Sea-doo 2001 RX Page 76 Shop Manual Download | Manualshive

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Section 04

ENGINE

Subsection 05

(TOP END)

SMR2000-046_04_05A.FM

04-05-3

GENERAL

The 2-stroke ROTAX engine rotates counterclock-
wise seen from the rear (PTO flywheel).

The 947 engine uses reed valves in the crankcase.

The 947 engines are also equipped with the RAVE
system (Rotax Adjustable Variable Exhaust).

CAUTION:

No engine components can be inter-

changed between engines.

RAVE System
(Rotax Adjustable Variable Exhaust)

BASIC OPERATION

The RAVE system changes the exhaust port
height. The exhaust port height is controlled by the
MPEM according to the engine RPM.

Carburetor-Equipped Engines

On top of the RAVE valves, there is a red plastic
adjustment knob. Turning the adjustment in or out
changes the preload on the return spring. On this
engine, the spring preload does not have a signif-
icant effect on the valve operation.

To open the RAVE valves, the MPEM activates a
solenoid which directs the positive pressure from
engine crankcase to the valves.

1. Solenoid
2. Pressure hose from crankcase
3. To atmospheric pressure

NOTE:

A check valve on the pressure line elimi-

nates the negative pressure from the crankcase.

To close the RAVE valves, the MPEM deactivates
the solenoid which blocks the crankcase positive
pressure. The RAVE valves are opened to the at-
mosphere.

RAVE VALVE OPENED

1. Pulse from crankcase
2. Check valve
3. Positive pressure to solenoid
4. Solenoid activated
5. Positive crankcase pressure to RAVE valves

RAVE VALVE 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

2

F06D3BA

1

3

3

F06D16A

2

1

4

5

3

F06D16B

2

1

4

5

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Summary of Contents for 2001 RX

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

Page 2: ...2000 Shop Manual VOLUME 2 RX RX DI GTX DI 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: ...GEMENT DI 01 Table of contents 05 01 1 02 Overview 05 02 1 03 Component inspection and adjustment 05 03 1 04 Diagnostic procedures 05 04 1 06 COOLING SYSTEM 01 Table of contents 06 01 1 02 Circuit components and care 06 02 1 07 FUEL SYSTEM 01 Table of contents 07 01 1 02 Fuel circuit 07 02 1 03 Air intake 07 03 1 04 Carburetor 07 04 1 08 LUBRICATION SYSTEM 01 Table of contents 08 01 1 02 Oil injec...

Page 5: ...2 Steering system 11 02 1 03 Adjustable steering 11 03 1 04 Alignment 11 04 1 12 HULL BODY 01 Table of contents 12 01 1 02 Adjustment and repair 12 02 1 13 TECHNICAL DATA 01 RX 13 01 1 02 RX DI and GTX DI 13 02 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: ...located on floorboard at the rear of the water craft TYPICAL 1 Hull Identification Number H I N All Models The Hull Identification Number is composed of 12 digits MODELS MODEL NUMBER RX 5513 RX International 5514 RX DI 5646 RX DI International 5656 GTX DI 5649 GTX DI International 5659 F00L2EA 1 F08L0QA 1 Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number F00A0CB Month of production Year of producti...

Page 8: ...ajor sections 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 ENGINE MANAGEMENT DI 06 COOLING SYSTEM 07 FUEL SYSTEM 08 LUBRICATION SYSTEM 09 ELECTRICAL SYSTEM 10 PROPULSION SYSTEM 11 STEERING SYSTEM 12 HULL BODY 13 TECHNICAL DATA 14 WIRING DIAGRAMS Several sections are divided in various subsections There is a table of contents at the beginning of many sections F06D15A...

Page 9: ...stration 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 10: ...place 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 Diaph...

Page 11: ...ft are designed with parts dimensioned in both the metric and the imperial systems When replacing fasteners make sure to use only those recommended by Bombardier As many of the procedures in this manual are in terrelated we suggest that before undertaking any task you read and thoroughly understand the entire section or subsection in which the proce dure is contained DESCRIPTION AC Alternate Curre...

Page 12: ...to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predeter mined factory specifications Single engine exceptions may be allowed with permission from the EPA for racing and testing EPA Emission Regulations All new 1998 and later watercrafts manufactured by Bombardier are certified to the United States Environmental Protection Agency as conf...

Page 13: ...olt in the hole 5 Apply a few drops of threadlocker at proposed tightened nut engagement area 6 Position nut and tighten as required Blind Holes 1 On threads 2 On threads and at the bottom of hole 1 Clean threads bolt and hole with solvent 2 Apply Loctite Primer N P N 293 800 041 on threads bolt and nut and allow to dry for 30 seconds 3 Choose proper strength Loctite threadlocker 4 Apply several d...

Page 14: ...rops of proper strength Loctite on bolt nut contact surfaces 5 Avoid touching metal with tip of flask NOTE For preventive maintenance on existing equipment retighten nuts and apply proper strength Loctite on bolt nut contact surfaces Adjusting Screw 1 Apply here 2 Plunger 1 Adjust screw to proper setting 2 Apply drops of proper strength Loctite thread locker on screw body contact surfaces 3 Avoid ...

Page 15: ...1 Proper strength Loctite 2 Loctite Primer N P N 413 708 100 and Gasket Eliminator 515 P N 293 800 038 on both sides of gasket 3 Loctite Primer N only 1 Remove old gasket and other contaminants with Loctite Chisel remover P N 413 708 500 Use a mechanical mean if necessary NOTE Avoid grinding 2 Clean both mating surfaces with solvent 3 Spray Loctite Primer N on both mating surfaces and on both side...

Page 16: ...lic 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 and gap are required 4 Install according to stan...

Page 17: ...24 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 53 73 54 74...

Page 18: ...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 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 147 108 148 10...

Page 19: ...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 20: ... 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 NEW NEW Carbon dam compressor P N 529 035 716 APPLICATION 947 DI engine PTO flywheel remover installer P N 295 000 001 F01J0T4 APPLICATION 717 engine NOTE This tool is also used for the impeller Bearing pusher P N 420 876 501 F00B074 APPLICATION 717 and 7...

Page 21: ...0Y4 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 ...

Page 22: ...APPLICATION 787 RFI and 947 engines NOTE This kit is supplementary to P N 295 500 352 Intake plug P N 529 035 708 APPLICATION 947 DI engine 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 NEW Ring gear blocking tool P N 295 000 155 F01B2...

Page 23: ...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 1 Fuel pressure gauge P N 529 035 709 2 Fuel pressure gauge T fitting P N 529 035 710 3 Fuel pressure gauge pressure relief valve P N 529 035 711 4 Fuel pressure gauge air compressor adapter P N 529 035 712 F12R014 APPL...

Page 24: ...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 25: ...Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 MANDATORY SERVICE TOOLS 01 02 6 SMR2000 038_01_02A FM WORKSHOP Tool board P N 295 500 608 F00A0S4 APPLICATION All models 01 www SeaDooManuals net ...

Page 26: ...5 in 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 A00B4E4 APPLICATION All models Digital induction type tachome...

Page 27: ...sed 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 engine Exhaust outlet tool P N 295 000 132 F01B2A4 APPLICATION All models Engine lifting device Not sold by Bombardier Do it yourself Refer to REMOVAL AND INSTAL LA...

Page 28: ...nes 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 420 876 330 947 engine 5 Distance ring MAG P N 420 876 569 6 Ring halves MAG P N 420 276 025 2 7 Screw M8 x 40 P N 420 840 681 2 8 ...

Page 29: ...ll models 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 coup...

Page 30: ... 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 Deep socket 14 mm 9 16 in Impeller hou...

Page 31: ...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 32: ... 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 Loctite 495 A00B2V4 Gasket elimina...

Page 33: ...12 oz A00B3M4 Molykote 111 P N 413 707 000 A00B3W4 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 50 mL B Loctite 567 250 mL A00B2W4 Hylomar sealant P N 293 800 001 PL 32 100 g A00B3F4 111 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 g...

Page 34: ...54 Super Lube grease P N 293 550 014 A00B474 R 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 ...

Page 35: ... 4 L P N 413 710 700 205 L F01B354 Injection Oil Two stroke BOMBARDIER Formula XP S DI synthetic injection oil P N 293 600 032 12 x 1 L BOMBARDIER Formula XP S DI synthetic injection oil P N 293 600 033 3 x 4 L P N 293 600 034 205 L Sealant adhesive P N 293 800 033 Adchem 4511 clear F01B1S4 The Right Stuff sealant P N 293 800 053 Permatex 198 g F00B0V4 NEW NEW Jet pump oil P N 293 600 011 12 x 6 o...

Page 36: ...AL 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 ENGINE DRAINING 02 05 1 FUEL SYSTEM 02 05 1 COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION 02 05 2 PROPULSION SYSTEM 02 05 2 BATTERY 02 05 2 WATERCRAFT CLEANING 02 05 2 ANTICORROSION TREATMENT 02 05 3 ADDITIONAL RECOMMENDED PROTECTION 02 05 3 www SeaDooManuals net ...

Page 37: ...se condition and fasteners Inspect clean engine drain tubes Water flow regulator valve inspection carburetor equipped models FUEL SYSTEM Carburetor adjustment including choke throttle cable adjustments carburetor equipped models Throttle choke cables carburetor equipped models inspection lubrication Fuel filter carburetor equipped models and lines inspection Fuel filter replacement Visually check ...

Page 38: ...M mounting brackets fasteners Digitally Encoded Security System Monitoring beeper Battery condition and straps STEERING SYSTEM Inspection and cable adjustment PROPULSION SYSTEM Drive shaft boot and spline condition if so equipped PTO flywheel lubrication Shifter system cable adjustment VTS Variable Trim System if so equipped Jet pump reservoir oil level oil condition Replace Replace Jet pump cover...

Page 39: ... entire procedure PROCEDURE Clean jet pump by spraying water in its inlet and outlet and then spray BOMBARDIER LUBE lubri cant Install flushing adapter P N 295 500 473 to the water outlet located at the rear of the watercraft 1 Install flushing adaptor Connect a garden hose to the flushing adaptor NOTE A quick connect adapter can be used to ease garden hose installation The quick connect adapter m...

Page 40: ...raft is out of water Spray BOMBARDIER LUBE lubricant where shown keeping engine at fast idle for approximate ly one minute Carburetor Equipped Models 1 Air intake silencer 2 Spray BOMBARDIER LUBE here DI Models Spray through hole of air intake silencer NOTE An increase of engine RPM may be noticed while spraying the lubricant in the air intake silencer 1 Partially pull tube out of air box to injec...

Page 41: ...TE Proceeding in this order no fuel will be in jected and no ignition will occur in the engine While engine is stopped fully depress throttle le ver and HOLD for cranking Press the start stop button to crank the engine a few turns and distribute the lubricant onto cylinder walls NOTE A 1 second beep every second indicates the drowned mode is active All Models Apply anti seize lubricant on spark pl...

Page 42: ...jected into the engine and ignition will be cut While engine is stopped fully depress throttle le ver and HOLD for cranking Crank engine several times to drain crankcase NOTE A 1 second beep every second indicates the drowned mode is active If water does not completely go out it may be nec essary to remove the air intake silencer then to lean the vehicle so that water can flow out from throttle bo...

Page 43: ...or deflected Refer to BOTTOM END After engine has started spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running Carburetor Equipped Models 1 Air intake silencer 2 Spray BOMBARDIER LUBE here DI Models Spray through hole of air intake silencer NOTE An increase of engine RPM may be no ticed while spraying the lubricant in the air intake silencer 1 Partially pull tube out...

Page 44: ...n hose DI Models Disconnect the quick connect fitting Press both tabs and pull fitting DISCONNECT THIS HOSE Lower hose as necessary so that draining can take place Reconnect fitting when done Also ensure air compressor drain line is not ob structed Clean as necessary All Models FUEL SYSTEM Sea Doo Fuel Stabilizer P N 413 408 600 or equiv alent should be added in fuel tank to prevent fuel deteriora...

Page 45: ...CAUTION Do not lubricate excessively Imme diately stop when a slight movement is noticed on rubber boot 1 Grease PTO flywheel CAUTION Never leave any clothing tool or other objects near PTO flywheel and drive shaft BATTERY For battery removal cleaning and storage refer to CHARGING SYSTEM WATERCRAFT CLEANING Clean the bilge with hot water and mild detergent or with bilge cleaner Rinse thoroughly Li...

Page 46: ...d This operation requires a good technical knowl edge of the cooling system path If antifreezing is not performed adequately engine exhaust system may freeze and cause severe engine damage Always use ethylene glycol antifreeze containing corrosion inhibitors specifically rec ommended for aluminum engines NOTE The engine will not have to run during this operation Air Pressure Method Install an air ...

