Sea-doo 2003 GTI LE RFI Shop Manual Download

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Section 04

ENGINE (2-STROKE)

Subsection 08

(EXHAUST SYSTEM)

SMR2003-013_04_08A.FM

04-08-9

9. 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

10. Loosen bolt

no. 20

of tuned pipe head above

the engine magneto then remove bolts retain-
ing bracket to engine.

1. Remove bolt

11. Remove tuned pipe head

no. 10

12. Loosen bolt

no. 6

of tuned pipe cone beside

the engine water return hose.

1. Loosen bolt

13. Remove tuned pipe cone

no. 5

14. Block exhaust opening in the manifold to keep

debris from entering cylinder during threads
cleaning procedure.

15. Remove the stud

no. 21

from “Y” manifold.

16. Use a M10 x 1.5 screw/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.

Tuned Pipe Removal without Separation from
Tuned Pipe Head and Tuned Pipe Cone

Execute the above procedures 1 through 5.

Then proceed as follows:

Remove the strap

no. 2

retaining the muffler then

remove the exhaust hose

no. 3

from tuned pipe

cone

no. 5

F06D1TA

F06D1UA

F06D1VA

www.SeaDooManuals.net

Summary of Contents for 2003 GTI LE RFI

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

Page 2: ...2003 Shop Manual GTI GTI LE GTI LE RFI GTX DI XP DI RX DI LRV DI GTX 4 TEC SERIES www SeaDooManuals net ...

Page 3: ...ademark of Korkay System Ltd GTX is a trademark of Castrol Ltd Used under license 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 The following trademarks are the property of Bombardier Inc or its subsidiaries SEA DOO BOMBARDIER ROTAX BOMBARDIER LUBE BOMBARDIER ROTAX Formula XP S Synthetic Inj...

Page 4: ...ontents 05 01 1 02 Leak test 05 02 1 03 Intake system 05 03 1 04 Exhaust system 05 04 1 05 Removal and installation 05 05 1 06 PTO housing magneto 05 06 1 07 Lubrication system 05 07 1 08 Cylinder head and valves 05 08 1 09 Engine block 05 09 1 06 ENGINE MANAGEMENT RFI 01 Table of contents 06 01 1 02 Overview 06 02 1 03 Diagnostic procedures 06 03 1 04 Component inspection 06 04 1 05 Troubleshooti...

Page 5: ...rbureted and RFI engines 12 06 1 13 PROPULSION SYSTEM 01 Table of contents 13 01 1 02 Jet pump 13 02 1 03 Drive system 13 03 1 04 Reverse system 13 04 1 05 Variable trim system 13 05 1 14 STEERING SYSTEM 01 Table of contents 14 01 1 02 Steering system 14 02 1 03 Alignment 14 03 1 15 SUSPENSION 01 Table of contents 15 01 1 02 Direct action suspension 15 02 1 16 HULL BODY 01 Table of contents 16 01 ...

Page 6: ...ecommended 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 fasten...

Page 7: ...2 GTI LE International earthen clay 717 6101 GTI LE RFI 787 RFI 6104 GTI LE RFI International 787 RFI 6103 GTX DI 947 DI 6119 GTX DI International 947 DI 6118 RX DI 947 DI 6123 RX DI International 947 DI 6122 LRV DI 947 DI 5771 GTX 4 TEC 1503 6112 GTX 4 TEC International 1503 6111 GTX 4 TEC Vans Triple Crown Edition 1503 6126 GTX 4 TEC Vans Triple Crown Edition International 1503 6125 GTX 4 TEC Su...

Page 8: ...DI Engines The Engine Identification Number is located on the upper crankcase on MAGNETO side 1 Engine Identification Number E I N ARRANGEMENT OF THIS MANUAL The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual Several sections are divided in various subsections There is a table of contents at the beginning of many sections Z Z ...

Page 9: ...lustration 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 cas...

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 Diap...

Page 11: ...t parts which have the same or a similar function CAUTION These watercraft are designed with parts dimensioned mostly in the metric system Howeversomecomponentsmaybefromtheimpe rial system Whenreplacing fasteners makesureto use only those recommended by Bombardier DESCRIPTION ADC Analog to Digital Conversion AC Alternate Current APS Air Pressure Sensor ATS Air Temperature Sensor B U D S Bombardier...

Page 12: ... performed to maintain emission lev els within prescribed certification standards The owner operator is not to and should not allow anyone to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory spec ifications EPA Emission Regulations All new 1999 and more recent Sea Doo watercrafts manufactured by Bombardier are certified...

Page 13: ... bolt 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...

Page 14: ...drops 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: ... 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 sides of gasket Allow to dry 1 or 2 minutes 4 Apply GASKET ELIMINATOR 518 P N 293 800 038 on both sides of gasket using a clean ap plicator 5 Place gasket on matin...

Page 16: ...stall according to standard procedure 5 Wipe off surplus 6 Allow it to cure for 30 minutes NOTE Normally used on worn out housings to prevent leaking or sliding It is generally not necessary to remove gasket compound applied on outer gasket diameter TIGHTENING TORQUES Tighten fasteners to torque mentioned in explod ed views and text When they are not specified refer to following table The table al...

Page 17: ... 72 53 73 54 74 55 75 55 76 56 77 57 78 58 79 58 80 M12 59 81 60 82 60 N m FASTENER SIZE 8 8 Lbf ft N m FASTENER SIZE 8 8 Lbf ft 83 61 84 62 85 63 86 63 87 64 88 65 89 66 90 66 91 67 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 73 100 74 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 109 80 110 81 111 82 112 83 113 83 114 84 115 85 116 86 117 86 118 87 119 88 120 89 121 89 122 90 123 91 1...

Page 18: ...chnical Publications Bombardier Inc Valcourt Quebec Canada N m FASTENER SIZE 8 8 Lbf ft 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 147 108 148 109 149 110 150 111 www SeaDooManuals net ...

Page 19: ... MANDATORY SERVICE TOOLS 01 02 1 ENGINE 01 02 1 COOLING FUEL OIL SYSTEMS 01 02 5 PROPULSION SYSTEM 01 02 7 STEERING SYSTEM 01 02 9 OPTIONAL SERVICE TOOLS 01 03 1 ENGINE 01 03 1 COOLING FUEL OIL SYSTEMS 01 03 6 PROPULSION SYSTEM 01 03 7 BODY 01 03 8 WATERCRAFT HANDLING 01 03 9 SERVICE PRODUCTS 01 04 1 www SeaDooManuals net ...

Page 20: ... 7 0 8 0 9 0 1 0 0 1 1 0 1 2 0 1 3 0 1 4 0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 2 0 0 2 1 0 2 2 0 2 3 0 2 4 0 2 5 0 2 6 0 2 7 0 2 8 0 2 9 0 3 0 0 3 1 0 320 330 340 350 360 Sleeve set A P N 529 035 542 20 mm sleeve B P N 529 035 543 21 mm sleeve F00B0U4 APPLICATION A 717 and 787 RFI engines B 947 DI engines Air compressor ring compressor P N 529 035 713 F12B0L4 APPLICATION 947 DI engines Carbon dam guide ...

Page 21: ...e 3 P N 290 847 220 F00A0A4 APPLICATION 717 engines Puller is also used for PTO fly wheel on 947 DI engines Pusher P N 420 876 605 A00C0Y4 APPLICATION 717 engines Puller ass y P N 290 876 488 1 Screw P N 290 240 860 2 Hexagonal nut P N 290 242 210 F01B0I4 APPLICATION 717 and 787 RFI engines 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...

Page 22: ... 295 500 352 Pump only P N 529 021 800 F01B2Q5 APPLICATION 717 787 RFI 947 DI engines Supplementary engine leak test kit P N 295 500 780 1a 787 RFI Intake plate P N 296 000 024 1b 947 DI Intake plate P N 296 000 025 2 947 DI Rave plate P N 296 000 026 3 947 DI Exhaust plate P N 296 000 027 APPLICATION 787 RFI and 947 DI engines NOTE This kit is supplementary to P N 295 500 352 Handle P N 420 877 6...

Page 23: ...FI engines B 947 DI engines A B Polygonal wrench P N 529 035 505 F00B0Y4 APPLICATION Exhaust system of the 947 DI en gines Ring gear blocking tool kit A P N 529 035 846 B P N 529 035 946 F15B014 APPLICATION A 787 RFI engines B 947 DI engines Intake plug P N 529 035 708 F12B0O4 APPLICATION 947 DI engines Crankshaft looking tool P N 529 035 821 F18B064 APPLICATION 4 TEC engines NEW Camshaft looking ...

Page 24: ... used for the propulsion system Fuel pressure gauge P N 529 035 591 F02B0B4 APPLICATION 787 RFI and 4 TEC engines Fuel line disconnect tool P N 529 035 714 F12B0G4 APPLICATION 947 DI engines 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 com pressor adapter P N 529 035 712 F...

Page 25: ...OLS 01 02 6 SMR2003 002_01_02A FM Engine oil pressure adapter P N 529 035 652 V00B074 APPLICATION 4 TEC engines Oil seal guide P N 529 035 822 F18B094 APPLICATION 4 TEC engines Coolant pump seal pusher P N 529 035 823 F18B084 APPLICATION 4 TEC engines www SeaDooManuals net ...

Page 26: ...W4 APPLICATION All 2 stroke models Jet pump bearing remover P N 295 000 144 F01J114 APPLICATION All 2 stroke models Bearing seal installer P N 295 000 107 F01J4K4 APPLICATION All 2 stroke models 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 2 stroke models Pliers P N 295 000 054 Caillau F01B1T4 APPLI...

Page 27: ...Drive shaft holder P N 529 035 871 F18B0G4 APPLICATION GTX 4 TEC models Drive shaft floating ring P N 529 035 841 F18B044 APPLICATION GTX 4 TEC models Seal bearing pusher P N 529 035 818 F18B0D4 APPLICATION GTX 4 TEC models Shaft pusher P N 529 035 819 F18B0E4 APPLICATION GTX 4 TEC models Pressure cap P N 529 035 843 F18B054 APPLICATION GTX 4 TEC models www SeaDooManuals net ...

Page 28: ...S AND PRODUCTS Subsection 02 MANDATORY SERVICE TOOLS SMR2003 002_01_02A FM 01 02 9 STEERING SYSTEM O P A S cylinder nut wrench P N 529 035 840 F18B0A4 APPLICATION Models equipped with the O P A S system www SeaDooManuals net ...

Page 29: ...A00B6B4 APPLICATION All models Coil centering tool P N 420 876 922 A01B1V4 APPLICATION 717 engines Cylinder aligning tool P N 420 876 904 A00B084 APPLICATION 717 engines NEW Distance gauge A P N 529 034 800 14 mm 551 in B P N 529 034 900 15 4 mm 606 in C P N 529 035 100 11 5 mm 453 in D P N 529 035 000 7 5 mm 295 in F01B0H4 APPLICATION A 717 engines B 787 RFI engines C 947 DI engines MAG D 947 DI ...

Page 30: ... Bombardier Snap on YA 8230 V02B064 APPLICATION 4 TEC engines Valve stem seal installer P N 529 035 687 V04B0H4 APPLICATION 4 TEC engines Torque angle gauge Not sold by Bombardier Snap on TA362 V04B0I4 APPLICATION 4 TEC engines Leak test kit pump P N 529 021 800 V00B084 APPLICATION 4 TEC engines Oil VAC P N 529 035 880 F18B0B4 APPLICATION 4 TEC engines Stroboscopic timing light P N 529 031 900 A00...

Page 31: ...PLICATION 787 RFI 947 DI engines Crimping tool P N 295 100 164 AMP crimping tool and die for MPEM P N 529 035 905 EMS ECU crimping tool and die Crimping tool F00B0E4 Die P N 529 035 906 individual die for EMS ECU connector A00B6942 APPLICATION Contacts of AMP and EMS ECU plug connectors NEW NEW Crimp pliers P N 529 035 730 A00B6A4 APPLICATION Starter and battery cable terminals Terminal Packard re...

Page 32: ...uller P N 290 877 665 F04B034 APPLICATION 787 RFI engines Exhaust outlet tool P N 295 000 132 F01B2A4 APPLICATION All models Feeler gauge 45 Not sold by Bombardier Snap on FB 300 A F01B1K4 APPLICATION 717 and 787 RFI engines Steering cable tool P N 295 000 145 F01B2P4 APPLICATION All models Rubber pad P N 295 000 101 F01B0J4 APPLICATION 717 and 787 RFI engines Rubber pad P N 290 877 032 F06B064 AP...

Page 33: ...76 557 P N 290 877 414 947 DI engines 3 Ring both ends P N 420 977 490 P N 420 977 480 947 DI engines 4 Ring halves PTO P N 420 977 475 2 P N 420 876 330 947 DI engines 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 Screw M8 x 70 P N 420 841 201 2 9 Puller bolt P N 420 940 755 APPLICATION All 2 stroke engines MAG side PTO side 8 1 5 2 3 ...

Page 34: ...1I4 APPLICATION All models Hose pincher P N 529 032 500 F01B234 APPLICATION All models Hose pincher P N 295 000 076 A01B2I4 APPLICATION All models 35 4 3 25 2 15 1 5 60 50 4 0 30 2 0 10 Flexible spout oil P N 414 837 300 F04B044 APPLICATION All models Flushing adapter P N 295 500 473 F00B104 APPLICATION All models Use with coupler hose P N 295 500 258 Test radiator cap P N 529 021 400 F18E1P4 APPL...

Page 35: ...P N 295 000 086 F01B0Z4 APPLICATION All models Slide hammer puller Not sold by Bombardier Snap on Handle CJ93 1 Hammer CJ125 6 Claws CJ93 4 F01J0Z4 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 www SeaDooManuals net ...

Page 36: ...OOLS 01 03 8 SMR2003 002_01_03A FM BODY Spring compressor P N 529 035 504 A01B4O4 APPLICATION XP DI models Suspension adjustment wrench P N 529 012 200 A25A014 APPLICATION XP DI models Suction cup P N 295 000 163 F00B1Y4 APPLICATION 4 TEC models NEW www SeaDooManuals net ...

Page 37: ...ls P N 295 000 126 F01B014 Beach wheels set of 2 wheels P N 295 000 005 F01B074 APPLICATION Dolly Tie down 1 50 m 5 ft long P N 295 100 103 F00B014 APPLICATION All models Lift kit A P N 295 100 206 B P N 295 100 205 C P N 295 100 204 F00B1Z4 APPLICATION A 2 stroke models except LRV DI B 4 TEC models B LRV DI models NEW www SeaDooManuals net ...

Page 38: ...lue 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 eliminato...

Page 39: ...000 A00B3W4 NEW 111 Primer for gasket eliminator P N 293 800 041 Loctite 764 A00B3N4 Pipe sealant A P N 293 800 018 B P N 293 800 013 A Loctite 592 50 mL B Loctite 567 250 mL A00B2W4 Hylomar sealant P N 293 800 001 PL 32 100 g A00B3F4 Sealant P N 293 530 011 Sikaflex 221 black 350 mL F01B1D4 Dielectric grease P N 293 550 004 Dow Corning 150 g A00B1X4 High temperature RTV sealant P N 293 800 090 Ul...

Page 40: ...0 V00B0I4 Anti seize lubricant P N 293 800 070 Loctite 76764 454 g 16 oz A00B594 Grease Isoflex P N 293 550 021 50 g A00B554 BOMBARDIER LUBE P N 293 600 016 12 x 14 oz A00B624 BOMBARDIER storage oil P N 413 711 600 CDN P N 413 711 900 U S 12 x 350 g A00B634 Sea Doo fuel stabilizer P N 413 408 600 236 mL 8 oz A00B604 732 Multi purpose sealant P N 293 800 033 Dow Corning 90 mL clear F01B1C4 NEW www ...

Page 41: ...ter A00B5T4 P N 293 600 046 3 x 4 liter A00B5U4 P N 293 600 247 205 liter Sealant adhesive P N 293 800 086 Loctite 5150 29647 A00B5S4 Instant gasket P N 293 800 088 7 oz A02B0C4 Jet pump oil P N 293 600 011 Sea Doo synthetic jet pump oil 12 x 6 oz F01B0P4 Jet pump bearing grease P N 293 550 032 110g F18B0H4 Sea Doo Cleaner P N 293 110 001 400 g P N 293 110 002 4 L F01B2J4 Pulley flange cleaner P N...

Page 42: ... ENGINE 02 04 1 GENERAL 02 04 1 PROCEDURE 02 04 1 STORAGE 02 05 1 ENGINE DRAINING 02 05 1 PROPULSION SYSTEM 02 05 3 FUEL SYSTEM 02 05 3 ENGINE OIL CHANGE AND FILTER 02 05 4 COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION 02 05 4 ENGINE LUBRICATION 02 05 4 BATTERY 02 05 5 WATERCRAFT CLEANING 02 05 5 ADDITIONAL RECOMMENDED PROTECTION 02 05 5 ANTICORROSION TREATMENT 02 05 14 CHECKLIST 02 05 1...

Page 43: ...uipped C C Top end leak test piston and ring clearance DI models only Counterbalance shaft oil level if so equipped I I Spark plug I R Ignition timing all models except DI I TDC setting DI models only COOLING SYSTEM Flushing C Hose and fasteners I I Engine drain tubes I Water flow regulator valve if so equipped I FUEL SYSTEM Carburetor including choke throttle cable carburetor equipped models I I ...

Page 44: ...DI models etc I I MPEM mounting brackets fasteners I Digitally Encoded Security System I I Monitoring beeper I I Battery and strap s fasteners I I STEERING SYSTEM Steering cable I I O P A S SYSTEM O P A S system I I PROPULSION SYSTEM Drive shaft boot and splines if so equipped I Drive shaft protection hose I PTO flywheel L L Shifter system cable I I VTS Variable Trim System if so equipped I I Jet ...

Page 45: ...ystem C Hose and fasteners I I Coolant Coolant expansion tank cap cooling system pressure test FUEL SYSTEM Throttle cable I Fuel injection system sensors I I Throttle body Fault code reading I Fuel vent line pressure relief valve I Fuel lines connections and fuel system pressurization I I Throttle body sensors fuel lines fuel rail and fittings I I Air intake silencer fit tightness I I Fuel tank st...

Page 46: ...5 hours when riding in weed areas Every 200 hours of use not every 2 years PROPULSION SYSTEM Drive shaft protection boot I Grease splines in jet pump L Shifter system cable I I Impeller shaft seal sleeve and O ring Impeller and impeller wear ring clearance I Water intake grate I Ride plate including coolant leak I I Drive shaft hull sealing system I I HULL BODY Bailer pick ups check for obstructio...

Page 47: ...tem Never flush a hot engine Make sure engine operates during 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...

Page 48: ...s 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 inject BOMBARDIER LUBE lubricant or equivalent Push tube in when finished All Models except 4 TEC Models Close the water tap then stop the engine CAUTION Always close the water tap before stopping the engine Discon...

Page 49: ...stall them Reinstall plug on air intake silencer cover if so equipped on 717 and 787 RFI engines NOTE Engine fogging should be done with BOMBARDIER LUBE lubricant whenever the water craft is to be stored for a few days or a long period CAUTION Never leave rags or tools in the en gine compartment or in the bilge 4 TEC Engines Closed Loop Cooling System 4 TEC engines are equipped with a closed loop ...

Page 50: ...ent This flushing connector allows flushing while wa tercraft is on a lift or if you prefer to flush from this location Either flushing connector can be used to flush the exhaust cooling system The one at the jet pump support see above or the one in the en gine compartment see below Remove seat to gain access 1 Flushing connector 2 Dust cap Remove dust cap from flushing connector and at tach coupl...

Page 51: ...t 20 seconds at a fast idle between 4000 5000 RPM CAUTION Never run engine without supplying water to the exhaust cooling system when wa tercraft is out of water Ensure water flows out of jet pump while flushing CAUTION Never run engine longer than 5 min utes Drive line seal has no cooling when water craft is out of water Close the water tap then stop the engine CAUTION Always close the water tap ...

Page 52: ... Grounding device Remove spark plugs and dry them with a clean cloth A contact cleaner spray can be used It may be preferable to replace spark plugs Do NOT in stall spark plugs on engine yet Cover spark plug holes with a rag Carburetor Equipped Models Fully depress the throttle lever then crank the en gine to drain crankcase NOTE Ensure choke lever is completely pushed in 787 RFI Models NOTE Proce...

Page 53: ...ompletely 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 bodies All Models except 4 TEC Spray BOMBARDIER LUBE lubricant P N 293 600 016 into spark plug holes Crank engine again Reinstall spark plugs and spark plug cables 787 RFI Engines Remove the filler plug of the counterbalance shaft on the engine crankcase 787 RFI...

Page 54: ...ile engine is running All Models except 947 DI and 4 TEC Models 717 AND 787 RFI ENGINES 1 Air intake silencer 2 Pull plug 3 Spray BOMBARDIER LUBE here 947 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 inject BOMBARDIER LUBE lubricant or equivalent Push...

Page 55: ...r remove the mufflers to drain them or siphon the water out of them Refer to subsection EXHAUST SYSTEM If water gets in the oil oil will be milky change the engine oil and filter as follows Oil Change Procedure water contaminated oil 1 Using the oil VAC P N529 035 880 siphon oil from reservoir through dipstick hole CAUTION Never crank or start engine when si phon tube is in dipstick hole Never sta...

Page 56: ... coolant inlet hose 3 Continue to run the engine at 3500 RPM for 15 more minutes 20 minutes total run time 4 Shut the engine off 5 Remove the hose pincher on the coolant line going to the oil cooler CAUTION Hose pincher must be removed pri or to operating the watercraft Failure to do this will result in damage to the engine 6 Change the oil and filter again 7 Procedure is now completed Procedure C...

Page 57: ...and filter again 9 Move rearward the Ring Seal Carrier and rein stall the C Clip Refer to DRIVE SYSTEM sec tion Water in Supercharger Supercharged 4 TEC Engines If there was water in Tthe oil and presence of wa ter is suspected in the shaft and bearing area of the supercharger it is recommended to take the supercharger apart dry all the components includ ing the slip clutch and replace both ball b...

Page 58: ... water freeze in engine severe damage will occur Check engine drain hose for obstructions TYPICAL 1 Engine drain hose RFI Models Disconnect the water supply hose used to cool the magneto It features a quick connect fitting Press both tabs and pull fitting in order to disconnect hose This hose is located at the bottom of the magneto cover beside the engine support TYPICAL 1 Press tabs here and disc...

Page 59: ...e severe damage will occur Reconnect hose when done DI Models Disconnect the quick connect fitting Press both tabs and pull fitting RX DI MODELS DISCONNECT THIS HOSE GTX DI MODELS DISCONNECT THIS HOSE XP DI MODELS DISCONNECT THIS HOSE 1 Disconnect engine drain hose crankcase cooling outlet 2 Air compressor drain line F07E0HA F18E02A F08E0FA 1 2 www SeaDooManuals net ...

Page 60: ...o 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 SEAL CARRIER XP DI Models Lubricate seal carrier of drive shaft support with synthetic grease Stop lubricating when grease is just coming out of seal 1 Grease seal carrier FUEL SYSTEM All Models...

Page 61: ... rings condition before rein stalling fuel injectors Replace O rings with new ones if damaged Lubricate O rings with injec tion oil prior to installing Reinstall the injectors Apply Loctite 243 and torque the two bolts to 10 N m 89 lbf in that hold the fuel rail on Make sure there is no leak at injectors when cranking the engine in the upcoming steps Pull engine cover upward to remove it Disconnec...

Page 62: ...e available Replace damaged labels decals Wash the body with soap and water solution only use mild detergent Rinse thoroughly with fresh water Remove marine organisms from the hull Apply a nonabrasive wax CAUTION Never clean fiberglass and plastic parts with strong detergent degreasing agent paint thinner acetone etc If the watercraft is to be stored outside cover it with an opaque tarpaulin to pr...

Page 63: ... GTI AND GTI LE MODELS 717 ENGINES 1 Engine drain hose RFI MODELS 787 ENGINES 1 Hose pincher installed on engine drain hose NOTE On RFI models make sure the hose is properly connected to the magneto cover 1 Fitting properly connected Install hose pincher on injection hose going to tuned pipe GTI AND GTI LE MODELS 717 ENGINES 1 Hose pincher on injection hose going to tuned pipe 1 F17E05A F15E01A 1 ...

Page 64: ...hort piece of hose to engine water inlet at cylinder head All 2 Stroke Models except DI Insert a funnel into hose and pour antifreeze mixed with water 40 water 60 antifreeze in engine until the colored solution appears at the cooling sys tem bleed outlet 787 RFI Engines Disconnect hose just above T fitting as shown 1 Hose connecting to cylinder head inlet fitting 2 Disconnect hose above T fitting ...

Page 65: ...ncher if applicable All 2 Stroke Models except DI Remove temporary hose on 717 engines and re connect engine water outlet hose Remove hose pinchers All DI Models except XP DI Hose Pinchers Installation Some hoses have to be plugged to prevent drain ing before filling cooling system jackets with the antifreeze Install hose pinchers at the following location RX DI MODELS 1 Water outlet hose GTX DI M...

Page 66: ...GTX DI MODELS 1 Crankcase cooling cover outlet hose RX DI GTX DI AND LRV DI MODELS 1 Engine cylinder drain hose Hose Disconnection Disconnect water INLET hose at engine between T fitting and cylinder head fitting RX DI AND LRV DI MODELS 1 Disconnect this side of the T fitting F12E0AA 1 F18E0FA 1 F07E0JA 1 F12E0BA 1 www SeaDooManuals net ...

Page 67: ...to replace the one removed Antifreeze Insert a funnel into the temporary hose and pour antifreeze mix in engine until the colored solution appears at cooling system bleed outlet At this point install a hose pincher on bleed outlet hose RX DI MODELS 1 Bleed outlet hose GTX DI AND LRV DI MODELS 1 Bleed outlet hose F18E0BA 1 F07E0LA F07E0OA 1 F18E0EA 1 www SeaDooManuals net ...

Page 68: ...t of the antifreeze will drain out when removing the hose pinchers Use a container to recover it DIS POSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS NOTE Although antifreeze will mainly drain out the antifreeze has mixed with the water that was possibly trapped in the water jackets and thus pre venting freezing problems At preseason preparation drain the remaining an tifreeze from cooling s...

Page 69: ...y 1 m 3 ft with an internal diameter of 12 7 mm 1 2 in over the previously disconnected hose Antifreeze Insert a funnel into the temporary hose Ensure to hold the funnel approximately 1 m 3 ft above the deck when pouring the antifreeze to cre ate enough pressure so that it flows properly A 1 m 3 ft to ease antifreeze flow Pour antifreeze mix in engine until the colored so lution appears at cooling...

Page 70: ... antifreeze appears at the en gine drain hose crankcase cooling outlet Then install a hose pincher on this hose 1 Engine drain hose crankcase cooling outlet Continue to pour until antifreeze flows in air com pressor water outlet hose XP DI MODELS 1 Air compressor water outlet hose F08E0MA 1 F08E0JA 1 F08E0EA 1 www SeaDooManuals net ...

Page 71: ...oper antifreeze mixture might allow freezing of the liquid in the cooling system if vehicle is stored in area where freezing point is reached This would seriously damage the en gine Failure to replace the antifreeze for storage may allow its degradation that could result in poor cooling when engine will be used All Models ANTICORROSION TREATMENT Wipe off any residual water in the engine compart me...

Page 72: ...y DESS auxil liary module if so equipped on 4 TEC models Refer to ENGINE MANAGEMENT Burnt fuse on MPEM or in electrical box battery starting system Also fuel pump on fuel injection models Check wiring then replace fuse Starting system fuse keeps on burning Check wiring starting system solenoid and MPEM Discharged or disconnected battery Check recharge Defective or disconnected start stop switch Ch...

Page 73: ...ve fuel injection models Release throttle lever Low battery voltage Recharge or replace battery Low or no fuel pressure fuel injection models Check fuel pump operation Check fuel pump pressure output Check air fuel rail Check fuel pump fuse Check wiring harness Fuel injectors not working fuel injection models Check fuel injector operation Replace as necessary Check output signal from MPEM Low or n...

Page 74: ...der trigger wheel fuel injection models Check refer to ENGINE MANAGE MENT Incorrectly aligned flywheel and en coder trigger wheel fuel injection models Properly position flywheel and encoder trigger wheel refer to PTO HOUSING MAGNETO Insufficient engine compression Replace defective part s Idle bypass valve stuck not function ing or frozen 4 TEC models Check refer to ENGINE MANAGEMENT No spark at ...

Page 75: ... remove water Refer to INTAKE SYSTEM in ENGINE MANAGEMENT Water in fuel reservoir or contaminated fuel Flush reservoir and refill with fresh gas Mechanical engine failure Check cylinder compression Check for cylinder head leaks Check starting system Spark plug faulty fouled or worn out Check spark plug condition Low fuel pressure fuel injection models Check fuel pump operation Refer to ENGINE MANA...

Page 76: ...el level carburetor models Check refill Carburetion dirty or out of adjust ment carburetor models Check clean adjust refer to FUEL SYSTEM Low fuel pressure fuel injection models Check pump regulator injectors and hose pinchers or if filter is plugged Replace if necessary Leaking crankshaft seal s or intake manifold carburetor models Pressure check engine to ENGINE Restricted fuel valve carburetor ...

Page 77: ...NE MANAGEMENT Oil injection pump adjustment 2 stroke engines Check adjust refer to LUBRICATION SYSTEM Worn needles and seals carburetor models Check refer to section FUEL SYSTEM Excessive rotary valve clearance if so equipped Check refer to ENGINE Fuel pressure fluctuating fuel injection models Inspect fuel pressure regulators Refer to ENGINE MANAGEMENT High fuel pressure fuel injection models Che...

Page 78: ...to ENGINE Carburetor if so equipped Carburetion too lean Check adjust refer to FUEL SYSTEM Engine Intake or exhaust valve s leak 4 TEC models Pressure check engine refer to ENGINE OTHER OBSERVATION POSSIBLE CAUSE REMEDY Ignition Timing too far advanced Check reset Spark plug heat range too high Check change to correct range Engine exhaust high temperature Engine overheats and exhaust over heats Ch...

