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Sea-Doo PWC and Sport Boats


2006 Technical Update
Troubleshooting & Tech Tips

In this section you will find the most current tips


and solutions concerning situations that occurred
during last season, as well as the latest updated
procedures.

NOTE: All the troubleshooting procedure should


be used in conjunction with the Shop Manuals and
other BRP service publications.

Troubleshooting & Tech Tips Sea-Doo


PWC ...... ............... ............... .... 3A
Troubleshooting & Tech Tips Sea-Doo
PWC and Sport Boats .............. ..... 3B
Troubleshooting & Tech Tips Sea-Doo
Sport Boats ............ ............... ..... 3C

SECTION

3A

TROUBLESHOOTING & TECH TIPS


SEA-DOO PWC

sdd2006-003-001

SECTION

3A

Troubleshooting & Tech Tips

4-TEC SUPERCHARGERS
Engine performance is directly related to the condition of the supercharger if so equipped. If a supercharged Sea-Doo comes into your shop that's down on power, after initial checks are made compression,
spark plugs, fuel pressure, etc.) the supercharger clutch must be checked for slippage, and the impeller
for smooth rotation.
A good percentage of time the supercharger either works or it doesn't work. A quick check to find out
whether the supercharger is building pressure is to squeeze the hose going from the supercharger to
the throttle body. Start the engine and rev it up to 5000-6000 RPM's a few times, if the supercharger is
building pressure the hose should expand, if it doesn't, there is a problem. (Try this on a known good unit
to get the "feel" of what we are talking about here.)
Obviously, a failed supercharger either needs to be rebuilt or replaced. In the past, we offered two different rebuild kits: a booster shim kit, and a shaft kit. Now we only offer the complete rebuild kit as per
Service Bulletin 2005-9. The entire supercharger needs to be rebuilt regardless of the failure.
supercharger Kit (P/N 420 881 947)
supercharged intercooler Kit (P/N 420 881 946)
NOTE: As per kit instructions, after assembly of the clutch, hold the gear and rotate the clutch a minimum
of 10 turns to dissipate the grease on the ceramic washers to get a proper reading of the slip torque.
We offer rebuilt superchargers through our Rebuild Center. These can be used in any warranty situation
vs rebuilding it at the dealer.
supercharger (P/N 421 000 632)
supercharged intercooler (P/N 421 000 633)

We also have complete superchargers in stock, but


they can only be used in warranty situations if the
original supercharger's housing and impeller is damaged. See parts catalog for part numbers. Superchargers that are returned under warranty that have
no damage to the housing and impeller will be rejected.
ssi2005-008-001_a

2006 Technical Update Sea-Doo PWC and Sport Boats

3A-1

SECTION

Troubleshooting & Tech Tips

3A
3D TPS (THROTTLE POSITION SENSOR)
There have been a few reports on 3D's where the
engine is losing performance and/or misfires. The
condition may only happen when the engine is hot,
or be a lot more noticeable when the engine is hot.
No Faults were recorded. This happened when the
units had 80 or more hours on them.
The TPS was found to be the problem. The TPS
is positioned a little different on a 3D and the load
forces are also different. This in combination may
cause the wiper to momentarily lose contact when
riding in rough conditions to cause the above performance issues.

sdd2006-003-058_a

3D O.T.A.S. SWITCH (OFF THROTTLE ASSISTANCE SYSTEM)


The 947 DI 3-D will have a new OTAS switch. It's 10
mm in diameter vs the old switch that was used on
MY2004's and MY2005's which was 6 mm. Once
we run out of the old switch, the new switch will be
all that's available. It is completely interchangeable
with the exception of having to drill the existing hole
out to 10 mm so the new switch will fit.
Old Switch (P/N 278 002 029)
New Switch (P/N 278 002 068)
Refet to Section 4B: New Technology for all the details on the 3D.

sdd2006-003-070_a

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2006 Technical Update Sea-Doo PWC and Sport Boats

SECTION

3A

Troubleshooting & Tech Tips

LANYARDS
In 2005, we had an issue with some lanyards on
some PWC (except GTI / GTI LE with 717 engine)
in that they could be successfully programmed, yet
the ECM would not recognized them.
As per Service Bulletin 2005-8, the problem was
identified, and all lanyards questionable were removed from inventory. All remaining inventory and
new lanyards that were produced then received 2
divots (vs one divot on the old lanyards) on their
cap to denote they were good.
A: 1 Divot
B: 2 Divots
C: No divot

sbs2005-009-003_a

Since that time, the lanyards that were removed from stock were tested, and if they were good, were
then put back into inventory. Unfortunately these lanyards did not receive another divot, so we now
have lanyards going out into the field again with just one divot. On top of that, the next production of
lanyards won't have ANY divots on their cap however a DI will be embossed inside the cap.
The bottom line here is that all lanyards with no divots or two divots are good. Furthermore, all one divot
lanyards that were packaged before March 2005, and after June 2005 are good, that includes the one
divot lanyards coming with MY2006 Sea-doo's.

