Sea-doo 2001 GS Shop Manual Download

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Section 01

SERVICE TOOLS AND PRODUCTS

Subsection 04

(SERVICE PRODUCTS)

SMR2000-002_01_04A.FM

01-04-3

Grease

P/N 293 550 005

(400 g)

A00B2L4

Synthetic grease

P/N 293 550 010

(400 g)

F01B154

Super Lube grease

P/N 293 550 014

A00B474

Anti-seize lubricant

P/N 293 800 023

Loctite 767

454 g (16 oz)

F01B174

BOMBARDIER LUBE

P/N 293 600 016

(12 x 14 oz)

F01B0S4

Bombardier storage oil

P/N 413 711 600

(12 x 350 g)

A02B054

Sea-Doo fuel stabilizer

P/N 413 408 600

236 mL (8 oz)

A00B3V4

732 Multi-purpose sealant

P/N 293 800 033

Dow Corning (90 mL)

(clear)

F01B1C4

BOMBARDIER injection oil

P/N 413 802 900

(12 x 1 L)

F01B184

BOMBARDIER injection oil

P/N 413 803 000 (3 x 4 L)

P/N 413 803 200 (205 L)

F01B2H4

www.SeaDooManuals.net

Summary of Contents for 2001 GS

Page 1: ...www SeaDooManuals net ...

Page 2: ...2000 Shop Manual VOLUME 1 GS GTI GTS GTX XP GSX RFI GTX RFI www SeaDooManuals net ...

Page 3: ...hout the prior written permission of Bombardier Inc Bombardier Inc 2000 Technical Publications Bombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc Loctite is a trademark of Loctite Corporation Snap on is a trademark of Snap on Tools Corporation Gelcote is a trademark of Gelcote International Limited www SeaDooManuals net ...

Page 4: ...6 Bottom end 04 06 1 07 Rotary valve 04 07 1 08 Exhaust system 04 08 1 05 COOLING SYSTEM 01 Table of contents 05 01 1 02 Circuit components and care 05 02 1 06 FUEL SYSTEM 01 Table of contents 06 01 1 02 Fuel circuit 06 02 1 03 Air intake 06 03 1 04 Carburetor 06 04 1 05 Fuel injection 06 05 1 07 LUBRICATION SYSTEM 01 Table of contents 07 01 1 02 Oil injection system 07 02 1 03 Oil injection pump ...

Page 5: ...1 SUSPENSION 01 Table of contents 11 01 1 02 Direct action suspension 11 02 1 12 HULL BODY 01 Table of contents 12 01 1 02 Adjustment and repair 12 02 1 13 TECHNICAL DATA 01 GS 13 01 1 02 XP 13 02 1 03 GTS 13 03 1 04 GTI and GTX 13 04 1 05 GTX RFI and GSX RFI 13 05 1 14 WIRING DIAGRAMS 01 Wiring diagrams 14 01 1 TABLE OF CONTENTS www SeaDooManuals net ...

Page 6: ...ly recommended when considering replacement of any com ponent Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications must be strictly adhered to Locking devices ex locking tab self locking fa...

Page 7: ...dded the following new products medium strength threadlocker Loctite 243 Molykote 111 STORAGE New procedure with air pressure to empty the cooling system EXHAUST SYSTEM New procedure to install tuned pipe on 787 RFI engine New procedure to remove and install tuned pipe on 947 engine COOLING SYSTEM New diagram for the cooling system all engines FUEL SYSTEM Procedure to remove fuel tank on all model...

Page 8: ...SMR2000_001_00A2 FM V TECHNICAL DATA Updated specifications for each model WIRING DIAGRAMS Updated wiring diagrams for each model WHAT S NEW www SeaDooManuals net ...

Page 9: ... All Models The Hull Identification Number is composed of 12 digits MODELS MODEL NUMBER GS 5644 GS International 5827 GSX RFI 5645 GSX RFI International 5654 XP 5651 XP International 5655 GTI 5647 GTI International 5657 GTS International 5639 GTX 5653 GTX International 5669 GTX RFI 5648 GTX RFI International 5658 GTX RFI green 5515 GTX RFI International green 5516 F01L8XA 1 F08L0QA 1 Z Z N 1 2 3 4...

Page 10: ...ed on the upper crankcase on MAGNETO side 1 Engine Identification Number E I N ARRANGEMENT OF THIS MANUAL The manual is divided into 14 major sections 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL SYSTEM 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 SUSPENSION 12 HULL BODY 13 TECHNICAL DATA 14 WIRING DIAG...

Page 11: ...ustration number for publishing process Subsection title indicates beginning of the subsection Dotted box contains parts of a particular model or an exploded view Page numbering system 03 ENGINE section 04 MAGNETO SYSTEM subsection 1 First page of this subsection Italic sub title above exploded view indicate pertaining models Drop represents a liquid product to be applied to a surface In this case...

Page 12: ...lace other wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI Diaphr...

Page 13: ...rent from the ones of the Parts Cata logs When ordering parts always refer to the specific model Parts Catalogs DESCRIPTION AC Alternate Current APS Air Pressure Sensor ATS Air Temperature Sensor CDI Capacitor Discharge Ignition CPS Crankshaft Position Sensor CSI Cooling System Indicator DC Direct Current DESS Digitally Encoded Security System E I N Engine Identification Number ECU Electronic Cont...

Page 14: ...equivalents SELF LOCKING FASTENERS PROCEDURE The following describes the most common appli cation procedures when working with self locking fasteners Use a metal brush or a screwtap to clean the hole properly then use a solvent Methyl Chloride let act during 30 minutes and wipe off The solvent utilization is to ensure the adhesive works properly LOCTITE APPLICATION PROCEDURE The following describe...

Page 15: ...le 4 Apply several drops of proper strength Loctite on stud threads 5 Install stud 6 Install cover etc 7 Apply drops of proper strength Loctite on un covered threads 8 Tighten nuts as required Preassembled Parts 1 Apply here 2 Do not apply 1 Clean bolts and nuts with solvent 2 Assemble components 3 Tighten nuts 4 Apply drops of proper strength Loctite on bolt nut contact surfaces 5 Avoid touching ...

Page 16: ...ud or thread on desired length 2 DO NOT apply release agent on stud 3 Do a Standard Thread Repair 4 Allow to cure for 30 minutes 5 Assemble GASKET COMPOUND All Parts 1 Proper strength Loctite 2 Loctite Primer N P N 413 708 100 and Gasket Eliminator 515 P N 413 702 700 on both sides of gasket 3 Loctite Primer N only 1 Remove old gasket and other contaminants with Loctite Chisel remover P N 413 708 ...

Page 17: ...assemble as shown above CASE IN COMPONENTS Metallic Gaskets 1 Proper strength Loctite 1 Clean inner housing diameter and outer gasket diameter 2 Spray housing and gasket with Loctite Primer N P N 293 800 041 3 Apply a strip of proper strength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low strength liquid is recommended as normal strength ...

Page 18: ... 13 115 14 124 15 133 16 142 17 150 18 159 19 168 N m FASTENER SIZE 8 8 Lbf ft 20 15 21 15 22 16 23 M8 17 24 18 25 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 41 30 42 31 43 32 44 32 45 33 46 34 47 35 48 M10 35 49 36 50 37 51 38 52 38 53 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 65 48 66 49 67 49 68 50 69 51 70 52 71 52 72...

Page 19: ...0 96 71 97 72 98 72 99 73 100 74 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 109 80 110 81 111 82 112 83 113 83 114 84 115 85 116 86 117 86 N m FASTENER SIZE 8 8 Lbf ft 118 87 119 88 120 89 121 89 122 90 123 91 124 91 125 92 126 93 127 94 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 ...

Page 20: ...CONTENTS 0 MANDATORY SERVICE TOOLS 01 02 1 ENGINE 01 02 1 COOLING FUEL OIL SYSTEMS 01 02 4 PROPULSION SYSTEM 01 02 5 WORKSHOP 01 02 6 OPTIONAL SERVICE TOOLS 01 03 1 ENGINE 01 03 1 COOLING FUEL OIL SYSTEMS 01 03 4 PROPULSION SYSTEM 01 03 5 WATERCRAFT HANDLING 01 03 6 SERVICE PRODUCTS 01 04 1 www SeaDooManuals net ...

Page 21: ... 1 3 0 1 2 0 1 1 0 1 0 0 9 0 8 0 7 0 6 0 50 40 30 20 10 10 20 30 40 5 0 6 0 7 0 8 0 9 0 1 0 0 1 1 0 1 2 0 1 3 0 1 4 0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 2 0 0 2 1 0 2 2 0 2 3 0 2 4 0 2 5 0 2 6 0 2 7 0 2 8 0 2 9 0 3 0 0 3 1 0 320 330 340 350 360 Bearing pusher P N 420 876 501 F00B074 APPLICATION 717 and 787 engines Starter drive bearing pusher P N 290 876 502 F06B054 APPLICATION 947 engine Piston pin pu...

Page 22: ...APPLICATION 717 engine Alignment support plate kit P N 529 035 506 1 Alignment plates A P N 529 035 507 B P N 529 035 508 2 Support P N 529 035 511 3 Screw 2 P N 207 182 544 4 Lock washer 2 P N 234 181 601 5 Flat washer 2 P N 234 081 410 F00B0F4 APPLICATION All models A 155 6 mm jet pump B 139 5 mm jet pump Alignment shaft P N 295 000 141 F00B0G4 APPLICATION All models Adapter P N 529 035 590 F00B...

Page 23: ...LICATION 787 RFI and 947 engines NOTE This kit is supplementary to P N 295 500 352 Handle P N 420 877 650 A00C3V4 APPLICATION Use with pushers P N 290 876 609 and 290 877 740 Ring gear puller tool P N 420 976 235 puller ass y P N 529 035 549 puller bolt F01B294 APPLICATION 787 and 947 engines Ring gear blocking tool P N 295 000 155 F01B264 APPLICATION 787 engine Puller plate P N 529 035 533 F00B17...

Page 24: ...APPLICATION 717 engine Pliers P N 295 000 070 Oetiker 1099 F01D174 APPLICATION All models Pliers P N 295 000 054 Caillau F01B1T4 APPLICATION All models NOTE This tool is also used for the propulsion system Coupler hose P N 295 500 258 41 cm 16 in F01E0Z4 APPLICATION GTS model Fuel pressure gauge P N 529 035 591 F02B0B4 APPLICATION 787 RFI engine www SeaDooManuals net ...

Page 25: ...models Jet pump bearing remover P N 295 000 144 F01J114 APPLICATION All models Bearing seal installer P N 295 000 107 F01J4K4 APPLICATION All models except GTX and XP Inner seal installer P N 529 035 609 F08B014 APPLICATION 155 6 mm 6 1 8 in jet pump Impeller shaft guide P N 295 000 002 F01J1O4 APPLICATION All models NEW Pliers P N 295 000 054 Caillau F01B1T4 APPLICATION All models NOTE This tool ...

Page 26: ...Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 MANDATORY SERVICE TOOLS 01 02 6 SMR2000 002_01_02A FM WORKSHOP Tool board P N 295 500 608 F00A0S4 APPLICATION All models 01 www SeaDooManuals net ...

Page 27: ... 15 4 mm C P N 529 035 100 11 5 mm D P N 529 035 000 7 5 mm F01B0H4 APPLICATION A 717 engine B 787 engine C 947 engine MAG D 947 engine PTO Stroboscopic timing light P N 529 031 900 A00B4F4 APPLICATION All models A Four pin magneto harness P N 295 000 131 B Six pin magneto harness P N 295 000 136 F01B284 APPLICATION A 717 engine B 787 and 947 engines Dial indicator TDC gauge P N 295 000 143 A00B4E...

Page 28: ...els Slide hammer puller Not sold by Bombardier Snap on Handle CJ93 1 Hammer CJ125 6 Claws CJ93 4 F01J0Z4 APPLICATION 717 and 787 engines NOTE This tool is also used to pull out impeller shaft seal Protective mat P N 295 000 128 F02B0A4 APPLICATION All models Crankshaft protector P N 420 876 552 F00B034 APPLICATION For use with pullers Gear bearing puller P N 290 877 665 F04B034 APPLICATION 787 RFI...

Page 29: ...iston ring compressor 2 A P N 290 876 965 88 mm B P N 290 876 979 82 mm F01B1T4 APPLICATION A 947 engine B 717 and 787 RFI engines Digital multimeter P N 529 022 000 F01B1O4 APPLICATION All models F01D885 1 Puller ass y P N 420 877 635 2 Protective cap P N 420 876 557 P N 290 877 414 947 engine 3 Ring both ends P N 420 977 490 P N 420 977 480 947 engine 4 Ring halves PTO P N 420 977 475 2 P N 420 ...

Page 30: ...odels Hose pincher P N 529 032 500 F01B234 APPLICATION All models 35 4 3 25 2 15 1 5 60 50 4 0 30 2 0 10 Spring compressor P N 529 035 504 A01B4O4 APPLICATION XP model Suspension adjustment wrench P N 529 012 200 A25A014 APPLICATION XP model Flexible spout oil P N 414 837 300 F04B044 APPLICATION All models Flushing adapter P N 295 500 473 F00B104 APPLICATION All models except GTS Use with coupler ...

Page 31: ... APPLICATION All models NOTE This tool is also used to re move rotary valve shaft bearing Hacksaw Not sold by Bombardier Snap on HS3 F01B1M4 APPLICATION All models Machinist s square Not sold by Bombardier Snap on PMF 122 F02B064 APPLICATION GTS model Fitting remover Not sold by Bombardier Do it yourself Refer to JET PUMP section F01J2R4 APPLICATION GTS model Impeller housing remover P N 295 000 1...

Page 32: ...th wheels P N 295 000 126 F01B014 Beach wheels set of 2 wheels P N 295 000 005 F01B074 APPLICATION Dolly Tie down with ratchet 3 60 m 12 ft long P N 295 100 104 APPLICATION All models Lift kit P N 295 100 044 F00B0Z4 APPLICATION All models Tie down 1 50 m 5 ft long P N 295 100 103 F00B014 APPLICATION All models www SeaDooManuals net ...

Page 33: ... P N 293 800 060 Loctite 243 blue 10 mL F00A0O4 High strength threadlocker P N 293 800 005 Loctite 271 red 10 mL A00B2U4 High temperature threadlocker P N 420 899 788 Loctite 648 green 5 g A00B3D4 High temperature retaining compound P N 293 800 054 Loctite 642 50 mL F00B024 Retaining compound P N 413 703 100 Loctite RC 609 green 10 mL A00B2S4 General purpose instant adhesive P N 293 800 021 Loctit...

Page 34: ...413 707 000 A00B3W4 111 Primer for gasket eliminator P N 293 800 041 Loctite 764 A00B3N4 Pipe sealant A P N 293 800 018 B P N 293 800 013 A Loctite 592 B Loctite 567 50 mL 250 mL A00B2W4 Hylomar sealant P N 293 800 001 PL 32 100 g A00B3F4 Sealant P N 293 530 011 Sikaflex 221 black 350 mL F01B1D4 Ultra Copper High temp sealant P N 413 710 300 80 g A02B044 Dielectric grease P N 293 550 004 Dow Corni...

Page 35: ...N 293 800 023 Loctite 767 454 g 16 oz F01B174 R BOMBARDIER LUBE P N 293 600 016 12 x 14 oz F01B0S4 Bombardier storage oil P N 413 711 600 12 x 350 g A02B054 Sea Doo fuel stabilizer P N 413 408 600 236 mL 8 oz A00B3V4 732 Multi purpose sealant P N 293 800 033 Dow Corning 90 mL clear F01B1C4 BOMBARDIER injection oil P N 413 802 900 12 x 1 L F01B184 BOMBARDIER injection oil P N 413 803 000 3 x 4 L P ...

Page 36: ...la XP S synthetic injection oil P N 413 711 000 3 x 4 L P N 413 710 700 205 L F01B354 Sealant adhesive P N 293 800 033 Adchem 4511 clear F01B1S4 Injection Oil Two stroke The Right Stuff sealant P N 293 800 053 Permatex 198 g F00B0V4 Jet pump oil P N 293 600 011 12 x 6 oz Sea Doo synthetic jet pump oil F01B0P4 Sea Doo Cleaner P N 293 110 001 400 g P N 293 110 002 4 L F01B2J4 www SeaDooManuals net ...

Page 37: ... SMR2000 003_02_01ATOC FM 02 01 1 TABLE OF CONTENTS 0 PERIODIC INSPECTION CHART 02 02 1 FLUSHING AND LUBRICATION 02 03 1 GENERAL 02 03 1 PROCEDURE 02 03 1 WATER FLOODED ENGINE 02 04 1 GENERAL 02 04 1 PROCEDURE 02 04 1 STORAGE 02 05 1 www SeaDooManuals net ...

Page 38: ...egulator valve inspection 787 RFI and 947 engines Oil injection pump adjustment Fuel filter and oil filter inspection Fuel filter and oil filter replacement Engine head bolts or nuts retorque Steering system inspection Reverse system reverse cable adjustment if applicable Variable trim system if applicable Fastener tightening flame arrester support carburetor s engine mount exhaust system etc Muff...

Page 39: ...nd outlet and then spray BOMBARDIER LUBE lubri cant GTS Model Remove seat to allow access to cooling system Remove dust cap from fitting spigot and attach coupler hose P N 295 500 258 Make sure cou pler hose is properly locked to fitting spigot Install a hose pincher on water outlet hose CAUTION This prevents water from exiting through outlet socket Remove hose pincher after flushing operation GTS...

Page 40: ...UBE lubricant through air intake silencer keeping engine at fast idle GS GTS GTI GSX RFI AND GTX RFI MODELS 1 Air intake silencer 2 Pull plug 3 Spray BOMBARDIER LUBE here XP AND GTX MODELS 1 Air intake silencer 2 Spray BOMBARDIER LUBE here NOTE Lubrication of engine should be done at least for 1 minute After approximately half a minute close fuel valve to run engine out of fuel while lubricating C...

Page 41: ...pt GTS CAUTION Remove quick connect adapter after flushing operation if used All Models Wipe up any residual water from the engine Remove spark plug cables and connect them on the grounding device GTS MODEL 1 Spark plug cables on grounding device GS AND GTI MODELS 1 Spark plug cables on grounding device XP MODEL 1 Grounding device GTX MODEL 1 Grounding device WARNING Always use spark plug cable gr...

Page 42: ...lly depress throttle lever and connect the safety lanyard to the switch Press the start stop button to crank the engine a few turns and distribute the lubricant onto cylinder walls NOTE Proceeding in this order no fuel will be in jected into the engine Apply anti seize lubricant on spark plug threads then reinstall them Reinstall plug on air intake silencer cover GS GTS and GTI models NOTE Engine ...

Page 43: ...E Check fuel and oil reservoirs for water contamina tion If necessary siphon and refill with fresh fluids Turn fuel valve to OFF position then drain fuel filter bowl Refer to FUEL CIRCUIT Drain bilge if water is present Remove spark plug cables and connect them on the grounding device GTS MODEL 1 Spark plug cables on grounding device GS AND GTI MODELS 1 Spark plug cables on grounding device XP MOD...

Page 44: ...FI Engine Remove the filler plug of the counterbalance shaft on the engine crankcase 787 RFI ENGINE 1 Remove filler plug Insert a wire through oil filler hole to check oil con dition A whitish oil indicates water contamination and must be replaced In order to replace the oil remove the drain plug of the counterbalance shaft located on the PTO side of the lower crankcase 787 RFI ENGINE 1 Drain plug...

Page 45: ...f 30 seconds should be observed between cranking cycles NOTE If engine does not start after several at tempts check ignition system for spark occur rence Refer to IGNITION SYSTEM Check crankshaft if needed it may be misaligned or deflected Refer to BOTTOM END After engine has started spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running 717 AND 787 RFI ENGINES 1 Air i...

Page 46: ...drain hose for obstructions TYPICAL 1 Engine drain hose GSX RFI and GTX RFI Models Disconnect the water supply hose used to cool the magneto It features a quick connect fitting Press both tabs and pull fitting in order to disconnect hose This hose is located at the bottom of the magneto cover beside the engine support 1 Disconnect this hose Water should flow out of the fitting magneto cooling circ...

Page 47: ...lubricated to prevent corrosion on internal parts For proper procedure refer to FLUSHING AND LUBRICATION Propulsion System JET PUMP Lubricant in impeller shaft reservoir should be drained Reservoir should be cleaned and refilled with SEA DOO synthetic 75W90 GL5 polyolester oil Refer to JET PUMP for proper procedure CAUTION Use only SEA DOO jet pump oil or equivalent synthetic gear oil otherwise co...

Page 48: ... lubricant over all me tallic components in engine compartment Lubricate the throttle cable with BOMBARDIER LUBE lubricant The seat should be partially left opened during storage the engine cover for the XP model This will avoid engine compartment condensation and possible corrosion Additional Recommended Protection All Models In cool regions where freezing point may be en countered cooling system...

Page 49: ...ake sure the water supply hose from crankcase heat exchanger is connected to the magneto cool ing system 1 Water supply hose from crankcase heat exchanger 2 Quick connector 3 Magneto heat exchanger RFI MODELS 787 ENGINE 1 Hose pincher installed on engine drain hose Disconnect engine water return hose 717 AND 787 RFI ENGINES 1 Disconnect engine water return hose 1 F08E04A 1 F07E0EB 2 3 1 F07E0DA F0...

Page 50: ...ion appears in the engine drain hose TYPICAL 1 Hose and funnel installed at water outlet on cylinder head 2 Hose pincher installed on water supply hose Remove temporary hose and reconnect engine water return hose Remove hose pinchers All Models Most of the antifreeze will drain out when remov ing hose pincher s Use a container to recover it Dispose of antifreeze as per your local laws and regulati...

Page 51: ...ety lanyard refer to DIGITALLY ENCODED SECURITY SYSTEM Safety lanyard switch or harness damaged Replace Burnt 5 A fuse on MPEM Check wiring then replace fuse 5 A fuse keeps on burning Check wiring solenoid and MPEM Discharged battery Check recharge Battery connections Check clean tighten Water fuel hydrolock Check refer to subsection 02 04 Starter Check refer to subsection 08 04 Seized engine Chec...

Page 52: ...ction 08 02 Burnt fuel pump fuse RFI Check wiring then replace fuse Flooded engine Check refer to subsection 06 04 Carburetor needle valve stuck open Excessive rotary valve clearance if applicable Check refer to subsection 04 07 Internal engine damage Check refer to subsections 04 05 and 04 06 Sheared flywheel key Check timing mark refer to subsection 08 02 Incorrect rotary valve timing if applica...

Page 53: ...ing crankshaft seal s intake or rotary valve cover O ring Pressure check engine refer to subsection 04 02 Restricted fuel valve Check replace Loose carburetor Tighten carburetor s Rich fuel mixture Fouled spark plug Partially closed choke Check adjust choke cable Flame arrester dirty or restricted Check replace Carburetor adjustment Check adjust refer to subsection 06 04 Loose main jet Check refer...