Page 79: ...fer to ENGINE Poor fuel quality Siphon then refill with fresh fuel Clogged direct injectors DI models Remove and clean direct injectors Clogged fuel injectors fuel injection models Remove and clean fuel injectors Low fuel pressure fuel injection models Check fuel line and fuel pump pressure Incorrect throttle position sensor TPS adjustment fuel injection models Check and adjust TPS refer to ENGINE...

Page 80: ...ssor Refill fuel tank Engine start but stops after approximately 2 seconds Engine running out of fuel Air in fuel rail RFI and 4 TEC models Check fuel delivery system for proper fuel pressure and delivery Refill fuel tank Low air pressure DI models Check air system compressor air fuel rail etc OTHER OBSERVATION POSSIBLE CAUSE REMEDY RAVE valve does not open if so equipped Check refer to ENGINE and...

Page 81: ... up while watercraft is at speed Clogged filter square rings damaged leakage in hoses or mechanical malfunction Refer to STEERING SYSTEM O P A S side vanes do not go down while engine is at idle Broken spring inside side vane cylinder Refer to STEERING SYSTEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY Coolant level too low 4 TEC models Coolant level low Refill check for leaks Water leaking out of wee...

Page 82: ... CAUSE REMEDY White smoke Coolant leak Check repair Refer to LEAK TEST Damaged cylinder head gasket Check replace cylinder head gasket Water ingestion Inspect intake manifold for water infil ration Blue smoke Valve guide seals Check replace valve guide seals refer to cylinder head and valves PTO oil scavenge port blocked or scavenge pump malfunction Inspect and clean or replace pump at engine star...

Page 83: ...ture without leaking out at weep hole PTO housing The same causes as above apply However look at the following added cause Weep hole plugged Check clean weep hole OTHER OBSERVATION POSSIBLE CAUSE REMEDY Worn chain tensioner Replace Worn chain guide Replace Stretched chain and or worn out sprockets Replace chain and sprockets Sprocket screws got loose Retorque Hydraulic element inside rocker arm s ...

Page 84: ...a EMS ECU 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 if so equipped Check troubleshoot source of leak refill supply refer to PROPULSION SYSTEM Worn anti rattle system if so equipped Check replace pusher in cover refer to PROPULSION SYSTEM Damaged or bent drive shaft Check replace re...

Page 85: ...ON 04 03 6 MAGNETO SYSTEM 04 04 1 DISASSEMBLY 04 04 4 CLEANING 04 04 10 ASSEMBLY 04 04 10 TOP END 04 05 1 GENERAL 04 05 4 DISASSEMBLY 04 05 6 CLEANING 04 05 14 INSPECTION 04 05 14 USED PISTON MEASUREMENT 04 05 15 ASSEMBLY 04 05 18 ADJUSTMENT 04 05 27 BOTTOM END 04 06 1 DISASSEMBLY 04 06 4 CLEANING 04 06 11 INSPECTION 04 06 12 ASSEMBLY 04 06 16 ROTARY VALVE 04 07 1 GENERAL 04 07 2 INSPECTION ON WAT...

Page 86: ...Section 04 ENGINE 2 STROKE Subsection 01 TABLE OF CONTENTS 04 01 2 SMR2003 049_04_01ATOC FM EXHAUST SYSTEM 04 08 1 REMOVAL 04 08 6 TUNED PIPE REPAIR 04 08 11 INSTALLATION 04 08 12 www SeaDooManuals net ...

Page 87: ...t or Supplementary Engine Leak Test Kit are not leak ing by spraying a solution of soapy water on all hoses connections fittings plates etc If there is a leak bubbles will indicate leak location Three areas of the engine will be tested in se quence as per the diagnostic flow chart see the end of this subsection 1 Engine Cooling System 2 Bottom End and Top End 3 Rotary Valve Shaft except DI engine ...

Page 88: ...gine drain hose blocked with a hose pincher 717 ENGINES FRONT VIEW 1 Loop hose and use clamps 2 Use two washers with exhaust manifold stud 3 Hose with adapter and nipple 787 RFI ENGINES REAR VIEW 1 Loop hose and use clamps 2 Hose with clamps Install pump to the end 3 Block engine drain hose with a hose pincher 787 RFI ENGINES FRONT VIEW 1 Exhaust manifold plate F01B2UB 1 F01B2VA 2 3 1 3 2 1 F02E0D...

Page 89: ...ing between the spark plug area and the engine cylinder head cover If none of these components are leaking there is an internal leak and it can be detected with Bottom End and Top End testing Bottom End and Top End Carburetor Equipped Models Remove the carburetor s and gasket s Make sure the surface of the intake manifold 717 en gines or rotary valve cover 787 RFI engines are clean Install the int...

Page 90: ... pincher 3 Exhaust plate 787 RFI ENGINES 1 Intake plates 2 RAVE valve plates 3 Pulse hose blocked with a hose pincher 4 Exhaust plate 947 DI ENGINES 1 Exhaust plate 2 Rave valve plates 3 Intake plates Activate pump and pressurize engine to 34 kPa 5 PSI CAUTION Do not exceed this pressure Wait 3 minutes and check if pressure drops if so verify all testing components If kit components are not leakin...

Page 91: ...VALVE SHAFT testing if so equipped 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 Proceed with the ROTARY VALVE SHAFT testing if so equipped if the crankshaft outer seals are not leaking Rotary Valve Shaft if so equipped NOTE It is mandatory to drain the injectio...

Page 92: ...ve MAG side spark plug If pressure drops it indicates a defective MAG side crankshaft inner seal or crankcase is not sealed correctly If the above mentioned components are not leaking and there is a pressure drops remove the rotary valve cover Check the seal of the rotary valve shaft If the rotary valve shaft is not leaking it could indi cates a defective engine casting Disassemble en gine and car...

Page 93: ...VALVE COVER CHECK SEAL OF ROTARY VALVE SHAFT IS SEAL LEAKING CAREFULLY INSPECT ENGINE CASTINGS PARTICULARLY THE THREADED HOLE AREAS YES YES NO PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING CHECK TESTING KIT REPLACE O RING OF CYLINDER HEAD AND OR CYLINDER BASE GASKET YES YES NO CHECK TESTING KIT IS RESERVOIR LEAKING PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE REPLACE GASKET OR O RING R...

Page 94: ...Section 04 ENGINE 2 STROKE Subsection 02 LEAK TEST 04 02 8 SMR2003 007_04_02A FM 947 DI Engines F00D28T www SeaDooManuals net ...

Page 95: ...t electrical con nections prior to disconnecting fuel lines Disconnect temperature sensor wire and spark plug cables Disconnect magneto wiring harness 717 ENGINES 1 Unplug connector 787 RFI ENGINES 1 Unplug connector 947 DI ENGINES 1 Unplug connector GTI LE RFI Models Disconnect throttle position sensor TPS air pres sure sensor APS and air temperature sensor ATS Disconnect crankshaft position sens...

Page 96: ...o DRIVE SYSTEM Cooling System Disconnect the engine water supply hose Disconnect the engine water return hose NOTE Engine will have to be raised inside bilge to disconnect drain hose before removing from bilge Refer to COOLING SYSTEM for proper water hose location Tuned Pipe To remove tuned pipe refer to EXHAUST SYSTEM Air Intake Silencer To remove air intake silencer refer to AIR INTAKE Carbureto...

Page 97: ...lation to avoid altering engine alignment Remove engine support mount screws 717 ENGINES 1 Remove screw of each engine support TYPICAL 787 RFI AND 947 DI ENGINES FRONT SUPPORT 1 Remove screw TYPICAL 787 RFI AND 947 DI ENGINES REAR SUPPORT 1 Remove screws Lifting Engine 717 Engines Engine can be easily lifted using lifting rings P N 529 035 830 and the engine lift tool P N 529 035 940 LIFTING RING ...

Page 98: ...ting a hook into exhaust manifold eyelet TYPICAL Using a chain block a hoist or other suitable equip ment slightly lift engine to ease the remaining com ponent removal CAUTION Take care not to damage cable or oil injection hoses Remove rear engine support TYPICAL 1 Rear support Removal of Remaining Components Lift up engine slowly until oil injection hoses can be reached All Engines Install a hose...

Page 99: ... ENGINES 1 Rotary valve oil supply line 2 Hose pincher installed 3 Disconnect RED positive cable Disconnect RED positive cable from starter post TYPICAL 1 Disconnect RED positive cable 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 scratc...

Page 100: ...emoved apply Loctite 243 blue on screw threads Torque screws to 25 N m 18 lbf ft CAUTION Strict adherence to this torque is im portant to avoid damaging threads of alumi num insert in bilge Engine Support 717 Engines Torque front and rear engine supports as shown in the following illustration 1 Torque screws to 22 N m 16 lbf ft 2 Torque nuts to 39 N m 29 lbf ft 787 RFI Engines Apply Loctite 243 bl...

Page 101: ...rter cable to 6 N m 53 lbf in Apply dielectric grease on nut Engine Jet Pump Alignment Alignment is necessary to eliminate possible vi bration and or damage to components Check alignment of engine using the following alignment tools Support plate kit P N 529 035 506 NOTE Use plate P N 529 035 508 for the 139 5 mm 5 1 2 in jet pump and plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plat...

Page 102: ...n 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 on the 947 DI engines and 3 mm 0 12 in on the 717 and 787 engines XP DI Models Use plate P N 529 035 507 1 Plate 2 Support alignment shaft P N 295 000 141 1 Alignment shaft PTO flywheel adapter P N 529 035 590 1 Adapter ...

Page 103: ...ts and rubber mounts to correct alignment TYPICAL 1 Shim CAUTION Whenever shims are used to correct alignment neverinstallmorethan1 3 mm 0 051 in shim thickness Remove alignment shaft Ensure the alignment washers of mid bearing are still loose Reinstall drive shaft Refer to DRIVE SYSTEM Ensure grease fitting of seal carrfier is located on the top Apply Loctite 243 blue on studs and install nuts no...

Page 104: ...te cable with BOMBARDIER LUBE lubricant After its installation properly adjust and bleed oil in jection pump as specified in OIL INJECTION PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT DI models 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 wate...

Page 105: ... 44 lbf in 9 N m 80 lbf in 16 Loctite 243 4 6 7 Loctite 243 6 N m 53 lbf in 23 6 N m 53 lbf in 22 Loctite 243 3 6 N m 53 lbf in 15 Loctite 243 14 13 150 N m 110 lbf ft Loctite 648 25 1 12 11 10 N m 88 lbf in Anti seize lubricant 10 N m 88 lbf in 11 Anti seize lubricant 10 N m 88 lbf in 11 2 6 N m 23 lbf in 2 F02D12S www SeaDooManuals net ...

Page 106: ...m 80 lbf in 8 17 10 N m 88 lbf in 13 120 N m 89 lbf ft Loctite 243 Loctite 243 14 3 4 N m 35 lbf in 27 9 N m 80 lbf in 9 Dielectric grease 25 1 Molykote 111 11 Ground cable Dielectric grease Anti seize lubricant 6 N m 53 lbf in Anti seize lubricant 26 Anti seize lubricant 4 N m 35 lbf in 20 9 N m 80 lbf in Anti seize lubricant 11 9 N m 80 lbf in Dielectric grease Loctite 243 Anti seize lubricant w...

Page 107: ... 3 947 DI Engines F18D2SS Molykote 111 9 N m 80 lbf in Loctite 243 Molykote 111 Loctite 243 13 N m 115 lbf in 9 N m 80 lbf in 5 N m 44 lbf in Loctite 243 Loctite 243 Loctite 243 115 N m 85 lbf ft 3 8 14 21 20 16 29 9 25 1 11 13 17 13 N m 115 lbf in Loctite 648 30 www SeaDooManuals net ...

Page 108: ...leeves on screws then secure puller plate on magneto flywheel so that sleeves are against ring gear no 3 Install extension handle on end of puller plate TYPICAL 1 Sleeves on opposite side Using a suitable socket unscrew retaining nut no 13 COUNTERCLOCKWISE when facing it NOTE If socket is found too large to be inserted in puller plate machine or grind its outside diameter as necessary TYPICAL 1 Ex...

Page 109: ...es old and new to position armature plate Proceed as follows Before removing the armature plate find a crank case locating lug the top one in this example Place a cold chisel at the end of chosen lug then punch a mark on armature plate at this point 1 Crankcase locating lug 2 Mark armature plate at the end of lug At assembly align armature plate mark previ ously punched with the end of the corresp...

Page 110: ...dlocker bond 1 Heat the armature plate CAUTION Protect harness from flame Remove screws Uncrimp and unsolder YELLOW and YELLOW BLACK wires from coil Uncrimp and unsolder ground wire BLACK from coil core 1 Uncrimp and unsolder ground wire BLACK 2 Uncrimp and unsolder YELLOW and YELLOW BLACK wires 787 RFI Engines Magneto Housing Cover Disconnect water hoses from heat exchanger cover Loosen screws no...

Page 111: ...r procedure refer to BOTTOM END Lock ring gear using special tool P N 529 035 846 SPECIAL TOOL P N 529 035 846 1 Special tool P N 529 035 846 Remove crankshaft position sensor no 18 before removing the ring gear Alternatively you can lock ring gear using special tool assembly P N 295 000 155 1 Ring gear blocking tool P N 295 000 134 2 Retaining plate P N 295 000 154 1 Ring gear blocking tool with ...

Page 112: ...nd fully thread puller in magneto rotor TYPICAL 1 Puller Tighten puller screw and at the same time tap on screw head using a hammer to release magneto rotor from its taper Magneto Housing To remove magneto housing no 5 starter has to be removed Refer to STARTING SYSTEM Unscrew retaining screws no 19 then withdraw housing REMOVE SCREWS 1 Magneto housing Stator Assembly 787 RFI Engines Remove holdin...

Page 113: ...cessary the magneto rotor can be removed without removing the ring gear and trigger wheel Re move the six screws no 17 TYPICAL 1 Screw To remove the ring gear rotor assembly unscrew nut no 13 counterclockwise when facing it TYPICAL 1 Nut The magneto rotor 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 magneto...

Page 114: ...ls and magnets using only a clean cloth Clean crankshaft taper and threads using acetone Apply the acetone on a rag first then clean the crank shaft ASSEMBLY 717 Engines Generating Coil Strip end of old wire then crimp and solder on new coil Apply Loctite 243 blue to screws no 22 and in stall the new coil on armature plate Use magneto coil centering tool P N 420 876 922 and install so that it fits...

Page 115: ...t part using a non oil base solvent 2 Apply coating in light thin coats using a spray gun NOTE Do not spray Gun Kote into magneto fly wheel threaded holes 3 Bake parts in oven at 175 C 350 F for 1 hour to cure Gun Kote CAUTION Do not eliminate Gun Kote heat cur ing time because it will lose all its resistance and it will not give any protection Magneto Housing Install gasket no 24 between magneto ...

Page 116: ...ignition timing procedures of the 717 engine refer to IGNITION SYSTEM Magneto Housing Cover Properlyinstall O ring no 25 in magneto housing Ap ply Loctite 767 anti seize on screws no 11 install cover and wire supportno 12 Torque screws no 11 in a criss cross sequence to 9 N m 80 lbf in 787 RFI Engines Stator Install the stator no 9 in magneto housing cover no 1 and torque screws no 20 to 9 N m 80 ...

Page 117: ...tallation properly install O ring no 25 in engine magneto cover no 1 Apply Loctite 767 anti seize compound on screws no 11 Torque screws in a criss cross sequence to 9 N m 80 lbf in 947 DI Engines Stator and Trigger Coil CPS Crankshaft Position Sensor Install the stator no 9 and trigger no 10 coil in engine magneto cover Torque screws to 9 N m 80 lbf in Reinstall wiring harness bracket no 29 using...

Page 118: ...l 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 wash er and torque to 19 N m 14 lbf ft Cover Before installation properly install O ring no 25 in engine magneto cover no 1 Apply Loctite ...

Page 119: ...04_05A FM 04 05 1 TOP END 0 717 Engines F17D02S 10 11 12 12 14 6 2 13 9 13 5 3 4 3 4 5 6 24 N m 17 lbf ft 24 N m 17 lbf ft 24 N m 17 lbf ft Loctite 243 Loctite 243 Loctite 243 Engine oil Molykote 111 Molykote 111 Molykote 111 Engine oil 8 7 www SeaDooManuals net ...

Page 120: ...s F07D0US 27 N m 17 lbf ft 7 8 3 5 4 5 6 34 rollers Engine oil Loctite 243 Molykote 111 14 1 11 12 12 2 13 Loctite 243 Molykote 111 40 N m 30 lbf ft 9 10 30 Molykote 111 10 N m 89 lbf in 15 16 17 19 18 20 Molykote 111 3 N m 27 lbf in 21 29 27 8 26 25 24 23 22 Molykote 111 www SeaDooManuals net ...

Page 121: ... 05 3 947 DI Engines 40 N m 30 lbf ft 7 8 3 4 5 6 Engine oil Loctite 243 Molykote 111 14 13 Loctite 243 Molykote 111 40 N m 30 lbf ft 9 10 34 2 10 N m 89 lbf in 15 16 17 19 18 3 N m 27 lbf in 26 24 23 22 Molykote 111 20 25 F12D0TS Loctite 243 Engine oil www SeaDooManuals net ...

Page 122: ...top of the RAVE there is a red plastic adjust ment knob Turning the adjustment in or out changes the preload on the return spring which in turn will change the RPM at which the RAVE valve opens and closes On 947 DI engines the spring preload does not have a significant effect on the valve operation 787 RFI Engines On these engines the RAVE valves are controlled by the Multi Purpose Electronic Modu...

Page 123: ...2 Pressure from air compressor 3 Pressure to RAVE valves 4 Vent to air intake silencer 5 Check valve 6 Vent from counterbalancing shaft oil cavity To close the RAVE valves the MPEM deactivates the solenoid which blocks the air compressor pressure The RAVE valves are opened to the atmosphere The vent on couterbalancing shaft oil cavity is nec essary to prevent pressure buildup in the cavity by the ...

Page 124: ...er than recommended quality oil more frequent cleaning may be re quired No special solvents or cleaners are required when cleaning the valve BORING PRECAUTION In its stock configuration the RAVE valve guillotine has a minimum of 0 5 mm 020 in clearance to the cylinder bore measured at the center line of the cyl inder This is the minimum production clearance There is only a first oversize piston av...

Page 125: ...e compression spring no 19 1 Remove spring 787 RFI engines Remove spring no 30 retaining bellows no 21 to valve piston no 20 1 Spring Free bellows no 21 from valve piston no 20 1 Bellows removed from piston WARNING Firmly hold cover to valve base The com pression spring inside the valve is applying pressure against the cover F06D0RA 1 F06D25A 1 F06D0SA 1 F06D0TA 1 www SeaDooManuals net ...

Page 126: ...liding 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 Remove supporting ring no 28 1 Remove supporting ring Remove O ring no 23 1 Remove O ring F06D0TB 2 1 A06D26A 1 F06D27A 1 F06D28A 1 www SeaDooManuals net ...

Page 127: ...ws 947 DI Engines Loosen Allen screws no 26 each side of RAVE valve 1 Remove screws Remove RAVE valve no 15 Remove the cover no 18 of the valve by releasing the spring no 16 1 Spring F06D0UA 1 F06D0VA 1 WARNING Firmly hold cover to valve base The com pression spring inside the valve is applying pressure against the cover 1 F12D0UA 1 1 F12D0VA www SeaDooManuals net ...

Page 128: ...e sensor wire and spark plug cables Connect spark plug cables on grounding device 717 Engines Remove air intake silencer and support refer to AIR INTAKE 717 and 787 RFI Engines Remove screws no 14 Remove cylinder head cover no 1 If shells sand salt or any other particles are present in cylinder head clean with a vacuum cleaner Remove cylinder head no 2 If shells sand salt water or any other partic...

Page 129: ... Even if only 1 cylinder needs repair both cylinders should be lifted to allow 1 piece cylinder base gasket replacement 947 DI Engines Remove cylinders screws then cylinders no 9 Piston NOTE All engines feature cageless piston pin bearings 717 and 787 RFI Engines Bring piston to Top Dead Center and install rubber pad P N 295 000 101 over crankcase opening Secure with screws Lower piston until it s...

Page 130: ...n pin no 4 use piston pin puller P N 529 035 503 with the appropriate set of sleeves 1 Puller 2 Shoulder sleeve 3 Sleeve Fully thread on puller handle Insert extractor spindle into the piston pin Slide the sleeve and shoulder sleeve onto the spindle Screw in extracting nut with the movable ex tracting ring toward spindle 1 Puller 2 Sleeve 3 Shoulder sleeve 4 Extracting nut WARNING Always wear safe...

Page 131: ...tate spindle until the shoulder sleeve is flushed with the piston recess 1 Shoulder sleeve flush with piston recess Loosen the extracting nut and remove puller Remove the shoulder sleeve from piston 1 Remove shoulder sleeve Carefully remove the piston no 3 The needles thrust washers and the sleeve re main in the connecting rod bore and may be used again 1 Needles and thrust washer 2 Sleeve F00B0KA...

Page 132: ... Applicable NOTE Replacement cylinder sleeves are avail able if necessary Also oversize pistons of 0 25 mm 010 in are available for all engines and over size pistons of 0 5 mm 020 in are available for the 717 engine ENGINE MEASUREMENT TOLERANCES NEW PARTS min max WEAR LIMIT Cylinder taper N A 0 05 mm 002 in 0 1 mm 004 in Cylinder out of round N A 0 008 mm 0003 in 0 08 mm 003 in Piston cylinder wal...

Page 133: ...uring perpendicularly 90 to piston pin axis 2 Auxiliary transfer port A 16 mm 5 8 in Cylinder Out of Round Using a cylinder bore gauge measure cylinder di ameter at 16 mm 5 8 in from top of cylinder Mea sure diameter in piston pin axis direction then per pendicularly 90 to it If the difference between readings exceed specification cylinder should be rebored and honed or replaced 1 Measuring in pis...

Page 134: ...ORTANT Make sure used piston is not worn more than specified See USED PISTON MEA SUREMENT above To determine the piston dimension take the mea surement on the piston dome 1 Piston dome 2 Piston measurement Adjust and lock a micrometer to the specified val ue on the piston dome 1 Micrometer set to the piston dimension With the micrometer set to the piston dimension adjust a cylinder bore gauge to t...

Page 135: ...micrometer otherwise the reading will be false Ring Piston Groove Clearance 717 and 787 RFI Engines Using a feeler gauge check clearance between rectangular ring and groove If clearance exceeds specified tolerance replace piston NOTE Ring piston groove clearance can be cor rectly measured only on rectangular ring which is bottom ring 1 Feeler gauge 2 Rectangular ring bottom 947 DI Engines Due to t...

Page 136: ...stment of the combustion chamber volume To identify gasket thickness refer to the identifi cation holes on the gasket TYPICAL 1 Identification holes All Engines RAVE Valve 787 RFI and 947 DI Engines Check RAVE valve bellows no 21 for cracks ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following RAVE Valve 787 RFI Engines Make sure ...

Page 137: ...m of valve housing When the valve is mounted onto the cylinder move the valve piston no 20 to ensure the sliding valve no 22 moves easily and does not stick 947 DI Engines Check the piston valve O ring Replace if neces sary 1 Piston valve O ring Check the sliding valve O ring Replace if neces sary 1 Sliding valve O ring F01D8JB 1 F01D8LA F12D0ZA 1 1 F12D10A www SeaDooManuals net ...

Page 138: ...rankcase 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 conn...

Page 139: ...piston Plastic Mounting Device Method This is an alternate method when no 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...

Page 140: ...y pull halves of inner sleeve with long nose pliers 1 Pulling inner sleeve half Circlip Always use new circlips CAUTION Always use new circlips At installa tion take care not to deform them Circlips must not move freely after installation 717 and 787 RFI Engines Secure circlip with its opening located at the bot tom of the piston CAUTION To minimize the stress on the cir clips it is important to i...

Page 141: ...b the energy to protect the connecting rod Cylinder Base Gasket Install new 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 crankshaft and or crankcase repair or re placement was involved refer to the COMBUS TION CHAMBER VOLUME MEASUREMENT to properly determine the required gasket thi...

Page 142: ...ocating pin Slide cylinder over piston When reassembling cylinders to crankcase it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold 717 Engines The aligning tool P N 420 876 904 or the exhaust manifold can be used to align cylinders 717 ENGINES 1 Exhaust flange aligning tool 717 ENGINES 1 Aligning cylinders using exhaust manifold F01D0ZA 1 ...

Page 143: ...r pistons use ring compressor P N 290 876 965 1 Slide this edge NOTE For each ring make sure to align ring end gap with piston locating pin Install cylinder block Apply Molykote 111 on O ring no 31 and install it CAUTION The O rings must be installed and properly positioned in the cylinder block The O rings are meant to dampen stud vibration Cylinder Screw 717 Engines Apply Molykote 111 below the ...

Page 144: ...ykote 111 below the screw heads Install and torque screws to 40 N m 30 lbf ft in the indicated order Refer to the following illustration All Engines Cylinder Head Install cylinder head gasket 717 and 787 RFI Engines Make sure to install O rings no 12 around spark plug holes and O ring no 11 of cylinder head as shown in the following illustration 1 O rings Apply Loctite 518 in O ring groove of cyli...

Page 145: ... Measurement All Engines NOTE This procedure is required to determine the thickness of the cylinder base gasket to be in stalled if a crank repair has involved replacement of connecting rods or if you are experiencing re petitive engine seizure The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center It is measured with the cylinder head in stalled on th...

Page 146: ...en piston and cylinder The recorded vol ume would be false 5 Let burette stand upward for about 10 minutes until liquid level is stabilized 6 Read the burette scale to obtain the quantity of liquid injected in the combustion chamber Compare the obtained value with the table below The volume should be within the allowable range If the volume of the combustion chamber is not within specifications ch...

Page 147: ...tite 518 11 Molykote 111 4 Anti seize lubricant 12 3 110 N m 81 lbf ft 1 6 5 6 Anti seize lubricant Loctite 642 12 4 Anti seize lubricant Loctite 243 6 6 4 5 Loctite 5910 2 11 7 24 N m 17 lbf ft 10 10 N m 88 lbf in Loctite 518 Loctite 518 8 40 N m 30 lbf ft 4 9 F00D0YU Molykote 111 Molykote 111 Molykote 111 www SeaDooManuals net ...

Page 148: ...ubricant 4 Loctite 243 Loctite 642 Anti seize lubricant Loctite 5910 Loctite 518 40 N m 30 lbf ft Loctite 518 Loctite 518 24 N m 17 lbf ft 30 mL 1 oz SAE 30 motor oil 5 6 12 6 15 16 6 4 6 2 7 11 12 18 11 4 3 4 19 15 14 F07D0VS 9 N m 80 lbf in Anti seize lubricant Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 8 40 N m 30 lbf ft 8 7 24 N m 17 lbf ft Anti seize lubrica...

Page 149: ...e 111 Loctite 518 27 N m 20 lbf ft Loctite 5910 6 5 N m 58 lbf in 9 N m 80 lbf in 7 N m 62 lbf in Anti seize lubricant Anti seize lubricant 1 5 N m 13 lbf in Loctite 243 Molykote 111 115 N m 85 lbf ft 6 5 N m 58 lbf in Engine oil 27 N m 20 lbf ft 40 N m 30 lbf ft 20 N m 15 lbf ft Anti seize lubricant 28 5 4 6 16 15 17 29 30 14 13 2 24 25 9 27 23 3 2 4 4 6 6 5 1 22 20 21 7 8 7 7 31 32 15 13 8 XP DI...

Page 150: ...cial tool in PTO flywheel splines TYPICAL 1 PTO flywheel remover P N 295 000 001 Using a suitable wrench or socket with a breaker bar unscrew PTO flywheel COUNTERCLOCK WISE when facing it and hold extension handle locking the magneto flywheel TYPICAL 1 Extension handle locking crankshaft NOTE When splines of PTO flywheel are worn out and special tool cannot be used proceed with the following alter...

Page 151: ... facing it 947 DI Engines except XP DI Use PTO flywheel remover P N 295 000 001 to hold flywheel and remove Allen screws no 21 re taining coupler no 20 to PTO flywheel PTO FLYWHEEL REMOVER TOOL 1 Loosen Allen screws 2 Breaker bar locking crankshaft Remove the coupler no 20 XP DI Models Remove Allen screws no 21 1 PTO flywheel 2 Coupler 3 Loosen Allen screw Remove coupler no 20 F06I02A 1 F01J0TA F0...

Page 152: ...t with socket and breaker bar Remove the PTO flywheel using puller plate P N 529 035 533 and puller P N 529 035 547 and bolt P N 529 035 549 1 Puller plate 2 Puller 3 Bolt 4 Extension handle Starter Drive Assembly 947 DI Engines Only Loosen 2 Allen screws no 24 retaining starter drive cover no 25 1 Cover 2 Allen screw Remove starter drive cover no 25 and spring no 9 Remove starter drive assembly n...

Page 153: ...engine on a stand Loosen crankcase screws 717 ENGINES 1 M10 x 73 5 flanged screws 2 M8 x 68 5 flanged screws 3 M8 x 45 socket head screws 787 RFI ENGINES 1 M10 x 73 5 flanged screws 2 M8 x 53 5 flanged screws 947 DI Engines Place engine upright on crankcase magneto side Loosen crankcase screws 947 DI ENGINES 1 M8 x 45 flanged screws 2 M10 x 73 5 flanged screws All Engines Put engine back on a supp...

Page 154: ... P N 420 876 557 3 Distance ring MAG side only P N 420 876 569 4 Ring both sides P N 420 977 490 5 MAG side ring halves P N 420 276 025 6 PTO side ring halves P N 420 977 475 7 Screw M8 x 40 P N 420 840 681 8 Screw M8 x 70 P N 420 841 201 NOTE To facilitate ring or distance ring installa tion lubricate their inside diameters 787 RFI Engines To remove end bearings no 4 from crankshaft use the follo...