2006 Technical Update Sea-Doo PWC and Sport Boats

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SECTION

3B

TROUBLESHOOTING & TECH TIPS


SEA-DOO PWC AND SPORT BOATS

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SECTION

3B

Troubleshooting & Tech Tips

SHOP MANUALS (PWC AND SPORT BOATS)


In an effort to be more efficient the Tech Pubs Department divided up the Service Manuals so that 4
TEC Models will be in one manual, 2 Stroke Models in another, also 2 and 4 stroke engines also have
separate manuals.
Some Techs are not aware of this and are calling the
Service Department asking why particular sections
are not in the Shop Manual they have in their hands.
Please be aware of this change and organize your
service literature accordingly.

sdd2006-003-054

ECM ADAPTER TOOL FOR 4-TEC (PWC AND SPORT BOATS)


We have a great new electrical troubleshooting
tool that was auto-shipped to your dealership in the
spring of 2005. This tool allows you to take resistance checks from a component's connector to the
other side of the ECM's connector. Simply unplug
the ECM, plug in the tool and take the resistance
check from the corresponding circuit board, to the
component's connector.
This will eliminate any possibility of damaging the
ECM's connector by probing the female terminals,
and will also ensure the female terminals of the connector are making a good connection with the male
terminals of the ECM.
This tool will save hours of valuable troubleshooting
time while reducing the replacement of good electrical components.
(P/N 420 277 010)

2006 Technical Update Sea-Doo PWC and Sport Boats

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SECTION

3B

Troubleshooting & Tech Tips

BENT ENCODER TOOTH (PWC AND SPORT BOATS)


When troubleshooting a running problem such as a
high speed miss, not able to achieve top RPM's, top
RPM's drop after the engine warms up, and there
are no Fault Codes to give you any clues, do not forget to check the teeth on the encoder wheel.

sdd2006-003-066

Throughout the years Techs have changed out numerous electrical components, such as ECM and
MPEM, fuel rails, injectors, batteries, CPS, fuel
pumps, wire harnesses etc, and the problem still
exists.

sdd2006-003-067

We have had several Sea-Doo's brought to Wausau


that have experienced the above running problems
and found that one of the encoder wheel's teeth was
bent.
The PTO cover takes some time to remove, but if
you have a Sea-Doo that has the above problem,
especially if the problem existed since it was new,
or was noticed after a repair that included removing
the PTO cover, then that is an area that must be
checked.
The teeth should be parallel to the flywheel and
should not vary more then .009"

sdd2006-003-065

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2006 Technical Update Sea-Doo PWC and Sport Boats

SECTION

3B

Troubleshooting & Tech Tips

4-TEC FLYWHEEL BOLTS (PWC AND SPORT BOATS)


Flywheels bolts are no longer to be reused. We have
found that if not enough Loctite is applied on a used
bolt, and/or it is not torqued correctly, it may loosen
up.
Whenever installing a magneto on any 1503 4-TEC
engine, ensure to use the following procedure.
NOTE: The procedure has been revised and is different than the one proposed in the MY02-MY05
shop manual.
Do not reuse any bolts [1] and replace all 6 of them
with new ones provided in this kit. All bolts should
be used only once; these are stretch bolts.
Torque all bolts to 15 Nm (11 lbfft) in a crisscross
sequence.
Finish tightening bolts with an additional 50 rotation with a torque angle gauge.

1
R1503motr53B

WIRE HARNESS ON 4-TEC SUPERCHARGED SNTERCOOLED


ENGINES (PWC AND SPORT BOATS)
The engine wire harness (P/N 420 664 951) on a MY2004 RXP has been superseded to the MY2005 wire
harness (P/N 420 664 952).
The new harness has 2 resistors for the knock sensor integrated in it, so therefore if it's installed on a
MY2004 RXP that has had an external knock sensor adapter installed as per Warranty Bulletin 2004-4,
the external adapter must be removed or engine performance will be compromised.
See the below Kit Instructions.
MY 04 SC IC with wire harness (P/N 420 664 951):
It is necessary to do the RXP recalibration and knock sensor adapter update.
The adapter has a resistor in it. Refer to Warranty Bulletin 2004-4.
MY 05 SC IC with wire harness (P/N 420 664 952):
The resistor is integrated in the wiring harness.
If wire harness (P/N 420664952) with integrated knock sensor resistor, is installed on a MY 04 RXP
equipped with the external knock sensor adapter, then the external knock sensor adapter needs to be
removed!
If the engine is run with the integrated resistor and the external adapter the ECM will retard the ignition
timing and engine performance will be compromised.
NOTE: It must be understood that MY2004 RXPs must be recalibrated as per Warranty Bulletin 2004-4
regardless of which wire harness is installed. Again the only difference between the 2 harnesses is the
integrated resistor.

2006 Technical Update Sea-Doo PWC and Sport Boats

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SECTION

3B

Troubleshooting & Tech Tips

4-TEC INTERCOOLERS (PWC AND SPORT BOATS)


Intercoolers were first installed on our 1503 engines
in 2004 with the introduction of the RXP. It is located in the intake manifold and water from the water
that the watercraft is being ridden on is circulated
through the intercooler to cool the air going into the
combustion chamber.
In 2004 we used an intercooler that had a plastic end
cap and fittings, then in 2005 we changed vendors
and now the end cap and fittings are copper.
Both intercoolers have been very reliable with very
little problems. We have, however, experienced a
few incidences where the intercooler will spring a
leak. A very small leak will be hard to detect as the
water will vaporize and be processed through the engine.
A little larger leak may affect engine performance
and if you remove the injectors you may be able to
detect some water droplets on them.

sdd2006-003-074

Larger leaks will most likely affect engine performance, the spark plugs will be white ( in salt water
you may see salt crystals) and the oil will begin to
turn milky.
To leak test an intercooler accurately a pressure regulator and a gauge must be used. We suggest going
to an Industrial Supply Store such as Grainger's to
purchase the regulator and gauge, along with the fittings, hoses, and clamps necessary to fabricate the
tool. ( the parts required to make the tool pictured
cost approx. $50)
Remove the intercooler from the intake manifold.
Connect the intercooler to the pressure testing tool.
Get a container of water large enough to totally
immerse it. Pressure it up to 80 PSI for 10 minutes.
Look for air bubbles. Replace if any leaks are found.