Page 54: ...fer to subsection 08 02 Ignition timing Incorrect setting Check reset refer to subsection 08 02 Sheared flywheel key Check replace refer to subsections 08 02 and 04 04 Rotary valve if applicable Incorrect timing Check reset refer to subsection 04 07 Carburetor Carburetion to lean Check adjust refer to subsection 06 04 Engine Intake leak crankshaft seal failure Pressure check engine refer to subsec...

Page 55: ...mp pressure Incorrect throttle position sensor TPS adjustment Check and adjust TPS refer to subsection 06 05 Engine revs lower than its maximumoperationalRPM 787 RFI and 947 engines RAVE valve does not open Check refer to subsection 04 05 Peak performance is delayed until higher RPM range is reached 787 RFI and 947 engines RAVE valve is stuck opened Check refer to subsection 04 05 OTHER OBSERVATIO...

Page 56: ...is caught in intake grate or impeller Check clean Low oil level in jet pump Check troubleshoot source of leak refill supply refer to subsection 09 02 Worn anti rattle system Check replace anti rattle system refer to subsection 09 02 Damaged or bent drive shaft Check replace refer to subsection 09 03 Broken motor mounts Check replace refer to subsection 04 03 www SeaDooManuals net ...

Page 57: ... 1 DISASSEMBLY 04 04 4 CLEANING 04 04 10 ASSEMBLY 04 04 10 TOP END 04 05 1 GENERAL 04 05 4 DISASSEMBLY 04 05 7 CLEANING 04 05 14 INSPECTION 04 05 14 ASSEMBLY 04 05 17 ADJUSTMENT 04 05 25 BOTTOM END 04 06 1 DISASSEMBLY 04 06 4 CLEANING 04 06 11 INSPECTION 04 06 11 ASSEMBLY 04 06 16 ROTARY VALVE 04 07 1 GENERAL 04 07 2 INSPECTION ON WATERCRAFT 04 07 2 DISASSEMBLY 04 07 3 CLEANING 04 07 5 INSPECTION ...

Page 58: ... 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 except 947 engine NOTE If a leak is found it is important to contin ue testing as th...

Page 59: ...1 Loop hose and use clamps 2 Use two washers with exhaust manifold stud 3 Hose with adapter and nipple 787 RFI ENGINE REAR VIEW 1 Loop hose and use clamps 2 Hose with clamps Install pump to the end 3 Block engine drain hose with a hose pincher 787 RFI ENGINE FRONT VIEW 1 Exhaust manifold plate F01B2UB 1 F01B2VA 2 3 1 3 2 1 F02E0DA F02D0WA 1 www SeaDooManuals net ...

Page 60: ...and gasket s Make sure the surface of the intake manifold 717 and 947 engines or rotary valve cover 787 RFI engine are clean Install the intake plate s with fasteners from the kit and tighten adequately NOTE For the 787 RFI and 947 engines use the intake and exhaust plates included in the Supple mentary Engine Leak Test Kit P N 295 500 780 On engines with the RAVE system remove the RAVE valves and...

Page 61: ...on pump 717 engine Check also small oil injection pump lines and fit tings check for air bubbles or oil column going to ward pump which indicate a defective check valve If the above mentioned components are not leak ing block both oil hoses of the rotary valve shaft using hose pinchers NOTE If leakage stops at this point proceed with Rotary Valve Shaft testing If there is still some leakage remove...

Page 62: ...ve PTO side spark plug If pressure drops it indicates a defective PTO side crankshaft inner seal Remove MAG side spark plug If pressure drops it indicates a defective MAG side crankshaft inner seal If the above mentioned components are not leaking and there is a pressure drops remove the rotary valve cover Check the seal of the rotary valve shaft If the rotary valve shaft is not leaking it could i...

Page 63: ... COVER CHECK SEAL OF ROTARY VALVE SHAFT IS SEAL LEAKING CAREFULLY INSPECT ENGINE CASTINGS PARTICULARLY THE THREADED HOLE AREAS YES YES NO PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING CHECK TESTING KIT REPLACE O RING OF CYLINDER HEAD AND OR CYLINDER BASE GASKET YES YES NO CHECK TESTING KIT IS RESERVOIR LEAKING PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE REPLACE GASKET OR O RING RE SEA...

Page 64: ...Section 04 ENGINE Subsection 02 LEAK TEST SMR2000 007_04_02A FM 04 02 7 947 Engine F00D22S www SeaDooManuals net ...

Page 65: ...S model disconnect vent tube from battery and remove battery from watercraft GTS MODEL 1 Strap retaining RED positive cable 2 Vent tube connected and secured in support Electrical Connections It is recommended to disconnect electrical con nections prior to disconnecting fuel lines Disconnect temperature switch wire and spark plug cables Disconnect magneto wiring harness 717 ENGINE 1 Unplug connect...

Page 66: ...ore removing from bilge Refer to COOLING SYSTEM for proper water hose location Tuned Pipe To remove tuned pipe refer to EXHAUST SYSTEM Air Intake Silencer To remove air intake silencer refer to AIR INTAKE Carburetor All Models Except GSX RFI and GTX RFI Turn fuel valve to OFF Disconnect fuel supply and fuel return hoses To remove carburetor s refer to CARBURETOR for proper procedure GSX RFI and GT...

Page 67: ...two old spark plugs Weld a lock washer approximately 20 mm 3 4 in diameter on each spark plug as shown 1 Weld a lock washer 2 Old spark plug Remove spark plugs and replace by special tools Hook a sling into holes of special tools Using a chain block a hoist or other suitable equip ment slightly lift engine to ease the remaining component removal CAUTION Take care not to damage cable or oil injecti...

Page 68: ...tall a hose pincher to oil supply hoses of oil in jection pump and rotary valve shaft except the 947 engine then disconnect hoses TYPICAL 1 Hose pincher P N 295 000 076 Install a hose pincher to oil return hose of rotary valve shaft except the 947 engine then discon nect hose TYPICAL 717 ENGINE 1 Rotary valve oil supply line 2 Hose pincher installed TYPICAL 787 RFI ENGINE 1 Rotary valve oil supply...

Page 69: ... engine in watercraft is essentially the reverse of removal procedures However pay particular attention to the following Rubber Mount Shim and Screw Check tightness and condition of rubber mounts If they have been removed apply Loctite 243 blue on screw threads Torque screws to 25 N m 18 lbf ft CAUTION Strict adherence to this torque is im portant to avoid damaging threads of alumi num insert in b...

Page 70: ...N m 53 lbf in Apply dielectric grease on nut Engine Jet Pump Alignment Alignment is necessary to eliminate possible vi bration and or damage to components Check alignment of engine using the following alignment tools Support plate kit P N 529 035 506 NOTE Use plate P N 529 035 508 for the 139 5 mm 5 1 2 in jet pump and plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plate 2 Support Alig...

Page 71: ...e support screws to enable to align PTO flywheel with shaft end NOTE Use shim s P N 270 000 024 or P N 270 000 025 as necessary between engine supports and rubber mounts to correct alignment TYPICAL 1 Shim CAUTION Whenever shims are used to correct alignment never install more than 1 3 mm 0 051 in shim thickness XP Model Use plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plate 2 Suppor...

Page 72: ...sary between engine supports and rubber mounts to correct alignment TYPICAL 1 Shim CAUTION Whenever shims are used to correct alignment never install more than 1 3 mm 0 051 in shim thickness TYPICAL 1 Alignment tool 2 Seal carrier Place grease fitting on the top and torque seal car rier nuts in a criss cross sequence in two steps as per following illustration NOTE It is very important to tighten n...

Page 73: ...cable condition and lubricate cable with BOMBARDIER LUBE lubricant After its installation properly adjust and bleed oil in jection pump as specified in OIL INJECTION PUMP Check hose condition and pressure test fuel sys tem refer to FUEL CIRCUIT Verify all electrical connections Run engine and ensure there is no leakage CAUTION If watercraft is out of water engine must be cooled using the flush kit...

Page 74: ...e 243 9 N m 80 lbf in 16 6 7 Loctite 243 6 N m 53 lbf in 23 Loctite 243 6 N m 53 lbf in 22 6 N m 53 lbf in 5 Loctite 243 15 2 14 Loctite 243 13 145 N m 107 lbf in Loctite 648 3 1 25 GTS model only 9 N m 80 lbf in Anti seize lubricant 11 9 N m 80 lbf in 11 12 Anti seize lubricant 11 9 N m 80 lbf in 4 N m 35 lbf in www SeaDooManuals net PARTS ...

Page 75: ...ynthetic grease 24 18 5 Synthetic grease Loctite 243 19 3 14 Loctite 243 17 10 N m 88 lbf in 13 105 N m 77 lbf ft Anti seize lubricant Anti seize lubricant 11 9 N m 80 lbf in 6 N m 53 lbf in Anti seize lubricant 9 N m 80 lbf in Synthetic grease 1 25 9 26 Anti seize lubricant 27 4 N m 35 lbf in 20 9 N m 80 lbf in 8 www SeaDooManuals net PARTS ...

Page 76: ...gine F08D06S Loctite 243 1 9 N m 80 lbf in 11 Ground cable Dielectric grease 31 Synthetic grease 29 9 Loctite 243 13 N m 115 lbf in 20 21 9 N m 80 lbf in Loctite 243 10 30 Loctite 648 8 3 Loctite 243 14 17 13 N m 115 lbf in Loctite 648 13 115 N m 185 lbf ft www SeaDooManuals net PARTS ...

Page 77: ...eves on screws then secure puller plate on magneto flywheel so that sleeves are against fly wheel Install extension handle on end of puller plate TYPICAL 1 Sleeves on opposite side Using a suitable socket unscrew retaining nut no 13 COUNTERCLOCKWISE when facing it NOTE If socket is found too large to be inserted in puller plate machine or grind its outside diame ter as necessary TYPICAL 1 Extensio...

Page 78: ...ld and new to position armature plate Proceed as follows Before removing the armature plate find a crankcase locating lug the top one in this exam ple Place a cold chisel at the end of chosen lug then punch a mark on armature plate at this point 1 Crankcase locating lug 2 Mark armature plate at the end of lug At assembly align armature plate mark previ ously punched with the end of the correspond ...

Page 79: ... threadlocker bond 1 Heat the armature plate CAUTION Protect harness from flame Remove screws Uncrimp and unsolder BLACK RED wire from coil 1 Uncrimp and unsolder wire here 7 Battery Charging Coil To replace battery charging coil Heatthe armature plateto93 C 200 F around the screw holes to break the threadlocker bond 1 Heat the armature plate CAUTION Protect harness from flame Remove screws Uncrim...

Page 80: ...87 RFI ENGINE 1 Disconnect water inlet hose 2 Heat exchanger cover Remove oil pump shaft from flywheel nut 1 Oil pump shaft Rotor and Flywheel Remove starter Refer to STARTING SYSTEM NOTE Crankshaft can also be locked by using the PTO flywheel For procedure refer to BOTTOM END Lock ring gear using special tool 1 Ring gear blocking tool P N 295 000 134 2 Retaining plate P N 295 000 154 1 Ring gear ...

Page 81: ... tool locking ring gear Engine flywheel is easily freed from crankshaft with puller P N 420 976 235 and crankshaft pro tective cap P N 420 876 557 Insert crankshaft protector to outer end of crank shaft and fully thread puller in engine flywheel 1 Puller Tighten puller screw and at the same time tap on screw head using a hammer to release engine fly wheel from its taper Magneto Housing To remove m...

Page 82: ...screws 947 Engine Cover Loosen screws no 11 Remove engine magneto cover no 1 TYPICAL 1 Cover 2 Screw Remove oil pump shaft from flywheel nut 1 Remove oil pump shaft Rotor and Flywheel To remove the rotor no 8 or the flywheel no 3 the crankshaft must be locked For procedure refer to BOTTOM END If necessary the magneto rotor can be removed without removing the engine flywheel Remove the six screws n...

Page 83: ... to remove the stator no 9 and trigger coil no 10 from the engine magneto cover 1 Remove screws CLEANING Clean all metal components in a solvent CAUTION Clean coils and magnets using only a clean cloth Clean crankshaft taper and threads ASSEMBLY 717 Engine Generating Coil Strip end of old wire then crimp and solder on new coil Apply Loctite 243 blue to screws no 22 and in stall the new coil on arm...

Page 84: ...apply Gun Kote If not done correctly ring gear won t contact magneto fly wheel flange To apply Gun Kote proceed as follows 1 Clean thoroughly and degrease replacement part using a non oil base solvent 2 Apply coating in light thin coats using a spray gun NOTE Do not spray Gun Kote into magneto fly wheel threaded holes 3 Bake parts in oven at 175 C 350 F for 1 hour to cure Gun Kote CAUTION Do not e...

Page 85: ... magneto installation Ignition Timing For ignition timing procedures of the 717 engine refer to IGNITION SYSTEM Magneto Housing Cover Properly install O ring no 25 in magneto housing Apply Loctite 767 anti seize on screws no 11 in stall cover and wire support no 12 Torque screws no 11 in a criss cross sequence to 9 N m 80 lbf in 787 RFI Engine Stator Install the stator no 9 in magneto housing cove...

Page 86: ...ankshaft Position Sensor Install crankshaft position sensor no 18 on mag neto housing Torque screw to 9 N m 80 lbf in NOTE The throttle position sensor is not adjust able Cover Before installing cover make sure oil pump shaft is properly positioned Before installation properly install O ring no 25 in engine magneto cover no 1 Apply Loctite 767 anti seize compound on screws no 11 Torque screws in a...

Page 87: ...pply Loctite 243 blue on crankshaft taper 1 Loctite 243 blue on crankshaft taper Install flywheel and make sure to align keyway with the crankshaft Woodruff key Apply Loctite 243 blue on nut no 13 Install nut with lock washer and torque to 115 N m 85 lbf ft CAUTION Never use any type of impact wrench Unlock crankshaft Reinstall pulse fitting with washer and torque to 19 N m 14 lbf ft Cover Before ...

Page 88: ...TOP END 0 717 Engine 14 24 N m 17 lbf ft Loctite 243 Synthetic grease 1 11 12 12 2 13 Loctite 243 13 Loctite 243 Loctite 518 9 10 5 4 7 8 4 5 34 rollers 6 34 rollers 6 F00D25S Synthetic grease Synthetic grease Synthetic grease Synthetic grease www SeaDooManuals net PARTS ...

Page 89: ...12 12 2 34 rollers 13 Loctite 518 Synthetic grease 40 N m 30 lbf ft 10 Loctite 518 16 17 18 19 20 21 29 28 27 24 23 22 25 26 Loctite 243 4 5 5 7 8 3 6 F15D04S 9 N m 80 lbf in 9 Synthetic grease 15 30 Synthetic grease Loctite 243 24 N m 17 lbf ft 14 Synthetic grease www SeaDooManuals net PARTS ...

Page 90: ...f ft Loctite 243 2 Loctite 243 6 F08D09S 33 34 N m 25 lbf ft 31 5 N m 44 lbf in 16 17 18 19 20 21 29 28 27 24 23 22 25 26 Loctite 243 9 N m 80 lbf in 15 Loctite 243 34 32 9 10 30 7 8 5 3 4 5 Synthetic grease 34 rollers Synthetic grease Synthetic grease Synthetic grease www SeaDooManuals net PARTS ...

Page 91: ... RAVE system automatically changes the ex haust port height based on pressure in the exhaust system On 787 RFI and 947 engines the exhaust port height is controlled by the MPEM according to the engine RPM On top of the RAVE there is a red plastic adjust ment knob Turning the adjustment in or out changes the preload on the return spring which in turn will change the RPM at which the RAVE valve open...

Page 92: ... TOP END SMR2000 010_04_05A FM 04 05 5 RAVE VALVES OPENED 1 Pulse from crankcase 2 Check valve 3 Positive pressure to solenoid 4 Solenoid activated 5 Positive crankcase pressure to RAVE valves F06D16S 4 3 5 2 1 www SeaDooManuals net ...

Page 93: ... END 04 05 6 SMR2000 010_04_05A FM RAVE VALVES CLOSED 1 Pulse from crankcase 2 Check valve 3 Positive pressure blocked by the solenoid 4 Solenoid deactivated 5 RAVE valves are opened to atmosphere F06D16T 4 3 5 2 1 www SeaDooManuals net ...

Page 94: ...enter line of the cyl inder This is the minimum production clearance There is only a first oversize piston available for the 787 RFI and 947 engines That piston is 0 25 mm 010 in larger in diameter than the stock piston When the oversize is installed the guillotine will have a minimum clearance of 0 375 mm 015 in with the cylinder bore This is the minimum oper ating clearance the guillotine should...

Page 95: ...1 Spring Free bellows no 21 from valve piston no 20 1 Bellows removed from piston Unscrew valve piston no 20 from sliding valve no 22 NOTE Hold the sliding valve to prevent it from turning 1 Unscrew piston 2 Hold sliding valve Remove compression spring no 29 1 Remove spring F06D0SA 1 F06D0TA 1 F06D0TB 2 1 A06D26A 1 www SeaDooManuals net ...

Page 96: ..._05A FM 04 05 9 Remove supporting ring no 28 1 Remove supporting ring Remove O ring no 23 1 Remove O ring Remove sliding valve no 22 1 Remove sliding valve Remove bellows no 21 1 Remove bellows F06D27A 1 F06D28A 1 F06D0UA 1 F06D0VA 1 www SeaDooManuals net ...

Page 97: ...nt in cylinder head clean with a vacuum cleaner Remove cylinder head no 2 If shells sand salt water or any other particles are present in cylinder cooling jacket clean with a vac uum cleaner 947 Engine Disconnect hose of RAVE valves Loosen cylinder head bolts no 14 following the sequence shown in the next photo UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS Loosen nuts no 33 following the sequenc...

Page 98: ...h nuts together and unscrew the stud Repeat this operation for the other studs NOTE Studs must be removed prior cylinder block 1 Remove studs Remove cylinder block no 9 1 Remove cylinder block NOTE To ease removal a plastic tip hammer can be used Remove cylinder base gasket no 10 Piston NOTE All engines feature cageless piston pin bearings 717 and 787 RFI Engines Bring piston to Top Dead Center an...

Page 99: ...remove circlip no 5 insert a pointed tool in pis ton notch then pry it out and discard TYPICAL 1 Piston notch To extract piston pin no 4 use piston pin puller P N 529 035 503 with the appropriate set of sleeves 1 Puller 2 Shoulder sleeve 3 Sleeve Fully thread on puller handle Insert extractor spindle into the piston pin Slide the sleeve and shoulder sleeve onto the spindle WARNING Always wear safe...

Page 100: ...e bottom of the piston 1 Tool cutout toward bottom of piston Firmly hold puller and rotate handle to pull pis ton pin no 4 Rotate spindle until the shoulder sleeve is flushed with the piston recess 1 Shoulder sleeve flush with piston recess Loosen the extracting nut and remove puller Remove the shoulder sleeve from piston 1 Remove shoulder sleeve Carefully remove the piston no 3 F00B0JA 1 2 3 4 F0...

Page 101: ...ngine top end should include the following measurements N A Not Applicable NOTE Replacement cylinder sleeves are avail able if necessary Also oversize pistons of 0 25 mm 010 in are available for all engines and over size pistons of 0 5 mm 020 in are available for the 717 engine 1 2 F00B0NA ENGINE MEASUREMENT TOLERANCES NEW PARTS MIN MAX WEAR LIMIT Cylinder taper N A 0 05 mm 002 in 0 1 mm 004 in Cy...

Page 102: ...rt A 16 mm 5 8 in Cylinder Out of Round Using a cylinder bore gauge measure cylinder di ameter at 16 mm 5 8 in from top of cylinder Mea sure diameter in piston pin axis direction then per pendicularly 90 to it If the difference between readings exceed specification cylinder should be rebored and honed or replaced 1 Measuring in piston pin axis 2 Measuring perpendicularly 90 to piston pin axis A 16...

Page 103: ...ndicularly 90 to piston pin axis A 16 mm 5 8 in Read the measurement on the cylinder bore gauge The result is the exact piston cylinder wall clearance NOTE Make sure the cylinder bore gauge indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false Ring Piston Groove Clearance 717 and 787 RFI Engines Using a feeler gauge check clearance between rectan...

Page 104: ...for a precise adjustment of the combustion chamber volume To identify gasket thickness refer to the identifi cation holes on the gasket TYPICAL 1 Identification holes All Engines RAVE Valve 787 RFI and 947 Engines Check RAVE valve bellows no 21 for cracks ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following RAVE Valve 787 RFI Eng...

Page 105: ...Bottom of valve housing When the valve is mounted onto the cylinder move the valve piston no 20 to ensure the sliding valve no 22 moves easily and doesn t stick 947 Engine Install the supporting ring no 28 with the bevel side facing the O ring no 27 1 Bevel facing the O ring There is only one way to insert the sliding valve no 22 in valve housing no 25 1 Sliding valve ridge toward housing groove F...

Page 106: ...tool in the connecting rod bore Insert piston pin into piston until it comes flush with inward edge of piston hub Warm piston to approximately 50 60 C 122 140 F and install it over connecting rod NOTE Make sure thrust washers are present each side of needles Install the shoulder sleeve tool on the opposite side of the piston pin 1 Piston pin 2 Shoulder sleeve Insert extractor spindle into the pist...

Page 107: ...ver connecting rod and align bores then gently tap piston pin with a fiber hammer to push out inner plastic ring on oppo site side Support piston from opposite side As necessary pull halves of inner sleeve with long nose pliers 1 Pulling inner sleeve half Circlip Always use new circlips CAUTION Always use new circlips At installa tion take care not to deform them Circlips must not move freely afte...

Page 108: ...s To easily insert circlip into piston use circlip installer 1 Circlip installer Remove sleeve from pusher then insert circlip into its bore Reinstall sleeve onto pusher and push until cir clip comes in end of tool TYPICAL 1 Circlip near end of tool Position end of tool against piston pin opening Firmly hold piston against tool and tap tool with a plastic tip hammer to insert circlip into its groo...

Page 109: ...ckness refer to the identifi cation holes on the gasket Cylinder 717 and 787 RFI Engines To easily slide cylinder no 9 over piston install on piston ring compressor P N 290 876 979 1 Slide this edge NOTE Ring compressor will not fit on oversize parts Make sure to align ring end gap with piston locat ing pin Slide tool over rings 1 Ring end gap aligned with piston locating pin Slide cylinder over p...

Page 110: ...ith corresponding holes in cylin der block 1 Dowel To easily slide cylinder block over pistons use ring compressor P N 290 876 965 1 Slide this edge NOTE For each ring make sure to align ring end gap with piston locating pin Install cylinder block Install O rings no 31 CAUTION The O rings must be installed and properly positioned in the cylinder block The O rings are meant to dampen stud vibration...

Page 111: ... spark plug holes and O ring no 11 of cylinder head as shown in the following illustration 1 O rings Apply Loctite 518 in O ring groove of cylinder sleeves Install cylinder head 947 Engine Apply Loctite 243 blue on the threads of the cyl inder block studs no 32 Apply Loctite 243 blue below head of cylinder head bolts no 14 Apply synthetic grease on threads of cylinder head bolts no 14 Torque bolts...