Page 155: ...es P N 420 876 330 6 Screw P N 420 841 201 All Engines TYPICAL 1 Removing crankshaft bearing Or use a bearing extractor such as Proto no 4332 and a press to remove two bearings at a time ex cept on PTO side for the 787 RFI engines 1 Press bearings out 2 Bearing extractor Crankshaft Gear 787 RFI Engines The crankshaft gear no 18 and bearing no 5 can be removed in one step using the following puller...

Page 156: ... no 15 on counterbalance shaft no 13 can be removed by using the following tools 1 Puller P N 420 877 635 2 Protective cap P N 420 876 557 3 Ring P N 420 977 480 4 Ring halves P N 420 876 330 5 Screw M8 x 40 P N 420 840 681 1 Tool installed To remove gear no 14 first trace an index mark on the gear and counterbalance shaft NOTE There is no Woodruff key to position the gear on the counterbalance sh...

Page 157: ... Remove bearing no 31 and washer no 32 Use a press to remove gear no 14 CLEANING All Models Discard all oil seals gaskets O rings and sealing rings Clean oil passages and make sure they are not clogged Clean all metal components in a solvent Crankcase mating surfaces are best cleaned using a combination of the chisel gasket remover P N 413 708 500 and a brass brush Brush a first pass in one direct...

Page 158: ...t it can become misaligned or deflected Crankshaft can be twist ed on center main journal changing timing of one cylinder in relation with the other 1 Main journal alignment here To accurately check if crankshaft is twisted on cen ter main journal proceed as follows Remove magneto housing cover Remove flywheel nut and magneto rotor for the 787 RFI and 947 DI engines Refer to MAGNETO SYSTEM for pro...

Page 159: ...ndicates 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 Bearin...

Page 160: ...ings 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 deflection max 0 050 mm 002 in 0 030 mm 001 in F01D1SA 1 F01D1TA 1 CONNECT...

Page 161: ... that 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 947 DI Engines Only Check ...

Page 162: ...ollowing NOTE It is recommended to spray BOMBARDIER ROTAX injection 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...

Page 163: ...nkshaft Seal All Models When installing seal assembly no 5 apply a light coat of lithium grease on seal lips 787 RFI Engines Position PTO seal against the retaining shim the gap between the seal no 5 and bearing no 4 will ensure proper lubrication of the bearing 1 Seal against the retaining shim 947 DI Engines Seals are positioned with the outer lip in the crank case recess 1 Seal lip in crankcase...

Page 164: ...ith the crankcase If notches are not aligned with the crankcase re move the gear and repeat the procedure until the notches are properly aligned 947 DI Engines Install bearing no 31 and washer no 32 When installing seals no 17 apply a light coat of Molykote 111 on seal lips Prior to installation place bearings no 15 into a container filled with oil previously heated to 75 C 167 F This will expand ...

Page 165: ... bearing no 31 and washer no 32 Ensure to position lubrication hole on top if so equipped 1 Bearing 2 Washer in crankcase groove 3 Lubrication hole on top if so equipped Place seals no 17 in their respective positions 1 Seal in place Air Compressor 947 DI Engines Refer to ENGINE MANAGEMENT for procedures Crankcase All Engines Crankcase halves are factory matched and there fore are not interchangea...

Page 166: ... 800 081 on mating surfaces NOTE The sealant curing time is similar to the Loctite 518 without using the Primer N CAUTION Do not use Loctite 515 or 518 to seal crankcase Do not use Loctite Primer N with the Loctite 5910 Using these products or non silicone based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor adhesion and possibly a leaking crankcase These products a...

Page 167: ...d Molykote 111 below head screws Torque crankcase screws to 24 N m 17 lbf ft as per following illustrated sequence Torque 2 M10 crankcase screwsto 40 N m 30 lbf ft 1 Torque to 40 N m 30 lbf ft 787 RFI Engines Apply Loctite 518 on screw threads and Molykote 111 below head screws Torque crankcase screws to 12 N m 106 lbf in as per following sequence Repeat procedure re tightening all screws to 24 N ...

Page 168: ...equence Oil Fittings 717 and 787 RFI Engines If inlet and outlet oil fittings no 11 of rotary valve shaft have been removed from crankcase rein stall them with their end pointing toward ignition housing Apply Loctite 518 on threads of fittings Stud 717 Engines At assembly in crankcase apply Loctite 518 on threadsof studs no 10 Torque to 10 N m 89 lbf in Starter Drive Bearing 947 DI Engines To inst...

Page 169: ...te 243 blue to Allen screws no 21 of coupler and torque to 23 N m 17 lbf ft Final Assembly 717 and 787 RFI Engines For rotary valve timing and assembly procedures refer to ROTARY VALVE 787 RFI Engines When engine assembly is completed add 30 mL 1 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 947 DI Engines Add 40 mL...

Page 170: ...2_04_07A FM 04 07 1 ROTARY VALVE 0 717 and 787 RFI Engines F00D26T 8 2 20 N m 15 lbf ft Molykote 111 7 10 6 9 5 11 3 4 14 15 717 engines 13 12 1 20 N m 15 lbf ft 9 N m 80 lbf in 2 1 12 787 RFI engines Anti seize lubricant Engine oil Loctite 243 www SeaDooManuals net ...

Page 171: ...hod the soldering wire method 45 FEELER GAUGE METHOD Remove O ring no 12 from rotary valve cover no 1 Remove intake manifold from rotary valve cover except 787 RFI engines Reinstall cover no 1 in place WITHOUT its O ring and torque screws to 20 N m 15 lbf ft Insert feeler gauge blade through cover inlet ports to verify clearance At least verify clearance at two different places in each port Feeler...

Page 172: ...ng must remain as per original setting NOTE If rotary valve crankcase surface is worn it is possible to have it reworked at the factory Contact your dealer or distributor Rotary Valve Shaft Gear Backlash Remove PTO flywheel guard Remove spark plugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this way to complete one r...

Page 173: ...s spring and remove circlips no 5 1 Compress seat 2 Remove circlips Shaft Bearing To remove bearing no 8 use a bearing extractor such as Snap on no CJ 950 or equivalent as illus trated Slide off distance sleeve no 14 remove snap ring no 7 and washer no 15 then press shaft out 1 Bearing 2 Bearing extractor Snap on CJ 950 CAUTION Ensure that rotary valve shaft is per fectly perpendicular with press ...

Page 174: ...e no 14 INSPECTION Rotary Valve Cover Inspect rotary valve cover no 1 for warpage Small deformation can be corrected by surfacing with fine sand paper on a surface plate Surface part against oiled sand paper Bearings Inspect bearings no 8 and no 9 Check for scor ing pitting chipping or other evidence of wear Make sure plastic cage on bigger bearing is not melted Rotate them and make sure they turn...

Page 175: ...s seat Seal Apply Molykote 111 on seal lips Position seal no 11 with shielded portion against shaft splines Bearing Install ball bearing as illustrated 1 Seal 2 Ball bearing 3 Bearing extractor Snap on CJ 950 Install washer no 15 snap ring no 7 and slide dis tance sleeve no 14 on shaft 1 Seal 2 Ball bearing 3 Snap ring 4 Distance sleeve 5 Washer 0 5 mm 020 in 6 Rotary valve shaft Rotary Valve Shaf...

Page 176: ... pusher P N 290 876 609 and handle P N 420 877 650 1 Pusher 2 Handle Push shaft until it stops on bearing seat 717 and 787 RFI Engines Snap Ring Position snap ring no 4 so that its sharp edge faces outwards Rotary Valve The rotary valve no 13 controls the opening and closing of the inlet ports Therefore its efficiency will depend on the precision of its installation IDENTIFICATION OF THE ROTARY VA...

Page 177: ...TARY VALVE 04 07 8 SMR2003 012_04_07A FM There is no identification code on the valve To find out the duration place an angle finder on the valve and measure the valve cut out angle or use the following template F01D73W 159 www SeaDooManuals net ...

Page 178: ... wheel with BOTTOM of MAG side inlet port Then find 147 line on inner scale of degree wheel and mark crankcase at this point OPENING MARK Step Bottom of MAG inlet port Align 360 line of degree wheel Step Find 147 on inner scale of degree wheel and mark here NOTE Do not rotate the crankshaft ENGINE TIMING OPENING BTDC CLOSING ATDC 717 147 5 65 5 5 787 RFI 147 5 63 5 5 360 350 340 330 320 3 1 0 3 0 ...

Page 179: ...heel and mark here Remove degree wheel Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC NOTE Rotary valve is asymmetrical Therefore try flipping it over then reinstall on splines to obtain best installation position Apply BOMBARDIER injection oil on rotary valve before reassembling rotary valve cover Remove TDC gauge Rotary Valve C...

Page 180: ...013_04_08A FM 04 08 1 EXHAUST SYSTEM 0 717 Engines GTI and GTI LE Models F17D04S 24 N m 17 lbf ft 4 N m 35 lbf in 12 Loctite 243 9 18 19 16 14 5 10 25 N m 18 lbf ft 8 19 Loctite 243 6 4 15 Loctite 30542 1 Loctite 29647 11 2 1 3 4 N m 35 lbf in www SeaDooManuals net ...

Page 181: ...E RFI Models F15D0BS Loctite 518 7 9 16 48 N m 35 lbf ft Loctite 243 14 19 18 19 6 3 10 19 18 19 25 N m 18 lbf ft 13 12 4 N m 35 lbf in 1 20 25 N m 18 lbf ft Loctite 243 2 Silicone sealant 5150 40 N m 30 lbf ft Loctite 243 25 N m 18 lbf ft 1 25 Loctite sealant 1 24 1 Loctite sealant 20 www SeaDooManuals net ...

Page 182: ...8 Loctite 243 9 25 N m 18 lbf ft 18 19 40 N m 30 lbf ft 10 4 14 N m 124 lbf in 16 22 21 47 N m 35 lbf ft 25 N m 18 lbf ft 18 19 6 40 N m 30 lbf ft 5 2 3 4 N m 35 lbf in 1 11 Silicone sealant 23 N m 17 lbf ft 1 48 N m 35 lbf ft 20 14 12 13 7 9 48 N m 35 lbf ft 15 Loctite 243 Loctite 82046 Loctite 82046 www SeaDooManuals net ...

Page 183: ... 9 25 N m 18 lbf ft 18 19 40 N m 30 lbf ft 7 9 10 4 14 N m 124 lbf in 16 22 21 47 N m 35 lbf ft Loctite 243 25 N m 18 lbf ft 18 19 Loctite 243 2 4 N m 35 lbf in 11 1 48 N m 35 lbf ft 20 14 12 13 48 N m 35 lbf ft 15 1 3 1 6 5 Loctite 82046 40 N m 30 lbf ft Loctite 82046 Loctite 243 Silicone sealant F16D06S www SeaDooManuals net ...

Page 184: ...N m 35 lbf ft 7 9 14 N m 124 lbf in 4 15 5 Loctite 82046 25 N m 18 lbf ft 19 18 6 40 N m 30 lbf ft 8 9 48 N m 35 lbf ft 16 22 21 14 12 13 25 N m 18 lbf ft 40 N m 30 lbf ft 19 18 20 1 3 2 1 1 11 Silicone sealant 5150 Body Loctite 243 Loctite 30542 Loctite 30542 Loctite 82046 10 4 N m 35 lbf in Loctite 243 www SeaDooManuals net ...

Page 185: ...ICAL 1 Bleed hose removed 2 Injection hose removed 3 Supply hose removed Loosen exhaust hose collar no 1 at tuned pipe outlet Disconnect strap no 2 retaining muffler no 11 Remove exhaust hose no 3 from tuned pipe by pulling muffler Remove clamp no 4 from tuned pipe Remove tuned pipe cone no 5 Remove tuned pipe retaining screw no 6 from ex haust manifold side Remove screws no 12 nut no 8 and flat w...

Page 186: ...e are 2 possible ways to proceed The first procedure separates the tuned pipe head from the tuned pipe cone using the following pro cedure The second procedure removes the tuned pipe without tuned pipe head and tuned pipe cone separation This procedure is explained further Tuned Pipe Removal with Separation from Tuned Pipe Head and Tuned Pipe Cone 1 Disconnect water return hose at tuned pipe head ...

Page 187: ...etaining exhaust hose no 3 to tuned pipe cone no 5 TYPICAL 1 Loosen clamp 6 Loosen and remove clamp no 4 retaining tuned pipe head no 10 to tuned pipe cone no 5 1 Loosen and remove clamp 7 Loosen Allen screw retaining carburetor brack et to tuned pipe head 1 Loosen Allen screw 8 Remove external seal 1 F06E0BA 1 F06D14A 1 F06D1SA 1 F06D3JA www SeaDooManuals net ...

Page 188: ...pening in the manifold to keep debris from entering cylinder during threads cleaning procedure 15 Remove the stud no 21 from Y manifold 16 Use a M10 x 1 5 screw 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 se...

Page 189: ...opening in the manifold to keep de bris from entering cylinder during threads cleaning procedure Remove the stud no 21 from Y manifold Use a M10 x 1 5 screw 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 l...

Page 190: ... exhaust gas temperature sensor Disconnect hoses from muffler no 11 Disconnect hoses of the water flow regulator valve except 717 engines 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 DI and XP DI models remove the VTS motor Refer to VARIABLE TRIM SYSTEM TUNED PIPE REPAIR This procedure is give...

Page 191: ...6 are properly posi tioned prior to finalizing manifold installation 717 Engines Apply Molykote 111 on threads of screws no 12 Install exhaust manifold no 14 and torque screws no 12 to 24 N m 17 lbf ft as per following illus trated sequence 787 RFI Engines Apply Loctite 518 on 2 screws no 12 On the oth er screws no 12 apply Molykote 111 on threads Install screws Refer to the following illustration...

Page 192: ...ecified If the effiency of a locking device is impaired it must be renewed Ensure rubber bushings no 19 and sleeve no 18 are not damaged and are properly installed into tune pipe support s CAUTION Damage to bushings and or sleeve will eventually cause stress to tuned pipe and may cause cracking Make sure that gasket no 16 is properly located on exhaust manifold prior to finalizing pipe instal lati...

Page 193: ...be strictly adhered to Locking de vices ex locking tabs elastic stop nuts self locking fasteners etc must be installed or re placed with new ones where specified If the effiency of a locking device is impaired it must be renewed NOTE Loosen all pipe supports from engine be fore installing tuned pipe Ensure rubber bushings no 19 and sleeve no 18 are not damaged and are properly installed into tune ...

Page 194: ...f ft NOTE Press the pipe support on the engine before torquing the pipe support bolt 25 N m 18 lbf ft 1 N m 9 lbf in 40 N m 30 lbf ft 40 N m 30 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 7 3 9 5 6 N m 53 lbf in 48 N m 35 lbf ft 4 8 2 6 25 N m 18 lbf ft 25 N m 18 lbf ft 13 12 10 11 1 15 14 www SeaDooManuals net ...

Page 195: ...t P N 293 800 090 all around sealing ring no 15 CAUTION Damage to bushings and or sleeve will eventually cause stress to tuned pipe and may cause cracking CAUTION It is very important that the threads are free of debris before installing new self locking fasteners Refer to removal procedure for the proper thread cleaning procedure Clean the Y manifold and tuned pipe surfaces Screw stud no 21 into ...

Page 196: ...in 40 N m 30 lbf ft F07D0ST 14 N m 124 lbf in 25 N m 18 lbf ft 25 N m 18 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 5 15 6 40 N m 30 lbf ft 13 7 3 10 1 2 9 8 6 N m 53 lbf ft 12 14 4 11 www SeaDooManuals net ...

Page 197: ...Section 04 ENGINE 2 STROKE Subsection 08 EXHAUST SYSTEM 04 08 18 SMR2003 013_04_08A FM Install exhaust hose 1 Torque clamp to 4 N m 35 lbf in 1 F06D14A www SeaDooManuals net ...

Page 198: ...03 15 EXHAUST SYSTEM 05 04 1 EXHAUST PIPE 05 04 2 EXHAUST MANIFOLD 05 04 5 MUFFLER LH 05 04 6 MUFFLER RH 05 04 7 EXHAUST OUTLET 05 04 8 REMOVAL AND INSTALLATION 05 05 1 GENERAL 05 05 1 ENGINE REMOVAL 05 05 1 CLEANING 05 05 3 INSTALLATION 05 05 3 PTO HOUSING MAGNETO 05 06 1 GENERAL 05 06 2 PTO HOUSING 05 06 2 PTO SEAL 05 06 5 COUPLING 05 06 5 STATOR 05 06 6 ROTOR AND ENCODER WHEEL 05 06 7 RING GEAR...

Page 199: ...13 OIL COOLER 05 07 15 OIL SEPARATOR 05 07 16 CYLINDER HEAD AND VALVES 05 08 1 GENERAL 05 08 2 SPARK PLUG 05 08 2 VALVE COVER 05 08 2 ROCKER ARM 05 08 3 CAMSHAFT TIMING GEAR 05 08 7 TIMING CHAIN 05 08 8 CYLINDER HEAD 05 08 8 CAMSHAFT 05 08 10 VALVE SPRING 05 08 11 VALVE 05 08 12 ENGINE BLOCK 05 09 1 GENERAL 05 09 3 CRANKSHAFT LOCKING 05 09 3 CRANKSHAFT 05 09 3 TIMING CHAIN 05 09 8 CHAIN TENSIONER ...

Page 200: ...spark plug from cylinder head NOTE Ignition coil may be used as an extractor 1 Ignition coil 2 Spark plug Remove valve cover cowl Unscrew and remove valve cover 1 Valve cover 2 Valve cover screw WARNING Prevent burning yourself due to handling on the hot engine WARNING Safety lanyard must be removed to prevent engine to be cranked while fuel rail is re moved to prevent fuel to be sprayed out Fuel ...

Page 201: ... test on cylinder no 1 rotate the crankshaft counterclockwise to 240 so that the cylinder no 1 is at TDC compression stroke Fol low the instructions mentioned below to check the leakage Rotate crankshaft counterclockwise to 240 so that the cylinder no 2 is at top dead center TDC compression stroke Follow the below given pro cedure to check the leakage The following procedure should be done for eac...

Page 202: ...General Engine Leakage Spray soap water solution at the indicated location and look and or listen for air bubbles Paying attention to the following checkpoints clamp s tightened coolant hoses air oil escaping from crankcase means damaged gasket s and or loosened screws refer to ENGINE BLOCK air water escaping from cylinder head means damaged gasket s and or loosened screws refer to CYLINDER HEAD A...

Page 203: ...03A FM 05 03 1 INTAKE SYSTEM 0 4 TEC Engines TYPICAL R1503motr63S 10 N m 89 lbf in Loctite 243 10 N m 89 lbf in 6 N m 53 lbf in 10 N m 89 lbf in Loctite 243 6 N m 53 lbf in 18 N m 159 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 Oil Loctite 243 www SeaDooManuals net ...

Page 204: ... 015_05_03A FM 4 TEC Supercharged Engines R1503motr221S 30 N m 22 lbf ft 10 N m 88 lbf in Loctite 243 Loctite 5910 30 N m 22 lbf ft Loctite 243 Oil Loctite 243 Anti seize lubricant Loctite 243 30 N m 22 lbf ft Oil Klueber isoflex 30 N m 22 lbf ft www SeaDooManuals net ...

Page 205: ... SYSTEM SMR2003 015_05_03A FM 05 03 3 4 TEC Supercharged Engines R1503motr251A 10 N m 88 lbf in Loctite 243 Oil Loctite 243 6 N m 53 lbf in 18 N m 159 lbf in Loctite 243 6 N m 53 lbf in 10 N m 88 lbf in 10 N m 88 lbf in Oil www SeaDooManuals net ...

Page 206: ... locking tool P N 529 035 839 to prevent camshaft rota tion while checking slipping moment of super charger Refer to CYLINDER HEAD AND VALVES NOTE Rotate supercharger nut to align camshaft holes and to allow insertion of the locking tool 1 Camshaft locking tool Check slipping moment counterclockwise by us ing a torque wrench with actual torque viewer A mirror is useful to see the viewer 1 Torque w...

Page 207: ...rs from shaft Put spring washer package together as it is assa mbled on the supercharger shaft Measure the height of the unloaded spring washer package A Spring washer package height For reassembly of the superchager refer to SU PERCHARGER ASSEMBLY elsewhere in this sec tion Properly reinstall removed parts DRIVEN PLATE JOURNAL DEPTH mm in NEW MINIMUM 9 960 mm 3921 in NEW MAXIMUM 10 000 mm 3937 in...

Page 208: ...r to the following illustration to see it 1 Other lock tab under tube Unlock coolant expansion tank pull out then move away Step Push tab each side to release Step Pull tank out Remove vent tube support NOTE Pay attention not to drop the nuts under support when removing screws 1 Vent tube support 2 Remove retaining screws 3 Pay attention to nuts underneath Remove oil dipstick Pull fuel rail cover ...

Page 209: ...ENGINES 1 Cut locking ties to release harness coming from vehicle 4 TEC NA Normally Aspirated Engines Unplug connectors from ignition coils TOPS valve OSPS TPS idle bypass valve engine connector CTS CAPS KS CPS magneto OPS and EGT 4 TEC NA ENGINES 1 Ignition coils 2 TOPS 3 TPS hidden behind throttle body 4 Idle bypass valve 5 Engine connector 6 KS 7 CPS 8 Magneto 9 B Kostal connector 10 OSPS WARNI...

Page 210: ...the TOPS valve connector refer to the follow ing illustration 1 Push here and hold while pulling connector out 4 TEC NA Engines NOTE The TPS connector is hidden behind the TOPS hose Disconnect hose from TOPS valve then move away to access the TPS connector Slightly pry locking tab of connector to unlock 1 TOPS hose disconnected and moved away 2 TPS connector 3 Slightly pry tab to unlock All 4 TEC ...

Page 211: ...sed to unlock the connector from the sensor 1 Oil filter housing 2 OPS Unplug the B connector from the Engine ECU 1 Push this end to unlock 1 Pull here to release Pull the connectors for KS CPS and magneto out of the ECU support Refer to WIRING DIAGRAMS section Disconnect KS and CPS connectors 1 R1503motr65A 1 R1503motr66A 1 F18D0BA 2 1 R1503motr70A 1 R1503motr71A www SeaDooManuals net ...

Page 212: ...r 2 Unlock throttle cable housing 4 TEC Supercharged Engines Remove inlet hose from throttle body Disconnect throttle cable from throttle body 1 Detach hose 2 Disconnect cable All 4 TEC Engines Remove manifold retaining screws and push the oil dipstick tube out of the manifold slot Lift intake manifold up to pull it out of the mount ing brackets just enough to reach throttle cable end 1 Mounting b...

Page 213: ...s may result in damage of the supercharger Strictly follow the described procedures Remove seat storage basket vent tube and its support Refer to REMOVAL above Refer to EXHAUST SYSTEM section and remove the following components Cross over hose from LH muffler Resonator duct connected on LH muffler Detach exhaust pipe from exhaust manifold but keep exhaust pipe coupled with LH muffler This will eli...

Page 214: ...per screw use the Torx adapter P N 529 035 938 1 Upper retaining screws Mount supercharger ass y on support plate P N 529 035 947 1 Supercharger mounting plate Remove supercharger housing from supercharger ground plate 1 Retaining screws 2 Supercharger housing 3 Supercharger ground plate R1503motr225A 1 F00B20A 1 R1503motr250A F00B27A 1 1 F00B28A 3 2 1 1 1 www SeaDooManuals net ...

Page 215: ...r side while holding shaft with a re taining key P N 529 035 949 1 Cap nut Remove washer supercharger impeller O ring and step collar from supercharger shaft 1 Washer 2 Supercharger impeller 3 O ring 4 Step collar Loosen nut on supercharger shaft engine side while holding shaft with a retaining key P N 529 035 949 1 Nut 2 Retaining key F00B29A 1 R1503motr228A 1 R1503motr229A 2 3 4 2 F00B2BA 1 www ...

Page 216: ... supercharger shaft towards en gine side by using a press 1 Supercharger shaft CAUTION Every time when removing the su percharger shaft both ball bearings have to be replaced Remove ball bearing from supercharger shaft by using a press and retaining key P N 529 035 949 1 Supercharger shaft 2 Ball bearing 3 Retaining key Screw out retaining disc with seal by using the 4 pin socket P N 529 035 948 N...

Page 217: ...upercharger impel ler side Apply enough engine oil on ball bearing Install ball bearing on supercharger shaft by using support plate P N 529 035 947 to hold bearing CAUTION Ensure to position ball bearing against protrusion of support plate for the in stallation This way the installation pressure will be applied to the inner race and will not be transmitted to the bearing balls which would otherwi...

Page 218: ...o the bearing balls which would otherwise shorten the bear ing life Apply heat outside of the housing with a heat gun to expand its diameter prior to inserting the shaft Ensure there is no O ring on the housing prior to heating Apply engine oil on supercharger shaft Press shaft with distance sleeve together in supercharg er ground plate 1 Supercharger shaft 2 Distance sleeve Apply engine oil on se...

Page 219: ...he exact installation direction of the washers 1 Spring washers Complete installation on supercharger shaft en gine side Install spring washers and L Ring and tighten with nut Apply Loctite 243 on cap nut and torque to 30 N m 22 lbf ft cap nut 1 Drive gear 2 Needle pins 3 Lock washer 4 Spring washers 5 L ring 6 Nut Apply Loctite 5910 on supercharger housing seal ing surface For correct procedure r...

Page 220: ...e to install the tool perpendicularly 90 to torque wrench to apply the proper torque to the screw 1 Tool perpendicular 90 to torque wrench A 90 CAUTION Not installing the tool as shown will change the torque applied to the screw Proper torque and tightening sequence are important After complete installation of the supercherger assy the slipping moment has to be rechecked Refer to SLIPPING MOMENT I...

Page 221: ... slot of the man ifold 1 Oil dipstick tube Apply Loctite 243 blue on the intake manifold screws Torque them to 10 N m 88 lbf in follow ing the tightening sequence shown Ensure to properly route and resecure wiring har ness with locking ties Readjust throttle cable and reset the TPS using the VCK Refer to ENGINE MANAGEMENT section WARNING Always check O ring for damage such as defor mation at reins...

Page 222: ...UST SYSTEM SMR2003 016_05_04A FM 05 04 1 EXHAUST SYSTEM 0 9 Loctite 296 11 N m 97 lbf in 8 3 11 2 4 1 5 15 16 6 14 17 15 15 12 7 10 8 N m 71 lbf in 16 N m 142 lbf in 4 N m 35 lbf in 4 N m 35 lbf in Loctite 5150 13 F18D0HT www SeaDooManuals net ...

Page 223: ...ines Disconnect the 3 cooling hoses from exhaust pipe no 1 1 Exhaust pipe 2 Gear clamp 3 Exhaust clamp Loosen the exhaust hose clamp no 5 to the top portion of the hose between muffler LH no 6 and the exhaust pipe no 1 1 Exhaust hose clamp 2 Exhaust pipe WARNING Certain components in the engine compartment maybeveryhot Directcontactmayresultinskin burn Let exhaust system cool down prior to re movi...

Page 224: ...ap 3 Spring installer remover Slowly unscrew exhaust clamp nut no 4 and re move it NOTE Unscrewing the nut too fast generates heat that will make it harder to unscrew 1 Exhaust clamp 2 Exhaust pipe Move muffler LH no 6 backward enough to allow the exhaust pipe to be pulled out Squeezetheexhausthoseno 7goingtotheexhaust outlet with one hand and withdraw the exhaust pipe no 1 from the exhaust manifo...

Page 225: ...e necessary to push the exhaust pipe further down into the hose over its step Notedistanceifpushedoverstep thencuthose by obtained measure Add a second clamp no 5 to the top portion of the hose Thetwoclampsmustbeseparatedby3 5 mm 1 8 3 16 in and the screws must be at least 25 mm 1 in apart 1 Exhaust pipe step 2 Exhaust hose 3 Exhaust hose clamp Pre align the exhaust pipe no 1 by rotating axially a...

Page 226: ...e must be taken not to induce strain in the flexible joint of the exhaust tube Reconnect the water lines to the exhaust pipe and torque to 8 N m 71 lbf in CAUTION Never run engine without supplying water to the exhaust cooling system when water craft is out of water After installation ensure there is no wateror exhaust gas leak when engine is running Test run the engine while supplying water to th...

Page 227: ...ntion to the following NOTE There is no gasket between engine block and exhaust manifold Apply Loctite 518 on threads of screws To help holding the manifold while installing screws first insert the exhaust manifold into the exhaust pipe no 1 then install the upper front screw Continue with the remaining screws Torque screws to 10 N m 88 lbf in as per follow ing illustrated sequence Repeat the proc...

Page 228: ...n ensure there is no coolant or ex haust gas leak when the engine is running Test run the engine while supplying water to the flushing con nector MUFFLER RH Removal Supercharged Models Disconnect plastic resonator from muffler All 4 TEC Engines Loosen both exhaust hose clamps no 15 and discon nect the exhaust hoses no 7 and no 16 from the muffler RH no 10 1 Disconnect inlet and outlet hoses from m...

Page 229: ...n assembly from pump support Refer to PROPULSION SYSTEM From outside of hull unscrew nut no 13 with the exhaust outlet tool P N 295 000 132 TYPICAL 1 Exhaust outlet nut 2 Tool From inside the bilge pull out the exhaust hose no 7 and the adapter no 14 together Detach the adapter no 14 from the exhaust hose no 7 Inspection Inspect parts condition paying attention for cracks or other damage Check hos...

Page 230: ...G section Jet Pump Removal To withdraw jet pump refer to PROPULSION section CAUTION Whenever removing engine from watercraft engine jet pump alignment must be performed at reinstallation Drive System To withdraw drive shaft refer to PROPULSION section Cooling System To remove cooling system hoses refer to COOL ING SYSTEM section Exhaust Pipe To remove exhaust pipe refer to EXHAUST SYS TEM in ENGIN...