NOTE: The intercooler is not self draining, ensure to


add anti-freeze in it as per Service Bulletin 2005-10
in areas of the country that experience freezing temperatures.
sdd2006-003-075

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2006 Technical Update Sea-Doo PWC and Sport Boats

SECTION

3B

Troubleshooting & Tech Tips

4-TEC ENGINES BENT RODS (PWC AND SPORT BOATS)


The past years we have been receiving warranty return engines and engine parts with the connecting
rod bent and/or broke. The rods are very strong on these engines and about the only way to bend them
( which eventually will break in some instances) is to hydro-lock them. So before such a failure is warranted, ensure that there was a manufacturing defect that would cause a hydro-lock. If a manufacturing
defect can't be found, then most likely the Sea-Doo was turned over, it was sunk for some reason, it was
towed without the water feed line clamped off, or the exhaust system was being flushed without the
engine running.
When a motor is hydro-locked, the rod bends and the piston is damaged or in some cases it breaks. If
it isn't broke the bent rod pushes the piston against the cylinder wall and scuffs it, and eventually it will
break.
When a piston breaks into pieces and all that debris is flying around the bent rod may now break as well.
The cylinder liner may break, and the stub of the rod may break right through the cases.
A hydro-locked rod on a 2 stroke will bend in an S
shape; the upper and lower rod pins will remain parallel. This is because there is a piston skirt 360 degrees around the piston that supports it-keeping it
perpendicular with the head, thus the rod can not
bend to one side.
When a 1503 hydro-locks, the upper part of the rod
will bend either toward the front or the rear of the
motor because the piston has no skirt in that area to
support it. The piston will rock to one side, and bend
the rod with it. Therefore the upper and lower crank
pins are no longer parallel. Most likely the rod will
twist as well.

Pictured are some examples:

Bent and twisted rod where the upper and lower


pins are not parallel.

sdd2006-003-071

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SECTION

3B

Troubleshooting & Tech Tips

Scuffing one side of the cylinder liner indicating the


rod was bent.

sdd2006-003-073

Bent and twisted rod, with a destroyed piston and


cylinder liner broke.

If we receive an engine or engine parts that have a


bent rod without a manufactures defect causing the
failure, the claim will be rejected. As always, if there
are questions, contact a Service Rep.

sdd2006-003-072

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2006 Technical Update Sea-Doo PWC and Sport Boats

SECTION

3B

Troubleshooting & Tech Tips

4-TEC COLLAPSED OIL FILTER (PWC AND SPORT BOATS)


A collapsed oil filter usually is caused by excessive debris in the engine oil, and the debris would come
from a failed internal engine part. However, we have had reports on collapsed oil filters where there is
no apparent debris in the oil. The unit will come into the shop because of low oil pressure. Tech's will
replace the oil and filter, only to have the unit come back into the shop with low oil pressure, and again
finding that the oil filter is collapsed.
A small anti-freeze leak will cause such an issue. The
leak is small enough in that the water in it evaporates
because of the high engine heat, but the ethylene
glycol turns into an invisible gel that will clog the filter and collapse it. In some cases the gel is thick
enough so it can be felt and seen. The oil will be
clear, and not milky because the leak is so small.
In most cases we have found this leak coming from
the head gasket, but it also could be from the water pump seal, PTO gasket, or a casting flaw. Pressure check the cooling system and try to determine
where the leak is.

2006 Technical Update Sea-Doo PWC and Sport Boats

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SECTION

3B

Troubleshooting & Tech Tips

VINYL CLEANING RECOMMENDATIONS (PWC & SPORT BOATS)


For general purpose cleaning, use Vinyl Finish Vinyl Cleaner, Fantastik, or warm water with a mild dish
soap such as Dawn or Ivory. Gently scrub with a small, soft bristle brush.
For dirt build-up, use Vinyl Finish Vinyl Cleaner or equivalent. Let soak for approximately 10 minutes, then
gently scrub with a soft bristle brush. For specific stain removal, refer to your cleaning and care card.
Do not use 409 (the bottle states not to use on vinyl), kerosene, gasoline,or acetone. They will remove
the protective marine top coat.
Do not use any silicone-based protectants. They will extract the plasticizers, leaving the vinyl hard and
brittle, and eventually cracking will occur.