Page 47: ...l the colored solution appears at the other cooling system bleed outlet stern eye let Remove the remaining hose pinchers in this order to allow proper flow of antifreeze 1 Engine cylinder drain hose 2 Water outlet hose Pour approximately 200 mL 7 oz of antifreeze in the water regulator valve supply hose to allow an tifreeze flowing through the valve and into muffler to protect it Reconnect hose to...

Page 48: ...2 Crankcase cooling cover outlet hose 3 Engine cylinder drain hose 4 Water outlet hose Pour approximately 200 mL 7 oz of antifreeze in the water regulator valve supply hose to allow an tifreeze flowing through the valve and into muffler to protect it Remove temporary hose and reconnect engine water outlet hose All Models Most of the antifreeze will drain out when removing the hose pinchers Use a c...

Page 49: ...el pump DI models Check wiring then replace fuse Starting system fuse keeps on burn ing Check wiring solenoid and MPEM Discharged battery Check recharge Defective Start stop switch Check refer to Starting System or ENGINE MANAGEMENT Battery connections Check clean tighten Water fuel hydrolock Check refer to section MAINTENANCE Starter Check refer to section ELECTRICAL SYSTEM Seized engine Check re...

Page 50: ...t working DI models Check direct injector operation Check output signal from MPEM No spark at the spark plug Check spark plugs condition and replace as necessary Check ignition system and repair Defective MPEM Replace MPEM Defective crankshaft position sensor Check operation of CPS and replace if necessary Fuel water contaminated Check siphon and refill Dirty fuel filter Clean replace Water in eng...

Page 51: ... pressure DI models Check air fuel rail Refer to ENGINE MANAGEMENT Check air compressor system Refer to ENGINE MANAGEMENT Check RAVE valve for leaks Water in fuel Flush fuel from tank and refill with fresh gas OTHER OBSERVATION POSSIBLE CAUSE REMEDY DI models The DI system is in limp home mode Refer to section ENGINE and check the fault codes in the MPEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY Wea...

Page 52: ...per air fuel rail pressure DI models Check pressures refer to ENGINE MANAGEMENT Direct injector s DI models Remove and replace direct injector s refer to section ENGINE MANAGE MENT Defective sensor or MPEM DI models Check faulty codes in MPEM memory refer to section ENGINE MANAGE MENT Damaged reed valve Check refer to Bottom End in ENGINE SECTION Leaking crankshaft seal s or intake DI models Press...

Page 53: ...reset refer to section ELECTRI CAL SYSTEM Sheared flywheel key Check replace refer to sections ELEC TRICAL SYSTEM and ENGINE Carburetor if so equipped Carburetion too lean Check adjust refer to section FUEL SYSTEM Engine Intake leak crankshaft seal failure carburetor models Pressure check engine refer to section ENGINE OTHER OBSERVATION POSSIBLE CAUSE REMEDY Ignition Timing too far advanced Check ...

Page 54: ...t injectors DI models Remove and clean direct injectors Low fuel pressure Check fuel line and fuel pump pressure Incorrect throttle position sensor TPS adjustment DI models Check and adjust TPS refer to section ENGINE MANAGEMENT Overheated engine See ENGINE OVERHEATS in this chart Engine revs lower than its maximum operational RPM RAVE valve does not open Check refer to section ENGINE Peak perform...

Page 55: ...kage Check and repair OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine RPM too high Faulty rev limiter in MPEM carburetor models Check refer to section ELECTRICAL SYSTEM Improper impeller pitch too low Check replace refer to section PROPUL SION SYSTEM Jet pump cavitation Damaged leading or trailing edge of impeller Check replace NOTE Leading edge damage contributes to poor performance from start Tra...

Page 56: ...a MPEM that could otherwise be good OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weeds debris caught in intake grate or impeller Check clean Low oil level in jet pump Check troubleshoot source of leak re fill supply refer to section PROPUL SION SYSTEM Worn anti rattle system Check replace pusher in cover refer to section PROPULSION SYSTEM Damaged or bent drive shaft Check replace refer to section PRO P...

Page 57: ... 03 1 ENGINE REMOVAL 04 03 1 CLEANING 04 03 3 INSTALLATION 04 03 4 MAGNETO SYSTEM 04 04 1 DISASSEMBLY 04 04 3 CLEANING 04 04 4 ASSEMBLY 04 04 4 TOP END 04 05 1 GENERAL 04 05 3 DISASSEMBLY 04 05 5 CLEANING 04 05 11 INSPECTION 04 05 11 ASSEMBLY 04 05 14 ADJUSTMENT 04 05 19 BOTTOM END 04 06 1 DISASSEMBLY 04 06 3 CLEANING 04 06 6 INSPECTION 04 06 6 ASSEMBLY 04 06 10 EXHAUST SYSTEM 04 07 1 REMOVAL 04 0...

Page 58: ...n all hoses connections fittings plates etc If there is a leak bubbles will indicate leak location Two areas of the engine will be tested in sequence as per the diagnostic flow chart see the end of this subsection 1 Engine Cooling System 2 Bottom End and Top End NOTE If a leak is found it is important to contin ue testing as there is the possibility of having more than one leak Continue pumping to...

Page 59: ...fold plate 947 DI ENGINE SIDE VIEW 1 Block engine drain hose with a hose pincher 2 Install pump to inlet drain 947 DI ENGINE FRONT VIEW 1 Exhaust manifold plate NOTE Water is not required for testing On the DI models it is not necessary to pressurize the bottom crankcase cover nor the magneto cover There is no possible water leak path toward the internal components of the engine 1 2 F08E06A 1 F08D...

Page 60: ... Models Remove throttle bodies on DI models Install intake manifold plugs P N 529 035 708 All Models Remove the RAVE valves and gaskets Install the RAVE valve plate with fasteners from the kit and tighten adequately NOTE The boot carburetor equipped engines and O ring can be checked for leakage with the valve in place Simply remove the cover to expose the parts Make sure the spark plugs and the ai...

Page 61: ...tting oil return line underneath compressor indicates a seal leakage If there is still some leakage remove the PTO fly wheel to verify outer seal If no leak is found on the PTO side outer seal re move magneto flywheel and verify crankshaft out er seals If none of the above components is leaking it could indicates a defective engine casting Disas semble engine and carefully check for defects in cas...

Page 62: ...Section 04 ENGINE Subsection 02 LEAK TEST SMR2000 043_04_02A FM 04 02 5 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 947 Engine F00D28S www SeaDooManuals net ...

Page 63: ...ect throttle position sensors TPS mani fold air pressure sensor MAPS and manifold air temperature sensor MATS Disconnect connectors from fuel injectors and di rect injectors Disconnect connector from knock sensor Disconnect RAVE valve hose where shown In spect hose If it has hardened replace hose 1 Disconnect hose here Refer to ENGINE MANAGEMENT for location of sen sors and connectors Unplug air c...

Page 64: ...re DI Models Remove air fuel rail Refer to ENGINE MANAGE MENT All Models Engine Support NOTE Be careful when removing engine sup port s or rubber mount adapters shims could have been installed underneath Shims control engine jet pump alignment Always note position of shims for reinstallation to avoid altering engine alignment Remove engine support mount screws FRONT SUPPORT 1 Remove screw REAR SUP...

Page 65: ...nect hose TYPICAL 1 Hose pincher P N 295 000 076 Disconnect RED positive cable from starter post Disconnect BLACK negative cable from engine crankcase 1 Positive starter cable 2 Ground cable Carry on engine lifting then tilt engine so that it can be removed from the body opening CAUTION Be careful not to scratch body or to hit any component TYPICAL CLEANING Wipe off any spillage in bilge Clean wit...

Page 66: ...tive Starter Cable Torque nut of positive starter cable to 6 N m 53 lbf in Apply dielectric grease on nut Engine Jet Pump Alignment Alignment is necessary to eliminate possible vibra tion and ordamage to components Checkalignment of engine using the following alignment 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 2 Support Alignm...

Page 67: ...ssary 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 Engine Support Screws Apply Loctite 243 blue on screw threads Torque engine support screws to 25 N m 18 lbf ft when procedure is completed FRONT ENGINE SUPPORT 1 Torque to 25 N m 18 lbf ft REAR ENGINE SUPPORT...

Page 68: ...N PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT 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 WARNING Whenever doing any type of repair on water craft or if any components of the fuel system are di...

Page 69: ...uretor Equipped Engine 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 70: ...MR2000 045_04_04A FM 947 DI Engine F12D03S Loctite 243 1 31 29 9 20 13 N m 115 lbf in Loctite 243 21 9 N m 80 lbf in 30 Loctite 243 Molykote111 Synthetic grease 10 Loctite 243 13 115 N m 185 lbf ft Loctite 243 3 14 9 N m 80 lbf in www SeaDooManuals net PARTS ...

Page 71: ...ssary the magneto rotor can be removed without removing the engine flywheel Remove the six screws no 17 TYPICAL 1 Screw To remove the flywheel rotor assembly unscrew nut no 13 counterclockwise when facing it TYPICAL 1 Nut The flywheel is easily freed from crankshaft with puller P N 420 976 235 Install protective cap P N 290 877 414 to crank shaft Fully thread puller in engine flywheel CAUTION Ensu...

Page 72: ...neto 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 using acetone Apply the acetone on a rag first then clean the crankshaft ASSEMBLY Stator and Trigger Coil CPS Crankshaft Position Sensor Install the stator no 9 and trigger coil CPS no 10 in engine magneto cover Torque screws to 9 N...

Page 73: ...t 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 installation properly install O ring no 31 in engine magneto cover no 1 A...

Page 74: ... 14 34 N m 25 lbf 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 75: ...OP END 04 05 2 SMR2000 046_04_05A FM 947 DI Engines F12D09S Synthethic grease Loctite 518 Loctite 243 26 9 N m 80 lbf in 15 16 17 18 19 25 24 23 22 40 N m 30 lbf ft 14 Synthethic grease Loctite 243 34 10 9 2 www SeaDooManuals net PARTS ...

Page 76: ...ing On this engine the spring preload does not have a signif icant effect on the valve operation To open the RAVE valves the MPEM activates a solenoid which directs the positive pressure from engine crankcase to the valves 1 Solenoid 2 Pressure hose from crankcase 3 To atmospheric pressure NOTE A check valve on the pressure line elimi nates the negative pressure from the crankcase To close the RAV...

Page 77: ...tmosphere The vent on couterbalancing shaft oil cavity is nec essary to prevent pressure buildup in the cavity by the air compressor piston movement The check valve prevents the eventual possibility of any liquid that would otherwise flow toward the oil cavity and be trapped there RAVE VALVE OPENED 1 Pressure from air compressor 2 Solenoid activated 3 Pressure to solenoid 4 Pressure to RAVE valves...

Page 78: ... piston available for the 947 engines That piston is 0 25 mm 010 in larg er in diameter than the stock piston When the oversize is installed the guillotine will have a min imum clearance of 0 375 mm 015 in with the cylinder bore This is the minimum operating clear ance the guillotine should be used with Clearance less than 0 375 mm 015 in will require reworking of the guillotine to achieve the pro...

Page 79: ...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 80: ..._05A FM 04 05 7 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 81: ... studs it is recommended to remove the engine from the hull to service the top end However one might unfas ten the engine support to allow leaning the engine so that cylinder can be pulled out 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 sequence shown in the next photo UNTORQUING SEQ...

Page 82: ... both 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 10 947 DI Engines Remove cylinders screws then cylinders no 9 All Engines Piston NOTE All engines feature cageless pis...

Page 83: ...ide the sleeve and shoulder sleeve onto the spindle Screw in extracting nut with the movable ex tracting ring towards spindle 1 Puller 2 Sleeve 3 Shoulder sleeve 4 Extracting nut NOTE The tool cutout must be positioned toward the 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 flush...

Page 84: ...ings Clean all metal components in a solvent Clean water passages and make sure they are not clogged Remove carbon deposits from cylinder exhaust port RAVE valve cylinder head and piston dome Clean piston ring grooves with a groove cleaner tool or a piece of broken ring INSPECTION Visually inspect all parts for corrosion damage Inspect piston for damage Light scratches can be sanded with a fine sa...

Page 85: ...inder 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 mm 5 8 in ENGINE MEASUREMENT TOLERANCES NEW PARTS WEAR LIMIT min max Cylinder ...

Page 86: ... 1 Micrometer set to the piston dimension With the micrometer set to the piston dimension adjust a cylinder bore gauge to the micrometer di mension and set the indicator to zero 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge 1 Indicator set to zero Position the dial bore gauge at 16 mm 5 8 in be low cylinder top edge 1 Measuring perpendicularly 90 to piston pin axis A 16 mm ...

Page 87: ...ylinder Base Gasket NOTE The general procedure is to install a new gasket of the same thickness However if you do not know the gasket thickness that was installed or if a crank repair has involved replacement of connecting rods refer to the COMBUSTION CHAM BER VOLUME MEASUREMENT to properly deter mine the required gasket thickness Different thicknesses of cylinder base gaskets are used for a preci...