Page 231: ... com ponent removal CAUTION Take care not to damage cables TYPICAL 1 Transport brackets Removal of Remaining Components Disconnect RED positive cable from starter post TYPICAL 1 Disconnect RED positive cable Carry on engine lifting to remove from the body opening CAUTION Be careful not to scratch body or to hit any component NOTE An engine stand may be used to hold en gine 1 F18D14A 1 F18D11A 1 1 ...

Page 232: ...ct adherence to this torque is im portant to avoid damaging threads of alumi num insert in bilge Engine Support 1 Torque screws to 25 N m 18 lbf ft Positive Starter Cable Torque nut of positive starter cable to 7 N m 62 lbf in Apply dielectric grease on nut Engine Jet Pump Alignment Alignment is necessary to eliminate possible vi bration and or damage to components Check alignment of engine using ...

Page 233: ...emoved to check engine alignment If the alignment is correct the shaft will slide easily without any deflection in engine align ment adapter TYPICAL 1 Engine alignment adapter 2 Alignment shaft If the alignment is incorrect loosen engine support screws to enable to align engine alignment adapt er with shaft end NOTE Use shim s P N 270 000 024 or P N 270 000 025 as necessary between engine supports...

Page 234: ...e condition and lubricate it with BOMBARDIER LUBE lubricant After its installation properly adjust throttle cable as specified in ENGINE MANAGEMENT Check hose condition and pressure test fuel sys tem refer to FUEL SYSTEM section 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 1 1 1 Loctite 2...

Page 235: ...ctite 243 Multi purpose grease 23 4 TEC Supercharged only Loctite 648 10 3 N m 26 lbf in Left handed thread Oil 4 10 N m 88 lbf in Loctite 243 Oil 5 18 N m 159 lbf in Loctite 243 12 N m 106 lbf in Oil Loctite 243 10 N m 88 lbf in Loctite 5910 21 20 19 13 12 17 9 15 18 14 10 N m 88 lbf in Loctite 243 24 N m 21 lbf ft 7 6 8 Oil Loctite 243 16 Oil 250 N m 184 lbf ft Loctite anti seize 2 www SeaDooMan...

Page 236: ...tarted 1 Remove the scavenge oil pump cover drain plug and install a fitting P N 293 710 037 1 Scavenge oil pump cover drain plug 2 Connect the oil vac tool Bombardier P N 529 035 880 to the fitting 3 The front of the engine must be tilted down ap proximately 15 degrees to facilitate the removal of the oil Raise the rear of the watercraft ac cordingly Siphon the oil from the fitting 4 When done re...

Page 237: ... starter gear disc springs no 6 and washer no 7 do not fall down PTO housing no 5 CAUTION Ensure to use prying lugs to sepa rate PTO housing to prevent damaging contact surface 1 Disc springs 2 Washer 3 Flange washer 4 Starter drive gear gasket no 9 Inspection Check PTO housing for cracks or other damages Replace if necessary Installation NOTE Clean all metal component in a non ferrous metal clean...

Page 238: ...Pay attention that gasket remains properly positioned on this surface Refer to the following illustration for proper installa tion of screws 1 Screws M6 x 35 2 Screws M6 x 85 Tightening sequence for screws on PTO housing is as per following illustration Reinstall LH engine support Apply Loctite 243 blue on screw threads then torque to 24 N m 17 lbf ft Remove block under engine Properly reinstall c...

Page 239: ...h the pul ley flange cleaner P N 413 711 809 to prevent oil stains Remove Oetiker clamp no 11 located close to the PTO housing jet pump refer to JET PUMP in PROPULSION SYSTEM drive shaft refer to DRIVE SYSTEM in PROPUL SION SYSTEM PTO seal no 22 TYPICAL 1 Oetiker clamps 2 PTO seal Installation Reinstall removed parts in the reverse order COUPLING Removal Lock crankshaft with locking tool P N 529 0...

Page 240: ...ith CPS no 15 TYPICAL 1 CPS screws 2 Holding plate 3 CPS screws no 16 stator no 17 TYPICAL 1 Stator screws 2 Stator Inspection Check stator and CPS condition If damaged re place the faulty part For electrical inspection refer to CHARGING SYS TEM for the stator and to ENGINE MANAGEMENT for the CPS Installation For installation reverse the removal procedure However pay attention to the following NOT...

Page 241: ...ing hexagonal screws no 18 retaining rotor Withdraw rotor no 19 with encoder wheel no 20 TYPICAL 1 Hexagonal screws 2 Rotor 3 Encoder wheel Inspection Check rotor bent teeth and encoder wheel condi tion If damaged replace faulty part Installation For installation reverse the removal procedure However pay attention to the following Encoder wheel position has to be located with the location pin on t...

Page 242: ...aw rotor no 19 encoder wheel no 20 and starter ring no 21 TYPICAL 1 Hexagonal screws 2 Rotor 3 Encoder wheel 4 Ring gear Inspection Check ring gear condition especially teeth condi tion If damaged replace faulty part Installation For installation reverse the removal procedure However pay attention to the following Ring gear and encoder wheel position has to be lo cated with the location pin on the...

Page 243: ...on of the teeth shaft etc and if the spragclutch operates well If damaged replace faulty part Installation For installation reverse the removal procedure However pay attention to the following Apply some Isoflex Topas NB52 grease P N 293 550 021 on the starter drive bearing located in the engine block and on the starter drive support in the PTO housing cover 1 Starter drive bearing TYPICAL 1 Start...

Page 244: ... nozzle 2 Spray nozzle remover Remove oil spray nozzle carefully by using a slide hammer puller Installation For installation reverse the removal procedure However pay attention to the following Apply Loctite 648 on oil spray nozzle fitting surface CAUTION The oil spray nozzle must be in ex act position to supply enough oil to the super charger Any other installation will lead to a su percharger d...

Page 245: ... 10 N m 89 lbf in 10 N m 89 lbf in 24 N m 18 lbf ft Engine oil Engine oil Loctite 243 Engine oil Loctite 243 10 N m 89 lbf in 10 N m 89 lbf in 12 N m 106 lbf in Loctite 243 10 N m 89 lbf in 1 2 3 4 19 18 17 16 15 39 23 24 22 21 6 Loctite 243 Loctite 5910 Loctite 243 5 Loctite 243 25 26 25 20 Loctite 243 18 N m 159 lbf in Engine oil 4 TEC Supercharged only R1503motr273S www SeaDooManuals net ...

Page 246: ...m 89 lbf in 18 N m 159 lbf in Loctite 243 10 N m 89 lbf in Loctite 243 10 N m 89 lbf in 11 10 10 N m 89 lbf in 5 25 N m 44 221 lbf in Horizontal to exhaust side 9 Loctite 243 Loctite 243 10 N m 89 lbf in Loctite 243 8 Loctite 243 10 N m 89 lbf in Loctite 243 13 14 Loctite 243 10 N m 89 lbf in 18 N m 159 lbf in R1503motr113S Oil Oil Oil Oil Oil Oil Oil 29 30 7 www SeaDooManuals net ...

Page 247: ...se you will have a false oil level reading 1 Watercraft must be level Check oil level either with watercraft in water or out of water Engine should be warm CAUTION Never run engine without supplying water to the exhaust cooling system when wa tercraft is out of water 2 If out of water raise trailer tongue and block in position when bumper rail is level Link a garden hose to the flushing connector ...

Page 248: ...d oil Remove plug below oil filter housing Use oil pressure gauge P N 529 035 709 and hose adaptor P N 529 035 652 and install where shown Start engine and read pressure at different RPM as per following table 1 Oil filter housing 2 Pressure test plug NOTE Oil pressure switch works between 180 kPa 26 PSI and 220 kPa 32 PSI The engine oil pressure should be within the follow ing values If the engin...

Page 249: ...phon tube at 475 mm 18 7 in from its end Then insert siphon tube until you reach the tape 1 Oil VAC 2 Siphon tube in dipstick hole Pull siphon tube out of dipstick hole then crank engine do not start while in engine drown mode fully depress throttle lever and HOLD then crank engine Crank engine for 10 seconds Siphon oil again Re peat the crank siphon cycle 2 3 times Inspection Oil condition gives ...

Page 250: ...or installation reverse the removal procedure Pay attention to the following details Install a new oil filter Install O ring on oil filter cover TYPICAL Torque oil filter screw to 9 N m 80 lbf in OIL STRAINERS The oil strainers do not need to be cleaned at every oil change Clean them during other inspections especially when the engine is disassembled PTO Oil Strainer Removal Remove engine oil refe...

Page 251: ...1 TOPS ventilation hose Disconnect wiring harness from TOPS valve no 8 and OSPS no 9 Detach air silencer from throttle body Disconnect battery cables and vent tube then re move battery Refer to BATTERY in CHARGING SYSTEM section for proper procedures Remove retaining screws no 10 and no 11 Place rags under cover to prevent spillage If spillage occurs clean immediately with the pul ley flange clean...

Page 252: ...r rings are brittle cracked or hard replace them Clean both contact surfaces of oil strainer cover Check and clean the oil inlet and outlet area for dirt and other contaminations 1 Oil inlet to the oil pump Installation For installation reverse the removal procedure Position screws according to their length as shown 1 Screws M6 x 25 2 Screws M6 x 85 WARNING Always wear eye protector Chemicals can ...

Page 253: ...e piston 3 Compression spring 4 Oil pressure regulator plug Inspection Inspect valve piston and valve piston guide for scor ing or other damages Check compression spring for free length Replace parts if important wear or damage are present Clean bore and threads in the PTO housing from metal shavings and other contaminations Installation For installation reverse the removal procedure Pay attention...

Page 254: ...oil pump rotor no 23 1 Outer oil pump rotor extract the coolant oil pump shaft no 24 from outside PTO housing with a pusher remove rotary seal no 25 with a screwdriver TYPICAL CAUTION Be careful not to damage the surface of the rotary seal bore in PTO housing cover oil seal no 26 1 Oil seal Inspection Inspect oil pump shaft assembly housing and cov er for marks or other damages Check inner rotor f...

Page 255: ...lete oil pump and the PTO housing Using a vernier depth gauge measure side wear as shown 1 PTO housing surface 2 Vernier depth gauge 1 Oil pump outer rotor surface 2 Vernier depth gage Difference between pump housing and outer rotor should not exceed 0 1 mm 004 in If so replace replace the complete oil pump assembly NOTE When the axial clearance of the oil pump shaft assembly increases the oil pre...

Page 256: ... use a press to avoid damaging the ceramic com ponent TYPICAL 1 Rotary seal 2 Rotary seal pusher Install the coolant oil pump shaft using the rotary seal pusher P N 529 035 823 on the opposite side to support the rotary seal Use the oil seal guide P N 529 035 822 with a press 1 Oil seal guide 2 Coolant oil pump shaft 1 Coolant oil pump shaft with oil seal guide 2 Rotary seal pusher Tighten oil pum...

Page 257: ...NG SYSTEM section for proper procedures Remove retaining screws no 42 Place rags under cover to prevent spillage If spillage occurs clean immediately with the pul ley flange cleaner P N 413 711 809 to prevent stains Remove oil suction pump housing with oil sep arator Remove oil pump screws no 27 and cover no 28 1 Oil pump cover Remove oil pump shaft ass y no 29 Remove outer rotor no 30 1 Oil pump ...

Page 258: ...d cover and replace if damaged If clearance between outer rotor and its bore in oil pump exceeds the tolerance replace the com plete oil pump and the PTO housing Using a vernier depth gage measure side wear as shown 1 Oil pump housing surface 2 Vernier depth gage 1 Oil pump outer rotor surface 2 Vernier depth gage Difference between pump housing and outer rotor should not exceed 0 1 mm 004 in If s...

Page 259: ...ews to 10 N m 88 lbf in Tighten suction pump screws as per following se quence and torque to 10 N m 88 lbf in Apply Loctite 243 blue on threads OIL COOLER The oil cooler is located below the air intake man ifold TYPICAL 1 Oil cooler Removal Remove cooling hoses no 34 and no 35 retaining screws no 36 oil cooler no 37 1 Screws 2 Oil cooler 2 1 R1503motr134A 2 R1503motr145A 1 4 5 8 6 7 3 2 1 R1503mot...

Page 260: ...lation hose Disconnect wiring harness from TOPS valve no 8 and OSPS no 9 Detach air silencer from throttle body Disconnect battery cables and vent tube then remove battery Refer to BATTERY in CHARG ING SYSTEM section for proper procedures Remove retaining screws no 42 Place rags under cover to prevent spillage If spillage occurs clean immediately with the pul ley flange cleaner P N 413 711 809 to ...

Page 261: ... surfaces of oil separator Check and clean the oil and blow by channels for dirt and other contaminations Installation For installation reverse the removal procedure Pay attention to the following details 1 Screws M6 x 25 2 Screws M6 x 85 Apply grease on O rings and rubber rings Torque screws to 10 N m 88 lbf in Apply Loctite 243 blue on threads 1 R1503motr119A 2 www SeaDooManuals net ...

Page 262: ...5 lbf ft 120 90 10 N m 88 lbf in Loctite 243 Engine oil 4 5 10 11 10 1 6 8 Loctite 243 10 N m 88 lbf in Engine oil 17 18 19 Loctite 243 10 N m 88 lbf in 26 27 Engine oil 20 Loctite 243 10 N m 88 lbf in 9 18 N m 159 lbf in 24 23 16 2 10 N m 88 lbf in 18 N m 159 lbf in 6 N m 53 lbf in 21 Engine oil 15 13 10 N m 88 lbf in 6 N m 53 lbf in Grease Klueber Isoflex Topas NB52 7 Loctite 243 14 12 25 22 20 ...

Page 263: ...d be the cause and it would be easy to know which one among the springs is the cause to replace it if you grouped them at disassembly Besides since used parts have matched together during the engine operation they will keep their matched fit when you reassemble them together within their group SPARK PLUG Removal Remove fuel rail cover from engine Unplug the single spark ignition coil connector on ...

Page 264: ...er screw accordingly Installation For installation reverse the removal procedure Check valve cover gasket If there is a rubber tab on chain guide side cut it out CAUTION Never assemble the cover on a gas ket having this tab The tab must be cut out 1 Cut this tab NOTE Install the valve cover screws according to following sequence Torque screws to 10 N m 89 lbf in ROCKER ARM Removal Lock crankshaft ...

Page 265: ...nd intake side no 11 1 Rocker arm shaft 2 Rocker arms exhaust side 3 Rocker arm intake side 1 Oil supply from the camshaft to the rocker arm shaft then to the rocker arms and finally to the valve adjustment Inspection Spark Plug Tube Check seals on spark plug tube If seals are brittle cracked or hard replace spark plug tube 1 Spark plug tube 2 Seal to the valve cover 3 Seal to the cylinder head 1 ...

Page 266: ...ress the hydraulic lifter with your thumb If the hydraulic lifter groove disappears inside rocker arm casting replace rocker arm assembly Lifter must turn freely in rocker arm bore Otherwise replace 1 Hydraulic lifter groove Rocker Arm Shaft Check forscoredfrictionsurfaces if so replaceparts Measure rocker arm shaft diameter A Measure rocker arm shaft diameter here Any area worn excessively will r...

Page 267: ...ace 1 Camshaft locking tool Then the camshaft sprocket lines should be lined up as shown in the following illustration 1 Position lines Position the rocker arm shaft with the notches on top 1 Rocker arm shaft 2 Rocker arm shaft notches Install NEW rocker arm shaft screws no 8 Torque as per following procedure CAUTION This assembly uses stretch screws As the screws have been stretched from the prev...

Page 268: ...e no 12 Allen screws no 13 camshaft timing gear no 14 NOTE Secure timing chain no 15 with a retaining wire Inspection Check camshaft timing gear for wear or deteriora tion If gear is worn or damaged replace it as a set camshaft timing gear and timing chain For crankshaft timing gear refer to ENGINE BLOCK section Installation For installation reverse the removal procedure Pay attention to the follo...

Page 269: ...UTION Crankshaft and camshaft must be locked on TDC position to place camshaft tim ing gear and timing chain in the proper posi tion To double check take a look at the timing gear lines They must be parallel to the cylinder head surface 1 Position lines CAUTION Ensure to remove locking tools when finished TIMING CHAIN Refer to ENGINE BLOCK section CYLINDER HEAD Removal Lock crankshaft with cranksh...

Page 270: ... gasket Using a gasket twice will cause engine damage even if the engine had not run Install cylinder screws M11 no 17 Torque screws as per following procedure CAUTION This assembly uses stretch screws As the screws have been stretched from the previous installation it is very important to measure each screw at assembly If screw is out of specification replace by a new Failure to replace screws an...

Page 271: ...ts that are not within specifications 1 2 R1503motr101A A R1503motr102A B C D A C A B C A C A B C A CAMSHAFT LOBE EXHAUST VALVE NEW MINIMUM 31 699 mm 1 248 in NEW MAXIMUM 31 809 mm 1 252 in SERVICE LIMIT 31 670 mm 1 247 in CAMSHAFT LOBE INTAKE VALVE NEW MINIMUM 31 480 mm 1 239 in NEW MAXIMUM 31 590 mm 1 244 in SERVICE LIMIT 31 450 mm 1 238 in CAMSHAFT BEARING JOURNAL NEW MINIMUM 39 892 mm 1 5705 i...

Page 272: ...refer to proper installation proce dure VALVE SPRING Removal Remove rocker arms cylinder head Compress valve springs no 22 and no 23 Use valve spring compressor clamp P N 529 035 724 and valve spring compressor cup P N 529 035 725 1 Valve spring compressor clamp 2 Valve spring compressor cup LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters no 24 WARNING Always wear ...

Page 273: ...ngth Installation For installation reverse the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top NOTE Valve cotters must be properly engaged in valve stem grooves 1 Position of the valve spring VALVE Removal Remove valve spring Push valve stem then pull valves no 26 and no 27 out of valve guides 1 Intake valve 38 mm 2 Exhaust valve 31 m...

Page 274: ...f so replace by a new one Valve Stem and Valve Guide Clearance Measure valve stem and valve guide in three places using a micrometer and a small bore gauge NOTE Clean valve guide to remove carbon depos its before measuring Change valve if valve stem is out of specification or has other damages such as wear or friction sur face A Valve stem diameter R610motr125A VALVE STEM DIAMETER mm in NEW MINIMU...

Page 275: ...guide must be machined away Otherwise it will foul the valve guide hole in the cylinder head and destroy the cylinder head as the valve guide is removed Use a special reamer as far as the top of the notch TYPICAL 1 Special reamer 2 Notch Chase valve guide out of the cylinder head to wards combustion chamber by using a suitable punch TYPICAL 1 Punch VALVE GUIDE DIAMETER mm in NEW MINIMUM Exhaust 5 ...

Page 276: ...3 Jig With a suitable jig press the valve guide into the cold cylinder head as shown TYPICAL A Protrusion NOTE For lubrication of the reamer use only cut ting oil Turn the reamer only forward in cutting direction never backward Clean the reamer at short intervals from swarf moving the reamer only while turning in cutting direction Ream the new valve guide with a reamer 6 mm diameter Clean cylinder...

Page 277: ...t width using a caliper If valve seat contact width is too wide or has dark spots replace the cylinder head A Valve face contact width B Valve seat contact width Valve Seat Grinding NOTE The valve seats may be reground with a valve seat grinder which centers on the valve guide Grind the valve seat at 45 Remove no more material than absolutely necessary to clean the seat up Using a 35 stone narrow ...

Page 278: ...5 and then advancing the valve 45 before repeat ing this operation Installation For installation reverse the removal procedure Pay attention to the following details Install valve stem seal no 28 1 Valve stem seal Apply engine oil on valve stem and install it CAUTION Be careful when valve stem is passed through sealing lips of valve stem seal 1 Sealing lips of valve stem seal To ease installation ...

Page 279: ...ngine oil Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Engine oil Engine oil 24 N m 18 lbf ft 18 N m 159 lbf in 24 N m 18 lbf ft 24 N m 18 lbf ft 10 N m 89 lbf in 24 N m 18 lbf ft 10 N m 89 lbf in 18 N m 159 lbf in 18 N m 159 lbf in 24 N m 18 lbf ft 24 N m 18 lbf ft 21 22 20 18 3 2 1 7 17 16 19 40 N m 30 lbf ft 55 N m 41 lbf ft Grease www SeaDooManuals net ...

Page 280: ...tr02S 8 9 10 8 12 11 13 5 14 15 15 6 4 4 Engine oil 45 N m 33 lbf ft 90 260 N m 191 lbf ft Loctite anti seize Engine oil Engine oil Engine oil Engine oil 6 Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil 23 www SeaDooManuals net ...

Page 281: ...nt tube support air intake manifold refer to AIR INTAKE MANI FOLD REMOVAL in ENGINE section fuel rail cover spark plugs plug screw 1 Plug screw 2 Gasket ring Put a screwdriver or similar tool into the spark plug hole of cylinder no 3 and feel when the piston reaches TDC 1 Screwdriver In this position the crankshaft can be locked by using crankshaft locking tool P N 529 035 821 When finished reinst...

Page 282: ...rews no 3 and no 7 BOTTOM VIEW OF ENGINE 1 Screws bottom engine block half connecting rod screws 1 Connecting rod screws NOTE Before removing the connecting rod bear ing caps mark them to remember the right posi tion when reassembling 1 Mark on connecting rod thrust washers no 4 1 Thrust washer 1 R1503motr05A 1 R1503motr109A 1 R1503motr08A R1503motr07A 1 R1503motr09A 1 www SeaDooManuals net ...

Page 283: ...ace of connecting rod and crankshaft counterweight If the distance exceeds specified tolerance replace the worn part 1 Crankshaft 2 Feeler gauge Crankshaft Radial Play Measure all crankshaft journals Compare to inside diameter of crankshaft bushings elsewhere in this section 1 Micrometer 2 Crankshaft area for bushing 1 R1503motr10A R1503motr11A 1 2 CONNECTING ROD BIG END mm in NEW MINIMUM 0 150 mm...

Page 284: ...aligned 1 Mark on balancer shaft 2 Mark on crankshaft For correct installation of the connecting rods refer to CONNECTING ROD INSTALLATION elsewhere in this section CAUTION It is absolutely necessary to follow this procedure Otherwise severe engine dam age can occur CAUTION Never forget thrust washers no 4 on center of crankshaft to control axial adjust ment CRANKSHAFT JOURNAL DIAMETER mm in NEW M...

Page 285: ... elsewhere in this section for proper procedure to clean surfaces apply Loctite 5910 and proper torquing sequence Install the crankshaft cover before mounting the engine bracket Apply oil on O ring and press cover in Crankshaft cover has to be flush with engine block surface 1 O ring 2 Crankshaft cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to position crankshaft at TDC...

Page 286: ... the re moval procedure but pay attention to the follow ing details Ensure to perform proper valve timing Lock crank shaft and camshaft at TDC refer to CYLINDER HEAD AND VALVES Install chain then install chain tensioner CAUTION Improper valve timing will damage engine components CHAIN TENSIONER Removal NOTE Removal of the air intake manifold allows easier access to the chain tensioner but is not n...

Page 287: ...EMOVAL in PTO HOUSING MAGNETO section starter gear refer to STARTER GEAR REMOV AL in PTO HOUSING MAGNETO section starter drive ass y oil suction pump with oil separator ass y refer to SUCTION PUMP REMOVAL in LUBRICA TION section engine mounting brackets oil reservoir plug screws no 1 with O ring no 2 ENGINE UPSIDE DOWN 1 Oil reservoir plug screw with O ring engine block screws no 3 1 Screws bottom...

Page 288: ...ing Installation For installation reverse the removal procedure Pay attention to following detail CAUTION Balancer shaft and crankshaft marks have to be aligned 1 Mark on balancer shaft 2 Mark on crankshaft CAUTION Never forget thrust washers no 6 on PTO side to control axial adjustment on bal ancer Insert thrust washers as soon as balancer shaft is in place as per following illustration THRUST WA...

Page 289: ... installing the camshaft and rockers refer to CYLINDER HEAD AND VALVES 1 Crankshaft locking tool ENGINE BLOCK Removal Remove engine oil refer to OIL CHANGE in LUBRICATION section engine from vehicle refer to REMOVAL AND INSTALLATION cylinder head refer to CYLINDER HEAD REMOV AL in CYLINDER HEAD AND VALVES section PTO housing refer to PTO HOUSING REMOVAL in PTO HOUSING MAGNETO section starter gear ...

Page 290: ...aft 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 Inspection Cylinder Check cylinder for cracks scoring and wear ridges on the top and bottom of the cylinder If so replace cylinder Cylinder Taper Meas...

Page 291: ... and balancer shaft bushings no 15 both engine block halves with OLD bush ings have to be screwed together as per tighten ing procedure described below Measure the inside diameter of the bushings with a bore gauge ENGINE UPSIDE DOWN 1 Bore gauge ENGINE UPSIDE DOWN 1 Bore gauge Replace bushings if they are out of specifications CYLINDER TAPER IN DIAMETER mm in NEW MAXIMUM 0 038 mm 001 in SERVICE LI...

Page 292: ...sition as they were before Correctly install bushings Top crankshaft bushing halves have a bore which has to be placed in the upper engine block 1 Upper engine block half 2 Oil bore in engine block 3 Oil bore in bushing Bushings have to be flush with the engine block split surface and their protrusions have to fit in the notched areas in the engine block seat 1 Bushing protrusion in engine block n...

Page 293: ...ON Do not use Loctite 515 or 518 to seal crankcase Do not use Loctite Primer N with the Loctite 5910 Using these products or non sili cone based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor ad hesion and possibly a leaking crankcase These products are chemically incompatibles Even af ter cleaning the Loctite 5910 would leave incom patible microscopic particles Use...

Page 294: ... cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to position crankshaft at TDC before installing the camshaft and rockers refer to CYLINDER HEAD AND VALVES 1 Crankshaft locking tool Install cylinder head PTO housing and the other parts in accordance with the proper installation procedures CRANKSHAFT AXIAL CLEARANCE mm in NEW MINIMUM 0 08 mm 003 in NEW MAXIMUM 0 22 mm 009 i...

Page 295: ...g Pull piston with connecting rod out of the cylin ders Remove one piston circlip no 8 and discard it 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin no 9 out of piston 1 Piston 2 Piston pin 3 Circlip Detach piston no 10 from connecting rod Inspection Connecting Rod Piston Pin Clearance Measure piston pin Compare to inside diameter of...

Page 296: ...lly Do the torque procedure as described below A Connecting rod big end bushing Use NEW bushings no 12 when connecting rod big end diameter is out of specification CONNECTING ROD SMALL END DIAMETER mm in NEW MINIMUM 23 01 mm 9059 in NEW MAXIMUM 23 02 mm 9063 in SERVICE LIMIT 23 07 mm 908 in PISTON PIN DIAMETER mm in NEW MINIMUM 22 996 mm 9053 in NEW MAXIMUM 23 000 mm 9055 in SERVICE LIMIT 22 990 m...

Page 297: ...to the dimension adjust a cylinder bore gauge to the micrometer dimen sion and set the indicator to 0 zero 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge 62 mm 2 44 in above cylinder base measuring perpendicularly 90 to piston pin axis Read the measurement on the cylinder bore gauge The result is the exact piston...

Page 298: ...g Clearance Measure inside diameter of connecting rod 1 Bore gauge 2 Connecting rod Replace connecting rod if diameter of connecting rod small end is out of specifications Refer to CRANKSHAFT AND BALANCER SHAFT for removal procedure of connecting rod Installation For installation reverse the removal procedure Pay attention to the following details Apply engine oil on the piston pin Insert piston p...

Page 299: ...rotrusion of bushing in line with connecting rod groove Torque NEW connecting rod screws no 11 as per following procedure Install screws and torque to 45 N m 33 lbf ft Do not apply any thread locker product Finish tightening the screws with an additional 90 turn using an angle torque wrench CAUTION Failure to strictly follow this proce dure may cause screw to loosen and lead to en gine damage Know...

Page 300: ...Installation For installation reverse the removal procedure Pay attention to the following details Install the oil scraper ring first then the taper face ring with the word TO facing up then the rectan gular ring with the word T facing up 1 Rectangular ring 2 Taper face ring 3 Oil scraper ring RING PISTON GROOVE CLEARANCE mm in NEW MINIMUM RECTANGULAR 0 025 mm 001 in TAPER FACE 0 015 mm 0006 in OI...

Page 301: ...reakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after installation Space the piston ring end gaps 120 apart and do not align the gaps with the piston pin bore or the thrust side axis 1 DO NOT align ring gap with piston trust side axis 2 DO NOT align ring gap with piston pin bore axis A 120 A31C2OA 1 2 A A A www SeaDooManuals net ...

Page 302: ...MPEM PROGRAMMER 06 03 1 FAULT CODE TABLES 06 03 3 ECU FAULTS 06 03 3 INPUT SIGNAL FAULTS 06 03 3 OUTPUT SIGNAL FAULTS 06 03 4 COMPONENT INSPECTION 06 04 1 GENERAL 06 04 1 AIR INDUCTION SYSTEM 06 04 3 THROTTLE BODY 06 04 3 FUEL DELIVERY 06 04 3 FUEL FILTER 06 04 3 FUEL PUMP 06 04 3 REGULATOR 06 04 3 FUEL INJECTOR 06 04 4 LEAK TEST SUPPLY AND VENTILATION CIRCUITS 06 04 5 HIGH PRESSURE TEST fuel pump...

Page 303: ...30 SECONDS 06 05 1 ENGINE CANNOT REACH MAXIMUM REVOLUTIONS 06 05 1 ADJUSTMENT 06 06 1 THROTTLE CABLE ADJUSTMENT 06 06 1 THROTTLE POSITION SENSOR TPS 06 06 1 CLOSED TPS 06 06 1 IDLE SPEED 06 06 1 REMOVAL AND INSTALLATION 06 07 1 MPEM 06 07 1 THROTTLE POSITION SENSOR TPS 06 07 1 AIR TEMPERATURE SENSOR ATS 06 07 1 AIR PRESSURE SENSOR APS 06 07 1 WATER TEMPERATURE SENSOR WTS 06 07 1 CRANKSHAFT POSITIO...