RECOMMENDED

NOT RECOMMENDED

1. Vinyl Finish Vinyl Cleaner

1. 409 (states not for use on vinyl)

2. Dish Soap (Dawn, Ivory)

2. Murphys Soap

3. Fantastik

3. Simple Green

4. 3M Citrus Cleaner

4. DC Plus

5. 303 Protectant

5. Armor All
6. Top Kote Sealant
7. Son Of A Gun
8. Orange 88 Degreaser
9. Roll Off
10. Bleach / Baking Soda
11. Turtle Wax / Tar Removal (states not for use on
vinyl)
12. APCO
13. Tannery
14. Harbor Master
15. Equivalent Or Similar Products

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2006 Technical Update Sea-Doo PWC and Sport Boats

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Troubleshooting & Tech Tips

3B

VINYL CLEANING RECOMMENDATIONS (PWC & SPORT BOATS)


Type of Stain

Step 1

Step 2

Step 3

Ballpoint ink *

Chewing gum

Coffee, tea, chocolate

Crayon

Grease

Household soil

Ketchup

Latex paint

Lipstick

Mildew or wet leaves *

Motor oil

Oil-based paint

Permanent marker *

Spray paint

Suntan lotion

Tar / Asphalt

Yellow mustard

Legend
A. Medium-soft brush, warm soapy water,
rinse/dry

B. Vinyl Finish Vinyl Cleaner, rinse/dry

C. One (1) tablespoon of ammonia,


one-fourth () cup hydrogen peroxide,
three-fourths cup of water, rinse/dry

D. Wipe or scrape off excess (chill gum with


ice beforehand)

E. Denatured alcohol, rinse/dry

All cleaning methods must be followed by a thorough rinse with warm water.
* Suntan lotion, tree pollen, wet leaves and some other products can contain dyes that stain permanently.
Certain household cleaners, powdered abrasives, steel wool, and industrial cleaners can cause damage
and discoloration and are not recommended. Dry cleaning fluids and lacquer solvents should not be used
as they will remove printed pattern and gloss. Waxes should be used with caution as many contain dyes
or solvents that can permanently damage the protective coating.
Please contact G dustries Marine Specialties Group hot line at (800) 318-2887 for any cleaning and care
questions.

2006 Technical Update Sea-Doo PWC and Sport Boats

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SECTION

3C

TROUBLESHOOTING & TECH TIPS


SEA-DOO SPORT BOATS

sdd2006-003-002

SECTION

3C

Troubleshooting & Tech Tips

SPORT BOATS SPEEDOMETER CALIBRATION


If you suspect that a speedometer on a boat is not accurate, check it by using a GPS to validate the speed.
Comparing speeds over long runs on smooth water will yield better results.
If the indicated speed is correct at lower speeds but
falls off with respect to the GPS as speed increases, inspect the paddle wheel position on the back of
the hull. It may be too low in the water causing the
wheel to turn slower. 1/2 to 2/3 of the paddle should
be in the water when in operation.
Any more than that will cause the water to hit the
hub (round part) of the wheel and slow rotation at
higher boat speeds.
Check it's wheel position by placing a straight edge
in the trough leading to the wheel and extending out
under the wheel. The gap should be similar to what
is shown in the following picture.
sdd2005-002-052

If the wheel is to low the entire sensor must be moved up either by slotting the holes in the bracket or
filling the holes in the hull and drilling new holes further up. This should not be a common problem.
If the indicated speed is too high or low with respect to the GPS, the speedometer can be adjusted to a
more accurate setting.
The speedometer counts electrical pulses generated by magnets embedded in the paddle wheel as it
rotates past the sensor.
It was calibrated using an electrical signal generator
and adjusting a potentiometer to match the correct
speed.
To adjust the speedometer, open the helm area to
gain access to the rear of the speedometer head.
Make sure the selector switch on the bottom back
(6 o-clock position) is pointing to the number "5".
Remove the rubber plug just below the speedometer mounting stud (8:30 o-clock position). Insert a
2mm allen wrench into the adjustment pot.
sdd2005-002-053_a

Turning clockwise will increase indicated speed, and counter clockwise will decrease indicated speed.
Make small adjustments then compare speedometer readout to that of the GPS. Some trial and error
may be necessary. Replace rubber plug when finished.

2006 Technical Update Sea-Doo PWC and Sport Boats

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Troubleshooting & Tech Tips

3C

SPEEDSTER WAKE: PERFECT PASS SYSTEM GUIDE

WAKEBOARDPRO
STERN DRIVE BOATS
SeaDoo

Version 6.5N
August 2005
Information or assistance:
PerfectPass Control Systems Inc.
14 Trider Crescent
Burnside Industrial Park
Dartmouth, Nova Scotia
CANADA B3B 1R6
By phone
(902) 468-2150
By fax
(902) 468-8837
By email techsupport@perfectpass.com

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Troubleshooting & Tech Tips

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Table of Contents
Page
Number
Users Guide

Section 1

Section 2

Section 3

Using WakeboardPro
Wakeboard Speed Mode
Slalom Mode
RPM Mode
Driving Tips

1
2
3
4

Display Features / System Settings


General Information
Personalizing Screen Quick List

5
7

Troubleshooting
Common Questions & Answers
Linkage Test / Servo Motor Test

8
10

Warning: PerfectPass highly recommends you become familiar with the operation of
your new boat prior to using the speed control. (Leave in OFF position).
Once you are familiar and comfortable with the operation and handling of your boat, try
the speed control in the different modes without a skier to familiarize yourself with its
operation. If you feel it is not working properly or have questions, leave in the OFF
position and contact PerfectPass or your dealer immediately.

