Expected Range Code 2 -- EMM Temperature Above Expected Range Code Water Temperature Above Expected Range

2 Fuel Injection ystem DIt ervice pecifications FUEL YTEM PREURE INJECTOR UNIT REITANCE PARK PLUG LEAD REITANCE IGNITION COIL PRIMARY REITANCE IGNITION COIL ECONDARY REITANCE CRANKHAFT POITION ENOR REITANCE AIR TEMPERATURE ENOR 77 F(2 C) WATER TEMPERATURE ENOR 77 F(2 C) 2 VOLT TATOR WINDING REITANCE (PIN: AND 2 / 2 AND ) 4 VOLT TATOR WINDING REITANCE (PIN: 3 AND 0 / 4 AND 9 / AND ) TATOR PIN: - 2 (EACH) TO GROUND TATOR CRANKING VOLTAGE (APPROXIMATE) (WIRE COLOR AOCIATED WITH PIN LOCATED ON WIRING DIAGRAM) CHARGE BATTERY TO 2VDC PRIOR TO TETING THROTTLE POITION ENOR (TP DATA CAN BE VIEWED UING PODIAG / ENGINE MONITOR- ING FUNCTION) WATER INJECTION OLENOID (VIRAGE I) PI (3-207 KPA) (MAXIMUM) OL PIN: AND 2 7VAC 2 AND 7VAC 3 AND 0 VAC 4 AND 9 VAC AND VAC 470 VDC 0 THROTTLE OPENING (UE THROTTLE FLIPPER) APPROXIMATELY 30 VDC CLOED REITANCE= EMM Information pecifications The following information should be verified against what the EMM displays when using the Polaris Ficht Diagnostic oftware When using the software, this information is displayed on the EMM INFORMATION screen must match the information in the table below Reference page 2 for more information EMM Information 2003 Virage i 2003 Genesis i Part Number 40040b 4004 Program Version Map Version 40040b Wolf 7 Development Name Hawk Wolf EMM / Fuel Part Numbers Model EMM Fuel Replacement Kit 2003 Virage i Genesis i NOTE: Part numbers subject to change Always reference updated Polaris parts book for current information before placing orders 2

3 Fuel Injection ystem Fuel Injection Wiring Diagram Reverse ync witch Tether witch 40 Pin Connector 3 Reverse RPM Limit Input (GRY / RED) Check Engine Light (T / O) 24 Overheat (T) 3 Tach (Y) Ignition Kill Input (BLK / Y) 39 WTR Injection (BLU / W) (Virage i Only) Water Injection LR-03 tart/top Module TP ensor Resistance TP upply v DC (RED) 3 TP ignal In (GREEN) Analog Ground (BLACK) 40 Fuel Pump Control (BRN) 22 (OR / BLU) Fuel Pump R/W (2 vdc) 20-30psi A FUED Pri 0- ec Coil MAG Air Temperature ensor F Air Temp ignal In (PINK / BLU) 3 Water Temp ignal In (PINK / BLK) 29 (BLUE) 2 (OR / PUR) R=0-0 Coil 2 Pri 0- ec Water Temperature ensor F 9-0 Crankshaft Position ensor Resistance 200 (Max) Crank Position ensor ignal In (ORANGE) 9 (PUR) CENTER R=0-0 4v DC Diagnostic Port 37 Crank Position ensor Ground (BLACK) 32 Ignition Charge Transformer Input (WHT / RED) 33 Ignition Charge Transformer Input (WHT / RED) 7 Power Input 4v DC (WHT / RED) 7 COM Input (WHT) 2 (OR / GRN) 9 (GREEN) Coil 3 PTO R=0-0 Pri 0- ec BLACK tator Connector 7 BLACK tator Windings 2 COM Out (RED) 27 COM Ground (BLACK),,2,3,0,20,30 Ground (BLACK) 2 Pin Connector Pin Connector tator # (brn/w) 2 DC upply 4v DC 7 DC upply 4v DC 2 tator # (brn) 2 tator #2 (brn/blk) tator #2 (brn/y) 3 tator #3 (y/blu) 0 tator #3 (y) 4 tator #4 (y/pur) 9 tator #4 (y/blk) tator # y/grn) tator # (y/gry) 3 Ground (blk) 4 Ground (blk) Ground (blk) Ground (blk) DC upply 2v DC (r/p) DC upply 2v DC (r/p) Power upply Connector 4 Large Capacitor BLACK (Ground) RED / PUR (2 vdc) A FUED RED + - 3