Page 88: ... crankcase opening as for disas sembly Piston Pin and Roller Bearing To install roller bearing no 4 and piston pin no 6 use piston pin puller P N 529 035 503 with the appropriate set of sleeves as for disassembly Replacement bearings are held in place by a lo cating sleeve outside and 2 plastic cage halves inside Push needle bearing together with inner halves out of the locating sleeve into the co...

Page 89: ...o service tool is available Replacement roller bearings are delivered in a con venient plastic mounting device For installation proceed as follows Align replacement roller bearing with connect ing rod bore Carefully push inner plastic sleeve into connect ing rod bore outer plastic ring will release rollers 1 Outer ring removal after inner sleeve insertion into bore Make sure thrust washers are pre...

Page 90: ...y after installation 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 ci...

Page 91: ... to insert in crank case Remove O rings from studs All Engines Install cylinder base gasket no 10 There is only one way to install gasket The cylinder block is positioned with locating dowels Line up dowels with corresponding holes in cylin der block 1 Dowels 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...

Page 92: ... 34 N m 25 lbf ft TORQUING SEQUENCE 947 DI Engines 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 to 20 N m 15 lbf ft as per following sequence in the next picture Repeat the torquing sequence by retightening to 40 N m 30 lbf ft ADJUSTMENT RAVE Valve 947 Carburetor Equipped Engines Turn the red plastic knob...

Page 93: ...st be free of carbon deposit and cylinder head must be leveled 947 Carburetor Equipped Engines 1 Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge 1 Bring piston to TDC 947 DI Engines 1 Remove both direct injectors and bring one pis ton to Top Dead Center using a TDC gauge Keep spark plugs in their holes All 947 Engines 2 Obtain a graduated burette capacity 0 50 c...

Page 94: ... 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 A higher volume dictates a thinner gasket A lower volume dictates a thicker gasket 947 Carburetor Equipped Engines NOTE When the combustion chamber is filled to top of spark plug hole it includes an amount of 2 39 cc corresponding to the ...

Page 95: ...ease Loctite 648 23 N m 17 lbf ft Loctite 243 115 N m 85 lbf ft 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 243 9 N m 80 lbf in Loctite 518 Anti seize lubricant Anti seize lubricant 40 mL 1 35 oz SAE ...

Page 96: ...243 Loctite 243 Loctite 648 Loctite 648 23 N m 17 lbf ft Synthetic grease Loctite 243 Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 Loctite 518 27 N m 20 lbf ft Loctite 5910 6 5 N m 58 lbf in 9 N m 80 lbf in 9 N m 80 lbf in Anti seize lubricant Anti seize lubricant Synthetic grease www SeaDooManuals net PARTS ...

Page 97: ...01 to hold flywheel and remove Allen screws no 21 re taining coupler no 20 to PTO flywheel PTO FLYWHEEL REMOVER TOOL 1 Loosen Allen screws 2 Breaker bar locking crankshaft Remove the coupler no 20 Starter Drive Assembly 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 assembly no 27 1 Starter...

Page 98: ...to MAGNETO SYSTEM starter starter drive assembly reed valves air compressor cover 947 DI engines Place engine upright on crankcase magneto side Loosen crankcase screws 1 M8 x 45 flanged screws 2 M10 x 73 5 flanged screws Put engine back on a support Insert a pry bar be tween crankcase lugs to separate halves CAUTION Be careful to precision machined surfaces TYPICAL 1 Separate halves by prying at p...

Page 99: ...d NOTE Do not needlessly remove crankshaft bear ings Remove end seal s TYPICAL 1 End seal To remove end bearings from crankshaft use the following tools 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 TYPICAL 1 Removing crankshaft bearing Or use a bearing extractor such as Proto n...

Page 100: ...essor lubrica tion nipple All Models CAUTION Be careful not to spray cleaner on the painted surface of the engine CAUTION Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing INSPECTION Assembled Engine The following checks can be performed with en gine in watercraft without overhauling engine Crankshaft Alignment at Center Main Journal S...

Page 101: ... worn bearing s bent and or disaligned crankshaft Proceed with the disassem bly of the engine Disassembled Engine The following verifications can be performed with the engine disassembled Crankcase Inspect plane surfaces for warpage Small defor mation can be corrected by grinding surface with a fine sandpaper Install sandpaper on a surface plate and rub part against oiled sand paper Bearing Inspec...

Page 102: ...Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V shaped blocks as illustrated 1 Measuring MAG side deflection on V shaped blocks 1 Measuring PTO side deflection on V shaped blocks NOTE Crankshaft deflection cannot be correctly measured between centers of a lathe Connecting Rod Big End Axial Play MEASUREMENT MAG SIDE PTO SIDE Crankshaft deflectio...

Page 103: ... they can be inserted in end bearing Holding claws turn puller shaft clock wise so that claws open and become 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 Check reed valve petals no 29 f...

Page 104: ... oil on all moving parts when re assembling the engine Crankshaft and Bearing Apply Loctite 767 anti seize on part of crankshaft where bearing fits Prior to installation place bearings no 4 into a container filled with oil previously heated to 75 C 167 F This will expand bearing and ease instal lation To properly position the outer bearing s a dis tance gauge must be temporarily installed against ...

Page 105: ...lign index marks previously traced Crankshaft and Counterbalance Shaft Install crankshaft no 3 first in crankcase After crankshaft installation install counterbal ance shaft no 13 Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears CAUTION Marks on the crankshaft and coun terbalance shaft must be aligned otherwise engine will vibrate and premature wear will o...

Page 106: ...beginning the application of the crankcase sealant the assembly and the first torquing should be done within 10 minutes It is suggested to have all you need on hand to save time NOTE It is recommended to apply this specific sealant as described here to get an uniform appli cation without lumps Use the silicone based Loctite 5910 P N 293 800 081 on mating surfaces Use a plexyglass plate and apply s...

Page 107: ...f ft as per following sequence Starter Drive Bearing To install bearing no 23 of starter drive assembly use pusher P N 290 876 502 and handle P N 420 877 650 1 Handle 2 Pusher PTO Flywheel Apply Loctite 243 blue on bolt no 22 Using the same tools as for disassembly 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 b...

Page 108: ...04_06A FM Final Assembly 947 Carburetor Equipped Engines When engine assembly is completed add 40 mL 1 35 oz of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug 1 Remove plug and add SAE 30 motor oil F06D2CA 1 www SeaDooManuals net ...

Page 109: ...in 1 3 5 25 N m 18 lbf ft 6 Loctite 243 19 18 25 N m 18 lbf ft Loctite 243 1 11 23 N m 17 lbf ft Silicone sealant Ultra Cooper sealant 15 4 14 N m 10 lbf ft 10 4 7 48 N m 35 lbf ft 8 9 38 N m 28 lbf ft 25 N m 18 lbf ft Loctite 243 16 22 21 47 N m 35 lbf ft 19 18 20 25 N m 18 lbf ft 12 13 14 www SeaDooManuals net PARTS ...

Page 110: ...ect 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 Disconnect the water bleed hose 1 Water bleed hose F07L1KA 2 2 1 1 F06E08A 1 F06E09A 1 F06E0AA 1 F06E0BA www SeaDooManuals net ...

Page 111: ... no 4 retaining tuned pipe head no 10 to tuned pipe cone no 5 1 Loosen and remove clamp Loosen Allen screw retaining carburetor throttle body 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 112: ...tap 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 RX Models Remove vent tube sup...

Page 113: ...sconnect hoses of the water flow regulator valve 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 RX models remove the VTS motor Refer to VARIABLE TRIM SYSTEM All Models TUNED PIPE REPAIR This procedure is given to repair tuned pipe cracks using T I G welding process Procedure Sand the cracked area t...

Page 114: ... no 12 as per following picture 1 M10 x 60 Allen screws 2 M10 x 110 Allen screws Torque Allen screws to 24 N m 17 lbf ft as per fol lowing illustrated sequence Repeat the procedure retightening Allen screws to 40 N m 30 lbf ft Tuned Pipe 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 ...

Page 115: ...OTE Apply Loctite 243 on the stud threads Retorque the 3 screws no 7 to 48 N m 35 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 Ins...

Page 116: ...Section 04 ENGINE Subsection 07 EXHAUST SYSTEM 04 07 8 SMR2000 049_04_07A FM 1 Torque clamp to 4 N m 35 lbf in 1 F06D14A www SeaDooManuals net ...

Page 117: ...AMP CONNECTOR PIN OUT 05 03 3 AIR INDUCTION SYSTEM 05 03 4 THROTTLE BODY 05 03 4 AIR COMPRESSOR 05 03 7 PRESSURE TEST 05 03 7 REPAIR 05 03 7 FUEL DELIVERY 05 03 11 AIR FUEL RAIL 05 03 11 FUEL PUMP 05 03 14 ELECTRONIC MANAGEMENT 05 03 19 MPEM REPLACEMENT 05 03 19 THROTTLE POSITION SENSOR TPS 05 03 19 CRANKSHAFT POSITION SENSOR CPS 05 03 21 MANIFOLD AIR TEMPERATURE SENSOR MATS 05 03 22 WATER TEMPERA...

Page 118: ...2 SMR2000 037 05 01ATOC FM DIAGNOSTIC PROCEDURES 05 04 1 GENERAL 05 04 1 DESS SYSTEM 05 04 2 FAULT DETECTION AND COMPENSATORY ACTIONS 05 04 4 COMPONENT FAILURE WARNING SYSTEM 05 04 4 VCK VEHICLE COMMUNICATION KIT 05 04 6 DI SYSTEM FAULT CODES 05 04 7 www SeaDooManuals net ...

Page 119: ...Section 05 ENGINE MANAGEMENT DI Subsection 02 OVERVIEW SMR2000 050 05 02A FM 05 02 1 OVERVIEW 0 F12F03T www SeaDooManuals net ...

Page 120: ...sition sensor TPS AIR COMPRESSOR SYSTEM The air compressor supplies the compressed air required for fuel atomization in the air injector It is integrated with the engine and mechanically driv en by the counterbalance shaft It also supplies the air pressure required to operate the RAVE valves FUEL DELIVERY SYSTEM BASIC OPERATION When the piston reaches the correct position the MPEM opens the fuel i...

Page 121: ...pen the regulator will increase equally The differential pressure regulation utilizes the air pressure reference signal to maintain constant pressure drop across fuel injector orifice The initial operating pressure of the regulator is preset by the manufacturer and is not adjustable Direct Injector Also called air injector two direct injectors one per cylinder are used to inject air fuel mixture i...

Page 122: ... General Functions Automatic Power Shut Down The MPEM is equipped with an automatic power shut down This feature prevents the battery from losing its charge if the safety lanyard cap is left on the post when the engine is not running After connecting the safety lanyard cap the MPEM will remain in standby mode during the next 10 minutes waiting for a starting If the start stop button is not depress...

Page 123: ...cap on its post or when pressing the start stop switch without the safety lanyard on the DESS post NOTE The fuel pump will be activated for 2 sec onds to build up pressure in the fuel injection sys tem only when connecting the safety lanyard cap to the post Engine Starting If the MPEM recognizes a valid safety lanyard it allows engine to start when the start stop switch is pressed If the safety la...

Page 124: ...MPEM distributes power from battery to all accessories Accessories are protected by fuses integrated in the MPEM Fuses are identified be sides their holder IMPORTANT The sensors and injectors are con tinuously powered with the supply from the bat tery The MPEM switches the ground to com plete the electrical circuits it controls Take this into account when troubleshooting the electrical system MPEM...

Page 125: ...llow proper operation for all possi ble conditions Cranking flare idle warm up nor mal operation Sea Doo LK learning key limit ed vehicle speed engine speed limiter drowned engine and limp home see below Flooded Engine drowned mode If the engine does not start and it is flooded pro ceed as follows Remove spark plug cables and connect them on the grounding device Remove spark plugs and dry them usi...

Page 126: ...ng system A 12 Volts battery supplies the Multi Purpose Elec tronic Module MPEM with DC current Refer to CHARGING SYSTEM The following type of ignition system is used Digital Inductive System Magneto System The magneto is the primary source of electrical energy It transforms magnetic field into electric current AC The magneto has a 3 phases delta wound stator on 18 poles Capacity is 270 watts Igni...

Page 127: ...tip of the direct injectors if necessary WARNING Air compressor hose may be hot Use a rag or gloves or let hose cool down WARNING The fuel system of a fuel injection system holds much more pressure than on a carbu reted watercraft Prior to disconnecting a hose or to removing a component from the fuel system follow the recommendation de scribed here WARNING Fuel lines remain under pressure at all t...

Page 128: ...em If the newly re placed MPEM is working try the old one and re check if it works Ensure that all electronic components are genu ine particularly in the ignition system Installing resistive caps non resistive spark plug cables or modified length or non resistive spark plugs may lead to generate fault codes or bad operation NOTE Diagnostics Communication Kit See DI AGNOSTICS section After a proble...