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3C

Section 1.

Using WakeboardPro

There are three operating modes to choose from: (1) Wakeboard mode controls from the
paddlewheel speed sensor and allows the user to set a desired speed; (2) RPM mode
allows the user to set an rpm control value, and (3) Slalom mode allows for recreational
slalom skiers to enter a speed for open water skiing (24 36 mph).
The ON/OFF key is pressed to turn control ON or OFF. System should always be OFF
when not using speed control. Turning system ON / OFF must always be done with boat
in neutral or at idle for safety reasons.
Before towing a rider / skier with WakeboardPro, practice without anyone in tow to familiarize yourself
with system operation. If you feel the system is not operating properly or have questions, leave control OFF
and contact PerfectPass or your dealer.

When you are ready to tow a rider, with boat in neutral turn control ON. Screen will ask
you to confirm boat is in neutral by pressing UP key. This will appear as [ IN NEUTRAL
^ = Yes ].
Typically, most wakeboarders prefer the pull characteristics of the Wakeboard mode.
This mode has been designed for the 15 25 mph range. For open water skiing or if
using the speed control at speeds above 25 mph, the RPM mode or Slalom mode is
recommended.

Wakeboard Mode
In this mode, the screen will appear as follows:
System Off
OFF

20.0
Set Speed

System On
0.0
Actual Speed

WAKB

20.0

Set Speed

0.0
Actual Speed

Select the desired operating set speed by pressing the UP or DOWN keys. Pull the rider
up normally and accelerate smoothly up to or slightly beyond the target speed. Once
PerfectPass sees the actual speed reach the set speed it will automatically take control
and will notify you of this with an audible beep. (Underlines will appear during engagement).
While in control, WakeboardPro should hold a smooth steady speed in a straight course
down the lake. The driver should keep their hand on the throttle for safety, and to prevent
it from pulling back on its own which will cause PerfectPass to disengage.
To Disengage System: If the rider falls simply slow boat down which will disengage
speed control. Return to rider slowly and pull up again. System will once again take over
when target speed is reached.
Speed Changes: Speed changes can be made prior to pulling up a rider or on the fly.
1
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Troubleshooting & Tech Tips

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Turns / Over-riding the system: As the boat enters a turn, the engine rpm may increase
to keep the craft at the set speed. If the driver would like less throttle (so the rider does
not get whipped) then simply pull back some on the throttle and help the system maintain
a safe speed. As you complete the turn, move the throttle gently forward and the system
will regain control. (The driver can override the system at any time by pulling back, or
advancing the throttle).
The digital speed readout should be checked & calibrated at 20 mph & again at 28 mph.
See Digital Speedometer Adjust on page 5.
To move from Wakeboard mode to Slalom mode, simply press MENU key twice and the
following will appear: [ WAKBD SPD ^ = slm ]. Press UP key to enter Slalom mode.

Slalom Mode
This mode allows you to set speeds in 2 mph increments ranging from 24 36 mph. This
mode is designed for those wishing to use the system for open water skiing.
System Off
OFF

System On
00

Tachometer

0.0

Actual speed

SL32

00

Set Speed
Tachometer
(Slalom 32 mph)

0.0
Actual speed

The set speed is changed by pressing the UP or DOWN keys, which can be done on the
fly. The tachometer is shown in the center and actual boat speed is shown on the right.
Slalom Calibration
Step 1:Calibrate Speedometer - Although a speed is selected, the speed is actually
being controlled via rpm so an initial Digital Speedometer Adjust is required.
This calibration is done at 20 & 28 mph in Wakeboard mode and must be done
prior to calibrating RPM baselines. See Digital Speedometer Adjust on Page 5.
Step 2:Calibrate RPM Baseline Initial calibration of baselines should be done with 2
3 people in boat and without a skier. If you set the speed at 32 mph, but your
digital speed readout shows something different such as 31, simply press the
MENU key on the fly to enter the Slalom Calibration Screen. In this example, the
actual speed is only 31 so the rpm in the center of screen must be raised. Press
the UP key several times and the rpm baseline will increase 25 rpm per press.
This will increase the rpm on the boat which will increase the actual speed.
Adjust the rpm until the actual speed matches the set speed. MENU will take you
back to main screen.
Set Speed (Slalom 32 mph)
R=32

3200

Baseline RPM

31.0

Slalom Calibration Screen

Actual Speed

2
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Step 3:Change speed and repeat Step 2 until all desired slalom speeds have been
calibrated.
Note: Each slalom speed must be adjusted independently to the correct rpm.
If you are towing skiers, you can change the set speed on the fly (ie. 30-32), or you can
raise the rpm baseline setting on the fly by pressing MENU. For example, you have 32
mph set, but because you have five people in the boat, the speed may be running a little
slow due to the extra weight. You can adjust the speed by entering the slalom calibrate
screen and raising the rpm baseline until the digital speedometer matches the desired
speed.
(This Slalom mode is for recreational skiing and will provide an excellent, tournament
quality pull, however, it is not designed to be as accurate as a tournament class speed
control).
Press MENU key twice and the following will appear: [ SLALOM ^ = rpm ]. Press UP
key to move to RPM mode.