Page 304: ...4 Regulator 5 Fuel rail 6 Fuel injector 7 Electronic Control Unit ECU 8 Multi Purpose Electronic Module MPEM 9 Throttle plate 10 Throttle Position Sensor TPS 11 Air Pressure Sensor APS 12 Air Temperature Sensor ATS 13 Crankshaft Position Sensor CPS 14 Water Temperature Sensor WTS 15 Battery 16 Ignition coil F07F18S 1 3 2 4 5 6 15 7 8 9 11 12 10 14 13 16 www SeaDooManuals net ...

Page 305: ...s the advantage of optimizing the engine power fuel economy and emission con trols under all engine operating conditions by man aging both the fuel injection duration and ignition timing The Rotax Fuel Injection RFI is composed of the 3 following basic systems 1 air induction 2 fuel delivery 3 electronic management AIR INDUCTION A single throttle body 56 mm breath through the air intake silencer t...

Page 306: ...oved 2 Internal fuel filter FUEL PUMP MODULE All these components are comprised in a single module mounted in the fuel tank The fuel gauge sender is also mounted on this module FUEL PUMP ASSEMBLY FUEL INJECTORS The injectors inject a metered quantity of fuel from the fuel rail into the cylinder rear transfer port in accordance with the signal from the Electronic Control Unit ECU INJECTOR F07F0KA 1...

Page 307: ...m Engine Speed The ECU limits the maximum allowable engine speed The RPM rev limiter is set at 7200 50 RPM Fail Safe Function In the event of a sensor malfunction the ECU will use a default operating mode to ensure driveability to shore A message may be displayed on the Info Center to inform the operator Diagnostic Mode The ECU is able to detect malfunctions in the sen sor network The malfunction ...

Page 308: ...osition Idle to wide open throttle Engine temperature Intake air temperature Battery voltage Start stop signal Air Pressure Sensor APS Water Temperature Sensor WTS Air Temperature Sensor ATS Fuel tank Fuel filter Fuel pump Regulator Injectors Multi Purpose Electronic Module MPEM Electronic Control Unit ECU PARAMETERS SENSORS FUEL DELIVERY Throttle Position Sensor TPS To engine F07F0NS www SeaDooMa...

Page 309: ...ction used is properly selected in MPI under Choose protocol as per the following chart MPEM PROGRAMMER The MPEM programmer is the alternative tool to diagnose fuel injection related problems The latest software designed for the RFI model allows sensor inspection diagnostic options and adjustment such as the Throttle Position Sensor TPS NOTE Make sure your MPEM programmer is up dated with the late...

Page 310: ...cation of the watercraft and the MPEM ECU By selecting READ FAULT the MPEM program mer will display the number of faults in the ECU memory and the codes related with the fault s The programmer will offer PRESS ANY KEY If there is more than 1 fault in the ECU memory the next fault code will be displayed NOTE On this model there is always at least the 04 FC fault code Ignore this fault code Also whe...

Page 311: ...0563 Voltage from the battery too high Engine Water Temperature Sensor WTS 02 0A 1D P 0117 Sensor circuit shorted to ground 02 0A 1E P 0118 Signal interruption or short circuit to battery 02 0A 1B P 0116 Non plausible signal Throttle Position Sensor TPS 02 06 1F P 0122 Sensor circuit shorted to ground 02 06 1C P 0123 Sensor circuit shorted to battery Crankshaft Position Sensor CPS 02 1F 06 02 1F 2...

Page 312: ... circuit to ground 04 E1 1E P 1200 Interruption or open circuit Injector 2 04 E2 1C P 0265 Short circuit to battery 04 E2 1D P 0264 Short circuit to ground 04 E2 1E P 1201 Interruption or open circuit Fuel pump 04 EB 1C P 0230 Short circuit to battery Not applicable 04 FC N A Not applicable RAVE vacuum solenoid 04 DB 1C P 0478 Short circuit to battery 04 DB 1D P 0477 Short circuit to ground 04 DB ...

Page 313: ... sual inspection could lead to false results To perform verifications a good quality multimeter such as Fluke 111 P N 529 035 868 should be used WARNING The fuel system of a fuel injection system holds much more pressure than on a carbureted wa tercraft Prior to disconnecting a hose or to re moving a component from the fuel system fol low the recommendation described here WARNING Fuel lines remain...

Page 314: ...has been solved ensure to clear the fault s in the MPEM using the VCK Refer to DIAGNOSTIC PROCEDURES Resistance Measurement When measuring the resistance with an ohmmeter all values are given for a temperature of 20 C 69 F The resistance value of a resistance varies with the temperature The resistance value for usual resistor or windings such as injectors in creases as the temperature increases Ho...

Page 315: ...be used to validate the injector operation AIR INDUCTION SYSTEM THROTTLE BODY Check that the throttle plate moves freely and smoothly when depressing throttle lever FUEL DELIVERY FUEL FILTER To inspect the fuel filter the fuel pump assembly has to be removed from the fuel tank See REMOVAL in this subsection for the procedure FUEL PUMP The fuel pump operation can be checked as fol lows Install the ...

Page 316: ...ssure is too low check the following com ponents fuel hoses and connections fuel filter fuel pump regulator voltage at fuel pump minimum 8 Vdc FUEL INJECTOR 1 Inlet side 2 Filter 3 Wiring terminal 4 Coil 5 Plunger 6 Needle valve 7 Injection side Touch the injector while cranking the engine to feel the operation of the injector If there is no signal detected from the injector dis connect the plug c...

Page 317: ... for the procedure NOTE Do not detach injectors from fuel rail Reconnect the wire connector of the injector Place each injector in a clean bowl Install the safety lanyard cap on the switch to ac tivate the fuel pump Check for fuel leakage from the injector nozzle There should be less than 1 drop of fuel per minute 1 Fuel injectors 2 Fuel rail 3 Injector nozzles If not within specification replace ...

Page 318: ... and the fuel pressure should be between 386 414 kPa 56 60 PSI Check hose connections at fuel pump and at fuel rail ELECTRONIC MANAGEMENT THROTTLE POSITION SENSOR TPS Check the resistance value of the throttle position sensor 1 Throttle position sensor TPS Disconnect the AMP plug connector 4 on the MPEM Using a multimeter check the resistance between terminal 3 PURPLE BROWN wire and terminal 4 BLA...

Page 319: ...e TPS closed position must be re adjusted Voltage Test If the sensor resistance value is good check the volt age output from MPEM to throttle position sensor Disconnect plug connector from throttle position sensor and connect a voltmeter between the PURPLE BROWN wire and the BLACK BROWN wire in the wiring harness Depress the start stop button with the safety lan yard removed to activate the timer ...

Page 320: ... is below specifications replace air temperature sensor ATS If resistance is above specifications disconnect the connector of the air temperature sensor and check resistance of wiring harness and terminals between AMP plug connector and ATS sensor connector If there is an open circuit repair or replace the de fective wire or terminal Reconnect the air temperature sensor connector and recheck the r...

Page 321: ...ot 5 V check the wiring harness and pin 12 on the 4 AMP plug connector Remove the TAN ORANGE wire from the 12 po sition on the AMP plug connector install a test connector a female connector with about 25 mm 1 in of wire then reconnect the AMP plug con nector Press the start stop button and check for 5 V on the test wire If none is present replace the MPEM On the WTS connector check for continuity ...

Page 322: ...nals between AMP plug connector and APS sensor connector Reconnect the air pressure sensor connector and recheck the resistance value between terminals in the AMP plug connector 4 If not within specification replace the air temper ature sensor Voltage Test If the sensor resistance value is within specifications disconnect the plug connector from the APS sensor and check the voltage between the PUR...

Page 323: ...ottle position sensor 3 and 4 PU BW and BK BW 1 6 k 2 4 k ohms 5 Vdc between PU BW and BK BW 4 and 11 BK BW and WH BW 710 1380 ohms Water temperature sensor 5 and 12 BK OR and TA OR 2280 2736 ohms N A Air temperature sensor 6 and 13 BK WH and WH GY 2280 2736 ohms N A Crankshaft position sensor 7 and 14 GY YL and GY RE 774 946 ohms N A Rave solenoid 16 and 23 PU GY and BK GY 30 ohms N A Injector no...

Page 324: ...run Unlike other Sea Doo models the spark plugs spark independently on each piston stroke Re versed high tension cables will cause backfires ECU FAULT CODES Fault codes in the ECU memory will identify poten tial problems with the RFI system When checking fault codes without engine in operation the CPS fault code will always appear Also the 04 FC fault code will always appear Disconnecting the batt...

Page 325: ...mmer Access the BOSCH SYSTEM in the MPEM pro grammer Then select ADJUSTMENT in the sub menu Choose CLOSE TPS in the ADJUSTMENT menu The screen will display the actual adjustment of the TPS in degrees and it will also offer to adjust it CAUTION Do not select YES until the idle speed screw is loosened to allow the throttle plate to close Loosen the lock nut of the idle speed screw Loosen the idle sp...

Page 326: ...e APS At installation apply Loctite 243 blue on screw threads WATER TEMPERATURE SENSOR WTS Disconnect the connector of the WTS Loosen the WTS from the cylinder head At installation apply Loctite 518 on threads of the WTS CRANKSHAFT POSITION SENSOR CPS Disconnect the connector of the CPS Loosen Allen screw retaining the CPS Remove the CPS At installation apply Loctite 243 blue on the Allen screw NO...

Page 327: ... injec tors 1 Press retaining clip to unlock the connector Loosen both screws retaining the fuel rail to the cylinders 1 Loosen screws retaining the fuel rail Remove the fuel rail with both fuel injectors To remove the fuel injector from the fuel rail pry off the retaining clip 1 Pry the clip Carefully inspect O rings condition before rein stalling fuel injectors Replace O rings with new ones if d...

Page 328: ...03 2 AMP CONNECTOR PIN OUT 07 03 3 QUICK FUEL PRESSURE TEST 07 03 4 AIR INDUCTION SYSTEM 07 03 5 THROTTLE BODY 07 03 5 AIR COMPRESSOR 07 03 9 PRESSURE TEST 07 03 9 REPAIR 07 03 10 FUEL DELIVERY 07 03 13 FUEL PRESSURE REGULATOR 07 03 13 FUEL INJECTOR 07 03 14 AIR FUEL RAIL 07 03 15 DIRECT INJECTOR 07 03 17 FUEL PUMP 07 03 18 ELECTRONIC MANAGEMENT 07 03 23 MPEM REPLACEMENT 07 03 23 THROTTLE POSITION...

Page 329: ...7 03 34 SPARK PLUGS 07 03 38 CRANKING SYSTEM 07 03 39 DI SYSTEM TEST SUMMARY 07 03 39 DIAGNOSTIC PROCEDURES 07 04 1 GENERAL 07 04 1 FAULT DETECTION AND COMPENSATORY ACTIONS 07 04 2 COMPONENT FAILURE WARNING SYSTEM 07 04 2 VCK Vehicle Communication Kit 07 04 4 DI SYSTEM FAULT CODES 07 04 5 www SeaDooManuals net ...

Page 330: ...Section 07 ENGINE MANAGEMENT DI Subsection 02 OVERVIEW SMR2003 023_07 02A FM 07 02 1 OVERVIEW 0 F12F03T www SeaDooManuals net ...

Page 331: ...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 332: ... 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 into...

Page 333: ...ft MPEM General Functions Safety Lanyard Reminder If engine is not started within 5 seconds after in stalling the safety lanyard on its post 4 short beeps every 3 second interval will sound for ap proximately 2 hours to remind you to start the en gine or to remove safety lanyard Afterwards the beeps will stop The same will occur when safety lanyard is left on its post 5 seconds after engine is sto...

Page 334: ...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 button is pressed If start stop button is held after engine has started the MPEM automatically stops the starter when the engine speed reaches...

Page 335: ...Section 07 ENGINE MANAGEMENT DI Subsection 02 OVERVIEW 07 02 6 SMR2003 023_07 02A FM MPEM Engine Management Functions F12D0CS www SeaDooManuals net ...

Page 336: ... allow proper operation for all possi ble conditions Cranking start up idle warm up normal operation Sea Doo LK learning key limited vehicle speed engine speed limiter flooded 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 ...

Page 337: ... and regu lated for the charging 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 phase delta wound stator on 18 pol...

Page 338: ...re than on a carbureted wa tercraft Prior to disconnecting a hose or to re moving a component from the fuel system fol low the recommendation described here Note thatsomehosesmayhavemorethanoneclamp at their ends Ensure to reinstall the same quan tity of clamps at assembly WARNING Fuel lines remain under pressure at all times Al ways proceed with care and use appropriate safety equipment when work...

Page 339: ...uses Before replacing a MPEM always check electrical connections Make sure that they are very tight and they make good contact and that they are corrosion free A defective module could possibly be re paired simply by unplugging and replugging the MPEM The voltage and current might be too weak to go through dirty wire terminals Check carefully if posts show signs of moisture corro sion or if they l...

Page 340: ... To test it the sensor could be removed from the engine muffler and heated with a heat gun while it is still connected to the harness to see if the 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...

Page 341: ... is within limits air fuel rail is working adequately Proceed with the fuel pressure test below If pressure is out of limits refer to FUEL DELIV ERY below and proceed with the tests described there Crank or start engine and observe fuel pressure If pressure is within limits fuel and air systems are working adequately No subsequent tests are nec essary for the air fuel system Remove pressure gauge ...

Page 342: ...ttle 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 343: ... few times to ensure it is com pletely closed Using an ohmmeter measure resistance between terminals 2 and 3 Note the resistance value Add 175 Ω to that value Turn idle set screw clockwise until ohmmeter reading reaches the computed value above 20 Ω 1 Measure resistance between terminals 2 and 3 2 Turn screw clockwise to increase resistance Tighten lock nut Recheck reading and readjust as necessar...

Page 344: ...ate is still closed Turn synchronizing screw clockwise until read ing reaches the computed value above 20 Ω 1 Measure resistance between terminals 2 and 3 2 Turn screw clockwise to decrease resistance Ensure spring is still well positioned on stoppers Properly reinstall the plastic cap on the synchroni zation screw Apply Loctite 5900 P N 293 800 066 RTV silicone sealant on idle set screw head 1 Pl...

Page 345: ...ut 2 Turn adjuster XP DI MODELS 1 Slacken nut 2 Turn adjuster NOTE On GTX DI models vent tube removal in front storage compartment may be necessary to reach the adjusting device CAUTION Improper cable adjustment will cause 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 ...

Page 346: ... and pressure relief valve to pres sure gauge as shown 1 Pressure gauge P N 529 035 709 2 Adapter for air compressor P N 529 035 712 3 T adapter P N 529 035 710 4 Pressure relief valve P N 529 035 711 CAUTION Make sure to install pressure relief valve to allow excess pressure to escape and to point valve arrow as shown above Note the ar row on the valve Otherwise air compressor components might be...

Page 347: ...emble the com pressor to then make a pressure test If it fails check bottom end When changing reed valve ensure to position ring plate opening so that 2 holes align inside the open ing Holes must not be obstructed by the opening edges 1 Reed valve opening 2 Rotate opening to align 2 holes inside without obstructing the holes Ensure to position O ring around top of cylinder sleeve 1 O ring on top o...

Page 348: ...an be sanded with a fine sandpaper If you find aluminum dust or debris in this area some may have traveled toward the injection oil reservoir In this case the oil reservoir and lines must be flushed and the filter 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 Pi...

Page 349: ...pin strict ly follow this procedure 1 Block counterbalance shaft to prevent any rota tion 2 Install the crankpin bushing so that its grooved end is on the screw head side 1 Groove here 3 Install a NEW screw and torque to 6 5 N m 58 lbf in Do not apply any thread locker product 4 Turn the screw clockwise an additional 80 de grees 5 degrees CAUTION Failure to strictly follow this proce dure may caus...

Page 350: ...9 035 714 Connect T adapter to pressure gauge as shown 1 Pressure gauge P N 529 035 709 2 T adapter P N 529 035 710 Install pressure gauge between disconnected ends inline installation 1 Fuel filter 2 Fuel line going to air fuel rail 3 Pressure gauge between disconnected ends inline installation Install safety lanyard and observe fuel pressure Do not crank engine If pressure is within limits fuel ...

Page 351: ...l pressure regulator pull the fuel regulator and the cover out of rail Installation For the installation reverse the removal procedure but pay attention to the following If the same regulator is reinstalled it is recommend ed to change the O rings Insert the fuel pressure regulator into the cover then install both regulators together in place with your hand Do not use any tool NOTE A thin film of ...

Page 352: ...of rail Installation For the installation reverse the removal proce dure Paying attention to the following details If the same injector is reinstalled carefully inspect O ring condition before reinstalling fuel injector Replace O ring with a new one if damaged Insert the fuel injector in place with your hand Do not use any tool NOTE A thin film of injection oil may be applied to O ring to ease ins...

Page 353: ...t rail draining Disconnect spark plug cables from spark plugs and fuel injector wires Cut locking ties of wiring Unscrew rail retaining screws 1 Air fuel rail 2 Air supply hose 3 Fuel supply hose 4 Retaining screws 1 Push clip toward injector to release connector Gently pull rail up by hand working each side slight ly at a time Pull rail out Disconnect hose ends at their inline connectors and drai...

Page 354: ...ork disconnect the con nector from the injector Install a temporary connector on the injector with wires long enough to make the connection out side the bilge and apply voltage 12 V to this test harness This will validate its mechanical and electrical op eration If it does not work replace the direct injector Otherwise check the resistance of the direct in jector circuit Reconnect the injector and...

Page 355: ...ing a small pick Install seal guide P N 529 035 715 on end of injec tor Carefully slide carbon dam in injector groove Use carbon dam compressor P N 529 035 716 to compress carbon dam evenly FUEL PUMP Pressure Test The pressure test will show the available pressure from the fuel pump Ensure there is no leak from hoses and fittings Repair any leak Ensure there is enough gas in fuel tank Use the VCK ...

Page 356: ...g the safety lanyard to the DESS post the fuel pump should run for 2 seconds to build up the pressure in the system If the pump does not work disconnect the con nector from the fuel pump Install a temporary connector on the fuel pump with wires long enough to make the connection outside the bilge and apply voltage 12 V to this test harness If pump does not run replace the fuel pump Otherwise check...

Page 357: ...ear access panel Referring to DIRECT ACTION SUSPENSION de tach shock absorber to allow tilting of seat for ward Remove access plug All Models except XP DI From glove box opening remove fuel pump retain ing nuts 1 Fuel pump 2 Retaining screw All Models Disconnect electrical connector Disconnect vent tube from fuel pump Disconnect inlet and outlet hoses from fuel pump using tool P N 529 035 714 XP D...

Page 358: ... spillage in the bilge TYPICAL 1 Pull fuel pump toward front XP DI Models Pull fuel pump out Wipe off any fuel spillage in the bilge All Models Installation For installation reverse the removal process but pay attention to the following Install fuel pump on fuel tank and torque nuts to 2 5 N m 1 8 lbf in Ensure to align the arrow with the dot on the gas ket towards the LH side of fuel tank TORQUE ...

Page 359: ... PSI Check air return line for blockage Check for air leaks Repair leaks Check direct injector yes Perform fuel pump test Replace fuel pump module pass no leaks Check RAVE for air leaks Repair air compressor Air pressure more than 621 kPa 90 PSI OK Replace direct injector Connect safety lanyard Fuel pump does not run Fuel pump runs for 2 sec then stops Check fuses Check lanyard connection Check pu...

Page 360: ...ew MPEM on the vehicle Reconnect AMP connectors to MPEM then bat tery cables If the previous MPEM was read with B U D S Transfer the data from the previous MPEM to the new one using B U D S then proceed with the re quired resets after following the procedure in VAL IDATING TPS SYNCHRONIZATION below If the previous MPEM was NOT read with B U D S Enter the vehicle and engine serial numbers in the Ve...

Page 361: ...cable Using the vehicle communication kit VCK with the B U D S software use the THROTTLE OPENING display under Monitoring Slowly and regularly depress the throttle Observe the needle movement It must change gradually and regularly as you move the throttle If the nee dle sticks bounces suddenly drops or if any dis crepancy between the throttle movement and the needle movement is noticed it indicate...

Page 362: ...ottle plate in idle position The resistance should be 2500 Ω Test Results Both TPS If resistance values are correct try a new MPEM Re fer to MPEM REPLACEMENT procedures else where in this section If resistance values are incorrect disconnect the TPS and perform the resistance measurement di rectly to the TPS terminals If TPS is good repair the wiring harness connectors between AMP connector and th...

Page 363: ...ANKSHAFT POSITION SENSOR CPS 1 Magneto cover 2 CPS connector Check for RPM display at the information center while cranking engine first ensure information center is in tachometer mode If it displays ap proximately 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 Activation first ensure ...

Page 364: ...nnector terminals for corrosion or damage Check the voltage readings on the harness side as follows If voltage tests good the CPS is defective and needs replacement If voltage does not test good perform the follow ing tests Resistance Test Check the continuity of the wiring harness Disconnect the AMP connector number 2 on the MPEM Using a multimeter check continuity of circuits 6 7 and 14 If wirin...

Page 365: ...ck resistance value be tween terminals 16 and 19 If resistance value is correct try a new MPEM Re fer to MPEM REPLACEMENT procedures else where in this section If resistance value is incorrect repair the wiring harness connectors between AMP connector and the MATS Replacement Remove the air intake silencer Remove the air duct Disconnect the connector of the MATS Pull MATS out while turning right a...

Page 366: ...Otherwise the MAPS could generate a fault code for an unexpected sensor range at idle when it reads the atmospheric pressure Ensure the cor rect connector is plugged and not mixed with the MAG TPS Remove sensor and check for oil or dirt on its end and if problem persists check throttle plate condition position and the wiring harness Perform the following tests Voltage Test Check the MPEM voltage o...

Page 367: ...te 518 on threads of the EGT then in stall Replug connector KNOCK SENSOR KS 1 Knock sensor KS Dynamic Test Using the vehicle communication kit VCK with the B U D S software monitor the knock sensor using the FAULTS section Start the engine and bring engine RPM above 4500 RPM If no fault code occurs the knock sen sor is good Otherwise do the following Ensure sensor and cylinder head contact surface...

Page 368: ...d supply hose Install leak test pump P N 529 021 800 on hose end and pressurize air line to 69 103 kPa 10 15 PSI Wait some time to see if pressure drops If so check line for leaks Otherwise the solenoid is de fective and needs to be replaced Using the vehicle communication kit VCK with the B U D S software energize the RAVE sole noid from the ACTIVATION section The pressure should drop when the so...

Page 369: ...stance value is correct try a new MPEM Refer to MPEM REPLACEMENT procedures elsewhere in this section If resistance value is incorrect repair the wiring harness connectors between AMP connector and solenoid IGNITION COIL NOTE The MPEM energizes the primary side of each ignition coil individually It can detect open and short circuit in the primary winding but it does not check the secondary winding...

Page 370: ...igh tension leads They must be as follows Otherwise replace the lead NOTE It is not necessary to remove the spark plug cap IMPORTANT Always replace leads with genuine parts Otherwise fuel injection system operation may be impaired Check continuity between ignition coil ground cir cuits and engine Dynamic Test Use an ignition coil tester available from after market tool equipment suppliers 1 With i...

Page 371: ...ot be required It has been set at factory and it should remain cor rectly set since every part is fixed and not adjust able The only time the TDC setting might have to be changed would be when replacing the crank shaft the magneto rotor the CPS the encoder wheel or the MPEM If the TDC setting is found to be incorrect you should first check for proper crankshaft alignment This might be the indicati...

Page 372: ...ten adaptor lock nut Since we are working with an indirect mea surement ensure that dial gauge face is po sitioned in the same direction as the connect ing rod Rotate magneto flywheel clockwise until pis ton is at Top Dead Center Unlock outer ring of dial and turn it until 0 zero on dial aligns with pointer Lock outer ring in position 6 From this point rotate magneto flywheel back 1 4 turn then ro...

Page 373: ...th timing mark pointer no adjustment is re quired If mark does not align with pointer recheck PTO flywheel mark before performing the TDC setting to ensure PTO flywheel has not loosen or tightened TDC Setting General To correct the TDC setting the data of the MPEM is changed using the VCK Vehicle Communication Kit P N 295 035 844 Look in SETTING section of the software B U D S NOTE For more inform...

Page 374: ...n open circuit switch is normally open Depress and hold switch the ohmmeter should read close to 0 ohm Other wise replace switch If the switch tests good check continuity of cir cuits 2 8 and 2 12 using a multimeter If wiring harness tests good it could be the MPEM Try a new MPEM referring to MPEM REPLACE MENT procedures elsewhere in this section Safety Lanyard Switch Verification If 2 short beeps...

Page 375: ...eat path the colder the operating tem perature 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 combustion de...

Page 376: ...start stop switch and the DESS post testing Refer to STARTING SYSTEM section for other tests DI SYSTEM TEST SUMMARY Pressure Tests ENGINE SPARK PLUG TORQUE GAP mm in DI NGK ZFR4F 11 Hand tighten 1 4 turn with a socket 1 1 043 COMPONENT VALUE kPa PSI Air compressor 621 14 90 2 at cranking Fuel pressure regulator 185 14 27 2 when installing safety lanyard Fuel pressure 738 14 107 2 inline test at cr...

Page 377: ...t idle Throttle position sensor PTO TPS TPS 1 and engine ground PU RD 5 V 2 and engine ground BK RD 0 0 5 V 3 and engine ground WH RD 0 V AMP no 4 3 and 18 BK RD and PU RD 1600 2400 ohms 1 and 3 WH RD and BK RD 1000 ohms at idle 1 and 18 WH RD and BK RD 2500 ohms at idle Crankshaft position sensor CPS CPS Deutsche connector Terminal 4 and ground BK 0 V with a small mV tolerance Terminal 5 and grou...

Page 378: ... 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 10200 ohms secondary winding w o high tension leads High tension leads RX DI and XP DI models MAG 5700 ohms lead alone PTO White tape 4300 ohms lead alone High tension le...

Page 379: ... 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 hasbeen programmed for the watercraft If it does not work check safe ty lanyard condition with the programmer Re place safety lanyard if reported ...

Page 380: ... MAINT ON ON 5 Limited RPM idle speed if both TPS s fail Water temperature sensor WTS MAINT ON OFF ON 7 5 Limited RPM code 5 if EGT also fails Direct injector single injector MAINT ON OFF 7 Limited RPM Fuel injector single injector MAINT ON OFF 7 Limited RPM Ignition no firing on one cylinder MAINT ON OFF 7 Limited RPM RAVE solenoid MAINT ON OFF 7 Limited RPM Starter solenoid MAINT ON OFF 7 Engine...

Page 381: ...NT ON ON 3 Limited RPM Throttle position sensor dual TPS MAINT ON ON 5 Idle RPM Throttle position sensor single adaption fault None OFF OFF 7 None Throttle position sensor dual adaption fault MAINT ON OFF 7 Limited RPM Sensor supply fault TPS and MAPS MAINT ON ON OFF 5 7 Limited RPM code 7 and idle RPM if both in fault Encoder CPS fault bad pattern MAINT ON OFF 7 Limited RPM Low battery voltage 12...

Page 382: ...ion pertaining to the use of the software B U D S use its help which contains de tailed information on its functions Always OFF 2 second beep every 15 minutes 2 second beep every 58 seconds 2 second beep every 2 seconds Always ON continuously beep 1 second beep every second BUZZER PATTERN BUZZER CODE 5 3 4 2 1 NOTE 6 7 4 short beeps every 3 seconds 2 SEC 15 MIN 58 SEC ON OFF 2 SEC 2 SEC 2 SEC 1 SE...

Page 383: ...te count first etc and report refer to B U D S online help Supplemental Information for Some Specific Faults ECU fault code P0606 This code may occur in the following situations Electrical noise is picked up by the MPEM Ensure that all 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 gen...

Page 384: ...s 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 Failed Replace and reset closed TPS POSSIBLE CAUSES RESULT ACTION Sensor has been replaced and TPS closed p...

Page 385: ...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 1 7 1 9 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 windi...

Page 386: ...angles at idle Possible causes No initialisation after throttle body or ECU changes throttle idle stop drifted P1103 TPS MAG TPI_2_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 P0116 W...

Page 387: ...heck tune pipe injection valve Possible causes Exhaust system overheated damaged sensor damaged circuit wires P0460 Fuel level sensor FUEL_SENS Sensorout of range Yes No As soon as fault is not present Service action TBD Possible causes Damaged sensor damaged circuit wires damaged connector damaged ECU pins ECU failure P0230 Fuel pump FUEL_PUMP Open or short circuit Yes short circuit Yes open circ...

Page 388: ...0 or 3 3 Possible causes Damaged circuit wires associated sensor failure TPI 2 or MAP ECU fault P0222 Sensor supply 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 circuit 4 18 Possible causes Damaged circuit wires associated sensor failure TPI 1 ECU fault P1600 ECU SETUP TDC and ECU not initialised Yes Yes Reiniti...

Page 389: ... INSPECTION AND ADJUSTMENT 08 03 1 GENERAL 08 03 1 FUEL SYSTEM 08 03 1 ELECTRICAL SYSTEM 08 03 2 ENGINE CONNECTOR PIN OUT 08 03 3 CONNECTORS ON ENGINE 08 03 4 AIR INDUCTION SYSTEM 08 03 5 THROTTLE BODY 08 03 5 FUEL DELIVERY 08 03 8 FUEL PUMP 08 03 9 FUEL RAIL 08 03 11 FUEL INJECTOR 08 03 11 ELECTRONIC MANAGEMENT 08 03 13 EMS ECU AND MPEM REPLACEMENT 08 03 13 ENGINE WIRING HARNESS 08 03 15 THROTTLE...

Page 390: ... 29 IGNITION COILS 08 03 31 TDC SETTING TOP DEAD CENTER 08 03 32 ENGINE START STOP SWITCH VERIFICATION 08 03 32 SAFETY LANYARD SWITCH VERIFICATION 08 03 33 SPARK PLUGS 08 03 33 CRANKING SYSTEM 08 03 34 DIAGNOSTIC PROCEDURES 08 04 1 GENERAL 08 04 1 SELF DIAGNOSTIC MODE 08 04 3 VCK Vehicle Communication Kit 08 04 4 4 TEC SYSTEM FAULT CODES 08 04 5 www SeaDooManuals net ...