Page 112: ... 1 Knob fully tightened This will ensure the correct preload on the return spring no 19 in order to open and close the RAVE valve at the proper RPM Combustion Chamber Volume Measurement All Engines NOTE This procedure is required to determine the thickness of the cylinder base gasket to be in stalled if a crank repair has involved replacement of connecting rods or if you are experiencing re petiti...

Page 113: ...stand upward for about 10 minutes until liquid level is stabilized 6 Read the burette scale to obtain the quantity of liquid injected in the combustion chamber Compare the obtained value with the table below The volume should be within the allowable range If the volume of the combustion chamber is not within specifications change cylinder base gasket thickness as follow To increase the volume of t...

Page 114: ...octite 518 11 Molykote 111 4 Anti seize lubricant 12 3 1 6 5 6 Anti seize lubricant Loctite 642 12 4 Anti seize lubricant Loctite 243 6 6 4 5 Loctite 518 2 11 7 24 N m 17 lbf ft 10 10 N m 88 lbf in Loctite 518 Loctite 518 8 40 N m 30 lbf ft 4 9 F00D0YT Molykote 111 Molykote 111 Molykote 111 www SeaDooManuals net PARTS ...

Page 115: ...nt 4 Loctite 243 Loctite 642 Anti seize lubricant Loctite 518 Loctite 518 40 N m 30 lbf ft Loctite 518 Loctite 518 24 N m 17 lbf ft 30 mL 1 oz SAE 30 motor oil 5 6 12 6 15 16 6 4 6 2 7 11 12 18 11 4 3 4 19 15 14 F01D92T 9 N m 80 lbf in Anti seize lubricant Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 8 40 N m 30 lbf ft 8 7 24 N m 17 lbf ft www SeaDooManuals net PAR...

Page 116: ... ft Loctite 243 115 N m 85 lbf ft 23 N m 17 lbf ft XP only 40 N m 30 lbf ft Loctite 518 Molykote 111 27 N m 20 lbf ft Molykote 111 40 N m 30 lbf ft Loctite 518 Loctite 518 Molykote 111 10 N m 89 lbf in 27 N m 20 lbf ft 27 N m 20 lbf ft Molykote 111 Loctite 518 Synthetic grease Synthetic grease Loctite 242 9 N m 80 lbf in Loctite 518 Anti seize lubricant Anti seize lubricant 40 mL 1 35 oz SAE 30 mo...

Page 117: ...tool in PTO flywheel splines TYPICAL 1 PTO flywheel remover P N 295 000 001 Using a suitable wrench or socket with a breaker bar unscrew PTO flywheel COUNTERCLOCK WISE when facing it and hold extension handle locking the magneto flywheel TYPICAL 1 Extension handle locking crankshaft NOTE When splines of PTO flywheel are worn out and special tool cannot be used proceed with the following alternate ...

Page 118: ...en facing it 947 Engine Except XP Use PTO flywheel remover P N 295 000 001 to hold flywheel and remove Allen screws no 21 re taining coupler no 20 to PTO flywheel PTO FLYWHEEL REMOVER TOOL GSX AND GTX MODELS 1 Loosen Allen screws 2 Breaker bar locking crankshaft Remove the coupler no 20 XP Model Remove Allen screws no 21 XP MODEL 1 PTO flywheel 2 Coupler 3 Loosen Allen screw F06I02A 1 F01J0TA F06D...

Page 119: ... 3 Loosen bolt with socket and breaker bar Remove the PTO flywheel using puller plate P N 529 035 533 and puller P N 529 035 547 and bolt P N 529 035 549 1 Puller plate 2 Puller 3 Bolt 4 Extension handle Starter Drive Assembly 947 Engine Only Loosen 2 Allen screws no 24 retaining starter drive cover no 25 1 Cover 2 Allen screw Remove starter drive cover no 25 and spring no 9 Remove starter drive a...

Page 120: ...lve except 947 engine starter drive assembly 947 engine reed valves 947 engine 717 and 787 RFI Engines Put engine on a trestle Loosen crankcase screws 717 ENGINE 1 M10 x 73 5 flanged screws 2 M8 x 68 5 flanged screws 3 M8 x 45 Socket head screws 787 RFI ENGINE 1 M10 x 75 flanged screws 2 M8 x 55 flanged screws 947 Engine Place engine upright on crankcase magneto side Loosen crankcase screws 947 EN...

Page 121: ...t for the MAG side seal on the 787 RFI engine which is mounted on the magneto housing NOTE Do not needlessly remove crankshaft bear ings Remove end seal s TYPICAL 1 End seal 717 Engine To remove end bearings no 4 from crankshaft use the following tools 717 ENGINE 1 Puller P N 420 877 635 2 Protective cap P N 420 876 557 3 Distance ring MAG side only P N 420 876 569 4 Ring both sides P N 420 977 49...

Page 122: ...8 x 70 P N 420 841 201 NOTE To facilitate ring or distance ring installa tion lubricate their inside diameters 947 Engine To remove end bearings from crankshaft use the following tools 947 ENGINE 1 Puller P N 420 877 635 2 Protective cap P N 290 877 414 3 Distance ring P N 420 876 569 4 Ring P N 420 977 480 5 Ring halves P N 420 876 330 6 Screw P N 420 940 755 All Engines TYPICAL 1 Removing cranks...

Page 123: ...re puller in a vise and remove gear and bearing NOTE If the inner PTO bearing needs to be re placed remove the Woodruff key on the crank shaft Counterbalance Shaft 787 RFI Engine Bearings no 15 on counterbalance shaft no 13 can be removed by using the following tools 1 Puller P N 420 877 635 2 Protective cap P N 420 876 557 3 Ring P N 420 977 480 4 Ring halves P N 420 876 330 5 Screw M8 x 40 P N 4...

Page 124: ...32 Use a press to remove gear no 14 CLEANING Discard all oil seals gaskets O rings and sealing rings Clean oil passages and make sure they are not clogged Clean all metal components in a solvent Remove old Loctite from crankcase mating surfac es with gasket remover P N 413 708 500 CAUTION Be careful not to spray cleaner on the painted surface of the engine Never use a sharp object to scrape away o...

Page 125: ...ton at Top Dead Center As a needle pointer secure a wire with a cover screw and a washer Rotate degree wheel NOT crankshaft so that needle pointer reads 360 TYPICAL 1 TDC gauge 2 Degree wheel 3 Hand tighten nut 4 Needle pointer Remove TDC gauge and install on PTO side Bring PTO piston at Top Dead Center Interval between cylinders must be exactly 180 therefore needle pointer must indicate 180 on de...

Page 126: ...other evidence of wear Make sure plastic cage is not melted Ro tate and make sure they turn smoothly Crankshaft NOTE If crankshaft and or components are found defective it must be repaired by a specialized shop or replaced Connecting Rod Straightness Align a steel ruler on edge of small end connecting rod bore Check if ruler is perfectly aligned with edge of big end 1 Ruler must be aligned with ed...

Page 127: ...ctly measured between centers of a lathe Connecting Rod Big End Axial Play Using a feeler gauge measure distance between thrust washer and crankshaft counterweight 1 Measuring big end axial play 2 Feeler gauge 1 F01D97A F01D98A 1 CONNECTING ROD BIG END AXIAL PLAY MODEL NEW PARTS WEAR LIMIT MIN MAX 947 engine 0 390 mm 015 in 0 737 mm 029 in 1 2 mm 047 in 787 RFI engine 0 230 mm 008 in 0 617 mm 024 ...

Page 128: ...ome firmly tight against bearing Slide puller hammer outwards and tap puller end Retighten claws as necessary to always maintain them tight against bearing Continue this way until bearing completely comes out For installation see below in this section Reed Valve 947 Engine Only Check reed valve petals no 29 for cracks or other defects The reed petals must lie completely flat against the reed valve...

Page 129: ...xpand bearing and ease instal lation To properly position the outer bearing s a dis tance gauge must be temporarily installed against the inner bearing Slide the outer bearing until stopped by the distance gauge then remove it 1 Distance gauge TYPICAL 1 Distance gauge 2 Outer bearing Distance Ring When installing the distance ring no 12 make sure to position it with its chamfer toward the counterw...

Page 130: ...Position PTO seal against the retaining shim the gap between the seal no 5 and bearing no 4 will ensure proper lubrication of the bearing 1 Seal against the retaining shim 947 Engine Seals are positioned with the outer lip in the crank case recess 1 Seal lip in crankcase recess Drive Pin Make sure drive pins no 6 of bearings are proper ly installed in crankcase recesses at assembly 1 Drive pins F0...

Page 131: ...are not aligned with the crankcase re move the gear and repeat the procedure until the notches are properly aligned 947 Engine Install bearing no 31 and washer no 32 When installing seals no 17 apply a light coat of Molykote 111 on seal lips Prior to installation place bearings no 15 into a container filled with oil previously heated to 75 C 167 F This will expand bearings and ease their installat...

Page 132: ...e as single halves Prior to joining crankcase halves apply a light coat of Loctite 518 on mating surfaces Do not apply in excess as it will spread out inside crankcase NOTE On aluminum material it is recommended to use Loctite Primer N to reduce curing time and increase gap filling capability Refer to manufactur er s instructions 717 and 787 RFI Engines Rotary valve shaft must be installed in cran...

Page 133: ...ote 111 below head screws Torque crankcase screws to 24 N m 17 lbf ft as per following illustrated sequence Torque 2 M10 crankcase screws to 40 N m 30 lbf ft 1 Torque to 40 N m 30 lbf ft 787 RFI Engine Apply Loctite 518 on screw threads and Molykote 111 below head screws Torque crankcase screws to 12 N m 9 lbf ft as per following sequence Repeat procedure re tightening all screws to 24 N m 17 lbf ...

Page 134: ...al step torque only the M10 x 73 5 bolts to 40 N m 30 lbf ft as per following sequence Oil Fittings 717 and 787 RFI Engines If inlet and outlet oil fittings no 11 of rotary valve shaft have been removed from crankcase rein stall them with their end pointing toward ignition housing Apply Loctite 518 on threads of fittings Stud 717 Engine At assembly in crankcase apply Loctite 518 on threadsof studs...

Page 135: ...sassembly proce dure torque bolt no 22 to 115 N m 85 lbf ft Apply Loctite 648 on mating surface of PTO fly wheel and coupler Apply Loctite 243 blue to Allen screws no 21 of coupler and torque to 23 N m 17 lbf ft Final Assembly 717 and 787 RFI Engines For rotary valve timing and assembly procedures refer to ROTARY VALVE 787 RFI Engine When engine assembly is completed add 30 mL 1oz of motor oil SAE...

Page 136: ...00 012_04_07A FM 04 07 1 ROTARY VALVE 0 717 and 787 RFI Engines F00D26S 8 2 20 N m 15 lbf ft Molykote 111 7 10 6 9 5 11 3 4 14 15 717 engine 13 12 1 20 N m 15 lbf ft 9 N m 80 lbf in 2 1 12 787 RFI engine Anti seize lubricant www SeaDooManuals net PARTS ...

Page 137: ...d the soldering wire method 45 FEELER GAUGE METHOD Remove O ring no 12 from rotary valve cover no 1 Remove intake manifold from rotary valve cover except 787 engine Reinstall cover no 1 in place WITHOUT its O ring and torque screws to 20 N m 15 lbf ft Insert feeler gauge blade through cover inlet ports to verify clearance At least verify clearance at two different places in each port Feeler gauge ...

Page 138: ...ust remain as per original setting NOTE If rotary valve crankcase surface is worn it is possible to have it reworked at the factory Contact your dealer or distributor Rotary Valve Shaft Gear Backlash Remove PTO flywheel guard Remove spark plugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this way to complete one revol...

Page 139: ...ing and remove circlips no 5 1 Compress seat 2 Remove circlips Shaft Bearing To remove bearing no 8 use a bearing extractor such as Snap on no CJ 950 or equivalent as illus trated Slide off distance sleeve no 14 remove snap ring no 7 and washer no 15 then press shaft out 1 Bearing 2 Bearing extractor Snap on CJ 950 CAUTION Ensure that rotary valve shaft is per fectly perpendicular with press tip E...

Page 140: ...14 INSPECTION Rotary Valve Cover Inspect rotary valve cover no 1 for warpage Small deformation can be corrected by surfacing with fine sand paper on a surface plate Surface part against oiled sand paper Bearings Inspect bearings no 8 and no 9 Check for scor ing pitting chipping or other evidence of wear Make sure plastic cage on bigger bearing is not melted Rotate them and make sure they turn smoo...

Page 141: ...2 Pusher Seal Apply lithium grease on seal lips Position seal no 11 with shielded portion against shaft splines Bearing Install ball bearing as illustrated 1 Seal 2 Ball bearing 3 Bearing extractor Snap on CJ 950 Install washer no 15 snap ring no 7 and slide dis tance sleeve no 14 on shaft 1 Seal 2 Ball bearing 3 Snap ring 4 Distance sleeve 5 Washer 0 5 mm 020 in 6 Rotary valve shaft Rotary Valve ...

Page 142: ...er P N 290 876 609 and handle P N 290 877 650 1 Pusher 2 Handle Push shaft until it stops on bearing seat 717 and 787 RFI Engines Snap Ring Position snap ring no 4 so that its sharp edge faces outwards Rotary Valve The rotary valve no 13 controls the opening and closing of the inlet ports Therefore its efficiency will depend on the precision of its installation IDENTIFICATION OF THE ROTARY VALVE A...

Page 143: ...VALVE 04 07 8 SMR2000 012_04_07A FM There is no identification code on the valve To find out the duration place an angle finder on the valve and measure the valve cut out angle or use the following template F01D73W 159 www SeaDooManuals net ...

Page 144: ...l with BOTTOM of MAG side inlet port Then find 147 line on inner scale of degree wheel and mark crankcase at this point OPENING MARK Step Bottom of MAG inlet port Align 360 line of degree wheel Step Find 147 on inner scale of degree wheel and mark here NOTE Do not rotate the crankshaft ENGINE TIMING OPENING BTDC CLOSING ATDC 717 147 5 65 5 5 787 RFI 147 5 63 5 5 360 350 340 330 320 3 1 0 3 0 0 2 9...

Page 145: ... and mark here Remove degree wheel Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC NOTE Rotary valve is asymmetrical Therefore try flipping it over then reinstall on splines to obtain best installation position Apply BOMBARDIER injection oil on rotary valve be fore reassembling rotary valve cover Remove TDC gauge Rotary Valve Cove...

Page 146: ...S Loctite 243 8 25 N m 18 lbf ft 10 N m 88 lbf in GTS GS GTI 9 19 18 10 19 6 Loctite 243 4 15 4 N m 35 lbf in 3 1 5 7 Loctite 243 16 17 24 N m 17 lbf ft 12 13 Molykote 111 14 2 11 4 N m 35 lbf in Silicone sealant 27 N m 20 lbf ft 2 11 4 N m 35 lbf in 27 N m 20 lbf ft Silicone sealant www SeaDooManuals net PARTS ...

Page 147: ...5D02S Loctite 518 7 9 16 40 N m 30 lbf ft Loctite 243 14 19 18 19 6 Loctite 243 1 3 10 19 18 19 25 N m 18 lbf ft 2 13 12 4 N m 35 lbf in 1 1 20 25 N m 18 lbf ft Loctite 243 22 1 21 1 26 2 27 1 11 28 24 1 4 N m 35 lbf in 1 1 24 Loctite 17914 sealant 25 Silicone sealant www SeaDooManuals net PARTS ...

Page 148: ... 18 lbf ft 18 19 25 N m 18 lbf ft 10 4 14 N m 10 lbf ft 16 22 21 47 N m 35 lbf ft Loctite 243 25 N m 18 lbf ft 18 19 6 Loctite 243 25 N m 18 lbf ft 5 XP only 2 3 4 N m 35 lbf in 1 11 Silicone sealant 23 N m 17 lbf ft 1 38 N m 28 lbf ft 20 14 12 13 Ultra Cooper Sealant 7 9 48 N m 35 lbf ft 15 www SeaDooManuals net PARTS ...

Page 149: ... hose TYPICAL 1 Bleed hose removed 2 Injection hose removed 3 Supply hose removed Loosen exhaust hose collar no 1 at tuned pipe outlet Disconnect strap no 2 retaining muffler no 11 Remove exhaust hose no 3 from tuned pipe by pulling muffler Remove clamp no 4 from tuned pipe Remove tuned pipe cone no 5 Remove tuned pipe retaining screw no 6 from ex haust manifold side Remove screws no 7 nut no 8 an...

Page 150: ...pe head flange Remove screw no 6 and screw no 20 retaining tuned pipe to engine Remove tuned pipe from watercraft 947 Engine Disconnect water return hose at tuned pipe head no 10 1 Water return hose Disconnect small hose from water outlet fitting at the tuned pipe head no 10 1 Disconnect hose from outlet fitting Disconnect the water injection hose at tuned pipe head no 10 1 Water injection hose Di...

Page 151: ...e clamp no 4 retaining tuned pipe head no 10 to tuned pipe cone no 5 1 Loosen and remove clamp Loosen Allen screw retaining carburetor bracket to tuned pipe head 1 Loosen Allen screw Loosen Allen screws no 7 and nut no 8 at tuned pipe flange NOTE To loosen nut use polygonal wrench P N 529 035 505 1 Tuned pipe flange 1 F06D14A 1 F06D1SA F06D2DA 1 1 F06D1TA www SeaDooManuals net ...

Page 152: ...ld Use a M10 x 1 5 screwtap to clean the 4 threaded holes on the Y manifold and the 2 threaded holes on tuned pipe Clean out the debris with a spray cleaner and air pressure CAUTION It is very important that the threads are free of debris before installing new self locking fasteners Exhaust Manifold Remove 8 Allen screws no 12 and lock washers no 13 then withdraw exhaust manifold Resonators Upper ...

Page 153: ... flow regulator valve except 717 engine TYPICAL 1 Water supply hose 2 To injection fitting on tuned pipe Disconnect retaining strap no 2 of muffler Pull muffler no 11 out of bilge NOTE On GSX and XP remove the VTS motor Refer to VARIABLE TRIM SYSTEM TUNED PIPE REPAIR This procedure is given to repair tuned pipe cracks using T I G welding process Procedure Sand the cracked area to obtain bare metal...

Page 154: ...e properly posi tioned prior to finalizing manifold installation 717 Engine Apply Molykote 111 on threads of screws no 12 Install exhaust manifold no 14 and torque screws no 12 to 24 N m 17 lbf ft as per following illus trated sequence 787 RFI Engine Apply Loctite 518 on 2 screws no 12 On the oth er screws no 12 apply Molykote 111 on threads Install screws Refer to the following illustration for p...

Page 155: ...exhaust manifold prior to finalizing pipe instal lation Apply Loctite 243 blue on nut no 8 and screws no 6 and no 7 Hand tighten all fasteners before torquing any of them For torquing specifications see the main illustra tions at the beginning of this subsection Install tuned pipe cone no 5 with collar no 15 and clamp no 4 Position clamp no 4 as illustrated Do not tighten clamp yet 1 Clamp 2 Exhau...

Page 156: ...torque the Allen screws no 7 to 47 N m 35 lbf ft using the same sequence that the previous step First torque screw no 20 to 25 N m 18 lbf ft then torque screw no 6 to 25 N m 18 lbf ft 947 Engine Make sure to install the sealing ring no 15 on tuned pipe cone if it was removed TYPICAL 1 Sealing ring Apply a thin layer of Ultra Copper heat resistant sealant P N 413 710 300 all around sealing ring no ...

Page 157: ...5 lbf ft and the nut no 8 to 38 N m 28 lbf ft Use the same order as the previous step Torque bolt of tuned pipe head above the engine magneto to 40 N m 29 lbf ft 1 Torque bolt to 40 N m 29 lbf ft Torque bolt of tuned pipe cone beside the engine water return hose to 40 N m 29 lbf ft 1 Torque bolt to 40 N m 29 lbf ft Install the recovery envelope no 22 and secure with a tie rap Torque clamp of tuned...

Page 158: ...05 COOLING SYSTEM Subsection 01 TABLE OF CONTENTS SMR2000 014_05_01ATOC FM 05 01 1 TABLE OF CONTENTS 0 CIRCUIT COMPONENTS AND CARE 05 02 1 CIRCUIT 05 02 8 COMPONENTS 05 02 12 CARE 05 02 15 www SeaDooManuals net ...

Page 159: ...and GTX RFI Models F02E08S Loctite 592 Engine drain hose Water injection hose Tune pipe water inlet hose Outlet Inlet Hull Loctite 592 Loctite 592 Loctite 592 Loctite 592 1 2 N m 11 lbf in 1 2 N m 11 lbf in 7 8 10 0 11 N m 1 lbf in 9 6 5 0 6 N m 5 lbf in 5 N m 44 lbf in 1 5 6 Regulator valve water supply hose www SeaDooManuals net PARTS ...

Page 160: ...te 592 3 Loctite 592 Bleed hose Loctite 592 Water injection hose 1 2 N m 11 lbf in Tuned pipe water inlet hose 1 2 N m 11 lbf in Engine water outlet hose Loctite 592 Engine drain hose 1 2 N m 11 lbf in 1 2 N m 11 lbf in Cooling System Indicator CSI Loctite 592 To exhaust outlet Engine water supply hose www SeaDooManuals net PARTS ...

Page 161: ... 3 Loctite 592 Loctite 592 1 2 N m 11 lbf in Loctite 592 Loctite 592 1 2 N m 11 lbf in 2 1 2 N m 18 lbf in 2 5 N m 22 lbf in Bleed hose Water injection hose Tuned pipe water inlet hose Engine water supply hose Engine drain hose 1 2 N m 11 lbf in Cooling System Indicator CSI Engine water return hose To exhaust outlet 1 www SeaDooManuals net PARTS ...

Page 162: ... 02 4 SMR2000 014_05_02A FM XP and GTX Models 11 N m 1 lbf in 10 6 5 9 8 5 N m 44 lbf in Loctite 592 Loctite 592 Loctite 592 Loctite 592 8 12 13 12 14 Loctite 592 Loctite 592 1 2 N m 11 lbf in 1 2 N m 11 lbf in Loctite 592 Loctite 592 F02E09S 1 www SeaDooManuals net PARTS ...

Page 163: ...g Calibrated outlet fitting limits water flow ALSO used as flushing connector Cooling System Indicator CSI Small stream of water flows out of bleed outlet located behind stern ring Engine water hose outlet Pressure zone Calibrated outlet fitting limits water flow Tuned pipe bleed hose injects water into muffler to cool exhaust components Lowest point of circuit allows draining whenever engine is s...

Page 164: ...rformance improvement Water flows through the tuned pipe and manifold water jackets then to the cylinder water jackets Engine water supply hose Magneto heat exchanger water outlet hose exits at the exhaust outlet for noise reduction Serial cooling system cylinder head combustion chambers are cooled with the water from the jet pump Engine heat exchanger inlet Engine drain hose supplies crankcase he...