RPM Mode
In this mode, the screen will appear as follows:
System Off
OFF

System On
00

Tachometer

0.0
Actual Speed

2800
Set RPM

00
Tachometer

0.0
Actual Speed

Operating in this mode is very similar to using the Wakeboard mode, except the system is
controlling to a set rpm, 2800 in this case.
Prior to towing the rider / skier, select the rpm set point by using the UP or DOWN keys.
Pull the rider up smoothly and continue to accelerate up to or beyond the set rpm point
so the system can take control.
Rpm changes can be made on the fly to fine tune the rpm.
When you have finished using PerfectPass, return to neutral and press the ON/OFF key.
Press MENU key and the following will appear: [ RPM ^ = wkb ]. Press UP key to
move to Wakeboard mode.

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Driving Tips:
1. Always pull a rider up smoothly. If you accelerate too far past the target speed,
you can gently pull the throttle handle back to assist PerfectPass in taking
control. When PerfectPass engages you will hear an audible beep. In addition
when engaged some of the characters on screen will become underlined.
2. When running twin-engine boats, the right engine is the one PerfectPass
controls. For best performance, you should slightly reduce power on left
throttle after engagement.
3. Always leave your hand on the throttle and look ahead. Pull back throttle to
neutral to stop boat. (The system will immediately disengage and the boat will be
under manual control).
4. When returning to a rider in the water, drive very slowly and carefully. Always
turn engine off when loading or unloading a rider from platform. Never back a
boat up when someone is in water behind.
5. The speed based mode is not designed for skiing & speeds over 25 mph as the
control may not be smooth. RPM or Slalom mode is designed for smooth control
over 25 mph.
6. More throttle If you see the # sign on the screen, this means PerfectPass is
running out of control room, press throttle handle slightly ahead until the #
disappears.
7. You can temporarily over-ride the system by applying more throttle. The engine
speed will increase for about 5 seconds before PerfectPass regains control.

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Section 2.

Troubleshooting & Tech Tips

Display Features / System Settings

Every time you turn ignition on, the Display will return to the last mode & speed (or rpm)
that was used. You do not need to turn control OFF prior to turning off boat ignition, but
it is recommended that when you are finished using the system that it be placed in the
OFF mode.
When in OFF mode, the display remains active and digital speedometer will continue to
read. The servo motor is powered, but is locked in OFF position. The tachometer will
continue to read when in RPM or Slalom mode.
Moving through Menu To move from mode to mode, simply press MENU key until
you see the prompt. In this example [WAKBD SPD ^ =slm]
you are in the Wakeboard mode, press the UP key to move to
Slalom mode.
Quick List

- To enter the list to recall a Riders Name & speed, press


MENU & UP keys together. For details on establishing
names, see Page 7.

Lake Temperature

- To view lake temperature press MENU & UP keys together,


then press the MENU key once. When the system is set to
read in kph, then temperature will be in degrees Celsius.
Note: If temperature does not appear, feature is unavailable
for your boat

Hour Meter

- To view hour meter press MENU & UP keys together, then


press MENU key until engine hours appear. If engine hours
cannot be found then this feature has been disabled and is
not present on your system. The hour meter counts when rpm
is detected by the Master Module, and is not RESET to 000
after system reset.

Calibrate Lake Temp

- To calibrate lake temperature press the UP & DOWN keys


together when temperature is being displayed.

Battery Voltage

- To view battery voltage press MENU & UP keys together,


then press the MENU key once or twice (depending if lake
temperature is present).

Digital Speedometer
Adjust (Calibrate)

- If you believe the system is not controlling at an accurate


speed, by pressing the MENU key, while in Wakeboard mode
you can access [SPEEDOMTER ADJST]. Example: You
have the system set and engaged at 20 mph, but you believe
the boat is actually traveling at 23 mph. While engaged,
access [SPEEDOMTER ADJST] via MENU key, then press
the DOWN key until the boat slows by 3 mph. Run the boat
and fine tune if necessary. All wakeboard speeds should now
be accurate. (A hand held GPS is ideal for confirming
accuracy). You should check and calibrate the speed in

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Wakeboard mode at 20 mph and again at 28 mph for


accuracy.
KdW (Pull
Characteristic)

- If you wish to change this control parameter, turn OFF


control in Wakeboard mode, then press UP & DOWN keys
together. KdW can be changed using the UP or DOWN
keys. Higher values = more aggressive control response.
Factory setting is 80. (Example: Heavily loaded boats may
need a higher value to maintain a steady, crisp pull. Try 100
150). After adjustment, press MENU to proceed.
(Maximum recommended setting 200).

NN (Paddle Filtering)

- This follows KdW and represents the filter factor of the


paddlewheel. Typical values 120 160. Higher values
mean the system will sample more revolutions prior to
making a speed adjustment. If you feel the system should be
smoother try increasing the NN. This parameter only
affects the operation of Wakeboard mode.