Page 129: ...he MPEM will detect the high temperature condition and gener ate a fault code When working with injectors the resistance value might test good while the complete current would not flow through the wire when pulsating current is supplied to the injector in its normal operation A solution would be to use a jumper wire to direct ly supply the injector from the MPEM If it now works replace the defecti...

Page 130: ...tle bodies and pull out together If only one throttle body replacement is required detach them and remove the sealant on idle set screw head Gently remove the plastic cap from the synchronization screw Remove TPS throttle lever spring and guide from the old throttle body Installation Reinstall removed parts on the new throttle body For TPS replacement procedures refer to Throt tle Position Sensor ...

Page 131: ...CLOCKWISE AND KEEP SLAVE THROTTLE PLATE FULLY CLOSED IN THE THROTTLE BODY 1 Screw here 2 Gap here Master TPS Using an ohmmeter measure resistance between pins 2 and 3 Turn idle set screw clockwise until ohmmeter reading changes by 175 20 Ω Tighten lock nut Slave TPS Measure resistance between pins 2 and 3 Turn synchronizing screw clockwise until reading changes by 175 20 Ω Ensure spring is still w...

Page 132: ... willcause strain on cable and or damage cable bracket or throttle lever at handlebar Use the vehicle communication kit VCK with the B U D S software to perform this adjustment Choose the Monitoring tab Press throttle lever to reach full throttle Turn cable adjustment until Throttle Opening meter indicates between 95 and 99 Closed TPS Adjustment Perform the Closed TPS adjustment as de scribed in T...

Page 133: ...nnected hose use the drowned engine mode to crank engine While engine is stopped depress and HOLD the throttle lever at full throttle position for cranking Ensure the battery is in good condition to get the normal cranking speed Crank engine and observe air pressure NOTE A 1 second beep every second indicates the drowned mode is active If pressure is within limits air compressor is work ing adequa...

Page 134: ...tom up CAUTION Failure to properly position screw head will lead piston to hit it If pressure is still low then continue with Bottom End Otherwise remove components again In stall a new gasket new O ring compressor head and cover Apply synthetic grease below screw head and Loctite 243 on threads Install screws then torque to 40 N m 30 lbf ft Bottom End To gain access to piston rings and connecting...

Page 135: ...r replaced CAUTION Failure to properly clean the oil sys tem will result in serious engine damage The inspection of top end should include the fol lowing measurements N A Not Applicable Piston Cylinder Wall Clearance Clearance can be quickly checked with a feeler gauge Insert feeler gauge in cylinder then slide piston without piston rings installed If clearance exceeds tolerance check cylinder top...

Page 136: ...he mark is present anymore place a straight edge against bushing end to find the tapered end concave A very small gap between the edge and the bushing will identify the tapered end to be installed against the counterweight 3 Install a NEW screw and torque to 6 5 N m 58 lbf in Do not apply any thread locker prod uct 4 Turn the screw clockwise an additional 80 de grees 5 degrees CAUTION Failure to s...

Page 137: ...e gauge P N 529 035709 2 T adapter P N 529 035 710 Install pressure gauge between disconnected hose inline installation 1 Fuel filter 2 Fuel line going to air fuel rail 3 Pressure gauge between disconnected hose inline installation Install safety lanyard and observe fuel pressure Do not crank engine If pressure is within limits air fuel rail is working adequately A rapid pressure fall indicates ex...

Page 138: ...e injector and disconnect the AMP plug connector number 4 on the MPEM Using a multimeter check resistance value be tween terminals as follows The resistance should be between 1 7 and 1 9 Ω If resistance value is correct try a new MPEM Refer to MPEM replacement procedures else where in this section If resistance value is incorrect repair the wiring harness connectors between AMP plug connec tor and...

Page 139: ...9 719 Direct Injector The direct injectors can be replaced individually by lifting the air fuel rail Leakage Test If direct injector leaks through its large top O ring there will be an air fuel leak between the injector and the air fuel rail Replace O ring of both injec tors If there is an injector internal leak the high tem perature from the combustion chamber will make visible overheated area Re...

Page 140: ...attention to carbon dam insertion Ensure to position connector pointing toward bottom of cyl inder head NOTE A thin film of injection oil may be applyed to carbon dam if necessary to ease insertion in cyl inder head Reconnect electrical connector 1 Carefully insert direct injector 2 Connector pointing toward bottom of cylinder head Reinstall air fuel rail Carbon Dam Replacement Remove direct injec...

Page 141: ...ve Otherwise fuel pump components might be damaged Install pressure gauge between disconnected hoses on fuel pump side closed loop installation on fuel pump Make sure the pressure relief valve is installed on the fuel pump return line side 1 Fuel pump outlet hose fuel filter side 2 Fuel pump return line 3 Fuel relief valve on the return line side 4 Pressure gauge between disconnected hose inline i...

Page 142: ...er check continuity between ter minals of circuits 24 and 26 If wiring harness is good try a new MPEM Refer to MPEM replacement procedures elsewhere in this section Otherwise repair the wiring harness connectors between AMP plug connector and fuel pump Fuel Pump Replacement Removal Open front storage compartment cover Remove the storage basket Remove glove box see HULL BODY section Remove front ve...

Page 143: ...reduce its height to allow pulling pump out All Models Pull fuel pump toward front of vehicle Wipe off any fuel spillage in the bilge 1 Pull fuel pump toward front Installation For installation reverse the removal process but pay attention to the following Tighten fuel pump screws in a criss cross se quence illustration 21 1 F12R0JA www SeaDooManuals net ...

Page 144: ...el pressure lower than 735 kPa 107 PSI Check for blocked fuel return line Repair or replace Line OK yes Replace fuel pump module Fuel pressure is 735 kPa 107 PSI Fuel pressure greater than 735 kPa 107 PSI Check air return line for blockage Check for air leaks Repair leaks Check direct injector fails yes Perform fuel pump test Replace fuel pump module fail pass no leaks Check RAVE for air leaks Rep...

Page 145: ...he DI sys tem two sensors are used for redundancy purposes The MPEM compares the signals from both sensors and determines if there is an error and uses the most appropriate sensor to operate the system 1 Throttle position sensor TPS IMPORTANT Prior to testing the TPS ensure that mechanical components adjustments are ad equate according to Throttle Body in Air Induc tion System above The MPEM may g...

Page 146: ...ng a multimeter check resistance value be tween terminal 3 and 18 The resistance should be 1600 2400 Ω Check the resistance between terminal 1 and ter minal 3 with the throttle plate in idle position The resistance should be 1000 Ω Check the resistance between terminal 1 and ter minal 18 with the throttle plate in idle position The resistance should be 2500 Ω Test Results Both TPS If resistance va...

Page 147: ...stem Fault Codes in DIAG NOSTIC PROCEDURES section for more informa tion CRANKSHAFT POSITION SENSOR CPS 1 Magneto cover 2 CPS connector Check for RPM display at the information center while cranking engine If it displays approximate ly 300 RPM the CPS circuitry is properly working Otherwise validate the information center is working by activating the tachometer using the software B U D S under Act...

Page 148: ...it could be either the CPS or the MPEM Try a new part one at a time When trying a new MPEM refer to MPEM replacement procedures elsewhere in this section Otherwise repair the wiring harness connectors between AMP plug connector and the CPS Replacement Remove tuned pipe Unscrew front engine support and slightly lift en gine to have access to magneto cover screws Block engine in this position Discon...

Page 149: ...ht and left Install the new MATS Reinstall remaining removed parts WATER TEMPERATURE SENSOR WTS 1 Water temperature sensor WTS Resistance Test Disconnect the plug connector from the WTS and check the resistance of the sensor itself The resistance should be between 2280 Ω and 2740 Ω Otherwise replace the WTS If resistance tests good reconnect the WTS and disconnect the AMP plug connector number 4 o...

Page 150: ...ut from MPEM to the mani fold air pressure sensor MAPS Disconnect plug connector from throttle position sensor and connect a voltmeter between pin 1 and 3 and also between pin 1 and 2 of wiring harness Remove and reinstall the safety lanyard to activate the MPEM There should be 5 Vdc in each test If voltage test is good replace the MAPS If voltage test is not good check the continuity of the MAPS ...

Page 151: ...mounting bolt and washer are correct and properly torqued down Check the knock sensor resistance Disconnect the AMP plug connector number 4 from the MPEM module Static Resistance Test Using a multimeter check the resistance between terminal 2 and terminal 17 on the plug connector The resistance should be approximately 5 MΩ Otherwise check the continuity of the knock sen sor circuit 4 2 and 4 17 If...

Page 152: ... proceed with the resistance test below Reconnect hose to compressor Unplug the outlet hose from RAVE solenoid 1 RAVE solenoid 2 Supply hose from air compressor 3 Check valve 4 Outlet hose to RAVE valves Install leak test pump on hose end and apply pres sure If pressure can not be held check hoses for leaks If hoses test good connect pump directly to each RAVE valve nipple and pressurize If pres s...

Page 153: ...ng In doubt use an inductive spark tester or a sealed tester available from after market tool equipment suppliers to pre vent spark occurring in the bilge Otherwise perform the following checks Primary Winding Disconnect the plug connector from the ignition coil and check the resistance of the primary circuit 1 PTO side ignition coil 2 Mag side ignition coil 3 Primary winding connector The resista...

Page 154: ...oil tester available from after market tool equipment suppliers 1 With ignition coil removed from craft hook high tension leads from tester to ignition coil high tension cables 2 Connect 2 smaller tester leads to primary of ig nition coil TYPICAL 1 Lead to secondary 2 Leads to primary 3 Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm 276 to 31...

Page 155: ...to be checked at any RPM with the timing light The TDC setting is best checked at idle speed as it is more accurate and easier than at higher speed also it will keep the engine tem perature lower for a longer time Ensure to prop erly cool the engine through the flushing fitting NOTE When checking the TDC setting the spark advance has to be locked to allow proper verifica tion of the TDC marks See ...

Page 156: ...ming mark pointer tool NOTE This mark becomes the reference when using the stroboscopic timing light CAUTION The static test cannot be used as a TDC setting procedure therefore always check the TDC setting with a stroboscopic timing light 8 Remove TDC gauge 9 Reinstall spark plug and connect wire Dynamic Test To check TDC setting use Bombardier timing light P N 529 031 900 10 Connect timing light ...

Page 157: ...ed in the MPEM 4 Now click the up or down arrow to change the number of the current angle so that the TDC setting marks align when checking with the tim ing light Each step makes an adjustment of 1 4 degree NOTE Each time the setting is changed on the screen the new value is also changed in the MPEM so there may be a slow response do not make changes too quickly 5 When marks align uncheck the Lock...

Page 158: ...orter the heat path the colder the operating temperature will be A cold type plug has a relatively short insulator nose and transfers heat very rapidly into the cylin der head Such a plug is used in heavy duty or continuous high speed operation to avoid overheating The hot type plug has a longer insulator nose and transfers heat more slowly away from its firing end It runs hotter and burns off com...

Page 159: ...tighten the spark plug clockwise an additional 1 4 turn with a proper socket 1 Proper socket 2 Improper socket CRANKING SYSTEM See above for start stop switch and the DESS post testing Refer to STARTING SYSTEM section for other tests ENGINE SPARK PLUG TORQUE GAP mm in DI NGK ZFR4F 11 Hand tighten 1 4 turn with a socket 1 1 043 A00E0BA 2 1 www SeaDooManuals net ...

Page 160: ...15 BL BW and BL PK 1 1 6 ohms Direct injector PTO 6 and 21 GR BW and GR PK Throttle position sensor MAG TPS TPS 1 and 3 PU BW and WH BW 5 V 1 and 2 PU BW and BK BW AMP no 3 10 and 14 PU BW and BK BW 1600 2400 ohms 5 and 14 WH BW and BK BW 2500 ohms at idle 5 and 10 WH BW and PU BW 1200 ohms at idle Throttle position sensor PTO TPS TPS 1 and 3 PU RD and WH RD 5 V 1 and 2 PU RD and BK RD AMP no 4 3 ...

Page 161: ...ck sensor KS AMP no 4 2 and 17 BK BL and YL BL 5 Mohms Rave solenoid RS AMP no 4 20 and 23 PU GY and BK GY 24 ohms Ignition coil MAG AMP no 3 21 and 22 RE GN and WH GN 45 55 ohms primary winding Coil terminal C and coil post 6800 10200 ohms secondary winding w o high tension leads Ignition coil PTO AMP no 3 20 and 23 RE BL and WH BL 45 55 ohms primary winding Coil terminal C and coil post 6800 102...