Page 165: ...t components Engine water supply hose fitting Temperature sensor activates monitoring beeper when temperature exceeds 86 94 C 187 201 F Water flows out of tuned pipe water jacket Water flows out of exhaust manifold water jacket and through tuned pipe water jacket before exiting the tuned pipe Water injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and perf...

Page 166: ...m jet pump 3 Water exiting head assembly to tuned pipe exhaust manifold and cylinders 4 Water from cylinder water jackets exiting engine The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation Water is pre heated by the exhaust system before entering the cylinder cooling jackets Water enters cylinder cooling jacket through pas sages located below exhaust port...

Page 167: ...ase heat exchanger 4 Water outlet hose to exhaust outlet The magneto heat exchanger supply hose has a quick connect hose fitting to facilitate engine draining 1 Heat exchanger water supply hose 2 Quick connect hose fitting The water coming out of the magneto heat ex changer is evacuated at the exhaust outlet for noise reduction 947 Engine The 947 engine has a conventional cooling sys tem The water...

Page 168: ...head through passages locat ed above and below exhaust ports 1 Water passages Water exits tuned pipe water jackets through an outlet fitting 1 Engine water outlet Water circulates in the water outlet hose and is expelled out of the cooling system through a fit ting located in the jet pump support on the tran som of the watercraft Draining of the cooling system is accomplished by the drain hose con...

Page 169: ...ose The water supply of the water flow regulator is provided by the water supply hose coming from the pump 1 Water flow going to CSI The lower hose of the valve is the water supply and the upper hose is the regulated injection water for the tuned pipe 1 Water from engine water supply hose 2 Regulated injection water to the tuned pipe 3 Muffler Regulated water is injected in the tuned pipe by a cal...

Page 170: ...se level and cools components of the exhaust sys tem CAUTION The elbow fittings are calibrated and can not be interchanged with one of a different size as severe engine damage could result The elbow fitting can be identified by using the number stamped onto the fitting or by measuring its inside diameter Refer to the following illustra tion and chart 1 Stamped number A Outlet diameter 4 6 mm 181 i...

Page 171: ...regulator valve has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe CAUTION Do not change the calibration of the spring otherwise serious engine damage can occur At low speed water pressure in the supply hose of the regulator valve is not sufficient to overcome the spring of the regulator valve more water is being delivered to the injection fitting at t...

Page 172: ...e the water flow regulator valve should be considered in the troubleshooting of the problem Disassembly Remove the cover no 6 of the valve by releasing the spring no 5 1 Spring 2 Cover Remove fitting no 7 from valve housing 1 Fitting Unscrew the tapered needle no 8 NOTE Hold the valve to prevent it from turning 1 Tapered needle Remove the tapered needle from valve housing 1 Remove tapered needle W...

Page 173: ...se is available unnecessary for models with the hose adapter to connect to the fitting spigot A garden hose is used to flush the whole system by backwash For flushing procedure refer to FLUSHING AND LU BRICATION For winterization of cooling system refer to STOR AGE GS GTS and GTI Models When servicing the hull always rotate watercraft counterclockwise seen from the rear Rotating watercraft on the ...

Page 174: ...e exhaust system Without the engine run ning there isn t any exhaust pressure to carry the water out the exhaust outlet CAUTION Failure to do this may result in dam age to the engine If you must tow a stranded watercraft in water and do not have a hose pincher be sure to stay well below the maxi mum towing speed of 24 km h 15 MPH Snugly install the hose pincher on the water sup ply hose as shown i...

Page 175: ...TMENTS 06 04 8 FUEL INJECTION 06 05 1 INTRODUCTION 06 05 2 AIR INDUCTION 06 05 2 FUEL DELIVERY 06 05 2 ELECTRONIC MANAGEMENT 06 05 4 DIAGNOSTIC PROCEDURES 06 05 6 FAULT CODE TABLES 06 05 7 COMPONENT INSPECTION 06 05 9 AIR INDUCTION SYSTEM 06 05 9 FUEL DELIVERY 06 05 9 ELECTRONIC MANAGEMENT 06 05 11 RFI SENSORS RESISTANCE VALUES 06 05 16 TROUBLESHOOTING SUMMARY 06 05 17 ENGINE DOES NOT START 06 05 ...

Page 176: ...EMOVAL AND INSTALLATION 06 05 19 THROTTLE POSITION SENSOR TPS 06 05 19 AIR TEMPERATURE SENSOR ATS 06 05 19 AIR PRESSURE SENSOR APS 06 05 19 WATER TEMPERATURE SENSOR WTS 06 05 19 CRANKSHAFT POSITION SENSOR CPS 06 05 19 FUEL PUMP ASSEMBLY 06 05 19 FUEL INJECTOR 06 05 20 www SeaDooManuals net ...

Page 177: ...17S 22 N m 16 lbf ft 8 4 N m 35 lbf in 4 4 N m 35 lbf in 5 7 Body Body 6 6 7 Body GTI GS 2 N m 18 lbf in 6 N m 53 lbf in 1 2 N m 11 lbf in 3 N m 27 lbf in 2 1 3 1 2 N m 11 lbf in 1 2 N m 11 lbf in 4 N m 35 lbf in 12 11 10 3 N m 27 lbf in 9 14 13 1 2 N m 11 lbf in Engine Dielectric grease 4 www SeaDooManuals net PARTS ...

Page 178: ... lbf in 2 N m 18 lbf in 6 N m 53 lbf in 1 2 N m 11 lbf in 7 6 22 N m 16 lbf ft 4 N m 35 lbf in 3 N m 27 lbf in 5 4 N m 35 lbf in Dielectric grease 4 14 9 8 10 11 12 1 2 N m 11 lbf in 1 2 N m 11 lbf in Engine Body 4 1 2 N m 11 lbf in 1 2 N m 11 lbf in 4 N m 35 lbf in 1 2 N m 11 lbf in 13 F06F0RS www SeaDooManuals net PARTS ...

Page 179: ...MR2000 015_06_02A FM 06 02 3 XP Model F08F06S Engine 1 2 N m 11 lbf in 1 2 6 N m 53 lbf in 2 N m 18 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 6 7 12 11 13 9 8 10 14 13 4 5 4 22 N m 16 lbf ft 4 N m 35 lbf in www SeaDooManuals net PARTS ...

Page 180: ...MR2000 015_06_02A FM GTS Model F02F1YS 3 N m 27 lbf in 2 N m 18 lbf in 6 N m 53 lbf in 1 2 3 7 6 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in Engine Dielectric grease 14 4 N m 35 lbf in 9 8 10 11 12 4 5 22 N m 16 lbf ft 13 4 www SeaDooManuals net PARTS ...

Page 181: ...L SYSTEM Subsection 02 FUEL CIRCUIT SMR2000 015_06_02A FM 06 02 5 GTX RFI and GSX RFI Models F02F1WS Body 6 7 2 1 10 10 11 8 22 N m 16 lbf ft 4 N m 35 lbf in 5 4 4 N m 35 lbf in 4 13 14 3 www SeaDooManuals net PARTS ...

Page 182: ...n engine cover and remove basket GTS Model Press on vent tube upper part to enable to with draw tube from body TYPICAL 1 Press on vent tube All Models Turn the fuel valve to OFF position Unscrew fuel filler cap to remove any fuel pres sure in system WARNING Whenever repairing the fuel system always verify for water infiltration in reservoir Re place any damaged leaking or deteriorated fuel lines F...

Page 183: ... Up All Models Except GSX RFI and GTX RFI NOTE The baffle pick up has an integrated fuel sender for the fuel gauge 1 Pick up tube 2 Fuel sensor 3 Baffle pick up Disconnect BLACK negative cable then RED pos itive cable of battery GTS Model Open storage compartment cover Remove storage basket from watercraft Siphon fuel tank F01F01A 2 1 1 2 F01F04A WARNING Always disconnect battery cables exactly in...

Page 184: ...tank 1 Disconnect fuel filler hose Loosen lock nut and remove fuel filter from re verse system support 1 Remove fuel filter Disconnect the fuel lines from baffle pick up and loosen lower clamp no 10 NOTE Identify fuel line positions to ease reas sembly 1 Disconnect fuel hoses 2 Loosen lower clamp F02L14A 1 F02F1MA 1 F02F1NA 1 F02F1OA 1 2 www SeaDooManuals net ...

Page 185: ...and loos en lower clamp no 10 TYPICAL 1 Disconnect fuel hoses 2 Loosen lower clamp Disconnect wiring harness of fuel sender Remove baffle from fuel tank All Models Remove upper clamp no 12 from adapter no 11 and slide adapter from baffle Push inward on the 3 clips at the base of the baffle in order to remove the filter Pry base off using a small slotted screwdriver if necessary Fuel tank All Model...

Page 186: ...ilt up in fuel system the valve should open at 10 kPa 1 5 PSI to release the pressure NOTE It is a one way valve with an arrow to indi cate the air flow Check Valve Black side of the one way check valve no 7 is the valve outlet It allows air to get in reservoir Baffle Pick Up Filter Inspect filter no 9 of baffle pick up Clean or re place as necessary Fuel Tank Visually inspect the inside and outsi...

Page 187: ...m 27 lbf in GTS Model Only Insert vent tube in body and clip it in place 1 Install vent tube FUEL SYSTEM PRESSURIZATION Pressure Test All Models Proceed as follows Fill up fuel tank Disconnect air inlet hose of fuel tank from body Install a hose pincher P N 295 000 076 on fuel tank vent hose TYPICAL 1 Disconnect air inlet hose 2 Install a hose pincher to vent hose Connect pump gauge tester P N 529...

Page 188: ...sure the battery is fully charged Battery voltage must be over 12 volts Press on both tabs and pull quick connect fitting to disconnect the fuel hose from fuel rail 1 Quick connect fitting 2 Fuel rail Install fuel pressure gauge P N 529 035 591 be tween fuel rail and fuel hose from fuel tank FUEL PRESSURE GAUGE P N 529 035 591 Install the safety lanyard cap on the switch to ac tivate the fuel pump...

Page 189: ...M Subsection 03 AIR INTAKE SMR2000 016_06_03A FM 06 03 1 AIR INTAKE 0 GS GTS and GTI Models F02F26S 10 N m 89 lbf in 3 4 2 10 N m 89 lbf in 8 6 10 N m 89 lbf in Loctite 518 10 Loctite 518 5 9 1 7 www SeaDooManuals net PARTS ...

Page 190: ...on 06 FUEL SYSTEM Subsection 03 AIR INTAKE 06 03 2 SMR2000 016_06_03A FM GSX RFI and GTX RFI Models F15F01S 2 1 4 9 3 10 N m 89 lbf in 5 10 10 N m 89 lbf in 6 7 10 N m 89 lbf in 8 www SeaDooManuals net PARTS ...

Page 191: ...Section 06 FUEL SYSTEM Subsection 03 AIR INTAKE SMR2000 016_06_03A FM 06 03 3 XP and GTX Models F08F0DS 2 Loctite 243 11 12 3 4 Loctite 243 3 13 www SeaDooManuals net PARTS ...

Page 192: ...no 3 and air intake silencer base no 4 1 Retaining plate 2 Remove screws Flame Arrester Base Remove flame arrester no 5 Remove screws no 8 retaining support no 6 of flame arrester base to the cylinder head cover 717 engine or to the exhaust manifold 787 engine TYPICAL 1 Remove support Remove screws no 10 from flame arrester base then withdraw base 947 Engine Air Intake Silencer Unlock the clip no ...

Page 193: ...lded piece and it can not be opened It has an integrated flame arrester ASSEMBLY Assembly is essentially the reverse of removal procedures However pay particular attention to the following CAUTION Do not modify air intake system otherwise calibration will be affected GS GTS and GTI Models Flame Arrester Base Apply Loctite 518 on mating surfaces of flame ar rester base no 7 Apply Loctite 243 blue o...

Page 194: ... tor and latch in place NOTE Make sure the air intake silencer is re tained by the lower bracket no 4 Place protector pads on duct supports Use slot in rubber to insert pad on bracket eyelet Side tongue of protector pad should be toward outside of vehi cle and bent downward toward the exhaust flange Put air ducts in intake adapters and secure them on duct supports with hexagonal screws no 13 wide ...

Page 195: ...17_06_04A FM 06 04 1 CARBURETOR 0 Mikuni BN 40i and BN 46i F02F1ZT Loctite 243 11 9 12 20 21 13 14 6 7 4 19 5 15 2 13 8 3 20 18 17 16 1 20 N m 15 lbf ft Anti seize lubricant Synthetic grease Loctite 243 PTO PTO MAG Synthetic grease www SeaDooManuals net PARTS ...

Page 196: ...A metering jet in the fuel inlet hose controls fuel flow to the pump A check valve on the fuel outlet hose helps to prime the system REMOVAL To remove carburetor s from engine proceed as follows Remove air vent tube support GTI only Remove air intake silencer Refer to AIR INTAKE Turn fuel valve to OFF position except RFI mod els Disconnect pulse line TYPICAL 1 Pulse line 2 Loosen gear clamp Discon...

Page 197: ...m Pump Diaphragm Leak Test Using a suitable pump gauge tester perform the following test proceeding as follows Install pump gauge tester P N 295 000 114 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI TYPICAL 1 Pump gauge tester 2 Install on pulse nipple Diaphragm must stand pressure for 10 seconds If pressure drops replace diaphragm no 3 Fuel Pump Valve Check fuel pump valve operation a...

Page 198: ...lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on inlet nipple of accelerator pump no 20 Obstruct outlet nipple with a finger and hold while pumping Pump tester until it reaches 28 kPa 4 PSI 1 Pump gauge tester 2 Hose installed to inlet nipple 3 Outlet nipple obstructed Diaphragm must stand pressure for 10 seconds If pressure drops replace accelerator pump dia phragm V...

Page 199: ...s illus trations if necessary Choke Plate and Throttle Plate When installing plate no 6 onto shaft no 7 close plate so that it centers into carburetor bore Firmly tighten screws CAUTION Always apply Loctite 243 blue on screw threads prior to installing screws Needle Valve Lever Rounded end of needle valve lever no 8 must be flush with surrounding metering chamber floor and not with body assembly P...

Page 200: ... 69 kPa 10 PSI for 30 seconds Otherwise hold carbure tor upside down pour oil over needle valve and apply pressure Check for bubbles If they come from seat or O ring bubbles will exit around seat Retighten as necessary If it still leaks remove needle and seat and replace O ring If bubbles come from needle replace needle and seat Main Jet and Pilot Jet Pilot jet no 10 and main jet no 9 are replacea...

Page 201: ... speed and high speed screws apply some BOMBARDIER LUBE P N 293 600 016 to prevent sticking Fuel Accelerator Pump Lubricate pump plunger roller and cam with syn thetic grease P N 293 550 010 and roller shaft with BOMBARDIER LUBE P N 293 600 016 TYPICAL 1 Apply synthetic grease to plunger 2 Apply BOMBARDIER LUBE on roller shaft INSTALLATION Carburetors At installation pay attention to the following...

Page 202: ...ease adjustment if to be performed in the wa tercraft TYPICAL 1 Throttle lever PTO side 2 Marks CAUTION Throttle plates must open simulta neously otherwise this will cause engine to vi brate and or misfire Throttle Cable Adjustment NOTE Do not activate throttle lever unnecessari ly Carburetors are equipped with fuel accelerator pump This pump is injecting fuel into carburetors each time throttle l...

Page 203: ...serious engine damage 947 Engine Throttle cable is equipped with a sensor which will send a signal to the MPEM at 80 throttle open ing in order to control the spark advance THROTTLE CABLE ASSEMBLY 1 Sensor 2 Throttle lever section 3 Carburetor section 4 Oil pump section NOTE Always perform the throttle cable adjust ment in the specified order as described in follow ing procedure Unscrew idle adjus...

Page 204: ... adjust oil pump cable prior to finalize adjustment of throttle cable CAUTION Improper oil injection pump syn chronization with carburetor throttle opening can cause serious engine damage Adjust throttle cable to obtain proper lever position at full throttle Turn adjuster knob as required to obtain proper throttle lever adjustment 1 Jam nut 2 adjustment nut 3 Throttle cable Throttle lever must rea...

Page 205: ...hly Make sure engine reacts quickly to throttle lever depres sion If necessary readjust low speed screw 1 4 turn NOTE On twin carburetor engines both low speed screws must be adjusted exactly the same way Never adjust screws more than 1 4 turn at a time High Speed Screw The high speed screw no 14 is sealed with a plas tic cap that allows an adjustment of 1 4 turn NOTE Turning screw 1 4 turn counte...

Page 206: ...talled Start engine and bring to normal operating temper ature CAUTION If watercraft is out of water engine must be cooled using the flush kit Turn screw so that engine idles at 1500 RPM in water or 3000 RPM out of water Fuel Accelerator Pump All Models Except 787 RFI Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM in water With the engine not running loosen adjustment...

Page 207: ...Ensure choke lever has a free play of 0 5 to 2 0 mm 1 64 to 5 64 in TYPICAL 1 Choke lever A Free play of 0 5 to 2 0 mm 1 64 to 5 64 in To adjust loosen jam nut on carburetor bracket then turn adjustment nut as necessary Tighten jam nut and recheck adjustment 1 F07F02A A www SeaDooManuals net ...

Page 208: ... 4 Regulator 5 Fuel rail 6 Fuel injector 7 Electronic Control Unit ECU 8 Multi Purpose Electronic Module MPEM 9 Throttle plate 10 Throttle Position Sensor TPS 11 Air Pressure Sensor APS 12 Air Temperature Sensor ATS 13 Crankshaft Position Sensor CPS 14 Water Temperature Sensor WTS 15 Battery 16 Ignition coil F07F18S 1 3 2 4 5 6 15 7 8 9 11 12 10 14 13 16 www SeaDooManuals net ...

Page 209: ...em has the advantage of optimizing the engine power fuel economy and emission con trols under all engine operating conditions by man aging both the fuel injection duration and ignition timing The Rotax Fuel Injection RFI is composed of the 3 following basic systems 1 Air Induction 2 Fuel Delivery 3 Electronic Management AIR INDUCTION A single throttle body 56 mm breath through the air intake silen...

Page 210: ...ed 2 Internal fuel filter Fuel Pump Module All these components are comprised in a single module mounted in the fuel tank The fuel gauge sender is also mounted on this module FUEL PUMP ASSEMBLY Fuel Injectors The injectors inject a metered quantity of fuel from the fuel rail into the cylinder rear transfer port in accordance with the signal from the Electronic Control Unit ECU INJECTOR F07F0KA 1 2...

Page 211: ...e operation 3 Maximum Engine Speed The ECU limits the maximum allowable engine speed The RPM rev limiter is set at 7200 50 RPM 4 Fail Safe Function In the event of a sensor malfunction the ECU will use a default operating mode to ensure driveability to shore A message may be displayed on the Info Center to inform the operator 5 Diagnostic Mode The ECU is able to detect malfunctions in the sen sor ...

Page 212: ...ition Idle to wide open throttle Engine temperature Intake air temperature Battery voltage Start stop signal Air Pressure Sensor APS Water Temperature Sensor WTS Air Temperature Sensor ATS Fuel tank Fuel filter Fuel pump Regulator Injectors Multi Purpose Electronic Module MPEM Electronic Control Unit ECU PARAMETERS SENSORS FUEL DELIVERY Throttle Position Sensor TPS To engine F07F0NS www SeaDooManu...

Page 213: ...lecting DIAGNOSIS the following message INITIALIZING IN PROCESS will be displayed a few seconds then a new menu will appear on the screen Select READ FAULT and press ENTER 1 BOSCH INFO 2 READ FAULT 3 ERASE FAULT 4 ADJUSTMENT 5 REAL TIME 6 END DIAGNOSIS NOTE Line no 1 BOSCH INFO will display the iden tification of the watercraft and the MPEM ECU By selecting READ FAULT the MPEM program mer will dis...

Page 214: ...sor circuit shorted to ground 1C sensor circuit shorted to battery Crankshaft Position Sensor CPS 02 1F 06 signal exceeding RPM limits Crankshaft Position Sensor CPS 02 01 03 no signal detected fault code active when engine is not running and ignition is on 1B synchronization error sensor toothed wheel Air Intake Temperature Sensor ATS 02 0F 1D sensor circuit shorted to ground 1E signal interrupti...

Page 215: ...0 P 1602 FF FD 25 P 0562 02 14 07 P 0563 02 14 06 P 0117 and P 0118 02 0A 1D P 0116 02 0A 1B P 0122 and P 0123 02 06 1F P 0219 02 1F 06 P 0335 02 01 03 P 0336 02 01 1B P 0112 02 0F 1D P 0113 02 0F 1E P 0107 02 10 1D P 0108 02 01 1E P 0262 04 E1 1C P 0261 04 E1 1D P 1200 04 E1 1E P 0265 04 E2 1C P 0264 04 E2 1D P 1201 04 E2 1E P 0230 04 EB 1C P 0478 04 DB 1C P 0477 04 DB 1D P 0479 04 DB 1E www SeaD...

Page 216: ...ver FUEL DELIVERY Fuel Filter To inspect the fuel filter the fuel pump assembly has to be removed from the fuel tank See RE MOVAL in this subsection for the procedure Fuel Pump The fuel pump operation can be checked as fol lows Install the safety lanyard cap on the switch The fuel pump should run for approximately 1 second and then shut off If not check the electrical circuit and the 10 A fuse on ...

Page 217: ...minimum 8 Vdc Fuel Injector 1 Inlet side 2 Filter 3 Wiring terminal 4 Coil 5 Plunger 6 Needle valve 7 Injection side Touch the injector while cranking the engine to feel the operation of the injector If there is no signal detected from the injector dis connect the plug connector from the injector and check the signal from the MPEM To check the signal verify voltage at the plug con nector There sho...

Page 218: ...uel rail Reconnect the wire connector of the injector Place each injector in a clean bowl Install the safety lanyard cap on the switch to ac tivate the fuel pump Check for fuel leakage from the injector nozzle There should be less than 1 drop of fuel per minute 1 Fuel injectors 2 Fuel rail 3 Injector nozzles If not within specification replace the fuel injector s ELECTRONIC MANAGEMENT Throttle Pos...

Page 219: ...nsor NOTE Whenever the TPS is replaced removed or adjusted the TPS closed position must be re adjusted Voltage Test If the sensor resistance value is good check the volt age output from MPEM to throttle position sensor Disconnect plug connector from throttle position sensor and connect a voltmeter between the PURPLE BROWN wire and the BLACK BROWN wire in the wiring harness Depress the start stop b...

Page 220: ...below specifications replace air temperature sensor ATS If resistance is above specifications disconnect the connector of the air temperature sensor and check resistance of wiring harness and terminals between AMP plug connector and ATS sensor connector If there is an open circuit repair or replace the de fective wire or terminal Reconnect the air temperature sensor connector and recheck the resis...

