Sea-doo 1997 GSI, Shop Manual

Page: 28 / 372

Section 03 ENGINE
Sub-Section 02 (LEAK TEST)
03-02-1
LEAK TEST 0
GENERAL
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352)
is available to help diagnose engine problems
such as engine seizure, poor performance, oil
leakage, etc.
Before disassembling any components of the en-
gine, it is important to perform a leakage test to
determine which part is defective.
It is also very important after servicing the engine,
even for a complete engine rebuilt, to perform an-
other leakage test; at this stage, it may avoid fur-
ther engine problems and minimizing the risk of
having to remove and reinstall the engine again.
Static bench testing is the most effective way to
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever
possible.
On 717 engines, cylinders can not be verified indi-
vidually due to leakage from one cylinder to anoth-
er through a common intake manifold.
When installing hoses of the Engine Leak Test Kit,
use the collars provided in the kit to ensure a prop-
er sealing.
When pressurizing the engine, first confirm that
the components of the Engine Leak Test Kit are
not leaking by spraying a solution of soapy water
on all hoses, connections, fittings, plates, etc. If
there is a leak, bubbles will indicate leak location.
Three areas of the engine will be tested in se-
quence as per the diagnostic flow chart (see the
end of this sub-section).
1. Engine Cooling System
2. Bottom End and Top End
3. Rotary Valve Shaft
NOTE: If a leak is found, it is important to contin-
ue testing as there is the possibility of having
more than one leak. Continue pumping to com-
pensate for the air lost to find another leak.
PREPARATION
Verify fuel system for leaks.
Disconnect battery BLACK negative cable.
Disconnect battery RED positive cable.
TESTING PROCEDURE
Engine Cooling System
Remove the tuned pipe.
Remove the exhaust manifold gasket and ensure
the surface is cleaned.
Disconnect engine cooling hoses.
Install the appropriate exhaust manifold plate
(
no. 1 for the 787 engine and no. 2 for 717 en-
gines) from the Engine Leak Test Kit. Tighten plate
using fasteners provided in the kit.
Use hoses provided in the kit and install them on
the engine.
Install pump using reducer and appropriate
tube(s) as necessary.
;
WARNING
If any fuel leak is found, do not start the en-
gine. Correct the leak and wipe off any fuel
spillage. Do not use electric powered tools
unless fuel system has passed pressure test.
;
WARNING
Always disconnect battery cables in the
specified order, BLACK negative cable first.
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