Page 162: ...rt in TROUBLESHOOTING sec tion to have an overview of problems and sug gested solutions Check if there is a MAINT signal reported by the vehicle information center If so use the VCK Vehicle Communication Kit and look for fault codes to diagnose the trouble Check all fuses Check air fuel rail pressure Check spark plugs condition Check RAVE valves if stuck Check fuel pump pressure Check air compress...

Page 163: ...op button Bad connection between safety lanyard cap and post Remove and replace the safety lanyard on the post until 2 short beeps are heard to indicate the system 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 ...

Page 164: ...AUSE 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 MPEM programmer or the VCK 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 the ...

Page 165: ... MAINT ON ON 4 Limited RPM idle speed if both TPS s fail Water temperature sensor WTS MAINT ON OFF ON 6 4 Limited RPM code 4 if EGT also fails Direct injector single injector MAINT ON OFF 6 Limited RPM Fuel injector single injector MAINT ON OFF 6 Limited RPM Ignition no firing on one cylinder MAINT ON OFF 6 Limited RPM RAVE solenoid MAINT ON OFF 6 Limited RPM Starter solenoid MAINT ON OFF 6 Engine...

Page 166: ...NT ON ON 3 Limited RPM Throttle position sensor dual TPS MAINT ON ON 4 Idle RPM Throttle position sensor single adaption fault None OFF OFF 6 None Throttle position sensor dual adaption fault MAINT ON OFF 6 Limited RPM Sensor supply fault TPS and MAPS MAINT ON ON OFF 4 6 Limited RPM code 6 and idle RPM if both in fault Encoder CPS fault bad pattern MAINT ON OFF 6 Limited RPM Low battery voltage 12...

Page 167: ...C setting For more information pertaining to the use of the software B U D S use its help which contains de tailed information on its functions IMPORTANT When using the software B U D S with the DI engines ensure that the protocol 947 DI is properly selected in MPI under Choose protocol Refer to the tables below for the fault codes you will find in the B U D S F12H0TS WARNING If the computer you a...

Page 168: ...connections are in good condition also grounds battery MPEM engine and ignition sys tem they are clean and well tightened and that all electronic components are genuine particularly in the ignition system Installing resistive caps non resistive spark plug cables or modified length non resistive spark plugs or knock sensor wiring routing mayleadto generatethisfault code Electrical noise might also ...

Page 169: ...r is loose Yes Fix and reset closed TPS Inspect sensor for damage or corrosion Yes Replace and reset closed TPS Inspect wiring voltage test Failed Repair Inspect wiring and sensor resistance test Failed If bad wiring repair If bad TPS replace and reset closed TPS Test sensor operation wear test Replace and reset closed TPS POSSIBLE CAUSES RESULT ACTION Sensor has been replaced and TPS closed posit...

Page 170: ...s damaged connector damaged ECU output pins ECU failure P0202 Fuel injector PTO FUEL_INJ_2 Open or short circuit Yes No Return to idle Service action Check for 2 5 ohm resistance between 4 14 and 4 8 Check for 12 volts on pin A of injector connector color Possible causes Damaged injector damaged circuit wires damaged connector damaged ECU output pins ECU failure P0351 Ignition coil primary winding...

Page 171: ...ed ECU pins ECU failure damaged or out of alignment throt tle bodies or sensor P1102 TPS PTO TPI_1_ADAP Throttle position adaption failure Yes No Full reset Key off and on Service action Check cable adjustment Check Idle stop for wear check throttle angles at idle Possible causes No initialisation after throttle body or ECU changes throttle idle stop drifted P1103 TPS MAG TPI_2_ADAP Throttle posit...

Page 172: ...CU failure P1401 EGT EXH_RED Overheat warning Yes No As soon as fault is not present Service action Check for debris or blockage in cooling system Check tune pipe injection valve Possible causes Exhaust system overheated damaged sensor damaged circuit wires P0460 Fuel level sensor FUEL_SENS Sensor out of range Yes No As soon as fault is not present Service action TBD Possible causes Damaged sensor...

Page 173: ...APS XDRP_1 Sensor 5 volt supply failure Yes Yes Return to idle Service action Check for shorts to ground or corrosion on the following system circuits 3 10 or 3 3 Possible causes Damaged circuit wires associated sensor failure TPI 2 or MAP ECU fault P0222 Sensorsupply TPS PTO XDRP_2 Sensor 5 volt supply failure Yes Yes Return to idle Service action Check for shorts to ground or corrosion on system...

Page 174: ... 06 COOLING SYSTEM Subsection 01 TABLE OF CONTENTS SMR2000 037_06_01ATOC FM 06 01 1 TABLE OF CONTENTS 0 CIRCUIT COMPONENTS AND CARE 06 02 1 CIRCUIT 06 02 3 COMPONENTS 06 02 6 CARE 06 02 9 www SeaDooManuals net ...

Page 175: ...er injected into muffler to cool exhaust 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 regul...

Page 176: ...r 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 performance improvement F12E09S Side of hull RX DI routing GTX DI routing Bleed hose upper point of circuit Air compressor silencer Quick connect hose fitting for easy engine...

Page 177: ...ri Water is directed to the water inlet fitting at cylin der head 1 Water supply hose DI Models Water from inlet hose also supplies the water reg ulator on muffler and magneto cover and crank case cover Water then is expulsed through the pump support drain All Models Water continues to circulates from inlet hose through the one piece cylinder head which fea tures improved combustion chamber and be...

Page 178: ...Models Water flows out of tuned pipe water jacket from upper fitting of tuned pipe and is directed to the air compressor then to the air silencer at the tran som Water continues to flow in the crankcase water jacket to cool the crankcase area to then be ex pulsed to the transom area All Models Draining of the cooling system is accomplished by the drain hose connected to a fitting at the bottom of ...

Page 179: ...n the tuned pipe by a calibrated fitting 1 Injection fitting CAUTION Never modify cooling system ar rangement otherwise serious engine damage could occur 1 F06E09A F06E0CA 2 1 3 TECHNICAL DATA TYPE TLCS Total Loss Cooling System COOLANT FLOW Pressure build up at impeller housing no water pump TEMPERATURE CONTROL Calibrated outlet fittings no thermostat SYSTEM BLEEDING Self bleed type hose at upper...

Page 180: ...o helps in reducing noise level and cools components of the exhaust sys tem CAUTION The elbow fittings are calibrated and can not be interchanged with one of a dif ferent size as severe engine damage could re sult 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 Out...

Page 181: ...AUTION 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 the tuned pipe LOW SPEED OPERATION 1 Water entering regulator valve 2 Water exiting regulator valve less restrictio...

Page 182: ...e maximum engine speed cannot be attained or if the engine has poor performance the water flow regulator valve should be considered in the troubleshooting of the problem Disassembly Remove the cover of the valve by releasing the spring 1 Spring 2 Cover Remove fitting from valve housing TYPICAL 1 Fitting Unscrew the tapered needle NOTE Hold the valve to prevent it from turning 1 Tapered needle WARN...

Page 183: ...ng purposes the cooling system is equipped with either a fitting spigot or a hose adapter depending upon the model For flushing operation a coupler hose 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 re...

Page 184: ...hich may lead to water being injected into and filling the 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 inst...

Page 185: ...ERAL 07 02 3 REMOVAL 07 02 3 INSPECTION 07 02 5 ASSEMBLY 07 02 6 FUEL SYSTEM PRESSURIZATION 07 02 6 AIR INTAKE 07 03 1 REMOVAL 07 03 3 ASSEMBLY 07 03 3 CARBURETOR 07 04 1 GENERAL 07 04 2 REMOVAL 07 04 2 CLEANING 07 04 3 DISASSEMBLY AND INSPECTION 07 04 3 ASSEMBLY 07 04 5 INSTALLATION 07 04 7 ADJUSTMENTS 07 04 8 www SeaDooManuals net ...

Page 186: ...n 1 2 N m 11 lbf in 2 N m 18 lbf in 6 N m 53 lbf in 1 2 N m 11 lbf in 22 N m 16 lbf ft 4 N m 35 lbf in 3 N m 27 lbf in 4 N m 35 lbf in Dielectric grease 1 2 N m 11 lbf in 1 2 N m 11 lbf in Engine Body 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 F06F0RU 14 13 12 11 10 4 3 1 5 6 7 8 9 3 2 www SeaDooManuals net PARTS ...

Page 187: ...Section 07 FUEL SYSTEM Subsection 02 FUEL CIRCUIT 07 02 2 SMR2000 055_07_02A FM GTX DI Models F12F0LS 10 11 16 15 4 3 4 N m 35 lbf in 22 N m 16 lbf ft 3 4 N m 35 lbf in 2 1 6 www SeaDooManuals net PARTS ...

Page 188: ... filler cap to remove any fuel pres sure in system WARNING DI Models The fuel system of a fuel injection system hold much more pressure than on a carbureted watercraft Prior to disconnecting a hose or to removing a component from the fuel system follow the recommendation de scribed in ENGINE MANAGEMENT DI under Fuel System WARNING Whenever repairing the fuel system always verify for water infiltra...

Page 189: ...NT DI section Fuel Baffle Pick Up Carburetor Equipped Models 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 Open storage compartment cover Remove storage basket from watercraft Remove front air intake Siphon fuel tank Remove steering assembly Refer to STEERING...

Page 190: ...arburetor Equipped Models Inspect fuel filter condition Carefully use low pressure compressed air to clean fuel filter Re place filter if permanently clogged or damaged Fuel Filter Bowl Check filter bowl for water contamination Gasket Inspect gasket condition Make sure gasket no 3 is well positioned into the filter bowl no 2 1 Gasket in bowl DI Models Inspect filter strainer condition Carefully us...

Page 191: ...e injection molded and the tank is then blow molded over the necks During the molding process a small molding seam may ap pear on the inner side of the necks at approximate ly 4 mm 5 32 in from the base of the neck It is a normal situation to have a molding seam and it should not be confused with a crack ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular...

Page 192: ...ystem must maintain a pressure of 34 kPa 5 PSI during 10 minutes Never pressurize over 34 kPa 5 PSI Reconnect air inlet hose of fuel tank to body NOTE Before removing the hose pincher block with your finger the outlet fitting to feel if air is coming out when removing hose pincher This will indicate that pressure relief valve and the outlet fitting are not blocked Remove hose pincher from fuel tan...

Page 193: ...Section 07 FUEL SYSTEM Subsection 03 AIR INTAKE SMR2000 056_07_03A FM 07 03 1 AIR INTAKE 0 Carburetor Equipped Models F08F0DS 2 Loctite 243 11 12 3 4 Loctite 243 3 13 www SeaDooManuals net PARTS ...

Page 194: ...Section 07 FUEL SYSTEM Subsection 03 AIR INTAKE 07 03 2 SMR2000 056_07_03A FM DI Models 2 Loctite 243 5 6 4 Loctite 243 7 1 Super Lube F12F0KS www SeaDooManuals net PARTS ...

Page 195: ...e silencer out of the carburetor adapter no 3 or the throttle bodies on the DI models Pull the air intake silencer rearward to remove it from the lower bracket no 4 and remove it in a rotating movement The air intake silencer is a molded 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 atten...

Page 196: ...nd that it has not pushed the gasket inside the air box All Models 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...

Page 197: ...000 057_07_04A FM 07 04 1 CARBURETOR 0 Mikuni 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 198: ...rottle valve via a linkage 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 carburetors from engine proceed as follows Remove air intake silencer Refer to AIR INTAKE Turn fuel valve to OFF position Disconnect pulse line TYPICAL 1 Pulse line 2 Loosen gear clamp Disconnect fuel supply line from fuel...

Page 199: ...gm 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 ...

Page 200: ...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 201: ...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 202: ...pressure of 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 a...

Page 203: ... 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 204: ... N 293 550 010 Connect linkage between both carburetor levers Ensure both throttle plates are still in closed posi tion NOTE The linkage installation is done with the marks located near PTO carburetor throttle lever to 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...

Page 205: ...e throttle cable between sen sor and carburetor Tighten jam nut 1 Throttle cable 2 Adjustment nut 3 Jam nut Turn idle adjustment screw clockwise until it comes in contact with stopper Refer to LOW SPEED SCREW ADJUSTMENT section for the proper ad justment Adjust oil pump cable Refer to OIL INJECTION PUMP NOTE It is important to adjust oil pump cable prior to finalize adjustment of throttle cable CA...

Page 206: ...ure and turning screw counterclockwise enriches mixture Start and warm up engine CAUTION If watercraft is out of water engine must be cooled using the flush kit Check that engine idles and runs smoothly Make sure engine reacts quickly to throttle lever depres sion If necessary readjust low speed screw 1 4 turn NOTE Both low speed screws must be adjusted exactly the same way Never adjust screws mor...

Page 207: ...that engine idles at 1400 RPM in water or 3000 RPM out of water Fuel Accelerator Pump Ensure throttle cable is properly adjusted and idle speed is set at 1400 RPM in water With the engine not running loosen adjustment screw lock nut Use a feeler gauge between lever tab and pump plunger Turn adjustment screw to achieve approximately 0 05 0 15 mm 002 005 in gap Tighten adjustment screw lock nut TYPI...