Page 221: ...CK BLUE wire on the plug connector The resistance should be between 3 4 kΩ and 8 2 kΩ Check also the resistance between terminal 2 BLACK BLUE wire and terminal 1 PURPLE BLUE wire of the plug connector The resistance should be between 2 4 kΩ and 8 2 kΩ If not within specification disconnect the connec tor of the water temperature sensor and check re sistance of wiring harness and terminals between ...

Page 222: ... PURPLE BLUE wire and the BLACK BLUE wire in the wiring harness from the MPEM Depress the start stop button with the safety lan yard removed to activate the timer There should be 5 Vdc Rave Solenoid RAVE SOLENOID Disconnect the AMP plug connector number 4 from the MPEM module Check resistance value between terminal 16 and terminal 23 on the plug connector The resistance value should be 30 Ω F07D0G...

Page 223: ...nsor 3 and 4 PU BW and BK BW 1 6 k 2 4 k ohms 5 Vdc between PU BW and BK BW 4 and 11 BK BW and WH BW 710 1380 ohms Water temperature sensor 5 and 12 BK OR and TA OR 2280 2736 ohms N A Air temperature sensor 6 and 13 BK WH and WH GY 2280 2736 ohms N A Crankshaft position sensor 7 and 14 GY YL and GY RE 774 946 ohms N A Rave solenoid 16 and 23 PU GY and BK GY 30 ohms N A Injector no 1 18 and 20 BL P...

Page 224: ...a Doo models the spark plugs spark independently on each piston stroke Re versed high tension cables will cause backfires ECU Fault Codes Fault codes in the ECU memory will identify poten tial problems with the RFI system When checking fault codes without engine in operation the CPS fault code will always appear Also the 04 FC fault code will always appear Disconnecting the battery will erase the ...

Page 225: ...degrees and it will also offer to adjust it CAUTION Do not select YES until the idle speed screw is loosened to allow the throttle plate to close Loosen the lock nut of the idle speed screw Loosen the idle speed screw until it does not con tact the throttle plate stopper Loosen the adjustment of the throttle cable 1 Idle speed screw Depress throttle lever a few times and ensure throttle plate is c...

Page 226: ...FT POSITION SENSOR CPS Disconnect the connector of the CPS Loosen Allen screw retaining the CPS Remove the CPS At installation apply Loctite 243 blue on the Allen screw NOTE Clean treads prior installing screw FUEL PUMP ASSEMBLY Open the front storage compartment cover Remove the storage basket Remove the glove box Disconnect the wire connector from the fuel pump assembly Disconnect fuel vent hose...

Page 227: ...fitting Disconnect the wire connectors of both fuel injec tors 1 Press retaining clip to unlock the connector Loosen both screws retaining the fuel rail to the cylinders 1 Loosen screws retaining the fuel rail Remove the fuel rail with both fuel injectors To remove the fuel injector from the fuel rail pry off the retaining clip 1 Pry the clip When reinstalling the fuel injector install the re tain...

Page 228: ... TABLE OF CONTENTS 0 OIL INJECTION SYSTEM 07 02 1 GENERAL 07 02 8 OIL SYSTEM PRESSURIZATION 07 02 8 OIL INJECTION PUMP 07 03 1 OIL PUMP IDENTIFICATION 07 03 4 REMOVAL 07 03 4 DISASSEMBLY 07 03 4 CLEANING 07 03 4 ASSEMBLY 07 03 4 ADJUSTMENT 07 03 5 CHECKING OPERATION 07 03 7 www SeaDooManuals net ...

Page 229: ... SYSTEM SMR2000 019_07_02A FM 07 02 1 OIL INJECTION SYSTEM 0 GTS Model F02G07S To electrical box 4 3 2 1 Dielectric grease 27 N m 20 lbf ft 3 5 N m 31 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 3 5 N m 31 lbf in www SeaDooManuals net PARTS ...

Page 230: ...section 02 OIL INJECTION SYSTEM 07 02 2 SMR2000 019_07_02A FM GS Model F06G03S Loctite 518 1 2 3 4 1 27 N m 20 lbf ft 3 5 N m 31 lbf in Dielectric grease 1 2 N m 11 lbf in 1 2 N m 11 lbf in 3 5 N m 31 lbf in www SeaDooManuals net PARTS ...

Page 231: ...n 07 LUBRICATION SYSTEM Subsection 02 OIL INJECTION SYSTEM SMR2000 019_07_02A FM 07 02 3 GSX Model F06G06S Loctite 518 2 1 4 Dielectric grease 3 3 5 N m 31 lbf in 27 N m 20 lbf ft www SeaDooManuals net PARTS ...

Page 232: ...Section 07 LUBRICATION SYSTEM Subsection 02 OIL INJECTION SYSTEM 07 02 4 SMR2000 019_07_02A FM XP Model F08G03S 4 3 Steering harness Oil pump www SeaDooManuals net PARTS ...

Page 233: ... 02 OIL INJECTION SYSTEM SMR2000 019_07_02A FM 07 02 5 GTI Model F07G09S 2 1 3 1 2 N m 11 lbf in 17 4 2 1 3 5 N m 31 lbf in 3 5 N m 31 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in Dielectric grease www SeaDooManuals net PARTS ...

Page 234: ...LUBRICATION SYSTEM Subsection 02 OIL INJECTION SYSTEM 07 02 6 SMR2000 019_07_02A FM GTX Model F07G03S Dielectric grease 27 N m 20 lbf ft 3 5 N m 31 lbf in 3 5 N m 31 lbf in 1 3 2 1 2 4 www SeaDooManuals net PARTS ...

Page 235: ...TEM SMR2000 019_07_02A FM 07 02 7 GSX RFI and GTX RFI Models 1 3 5 N m 31 lbf in F07G04S GSX RFI 1 3 5 N m 31 lbf in 2 2 1 2 N m 11 lbf in 3 5 N m 31 lbf in 27 N m 20 lbf ft 27 N m 20 lbf ft FRONT 1 2 N m 11 lbf in 4 3 1 Loctite 518 2 www SeaDooManuals net PARTS ...

Page 236: ...aft oil return hose except the 947 engine Install a hose pincher to oil injection pump sup ply hose Connect pump gauge tester P N 529 021 800 to check valve of oil injection reservoir vent NOTE Use the same pump included in the EN GINE LEAK TESTER KIT P N 295 500 352 TYPICAL 1 Connect pump to check valve Pressurize oil system to 21 kPa 3 PSI If pres sure is not maintained locate leak and repair re...

Page 237: ...P SMR2000 020_07_03A FM 07 03 1 OIL INJECTION PUMP 0 717 Engine F00G03S Loctite 243 1 4 5 N m 40 lbf in 8 N m 71 lbf in 8 N m 71 lbf in 2 3 10 N m 89 lbf in 5 Loctite 243 6 N m 53 lbf in 6 4 6 N m 53 lbf in Loctite 243 5 N m 44 lbf in www SeaDooManuals net PARTS ...

Page 238: ... LUBRICATION SYSTEM Subsection 03 OIL INJECTION PUMP 07 03 2 SMR2000 020_07_03A FM 787 RFI Engine F07G0AS 4 5 N m 40 lbf in 8 6 6 N m 53 lbf in 9 1 3 N m 27 lbf in 4 5 N m 40 lbf in 7 www SeaDooManuals net PARTS ...

Page 239: ...STEM Subsection 03 OIL INJECTION PUMP SMR2000 020_07_03A FM 07 03 3 947 Engine F07G0BS 6 N m 53 lbf in 6 6 6 N m 53 lbf in Loctite 243 1 4 5 N m 40 lbf in 8 To MPEM 7 To carburetor 4 5 N m 40 lbf in www SeaDooManuals net PARTS ...

Page 240: ... with flat washers retaining oil injection pump to intake manifold no 2 Remove pump 947 Engine Remove tuned pipe head Refer to EXHAUST SYS TEM 787 RFI and 947 Engines Disconnect oil injection pump cable no 7 Remove 2 Allen screws no 6 with flat washers retaining oil injection pump to magneto housing cover Pull pump Disconnect oil hoses from fittings of oil injection pump DISASSEMBLY NOTE Some oil ...

Page 241: ...mp cable ADJUSTMENT CAUTION As oil injection pump adjustment is dependent on throttle cable position make sure to perform throttle cable adjustment first except if otherwise specified Preliminary Synchronization NOTE To check synchronization of pump as a rou tine maintenance see Final Synchronization Make sure idle speed screw on carburetor is prop erly set Refer to CARBURETOR for throttle cable a...

Page 242: ... bleed system before operating engine Adjust idle speed to specification Refer to CAR BURETOR NOTE On RFI engines refer to FUEL INJECTION for idle speed adjustment procedure Stop engine Final Synchronization Eliminate throttle cable free play by depressing throttle lever until a slight resistance is felt In this position marks on pump body and lever must align NOTE A mirror may be used to facilita...

Page 243: ...sition Oil must advance into small oil lines NOTE The engine should have a rich mixture idling irregularly and emitting smoke at exhaust outlet If not remove pump assembly and check the pump gear 717 engine or shaft 787 RFI and 947 engines for defects replace as necessary Test pump as describes below NOTE Through normal use oil level must not drop in small tubes If oil drops verify check valve ope...

Page 244: ...it counterclockwise at 1500 RPM for a total time of 5 minutes NOTE To ensure accuracy of test oil lines should be completely filled before starting test Compare the results with the chart below If oil pump is out of specification replace it NOTE Test can also be done at 3000 RPM Dou ble quantities in chart ENGINE OIL PUMP FLOW RATE AT 1500 RPM 5 MINUTES 717 9 9 12 1 mL each port 787 RFI 5 7 6 9 mL...

Page 245: ...ARGING SYSTEM 08 03 1 GENERAL 08 03 1 TESTING PROCEDURE 08 03 1 BATTERY 08 03 4 STARTING SYSTEM 08 04 1 GENERAL 08 04 4 STARTING SYSTEM TROUBLESHOOTING 08 04 5 STARTER REMOVAL 08 04 6 STARTER DISASSEMBLY 08 04 6 CLEANING 08 04 8 PARTS INSPECTION 08 04 9 STARTER ASSEMBLY 08 04 9 STARTER INSTALLATION 08 04 11 STARTER SPECIFICATION 08 04 13 INSTRUMENTS AND ACCESSORIES 08 05 1 GENERAL 08 05 1 INSPECTI...

Page 246: ...e Igni tion DC CDI Digital Inductive System Magneto System The magneto is the primary source of electrical energy It transforms magnetic field into electric current AC 717 Engine The flywheel contains 4 permanent magnets and spins around the generating coil This electric cur rent flows to the ignition coil GTS model or the Multi Purpose Electronic Module GS and GTI models 1 Flywheel 2 Generating c...

Page 247: ...f the ignition coil The secondary winding of the ignition coil steps up the low voltage input to high voltage for both spark plugs GS and GTI Models The ignition coil steps up the voltage input from the Multi Purpose Electronic Module to high volt age current for both spark plugs The ignition coil is located in the rear electrical box on right side of watercraft GTX and XP Models Two separate igni...

Page 248: ...e started A wrong safety lanyard is a safety lanyard which is defective or not programmed in the MPEM memory To better understand the antistart feature refer to DESS DIGITALLY ENCODED SECURITY SYSTEM If the MPEM responds differently from what is mentioned above refer to the troubleshooting section to find out why Gauges Current Supply The purpose of this function is to allow reading of gauges with...

Page 249: ...acilitate the use of the watercraft a system controls the digitally encoded security sys tem DESS and sends through a buzzer some audible signals informing the operator of a specific situation The diagnostic mode is divided into 2 parts the basic mode and the advanced mode The basic mode is automatically activated when connect ing the safetylanyard cap to the switch The advance mode can only be ac...

Page 250: ...Injec tion system Electrical Box The high amperage voltage components are locat ed into the electrical box The electrical box can be located either at the front or at the rear of the watercraft GSX RFI 1 Electrical box GTX 1 Electrical box GTX RFI 1 Electrical box 2 Rectifier regulator F07H0BA F06E06A 1 F07H07B 1 F06H38A 2 1 www SeaDooManuals net ...

Page 251: ...should remain correctly adjusted since every part is fixed and not adjustable The only time the ignition tim ing might have to be changed would be when re placing the crankshaft the magneto rotor the trig ger coil and the MPEM If the ignition timing is found incorrect you should first check for proper crankshaft alignment This might be the indication of a twisted crankshaft With this DC CDI system...

Page 252: ...r to the following chart 8 Scribe a thin mark on PTO flywheel in the mid dle of tool slot 717 engine or aligned with tim ing mark pointer tool 947 engine TYPICAL 1 Tool slot 2 Flywheel mark NOTE This mark becomes the reference when using the stroboscopic timing light CAUTION The static test cannot be used as a timing procedure therefore always check the timing with a stroboscopic timing light 9 Re...

Page 253: ...ark plug wire 1 Tachometer pick up 2 Connect timing light pick up to MAG side spark plug wire 1 Timing light pick up 3 Start engine and point timing light straight in line with timing tool slot Bring engine to 6000 RPM 1 Timing light straight in line with tool slot CAUTION If engine is to be run more than a few seconds engine must be cooled using the flush kit 4 Check if PTO flywheel mark aligns w...

Page 254: ...gine and rev it to 3500 RPM and point beam of timing light straight in line with timing mark pointer 1 Timing light straight in line with tool slot CAUTION If engine is to be run more than a few seconds engine must be cooled using the flush kit NOTE If mark on PTO flywheel is perfectly align ed with timing mark pointer no adjustment is re quired If mark does not align with pointer recheck PTO flyw...

Page 255: ... left side of timing tool slot it indicates retarded timing 1 Retarded timing In this case turn armature plate counterclockwise when facing it After adjustment tighten armature plate retaining screws CAUTION Armature plate screws must have Loctite 243 blue applied before tightening Make sure armature plate screws are well se cured Reinstall removed parts Refer to MAGNETO SYS TEM Recheck ignition t...

Page 256: ... the programmer You recheck the timing with the timing light and if the mark is aligned ignition timing is properly set b You found the flywheel mark advanced You must retard the ignition timing The programmer gives you the number 3 Re ferring to the chart number 3 returns a cor rection of 2 advanced and this is too much in this case You estimate the correction should be set to 1 advanced to align...

Page 257: ...ted first This func tion allows to perform ignition timing at any RPM due to its ignition which is speed and load inde pendent NOTE Fixed Timing function must be activated before starting engine Fixed Timing Function 1 Connect the communication cable to the MPEM programmer and the other end to the safety lanyard switch on the craft 2 Press the ON C button on programmer and enter your password 3 Pr...

Page 258: ...gnition coil output CAUTION Whenever replacing a component in ignition system check ignition timing NOTE To perform verification a good quality mul timeter such as Fluke 73 P N 529 022 000 should be used Engine Start Stop Switch Verification Disconnect the YELLOW RED wire of the start stop switch Using an ohmmeter connect test probes to YELLOW RED wire and to ground Measure resistance it must be a...

Page 259: ...ted with an ohmmeter but a 100 test doesn t mean the MPEM is in perfect condition CAUTION Whenever connecting MPEM al ways have battery disconnected from circuit If MPEM must be connected when circuit is acti vated always connect BLACK RED wire first to ignition coil CDI module to prevent wire from touching solenoid positive terminal All Other Models It is not possible to accurately check the MPEM...

Page 260: ... of the 4 pin magneto harness adapter 6 Set multimeter to Vac scale 7 Crank engine and note result The obtained val ue should be between 18 and 25 Vac 8 If the generating coil is out of specification re place it NOTE If the generating coil tests good discon nect the primary wires of the ignition coil Crank engine and check voltage at primary wires It should be at least 20 Vdc If there is insuffici...

Page 261: ...ement can still be faulty Voltage leak can occur at high voltage level which is not detectable with an ohmmeter Primary Winding GTS Model Due to the integrated CDI module it is not possi ble to take any resistance measurement GSX RFI and GTX RFI IGNITION COIL 1 Primary side 2 Secondary side 3 Ground wire Disconnect the wire connector on the primary side of the ignition coil Using a multimeter chec...

Page 262: ... Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm 276 to 311 in If there is no spark if it is weak or intermittent the coil is defective and should be replaced SPARK PLUGS Disassembly First unscrew the spark plug one turn Clean the spark plug and cylinder head with pres surize air then completely unscrew Heat Range The proper heat range of the ...

Page 263: ...ment or incorrect fuel The plug face of a fouled spark plug has either a dry coating of soot or an oily glossy coating given by an excess either of oil or of oil with soot Such coatings form a conductive connection between the center electrode and ground Spark Plug Analysis 1 Overheated light grey 2 Normal brownish 3 Fouled black The plug face and piston dome reveals the con dition of the engine o...

Page 264: ... IGNITION SYSTEM SMR2000 021_08_02A FM 08 02 19 Spark Plug Chart NOTE Refer to next page for NGK Spark Plug Symbol Explanation ENGINE SPARK PLUG TORQUE N m lbf ft GAP mm inch 717 787 RFI 947 NGK BR8ES 24 17 0 5 0 6 020 024 www SeaDooManuals net ...

Page 265: ...Cold 18 mm 14 mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach A B C D E J Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V Grooved Center Electrode A GV B C G L S V X Y Blank 18 mm ø 12 mm 31 64 14 mm ø 9 5 mm 3 8 F02H0MS Compact Type Projected Insulator Type Resistor...

Page 266: ...rms AC from the magneto into DC to allow battery charging Battery The battery is the DC source for the electric start er the Multi Purpose Electronic Module and all ac cessories Fuse If the battery is regularly discharged check fuse condition The rectifier regulator could be the culprit of a blown fuse To check simply disconnect the rectifier regulator from the circuit If the fuse still burns chec...

Page 267: ...the rectifier regulator GS and GTI Models Disconnect the connector housing of the rectifier regulator Using an appropriate terminal remover Snap on TT600 4 remove the RED and BLACK wires from the tab housing of the rectifier regulator Reconnect the connector housing GS GTS and GTI Models Connect the positive probe of a multimeter to the RED wire and the negative probe to the BLACK wire Set multime...

Page 268: ...C TEST INSULATION 1 Disconnect the magneto wiring harness connec tor 2 Install the 6 pin magneto harness adapter P N 295 000 136 3 Insert multimeter positive probe to one of the YELLOW wire of the 6 pin magneto harness adapter 4 Ground the multimeter negative probe to the engine or the stator iron core and note the read ing 1 Multimeter 2 Magneto harness adapter 3 Positive probe to YELLOW wire 4 N...

Page 269: ...s connec tor 2 Install the 4 pin magneto harness adapter P N 295 000 131 3 Connect test probes of the multimeter to the YELLOW BLACK and RED BLACK wires of the 4 pin magneto harness adapter 4 Set multimeter to Vac scale 5 Start and rev engine to 3500 RPM The obtained value should be between 45 and 70 Vac 6 Repeat test with the BLACK wire and either the RED BLACK or YELLOW BLACK wires of the 4 pin ...

Page 270: ...ng soda Inspect battery posts for security of mounting Inspect for cracked or damaged battery caps re place defective caps Electrolyte Level Check electrolyte level in each cell add distilled water up to upper level line CAUTION Add only distilled water in an activat ed battery Battery Testing There are 2 types of battery tests electrolyte read ing and load test An electrolyte reading is made on a...

Page 271: ...TION Do not allow cleaning solution to en ter battery Rinse battery with clear water and dry well using a clean cloth Store battery on a wooden shelf in a cool dry place Such conditions reduce self discharging and keep fluid evaporation to a minimum Keep battery away from dew high moisture and direct sunlight During the storage period recheck electrolyte lev el and specific gravity readings at lea...

Page 272: ...adjust the electrolyte level to the UPPER LEVEL line 1 Battery electrolyte 2 Upper level line 5 Connect a 2 A battery charger for 3 to 5 hours Step Connect lead to battery post Step Connect lead to battery post Step Plug battery charger CAUTION If charging rate raises higher than 2 4 A reduce it immediately If cell temperature rises higher than 50 C 122 F or if the casing feels hot discontinue cha...

Page 273: ...This is the reason the battery will not accept current when the charging cycle first be gins As the battery remains on the charger the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then the battery will ac cept a higher charging rate Type of charger Battery chargers vary in the amount of voltage and current that they can su...

Page 274: ...the normal manner as specified in Activation of a new battery It is recommended that any battery recharged by this procedure be load tested prior to return ing it to service Charging Two or More Batteries at a Time Connect all positive battery posts together and use a charger with a capacity rated equal to num ber of battery to be charged multiply by 2 A For example Charging 5 batteries at a time ...

Page 275: ...00 023_08_04A FM 08 04 1 STARTING SYSTEM 0 717 Engine F00H1PS 16 Loctite 243 15 Loctite 271 14 Ground Cable 17 22 N m 16 lbf ft Loctite 243 13 22 N m 16 lbf ft 22 N m 16 lbf ft 5 N m 44 lbf in Dielectric grease 1 12 2 3 5 4 6 11 10 7 8 9 www SeaDooManuals net PARTS ...

Page 276: ...ection 04 STARTING SYSTEM 08 04 2 SMR2000 023_08_04A FM 787 RFI Engine F15H01S Loctite 243 6 7 8 9 10 11 4 1 2 3 5 5 N m 44 lbf in 12 22 N m 16 lbf ft 13 17 Dielectric grease Loctite 243 16 22 N m 16 lbf ft www SeaDooManuals net PARTS ...

Page 277: ...M Subsection 04 STARTING SYSTEM SMR2000 023_08_04A FM 08 04 3 947 Engine F07H0TS Dielectric grease 17 Loctite 243 16 10 N m 89 lbf in Synthetic grease Synthetic grease 18 10 11 19 Ground cable 1 2 3 5 www SeaDooManuals net PARTS ...

Page 278: ...ard refer to DIGITALLY ENCODED SE CURITY SYSTEM Engine Start Stop Switch and Safety Lanyard Switch Refer to IGNITION SYSTEM Solenoid NOTE Solenoid is located in the electrical box Inspect connections and clean as necessary Static Test Continuity With a multimeter check primary winding resis tance It should be approximately 5 ohms There should be no continuity between the posi tive posts of the sol...

Page 279: ...ean battery cable connections Poor contact of brush Straighten commutator and brush Burnt commutator Turn commutator on a lathe Worn commutator segments Undercut mica Shorted armature Repair or replace armature Weak brush spring tension Replace brush holder or spring Weak magnet Replace yoke assembly Worn bushings Replace clutch Weak battery Recharge or replace battery STARTER TURNS BUT OVERRUNNIN...

Page 280: ...ion STARTER DISASSEMBLY 717 and 787 RFI Engines Before disassembling trace index marks on yoke no 1 and clutch housing no 10 to ease further assembly TYPICAL 1 Trace indexing marks Remove starter support nuts no 12 then through bolts no 5 Separate end frame no 3 from yoke assembly no 1 Withdraw yoke assembly from ar mature no 11 Brush holder no 2 can be removed from end frame no 3 by unscrewing nu...