Page 391: ...uit by switching it to the ground COMPASS OUTSIDE AIR TEMPERATURE SENSOR VCK COMMUNICATION PORT COMMUNICATION LINK COMMUNICATION LINK POWER TO EMS ECU INFORMATION CENTER SET AND MODE SWITCHES SPEED SENSOR FUEL LEVEL SENDER BEEPER DEPTH GAUGE START STOP SWITCH STARTING SOLENOID FUEL PUMP FUEL INJECTORS IGNITION COILS TOPS VALVE TOPS SWITCH CAPS INFORMATION CENTER EMS ECU MPEM TPS MAPS MATS CTS EGT ...

Page 392: ...icle communication kit where B U D S Bombardier utility and diagnostic system is used for diagnosing and troubleshooting the system The fault code can be seen from either the infor mation center or B U D S Refer to DIAGNOSTIC PROCEDURES section R1503motr266S ENGINE MANAGEMENT SYSTEM OVERVIEW ROTAX 1503 4 TEC SUPERCHARGED EMS ECU KS CPS OPS CTS CAPS INJECTOR 1 2 3 MAPS MATS IDLE BYPASS VALVE TPS IG...

Page 393: ...on timing for each cylinder separately The fuel is injected into the intake port of each cylinder NOTE On the 1503 PTO and magneto MAG are on the same engine side rear Each cylinder is referenced as 1 2 and 3 instead of PTO CENTRE and MAG The numbers are stamped on the valve cover 1 Cylinder 1 2 Cylinder 2 3 Cylinder 3 NOTE The EMS includes an ECU electronic con trol unit sensors injectors electro...

Page 394: ...nic Control Unit opens the fuel injector and fuel is discharged into the in take port at the air intake manifold by the high fuel pressure inside the fuel rail The air fuel mixture enters then the combustion chamber through the open intake valve This mixture is then ignited by the spark plug INTAKE MANIFOLD INTAKE MANIFOLD 1 Electronic Control Unit EMS ECU 2 Fuel rail 3 Injector 4 Throttle body 5 ...

Page 395: ...stem if the engine backfires Throttle Body It is a 52 mm throttle body mounted on intake manifold Fitted on the throttle body the TPS and the idle bypass valve allow the EMS ECU to con trol the RPM while the throttle plate is closed FUEL PUMP MODULE The fuel pump module is located inside the fuel tank The module includes fuel pump fuel pres sure regulator and fuel level sensor Fuel Pump It provide...

Page 396: ...safety lanyard is left on its post 5 seconds after engine is stopped Always ensure safety lanyard is not left on its post after engine is stopped IMPORTANT Leaving the safety lanyard on its post when engine is not running will slowly dis charge the battery Antistart Feature This system allows starting the vehicle only with safety lanyard s that has been programmed to op erate a specific watercraft...

Page 397: ...no information is lost When ordering a new EMS ECU from the regular parts channel the DESS circuitry will be activated Engine Starting If the EMS ECU recognizes a valid safety lanyard it allows engine to start when the start stop button is pressed If start stop button is held after engine has started the EMS ECU automatically stops the starter when the engine speed reaches 1600 RPM If start button...

Page 398: ...Section 08 ENGINE MANAGEMENT 4 TEC Subsection 02 OVERVIEW 08 02 8 SMR2003 026_08 02A FM EMS ENGINE MANAGEMENT FUNCTIONS R1503motr220S www SeaDooManuals net ...

Page 399: ...on and firing order to achieve the proper engine requirements Ignition Coils Three separate ignition coils induce voltage to a high level in the secondary windings to produce a spark at the spark plug The ignition coils receive input from the EMS ECU Each coil provides high voltage to its correspond ing spark plug This ignition system allows spark plugs to spark independently NOTE Ignition coil wi...

Page 400: ...ically if the condi tion does not exist anymore Releasing throttle and letting the engine returning at idle speed may allow normal operation to come back If it does not work try removing and rein stalling the safety lanyard on its post Depending on the malfunction the watercraft speed may be reduced and not allowed to reach its usual top speed The engine speed will be lim ited to 2500 or 5000 RPM ...

Page 401: ...fuel level in the reservoir is low the fuel level sensor transmits a signal to the MPEM The MPEM sends out signals to the beeper and to the information center gauge Monitoring System The EMS ECU monitors the electronic compo nents of the fuel injection system and also the en gine components of the electrical system The MPEM monitors the vehicle electrical system and the accessories When a fault oc...

Page 402: ...YSTEM section Properly reconnect the battery WARNING The fuel system of a fuel injection system holds much more pressure than on a carbureted wa tercraft Prior to disconnecting a hose or to re moving a component from the fuel system fol low the recommendation described here Note that some hoses may have more than one clamp at their ends Ensure to reinstall the same quantity of clamps at assembly W...

Page 403: ...eck electrical connections Make sure that they are very tight and they make good contact and that they are corrosion free Particularly check MPEM and EMS ECU ground connections Ensure that con tacts are good and clean A defective module could possibly be repaired simply by unplugging and replugging the MPEM or EMS ECU The volt age and current might be too weak to go through dirty wire terminals Ch...

Page 404: ...e resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures If in doubt try a new sensor Also remember this validates the operation of the sensor at ambient temperature It does not vali date the over temperature functionality To test it the sensor could be removed from the engine muffler and heated with a heat gun while it is st...

Page 405: ... this diagram to locate the terminal numbers on the Engine connector of the wiring harness when performing tests CAUTION Before unplugging engine connec tor always remove safety lanyard first then wait 15 seconds Otherwise damage to CAPS may occur ENGINE CONNECTOR PIN OUT WIRING HARNESS SIDE CONNECTORS ON ENGINE Removal To remove connectors from engine connector bracket slide a flat screwdriver be...

Page 406: ...moothly when depressing throttle lever Take this opportunity to lubricate the throttle cable IMPORTANT The throttle body is designed to be tamper proof Changing the idle stop or modifying it in any way will not increase performance or change the idle speed but may cause poor startability and erratic idling Before replacing any part check the following as these could be causing the fault Perform th...

Page 407: ...s of throttle body 4 TEC NORMALLY ASPIRATED MODELS 1 Throttle body 2 Screws 4 TEC Supercharged Models Disconnect air intake hose from throttle body Move boot away Remove retaining screws of throttle body 4 TEC SUPERCHARGED MODELS 1 Throttle body 2 Screws Slightly pull throttle body out Disconnect connectors from idle bypass valve and TPS Disconnect throttle cable Installation Installation of the n...

Page 408: ...able Adjustment Mechanically adjust the throttle cable Lubricate cable with BOMBARDIER LUBE lubricant When throttle is released cable must have a free play of 0 5 4 mm 1 64 5 32 in Besides throttle lever must reach handlebar grip without causing strain to cable or brackets Ensure throttle lever fully closes on it s stopper 1 Must touch handlebar grip Ensure throttle body is fully open at full thro...

Page 409: ... safety lanyard connection Check fuel pump operation Repair or replace if necessary Fuel pressure is 303 kPa 44 PSI Fuel pressure more than 303 kPa 44 PSI Fuel pressure less than 303 kPa 44 PSI Perform fuel pump test Check fuel line rail for leaks Crank or start engine Fuel pressure less than 303 kPa 44 PSI Fuel pressure more than 303 kPa 44 PSI Check fuel injector Fails Connect safety lanyard Fue...

Page 410: ...Release pressure using B U D S between tests so that the gauge is reset to zero 0 Crank or start engine and observe fuel pressure The fuel pressure should be the same as above If pressure is within limits fuel pump and pressure regulator are working adequately A rapid pressure drop indicates leakage either from the fuel rail or from the fuel pump check valve Check fuel rail for leaks If it is not ...

Page 411: ...nuity of cir cuit B 29 going towards EMS ECU If it is good try a new EMS ECU b If battery voltage is not read check continuity of circuit 1 26 going towards MPEM If it is good try a new MPEM Fuel Pump Replacement Removal Open front storage compartment cover Remove the storage basket if so equipped Remove front access panel see HULL BODY sec tion Remove front vent tubes Remove glove box see HULL BO...

Page 412: ... oil should be applied to O rings of fuel injectors to ease installation in in take manifold Apply Loctite 243 on rail retaining screws then torque to 10 N m 89 lbf in When installing fuel line connector to the fuel rail put some oil on the O ring to ease installation FUEL INJECTOR IMPORTANT Never mix up fuel injectors of nor mally aspirated and supercharged 4 TEC engines Doing so will automatical...

Page 413: ...ector on harness side and battery ground a If 12 V is read check continuity of circuit as per following table If it is good try a new EMS ECU b If it does not read 12 V check continuity of circuit as per following table If it is good try a new MPEM Resistance Test Reconnect the injector and disconnect the EMS ECU connector A Remove safety lanyard and wait 15 seconds Dis connect engine connector CA...

Page 414: ... with your hand NOTE A thin film of engine oil should be applied to O rings to ease insertion in rail Apply Loctite 243 on rail retaining screws then torque to 10 N m 89 lbf in ELECTRONIC MANAGEMENT EMS ECU AND MPEM REPLACEMENT General Prior to replacing a suspected EMS ECU or MPEM ensure that all the recommendations in the general introduction of this section have been followed IMPORTANT When the...

Page 415: ...000 RPM to be sure no fault appears MPEM Replacement Disconnect battery cables Disconnect AMP connectors from MPEM Re move retaining nuts on top Pull MPEM out Install the new MPEM in vehicle Reconnect AMP connectors to MPEM If the previous MPEM was read with B U D S Transfer the data from the previous MPEM to the new one using B U D S Continue procedure as per FINALIZING MPEM REPLACEMENT below If ...

Page 416: ...T connector 4 CAPS connector 5 Fuel injector connector cylinder 1 6 Ignition coil connector cylinder 1 7 Fuel injector connector cylinder 2 8 Ignition coil connector cylinder 2 9 Fuel injector connector cylinder 3 10 Ignition coil connector cylinder 3 11 TOPS valve connector 12 OSPS connector 13 TPS connector 14 Idle bypass valve connector 15 MATS connector 16 Engine connector 17 MAPS connector 18...

Page 417: ... Locking tie Lead the cable bundle with the injector and igni tion coil connectors to the fuel rail and fix it also by using 4 locking ties 1 Locking ties Connect the fuel injectors ignition coils CAPS CTS and EGT to the wiring harness Install the engine connector on the appropriate bracket on the wiring support Then fix the other bundle on the appropriate sup ports on the wiring support and the E...

Page 418: ...e TPS ensure that mechanical components adjustments are adequate according to THROTTLE BODY in AIR INDUCTION SYSTEM above The EMS may generate several fault codes pertain ing to the TPS Refer to SYSTEM FAULT CODES in DIAGNOSTIC PROCEDURES section for more in formation Wear Test While engine is not running activate throttle and pay attention for smooth operation without physi cal stops of the cable...

Page 419: ...tance should be 1600 2400 Ω Check the resistance between terminal A 24 and terminal A 39 with the throttle plate in idle posi tion The resistance should be approximately 2500 Ω Check the resistance between terminal A 24 and terminal A 39 with the throttle plate in wide open position The resistance should be 1000 1100 Ω Check the resistance between terminal A 24 and A 25 with throttle plate in idle...

Page 420: ...ay lead to poor engine perfor mance and emission compliance could possi bly be affected In addition improper idle bypass valve reset may lead to poor engine starting improper idle too low or way too high and engine stop on deceleration Use the vehicle communication kit VCK with the B U D S software to perform this adjustment Ensure the throttle body plate stop lever rest against its stopper Open t...

Page 421: ...n of the idle bypass valve when it is dismounted Also do not move the piston by hand The screw drive is very sensitive and will be de stroyed Clean the parts and install the idle bypass valve on the throttle body Proceed with the Closed Throttle and Idle Actu ator Reset See above CRANKSHAFT POSITION SENSOR CPS TYPICAL 1 CPS connector Ensure that information center works Needles will sweep LED and ...

Page 422: ...ove the PTO cov er Refer to PTO HOUSING MAGNETO in ENGINE section Remove CPS 1 CPS inside PTO cover Apply Loctite 243 on screw threads then install the new CPS Torque to 10 N m 89 lbf in Reinstall remaining removed parts Encoder Wheel Inspection To check the encoder wheel for bent teeth pro ceed as follows Remove PTO cover Refer to PTO HOUSING MAGNETO in ENGINE section Install a dial indicator on ...

Page 423: ... V is read check continuity of circuits A 20 and A 34 If they test good perform the CAPS voltage test as explained below If CAPS tests good try a new EMS ECU EMS ECU CONNECTOR b If 12 V is not read check continuity of circuit 2 19 from MPEM to the CAPS If it tests good try a new MPEM Otherwise repair wiring harness Remove the CAPS from the cylinder head Set up the following electric circuit to per...

Page 424: ...lf The resistance should be between 2280 Ω and 2740 Ω at 20 C 68 F Otherwise replace the MATS If resistance tests good reconnect the MATS and disconnect the EMS ECU connector A on the EMS ECU Using a multimeter recheck resistance value be tween terminals 7 and 21 If resistance value is correct try a new EMS ECU Refer to EMS ECU REPLACEMENT procedures elsewhere in this section If resistance value i...

Page 425: ...e the fuel rail cover Disconnect CTS connector and remove CTS Install the new CTS and torque to 18 N m 159 lbf in Reinstall remaining removed parts MANIFOLD AIR PRESSURE SENSOR MAPS IMPORTANT Never mix up MAPS of normally as pirated and supercharged 4 TEC engines Doing so will automatically lead to a misfunction of the EMS ECU and will cause a bad engine calibration TYPICAL 1 Manifold air pressure...

Page 426: ...stall the new MAPS paying attention to index its tab into the adaptor notch Apply Loctite 243 blue on screw then torque to 10 N m 89 lbf in EXHAUST GAS TEMPERATURE SENSOR EGT 1 Muffler 2 Exhaust gas temperature sensor EGT Resistance Test Disconnect the connector from the EGT and check the resistance of the sensor itself The resistance should be between 2280 Ω and 2740 Ω at 20 C 68 F Otherwise repl...

Page 427: ...etween both terminals on the knock sensor harness side The resistance should be approximately 5 MΩ If resistance is not good replace knock sensor If resistance is good reconnect the knock sensor connector and disconnect the EMS ECU connec tor A from the EMS ECU Using a multimeter recheck resistance value be tween terminals 9 and 23 If wiring harness is good try a new EMS ECU Re fer to EMS ECU REPL...

Page 428: ...ance Test Disconnect the connector from the OPS and use a multimeter to check the resistance between OPS terminal and engine ground while engine is stopped without oil pressure and while engine is running with oil pressure When engine is stopped the resistance is infinitely high normally open switch When engine is running and the oil pressure reach es 180 220 kPa 26 32 PSI the resistance of the OP...

Page 429: ...ck the resistance between OSPS terminal and engine ground while engine is stopped without blow by pressure and while en gine is running with blow by pressure When engine is stopped and the blow by pressure is released the resistance of the OSPS is close to 0 Ω normally closed switch When engine is running and the blow by pressure exceeds 40 kPa 6 PSI the resistance is infinitely high If resistance...

Page 430: ...nocking noise Check TOPS switch Check output voltage on wiring harness Replace TOPS valve Lower than 8 V Greater than 8 V No OK Fails Repair or replace Install engine leak test pump gauge on oil dipstick tube Start engine Yes No Pressure drops down directly after reaching 40 kPa 5 8 PSI TOPS valve opens again TOPS OK Yes Check OSPS Fails OK Fails Yes No OK Fails Replace OSPS Retest Retest OK Try a...

Page 431: ...valve by installing the safety lanyard on the DESS post If you can hear the movement of the piston knock ing the valve works fine otherwise follow the pro cedure shown in the following chart NOTE Take into account that you could hear the piston movement and the valve might not be working properly The retaining washer could be unlocked from the piston shaft Disassembly will reveal its condition TOP...

Page 432: ... available from after market tool equipment suppliers to pre ventspark occurringin the bilge Otherwise perform the following checks An ignition coil with good resistance measure ment can still be faulty Voltage leak can occur at high voltage level which is not detectable with an ohmmeter Replacing the ignition coil may be nec essary as a test Voltage Test Disconnect the connector from the ignition...

Page 433: ...ound the seal area that touches the spark plug hole After installation ensure the seal seats properly with engine top surface TDC SETTING Top Dead Center The EMS is able to determine the exact position of camshaft and crankshaft That means that no TDC setting has to be performed It is used for both injection and ignition timings ENGINE START STOP SWITCH VERIFICATION A quick operation test can be d...

Page 434: ...module enhances safety lanyard recognition at the EMS ECU It is located under steering sup port It is an inline connection of the DESS post harness If a safety lanyard cannot be programmed or it fails to be recognized first refer to the basic self diagnos tic mode in DIAGNOSTIC PROCEDURES section If it still does not work disconnect the DESS aux iliary module and connect the regular 6 pin DESS har...

Page 435: ...llowing chart 2 Apply anti seize lubricant over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into cylinder head Then 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 T...

Page 436: ...er P followed by 4 digits P 1234 can be displayed in the information center for troubleshooting With safety lanyard on its post press 5 times the SET button to start the display of P codes onboard diagnostic Press MODE to scroll codes if more than one is present When list is over END will appear When END appears press MODE to exit 1 Press 5 times to activate display of P codes onboard diagnostic 1...

Page 437: ... MAPS Manifold Air Pressure Sensor APS Air Pressure Sensor or Atmospheric Pressure Sensor MATS Manifold Air Temperature Sensor ATS Air Temperature Sensor or Intake manifold Temperature Sensor Communication link CAN CTS Coolant Temperature Sensor WTS Water Temperature Sensor EGT Exhaust Gas Temperature ETS Exhaust Temperature Sensor TOPS valve Tip Over Protection System Blow by valve Idle bypass va...

Page 438: ...fety lanyard from its post A 2 seconds beep every minute interval High pressure in oil separator tank Refer to LUBRICATION SYSTEM section Low fuel level Refer to INSTRUMENTS AND ACCESSORIES section Fuel tank level sensor or circuit malfunction Refer to INSTRUMENTS AND ACCESSORIES section A 2 seconds beep every 15 minutes interval Watercraft is upside down Turn watercraft upright If it does not wor...

Page 439: ...he status bar shows the protocol KW2000 and a number 1 or 2 to the right To work with the watercraft number 2 must be displayed Number 2 means that 2 ECUs are connected MPEM and EMS ECU MPEM AND EMS ECU ARE CONNECTED Number 1 means that 1 ECU is connected ei ther MPEM or EMS ECU Therefore there is a problem Check fuses and connections ONLY ONE ECU IS WORKING THERE IS A PROBLEM If an X is shown the...

Page 440: ...nition system they are clean and well tightened and that all electronic components are genuine particularly in the ignition sys tem Installing resistive caps non resistive spark plugs or improper knock sensor wir ing routing may lead to generate this fault code Electrical noise might also lead engine to occa sional cutout without generating a fault code when engine is restarted When looking at the...

Page 441: ... Yes Fix and reset Closed Throttle and Idle Actuator Inspect sensor for damage or corrosion Yes Replace and reset Closed Throttle and Idle Actuator Inspect wiring voltage test Failed Repair Inspect wiring and sensor resistance test Failed If bad wiring repair If bad TPS replace and reset Closed Throttle and Idle Actuator Test sensor operation wear test Replace and reset Closed Throttle and Idle Ac...

Page 442: ...ND CARE 09 02 1 CIRCUIT 09 02 11 COMPONENTS 09 02 15 CARE 09 02 18 CIRCUIT 09 02 20 COOLING SYSTEM LEAK TEST 09 02 21 INSPECTION 09 02 22 DRAINING THE SYSTEM 09 02 23 COOLANT REPLACEMENT 09 02 23 COOLANT PUMP HOUSING 09 02 24 THERMOSTAT 09 02 25 COOLANT PUMP IMPELLER 09 02 26 ROTARY SEAL 09 02 27 CARE 09 02 29 www SeaDooManuals net ...

Page 443: ...FM 09 02 1 CIRCUIT COMPONENTS AND CARE 0 717 Engines F17E04T Loctite 567 Loctite 567 Bleed hose Water injection hose Tuned pipe water inlet hose Loctite 567 Engine drain hose Engine water supply hose Engine water return hose 1 2 N m 11 lbf in Pump support Loctite 567 www SeaDooManuals net ...

Page 444: ...5E04T 1 Loctite 592 Loctite 592 1 2 N m 11 lbf in Water injection hose Tuned pipe water inlet hose 1 2 N m 11 lbf in Regulator valve water supply hose 2 Loctite 592 Engine drain hose Inlet Outlet 4 3 7 8 6 0 6 N m 5 lbf in 5 5 N m 44 lbf in 0 11 N m 1 lbf in Inlet Outlet Loctite 567 Loctite 567 www SeaDooManuals net ...

Page 445: ...47 DI Engines TYPICAL F12E0XS Loctite 567 1 Loctite 567 2 Body Loctite 243 Loctite 518 4 7 0 11 N m 1 lbf in 8 6 0 6 N m 5 lbf in 5 5 N m 44 lbf in 3 Loctite 567 Loctite 567 Loctite 567 Loctite 296 Silicone sealant Loctite primer N Loctite 567 Loctite 567 Loctite 567 Loctite 567 www SeaDooManuals net ...

Page 446: ...Section 09 COOLING SYSTEM Subsection 02 CIRCUIT COMPONENTS AND CARE 09 02 4 SMR2003 029_09_02A FM 4 TEC Engines Closed Loop System F18E0ZS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 www SeaDooManuals net ...

Page 447: ...Section 09 COOLING SYSTEM Subsection 02 CIRCUIT COMPONENTS AND CARE SMR2003 029_09_02A FM 09 02 5 4 TEC Engines Open Loop System F18E1DS www SeaDooManuals net ...

Page 448: ...et fitting limits water flow ALSO used as flushing connector Cooling System Indicator CSI Small stream of water flows out of bleed outlet located under bumper line on front port side Engine water hose outlet Pressure zone Calibrated outlet fitting limits water flow Tuned pipe bleed hose injects water into muffler to cool exhaust components Lowest point of circuit allows draining whenever engine is...

Page 449: ...ce improvement Water flows through the tuned pipe and manifold water jackets then to the cylinder water jackets Engine water supply hose Engine heat exchanger water outlet hose exits at the exhaust outlet for noise reduction Serial cooling system cylinder head combustion chambers are cooled with the water from the jet pump Engine heat exchanger outlet Engine drain hose from cylinder heat exchanger...

Page 450: ...pipe water jacket Water flows out of exhaust manifold water jacket and through tuned pipe water jacket before exiting the tuned pipe Water injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and 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 ea...

Page 451: ... pipe water jacket Water flows out of exhaust manifold water jacket and through tuned pipe water jacket before exiting the tuned pipe Water injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and performance improvement Side of hull Air compressor silencer Quick connect hose fitting for easy engine draining Temperature sensor activates monitoring beeper when...

Page 452: ... ride plate Coolant housing including thermostat opens at 87 C 188 F and coolant pump impeller Bleed hose from cylinder head to expansion coolant tank Expansion coolant tank Coolant temperature sensor CTS activates when temperature exceeds 100 C 212 F Coolant flows to oil cooler Oil cooler Coolant returns from oil cooler Coolant returns from ride plate www SeaDooManuals net ...

Page 453: ...d pipe exhaust manifold and cylinders 4 Water from cylinder water jackets exiting engine The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation Water is pre heated by the exhaust system before entering the cylinder cooling jackets Water enters cylinder cooling jacket through pas sages located below exhaust ports from tuned pipe 1 Water passages No water ente...

Page 454: ...g The water coming out of the engine heat exchang er is evacuated at the exhaust outlet for noise re duction DI Engines The water supply is provided by a pressurized area in the jet pump between the impeller and venturi The water flow is controlled by a reducer located between the jet pump support and the jet pump on the inlet side The reducer is blue on the DI models The water is entering the eng...

Page 455: ...ran som of the watercraft 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 Draining of the cooling system is accomplished by the drain hose connected to a fitting at the bo...

Page 456: ...ated water is injected in the tuned pipe by a calibrated fitting 1 Injection fitting All 2 Stroke Engines CAUTION Never modify cooling system arrange ment 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 ...

Page 457: ... be interchanged with one of a different size as severe engine damage could result The elbow fitting can be identified by using the number stamped onto the fitting or by measuring its inside diameter Refer to the following illustra tion and chart 1 Stamped number A Outlet diameter 4 6 mm 181 in B Inlet diameter 5 5 mm 219 in Water Flow Regulator Valve A water flow regulator valve is mounted on mod...

Page 458: ...countries it is illegal to tamper with this valve as this will af fect the EPA certification 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 459: ...if the engine has poor performance the water flow regulator valve should be considered in the troubleshooting of the problem Disassembly Remove the cover no 4 of the valve by releasing the spring no 3 1 Spring 2 Cover Remove fitting no 5 from valve housing 1 Fitting Unscrew the tapered needle no 6 NOTE Hold the valve to prevent it from turning 1 Tapered needle Remove the tapered needle from valve ...

Page 460: ...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 refer to STOR AGE 717 Engines When servicing the hull always rotate watercraft counterclockwise seen from the rear Rotating watercraft on the opposite...

Page 461: ...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 wa tercraft in water and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km h 15 MPH Snugly install the hose pincher on the water sup ply hose as shown in the following illustrations 717 ENGINES GTI AND G...

Page 462: ...maller quantity of engine coolant enters the en gine block on the exhaust side for a better cooling In the cylinder head the water channels flow around the exhaust and then the intake valves and leave the engine through a large hose From there the coolant goes back to the water pump housing and depending on the engine temperature it flows through the thermostat directly back to the water pump impe...

Page 463: ...pressurized area in the jet pump between the impeller and venturi The water flow is controlled by a reducer located between the jet pump support and the jet pump on the inlet side The reducer is black on the 4 TEC models Water is directed to the exhaust manifold fitting located at front of manifold 1 Exhaust manifold 2 Water inlet 3 Water outlet Water enters the manifold end and is directed to wat...

Page 464: ...oles at the end of the water packet and mixes with exhaust gas in the muffler Water is expulsed from mufflers then through the exhaust outlet in transom area Clamp To cut or secure non reusable Oetiker clamps of cooling system hoses use pliers P N 295 000 070 1 Cutting clamp 2 Securing clamp INSPECTION Check general condition of hoses and clamp tight ness Check the weep hole if there is oil or coo...

Page 465: ...ntifreeze and 50 water Pure antifreeze will freeze at a higher tempera ture than the optimal water antifreeze mix Al ways use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines System Capacity Refer to TECHNICAL DATA Coolant Replacement Procedure Drain the system completely as described above Watercraft should be level engine cold and drain plu...

Page 466: ...y of the coolant using an antifreeze hydrometer NOTE Follow hydrometer manufacturer instruc tions for proper use The reading should be some degrees below the coldest temperature you expect in the area where the watercraft is to be used Add water or anti freeze accordingly Refill to the proper level CAUTION Pure antifreeze will freeze at a high er temperature than the optimal water anti freeze mix ...

Page 467: ...Screws M6 x 25 2 Screws M6 x 105 CAUTION To prevent leaking take care that the gaskets are exactly in groove when you re install the coolant pump housing Apply Loctite 243 on screw threads and torque to 10 N m 88 lbf in Tightening sequence for screws on coolant pump housing is as per following illustration THERMOSTAT The thermostat is a single action type Removal Remove the coolant pump housing fr...

Page 468: ...eturn hose connection to see the move ment of the thermostat Thermostat should open when water temperature reaches 87 C 188 F If there is no operation replace coolant pump housing and thermostat Installation For installation reverse the removal procedure paying attention to the following details Refer to COOLANT PUMP HOUSING REPLACE MENT in this section COOLANT PUMP IMPELLER Removal Remove coolant...

Page 469: ...s disassembled both parts have to be replaced together Removal Remove coolant pump housing no 6 CAUTION Always unscrew the impeller clock wise otherwise you can damage the compo nents unscrew the impeller no 8 clockwise remove PTO cover no 10 refer to PTO HOUSING MAGNETO section remove screws no 11 retaining oil pump cover 1 Retaining screws 2 Oil pump cover remove oil pump cover no 12 remove oute...

Page 470: ...ion to the following details NOTE Never use oil in the press fit area of the oil seal and rotary seal Push water pump shaft oil seal in place by using thumb Install the new rotary seal using the rotary seal in staller P N 529 035 823 CAUTION Never use a hammer for the rotary seal or water oil pump shaft installation Only use a press to avoid damaging the ceramic component 1 Rotary seal 2 Rotary se...

Page 471: ...ing your watercraft in water pinch the water supply hose from the jet pump housing to the engine with a large Hose Pincher P N 529 032 500 This will prevent the exhaust cooling system from filling which may lead to water being injected into and filling the exhaust system and the engine Without the engine running there isn t any ex haust pressure to carry the water out the exhaust outlet CAUTION Fa...

Page 472: ... CONTROL Thermostat SYSTEM BLEEDING Self bleed type through expansion tank hose at uppermost point of circuit SYSTEM DRAINING Self drain type on the exhaust cooling system hose at lowest point of circuit SYSTEM FLUSHING Required only for exhaust cooling system open loop system MONITORING BEEPER Turns on at 100 C 212 F COOLANT LIFE CYCLE 100 hours or 1 year Should be replaced before storage www Sea...

Page 473: ...0 02 6 REMOVAL 10 02 6 INSPECTION 10 02 9 ASSEMBLY 10 02 10 FUEL SYSTEM PRESSURIZATION 10 02 10 AIR INTAKE 2 STROKE 10 03 1 REMOVAL 10 03 4 ASSEMBLY 10 03 6 CARBURETOR 10 04 1 GENERAL 10 04 2 REMOVAL 10 04 2 CLEANING 10 04 3 DISASSEMBLY AND INSPECTION 10 04 3 ASSEMBLY 10 04 5 INSTALLATION 10 04 7 ADJUSTMENTS 10 04 7 www SeaDooManuals net ...