Page 208: ...1ATOC FM 08 01 1 TABLE OF CONTENTS 0 OIL INJECTION SYSTEM 08 02 1 GENERAL 08 02 2 OIL SYSTEM PRESSURIZATION 08 02 2 OIL INJECTION PUMP 08 03 1 REMOVAL 08 03 3 DISASSEMBLY 08 03 3 CLEANING 08 03 3 ASSEMBLY 08 03 3 ADJUSTMENT 08 03 3 CHECKING OPERATION 08 03 5 www SeaDooManuals net ...

Page 209: ...SYSTEM SMR2000 058_08_02A FM 08 02 1 OIL INJECTION SYSTEM 0 GTX DI Models F12G05S Dielectric grease 27 N m 20 lbf ft 3 5 N m 31 lbf in 3 5 N m 31 lbf in 1 2 1 2 4 3 To throttle body PTO side vent line From air compressor return line www SeaDooManuals net PARTS ...

Page 210: ...ir vent DI Models Connect pump gauge tester P N 529 021 800 to disconnected tube at throttle body All Models 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 pressure is not maintained locate leak and repair replace component leaking To ease leak search spray a solution of soapy water on co...

Page 211: ... Subsection 03 OIL INJECTION PUMP SMR2000 059_08_03A FM 08 03 1 OIL INJECTION PUMP 0 Carburetor Equipped Models 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 212: ...n 03 OIL INJECTION PUMP 08 03 2 SMR2000 059_08_03A FM DI Models F12G01S 6 N m 53 lbf in 1 Loctite 243 6 4 5 N m 40 lbf in 7 Throttle body 4 5 N m 40 lbf in 8 Molycote 111 To air compressor supply line To crankcase www SeaDooManuals net PARTS ...

Page 213: ...njection Pump and Shaft Make sure shaft no 8 is installed in crankshaft end Install pump Secure with flat washers and screws no 6 Torque to 6 N m 53 lbf in Install oil injection pump cable as per the following illustrations 1 Cable end completely inserted 2 Cable end NOT seated on the steps CAUTION Ensure cable end is completely en tered in its housing Ensure it is NOT seated on the steps ADJUSTME...

Page 214: ...on 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 If necessary turn cable adjustment nut to obtain pump mark alignment Refer to above illustrations Tighten jam nut and recheck alignment marks CAUTION Proper oil injection pump adjust ment is very important Any delay in the open ing of pump ca...

Page 215: ... If oil drops verify check valve operation Replace as necessary Bench Test Connect a hose filled with injection oil to main line fitting Insert other hose end in an injection oil con tainer Using a counterclockwise reverse position rotating drill rotate pump shaft Oil must drip from fittings in parts of rotary valve cover while holding lever in a fully open position TYPICAL 1 Supply oil line to an...

Page 216: ...HARGING SYSTEM 09 03 1 GENERAL 09 03 1 TESTING PROCEDURE 09 03 1 BATTERY 09 03 3 STARTING SYSTEM 09 04 1 GENERAL 09 04 2 STARTING SYSTEM TROUBLESHOOTING 09 04 3 STARTER REMOVAL 09 04 4 STARTER DISASSEMBLY 09 04 4 CLEANING 09 04 6 PARTS INSPECTION 09 04 6 STARTER ASSEMBLY 09 04 7 STARTER INSTALLATION 09 04 7 STARTER SPECIFICATION 09 04 8 INSTRUMENTS AND ACCESSORIES 09 05 1 GENERAL 09 05 1 INSPECTIO...

Page 217: ...Current Digital Capacitor Discharge Igni tion DC CDI Magneto System The magneto is the primary source of electrical energy It transforms magnetic field into electric current AC Trigger Coil The trigger coil is mounted outside the rotor in side the magneto housing of the engine and is not adjustable 1 Trigger coil Its purpose is to signal the piston position to the Multi Purpose Electronic Module T...

Page 218: ...utomatic Power Shut Down The MPEM is equipped with an automatic power shut down This feature prevents the battery from loosing its charge if the safety lanyard cap is left on the switch when the engine is not running After connecting the safety lanyard cap the MPEM will remain in standby mode during the next 10 minutes waiting for a starting If start stop button is not depressed then the MPEM will...

Page 219: ...ck on with the audible sig nal of safety lanyard validation Low Fuel Level Warning Device When the fuel level in the reservoir is low the fuel level sensor transmits a signal to the MPEM The MPEM sends out signals for the beeper RFI mod els only and to the info center gauge When the oil level is low in the reservoir the MPEM sends out a signal to the info center gauge and the pilot lamp on the gau...

Page 220: ...ng 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 the ignition timing can be checked with either the engine hot or cold Al so the ignition timing is to be chec...

Page 221: ...thin mark on PTO flywheel aligned with timing mark pointer tool 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 8 Remove TDC gauge 9 Reinstall spark plug and connect wire Dynamic Test To check ignition timing use Bombardier timing light P N 5...

Page 222: ...ed up to 4 The MPEM programmer corrects the ignition tim ing in 1 increments CAUTION If the ignition timing is adjusted too advanced this will cause serious damage to the engine The timing mark on the PTO flywheel refers to the physical component position when the spark must occurs The MPEM must be synchronized with the mark For instance on a particular engine the timing correction may need to be ...

Page 223: ...ives number 3 Enter this number with the programmer You recheck the timing with the timing light and if the mark is aligned the ignition timing is properly set Proceed as Follows to Adjust the Ignition Timing with the MPEM Programmer 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 y...

Page 224: ...med using an ohmmeter Disconnect switch wires Safety Lanyard Removed Connect test probes to switch BLACK and BLACK YELLOW wires Measure resistance there should be no continuity open circuit Connect one test probe to the WHITE GRAY wire and the other test probe to the switch terminal Measure resistance it must be close to 0 ohm Connect one test probe to the BLACK wire and the other test probe to th...

Page 225: ...0 2 and 0 5 Vac 6 If the trigger coil is out of specification replace it Ignition Coil Verification Before conducting any testing on the ignition coil make sure there is at least 12 Vdc at the primary wires If there is insufficient voltage the ignition problem is occurring before the ignition coil STATIC TEST NOTE An ignition coil with good resistance mea surement can still be faulty Voltage leak ...

Page 226: ... Range The proper heat range of the spark plugs is deter mined by the spark plugs ability to dissipate the heat generated by combustion The longer the heat path between the electrode tip to the plug shell the hotter the spark plug op erating temperature will be and inversely the short er the heat path the colder the operating tempera ture will be A cold type plug has a relatively short insulator n...

Page 227: ...he plug face and piston dome reveals the con dition of the engine operating condition method of driving and fuel mixture For this reason it is advisable to inspect the spark plug at regular inter vals examining the plug face i e the part of the plug projecting into the combustion chamber and the piston dome Spark Plug Installation Prior to installation make sure that contact surfac es of the cylin...

Page 228: ...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 229: ...y 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 check for a defective wire CAUTION Do not use a higher rated fuse as this cause severe damage Carburetor Equipped Models Two 15 A fuses protect the charging system The first one is mounted on the MPEM and the othe...

Page 230: ... stator will need to be replaced STATIC TEST INSULATION 1 Disconnect the magneto wiring harness con nector 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 TYPICAL 1 Multimeter 2 Magneto harne...

Page 231: ...e area with water and baking 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 acti vated battery SYMPTOM DISCHARGED OR WEAK BATTERY CAUSE REMEDY 1 Battery posts and or cable terminal oxidized ...

Page 232: ...ng device that has an adjustable load Apply a load of 3 times the ampere hour rating of the battery At 14 seconds into the test check bat tery voltage if battery is in good condition it will have at least 10 5 Vdc Battery Storage CAUTION Battery storage is critical for bat tery life Regularly charging the battery during storage will prevent cell sulfation Keeping the battery in vehicle for storage...

Page 233: ...torage period recheck electrolyte lev el and specific gravity readings at least every month If necessary keep the battery at its upper level line and near full charge as possible trickle charge Activation of a New Battery A new battery is factory fresh dry charged For storage purposes it is fitted with a temporary seal ing tube CAUTION Do not remove the sealing tube or loosen battery caps unless a...

Page 234: ...harging temporarily or reduce the charging rate 6 Disconnect battery charger Step Unplug battery charger Step Disconnect lead Step Disconnect lead 7 Test battery state of charge Use a hydrometer 1 Specific gravity 1 265 8 If electrolyte level has dropped after charging fill with distilled water to UPPER LEVEL line Af ter water is added continue charging for 1 to 2 hours to mix water with electroly...

Page 235: ...e of accurately measuring current of less than 1 ampere Unless this procedure is properly followed a good battery may be needlessly replaced Measure the voltage at the battery posts with an accurate voltmeter If it is below 10 volts the battery will accept current at very low rate in term of milliamperes because electrolyte is nearly pure water as explained above It could be some time before the c...

Page 236: ... as follows 1 Install battery in its emplacement 2 Secure vent line to the battery and support En sure vent line is not kinked or obstructed 3 First connect RED positive cable 4 Connect BLACK negative cable last 5 Apply dielectric grease on battery posts 6 Verify cable routing and attachment RX Models Reinstall bilge vent tube WARNING Always charge battery ies in a well ventilated area WARNING Alw...

Page 237: ...ubsection 04 STARTING SYSTEM SMR2000 062_09_04A FM 09 04 1 STARTING SYSTEM 0 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 238: ...ENCODED SECU RITY SYSTEM or ENGINE MANAGEMENT Engine Start Stop Switch and Safety Lanyard Switch Refer to IGNITION SYSTEM or ENGINE MANAGE MENT 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 t...

Page 239: ...onnections Clean 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 B...

Page 240: ...ative starter cable 3 Allen screw Remove bracket and starter NOTE To remove the starter drive assembly mag neto flywheel has to be removed Refer to MAG NETO SYSTEM and BOTTOM END To check and replace the starter end bearing refer to BOTTOM END of ENGINE section STARTER DISASSEMBLY Locate index marks on yoke no 1 and end covers no 3 and no 10 1 Index marks Loosen through bolts no 5 1 Through bolts ...

Page 241: ... Remove the other end cover no 10 and gasket Remove the 3 washers no 18 from armature shaft 1 Washers Remove armature no 11 1 Pull armature shaft Release brush wires of yoke from brush holder no 2 Remove brush holder no 2 1 Remove brush holder To remove brushes from yoke no 1 loosen nut and remove washers 1 Loosen nut and remove washers F06H1HA 1 F06H1IA 1 F06H1JA 1 F06H1KA 1 F06H1LA 1 www SeaDooM...

Page 242: ...used for the follow ing testing procedures except for the one con cerning shorted windings in armature Check commutator for roughness burnt or scored surface If necessary turn commutator on a lathe enough to resurface only Check commutator for mica depth If depth is less than 0 20 mm 008 in undercut mica Be sure that no burrs are left and no copper dust remains between segments after undercutting ...

Page 243: ...sassembly to reassemble starter However attention should be paid to the following operations Install new O rings and gaskets Insert thrust washers no 19 onto armature shaft 1 Non metallic surface on the side Install the 3 washers no 8 onto armature shaft When installing end covers no 3 and no 10 to yoke align index marks Apply Loctite 271 red on through bolts no 5 and torque to 6 N m 53 lbf in STA...

Page 244: ...crew to 10 N m 89 lbf in STARTER SPECIFICATION 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 F06H35B 2 1 3 3 Nominal output 0 8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 1 7 kg...

Page 245: ... gauge If not replace the temperature sensor Water Temperature Sensor L TEMP 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 Information Center and select the lake temperature mode With a garden hose spray the speed sensor with water The temperature reading on the Information Center sho...

Page 246: ...LE YELLOW wire and the negative probe to speed sensor BLACK ORANGE wire With the safety lanyard removed depress the start stop button to activate the MPEM timer Slowly rotate the paddle wheel Every 1 8 turn the observed voltage should fluctuate between 5 5 and 8 5 Vdc Speedometer 90 mm TYPICAL The PURPLE wire is the 12 Vdc power source of the speedometer The BLACK wire is the ground The PURPLE YEL...

Page 247: ...r PK MPH Average Speed The information center approxi mately calculates and displays the average speed AV KPH or AV MPH of the watercraft since the last engine start Trip Meter The information center approximately calculates the distance based on the operation time and the watercraft speed and displays the result in kilometers KM or miles MILES Hourmeter Displays the time in hours of the wa tercra...

Page 248: ...vated or displayed back after an alternate display was chosen The tachometer speedometer and chronometer are the only other modes that may be chosen to replace the default display When one of these is selected it will become the default display until it is changed again When another display mode is chosen the default display will be displayed back after 4 seconds As a self test all LCD segments an...