Page 281: ...sen through bolts no 5 1 Through bolts Remove end cover no 3 and gasket on armature shaft side Remove thrust washers no 19 from armature shaft 1 Thrust washers Remove the other end cover no 10 and gasket Remove the three washers no 18 from armature shaft 1 Washers Remove armature no 11 1 Pull armature shaft F06H1FA 1 F06H1GA 1 F06H1HA 1 F06H1IA 1 F06H1JA 1 www SeaDooManuals net ...

Page 282: ...d in cleaning solvent Discard all O rings Clean brushes and holders with a clean cloth soaked in solvent Brushes must be dried thor oughly with a clean cloth Blow brush holders clean using compressed air Remove dirt oil or grease from commutator using a clean cloth soaked in suitable solvent Dry well using a clean dry cloth Clean engine ring gear teeth and drive unit clutch NOTE Bushings or bearin...

Page 283: ...sh holder plate If continuity is found brush holder has to be repaired or replaced Brush Measure brush length If less than 8 5 mm 335 in replace them NOTE New brush length is 12 mm 472 in 1 New 2 Wear limit 8 5 mm 335 in Overrunning Clutch Pinion of overrunning clutch should turn smoothly in clockwise direction and should not slip in a counterclockwise direction If defective replace Check pinion t...

Page 284: ...h with yoke locating protrusion and properly sit brush holder no 2 into yoke no 1 1 Locating protrusion is the higher one 1 Brush holder locating notch To ease end frame installation retain brush holder with a small screwdriver while installing end frame Step Retaining brush holder with a screwdriver Step Align here Align end frame notch with brush holder notch yoke protrusion CAUTION Make sure en...

Page 285: ...o 13 and no 16 to 22 N m 16 lbf ft Nut Connect the RED positive cable to the starter and torque nut no 17 to 6 N m 53 lbf in Apply di electric grease on terminal and nut Screw and Teeth Washer Apply Loctite 271 red to screw Connect BLACK negative cable to starter using flat washer teeth washer no 15 and screw no 14 Torque screw to 22 N m 16 lbf ft Apply dielectric grease on terminal and screw 717 ...

Page 286: ...EL 1 Torque nut to 6 N m 53 lbf in apply dielectric grease and install protection cover 2 Negative BLACK cable 3 Apply Loctite 243 to threads and torque screw to 10 N m 89 lbf in WARNING Always connect RED positive cable first then BLACK negative cable last Whenever con necting the RED positive cable to the starter motor make sure the battery cables are dis connected to prevent electric shock F06H...

Page 287: ...Approx 2 kg 4 4 lb Performance specification at 20 C 68 F No load 11 5 V 20 A max 5500 RPM Load 8 5 V 170 A max 2200 RPM Stall 5 V 350 A max 0 RPM Battery 12 V 19 Ah Nominal output 0 8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 1 7 kg 3 7 lb Performance specification at 20 C 68 F No load 10 9 V 45 A max 8600 RPM Load 9 V 120 A max 5350 RPM Stall ...

Page 288: ...auge If not replace the temperature sensor Water Temperature Sensor GTX GSX RFI and GTX RFI The water temperature sensor is integrated with the speed sensor located on the ride plate To check if the water temperature sensor is oper ational activate the Info Center and select the lake temperature mode With a garden hose spray the speed sensor with water The temperature reading on the Info Center sh...

Page 289: ...er The paddle wheel is protected by the pick up housing 1 Pick up housing 2 Paddle wheel To check if the speed sensor is operational dis connect the speed sensor connector housing from inside bilge Using an appropriate terminal remover Snap on TT600 4 remove the PURPLE YELLOW and BLACK ORANGE wires from the tab housing of the speed sensor Reconnect the PURPLE YELLOW and BLACK ORANGE wires in the r...

Page 290: ...average speed trip meter VTS GSX RFI compass GTX and GTX RFI air temperature GTX and GTX RFI water temperature The Info Center also features a red warning LED which blinks whenever one of the following cir cumstances occur low fuel low oil low voltage and overheating For example if the fuel level is low the LED and the message LOW FUEL will blink As a self test all LCD segments and the LED will tu...

Page 291: ...press and hold both MODE and SET buttons for 2 seconds The clock will blink to confirm the setting mode Press the MODE button to adjust the hours and the SET button to adjust the minutes Press again on both the MODE and SET buttons to exit the setting mode or the gauge will auto matically exit the setting mode after 10 seconds MAINTENANCE INFORMATION When the watercraft is due for a maintenance in...

Page 292: ...R TEMPERATURE Disconnect the 2 circuit connector housing of the Info Center which contains a TAN WHITE and BLACK WHITE wires Connect potentiometer test probes to the TAN WHITE and BLACK WHITE wires Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge RESISTANCE Ω FUEL LEVEL LCD GRAPHIC LOW FUEL LEVEL RED LIGHT 0 2 2 FULL OFF 17 8 2 2 7 8 OFF 27 8 2...

Page 293: ... the tank The low oil warning light is part of the gauge It will light when injection oil level is low TYPICAL 56 MM Variable Trim Gauge XP Model The trim gauge shows the riding angle of the wa tercraft TYPICAL RESISTANCE Ω DISPLAY TEMPERATURE C 25590 1 5 2 20005 8 10 2 15761 7 15 2 12510 2 20 2 10000 0 25 2 8047 8 30 2 6518 7 35 2 RESISTANCE Ω DISPLAY TEMPERATURE F 22919 8 45 4 17491 7 55 4 13487...

Page 294: ...el sender To verify fuel sender a resistance test should be performed with a multimeter allowing the float to move up through a sequence 1 Pick up tube 2 Fuel sender 3 Baffle pick up The resistance measured between PINK BLACK and PINK wires must be in accordance with fuel level measured from under the flange as speci fied in the following charts RESISTANCE Ω GAUGE NEEDLE POSITION 24 3 45 42 2 60 1...

Page 295: ... let the oil en ter inside and one at the top to let the air enter allowing the oil to flow out FUEL LEVEL AND RESISTANCE GS GTI AND GTX FUEL LEVEL MM RESISTANCE Ω From 248 9 5 and more 0 2 2 From 234 4 to 248 8 5 17 8 2 2 From 200 9 to 234 3 5 27 8 2 2 From 167 4 to 200 8 5 37 8 2 2 From 134 0 to 167 3 5 47 8 2 2 From 100 5 to 133 9 5 57 8 2 2 From 67 0 to 100 4 5 67 8 2 2 From 40 1 to 66 9 5 77 ...

Page 296: ...onnect BLACK wire BLUE WHITE wire and GREEN WHITE wire of VTS switch Using a multimeter connect test probes to switch BLACK and BLUE WHITE wires then connect test probes to switch BLACK and GREEN WHITE wires Measure resistance in both test it should be high when button is released and must be close to zero when activated VTS Motor GSX RFI and XP Models Always confirm first that the fuse is in good...

Page 297: ...not running remove safety lanyard from switch and depress start stop button to activate MPEM timer Push on VTS switch down position until motor stops Read the resistance on the ohmmeter it should indicate a resistance of 24 ohms 1 Push on VTS switch up position until motor stops Read the resistance on the ohmmeter it should indicate a resistance of 167 ohms 1 NOTE If the VTS control module passes ...

Page 298: ...ety lanyard must be programmed to start the engine NOTE Actually it is the memory of the MPEM which is programmed to recognize the digital code of the safety lanyard cap This is achieved with the VCK P N 529 035 676 or with the MPEM pro grammer P N 529 034 500 Refer to Guide to pro gram a safety lanyard The system is quite flexible Up to eight safety lan yards may be programmed in the memory of th...

Page 299: ... is ready to allow engine starting Unprogrammed or defective safety lanyard Use the safety lanyard that has been programmed for the watercraft If it does not work check safety lanyard condition with the programmer Replace safety lanyard if reported defective If it still does not work enable advanced diagnostic mode to obtain more details about the failure Salt water or dirt in safety lanyard cap C...

Page 300: ...re resolved SIGNAL CAUSE REMEDY No beep Engine actually starts Everything is correct 1 long and 1 short beeps No safety lanyard has ever been programmed in watercraft MPEM Use programmer and program a safety lanyard This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed 2 short beeps MPEM can not read the digital code of the safety lanyard cap or ...

Page 301: ...02 19 INSTALLATION 09 02 20 DRIVE SYSTEM 09 03 1 GENERAL 09 03 4 REMOVAL 09 03 4 INSPECTION 09 03 8 ASSEMBLY 09 03 9 INSTALLATION 09 03 11 LUBRICATION 09 03 14 REVERSE SYSTEM 09 04 1 GENERAL 09 04 2 DISASSEMBLY 09 04 2 ASSEMBLY 09 04 3 ADJUSTMENT 09 04 5 DISASSEMBLY 09 04 8 INSPECTION 09 04 9 ASSEMBLY 09 04 9 ADJUSTMENT 09 04 11 VARIABLE TRIM SYSTEM 09 05 1 GENERAL 09 05 2 REMOVAL 09 05 2 DISASSEM...

Page 302: ...ET PUMP 0 Loctite 518 F00J0US 10 9 23 25 26 24 27 11 14 13 12 Loctite 243 5 Loctite 518 20 21 15 16 22 23 Loctite 518 6 7 8 3 4 4 3 1 2 29 28 18 19 Loctite 243 17 Synthetic grease 20 N m 15 lbf ft Loctite 518 Loctite 271 Loctite 518 Loctite 518 Pipe sealant www SeaDooManuals net PARTS ...

Page 303: ...chart 1 Stamped part number JET PUMP INSPECTION ON WATERCRAFT To work on watercraft securely install it on a stand Thus if access is needed to water inlet area it will be easy to slide underneath watercraft A lift kit P N 295 100 044 can be used to install watercraft on a stand TYPICAL 1 Lift kit 2 Work stand F00J0SA 5 2 1 6 3 4 F02J0VA 1 WATERCRAFT MODEL IMPELLER P N MATERIAL PITCH GS 204 160 072...

Page 304: ...check clearance from venturi side remove venturi nozzle assembly as described in Oil In spection in this subsection Using a feeler gauge with 30 cm 12 in blades measure clearance between impeller blade tip and wear ring Measure each blade at its center Clear ance should not exceed 1 0 mm 040 in If clear ance is greater disassemble jet pump and inspect impeller and wear ring Renew worn parts TYPICA...

Page 305: ...00 018 on plug threads and reinstall it on cover Properly reinstall removed parts Oil Replacement Remove venturi as described in Oil Inspection Remove 3 screws retaining cover 1 Screws Using a fiber hammer gently tap cover to release it from housing cover Thoroughly clean reservoir and inside of cover with a solvent Check O ring condition Replace as necessary Apply a thin layer of Loctite 518 on m...

Page 306: ...of trim ring 1 Remove screws Remove nozzle Venturi Disconnect steering cable from nozzle no 5 prior removing venturi no 11 Remove 4 retaining screws and withdraw venturi 1 Remove screws Jet Pump Housing GTS Model Disconnect engine water supply hose and both bailer pick up tubes in bilge TYPICAL 1 Bailer pick up tubes 2 Engine water supply hose GSX RFI and XP Detach ball joint of VTS link rod GTS G...

Page 307: ...ft is seized in the PTO flywheel refer to DRIVE SYSTEM DISASSEMBLY NOTE Whenever removing a part visually check for damage such as corrosion crack split break porosity cavitation deformation distortion heat ing discoloration wear pattern missing plating missing or broken needles in needle bearing wa ter damage diagnosed by black colored spots on metal parts etc Renew any damaged part As a quick ch...

Page 308: ...er P N 295 000 082 on impeller shaft flat end Using 2 screws previously removed from venturi secure shaft holder to housing 1 Shaft holder Heat impeller shaft end with a propane torch to approximately 150 C 300 F to break the Loctite bond before to remove impeller Do not heat im peller directly Install shaft holder in a vice 1 Shaft holder Impeller is loosened using impeller remover tool P N 295 0...

Page 309: ...ing can be cut using a jigsaw a small grinder or a low clearance hacksaw such as Snap on HS3 or equivalent TYPICAL TYPICAL 1 Snap on HS3 After cutting ring insert a screwdriver blade be tween jet pump housing and ring outside diameter Push ring so that it can collapse internally Pull ring out Impeller Shaft Remove shaft holder tool Remove impeller shaft no 24 with thrust washer and thrust bearing ...

Page 310: ...peller shaft diameter PARTS INSPECTION Impeller Visually inspect impeller splines Check for wear or deformation Renew parts if damaged NOTE Check also PTO flywheel and drive shaft condition Refer to BOTTOM END and DRIVE SYS TEM Examine impeller in wear ring for distortion Check if blade tips are blunted round chipped or broken Such impeller is unbalanced and will vi brate and damage wear ring impe...

Page 311: ... and lowest dial gauge reading is radial play Maximum permissible radial play is 0 05 mm 002 in TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to threads at shaft end To check both bearings proceed the same way with other shaft end Position gauge tip on diam eter close to flats on shaft TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to flats at...

Page 312: ... shaft no 24 is checked with shaft in housing without impeller and with cover no 18 installed Retain housing in a soft jaw vise making sure not to damage housing lug Set a dial gauge and position its tip on the end of shaft Move shaft end by pull ing and pushing Difference between highest and lowest dial gauge reading is end play Maximum permissible end play new is 0 12 0 54 mm 005 021 in Make sur...

Page 313: ...g wear ring to housing are installed on this models On the old models it is necessary to drill holes Use a bit no 20 and drill holes 9 mm 35 in deep maximum See the next illustrations for proper holes location NOTE Do not drill holes through the soft part of the wear ring CAUTION Drilling holes someplace else can cause important damages to the housing All Models Except GTX and XP To install ring i...

Page 314: ...using making sure it is equally inserted all around Press ring until it seats into bottom of housing Install retaining screws Seal and Needle Bearing Bearings no 23 and seal no 22 will be properly installed in housing using bearing seal installer tool P N 295 000 107 BEARING SEAL INSTALLER TOOL 1 Seal side 2 Bearing side 155 6 mm Jet Pump Models For outlet end of housing use inner bearing install ...

Page 315: ... Bearing on impeller side must be 1 5 to 2 5 mm 060 100 in inside reservoir measured from seal seat Bearing on venturi side must be 2 to 4 mm 080 157 in inside reservoir measured from thrust washer seat Refer to following illustration 1 Seal seat 2 Stamped end of bearing 3 Thrust washer seat 4 Stamped end of bearing A 1 5 2 5 mm 060 100 in B 2 4 mm 080 157 in Apply Loctite 518 P N 293 800 038 to s...

Page 316: ...ips 1 Loctite 518 all around and behind 2 Spring of seal lip this side Thrust Washer Position jet pump housing no 9 with the stator vanes on top Insert thrust washer no 25 in the stator seat 1 Thrust washer properly installed in stator seat Thrust Bearing Apply SEA DOO JET PUMP SYNTHETIC OIL P N 293 600 011 on both sides of thrust bearing Position thrust bearing no 26 on thrust washer no 25 1 Thru...

Page 317: ...primer is used to reduce Loctite 243 curing time and to activate stainless steel and aluminum surfaces for better bonding action If ap plied complete curing time is 6 hours if primer is not used allow 24 hours for curing time Apply Loctite 243 blue to shaft threads 1 Apply Loctite 243 blue on threads Using 2 screws previously removed from venturi secure impeller shaft holder tool to housing Instal...

Page 318: ...l play must be felt Torque impeller to 110 N m 81 lbf ft then remove tools CAUTION Never use any impact wrench to tighten impeller Apply synthetic grease P N 293 550 010 on im peller splines Insert a new boot no 15 and ring no 16 to impeller 1 Boot and ring Anti rattle System Install spring no 17 on slider no 28 1 Spring 2 Slider Insert slider and spring into cover NOTE Align the longer slider tab...

Page 319: ...do the proce dure Verify if the impeller is rotating freely Add oil Oil Fill NOTE It is highly recommended to perform a leak age test prior adding the oil See PUMP PRESSUR IZATION in this subsection Place housing horizontally as in its operating posi tion so that filler plug is located on top Remove filler plug from cover Pour SEA DOO JET PUMP SYNTHETIC OIL P N 293 600 011 in reservoir un til oil ...

Page 320: ...heck for leakage Proceed as follows Remove drain plug from cover Apply Loctite PST 592 on threads of fitting tool P N 295 000 086 then secure on cover Connect pump gauge tester P N 295 000 085 to fitting Pressurize pump to a maximum of 70 kPa 10 PSI Pump must maintain this pressure for at least 10 minutes CAUTION Repair any leak failure to correct a leak will lead to premature wear of pump com pon...

Page 321: ...lat washers no 8 lock washers no 7 and nuts no 6 Tighten nuts of jet pump housing in a criss cross sequence and torque to 33 N m 24 lbf ft NOTE Slightly lubricate wear ring with BOMBAR DIER LUBE lubricant to minimize friction during initial start GTS Model Secure water supply hose and both bailer tubes to jet pump housing using tie raps 1 Bailer tubes 2 Water supply hose Nozzle GS GTS GTI and GTX ...

Page 322: ... insert both sides at the same time taking care not to break plastic bushings Carefully use a plastic tip hammer if necessary Make sure steering arm of jet pump is on right side and trim arm is above venturi 1 Torque screws to 14 N m 10 lbf ft Steering Cable Refer to section STEERING SYSTEM Trim System Refer to VARIABLE TRIM SYSTEM Reverse Cable Refer to REVERSE SYSTEM F01J5FA 1 www SeaDooManuals ...

Page 323: ... Subsection 03 DRIVE SYSTEM SMR2000 027_09_03A FM 09 03 1 DRIVE SYSTEM 0 GS GTS and GTI Models F02I06S 1 2 3 4 5 6 8 7 9 2 N m 18 lbf in 10 11 13 Synthetic grease 12 Synthetic grease 13 2 N m 18 lbf in www SeaDooManuals net PARTS ...

Page 324: ...9 PROPULSION SYSTEM Subsection 03 DRIVE SYSTEM 09 03 2 SMR2000 027_09_03A FM GTX GSX RFI and GTX RFI Models F15J02S 2 3 4 5 6 8 9 1 7 13 12 13 Synthetic grease 11 10 Synthetic grease www SeaDooManuals net PARTS ...

Page 325: ...ft Loctite 243 22 N m 16 lbf ft Loctite 271 Loctite 518 Synthetic grease 23 15 17 16 15 14 Loctite 518 21 10 N m 89 lbf in 5 6 8 9 10 7 11 12 13 Synthetic grease Synthetic grease Right Stuff sealant 31 N m 23 lbf ft Right Stuff sealant Loctite 518 Loctite 243 31 N m 23 lbf ft Loctite 243 Synthetic grease Synthetic grease www SeaDooManuals net PARTS ...

Page 326: ...om engine and with draw from bilge XP Model Open engine compartment cover Remove storage basket Remove vent tubes from PTO flywheel guard Remove PTO flywheel guard Large Clamp All Models Except XP Model Unfasten large clamp of PTO flywheel boot no 3 as follows Use pliers P N 295 000 069 Insert pointed tips of pliers in closing hooks TYPICAL 1 Closing hooks Squeeze pliers to draw hooks together and...

Page 327: ...e following tool and use it in con junction with the jet pump housing remover P N 295 000 113 to withdraw drive shaft Raw Material 1 aluminum alloy square of 51 mm 2 in x 305 mm 12 in 2 aluminum rods of 28 5 mm 1 1 8 in dia x 30 mm 1 3 16 in 1 Use ball end mill for radius This section of the slot should be 38 mm 1 15 32 in deep 2 Drill 25 mm 1 in hole in center to remove material 3 Weld all around...

Page 328: ...ection or engine rubber mounts XP Model Rear Drive Shaft Remove rear access panel Remove protective plate no 18 1 Remove protective plate Pull rear drive shaft until coupler no 19 is disen gage from splines 1 Pull drive shaft to disengage coupler from splines Remove rear drive shaft Remove coupler no 19 Front Drive Shaft Remove PTO flywheel guard no 1 Remove bolts lock nuts and sleeves from sup po...

Page 329: ...1 Remove bolts and lock nuts Loosen 4 screws and remove bottom cover of seat 1 Remove cover Loosen gear clamp retaining the outer boot of the shock absorber 1 Loosen gear clamp Tilt seat Remove front drive shaft Seal Carrier of Mid Bearing To remove the seal carrier from support loosen the 6 nuts no 21 1 Nut 6 F08Q01A 1 F08L11A 1 F08L12A 1 F05I05A 1 www SeaDooManuals net ...

Page 330: ... feel machined surface of drive shaft If any irregular surface is found renew drive shaft 1 Surface condition 2 Groove condition 3 Splines condition Excessive deflection could cause vibration and damage to drive shaft splines impeller flywheel or floating ring seal carrier depending upon the model Place drive shaft on V blocks and set up a dial gauge in center of shaft Slowly rotate shaft differen...

Page 331: ...ngth measurement from the free length measurement A difference of 4 mm to 12 mm 5 32 in to 15 32 in should be obtained If the length is less than 4 mm 5 32 in install a spacer P N 293 250 017 between boot and thru hull fitting 1 Spacer NOTE Drive shaft mustbe removed to install spacer XP Model Seal Carrier of Mid Bearing Inspect seal carrier needle bearing no 16 Check parts for scoring pitting chi...

Page 332: ...no 15 with protector toward jet pump On both seals no 15 raised edge of lip must be located outwards of seal carrier 1 Double lip seal toward engine 2 Double lip seal with protector toward jet pump 3 Raised edge of lip outwards 4 Seal carrier Apply Loctite 518 all around seals outside diameter Seals no 15 can be carefully installed in housing using bearing seal installer tool P N 295 000 107 Push ...

Page 333: ...using the following tools support plate kit P N 529 035 506 NOTE Use plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plate P N 529 035 507 2 Support P N 529 035 511 alignment shaft P N 529 035 590 1 Alignment shaft PTO flywheel adapter Install support plate at rear of watercraft Install adapter on shaft 1 Alignment shaft 2 Adaptor Carefully slide shaft through support plate and seal car...

Page 334: ...areful not to damage seals CAUTION When sliding the drive shaft through seal carrier the double lip seal can be folded over This would cause a seal carrier bearing failure Reinstall protective plate no 18 Apply Loctite 243 blue on bolts and torque lock nuts to 10 N m 88 lbf in All Models Except the XP Drive Shaft and Dampers Install dampers no 13 on drive shaft no 12 NOTE Make sure dampers were no...

Page 335: ... pointed tips of pliers first in closing hooks TYPICAL 1 Closing hooks Squeeze pliers When both large and small win dows are directly over the 2 locking hooks press those windows down to engage hooks in windows NOTE At installation clamp tail should be in op posite direction of engine rotation 1 Engine rotation counterclockwise 2 Tail in opposite direction Small Clamp To secure small clamp no 4 pl...

Page 336: ... gun carefully lubricate PTO fly wheel with synthetic grease P N 293 550 010 until boot is just beginning to expand At this point immediately stop greasing Seal Carrier of Mid Bearing XP Model Using a grease gun lubricate seal carrier of mid bearing with synthetic grease P N 293 550 010 TYPICAL 1 Grease fitting F01I0BB F05I09A 1 www SeaDooManuals net ...