Page 474: ...I LE Models 22 N m 16 lbf ft 8 4 N m 35 lbf in 4 4 N m 35 lbf in 5 6 7 Body 2 N m 18 lbf in 6 N m 53 lbf in 1 2 N m 11 lbf in 3 N m 27 lbf in 2 1 3 1 2 N m 11 lbf in 1 2 N m 11 lbf in 4 N m 35 lbf in 12 11 10 3 N m 27 lbf in 9 13 1 2 N m 11 lbf in Engine Dielectric grease 4 F06F18S 14 www SeaDooManuals net ...

Page 475: ...Section 10 FUEL SYSTEM Subsection 02 FUEL CIRCUIT 10 02 2 SMR2003 030_10_02A FM XP DI Models F08F0OS 6 7 16 8 18 17 14 4 5 4 22 N m 16 lbf ft 4 N m 35 lbf in 13 www SeaDooManuals net ...

Page 476: ...ction 10 FUEL SYSTEM Subsection 02 FUEL CIRCUIT SMR2003 030_10_02A FM 10 02 3 GTI LE RFI Models F02F27S Body 6 7 10 11 8 22 N m 16 lbf ft 4 N m 35 lbf in 5 4 4 N m 35 lbf in 4 13 14 www SeaDooManuals net ...

Page 477: ...on 10 FUEL SYSTEM Subsection 02 FUEL CIRCUIT 10 02 4 SMR2003 030_10_02A FM All DI Models except XP DI F12F15S 6 7 16 5 4 4 N m 35 lbf in 22 N m 16 lbf ft 4 4 N m 35 lbf in 13 14 8 18 17 www SeaDooManuals net ...

Page 478: ...on 10 FUEL SYSTEM Subsection 02 FUEL CIRCUIT SMR2003 030_10_02A FM 10 02 5 4 TEC Engines F18F08S 2 5 N m 22 12 lbf in 7 6 5 4 13 22 N m 16 lbf ft 4 N m 35 lbf in 4 4 N m 35 lbf in 14 8 www SeaDooManuals net ...

Page 479: ...er Carburetor Equipped Models Open storage compartment cover Remove basket XP DI Models Open engine cover and remove basket GTI GTI LE Models Remove seat 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 recommendations de scribed in ENGINE MAN...

Page 480: ...condi tion of use 4 TEC Models Fuel filters are not replaceable on 4 TEC models They are lifetime reliable under the normal condi tion of use DI Models A replaceable inline filter is located near the fuel tank Refer to ENGINE MANAGEMENT DI sec tion CAUTION A pressure test needs to be com plete after replacement Fuel Baffle Pick Up Carburetor Equipped Models NOTE The baffle pick up has an integrate...

Page 481: ...apter from baffle Push inward on the 3 clips at the base of the baffle in order to remove the filter Pry base off using a small slotted screwdriver if necessary Electric Fuel Pump RFI 4 TEC and DI Models Refer to appropriate ENGINE MANAGEMENT section Fuel Tank All Models except 4 TEC Models NOTE On all models except RFI and LRV DI it is necessary to remove the engine Refer to RE MOVAL and INSTALLA...

Page 482: ...ed 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 RFI Models The filter at fuel pump inlet is not replaceable indi vidually The complete fuel pump unit has to be replaced Refer to ENGINE MANAGEMENT...

Page 483: ...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 attention to the following Reinstall fuel pu...

Page 484: ...pray a solution of soapy water on com ponents bubbles will indicate leak location NOTE The system 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 pr...

Page 485: ...NTAKE 2 STROKE SMR2003 031_10_03A FM 10 03 1 AIR INTAKE 2 STROKE 0 717 Engines F02F2CS 10 N m 89 lbf in 3 4 2 10 N m 89 lbf in 8 6 10 N m 89 lbf in Loctite 518 10 Loctite 518 5 9 1 7 Loctite 243 Loctite 243 15 Loctite 243 www SeaDooManuals net ...

Page 486: ...EL SYSTEM Subsection 03 AIR INTAKE 2 STROKE 10 03 2 SMR2003 031_10_03A FM 787 RFI Engines F15F01T 2 1 4 9 3 10 N m 89 lbf in 5 10 10 N m 89 lbf in 6 7 10 N m 89 lbf in 8 Loctite 243 Loctite 243 www SeaDooManuals net ...

Page 487: ...0 FUEL SYSTEM Subsection 03 AIR INTAKE 2 STROKE SMR2003 031_10_03A FM 10 03 3 947 DI Engines 2 11 12 4 13 3 Super Lube 14 Loctite 243 F18F0NS Loctite 243 Loctite 243 XP DI only Loctite 243 www SeaDooManuals net ...

Page 488: ...silencer base no 4 1 Retaining plate 2 Remove screws Flame Arrester Base Remove flame arrester no 5 Remove screws no 8 retaining support no 6 of flame arrester base to the cylinder head cover 717 engines or to the exhaust manifold 787 engines TYPICAL 1 Remove support Remove screws no 10 from flame arrester base then withdraw base NOTE On GTI and GTI LE models withdraw both arrester supports no 15 ...

Page 489: ...earward to remove it from the lower bracket no 4 and remove it in a rotating movement XP DI Models Detach 2 straps from the oil reservoir using spring remover tool P N 529 035 559 Unclip oil filter Pull oil reservoir out Remove foam under the fuel tank Remove air ducts and protector pads of air silencer Pull the air silencer forward to remove it from the lower bracket no 4 and remove it in a rotat...

Page 490: ...take silencer on throttle bodies and latch in place Clip air intake silencer back in place Properly reinstall hair pin to secure clip no 2 Ensure the elbow adaptor is well inserted and that it has not pushed the gasket inside the air intake silencer NOTE Make sure the air intake silencer is retained by the lower bracket no 4 Place protector pads on duct supports Use slot in rubber to insert pad on...

Page 491: ... 0 For fuel system on RFI DI and 4 TEC models refer to appropriate ENGINE MANAGEMENT section Mikuni BN 40i F17F01S Loctite 243 11 9 12 20 21 13 14 6 7 4 19 5 15 2 13 8 3 18 17 16 1 20 N m 15 lbf ft Anti seize lubricant Synthetic grease Loctite 243 Synthetic grease 20 www SeaDooManuals net ...

Page 492: ...e A metering jet in the fuel inlet hose controls fuel flow to the pump A check valve on the fuel outlet hose helps to prime the system REMOVAL To remove carburetor from engine proceed as fol lows Remove air vent tube support GTI and GTI LE models 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 ...

Page 493: ...m Pump Diaphragm Leak Test Using a suitable pump gauge tester perform the following test proceeding as follows Install pump gauge tester P N 295 000 114 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI TYPICAL 1 Pump gauge tester 2 Install on pulse nipple Diaphragm must stand pressure for 10 seconds If pressure drops replace diaphragm no 3 Fuel Pump Valve Check fuel pump valve operation a...

Page 494: ...lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on inlet nipple of accelerator pump no 22 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 495: ...previous 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 ass...

Page 496: ...se hold carbure tor upside down pour oil over needle valve and apply pressure Check for bubbles If they come from seat or O ring bubbles will exit around seat Retighten as necessary If it still leaks remove needle and seat and replace O ring If bubbles come from needle replace needle and seat Main Jet and Pilot Jet Pilot jet no 10 and main jet no 9 are replaceable Different jet sizes are available...

Page 497: ...r At installation pay attention to the following Install carburetor with gasket to intake manifold rotary valve cover Apply synthetic grease on screws no 20 Then install screws no 20 with lock washers no 21 and torque to 20 N m 15 lbf ft Fuel Lines and Hose Clamps If fuel line ends are damaged cut damaged end before reinstallation Properly install clamps For fuel system pressurization refer to FUE...

Page 498: ...nia Models Low Speed Screw Adjustment 1 Low speed screw CAUTION Donot attempt toset engine idle speed with low speed screw Tighten low speed screw until a slight resistance is felt Then back it off to the specification as per following chart NOTE Turning screw clockwise leans mixture and turning screw counterclockwise enriches mixture Start and warm up engine CAUTION If watercraft is out of water ...

Page 499: ...ine idles at 1500 RPM in water or 3000 RPM out of water Fuel Accelerator Pump All Engines Ensure throttle cable and idle speed are properly adjusted 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 TYPICAL 1 Adjustment screw ...

Page 500: ...01 1 TABLE OF CONTENTS 0 OIL INJECTION SYSTEM 11 02 1 GENERAL 11 02 4 OIL SYSTEM PRESSURIZATION 11 02 4 OIL INJECTION PUMP 11 03 1 OIL PUMP IDENTIFICATION 11 03 4 REMOVAL 11 03 4 DISASSEMBLY 11 03 4 CLEANING 11 03 4 ASSEMBLY 11 03 5 ADJUSTMENT 11 03 6 CHECKING OPERATION 11 03 9 www SeaDooManuals net ...

Page 501: ...STROKE Subsection 02 OIL INJECTION SYSTEM SMR2003 033_11_02A FM 11 02 1 OIL INJECTION SYSTEM 0 GTI Series 1 2 3 4 1 27 N m 20 lbf ft 3 5 N m 31 lbf in Dielectric grease 1 2 N m 11 lbf in 3 5 N m 31 lbf in F17G02S www SeaDooManuals net ...

Page 502: ...Section 11 LUBRICATION SYSTEM 2 STROKE Subsection 02 OIL INJECTION SYSTEM 11 02 2 SMR2003 033_11_02A FM XP DI Models F08G05S 4 3 Oil pump Under air compressor Steering harness www SeaDooManuals net ...

Page 503: ...2 STROKE Subsection 02 OIL INJECTION SYSTEM SMR2003 033_11_02A FM 11 02 3 RX DI and GTX DI Models Under air compressor F12G07S 3 5 N m 31 lbf in 1 4 1 2 2 3 3 5 N m 31 lbf in 27 N m 20 lbf ft Dielectric grease www SeaDooManuals net ...

Page 504: ...Connect pump gauge tester P N 529 021 800 to oil injection reservoir vent check valve 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 All Models If pressure is not maintained locate leak and r...

Page 505: ... SMR2003 034_11_03A FM 11 03 1 OIL INJECTION PUMP 0 717 Engines F00G03T Loctite 243 1 4 5 N m 40 lbf in 8 N m 71 lbf in 8 N m 71 lbf in 2 3 10 N m 89 lbf in 5 Loctite 243 6 N m 53 lbf in 6 4 6 N m 53 lbf in Loctite 243 5 N m 44 lbf in Synthetic grease www SeaDooManuals net ...

Page 506: ...UBRICATION SYSTEM 2 STROKE Subsection 03 OIL INJECTION PUMP 11 03 2 SMR2003 034_11_03A FM 787 RFI Engines F07G0DS 6 6 N m 53 lbf in 4 5 N m 40 lbf in 9 8 7 3 N m 27 lbf in 1 4 5 N m 40 lbf in www SeaDooManuals net ...

Page 507: ...STROKE Subsection 03 OIL INJECTION PUMP SMR2003 034_11_03A FM 11 03 3 947 DI Engines Throttle cable Oil pump 1 6 N m 53 lbf ft 8 6 N m 53 lbf ft 4 5 N m 40 lbf ft 6 6 Molykote 111 Loctite 243 Loctite 243 F12G08S www SeaDooManuals net ...

Page 508: ... 420 277 905 and unscrew lock nut no 4 1 Gear holder Remove 2 Allen screws no 6 with flat washers retaining oil injection pump to intake manifold no 2 Remove pump 947 DI Engines Remove tuned pipe head Refer to EXHAUST SYS TEM The cable end has a slight press fit in the lever Using a small screwdriver pry cable end out 787 RFI and 947 DI Engines Disconnect oil injection pump cable no 7 Remove 2 All...

Page 509: ...l Pump Gear Install gear no 3 to oil injection pump shaft Torque lock nut no 4 to 6 N m 53 lbf in NOTE Make sure 1 washer is installed on each side of gear Install intake manifold no 2 to rotary valve cover and torque screws no 5 to 10 N m 89 lbf in TYPICAL A 10 N m 89 lbf in 787 and 947 DI Engines Oil Injection Pump and Shaft Make sure shaft no 8 is installed in crankshaft end Install pump Secure...

Page 510: ...pecified Preliminary Synchronization NOTE To check synchronization of pump as a rou tine maintenance see Final Synchronization Make sure idle speed screw on carburetor is prop erly set on Carburetor Equipped Engines Refer to CARBURETOR for throttle cable adjust ment procedure NOTE On a twin carburetor engine make sure carburetors are properly synchronized Turn oil pump cable adjustment nut to alig...

Page 511: ...r All Engines Start and bring engine to normal operating temper ature CAUTION If watercraft is out of water engine must be cooled using the flush kit If air bubbles are present in the oil injection system bleed system before operating engine Adjust idle speed to specification on Carburetor Equipped Engines Refer to CARBURETOR NOTE On RFI engines refer to FUEL INJECTION for idle speed adjustment pr...

Page 512: ...l injection reservoir is sufficiently filled Install a dry rag below oil injection pump Loosen bleed screw to allow oil to flow 717 ENGINES 1 Bleed screw 787 RFI ENGINES 1 Bleed screw 947 DI ENGINES 1 Bleed screw Keep bleeding until all air has escaped from line Make sure no air bubbles remain in oil supply line Tighten bleed screw Wipe any oil spillage Check small oil lines of the pump They must ...

Page 513: ...e pump assembly and check the pump gear 717 engine or shaft 787 RFI and 947 DI engines for defects replace as necessary Test pump as described below NOTE Through normal use oil level must not drop in small tubes 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...

Page 514: ...3 6 CABLE TERMINAL INSTALLATION 12 03 12 STARTING SYSTEM 12 04 1 GENERAL 12 04 4 STARTING SYSTEM TROUBLESHOOTING 12 04 5 STARTER REMOVAL 12 04 6 STARTER DISASSEMBLY 12 04 7 CLEANING 12 04 10 PARTS INSPECTION 12 04 11 STARTER ASSEMBLY 12 04 12 STARTER INSTALLATION 12 04 13 STARTER SPECIFICATION 12 04 16 INSTRUMENTS AND ACCESSORIES 12 05 1 GENERAL 12 05 1 POWER SUPPLY CUT OFF RELAY VERIFICATION 12 0...

Page 515: ... together in this Digital CDI ignition sys tem 787 RFI Engines Unregulated AC current is produced by the mag neto This AC current is rectified and regulated by the charging system The resulting regulated DC is used to charge the battery The CPS MPEM ECU and the ignition coil work together in this Digital Inductive ignition system All Engines A 12 volts battery supplies the Multi Purpose Elec troni...

Page 516: ...s related to the ignition system ignition timing curve engine rev limiter For the other functions of the MPEM refer to IN STRUMENTS AND ACCESSORIES section 787 RFI Engines The MPEM is also used with the Rotax Fuel Injec tion system The RFI models use a Digital Inductive Ignition system The Bosch ECU controls the ignition tim ing and dwell time It receives input from the CPS and signals the ignitio...

Page 517: ...e activated before checking ignition timing See FIXED TIMING FUNCTION paragraph Static Test All Engines 1 Disconnect MAG side spark plug wire and con nect wire to grounding device then remove spark plug CAUTION Never crank engine with spark plugs removed unless spark plug cables are connect ed to the grounding device 2 Remove PTO flywheel guard 717 Engines 3 Install timing mark pointer tool on eng...

Page 518: ...slot 717 engines or aligned with timing mark pointer tool 787 RFI engines TYPICAL 1 Tool slot 2 Flywheel mark NOTE This mark becomes the reference when using the stroboscopic timing light CAUTION The static test cannot be used as a timing procedure therefore always check the timing with a stroboscopic timing light 9 Remove TDC gauge 10 Reinstall spark plug and connect wire Dynamic Test To check ig...

Page 519: ... wire 1 Timing light pick up 3 Start engine and point timing light straight in line with timing tool slot Bring engine to 6000 RPM 1 Timing light straight in line with tool slot CAUTION If engine is to be run more than a few seconds engine must be cooled using the flush kit 4 Check if PTO flywheel mark aligns with timing tool slot NOTE On this system timing advance decreases as engine speed increa...

Page 520: ...CAUTION If engine is to be run more than a few seconds engine must be cooled using the flush kit NOTE If mark on PTO flywheel is perfectly align ed with timing mark pointer no adjustment is re quired If mark does not align with pointer recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen or moved Ignition Timing Adjustment 717 Engines Remove magneto hous...

Page 521: ...tioning procedure if timing mark position is not adequate 787 RFI Engines CAUTION If the ignition timing is adjusted too advanced this will cause serious damage to the engine VCK Vehicle Communication Kit For the 787 RFI engines use the VCK Vehicle Communication Kit P N 295 035 676 NOTE For more information on the VCK refer to its online help B U D S Bombardier Utility Diagnostic Software is desig...

Page 522: ...mer display Timing 12 00 deg 9 Press any key to continue Programmer will go back one level to Adjustment 10 Press Menu to go back one level to Diagnosis 11 Press Menu to go back one level to Bosch sys tem 12 Programmer now ask Quit Bosch Diagnosis Choose yes to quit Press 2 to choose Start Vehicle the program mer will then ask Modify Max RPM press menu then start engine with start stop button NOTE...

Page 523: ...re of the start stop switch Using an ohmmeter connect test probes to YELLOW RED wire and to ground Measure resistance it must be an open circuit switch is normally open Depress and hold switch the ohmmeter should read close to 0 ohm Safety Lanyard Switch Verification NOTE The safety lanyard also controls the power supply cut off relay Refer to INSTRUMENTS AC CESSORIES for its testing procedure If ...

Page 524: ...4 pin magneto harness adapter 3 RED BLACK wire 4 BLACK wire DYNAMIC TEST 1 Connect spark plug cables to grounding device 2 Disconnect magneto wiring harness connector 3 Installthe4 pinmagnetoharnessadapter P N295 000 131 4 Connect positive test probe of the multimeter to the RED BLACK wire of the 4 pin magneto harness adapter 5 Connect negative test probe of the multimeter to BLACK wire of the 4 p...

Page 525: ...uld be 12 3 KΩ at 20 C NOTE A short circuit will read 0 ohm or close to on ohmmeter 787 RFI Engines Primary Winding IGNITION COIL 1 Primary side 2 Secondary side 3 Ground wire Disconnect the wire connector on the primary side of the ignition coil Using a multimeter check the resistance between the terminals 1 and 2 Repeat a resistance test be tween terminals 2 and 3 The resistance should be 0 3 to...

Page 526: ...lugs 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 shorter 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...

Page 527: ... 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 cylinde...

Page 528: ...7 8 9 10 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...

Page 529: ...7 DI Engines The unit is using a 3 phase in series rectifier regulator which transforms AC from the magneto into DC to allow battery charging Battery The battery is the DC source for the electric start er the Multi Purpose Electronic Module and all ac cessories Fuse If the battery is regularly discharged check fuse condition The rectifier regulator could be the culprit of a blown fuse To check sim...

Page 530: ...m the connector 1 RED wire Connect an ammeter across the fuse holder Start engine Bring engine to approximately 6000 RPM Note the reading This is the current supplied by the regulator Reinstall fuse Remove the 20 A fuse from the holder with the RED PURPLE wire coming from the connector 1 Fuse holder Connect an ammeter across the fuse holder Start engine Bring engine to approximately 6000 RPM Note ...

Page 531: ... the tab housing of the rectifier regulator Reconnect the connector housing Connect the positive probe of a multimeter to the RED wire and the negative probe to the BLACK wire Set multimeter to Vdc scale Start and rev engine to 3500 RPM The obtained value should be between 12 and 25 Vdc NOTE If the rectifier regulator is within the specifi cation either the MPEM or wiring harness between the recti...

Page 532: ...ed or repaired DYNAMIC TEST 1 Disconnect the magneto wiring harness connec tor 2 Installthe4 pinmagnetoharnessadapter P N 295 000 131 between connectors 3 Connect test probes of the multimeter to the YELLOW and BLACK YELLOW wires of the 4 pin magneto harness adapter 4 Start and rev engine to 3500 RPM The obtained value should be between 25 and 40 Vac 5 If the battery charging coil is out of specif...

Page 533: ... placed or repaired DYNAMIC TEST 1 Disconnect the magneto wiring harness connec tor 2 Installthe6 pinmagnetoharnessadapter P N 295 000 136 between connectors NOTE On 4 TEC engines disconnect the stator wiring harness connector and probe the three con nectors 3 Connect test probes of the multimeter to two of the YELLOW wires of the 6 pin magneto har ness adapter 4 Set multimeter to Vac scale 5 Star...

Page 534: ...00 131 between connectors 3 Connect test probes of the multimeter to the BLACK YELLOW and RED BLACK wires of the 4 pin magneto harness adapter 4 Set multimeter to Vac scale 5 Start and rev engine to 3500 RPM The obtained value should be between 45 and 70 Vac 6 Repeat test with the BLACK wire and either the RED BLACK or BLACK YELLOW wires of the 4 pin magneto harness adapter 7 If the stator is out ...

Page 535: ...f the watercraft Pull battery from under resonator and remove bat tery from watercraft All Models CAUTION Should any electrolyte spillage oc cur immediately wash off with a solution of baking soda and water Cleaning Clean the battery casing caps cables and battery posts using a solution of baking soda and water CAUTION Do not allow cleaning solution to en ter battery Remove corrosion from battery ...

Page 536: ...of specific gravity of the electrolyte A fully charge battery will have a specific gravity between 1 265 to 1 280 Most hydrometers give a true reading at 21 C 70 F 1 Specific gravity 1 265 In order to obtain correct readings adjust the initial reading by adding 004 points to the hydrometer readings for each 5 5 C 10 F above 21 C 70 F and by subtracting 004 point for every 5 5 C 10 F below 21 C 70 ...

Page 537: ... a light coat of dielectric grease on terminals Clean battery casing and caps using a solution of baking soda and water CAUTION Do not allow cleaning solution to en ter battery Rinse battery with clear water and dry well using a clean cloth Store battery in a cool dry place Such conditions reduce self discharging and keep fluid evaporation to a minimum Keep battery away from dew high moisture and ...

Page 538: ...Connect lead to battery post Step Plug battery charger CAUTION If charging rate raises higher than 2 4 A reduce it immediately If cell temperature rises higher than 50 C 122 F or if the casing feels hot discontinue charging temporarily or reduce the charging rate 6 Disconnect battery charger Step Unplug battery charger Step Disconnect lead Step Disconnect lead A17E0FB 2 1 3 A17E0GA 1 A17E0RB 1 2 W...

Page 539: ...the battery will not accept current when the charging cycle first begins As the battery remains on the charger the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then the battery will ac cept a higher charging rate Type of charger Battery chargers vary in the amount of voltage and current that they can supply Therefore the t...

Page 540: ...er as specified in ACTIVATION OF A NEW BATTERY It is recommended that any battery recharged by this procedure be load tested prior to return ing it to service Battery Installation Proceed 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...

Page 541: ... if the wire is properly crimped apply some pulling force on wire and the terminal at the same time from both directions CAUTION Never weld the wire to the terminal Welding can change the property of the wire and it can become brittle and break Install the protective heat shrink rubber tube P N 278 001 692 on the terminal Heat the heat shrink rubber tube using the heat gun so that it grasps the wi...

Page 542: ...R2003 037_12_04A FM 12 04 1 STARTING SYSTEM 0 717 Engines F00H1PS 16 Loctite 243 15 Loctite 271 14 Ground cable 17 22 N m 16 lbf ft Loctite 243 13 22 N m 16 lbf ft 22 N m 16 lbf ft 5 N m 44 lbf in Dielectric grease 1 12 2 3 5 4 6 11 10 7 8 9 www SeaDooManuals net ...

Page 543: ...ubsection 04 STARTING SYSTEM 12 04 2 SMR2003 037_12_04A FM 787 RFI Engines F15H01S Loctite 243 6 7 8 9 10 11 4 1 2 3 5 5 N m 44 lbf in 12 22 N m 16 lbf ft 13 17 Dielectric grease Loctite 243 16 22 N m 16 lbf ft www SeaDooManuals net ...

Page 544: ...EM Subsection 04 STARTING SYSTEM SMR2003 037_12_04A FM 12 04 3 947 DI Engines 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 ...

Page 545: ... CHARGING SYSTEM MPEM or EMS ECU on 4 TEC engines If 2 short beeps are not heard when installing the safety lanyard refer to DIGITALLY ENCODED SE CURITY SYSTEM or ENGINE MANAGEMENT Engine Start Stop Switch and Safety Lanyard Switch Refer to IGNITION SYSTEM or ENGINE MANAGE MENT or INSTRUMENTS AND ACCESSORIES Solenoid NOTE Solenoid is located in the electrical box or above MPEM on 787 RFI engines a...

Page 546: ...DOES NOT CRANK THE ENGINE Poor battery cable connections 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 batte...

Page 547: ... 2 Negative 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 section 4 TEC Engines Remove retaining screws no 1 refer to illustra tion above from starter Pull starter no 3 out Lift starter enough to reach starte...

Page 548: ... 3 by unscrewing nut retaining terminal Check that the radial play between the armature shaft and end frame is not greater than 0 20 mm 008 in Replace end frame if so Tap the pinion stop collar no 7 using a screwdriv er Remove circlip no 6 Disassemble pinion stop collar no 7 and spring no 8 1 Pinion stop collar Turn clutch assembly no 9 clockwise to remove it from armature assembly no 11 Pull hous...

Page 549: ... 10 and gasket Remove the three 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 SeaDooManuals net ...

Page 550: ...n end cover release tabs of retainer 1 Retainer 4 TEC Engines Remove bendix retaining circlip no 4 and starter bendix no 5 1 Retaining circlip 2 Starter bendix Locate index marks on yoke and end covers 1 Index marks Loosen through bolts 1 Through bolts Remove end cover F06H1MA 1 1 F18H0NA 2 1 F18H0OA 1 F18H0PA www SeaDooManuals net ...

Page 551: ...ot be immersed in cleaning solvent Discard all O rings Clean brushes and holders with a clean cloth soaked in solvent Brushes must be dried thoroughly with a clean cloth Blow brush holders clean using compressed air Remove dirt oil or grease from commutator using a clean cloth soaked in suitable solvent Dry well using a clean dry cloth Clean engine ring gear teeth and drive unit clutch NOTE Bushin...

Page 552: ...mutator out of round condition with V shaped blocks and an indicator If commutator out of round is more than 0 40 mm 016 in commu tator should be turned on a lathe Check commutator outer diameter If less than 27 mm 1 063 in replace 4 TEC Engines Check commutator condition with an indicator If out of specification replace the starter 1 Commutator undercut 0 20 mm 008 in All Engines Brush Holder Che...

Page 553: ...liding surfaces on arma ture shaft splines overrunning clutch and bushing 717 engine with G E Versilube G 341 M or ESSO Beacon 325 lubricant or equivalent After placing pinion stop collar no 7 on armature shaft no 11 fit circlip no 6 into armature shaft then make sure that it is properly secured Slide stop collar no 7 over circlip no 6 and secure in place by punching it at two or three places 1 Ar...

Page 554: ...ure 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 STARTER INSTALLATION Installation is essentially the reverse of removal procedure However pay particular attention to the following Make sure that starter and engine mating surfaces are free of debris Serious trouble may arise if starter is not pro...

Page 555: ...y Loctite 243 to threads and torque screw to 10 N m 89 lbf in 4 TEC Engines Apply grease Isoflex Topas NB52 P N 293 550 021 on O rings of starter Install Starter NOTE If starter does not mesh properly try to pull it out and slightly rotate the starter gear then re install starter One could also temporarily remove both O rings properly mesh gears then remove starter to reinstall O rings being caref...

Page 556: ... to hide metallic parts 1 Grease on O rings 2 Torque nut to 7 N m 62 lbf in and apply dielectric grease and install protection cover 3 Apply Loctite 243 to threads and torque screws to 10 N m 89 lbf in WARNING Always connect RED positive cable first then BLACK negative cable last Whenever con necting the RED positive cable to the starter motor make sure the battery cables are dis connected to prev...

Page 557: ...350 A max 0 RPM Battery 12 V 19 Ah Nominal output 0 8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 1 7 kg 3 7 lb Performance specification at 20 C 68 F No load 10 9 V 45 A max 8600 RPM Load 9 V 120 A max 5350 RPM Stall 2 25 V 390 A max 0 RPM Battery 12 V 19 Ah Nominal output 0 9 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed...

Page 558: ... wire from thecut off relay Reading should be 0 V Otherwise replace the cut off relay Keeping the test probes on the same wires con nect a jumper wire between the BLACK PURPLE wire from the cut off relay to the battery ground Measure voltage Reading should be 12 V Other wise check wiring and if it is good replace the cut off relay If there is no current supply to the electrical com ponents while t...

Page 559: ...gine to start when the start stop switch is pressed If start stop button is held after engine has started the MPEM automatically stops the starter when the engine speed reaches 1000 RPM Engine RPM Limiter The MPEM will limit the maximum engine speed Engine Stopping There are two ways to stop the engine Press start stop switch or remove the safety lan yard cap from the switch Low Fuel Level Warning...

Page 560: ...for 2 seconds while in the appropriate mode The information center includes the following dis play areas 1 General display 2 Message units display 3 Warning light 4 Fuel level display 5 VTS position indicator if so equipped General Display Repeatedly pressing the MODE button scrolls the following displays Compass if so equipped Ta chometer speedometer average speed trip meter hourmeter water tempe...

Page 561: ...ne overheating H TEMP low fuel FUEL LO low oil OIL LOW low voltage 12 V LOW A buzzer will sound when one of the four last cir cumstances occurs Except for low fuel and low oil which can be correct ed by refilling it is recommended to see an autho rized SEA DOO dealer when other messages occur The warning light will blink at the same time Warning Light The red warning LED Light Emitting Diode blink...