Page 249: ... MINUTES 1 Press TOGETHER to end NOTE If MODE and SET buttons are not pressed at the end the default display will come back after 10 seconds and the time entered will remain Chronometer While in the chronometer mode 1 Press to start or stop chronometer 1 Press and hold for 2 seconds to reset Maintenance Information When the watercraft is due for a maintenance in spection the message MAINT will bli...

Page 250: ...lowing chart to test the accuracy of the gauge NOTE The gauge must be activated to obtain a reading RX and RX DI VTS Disconnect the 2 circuit connector housing of the Information Center Connect potentiometer test probes to the BROWN WHITE and BROWN BLACK wires Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge NOTE The gauge must be activated to ...

Page 251: ...fy 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 12495 0 20 2 10000 0 25 2 8054 9 30 2 6528 3 35 2 RESISTANCE Ω DISPLA...

Page 252: ...critical LOW level inside the oil tank and therefore in sensor reservoir the sensor detects the absence of liquid and the light TURNS ON To check the oil sensor unplug its connector and pull sensor out of oil tank Using a multimeter check the continuity between the BLUE and BLUE BLACK terminals When sensor is out of oil tank and its reservoir is empty resistance must be infinite open circuit NOTE ...

Page 253: ...remove motor refer to VARIABLE TRIM SYS TEM Then manually rotate worm to verify VTS system actuating mechanism for free operation Connect motor through a 15 A fuse directly to the battery Connect wires one way then reverse polarities to verify motor rotation in both ways If VTS actuating mechanism is correct and the mo tor turns freely in both ways VTS module could be defective If VTS motor does n...

Page 254: ... ac tivated at the factory Therefore a safety 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 MPEM programmer P N 529 034 500 or the VCK P N 529 035 676 Refer to its Guide to program a safety lanyard The system is quite flexible Up to eight safety lan yard...

Page 255: ...button Bad connection between safety lanyard cap and switch Remove and replace the safety lanyard on the switch until 2 short beeps are heard to indicate the system 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...

Page 256: ...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 257: ...ZATION 10 02 18 INSTALLATION 10 02 18 DRIVE SYSTEM 10 03 1 GENERAL 10 03 2 REMOVAL 10 03 2 INSPECTION 10 03 4 INSTALLATION 10 03 5 LUBRICATION 10 03 7 REVERSE SYSTEM 10 04 1 DISASSEMBLY 10 04 2 INSPECTION 10 04 2 ASSEMBLY 10 04 2 ADJUSTMENT 10 04 2 DISASSEMBLY 10 04 4 INSPECTION 10 04 5 ASSEMBLY 10 04 5 ADJUSTMENT 10 04 6 VARIABLE TRIM SYSTEM 10 05 1 GENERAL 10 05 2 REMOVAL 10 05 2 DISASSEMBLY 10 ...

Page 258: ...18 Loctite 518 6 5 4 33 N m 24 lbf ft Loctite 243 Loctite 518 7 20 22 23 25 Synthetic grease 27 26 24 Loctite 518 Loctite 243 Loctite 262 21 110 N m 81 lbf ft Pipe sealant 15 16 3 2 20 N m 15 lbf ft 1 9 12 11 3 12 11 10 21 N m 16 lbf ft 10 21 N m 16 lbf ft Loctite 243 Loctite 243 8 41 39 40 43 42 31 38 32 38 30 29 33 20 N m 15 lbf ft 28 www SeaDooManuals net PARTS ...

Page 259: ...24 lbf ft 6 54 Loctite 243 28 14 13 17 18 19 20 Loctite 518 2 20 N m 15 lbf ft 45 44 3 1 10 21 N m 16 lbf ft 12 11 9 Loctite 243 12 11 Loctite 243 10 21 N m 16 lbf ft 3 16 15 24 Pipe sealant 23 21 20 22 Loctite 518 27 25 Synthetic grease 26 8 Loctite 518 7 Loctite 262 35 34 29 36 37 www SeaDooManuals net PARTS ...

Page 260: ...curely 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 Impeller Condition Condition of impeller no 17 boot no 13 and ring no 14 can be quickly checked from underneath of the watercraft Remove grate and look through water inlet ope...

Page 261: ...pection 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 TYPICAL MEASURING FROM WATER INLET SIDE 1 Feeler gauge TYPICAL MEASURING FROM VENTURI SIDE 1 Fe...

Page 262: ... of cover with a solvent Check O ring condition Replace as necessary Apply a thin layer of Loctite 518 on mating surface of cover and reinstall it with its O ring Apply Loctite 243 on threads and torque screws to 7 5 N m 66 lbf in Remove plug from cover Pour oil through hole until oil reaches the bottom of hole threads Use SEA DOO JET PUMP SYN THETIC OIL P N 293 600 011 only Oil will drain slowly ...

Page 263: ...1 Pivot bolts 2 Pivot support 3 Reverse gate Withdraw pivot support Connecting Rod Remove reverse gate pivot bolt no 89 Withdraw connecting rod Pivot Triangle Remove reverse gate connecting rod pivot bolts no 40 Withdraw pivot triangle no 41 Pivot Arm Remove reverse gate connecting rod spring pivot bolts no 42 Take note of bushing size for reinstallation Withdraw pivot arm no 43 1 Pivot bolts each...

Page 264: ...rews Jet Pump Housing RX and RX DI Models Detach reverse cable VTS link rod GTX DI Model Detach ball joint of reverse cable from reverse gate All Models Disconnect steering cable from jet pump nozzle Loosen 4 hexagonal nuts no 4 and remove flat washers and lock washers from jet pump housing Remove jet pump with a wiggle movement CAUTION When removing pump unit a shim could have been installed betw...

Page 265: ...Place container under cover no 15 to catch oil Using a fiber hammer gently tap cover to release it from jet pump housing Impeller Insert impeller shaft holder 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 befor...

Page 266: ...ICAL 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 21 with thrust washer and thrust bearing Seal and Needle Bearing Remove seal no 19 and bearings no 20 at the same time using bearing seal remover tool ...

Page 267: ... Brush and clean impeller shaft threads impeller and drive shaft splines with Loctite Safety solvent 755 P N 293 800 019 or equivalent Free threads and splines from any residue CAUTION Be careful not to damage impeller 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 conditio...

Page 268: ... onto shaft end close to end of threads Move shaft end up and down Difference between highest 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 o...

Page 269: ... shaft no 21 is checked with shaft in housing without impeller and with cover no 15 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 270: ...ng in housing making sure it is equally inserted all around Place wood piece over ring Using a hammer strike on wood to push ring Strike one side then rotate wood piece about 90 and strike again Frequently rotate wood piece so that ring slides in evenly until it seats into bottom of housing Seal and Needle Bearing Bearings no 20 and seal no 19 will be properly installed in housing using bearing se...

Page 271: ...seat Bearing on venturi side must be 2 to 3 mm 080 120 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 3 mm 080 120 in Thrust Washer Position jet pump housing no 7 with the stator vanes on top Insert thrust washer no 22 in the stator seat 1 Thrust wash...

Page 272: ...rimer 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 Install...

Page 273: ...er to 110 N m 81 lbf ft then remove tools CAUTION Never use any impact wrench to tight en impeller Apply synthetic grease P N 293 550 010 on im peller splines Insert a new boot no 13 and ring no 14 to impeller 1 Boot and ring Anti Rattle System Install spring no 27 on slider no 26 1 Spring 2 Slider Insert slider and spring into cover NOTE Align the longer slider tab with hole Apply synthetic greas...

Page 274: ...redo the proce dure 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 comes level with bottom of hole Let oil ...

Page 275: ...0 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 ponents NOTE If there is a pressure drop spray soapy wa ter around cover If there are no bubbles impeller shaft impeller shaft seal or jet pump housing is leaking through porosity and has to be replaced Jet pump unit has to be disassembled If jet ...

Page 276: ...ings no 3 Install nozzle on venturi position its steering arm on RH side Apply Loctite 243 blue on screw threads or use new screws with pre applied threadlocker Install screws no 2 and locking disks no 45 then torque to 20 N m 15 lbf ft TYPICAL 1 Locking disks 2 Torque screws to 20 N m 15 lbf ft Pivot Triangle Install head bolts toward inside NOTE Make sure the pivot triangle turn freely Reverse G...

Page 277: ...ection 10 PROPULSION SYSTEM Subsection 03 DRIVE SYSTEM SMR2000 066_10_03A FM 10 03 1 DRIVE SYSTEM 0 F15J02S 2 3 4 5 6 8 9 1 7 13 12 13 Synthetic grease 11 10 Synthetic grease www SeaDooManuals net PARTS ...

Page 278: ...h PTO flywheel guard from engine and with draw from bilge Large Clamp 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 dis engage windows from locking hooks TYPICAL 1 Locking hooks Small Clamp Unfasten small clamp of PTO flywheel boot as fol lows Use ...

Page 279: ... dia 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 4 Drill 9 mm 11 32 in hole 5 Drill through 9 mm 11 32 in 6 Drill and tap 6 mm 1 4 in holes A 305 mm 12 in B 105 mm 4 1 8 in C 16 mm 5 8 in D 51 mm 2 in E 36 mm 1 25 64 in F 22 mm 7 8 in G 17 mm 43 64 H 19 mm 3 4 in I 35 ...

Page 280: ...ondition 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 difference between highest and lowest dial gauge reading is deflection Refer to the following illustration Maximum permissible deflection is 0 5 mm ...

Page 281: ... 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 must be removed to install spacer INSTALLATION Installation is essentially the reverse of removal procedure However pay particular attention to the following Drive Shaft and Dampers Install dampers no 13 on drive shaft n...

Page 282: ...al Manually engage holding hook in large window This is a pre clamping position only PRE CLAMPING POSITION 1 Holding hook 2 Large window Insert 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 o...

Page 283: ... no 4 place notch side of plier on clamp embossment and squeeze plier 1 Squeeze plier LUBRICATION PTO Flywheel Using a grease 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 1 F02J0PB F01I0BB www SeaDooManuals net ...

Page 284: ...E SYSTEM SMR2000 067_10_04A FM 10 04 1 REVERSE SYSTEM 0 RX and RX DI Models F16J07S 16 Loctite 243 15 21 20 19 17 13 18 20 Loctite 243 18 Silicone sealant 14 Synthetic grease Synthetic grease 13 9 7 12 11 10 8 3 4 6 2 6 1 5 www SeaDooManuals net PARTS ...

Page 285: ...17 bolts no 18 Withdraw reverse cable support no 19 Handle Housing Remove shift lever inner lever reverse cable support bolts no 20 Then remove handle housing no 21 INSPECTION Visually inspect parts for wear or cracks Replace all defective parts ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Inner Lever Apply synthetic grea...

Page 286: ...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 287: ... 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 Inside Lever Remove glove box to have access to the shifting lever mechanism 1 Remove glove box Remove bolt no 12 and lock nut no 13 retaining reverse cable end to interior lever no 11 1 Rever...

Page 288: ...ts as required ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following CAUTION Apply all specified torques and ser vice products as per main illustration Spring Make sure to properly install spring no 15 into in terior lever no 11 as per following illustration 1 Spring Inner Lever and Shift Lever Install the inner lever no 11 in a r...

Page 289: ... Ensure cable ball joint is parallel to cable lever 90 5 to minimize tension on cable Adjust as required ADJUSTMENT Put shift lever in forward position Pull shift lever approximately 50 mm 2 in and push it back slowly in forward position 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 2...

Page 290: ... 068_10_05A FM 10 05 1 VARIABLE TRIM SYSTEM 0 RX and RX DI Models F16J01S 1 2 4 3 5 6 7 8 9 10 11 12 14 2 13 N m 115 lbf in Loctite 243 5 N m 44 lbf in 13 Loctite 243 3 N m 27 lbf in 13 N m 115 lbf in Loctite 243 Synthetic grease 7 N m 62 lbf in www SeaDooManuals net PARTS ...

Page 291: ...2 Remove boot no 3 TYPICAL 1 VTS rod 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 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 11 1 Remove nuts 2 Disconnect wires...

Page 292: ...t Apply synthetic 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 housing Install and torque nuts no 11 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 is essent...

Page 293: ... N 293 800 041 to threads of VTS housing and Loctite 243 blue to nut no 4 Install nut with sealing washer and torque to 6 N m 53 lbf in using the VTS socket tool Boot and Clamps Install rubber boot no 3 over sliding shaft and se cure with clamps ADJUSTMENT On these models no adjustment is required www SeaDooManuals net ...

Page 294: ...01 TABLE OF CONTENTS SMR2000 037_11_01ATOC FM 11 01 1 TABLE OF CONTENTS 0 STEERING SYSTEM 11 02 1 DISASSEMBLY 11 02 2 ASSEMBLY 11 02 4 ADJUSTABLE STEERING 11 03 1 DISASSEMBLY 11 03 2 ASSEMBLY 11 03 6 ALIGNMENT 11 04 1 www SeaDooManuals net ...