Page 337: ... REVERSE SYSTEM 0 GTS Model F02J10S 2 6 4 8 N m 71 lbf in 5 1 3 7 7 N m 62 lbf in 3 N m 27 lbf in 10 N m 89 lbf in 6 N m 53 lbf in 2 5 N m 22 lbf in 7 N m 62 lbf in 10 N m 89 lbf in 3 N m 27 lbf in 20 N m 15 lbf ft Loctite 243 Synthetic grease Synthetic grease www SeaDooManuals net PARTS ...

Page 338: ...ever no 1 from sliding block no 5 then slide off locking le ver from stem TYPICAL 1 Locking lever Triangular Lever and Sliding Block Remove screw lock nut washers and bushing holding reverse cable to triangular lever no 4 Remove lock nut and washer holding sliding block no 5 to triangular lever and to support Remove screw lock nut washer and bushing holding triangular lever to reverse support TYPI...

Page 339: ...cable 2 Reverse gate spring each side Unscrew reverse gate retaining screws from ven turi then remove gate 1 Screw each side ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Reverse Gate Install reverse gate no 7 with sleeve and washer Apply Loctite 243 blue on threads and torque to 20 N m 15 lbf ft CAUTION Always hook revers...

Page 340: ...in Torque triangular lever screw to 8 N m 71 lbf in Install sliding block no 5 to lever and torque nut to 8 N m 71 lbf in Locking Lever and Sliding Block Insert locking lever end in support hole then align lever no 1 and sliding block holes TYPICAL 1 Support hole Shift Lever NOTE Always install shift lever no 3 with its open end facing left side of watercraft then push shift lever stem through loc...

Page 341: ...r in a straight ahead position nozzle should be parallel to rear of watercraft Using a square set it to 129 3 mm 5 5 64 7 64 in then position square end at the top middle of nozzle A 129 3 mm 5 5 64 7 64 in Pull shift lever in REVERSE position TYPICAL 1 Shift lever in REVERSE position With the gate down to REVERSE position it should be at the specification NOTE Push slightly on the gate in order t...

Page 342: ...n position NOTE If reverse gate adjustment is not done ad equately performance and steering control will be reduced at reverse position TYPICAL 1 Support 2 Adjustment nuts Tighten adjustment nuts and recheck gate posi tion Reinstall vent tube 1 Install vent tube Reinstall storage tray WARNING Vent tube must be in place to provide proper bilge ventilation F02J06B 1 2 F02L14A 1 www SeaDooManuals net...

Page 343: ... 16 19 15 20 3 5 N m 31 lbf in 17 18 14 Loctite 243 1 11 4 N m 35 lbf in 3 N m 27 lbf in Loctite 243 10 N m 89 lbf in 2 5 N m 22 lbf in Synthetic grease 2 5 N m 22 lbf in 6 N m 53 lbf in 7 N m 62 lbf in 2 Loctite 243 6 N m 53 lbf in 5 N m 44 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 4 3 N m 27 lbf in Loctite 243 Silicone sealant www SeaDooManuals net PARTS ...

Page 344: ...retain ing reverse gate to support no 10 and remove re verse gate Cable Lever Remove Allen screw no 6 and detach cable lever from reverse gate Pawl Lock and Spring To remove pawl lock no 7 and spring no 8 re move roll pin no 9 Reverse Gate Support Unscrew 4 bolts which retain reverse gate support no 10 to venturi Remove reverse gate support from venturi 1 Reverse gate support 2 Remove bolts Interi...

Page 345: ... no 17 Detach adjustment nut no 23 from re verse cable support no 16 Remove 3 bolts no 19 retaining reverse cable support no 16 to body Remove reverse cable support INSPECTION Visually inspect parts for wear or cracks Replace parts as required ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following CAUTION Apply all specified torque...

Page 346: ...k Make sure spring no 8 is properly installed One end of the spring is hooked in the pawl lock no 7 and the other end is retained by the stopper lock nut 1 Pawl lock 2 Spring 3 Stopper lock nut Reverse Gate When installing the reverse gate pay attention to position its lever behind the reverse gate support stopper 1 Stopper Reverse Cable Install reverse cable to cable lever as per following illust...

Page 347: ...on The pawl lock no 7 should be engaged in the an chor no 22 If not adjust reverse cable Loosen 2 bolts no 18 at reverse cable support no 16 Turn adjustment nut no 23 as required 1 Reverse cable support 2 Loosen bolts 3 Adjustment nut When adjustment is completed there should be gap of 2 to 3 mm 5 64 to 7 64 in between handle and left cover A 2 to 3 mm 5 64 to 7 64 in F07J09A 1 2 3 2 F07J0AA A A w...

Page 348: ...1 VARIABLE TRIM SYSTEM 0 GSX RFI and XP Models F15J01S 7 Synthetic grease 8 9 10 2 3 2 13 1 15 16 2 5 N m 23 lbf in 10 N m 23 lbf in 14 Loctite 243 5 4 6 12 5 N m 44 lbf in 13 N m 115lbf in Loctite 243 13 N m 115lbf in 13 N m 115lbf in Loctite 243 7 N m 62 lbf in 11 www SeaDooManuals net PARTS ...

Page 349: ...aft Remove clamps no 2 Remove boot no 3 TYPICAL 1 Ball joint 2 Bolt 3 Lock nut 4 Rubber boot To loosen nut no 4 use VTS socket tool P N 295 000 133 Remove sealing washer no 5 All Models Disconnect wiring harnesses Pull out VTS assembly no 6 from bilge DISASSEMBLY Cover Remove VTS cover no 7 by pressing on tabs 1 Press tabs to remove cover Motor Disconnect wires from motor Remove retaining nuts no ...

Page 350: ...nthetic grease to worm Screw worm no 9 to sliding shaft no 10 Mesh worm splines to gear of motor 1 Mesh worm spline to gear of motor Install motor worm and sliding shaft in VTS hous ing Apply Loctite 243 blue to nuts no 11 and tighten to 7 N m 62 Ibf in Connect wires of motor CAUTION Make sure wire color codes match Install cover no 7 NOTE Make sure seal no 12 is in place INSTALLATION Installation...

Page 351: ... and nut no 15 Torque nut to 10 N m 88 lbf in TYPICAL 1 Washers 2 Bolt 3 Lock nut ADJUSTMENT Push on VTS button up position until motor stops When the nozzle is up 8 nozzle edge must not interfere with venturi there should be a gap of 1 mm 039 in NOTE Activate timer to be able to position VTS 1 No interference 2 Nozzle up If an adjustment is necessary loosen jam nut no 16 of link rod ball joint no...

Page 352: ...01ATOC FM 10 01 1 TABLE OF CONTENTS 0 STEERING SYSTEM 10 02 1 REMOVAL AND INSTALLATION 10 02 2 DISASSEMBLY 10 02 6 ASSEMBLY 10 02 9 DISASSEMBLY 10 02 12 ASSEMBLY 10 02 15 ADJUSTABLE STEERING 10 03 1 DISASSEMBLY 10 03 2 ASSEMBLY 10 03 6 ALIGNMENT 10 04 1 www SeaDooManuals net ...

Page 353: ... N m 19 lbf ft 3 2 3 5 N m 30 lbf in 15 N m 11 lbf ft Loctite 243 15 28 16 Anti seize lubricant 17 14 Loctite 243 15 N m 11 lbf ft 18 15 N m 11 lbf ft Loctite 243 28 19 20 13 40 N m 30 lbf ft Loctite 271 10 11 7 N m 63 lbf in 12 9 20 N m 15 lbf ft 22 7 N m 63 lbf in 21 23 24 10 N m 88 lbf in 27 26 25 2 5 N m 23 lbf in 2 N m 18 lbf in 22 31 6 N m 53 lbf in 30 www SeaDooManuals net PARTS ...

Page 354: ...perly inserted in the slot at the end of the handlebar tubing 1 Grip insert Install grip no 4 on handlebar no 29 matching it to the hex form on the grip insert Install flat washer no 7 and screw no 6 Torque screw to 7 N m 62 lbf in Install cap no 5 1 Grip insert 2 Grip 3 Flat washer 4 Screw Torque to 7 N m 62 lbf in 5 Cap CAUTION Ensure to install flat washer other wise screw will damage grip end ...

Page 355: ... mortise Apply Loctite 271 red on threads of screw no 13 Install large flat washer no 19 lock washer no 20 and screw no 13 Torque screw to 40 N m 30 Ibf ft CAUTION Always install large flat washer with the X stamped side facing the lock washer TYPICAL 1 Steering stem tenon 2 Steering stem arm 3 Mortise 4 Large flat washer with X 5 Lock washer 6 Screw apply Loctite 271 and torque to 40 N m 30 Ibf f...

Page 356: ... Remove half rings no 25 rubber washer no 26 and retaining ring no 27 NOTE Move shift lever in reverse position to low er reverse gate It will ease parts removal Remove steering cable from tie block and clips Pull out steering cable Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Inspect and reuse ball joints no 22 only if they are i...

Page 357: ...13 14 8 18 16 15 17 9 10 11 10 N m 88 lbf in 10 N m 89 lbf in Loctite 243 4 N m 35 lbf in 14 N m 10 lbf ft Loctite 243 3 N m 26 lbf in Loctite 243 6 N m 53 lbf in 6 N m 53 lbf in Loctite 243 6 N m 53 lbf in Loctite 243 26 N m 19 lbf ft 7 N m 62 lbf in 23 21 22 2 5 N m 22 lbf in 2 5 N m 22 lbf in 19 20 21 25 24 27 26 7 www SeaDooManuals net PARTS ...

Page 358: ...om handlebar no 22 NOTE Verify grip insert for damage Steering Cover Remove grips no 1 Loosen set screws no 5 of handlebar housings no 6 1 Set screw Remove 4 screws no 7 TYPICAL 1 Cover 2 Screws Remove 2 screws no 20 and flat washers no 21 each side of cover 1 Remove screws Remove cover Cable Support Loosen bolts no 9 and remove retaining block no 10 1 Retaining block F00K01A 1 F00K02A 2 1 1 F07K0...

Page 359: ...s Remove cable support no 8 Steering Support GTI and GTX Models Cut locking tie securing wiring harness boot 1 Boot 2 Locking tie All Models Disconnect the throttle and choke cables from car buretor levers Disconnect the wiring harnesses leading out of steering stem and cut locking tie GS AND GSX 1 Locking tie 2 Connectors F07K02A 1 2 1 2 F07K03A F07K04A 1 2 F06K03A 1 2 www SeaDooManuals net ...

Page 360: ...taining cable support no 8 to steering support no 12 Loosen bolts no 13 and lock nuts no 14 1 Steering support 2 Bolt 3 Lock nut Remove steering support no 12 with handlebar wiring harnesses and cables Steering Stem Arm and Support Loosen bolts no 17 retaining steering stem arm no 15 to support no 16 1 Steering stem arm 2 Bolts Remove steering stem arm and support F07K05A 2 1 F07K06A 1 2 1 F07K07A...

Page 361: ...p insert no 21 in the han dlebar no 22 ensure that it is properly inserted in the slot at the end of the handlebar tubing 1 Grip insert Install grip no 1 on handlebar no 22 matching it to the hex form on the grip insert Install flat washer no 23 and screw no 3 Torque screw to 7 N m 62 lbf in Install cap no 2 1 Grip insert 2 Grip 3 Flat washer 4 Screw Torque to 7 N m 62 lbf in 5 Cap CAUTION Ensure ...

Page 362: ...ing illustrations CAUTION Ensure the ball joint is parallel 5 to the nozzle arm GTX Model TYPICAL 1 Ball joint on top of steering arm 2 Torque nut to 7 N m 62 lbf in GS and GTI Models TYPICAL 1 Bolt 2 Flat washers 3 Lock nut Torque to 2 N m 18 lbf in STEERING ALIGNMENT For steering alignment procedure refer to ALIGN MENT F06K01A 1 2 F00J01A 2 1 3 www SeaDooManuals net ...

Page 363: ... m 62 lbf in 18 8 13 Synthetic grease 7 N m 62 lbf in 7 Loctite 243 10 26 N m 19 lbf ft 13 N m 10 lbf ft Engine cover Loctite 243 2 5 N m 22 lbf in Loctite 243 Loctite 243 20 19 6 N m 53 lbf in 11 24 21 2 5 N m 22 lbf in 23 7 N m 62 lbf in 22 26 25 27 Engine cover 17 6 N m 53 lbf in Loctite 243 16 15 7 N m 62 lbf in Synthetic grease 14 7 10 N m 89 lbf in 12 www SeaDooManuals net PARTS ...

Page 364: ...insert from handle bar NOTE Verify grip insert no 5 for damage Steering Cover To remove the steering cover no 6 loosen set screws no 7 of handlebar housing 1 Set screws Remove 4 screws no 8 and washers no 9 TYPICAL 1 Cover 2 Screws Remove 2 screws no 9 and flat washers each side of cover 1 Remove screws Detach upper and lower section of cover from steering 1 Upper section 2 Lower section F00K01A 1...

Page 365: ...n Allen screws Lift the top section of the engine cover and discon nect wiring harnesses Remove the top section of the engine compart ment cover Disconnect steering cable no 11 from lever no 10 1 Disconnect steering cable Remove link rod no 12 1 Remove link rod Remove bolt no 13 and washer retaining lever no 10 to steering support no 18 1 Remove bolt and washer 1 F08L0KB 1 1 1 1 F08K05A 1 F08K06A ...

Page 366: ... nuts and bolts Lift steering support no 18 and slightly pullback steering stem no 14 in order to remove the sup port no 16 and steering stem arm no 15 1 Remove support and steering stem arm Steering Stem Disconnect wiring harnesses choke and throttle cables from engine Remove steering stem no 14 Steering Cable Remove glove box Disconnect steering cable no 11 at lever no 10 1 Disconnect steering c...

Page 367: ...m bly procedure However pay particular attention to the following Lever Prior installing lever no 10 apply synthetic grease to pivot Steering Stem Apply synthetic grease to front and rear thrust bearing surface 1 Apply synthetic grease Steering Stem Arm and Support Position steering stem arm no 15 and support no 16 onto steering stem no 14 Handle Grip and Grip Insert When installing the grip inser...

Page 368: ...l flat washer other wise screw will damage grip end Ball Joint Secure the steering cable ball joint no 21 to the nozzle as per following illustration CAUTION Ensure the ball joint is parallel 5 to the nozzle arm TYPICAL 1 Ball joint on top of steering arm 2 Torque nut to 7 N m 62 lbf in STEERING ALIGNMENT For steering alignment procedure refer to ALIGN MENT WARNING Correct torque must be strictly ...

Page 369: ...T Synthetic grease Loctite 243 4 4 7 12 13 25 19 11 18 16 15 17 10 9 26 28 29 30 27 8 14 31 5 5 6 2 23 1 21 22 3 20 6 33 32 10 N m 89 lbf in Loctite 767 Loctite 243 Loctite 271 Loctite 243 Loctite 243 6 N m 53 lbf in 3 N m 20 lbf in 6 N m 53 lbf in Loctite 243 10 N m 88 lbf in 7 N m 62 lbf in www SeaDooManuals net PARTS ...

Page 370: ...ndle no 26 turn sup port bushing no 28 clockwise 1 Adjustment handle 2 Support bushing Hold jam nut no 27 and unscrew adjustment han dle no 26 from adjuster screw no 29 1 Loosen jam nut Steering Cover Loosen set screws no 5 of handlebar housings no 6 1 Set screw Pull handle bar housings to disengage from steer ing cover Remove 4 screws no 7 TYPICAL 1 Cover 2 Screws 2 1 F07K0MA 1 F07K0NA F00K01A 1 ...

Page 371: ...ster screws Remove both upper and lower steering covers 1 Upper cover 2 Lower cover Handle Bar Remove 4 elastic stop nuts M8 retaining steering clamp no 31 1 Remove nuts 2 Steering clamp Detach steering clamp no 31 and remove handle bar no 22 Withdraw rubber pad no 32 and stop per no 33 1 Rubber pad 2 Stopper 1 F07K0XA 3 4 2 2 F07K0KA 1 F07K0SA 1 2 F07K0TA 1 2 www SeaDooManuals net ...

Page 372: ...pport no 8 1 Retaining block Remove bolts no 11 each side of steering sup port no 12 LEFT SIDE 1 Steering support 2 Bolt RIGHT SIDE 1 Steering support 2 Bolts From inside bilge pull down cable support no 8 to detach it from steering support no 12 Steering Support Cut locking tie securing wiring harness boot 1 Locking tie 2 Boot 1 F01K18C F07K02A 1 2 1 2 F07K03A 1 2 F07K0IA www SeaDooManuals net ...

Page 373: ...tach throttle cable from throttle handle 1 Locking Tab From inside bilge remove lock nuts no 14 1 Steering support 2 Bolt 3 Lock nut Remove bolts no 13 and steering support no 12 with handlebar and wiring harnesses Steering Stem Arm and Support Loosen bolts no 17 retaining steering stem arm no 15 to support no 16 1 Steering stem arm 2 Bolt Remove steering stem arm and support Remove steering stem ...

Page 374: ...ts as per main illustration at the be ginning of this subsection Steering Stem Arm and Support Position steering stem arm no 15 and support no 16 onto steering stem 1 Keyways 2 Integrated flat key Replace lock nuts no 18 by new ones Torque bolts no 17 of steering stem arm to 6 N m 53 lbf in Steering Stem and Steering Support Install support bushings no 30 on steering sup port Apply Loctite 767 ant...

Page 375: ... locking tie 1 Locking tie holding harness to steering support Handle Bar Before installing handle bar position stopper no 33 and rubber pad no 32 CAUTION Rubber pad must not exceed stop per 1 Pad must not exceed stopper Position handle bar no 22 Install steering clamp no 31 and secure with new elastic stop nuts M8 Torque nuts to 26 N m 19 lbf ft as per the fol lowing sequence TORQUE SEQUENCE STEE...

Page 376: ... on each side of the straight edge It must be equalled TYPICAL 1 Measure the distance on each side of the straight edge If necessary steering alignment adjustment should be performed at steering cable support All Models Except the XP Open storage compartment cover and remove bas ket Loosen 2 bolts retaining block at cable support Turn adjustment nut as required ALL MODELS EXCEPT GTS AND XP 1 Retai...

Page 377: ...artment cover and remove storage basket 1 Remove storage basket TYPICAL XP MODEL 1 Support 2 Adjustment nut 3 Loosen bolts After adjustment torque retaining block bolts to 6 N m 53 Ibf in CAUTION Verify when the handlebar is turned completely to the left or right side that there is no interference with venturi F01H6WA 1 F08K03B 1 2 3 www SeaDooManuals net ...

Page 378: ...n 11 SUSPENSION Subsection 01 TABLE OF CONTENTS SMR2000 031_11_01ATOC FM 11 01 1 TABLE OF CONTENTS 0 DIRECT ACTION SUSPENSION 11 02 1 REMOVAL 11 02 2 INSPECTION 11 02 3 ASSEMBLY 11 02 3 www SeaDooManuals net ...

Page 379: ... SUSPENSION SMR2000 031_11_02A FM 11 02 1 DIRECT ACTION SUSPENSION 0 XP Model 10 11 3 13 12 5 8 6 9 4 7 F08Q02T 34 N m 25 lbf ft 2 1 10 N m 89 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 34 N m 25 lbf ft 5 N m 44 lbf in www SeaDooManuals net PARTS ...

Page 380: ... cover Loosen gear clamp no 2 of outer boot no 3 then pull outer boot downward 1 Loosen gear clamp Remove rear access panel from body Loosen lower gear clamp no 4 then push inner boot no 5 upward 1 Loosen gear clamp Remove bolt no 6 and lock nut no 7 from shock absorber lower support no 8 1 Bolt 2 Lock nut F08L11A 1 F08L12A 1 F08I03B 1 F08Q03A 2 1 www SeaDooManuals net ...

Page 381: ...tear re new boot s Shock Absorber Inspect shock absorber for wear Extend and com press the piston several times over its entire stroke it should move smoothly and with uniform resistance Pay attention to the following conditions that will denote a defective shock absorber A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme end of either stroke O...

Page 382: ... GRATE 12 02 17 RIDING PLATE 12 02 17 JET PUMP SUPPORT 12 02 19 DEFLECTOR 12 02 20 DRAIN PLUG INSTALLATION 12 02 20 SEAT REMOVAL 12 02 21 SEAT COVER REPLACEMENT 12 02 22 BUMPER REPLACEMENT 12 02 22 SPONSON REPLACEMENT 12 02 23 BAFFLE SEALING 12 02 23 ENGINE COMPARTMENT COVER REMOVAL 12 02 23 DECALS REPLACEMENT 12 02 24 HULL AND BODY REPAIR 12 02 24 TOOLS AND MATERIALS LIST 12 02 27 THRU HULL FITTI...

Page 383: ...2_12_02A FM 12 02 1 ADJUSTMENT AND REPAIR 0 GTS Model bow 3 8 N m 71 lbf in Loctite 271 Loctite 271 Loctite 243 Loctite 271 5 N m 44 lbf in Loctite 271 Loctite 271 15 N m 11 lbf ft Silicone sealant 6 7 7 10 8 F02L3NT 2 1 Silicone sealant 11 www SeaDooManuals net PARTS ...

Page 384: ...AND REPAIR 12 02 2 SMR2000 032_12_02A FM GTS Model stern F02L3OT 7 N m 62 lbf in Loctite 243 Loctite 271 Silicone sealant 15 N m 11 lbf ft 13 12 4 5 12 14 4 12 12 5 15 1 5 N m 13 lbf in Silicone sealant Silicone sealant www SeaDooManuals net PARTS ...

Page 385: ...GS and GSX RFI Models bow F06L0XT Loctite 243 5 N m 44 lbf in 3 5 N m 44 lbf in 5 N m 44 lbf in 5 N m 44 lbf in Loctite 271 8 N m 71 lbf in Loctite 243 Loctite 271 5 N m 44 lbf in 5 N m 44 lbf in Loctite 243 Loctite 243 10 5 N m 44 lbf in 7 8 6 Silicone sealant www SeaDooManuals net PARTS ...

Page 386: ... ADJUSTMENT AND REPAIR 12 02 4 SMR2000 032_12_02A FM GS and GSX RFI Models stern F06L10S 8 N m 71 lbf in 12 13 15 N m 11 lbf ft Loctite 271 Silicone sealant 15 Silicone sealant 4 5 12 14 12 12 4 5 Loctite 414 www SeaDooManuals net PARTS ...

Page 387: ... GTX Models bow F07L1LT 8 N m 71 lbf in 5 N m 44 lbf in Loctite 271 5 N m 44 lbf in 3 Loctite 243 10 Loctite 271 Loctite 271 5 N m 44 lbf in 10 5 N m 44 lbf in Silicone sealant Loctite 243 7 8 6 Left side only Loctite 271 15 N m 11 lbf ft Body Silicone sealant 8 N m 71 lbf in www SeaDooManuals net PARTS ...