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Using the Personalized Screen Quick List


AMANDA

20.0

20.5

This version of WakeboardPro allows you to store up to eight names and their preferred
speed. These can then be accessed via the Quick List (MENU & UP keys together).
Creating Names While in neutral, press MENU & UP keys together and [QUICK
LIST ^ = Yes] will appear. Press UP key and [ MENU = list ^ = new ] will appear. You
will press UP key to enter new names, MENU key to access names already entered.
If you press UP key to enter new name, [ NEW ENTRY ^ = Yes ] will appear. Press UP
key to enter new name. Screen will then appear as follows depending on mode you are in.
Mode cannot be changed while entering a name. You must be in the mode you want
before creating name.
Mode
_

Name (6 characters)

wkb

20.0

Preferred Speed

Scroll through the alphabet using UP & DOWN keys, and then press MENU to move to
next position. When the name & speed have been set, exit via MENU key and entry will
be saved.
Selecting Names Press MENU & UP keys together to access [ QUICK LIST ^ = Yes ].
Press UP key and then MENU key to enter list. Once in the list, the MENU key is used
to scroll through list. Once the name is on screen you wish to select, press the UP key.
Editing List As you scroll through the list of names, instead of pressing UP key to
select that name, press the DOWN key to edit. The mode cannot be edited.
Note: Names can be changed by Editing List but can only be deleted by performing
System Reset (ON/OFF & MENU on startup), or by performing a Partial Reset
(MENU & DOWN on startup). All names will be deleted.

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Section 3.

Troubleshooting & Tech Tips

Troubleshooting

Common Questions & Answers


Condition:
In both Wakeboard & RPM mode the system beeps to engage, but boat speed never
settles in and hunts above & below Set Speed.
Solution:
It appears that the PerfectPass throttle cable does not have free movement and is rubbing
against engine cover or some other obstacle. A Linkage Test should be performed. See
Page 10.
Condition:
System beeps to confirm engagement, but boat continues past set speed and never locks
in.
Solution:
Computer is attempting to control, but servo not responding. A Servo Motor Test should
be performed. (Servo motor could be seized). See Page 10.
Condition:
System hunting in Wakeboard mode only. RPM mode working perfectly.
Solution:
1. Inspect paddlewheel for damage. Does it spin freely?
2. Is paddlewheel fully seated in housing? Is arrow pointing forward?
Condition:
PerfectPass digital speed reading shows 22 mph, but GPS indicates boat speed is
actually 24 mph.
Solution:
Press MENU key once while in Wakeboard mode and [SPEEDOMTER ADJST] will
appear. Quickly press DOWN key several times and drop calibration speed by 2 mph.
(Can be done in the shop or on the water). Remember, the LCD screen simply shows the
data from Master Module so there is no reason to suspect the Display is a problem.
Condition:
PerfectPass green light in display is on, but no data on screen.
Solution:
Check to see if servo motor is powered, if not then the system does not have adequate
voltage or is poorly grounded and will not start. (Measure voltage on PerfectPass power
cable, which should be in excess of 12 V).
Note: When ignition is OFF, the black knob on servo motor turns easily. When powered,
knob is stiff and is difficult to turn by hand.
If servo motor is powered and performs auto tighten rotation but Display has no data,
then Display should be changed.

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Common Questions & Answers (Contd)


Condition:
PerfectPass has no digital speed reading.
Solution:
1. Check Master Module to ensure paddlewheel cable is properly connected and
pins are in proper position and not bent.
2. Does paddle spin freely?
3. If all looks well, perform a System Reset.
Condition:
UP key on Display does not respond.
Solution:
Make sure all 10 pins on Master Module are in-line where display connects. If
connection is OK, key pad switch is faulty, return to PerfectPass for repair.
Condition:
Boat speed drops and throttle handle must be pushed far down to get acceleration.
Solution:
Servo motor is not holding and rotating properly usually due to a bad connection at the
servo motor. See Servo Motor Test, page 10.
Condition:
System is blowing the 5 amp, 1.25 fuse on 12 V power cable.
Solution:
Generally caused by a short or grounding problem with the red 12 V power cable on
servo motor. Closely inspect wiring particularly around gold resistor. (Remember,
resistor & servo motor will run very hot which is normal).
Condition:
Speed in Slalom mode not accurate.
Solution:
Did you go into Calibrate by pressing MENU key once in Slalom mode? This screen
allows you to adjust an RPM baseline up or down so speed is more accurate. If you
believe the PerfectPass digital speedometer is not accurate, see Digital Speedometer
Adjust on Page 5.

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LINKAGE TEST
This test should confirm whether the PerfectPass throttle cable & linkage connection is properly working.
With key OFF, turn black knob on servo motor in clockwise direction until snug. (This is the normal start
position of the knob). It should always return to this position when returning to neutral. Now push the
manual throttle to 1/2 open position. Now take black knob on servo and slowly turn the knob in a
counterclockwise direction, and then in a clockwise direction.
As you rotate the knob back & forth, you should see the throttle lever on engine opening & closing very
smoothly with each step of the motor. As you turn the knob counterclockwise which lets out cable, the
throttle will close back towards neutral. When you rotate it clockwise the throttle will open.
As you rotate the knob back and forth (slowly and quickly), the throttle should open & close very smoothly
and the brass L Adapter at linkage should be rotating as well to follow cable. At no point should the
throttle cable catch, hook or come into interference with any part that could disrupt the cable movement.
If the cable is rubbing against a decorative engine cover, fuel rail, motor box etc, adjust servomotor and
cable to improve alignment. Many plastic decorative engine shrouds can cause this problem. Remove
temporarily and run boat if you suspect this could be a problem.
Final Test: With key OFF, push manual throttle to full open position. Watch PerfectPass throttle cable to
ensure it can move freely without binding or interference.
Throttle Return Spring: PerfectPass can open the throttle (by turning clockwise), but relies on the engine
return spring to close the throttle when the servo turns counterclockwise. (The return spring is always
applying pressure against the throttle back towards the neutral position). If the servo turns
counterclockwise to slow the boat, but the throttle lever on engine does not move or moves very slowly, the
return spring could be weak, broken, etc.
If you feel the spring is weak or damaged, an external return spring can be added.