Page 295: ...22 7 N m 62 lbf in 26 N m 19 lbf ft Synthetic grease 12 11 6 N m 53 lbf in Loctite 243 25 N m 22 lbf in 19 25 10 N m 89 lbf in 26 20 25 N m 22 lbf in 3 N m 26 lbf in 6 N m 53 lbf in 17 Loctite 243 15 16 18 9 6 N m 53 lbf in Loctite 243 10 8 14 Loctite 243 14 N m 10 lbf ft 13 7 4 4 N m 35 lbf in 10 N m 89 lbf in Loctite 243 4 www SeaDooManuals net PARTS ...

Page 296: ...ert from 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 and flat washers 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 F07K0JA 1 F...

Page 297: ...olts Remove cable support no 8 Steering Support Cut locking tie securing wiring harness boot 1 Boot 2 Locking tie Carburetor Equipped Models Disconnect the throttle and choke cables from car buretor levers All Models Disconnect the wiring harnesses leading out of steer ing stem and cut locking tie 1 Tie rap 2 Connectors F07K02A 1 2 1 2 F07K03A F07K04A 1 2 F07K05A 2 1 www SeaDooManuals net ...

Page 298: ...stem arm 2 Bolts Remove steering stem arm and support Steering Cable Disconnect steering cable no 24 from steering stem arm no 15 Remove retaining block no 10 Disconnect ball joint no 19 from jet pump nozzle Remove ball joint no 19 and jam nut from cable Loosen nut no 25 then remove half rings no 26 and O ring no 20 NOTE To loosen nut use steering cable tool P N 295 000 145 Remove steering cable f...

Page 299: ...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 Ball Joint Secure the steering cable ball joint no 19 to the nozzle as per following illustration CAUTION Ensure the ball joint is parallel 5 to the nozzle arm TYPICAL 1 Bal...

Page 300: ...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 301: ...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 302: ...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 303: ...pport no 8 1 Retaining block Remove bolts no 11 each side of steering support 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 304: ...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 305: ...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 306: ... 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 307: ...dge 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 Open storage compartment cover and remove bas ket Loosen 2 bolts retaining block at cable support Turn adjustment nut as required 1 Retaining block 2 Adjustment nut 3 Loosen bolts After adjustment torque retaining block bo...

Page 308: ...ORAGE COMPARTMENT COVER ADJUSTMENT 12 02 11 MIRROR 12 02 12 INLET GRATE 12 02 12 RIDING PLATE 12 02 12 JET PUMP SUPPORT 12 02 13 DEFLECTOR 12 02 14 DRAIN PLUG INSTALLATION 12 02 14 SEAT COVER REPLACEMENT 12 02 14 BUMPER REPLACEMENT 12 02 15 SPONSON REPLACEMENT 12 02 15 DECALS REPLACEMENT 12 02 15 HULL AND BODY REPAIR 12 02 16 TOOLS AND MATERIALS LIST 12 02 19 THRU HULL FITTING INSTALLATION 12 02 1...

Page 309: ...AIR 0 GTX DI 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 Right side only Loctite 271 15 N m 133 lbf in Body Silicone sealant 8 N m 71 lbf in www SeaDooManuals net PARTS ...

Page 310: ...AIR 12 02 2 SMR2000 071_12_02A FM GTX DI 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 133 lbf in www SeaDooManuals net PARTS ...

Page 311: ... SMR2000 071_12_02A FM 12 02 3 GTX DI 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 312: ...12 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 12 02 4 SMR2000 071_12_02A FM GTX DI 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 313: ...TMENT AND REPAIR SMR2000 071_12_02A FM 12 02 5 RX bow F16L01S Loctite 271 5 N m 44 lbf in 8 N m 71 lbf in Loctite 271 Silicone sealant Loctite 271 Body Silicone sealant 15 N m 133 lbf in Loctite 271 6 N m 53 lbf in www SeaDooManuals net PARTS ...

Page 314: ...02 ADJUSTMENT AND REPAIR 12 02 6 SMR2000 071_12_02A FM RX stern F16L02S Loctite 271 12 13 Loctite 243 4 Loctite 271 5 12 14 12 12 4 5 15 Silicone sealant Silicone sealant 15 N m 133 lbf in Silicone sealant www SeaDooManuals net PARTS ...

Page 315: ...Section 12 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2000 071_12_02A FM 12 02 7 RX cover F16L03S 5 N m 44 lbf in Loctite 243 3 N m 26 lbf in Loctite 243 www SeaDooManuals net PARTS ...

Page 316: ...Section 12 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 12 02 8 SMR2000 071_12_02A FM RX seat F16L04S www SeaDooManuals net PARTS ...

Page 317: ...g screws then remove side pan els 1 Unscrew Open front storage cover and remove basket Unscrew nut retaining vent tube to bracket 1 Unscrew Pull vent tube out From the engine compartment insert a hand through the vent tube hole and press glove box lock tabs to release 1 Insert your hand here to release the lock tabs 1 F16L07A 1 F16L08A 1 F16L09A 1 F16L0AA www SeaDooManuals net ...

Page 318: ... procedure SEAT ADJUSTMENT Seat Retainer RX MODELS 1 Lock pin 2 Adjustment nut apply Loctite 271 A 36 1 mm 1 5 16 13 32 in GTX DI MODELS FRONT SEAT 1 Lock pin 2 Adjustment nut Loctite 271 A 39 1 mm 1 35 64 3 64 in GTX DI MODELS REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 271 A 33 5 1 mm 1 5 16 3 64 in 1 F16L0BA F06L03A A 1 2 F07L08A A 2 1 F06L03A A 1 2 www SeaDooManuals net ...

Page 319: ... in bead of Loctite 454 Reinstall inner shell with its retaining screws Tighten screws starting with the one at the small end front and finish with rear end Care fully hand tighten STORAGE COMPARTMENT COVER ADJUSTMENT Adjust lock pin no 3 as per following specifica tions RX AND SOME GTX DI MODELS 1 Lock pin apply Loctite 271 2 Adjustment nut A 34 1 mm 1 11 32 3 64 in SOME GTX DI MODELS 1 Lock pin ...

Page 320: ...llustration Hand tighten screw numbers then Torque screw numbers and to 11 N m 97 lbf in Torque screw number to 26 N m 19 lbf ft All Models RIDING PLATE Removal 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 low height hydraulic bottl...

Page 321: ...gs and O rings from reverse cable Remove boot and nut from VTS sliding shaft RX models Disconnect 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 ...

Page 322: ...3 Torque screws to 1 5 N m 13 lbf in 4 From inside bilge apply 732 sealant on screws 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 Thi...

Page 323: ... DI Models Remove seat support Remove muffler Remove battery From inside bilge remove lock nuts no 10 using a 10 mm deep socket with an extension Remove sponsons no 6 Clean any residues of sealant 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 bi...

Page 324: ...erlapping strokes Remove front protective film once decal has ad hered to hull INSTALLATION ON PLASTIC storage cover Clean surface with isopropyl alcohol Using a pencil and the decal as a template mark the area where decal will be located Apply an activator P N 293 530 036 to prepare the surface using a clean cloth After a few seconds when the activator evaporates the surface is ready CAUTION Do n...

Page 325: ...h a white medium compound Finish off us ing a fine compound While buffing pay close at tention to avoid overheating the surface Blisters Possible causes Insert catalyst Improper catalyst gelcoat ratio A blister is a visible bump on the watercraft surface that may not necessarily come right through the gelcoat layer In the case of only a few blisters follow the same repair procedure as for air bubb...

Page 326: ...en repaired Outside Remove the damaged gelcoat and fiberglass with a 24 grit disk using a power sander Grind outward at least 2 inches from the fracture to allow the patch to bond to strong material Cut enough piec es of fiberglass mat necessary to build up the area The pieces should be cut so they overlap each oth er by at least a half inch For a smoother finish the last layer should be fiberglas...

Page 327: ...res BUFFING AND WAXING Refer to the buffing and waxing for Minor Gelcoat Fractures TOOLS AND MATERIALS LIST Tools safety glasses air mask white cloths sanding block putty knife plastic film stirring stick cover sheets for Sea Doo scissors buffing pad heavy duty polisher power sander paint brush plastic container mixing spray gun plastic squeegee Materials fiberglass mat fiberglass cloth polyester ...

Page 328: ...astic 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 insert NOTE The epoxy glue curing time is 30 minutes F01L2VA 1 2 F01L2WA...

Page 329: ...der 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 Cylinder out...

Page 330: ...ses MPEM 5 A Electrical system 2 x 15 A VTS system 7 5 A Bilge pump 3 A ADDITIONAL INFORMATION CARBURETION RX 5513 5514 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 331: ... 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 RX 5513 5514 Number of passenger driver incl 2 Overall length 285 cm 112 in Overall width 120 cm 47 in Overall height 104 cm 40 9 in Dry weight 275 kg 605 lb Load limit pass...

Page 332: ...toring beeper Standard Speedometer Standard Fuel oil gauge analog Not applicable Tachometer Not applicable Variable trim system VTS Standard Information Center Standard Storage compartment Standard Glove box Standard 2 Rear grab handle Standard Tool kit Standard ADDITIONAL INFORMATION Information Center standard functions Fuel level low fuel level low oil level low voltage high temperature tachome...

Page 333: ...ugs 24 N m 17 lbf ft 5 JET PUMP Impeller 113 N m 83 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 7 5 N m 66 lbf in 1 Inlet grate screws 11 N m 97 lbf in 1 Riding plate screws 22 N m 17 lbf ft 1 STEERING Cable retaining block bolts 6 N m 53 lbf in Steering cable lever 3 N m 26 lbf in Steering s...

Page 334: ...maximum 0 10 mm 004 in total Piston ring type and quantity 2 semi trapez chrome coated steel rings Ring end gap New 0 55 0 7 mm 022 028 in Wear limit 1 1 mm 043 in Ring piston groove clearance New 0 044 0 089 mm 002 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 12 mm 0047 in Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 mm 004 in Cylinder out of round maximum...

Page 335: ...rmation center ACC 2 A Fuel pump FP 15 A VTS system VTS 7 5 A Not applicable ADDITIONAL INFORMATION FUEL SYSTEM RX DI 5646 5656 GTX DI 5649 5659 Fuel injection type Orbital Direct Fuel Injection twin throttle body 46 mm 1 81 in Idle speed in water out of water 1450 50 RPM Throttle Position Sensor TPS 1 6 kΩ 2 4 kΩ Crankshaft Position Sensor CPS 5 Volts Manifold Air Temperature Sensor MATS 2 28 kΩ ...

Page 336: ...ft 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 RX DI 5646 5656 GTX DI 5649 5659 Number of passenger driver incl 2 3 Overall length 285 cm 112 in 315 cm 124 in Overall width 120 cm 47 in 123 cm 48 in Overall height 104 cm 41 in 107 cm 42 in Dry weight 275 k...

Page 337: ...rd Monitoring beeper Standard Speedometer Standard Fuel oil gauge analog Not applicable Tachometer Not applicable Information Center Standard Storage compartment Standard Glove box Standard 2 on RX models Rear grab handle Standard Tool kit Standard ADDITIONAL INFORMATION Information Center standard functions Fuel level low fuel level low oil level low voltage high temperature tachometer speedomete...

Page 338: ...ng screws 10 N m 89 lbf in 1 Spark plugs Hand tighten then tighten an additional 1 4 turn JET PUMP Impeller 113 N m 83 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 7 5 N m 66 lbf in 1 Inlet grate screws 11 N m 97 lbf in 1 Riding plate screws 22 N m 17 lbf ft 2 STEERING Cable retaining block bolts 6 N m 53 lbf in Steering cable ...

Page 339: ...si 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 to electrical box some mod els and to diagnostic tool VCK on DI models 1 Male housing 2 Fe...

Page 340: ... 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 341: ... connector from the header as sembly press 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 ...

Page 342: ...e time pry open the wedge lock to open position CAUTION 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 f...

Page 343: ...y pulling wire back until contact is removed Contact 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...

Page 344: ...l plug even if they are not pierced 1 Seal plug 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 c...

Page 345: ...SMR2000 073_14_00A FM RX MODEL 5513 5514 www SeaDooManuals net ...

Page 346: ...SMR2000 073_14_00A FM F16Z01 www SeaDooManuals net ...

Page 347: ...SMR2000 073_14_00A FM RX DI MODEL 5646 5656 www SeaDooManuals net ...

Page 348: ...SMR2000 073_14_00A FM F12Z02 www SeaDooManuals net ...

Page 349: ...SMR2000 073_14_00A FM GTX DI MODEL 5649 5659 www SeaDooManuals net ...

Page 350: ...SMR2000 073_14_00A FM F12Z01 www SeaDooManuals net ...

Page 351: ...www SeaDooManuals net ...

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