Page 388: ... 6 SMR2000 032_12_02A FM GTI GTX RFI and GTX Models stern F07L1GS 13 12 8 N m 71 lbf in 8 N m 71 lbf in Loctite 271 12 4 5 14 12 12 4 5 Silicone sealant 15 Silicone sealant Silicone sealant 1 5 N m 13 lbf ft Loctite 271 15 N m 11 lbf ft www SeaDooManuals net PARTS ...

Page 389: ...32_12_02A FM 12 02 7 GTI GTX RFI and GTX Models cover F07L1MT Loctite 243 0 8 N m 7 lbf in 8 N m 71 lbf in 1 4 N m 12 lbf in 5 N m 44 lbf in Loctite 243 5 N m 44 lbf in 8 N m 71 lbf in Loctite 243 5 N m 44 lbf in Loctite 243 3 N m 26 lbf in www SeaDooManuals net PARTS ...

Page 390: ...DY Subsection 02 ADJUSTMENT AND REPAIR 12 02 8 SMR2000 032_12_02A FM GTI GTX RFI and GTX Models seat F07L1NT Loctite 243 4 N m 35 lbf in Loctite 243 5 N m 44 lbf in Loctite 243 5 N m 44 lbf in www SeaDooManuals net PARTS ...

Page 391: ...ODY Subsection 02 ADJUSTMENT AND REPAIR SMR2000 032_12_02A FM 12 02 9 XP Model bow F08L1JT Loctite 243 Silicone sealant 10 6 Loctite 243 Silicone sealant Body 15 N m 11 lbf ft Loctite 271 8 7 www SeaDooManuals net PARTS ...

Page 392: ... 12 02 10 SMR2000 032_12_02A FM XP Model stern Loctite 271 732 sealant 3 5 N m 44 lbf in 15 N m 11 lbf ft Body 12 13 F08L15S Body 732 sealant Loctite 271 1 5 N m 13 lbf in 14 Loctite 271 3 5 N m 44 lbf in Body 15 4 5 12 12 12 5 4 www SeaDooManuals net PARTS ...

Page 393: ...R SMR2000 032_12_02A FM 12 02 11 XP Model seat F08L16T Loctite 243 15 N m 11 lbf ft 17 5 N m 44 lbf in Loctite 243 4 N m 35 lbf in Loctite 271 13 N m 10 lbf ft 3 N m 27 lbf in 23 22 21 20 19 18 3 N m 27 lbf in 24 Synthetic grease www SeaDooManuals net PARTS ...

Page 394: ...ND REPAIR 12 02 12 SMR2000 032_12_02A FM XP Model suspension F08L1KT Loctite 243 4 N m 35 lbf in Loctite 243 8 N m 71 lbf in Loctite 243 4 N m 35 lbf in Loctite 243 4 N m 35 lbf in Loctite 648 8 N m 71 lbf in Loctite 243 www SeaDooManuals net PARTS ...

Page 395: ...Section 12 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2000 032_12_02A FM 12 02 13 XP Model front cover Loctite 271 3 N m 27 lbf in F08L18S 2 N m 18 lbf in Engine cover www SeaDooManuals net PARTS ...

Page 396: ...LL BODY Subsection 02 ADJUSTMENT AND REPAIR 12 02 14 SMR2000 032_12_02A FM XP Model rear cover Loctite 243 4 N m 35 lbf in F08L19T 22 N m 16 lbf ft 4 N m 35 lbf in Loctite 243 Loctite 243 www SeaDooManuals net PARTS ...

Page 397: ...4 in GTS MODEL 1 Lock pin 2 Adjustment nut Loctite 271 3 Lock nut Torque to 5 N m 44 lbf in A 38 1 mm 1 1 2 3 64 in GTI GTX RFI AND GTX MODELS FRONT SEAT 1 Lock pin 2 Adjustment nut Loctite 271 A 39 1 mm 1 35 64 3 64 in GTI GTX RFI AND GTX MODELS REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 271 A 33 5 1 mm 1 5 16 3 64 in F06L03A A 1 2 F02L25C A 3 2 1 F07L08A A 2 1 F06L03A A 1 2 www SeaDooMa...

Page 398: ...ly Loctite 271 2 Adjustment nut A 34 1 mm 1 11 32 3 64 in GTI GTX RFI AND GTX MODELS 1 Lock pin apply Loctite 243 2 Rubber washer 3 Flat washers A 39 2 1 mm 1 35 64 3 64 in NOTE The GTI GTX RFI and GTX have a floating type lock pin It is normal to have a front and aft play of the lock pin To adjust tighten lock pin until any vertical play is eliminated Make sure a front and aft play remains when p...

Page 399: ...iver should be used to loosen tight screws When reinstalling inlet grate apply Loctite 271 on threads and torque screws to 11 N m 8 lbf ft RIDING PLATE Removal All Models Except some GTX Remove inlet grate Remove jet pump Refer to JET PUMP Remove the speed sensor from the riding plate if applicable Loosen riding plate screws NOTE An impact screwdriver should be used to loosen tight screws Using a ...

Page 400: ...e next illustrations Fol low also the torquing sequence if applicable as shown in the same illustrations GTS MODEL 1 Apply Loctite The Right Stuff Gasket as indicated by the shaded area GS GTI GTX GSX RFI AND GTX RFI MODELS XP MODEL GTX Model with serial number included between ZZN54056B000 and ZZN54929B000 Apply Loctite The Right Stuff Gasket as indicated by the shaded areas in the previous illus...

Page 401: ...nect water supply hose water return hose and bailer hoses Remove nuts lock washers and flat washers re taining jet pump support TYPICAL 1 Remove nuts Using a heat gun heat jet pump support until it is possible to pull it NOTE Shims may have been installed between support and body Do not remove these shims otherwise jet pump alignment will be altered Installation Apply Loctite The Right Stuff Gaske...

Page 402: ...wood Installation Apply Loctite The Right Stuff Gasket as indicated by the shaded area in the following illustration DRAIN PLUG INSTALLATION Refer to the following illustration to install drain plug no 15 1 Drain plug 2 Gasket and 732 sealant 3 Torque screws to 1 5 N m 13 lbf in 4 From inside bilge apply 732 sealant on screws 2 4 3 F15L02A 1 4 2 1 F07L23A 3 4 2 1 F08L1OA 3 F07L0BA F05L13A 1 2 3 4 ...

Page 403: ...en gear clamp of outer boot then pull outer boot downward 1 Loosen gear clamp Loosen gear clamp of inner boot then pull boot downward 1 Gear clamp Remove bolt and lock nut from shock absorber up per support 1 Bolt 2 Lock nut Remove protective caps no 18 and loosen screws no 19 to remove eyelet no 20 on each side of seat F08L11A 1 F08L12A 1 F08L13A 1 F08Q04A 2 1 www SeaDooManuals net ...

Page 404: ...products to be used SEAT COVER REPLACEMENT Install staples with an electric tacker such as Ar row tacker no ETN 50 or with a manual tacker such as Arrow tacker no T 50 NOTE For an easier installation it s highly recom mended to use an electric tacker Ensure that the seat rest firmly against a hard sur face such as a piece of wood This is done to get the staples completely pushed in place TYPICAL 1...

Page 405: ...t adhesive on hull Install gaskets no 7 on new sponsons no 6 Apply silicone sealant P N 293 800 033 around sponson studs Apply Loctite 243 blue on sponson studs Install sponsons no 6 on hull From inside bilge first insert flat washers no 8 over sponson studs Secure with lock nuts no 10 Tighten to 5 N m 44 lbf in NOTE To ease flat washer and lock washer instal lation use a flexible 4 claw Snap on p...

Page 406: ... few seconds when the activator evapo rates the surface is ready Using a pencil and the decal as a template mark the area where decal will be located For better adhesion a dry application is recom mended however to ease decal installation a mild solution of soapy water can be sprayed over sur face where decal will be installed Remove back protective film from decal and align decal with marks When ...

Page 407: ... grit wet paper Finish wet sanding with a 600 grit to remove deeper scratch es If needed you can wet sand with finer grit pa per such as 1000 grit BUFFING AND WAXING Buff the surface using a heavy duty polisher with a buffing pad Make sure the pad is free of dirt or you may damage the gelcoat Carefully begin buff ing with a white medium compound Finish off us ing a fine compound While buffing pay ...

Page 408: ...n air sander Sand the surface down with progressively finer grits of sandpaper until the de sired finish is achieved BUFFING AND WAXING Buff the surface using a heavy duty polisher with a buffing pad Make sure the pad is free of dirt or you may damage the gelcoat Carefully begin buff ing with a white medium compound Finish off us ing a fine compound While buffing pay close at tention to avoid over...

Page 409: ...oard that fits flush to the interior surface and has a plastic layer on the repair side It is held in place by tape or a support Inside Wipe down the area with acetone on a cloth Ap ply the same procedure as for outside repair when laminating the alternating pieces of fiberglass ma terial If a backing support was used remove it before starting the repair After the area has hard ened remove sharp e...

Page 410: ...epoxy glue on aluminum insert P N 292 000 075 knurled surface and on plastic insert inner bore CAUTION If you notice any clearance between plastic insert and aluminum insert fill gap with epoxy glue to obtain good adhesion of alumi num insert 1 Knurled surface 2 Inner bore Install aluminum insert into plastic hull insert NOTE Align aluminum insert as much as possible with PTO flywheel 1 Aluminum i...

Page 411: ...ing type and quantity 1 semi trapez 1 rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0 025 0 070 mm 001 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 10 mm 0039 in Wear limit 0 20 mm 008 in Cylinder taper New 0 05 mm 002 in Wear limit 0 10 mm 004 in Cylinder out of round New 0 008 mm 0003 Wear limit 0 0...

Page 412: ...uasa Exide Fuses MPEM 5 A Electrical system 2 x 15 A VTS system Not applicable Bilge pump Not applicable ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION GS 5644 5827 Carburetor Type Mikuni BN 40i diaphragm fuel accelerator pump Quantity 1 Main jet 167 5 Pilot jet 75 Spring 130 g Adjustment Low speed screw 1 turn 1 4 High speed screw 0 Idle speed in water 1500 RPM Idle speed out of water 30...

Page 413: ...000 016 in Wear limit 1 0 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GS 5644 5827 Number of passenger driver incl 2 Overall length 270 cm 106 in Overall width 116 cm 45 7 in Overall height 99 cm 39 in Dry weight 219 kg 483 lb Lo...

Page 414: ...DDITIONAL INFORMATION STANDARD EQUIPMENT GS 5644 5827 Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Standard Monitoring beeper Standard Fuel oil gauge analog Standard Mirrors Optional Storage compartment Standard Rear grab handle Standard Tool kit Standard ADDITIONAL INFORMATION PERFORMANCE GS 5644 5827 Estimated pump power 26 3 kW 35 3 HP Maximum fuel consum...

Page 415: ...lbf in 5 Starter mounting screws 22 N m 16 lbf ft 1 Spark plugs 24 N m 17 lbf ft 5 JET PUMP Impeller 110 N m 81 lbf ft 1 Pump hull nuts 31 N m 23 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Riding plate screws 22 N m 16 lbf ft 1 STEERING Cable retaining block bolts 6 N m 53 lbf in Steering cable stem arm b...

Page 416: ... 1 1 Cylinder head volume 51 8 0 6 cc Cylinder head warpage maximum 0 10 mm 0039 in total Piston ring type and quantity 2 semi trapez Ring end gap New 0 45 0 60 mm 018 024 in Wear limit 1 00 mm 039 in Ring piston groove New 0 048 0 075 mm 002 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 09 mm 0035 in Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 mm 004 in Cy...

Page 417: ...ses MPEM 5 A Electrical system 2 x 15 A VTS system 7 5 A Bilge pump 3 A ADDITIONAL INFORMATION CARBURETION XP 5651 5655 Carburetor Type Mikuni BN 46i diaphragm fuel accelerator pump Quantity 2 Main jet MAG and PTO 162 5 Pilot jet 75 Spring 95 g Adjustment Low speed screw 1 1 2 turn 1 4 High speed screw 0 Idle speed in water 1400 100 RPM Idle speed out of water 3000 RPM Fuel Type Regular unleaded g...

Page 418: ... 000 016 in Wear limit 1 00 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS XP 5651 5655 Number of passenger driver incl 2 Overall length 272 cm 107 in Overall width 112 cm 44 in Overall height 104 cm 40 9 in Dry weight 255 kg 562 lb...

Page 419: ...NFORMATION STANDARD EQUIPMENT XP 5651 5655 Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Standard Monitoring beeper Standard Speedometer Standard Fuel oil gauge analog Standard Tachometer Standard Variable trim system VTS Standard Storage compartment Standard Rear grab handle Standard Tool kit Standard ADDITIONAL INFORMATION PERFORMANCE XP 5651 5655 Estimated...

Page 420: ...gs 24 N m 17 lbf ft 5 JET PUMP Impeller 110 N m 81 lbf ft 1 Pump hull nuts 31 N m 23 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft 1 VTS ring screws 13 N m 10 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Riding plate screws 10 N m 89 lbf in 1 STEERING Cable retaining block bolts 6 N m 53 lbf in Steering cable lever 3 N m 26 lbf in Steering stem ...

Page 421: ... 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0 025 0 070 mm 001 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 10 mm 0039 in Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 mm 004 in Cylinder out of round maximum 0 080 mm 003 in Connec...

Page 422: ...A h Yuasa Exide Fuse MPEM 5 A Electrical system 15 A ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION GTS 5639 Carburetor Type Mikuni BN 40i diaphragm fuel accelerator pump Quantity 1 Main jet 167 5 Pilot jet 75 Spring 130 g Adjustment Low speed screw 1 turn 1 4 High speed screw 0 Idle speed in water 1500 RPM 100 Idle speed out of water 3000 RPM Fuel Type Regular unleaded gasoline Minimum o...

Page 423: ...ear limit 1 00 mm 040 in Impeller shaft end play new 0 12 0 54 mm 005 021 in Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTS 5639 Number of passenger driver included 3 Overall length 302 cm 119 0 in Overall width 119 cm 46 9 in Overall height 95 cm 37 4 in Dry weight 2...

Page 424: ...ON STANDARD EQUIPMENT GTS 5639 Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Standard Monitoring beeper Standard Fuel gauge low oil warning light Standard Tachometer Not applicable Speedometer Not applicable Variable trim system VTS Not applicable Storage compartment Standard Rear grab handle Standard Tool kit Standard ADDITIONAL INFORMATION PERFORMANCE GTS 5...

Page 425: ... 16 lbf ft 1 Spark plugs 24 N m 17 lbf ft 5 JET PUMP Impeller 110 N m 81 lbf ft 1 Pump hull nuts 31 N m 23 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft 1 Nozzle venturi screws 20 N m 15 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Riding plate screws 10 N m 89 lbf in 1 STEERING Steering cable jam nuts 10 N m 89 lbf in Steering support collar sc...

Page 426: ...Cylinder head volume 42 4 0 4 cc 51 8 0 6 cc Cylinder head warpage maximum 0 05 mm 002 in 0 10 mm 004 in total Piston ring type and quantity 1 semi trapez 1 rectangular 2 semi trapez Ring end gap New 0 25 0 40 mm 010 016 in 0 45 0 60 mm 018 024 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0 025 0 070 mm 001 003 in 0 048 0 075 mm 002 003 in Wear limit 0 2 mm 008 in Piston cylinder ...

Page 427: ...a Exide Fuses MPEM 5 A Electrical system 2 x 15 A VTS system Not applicable ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION GTI 5647 5657 GTX 5653 5669 Carburetor Type Mikuni BN 40i diaphragm fuel accelerator pump Mikuni BN 46i diaphragm fuel accelerator pump Quantity 1 2 Main jet 167 5 MAG and PTO 162 5 Pilot jet 75 Spring 115 g 95 g Adjustment Low speed screw 1 turn 1 4 1 1 2 turn 1 4 Hi...

Page 428: ...n Wear limit 1 0 mm 040 in Impeller shaft end play new 0 Impeller shaft side play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTI 5647 5657 GTX 5653 5669 Number of passenger driver incl 3 Overall length 315 cm 124 in Overall width 122 cm 48 in Overall height 104 cm 41 in Dry weight 275 kg 606 lb...

Page 429: ...peedometer Standard Fuel oil gauge analog Standard Not applicable Tachometer Not applicable Not applicable Info Center Not applicable Standard Storage compartment Standard Glove box Standard Rear grab handle Standard Tool kit Standard ADDITIONAL INFORMATION Info Center standard functions Fuel level low fuel level low oil level low voltage high temperature tachometer speedometer average speed peak ...

Page 430: ...18 lbf ft 1 Flame arrester screws 10 N m 89 lbf in 1 Not applicable Magneto housing cover screws 9 N m 80 lbf in 5 Starter mounting screws 22 N m 16 lbf ft 1 10 N m 89 lbf in 1 Spark plugs 24 N m 17 lbf ft 5 JET PUMP Impeller 110 N m 81 lbf ft 1 Pump hull nuts 31 N m 23 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 l...

Page 431: ... 7 in Corrected compression ratio 6 0 1 Cylinder head volume 47 7 0 4 cc Cylinder head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular Ring end gap New 0 40 0 55 mm 016 022 in Wear limit 1 00 mm 039 in Ring piston groove New 0 025 0 070 mm 001 003 in Wear limit 0 24 mm 009 in Piston cylinder wall clearance New minimum 0 13 mm 005 in Wear limit 0 22 mm 009 i...

Page 432: ...DITIONAL INFORMATION FUEL SYSTEM GTX RFI 5515 5516 5648 5658 GSX RFI 5645 5654 Fuel injection type Rotax Fuel Injection semi direct single throttle body 56 mm Idle speed in water 1500 100 RPM Throttle Position Sensor TPS 1 6 kΩ 2 4 kΩ terminals 1 2 710 Ω 1380 Ω terminals 2 3 Crankshaft Position Sensor CPS 774 Ω 946 Ω Air Temperature Sensor ATS 2 280 kΩ 2 74 kΩ Water Temperature Sensor WTS 2 280 kΩ...

Page 433: ...it 1 00 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTX RFI 5515 5516 5648 5658 GSX RFI 5645 5654 Number of passenger driver incl 3 2 Overall length 315 cm 124 in 270cm 106 3 in Overall width 122 cm 48 in 116 cm 45 7 in Overall h...

Page 434: ...16 5648 5658 GSX RFI 5645 5654 Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Standard Monitoring beeper Standard Speedometer Standard Not applicable Tachometer Not applicable Info Center Standard Adjustable handlebar Standard Not applicable Storage compartment Standard Glove box Standard Rear grab handle Standard Boarding ladder Standard Not applicable Tool k...

Page 435: ...g cover screws 9 N m 80 lbf in 5 Starter mounting screws 22 N m 16 lbf ft 1 Spark plugs 24 N m 17 lbf ft 5 JET PUMP Impeller 110 N m 81 lbf ft 1 Pump hull nuts 31 N m 23 lbf ft 1 Venturi pump housing screws 21 N m 16 lbf ft 1 Pump housing cover screws 4 N m 35 lbf in 1 Inlet grate screws 8 N m 71 lbf in 1 Riding plate screws 22 N m 16 lbf ft 1 STEERING Cable retaining block bolts 6 N m 53 lbf in S...

Page 436: ... indicates that the wire is posi tioned in the connector no 2 of the MPEM The second number indicates that the wire is po sitioned in the terminal no 18 The letter g indicates a common circuit with an other wire s bearing the same letter g in the cir cuit DEUTSCH CONNECTORS Deutsch connectors are used to connect wiring harness to magneto and to electrical box some models 1 Male housing 2 Female ho...

Page 437: ... of signal contact make sure the lock is removed Insert contact into appropriate circuit cavity and push as far as it will go Pull back on the contact wire to be sure the re tention fingers are holding the contact After all required contacts have been inserted the lock must be installed 1 Wire identification numbers PACKARD CONNECTOR Packard connectors are used to connect electrical harnesses and ...

Page 438: ... both tabs and pull plug Step Press tabs both sides Step Pull plug Installation Apply a thin coat of DEOXIT contact lubricant P N 293 550 015 to the pins of the header on the MPEM only 1 Apply a thin coat of DEOXIT contact lubricant CAUTION Do not apply lubricant excessively Care must be taken so that the lubricant will not come in contact with the mating seal the seal may loose its sealing capaci...

Page 439: ...ION The wedge lock should never be re moved from the connector for insertion or re moval of the signal wire contacts 1 Screwdriver between wedge lock and connector 2 Locking tab Repeat the same steps for the other locking tab retaining the wedge lock The wedge lock is now in the open position 1 Wedge lock opened While rotating the wire back and forth over a half turn 1 4 turn in each direction gen...

Page 440: ...act Crimping The size of the wires must be 20 to 16 AWG with a wire insulation diameter having a minimum di mension of 1 7 mm 067 in and a maximum di mension of 2 78 mm 106 in The wire strip length shall be 5 1 mm 13 64 in NOTE When stripping wires ensure conductor is not nicked scrapped or cut Wire stripping tool jaws may leave marks on the surface of the wire insulation If these marks occur at t...

Page 441: ...2 Wire seal CAUTION Do not pierce the diaphragm with a sharp point for electrical troubleshooting The resulting pinholes in the insulation will allow moisture to penetrate the system and possibly result in system failure Contact Installation For insertion of signal contact make sure the wedge lock is in the open position NOTE For insertion of power contact the wedge lock may or may not be on the o...

Page 442: ...SMR2000 034_14_00A FM GS MODEL 5644 5827 www SeaDooManuals net ...

Page 443: ...SMR2000 034_14_00A FM F00Z01 www SeaDooManuals net ...

Page 444: ...SMR2000 034_14_00A FM XP MODEL 5651 5655 www SeaDooManuals net ...

Page 445: ...SMR2000 034_14_00A FM F08Z01 www SeaDooManuals net ...

Page 446: ...SMR2000 034_14_00A FM GTS MODEL 5639 www SeaDooManuals net ...

Page 447: ...SMR2000 034_14_00A FM F02Z02 www SeaDooManuals net ...

Page 448: ...SMR2000 034_14_00A FM GTI MODEL 5647 5657 www SeaDooManuals net ...

Page 449: ...SMR2000 034_14_00A FM F02Z01 www SeaDooManuals net ...

Page 450: ...SMR2000 034_14_00A FM GTX MODEL 5653 5669 www SeaDooManuals net ...

Page 451: ...SMR2000 034_14_00A FM F02Z03 www SeaDooManuals net ...

Page 452: ...SMR2000 034_14_00A FM GSX RFI MODEL 5645 5654 www SeaDooManuals net ...

Page 453: ...SMR2000 034_14_00A FM F15Z01 www SeaDooManuals net ...

Page 454: ...SMR2000 034_14_00A FM GTX RFI MODEL 5515 5516 5648 5658 www SeaDooManuals net ...

Page 455: ...SMR2000 034_14_00A FM F15Z02 www SeaDooManuals net ...

Page 456: ...www SeaDooManuals net ...

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Sea-doo 2001 GS, Shop Manual

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Summary of Contents for 2001 GS

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