4 Fuel Injection ystem EMM Connectors EMM Pin Connector (EMM ide) EMM 2 Pin Connector (EMM ide) 2 Pin Connector Pin Connector TATOR WINDING (BROWN / WHITE) BATTERY POITIVE VOLTAGE (RED / PURPLE) 2 TATOR WINDING 2 (BROWN / BLACK) 2 4 vdc FICHT POWER UPPLY (WHITE / RED) 3 TATOR WINDING 3 (YELLOW / BLUE) 3 GROUND (BLACK) 4 TATOR WINDING 4 (YELLOW / BLUE) 4 GROUND (BLACK) TATOR WINDING (YELLOW GREEN) GROUND (BLACK) GROUND (BLACK) vdc FICHT POWER UPPLY (WHITE / RED) TATOR WINDING (YELLOW / GRAY) BATTERY POITIVE VOLTAGE (RED / PURPLE) 9 TATOR WINDING 4 (YELLOW / BLACK) 0 TATOR WINDING 3 (YELLOW) TATOR WINDING 2 (BROWN / YELLOW) 2 TATOR WINDING (BROWN) NOTE: Two color wires are shown with main/trace colors 4

5 Fuel Injection ystem EMM Connectors EMM 40 Pin Connector (EMM ide) IGNITION GROUND (BLACK) 2 IGNITION YTEM GROUND (BLACK) 2 PTO PRIMARY IGNITION (ORANGE / GREEN) 22 MAG PRIMARY IGNITION (ORANGE / BLUE) 3 THROTTLE POITION ENOR IGNAL (GREEN) 23 4 AIR TEMP ENOR IGNAL (PINK / BLACK) 24 OVERHEAT WARNING IGNAL (TAN) AIR, WATER, TP ENOR GROUND (BLACK) 2 V TP REFERENCE IGNAL (RED) 2 R232 RX OUT IGNAL (RED) 7 EMM POWER (WHITE / RED) 27 COMMUNICATION GROUND (BLACK) ENGINE KILL IGNAL (BLACK / YELLOW) 2 9 PTO FUEL INJECTOR DRIVER CIRCUIT (GREEN) 29 MAG FUEL INJECTION DRIVER CIRCUIT (BLUE) 0 FUEL INJECTION GROUND (BLACK) 30 FUEL INJECTION GROUND (BLACK) IGNITION YTEM GROUND (BLACK) 3 IGNITION YTEM GROUND (BLACK) 2 CTR PRIMARY IGNITION (ORANGE / PURPLE) 32 IGNITION YTEM POWER IN (WHITE / RED) 3 WATER TEMP ENOR IGNAL (PINK / BLACK) 33 IGNITION YTEM POWER IN (WHITE / RED) 4 34 CHECK ENGINE LAMP IGNAL (TAN / ORANGE) 3 TACHOMETER IGNAL / PULE -REV (YELLOW) CRANK POITION ENOR IGNAL (ORANGE) 3 REVERE MFI WARNING DIPLAY (GRAY / RED) 7 R232 RX IN IGNAL (WHITE) 37 CRANK POITION ENOR GROUND (BLACK) 3 9 CTR FUEL INJECTOR DRIVER CIRCUIT (PURPLE) 39 WATER INJECTION OLENOID GROUND (BLUE / WHITE) VIRAGE I ONLY 20 FUEL INJECTION GROUND (BLACK) 40 FUEL PUMP CIRCUIT GROUND (BROWN) NOTE: Two color wires are shown with main/trace colors

service bulletin MCM 454 Magnum EFI, MIE 454 EFI Ski GM Gen V Engine Specifications No Magnum 454 EFI Model EFI Ski (Average Octane Rating)

service bulletin MCM 454 Magnum EFI, MIE 454 EFI Ski GM Gen V Engine Specifications No Magnum 454 EFI Model EFI Ski (Average Octane Rating) service bulletin TO: SERVICE MANAGER MECHANICS PARTS MANAGER No. 93-25 MCM 454 Magnum EFI, MIE 454 EFI Ski GM Gen V Engine Specifications NOTE: Generation V Engines Have the Fuel Pump Mounted on the Belt