You are one of those rare tech's who are truly gifted! There are many engineers out there, but the majority of them don't have a diagnostic bone in their body. You my friend are blessed with the diagnostic gene! And, don't let your wife make fun of you because you went head and elbows deep in the bowels of yer doo! I can imagine the comments... I've been there too
I bet I know exactly what you said when you found that open crimp... "Holly shitt", but it sounded to your wife "mmmhooollee ssshheTTT" as she said, "What, how long is this going to take?" LOL
I share your diagnostic talents and abilities. I can't tell you how many times I have found defective crimped connections! I had a sneaking suspicion that the Rev Limiter would not fix this problem. I believe it to be a sensor of sort... in this case a sensor which was open. Active low sensors are great for design, manufacturing and testing purposes, but when a wire lead becomes open... they ARE a nightmare!
You did an excellent job diagnosing and documenting this problem. Yes, it would have cost you a bundle at shop and only a hand full would have even found the problem.
Crimped connections... engineers will tell you they are better, more reliable and less expense than solder connections. However, they are often once crimped and forgotten... never to be tested... basically assumed to be perfect every time. This is the fartherest from the truth and reality. I have found 1000's of defective crimps in my tenure as a technician. I would say I have found defect crimps to bad solder joints to be at least 100:1. In addition, for some reason manufacturers believe a crimp is permanent... they are not! If the insulator is not held captive... the wire will break... if the crimp is too tight... the wire will break... if the wire moves too much... the wire will break. I can't believe you found these wires crimped and not secured at all! Amazing! Even if they were secured... they would likely eventually break... these Doo's doo freakin jack around in normal use. I have never liked the methods SeaDoo used to secure wring bundles... you see a single tie wrap here and there... and the wires are rarely secure.
I have never trusted crimped connections... I always solder whenever I can and I even solder when it isn't easy and guess what? The connection never fails again! I have even had other tech's and customer's laugh at me because I took the time to solder... I solder because every connection should be "mission critical" and I don't have to fix it ever again.
I am so happy you found this problem because I can guarantee... others will have this same problem! This is a good fine... excellent work WAjetboating! Excellent find!
If you Doo draw up the "real" wiring schematic... please email me at rlehman@viewgistics.com. I would like to document this find for all Doers.
JetWild without detached crimps!!!
SpeedSter240EFI
Rj