Servo Motor Test / Auto Tighten Test


Every time you return the boat to neutral when PerfectPass is on, the servo will wind in the cable until snug
in a clockwise direct. This is the normal starting point for the servo.
Each time you turn the key on or start the boat, PerfectPass becomes powered and the servo will perform
an auto tighten function and will attempt to wind in the cable to confirm it is in normal position. (If in
proper position, it will appear simply as a click, click, click).
To check servo & servo power wire, with key off turn black knob on servo motor counter clockwise of a
turn. Now turn key on and black knob should turn clockwise about of a turn as part of auto tighten. If it
does, repeat procedure, except this time hold black knob gently to apply some resistance to auto tighten. If
it rotates with good strength then it would appear servo & servo power cable are fine.
If it does not rotate or just vibrates, then a wiring phase coming to the servo may be loose or broken.
Inspect all wiring around servo. Pull both white plugs apart at servo & inspect pins to ensure they are in
place. Gently tug on each wire to ensure they are securely in crimp. Check at Master Module where cable
is connected.
If you cannot locate problem, contact PerfectPass.
Important Notes:
1. The gold resistor will run extremely hot. This is normal.
2. If system is new, make sure servo power cable is plugged into Master Module correctly and not
upside down. Tips on plug should point up towards label on Module.

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WARNING
RELEASE OF LIABILITY ASSUMPTION OF RISK
IMPORTANT
(Detach, sign and mail immediately)

YOU MUST READ THIS!


The PerfectPass Speed Control device is a high performance mechanism designed solely
for use with water ski and wakeboard boats operating under ideal, calm conditions
utilizing a spotter and all other safety crew and requirements of tournament water
skiing. The PerfectPass Speed Control device should not be used for any other purpose
or under any other conditions.
YOUR USE OF YOUR PERFECTPASS SPEED CONTROL DEVICE IS
CONDITIONAL UPON YOU ASSUMING ALL RISKS, LOSSES AND
DANGERS RELATING TO USE OF THIS DEVICE.
Both purchaser and/or anyone utilizing the PerfectPass Speed Control device
acknowledges that their purchase and or use of this device is conditional upon them
releasing and forever discharging PerfectPass Speed Control Systems Inc., its directors,
officers, employees, agents and/or dealers, their heirs, and assigns from any and all
liability for personal injury or property loss and from any other claims, demands,
losses or causes of action, whether occurring prior to, during, or subsequent to or
directly or indirectly connected with the use of the PerfectPass Speed Control device,
and whether caused by any persons negligence or otherwise.
The PerfectPass release of liability, and warranty agreement shall be interpreted in
accordance with the laws of the Province of Nova Scotia, Canada, and IT IS
FURTHER AGREED that any legal proceedings that either directly or indirectly
relate to the PerfectPass Speed Control device shall be conducted within the Province of
Nova Scotia, Canada, regardless of where arising.
The purchaser hereby agrees to inform any subsequent purchasers or anyone using the
PerfectPass Speed Control device, of the conditions of this Release of Liability,
Assumption of Risk Agreement. It is agreed that there shall be absolutely no alterations
to this agreement whether by implication or otherwise.
___________________________________________

Purchaser Signature

__________________________________

Date

______________________________________________________

Address

____________________________________

____________________________
Serial Number
(found on Master Control Module)

____________________________________
Name (Please Print)
(Must be signed to affect valid purchase and activate warranty agreement, detach and mail immediately
to PerfectPass Control Systems Inc., 14 Trider Crescent, Dartmouth, Nova Scotia, B3B 1R6, Canada).

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LIMITED WARRANTY
During the first 12 months from date of original retail purchase, any PerfectPass
component that fails due to defects in materials or workmanship will be repaired or
replaced at the option of PerfectPass at no charge.
All warranty claims must be authorized in advance and a Return Authorization (R/A #)
issued. All packages, correspondence, documents and packing slips must reference this
R/A #.
Warranty excludes components damaged my improper installation or improper use of
boat. Servo Motors are water resistant, but not water proof. Servo motors may become
damaged if excess water is run in a boats bilge and this may void warranty. Ensure your
boat is properly bilged prior to operating.
Warranty Service:
1. If your PerfectPass was factory installed, any warranty issues should be directed
to your authorized dealer. PerfectPass encourages all customers to contact us
prior to visiting your dealer for technical support as many issues may be easily
handled direct with customer.
2. If your PerfectPass was purchased and installed by a dealer you may contact
your dealer direct or initiate a warranty claim with PerfectPass.
3. If your PerfectPass was purchased directly from the Company, contact us at the
number below.

Warranty Service / Technical Support


PerfectPass Control Systems Inc.
14 Trider Crescent
Dartmouth, Nova Scotia
CANADA B3B 1R6
(902) 468-2150
(Hours: Monday to Friday, 8:00 am 4:00 pm EST)

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