Page 562: ... chronometer mode 1 Press to start or stop chronometer 1 Press and hold for 2 seconds to reset Chronometer is reset every time engine is turned off Maintenance Information When the watercraft is due for a maintenance in spection the message MAINT will blink To clear the warning message while it is blinking 1 Press and hold for 2 seconds to reset NOTE If maintenance message MAINT contin ues to blin...

Page 563: ...uch as the speedometer trip hour meter etc Units and Messages Section This section shows the units related to the num bers displayed Units such as KMH MPH HOUR etc are displayed This section also display navigational and system fault informations See the gauge functions and message lists below for more details Gauge Functions Digital Tachometer Indicates the revolution per minute RPM of the engine...

Page 564: ...n such as the trip hour meter dis tance etc press and hold the SET button for 2 sec onds while in the appropriate mode Display Selection Repeatedly pressing the MODE button scrolls the following displays Compass tachometer speed ometer average speed distance hourmeter water temperature exterior temperature depth gauge if so equipped and trip hour meter 1 Press to change display mode When you are s...

Page 565: ...ile in the compass mode 1 Press and hold for 2 seconds 1 Repeatedly press 1 Press to end English Metric System Allows to display the units in the metric system or in the SAE English system NOTE This function is not available when informa tion center displays the compass hourmeter or trip hour meter 1 Press TOGETHER and hold for 2 seconds F18L09D 1 F18L09C 1 F18L09D 1 F18L09A 1 www SeaDooManuals ne...

Page 566: ...w liquid levels which can be corrected by refilling it is recommended to see an authorized Sea Doo dealer when other messages occur NOTE If a fault occurs this system generates num bered fault codes P XXXX that can be displayed through the information center using a special pro cedure In case of a failure refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT Warning Light The red warning LED Light E...

Page 567: ...accuracy of the Infor mation Center GTI LE RFI Models RX DI GTX DI and XP DI Models VTS Position Indicator Some Models Disconnect the AMP connector 1 from the MPEM Using an appropriate terminal remover remove the BROWN WHITE and BROWN BLACK wires from the AMP connector Connect potentiometer test probes to the BROWN WHITE and BROWN BLACK wires Adjust potentiometer to the resistance values as per fo...

Page 568: ...enter not Working 4 TEC Models When there is no display at the information center perform the following B U D S can be used to check its operation Look in the Monitoring tab Check fuses Check supply wire 1 23 and ground wire 1 8 from MPEM Check communication link wires WHITE RED and WHITE BLACK To quickly check if the communication link is working temporarily disconnect a sensor on the engine to c...

Page 569: ...ge as speci fied in the following charts RFI DI and 4 TEC Models The fuel pick up system is part of the fuel pump module mounted inside the fuel reservoir The fuel level gauge sender is also mounted on this module TYPICAL FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL PUMP MODULE Refer to ENGINE MANAGEMENT for fuel pump testing For fuel level sensor follow procedures below The resistance measured between...

Page 570: ...onnector 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 Wait about 15 20 seconds before taking any reading to give the oil enough time to flow out or inside sensor reservoir RESISTANCE Ω FLOAT HEIGHT bottom of float with bottom o...

Page 571: ...ground wires of the 2 circuit connec tor housing Measure resistance it should be close to 1 5 ohm If motor seems to jam and it has not reached the end of its stroke the following test could be per formed First 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 Co...

Page 572: ...e temperature reading on the Information Center should adjust to the water temperature If not replace the speed sensor Exterior Temperature Sensor Some Models The temperature sensor is located in the storage cover B U D S can be used to check the operation Look in the Monitoring tab Remove the back panel of the storage cover to access the temperature sensor 1 Temperature sensor To check if the tem...

Page 573: ...or is installed on riding plate It works with the water flow which turns a magnetic paddle wheel that triggers an electronic pick up that in turn sends a speed signal to the speedom eter through the MPEM The paddle wheel is protected by the pick up hous ing 1 Pick up housing 2 Paddle wheel To check if the speed sensor is operational dis connect the speed sensor connector housing from inside bilge ...

Page 574: ...HOOTING SYMPTOM POSSIBLE CAUSE REMEDY Nothing is displayed in the information center The depth gauge is not activated in the MPEM Activate the depth gauge in Options under Setting tab in B U D S 0 0 ft or m is displayed all the time Connector of the depth gauge is not connected Connect it properly There is not 12 V or ground is open at the depth gauge connector Check fuses and wiring harness There...

Page 575: ...The memory of the MPEM is permanent If the battery is disconnected no information is lost The MPEM features a self diagnostic mode Refer to the chart below When ordering a new MPEM from the regular parts channel the DESS circuitry will be activated Self Diagnostic Mode It is self activated when the safety lanyard cap is being installed on the watercraft switch It gives imme diate monitoring Refer ...

Page 576: ... 6 pin adapter 2 RFI 4 pin adapter 3 Connector under opening of front storage area After all connections are done connect the safety lanyard to the DESS post to activate the commu nication IMPORTANT When using the software B U D S ensure that the protocol matching the connection used is properly selected in MPI under Choose protocol as per the following chart The MPEM programmer P N 529 035 718 is...

Page 577: ...GENERAL 13 02 24 JET PUMP INSPECTION ON WATERCRAFT 13 02 24 REMOVAL 13 02 25 DISASSEMBLY 13 02 28 CLEANING 13 02 30 PARTS INSPECTION 13 02 31 ASSEMBLY 13 02 32 PUMP PRESSURIZATION 13 02 36 INSTALLATION 13 02 37 DRIVE SYSTEM 13 03 1 GENERAL 13 03 4 REMOVAL 13 03 4 INSPECTION 13 03 11 ASSEMBLY 13 03 13 INSTALLATION 13 03 14 LUBRICATION 13 03 21 REVERSE SYSTEM 13 04 1 DISASSEMBLY 13 04 2 INSPECTION 1...

Page 578: ...tion 01 TABLE OF CONTENTS 13 01 2 SMR2003 049_13_01ATOC FM VARIABLE TRIM SYSTEM 13 05 1 GENERAL 13 05 3 REMOVAL 13 05 3 DISASSEMBLY 13 05 4 INSPECTION 13 05 4 ASSEMBLY 13 05 4 INSTALLATION 13 05 5 ADJUSTMENT 13 05 6 www SeaDooManuals net ...

Page 579: ... 30 32 33 28 37 24 39 20 1 31 2 3 29 30 25 41 42 23 42 21 22 36 13 26 34 40 11 12 11 10 9 4 20 N m 15 lbf ft Loctite 518 Loctite 243 Synthetic grease 7 5 N m 66 lbf in Loctite 518 35 Pipe sealant 3 N m 27 lbf in Loctite 243 21 N m 16 lbf ft 115 N m 85 lbf ft Loctite 243 7 N m 62 lbf in 9 N m 80 lbf in 9 N m 80 lbf in www SeaDooManuals net ...

Page 580: ... 35 40 41 25 16 14 15 19 18 8 4 13 5 13 6 7 17 Loctite 454 6 N m 53 lbf in Loctite 518 6 N m 53 lbf in 2 5 N m 22 lbf in 2 5 N m 22 lbf in 20 N m 15 lbf ft 2 5 N m 22 lbf in 20 N m 15 lbf ft 2 5 N m 22 lbf in Loctite 243 115 N m 85 lbf ft Synthetic grease Loctite 518 Loctite 243 Pipe sealant 3 N m 27 lbf in 20 N m 15 lbf ft Loctite 243 21 N m 16 lbf ft 7 5 N m 66 lbf in 31 N m 23 lbf ft www SeaDoo...

Page 581: ...t will be easy to slide underneath watercraft A lift kit P N 295 100 044 can be used to install watercraft on a stand TYPICAL 1 Lift kit 2 Work stand F00J0SA 5 2 1 6 3 4 F02J0VA 1 WATERCRAFT MODEL IMPELLER P N MATERIAL PITCH XP DI 271 000 920 Stainless steel Progressive pitch 15 21 GTI 271 001 297 Stainless steel Progressive pitch 9 20 GTI LE 271 001 297 Stainless steel Progressive pitch 9 20 GTX ...

Page 582: ...ever the last method requires more work To check clearance from water inlet side remove inlet grate To check clearance from venturi side remove venturi nozzle assembly as described in OIL INSPECTION 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...

Page 583: ... The plug threads are perpendicular to the impeller shaft Oil Replacement Remove venturi as described in OIL INSPECTION Remove 3 screws retaining cover TYPICAL 1 Screws Using a fiber hammer gently tap cover to release it from housing cover Thoroughly clean reservoir and inside of cover with a solvent Check O ring condition Replace as necessary Apply a thin layer of Loctite 518 on mating surface of...

Page 584: ...8 LRV DI Models Put shift lever in reverse position Disconnect reverse cable from reverse gate Re move lock nut no 9 and bolt no 10 retaining cable end to cable lever 1 Bolt 2 Cable end 3 Cable lever 4 Lock nut Unscrew and remove2Allenscrewsno 11 retaining reverse gate to support no 12 and remove reverse gate Pivot Support All Models except LRV DI Remove reverse gate Unscrew pivot support bolts no...

Page 585: ... Take note of bushing size for reinstallation Withdraw pivot arm no 19 1 Pivot bolts each side 2 Spring 3 Pivot arm Nozzle All Models except LRV DI and XP DI Disconnect steering cable from jet pump nozzle no 20 Remove reverse gate spring pivot arm bolts no 18 retaining pivot arm and VTS ring if so equipped to nozzle Remove nozzle LRV DI Models Disconnect steering cable from jet pump nozzle Remove ...

Page 586: ...ri no 24 1 Remove screws Jet Pump Housing Remove nozzle venturi Loosen 4 hexagonal nuts no 24 and remove flat washers and lock washers from jet pump housing Remove jet pump with a wiggle movement NOTE After jet pump removal if drive shaft re mains in the PTO flywheel except XP simply pull it out If drive shaft is seized in the PTO flywheel refer to DRIVE SYSTEM DISASSEMBLY NOTE Whenever removing a...

Page 587: ...n impeller splines 1 Impeller remover tool Rotate impeller remover tool counterclockwise and unscrew completely impeller CAUTION Never use any impact wrench to loos en impeller To remove impeller apply a rotating movement and pull at same time Slide impeller out of hous ing Remove tool from impeller Wear Ring NOTE On the models with the large pump 947 engines remove the screws retaining wear ring ...

Page 588: ...t to damage bearing jour nals 1 Bearing seal remover tool NOTE It is always recommended to renew both bearings even if only one bearing needs to be re placed CLEANING All Models Thoroughly clean jet pump housing by applying Loc tite Stripper P N 293 110 004 Allow it some time to dissolve the old dried Loctite 10 to 15 minutes CAUTION DO NOT use Loctite Stripper on wear ring since it will cause irr...

Page 589: ...eformation Renew parts if damaged NOTE Check also PTO flywheel and drive shaft condition Refer to BOTTOM END and DRIVE SYS TEM Examine impeller in wear ring for distortion Check if blade tips are blunted round chipped or broken Such impeller is unbalanced and will vi brate and damage wear ring impeller shaft shaft seal or bearings Renew if damaged 1 Replaced if blunted round or damaged Check impel...

Page 590: ... and lowest dial gauge reading is radial play Maximum permissible radial play is 0 05 mm 002 in TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to threads at shaft end To check both bearings proceed the same way with other shaft end Position gauge tip on diam eter close to flats on shaft TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to flats at...

Page 591: ... or bearing it is recommended to renew both Anti Rattle Pusher Check for melted plastic around metal pad If so replace it Check for excessive wear of pad Seal Carefully inspect seal lips Make sure that lips are not worn distorted cracked or show signs of any other damage Replace after 150 hours even if it seems good ASSEMBLY Wear Ring All Models except LRV DI These models are equipped with large p...

Page 592: ...il it seats into bottom of housing 1 Piece of wood 2 Seal lip facing upward 3 Wear ring NOTE Do not forget install retaining screws on large pump models Seal and Needle Bearing LRV DI Models Bearings no 30 and seal no 29 will be properly installed in housing using bearing seal installer tool P N 295 000 107 BEARING SEAL INSTALLER TOOL 1 Seal side 2 Bearing side All Models except LRV DI Bearing no ...

Page 593: ...s and seal thus pro viding space for lubrication purposes The tool flanges allow this If a different pusher type is being used components must be properly po sitioned as follows Bearing on impeller side must be 1 5 to 2 5 mm 060 100 in inside reservoir measured from seal seat Refer to following illustration 1 Seal seat 2 Stamped end of bearing A 1 5 2 5 mm 060 100 in Apply Loctite 518 P N 293 800 ...

Page 594: ...ide All Models except LRV DI Stamped end of bearings showing identification markings must be located toward outside of hous ing Properly insert bearing on tool Using an arbor press only push tool until tool flange contacts housing 1 Stamped end this side CAUTION Never hammer the bearing into its housing 1 Press on tool until it stops CAUTION These tools have been designed to properly position bear...

Page 595: ... no 32 in the stator seat 1 Thrust washer properly installed in stator seat Thrust Bearing Apply SEA DOO JET PUMP SYNTHETIC OIL P N 293 600 011 on both sides of thrust bearing Position thrust bearing no 33 on thrust washer no 32 1 Thrust bearing on top of thrust washer Impeller Shaft To prevent seal lip damage when inserting impel ler shaft use impeller shaft guide P N 295 000 002 Insert tool onto...

Page 596: ...tallation apply BOMBARDIER LUBE lubricant on wear ring Insert impeller into wear ring Manually rotate im peller and push so that it slides on impeller shaft threads Carefully engage threads making sure they are well aligned Install impeller remover installer tool into impeller splines and tighten 1 Impeller remover installer tool CAUTION Make sure thrust washer and bear ing are not wedged in shaft...

Page 597: ... to push the tab It is possible to damage the inner threads Hold tab and torque screws Remove pencil or tool to release locking mecha nism Check if the mechanism worked properly Push tab with the pencil or tool if there is a small play the installation is correct If not redo the proce dure Verify if the impeller is rotating freely Add oil Oil Fill NOTE It is highly recommended to perform a leak ag...

Page 598: ...e 518 Gasket Eliminator on mating surface Position venturi no 24 with bailer passages on top Apply Loctite 243 blue on threads of screws no 39 Install screws no 39 lock washers and flat wash ers then torque to 21 N m 16 lbf ft 1 Torque screws to 21 N m 16 lbf ft O Rings Install O rings no 38 around bailer passages or make sure they are in place if they were not removed PUMP PRESSURIZATION Whenever...

Page 599: ... Pump Housing Generously apply synthetic grease on drive shaft splines Make sure rubber damper is on drive shaft end Install jet pump If necessary wiggle jet pump to engage drive shaft splines in impeller CAUTION Some watercraft require a shim be tween hull and pump if shim has been re moved at pump removal be sure to reinstall it otherwise engine alignment will be altered Apply Loctite 243 blue o...

Page 600: ...reverse gate support stopper 1 Stopper XP DI Models Install nozzle trim ring assembly Torque screws to 20 N m 15 lbf ft NOTE Trim ring has a tight fit to install insert both sides at the same time taking care not to break plastic bushings Carefully use a plastic tip hammer if necessary Make sure steering arm of jet pump is on right side and trim arm is above venturi 1 Torque screws to 20 N m 15 lb...

Page 601: ...243 21 N m 16 lbf ft 7 5 N m 66 lbf in 3 1 31 40 41 25 38 44 30 46 32 33 28 37 13 26 39 42 20 43 21 24 N m 18 lbf ft 23 22 2 5 N m 22 lbf in 15 20 N m 15 lbf ft 2 5 N m 22 lbf in 19 14 16 18 17 6 7 13 13 5 4 8 Loctite 518 6 N m 53 lbf in 2 31 N m 23 lbf ft 34 35 36 Alsaco grease 45 24 Loctite 767 49 48 47 GTX 4 TEC Supercharged models only www SeaDooManuals net ...

Page 602: ...P INSPECTION ON WATERCRAFT To work on watercraft securely install it on a stand Thus if access is needed to water inlet ar ea it will be easy to slide underneath watercraft A lift kit can be used to install watercraft on a stand TYPICAL 1 Lift kit 2 Work stand Impeller Condition Condition of impeller no 1 boot no 2 and ring no 3 can be quickly checked from underneath of the watercraft Remove grate...

Page 603: ...h 30 cm 12 in blades measure clearance between impeller blade tip and wear ring Measure each blade at its center For GTX 4 TEC clearance should not exceed 0 35 mm 014 in If clearance 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 Feeler gauge REMOVAL Pump Assembly Remov...

Page 604: ...8 Remove both reverse gate screws no 8 Pivot Support Remove reverse gate Unscrew pivot support bolts no 13 1 Pivot bolt 2 Pivot support 3 Reverse gate 4 Pivot support bolt no 13 Withdraw pivot support Connecting Rod Remove reverse gate pivot bolt no 14 Withdraw connecting rod Pivot Triangle Remove reverse gate connecting rod pivot triangle bolts no 15 Withdraw pivot triangle no 16 Pivot Arm Positi...

Page 605: ...her and bushings from nozzle TYPICAL 1 U lever screw Remove 2 retaining screws no 21 2 sleeves no 22 2 washers no 23 Remove nozzle Venturi Remove reverse gate nozzle bracket no 47 pivot arm Unplug OPAS hose from plastic elbow Remove 4 retaining screws no 39 and withdraw venturi no 24 It s possible to remove the venturi without remov ing the reverse gate and the nozzle see the fol lowing instructio...

Page 606: ...ly pull it out If drive shaft is seized in the PTO flywheel refer to DRIVE SYSTEM DISASSEMBLY NOTE Whenever removing a part visually check for damage such as corrosion crack split break porosity cavitation deformation distortion heat ing discoloration wear pattern missing plating missing or broken balls in ball bearing water dam age diagnosed by black colored spots on metal parts etc Renew any dam...

Page 607: ... a vise Install pump over this tool Using a 12 mm Allen key unscrew the impeller NOTE It may be needed to heat the impeller to break Loctite bond CAUTION Never use any impact wrench to loosen impeller To remove impeller apply a rotating movement and pull at same time Slide impeller out of hous ing Pull pump housing out Remove circlip no 49 seal no 34 and spacer no 48 F18J0NA F18J0OA 529 035 820 F1...

Page 608: ...crews retaining wear ring in the jet pump housing Place jet pump housing in a vise with soft jaws It is best to clamp housing using a lower ear Cut wear ring at two places CAUTION When cutting ring be careful not to damage jet pump housing NOTE Wear ring can be cut using a jigsaw a small grinder or a low clearance hacksaw such as Snap on HS3 or equivalent After cutting ring insert a screwdriver bl...

Page 609: ... 809 or equivalent Free threads and splines from any residue PARTS INSPECTION Impeller Visually inspect impeller splines Check for wear or deformation Renew parts if damaged NOTE Check also PTO flywheel and drive shaft condition Refer to BOTTOM END and DRIVE SYSTEM Examine impeller in wear ring for distortion Check if blade tips are blunted round chipped or broken Such impeller is unbalanced and w...

Page 610: ...rence between highest and lowest dial gauge reading is radial play Maximum permissible radial play is 0 75 mm 029 in MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to threads at shaft end Excessive play can come either from worn bearing or damaged jet pump housing bearing surface Seal Carefully inspect seal lips Make sure that lips are not worn distorted cracked or show signs of...

Page 611: ...into bottom of housing 1 Seal lip 2 Press wear ring If a press is not readily available a piece of wood such as a 2 x 4 in x 12 in long can be used Manually engage ring 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 ri...

Page 612: ...s to their original position The bearing no 33 can be installed either side Install spacer no 32 on shaft no 28 Install O ring no 46 in sleeve no 30 1 O ring Coat shaft surface with jet pump bearing grease P N 293 550 032 then install sleeve no 30 on impeller shaft no 28 From the outlet side of pump press impeller shaft assembly into housing using shaft pusher P N 529 035 818 Install circlip and O...

Page 613: ...ly BOMBARDIER Lube on the wear ring sur face Start screwing the impeller on its shaft If impeller is too tight use impeller tool to turn im peller to machine wear ring before installing on ve hicle Make sure to turn it smooth enough so that engine starter should turn it Mount impeller remover installer P N 529 035 820 in a vise Install partially screwed impeller on it Use a 12 mm Allen key to torq...

Page 614: ... to 21 N m 16 lbf ft 1 Torque screws to 21 N m 16 lbf ft O Rings Install O rings no 38 around bailer passages or make sure they are in place if they were not re moved PUMP PRESSURIZATION Whenever doing any type of repair on jet pump a pressure test should be done to check for leakage Proceed as follows Remove impeller cover no 13 Install pressure cap P N 529 035 843 on pump housing Connect pump ga...

Page 615: ...s which are red covered reducer no 44 is installed as shown CAUTION Misinstallation can cause overheat ing and damage to exhaust system 1 Black rubber covered reducer Generously apply synthetic grease on drive shaft splines Make sure rubber damper is on drive shaft PTO end Install jet pump If necessary wiggle jet pump to engage drive shaft splines in impeller CAUTION Some watercraft require a shim...

Page 616: ...que to 24 N m 18 lbf ft OPAS Reconnect OPAS hose Torque clamp screw to 1 7 N m 15 lbf in Fasten OPAS U lever to nozzle Apply Loctite 243 blue on screw threads or use new self lock ing screws Torque screw to 20 N m 15 lbf ft Pivot Triangle Install head bolts toward inside NOTE Make sure the pivot triangle turn freely Reverse Gate Install reverse gate with spacer and washer Torque to 20 N m 15 lbf f...

Page 617: ...ection 03 DRIVE SYSTEM SMR2003 041_13_03A FM 13 03 1 DRIVE SYSTEM 0 All Models except XP DI and 4 TEC Models F02I09S 2 3 4 5 6 8 7 9 2 N m 18 lbf in 10 11 13 Synthetic grease 12 Synthetic grease 13 2 N m 18 lbf in www SeaDooManuals net ...

Page 618: ...bf ft Loctite 271 Loctite 518 Synthetic grease 23 15 17 16 15 14 Loctite 518 21 10 N m 89 lbf in 5 6 8 9 10 7 11 12 13 Synthetic grease Synthetic grease Right Stuff sealant 31 N m 23 lbf ft Right Stuff sealant Loctite 518 Loctite 243 31 N m 23 lbf ft Loctite 243 Synthetic grease Synthetic grease Loctite 243 22 N m 16 lbf ft 2 N m 18 lbf in 28 27 30 31 32 29 www SeaDooManuals net ...

Page 619: ...ION SYSTEM Subsection 03 DRIVE SYSTEM SMR2003 041_13_03A FM 13 03 3 GTX 4 TEC Models F18I0MS 5 6 7 8 9 10 11 25 26 12 Penzoil Marine Z M corrosion protectant Penzoil Marine Z M corrosion protectant www SeaDooManuals net ...

Page 620: ...m engine and with draw from bilge XP DI Models Open engine compartment cover Remove storage basket Remove vent tubes from PTO flywheel guard Remove PTO flywheel guard Large Clamp All Models except XP DI and 4 TEC Models 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 h...

Page 621: ... and stop engine at this RPM This will move oil out of PTO housing into oil tank If engine cannot be started refer to the procedure in PTO HOUSING MAGNETO section and look for PTO HOUSING REMOVAL Remove seat Detach coolant expansion reservoir from vent tube support then move away 1 Detach expansion reservoir 2 Remove vent tube support Detach vent tube Remove vent tube support 4 TEC Supercharged Mo...

Page 622: ... rearwards when using the drive shaft float ing ring tool 1 Drive shaft holder Disconnect EGT sensor to make room For the following operations use the drive shaft floating ring tool P N 529 035 841 NOTE Note that there is a large opening and a small opening on the tool Depending on the step involved in the procedure it is sometimes re quired to reverse its installation position DRIVE SHAFT FLOATIN...

Page 623: ...g rearwards to expose the c clip Do not remove clip at this time NOTE This step is done to ensure floating ring is free and not stuck on the drive shaft Remove drive shaft floating ring tool and drive shaft holder Reinstall drive shaft floating ring tool as shown 1 Largest opening on PTO seal side A 18 mm 71 in 1 Largest opening here 2 Tell tale groove 3 Lubricate O rings contact area 1 F18I0NA F1...

Page 624: ...floating ring tool as shown Push floating ring rearwards to expose C clip and remove it 1 Largest opening on PTO seal side 1 Largest opening here 2 Remove C clip Remove drive shaft holder tool then drive shaft floating ring tool NOTE Use this sequence to minimize the amount of movement the drive will slide back into PTO seal assembly All Models except XP DI Drive Shaft Simply pull out drive shaft ...

Page 625: ... mm 1 3 8 in J 20 3 mm 18 mm 800 in 007 in Mount on drive shaft puller the jet pump housing remover then install assembly on drive shaft us ing screws TYPICAL 1 Jet pump housing remover 2 Drive shaft puller 3 Screws CAUTION Be careful not to damage hull rear section or engine rubber mounts XP DI Models Rear Drive Shaft Remove rear access panel Remove protective plate no 18 1 Remove protective plat...

Page 626: ...ove bolts lock nuts and sleeves Loosen bolts and lock nuts retaining the lower sup port of the shock absorber TYPICAL 1 Remove bolts and lock nuts Loosen 4 screws and remove bottom cover of seat 1 Remove cover Loosen gear clamp retaining the outer boot of the shock absorber 1 Loosen gear clamp Tilt seat Remove front drive shaft F08I04B 1 F08Q01A 1 F08L11A 1 F08L12A 1 www SeaDooManuals net ...

Page 627: ... the PTO seal assembly All Models Boot Loosen gear clamp no 11 holding boot then care fully pull boot and carbon ring no 8 from hull in sert Carbon Ring Loosen gear clamp no 9 then pull carbon ring from boot no 10 INSPECTION All Models Drive Shaft Inspect condition of drive shaft and PTO flywheel splines except XP DI models Inspect condition of groove With your finger nail feel machined surface of...

Page 628: ...urface 1 O rings 2 Floating ring contact surface PTO Seal 4 TEC Models Discard both O rings no 26 and install new ones All Models Boot Inspect the condition of boot If there is any dam age or evidence of wear replace it All Models except 4 TEC Models To verify the preload of the boot no 10 proceed as follows NOTE To verify the boot preload and free length jet pump and drive shaft must be installed...

Page 629: ...er XP DI Models Seal Carrier of Mid Bearing Inspect seal carrier needle bearing no 16 Check parts for scoring pitting chipping or other evi dence of wear Inspect seals no 15 for deterioration or excessive wear Replace if necessary 4 TEC Models Inspect PTO seal assembly Refer to PTO HOUS ING MAGNETO section ASSEMBLY XP DI Models Seal Carrier of Mid Bearing Properly support seal carrier housing no 1...

Page 630: ...ump 3 Raised edge of lip outwards 4 Seal carrier Apply Loctite 518 all around seals outside diameter Seals no 15 can be carefully installed in housing using bearing seal installer tool P N 295 000 107 Push seals until tool comes in contact with housing TYPICAL Pack seals and bearing with synthetic grease P N 293 550 010 INSTALLATION Installation is essentially the reverse of removal procedure Howe...

Page 631: ...ment shaft further in this procedure IMPORTANT Completely tightening nuts would make the alignment more difficult Align the seal carrier using the following tools support plate kit P N 529 035 570 1 Plate P N 529 035 507 2 Support P N 529 035 511 alignment shaft P N 295 000 141 1 Alignment shaft Install support plate at rear of watercraft Carefully slide shaft through seal carrier and shaft suppor...

Page 632: ...o ENGINE sec tion Front Drive Shaft Coupler and Damper Make sure to install dampers into drive shaft cou pler at both ends TYPICAL SAME COUPLER AND DAMPER AT BOTH ENDS 1 Damper 2 Drive shaft coupler Front Drive Shaft Install front drive shaft no 20 Rear Drive Shaft NOTE Ensure the alignment washers are still loose Install damper no 13 to rear drive shaft no 12 Install drive shaft and jet pump at t...

Page 633: ...aft through carbon ring no 8 and floating ring no 6 NOTE Make sure to install floating ring before in serting the drive shaft in the PTO flywheel While holding jet pump guide and engage drive shaft splines in PTO flywheel Rotate shaft to properly index splines Make sure boot is well po sitioned over shaft end All Models except 4 TEC Models Circlip Push the floating ring to compress the boot Insert...

Page 634: ...e rotation counterclockwise 2 Tail in opposite direction Small Clamp To secure small clamp no 4 place notch side of plier on clamp embossment and squeeze plier 1 Squeeze plier 4 TEC Models NOTE Ensure to install floating ring before insert ing the drive shaft in PTO seal assembly Before installing drive shaft inspect PTO seal as sembly The inner sleeve must be flush with outer circumference of the...

Page 635: ...s which could rub a hole in seal thus creating an oil leak 1 Tell tale groove Install PTO seal assembly InstallPTO sealsupport toolon PTO seal assembly To prevent possible drive shaft corrosion apply Penzoil Marine Z M Corrosion Protectant all over drive shaft NOTE Drive shaft should be dry and clean prior to applying the corrosion protectant If the drive shaft is corroded a rotating wire brush ma...

Page 636: ...same axis as the drive shaft When properly aligned maintain PTO seal assem bly in the proper position and tap shaft end until it bottoms against engine At this time the tell tale MUST NOT be visible This validate the correct po sition 1 PTO seal support 2 Drive shaft end 3 Insert floating ring on shaft end GOOD INSTALLATION 1 PTO seal assembly 2 Shaft pushed in hiding tell tale groove 3 Inner slee...

Page 637: ...sed inner sleeve is flush with outer circumference of PTO seal assembly and C clip is not exposed If tell tale mark is exposed push PTO seal assem bly rearwards to fully extend it If inner sleeve is not flush gently tap it until it is flush Reposition splash guard Reconnect EGT sensor Install jet pump Refer to JET PUMP section Check engine oil level Refill as necessary Run watercraft then ensure t...

Page 638: ... visible portion of drive shaft Spray also towards through hull fitting and towards splines of impeller Dispose of the soiled plastic sheet as per your lo cal environmental regulations NOTE On Supercharged models remove inlet hose from supercharger to gain access From inside bilge lift splash guard to expose PTO seal assembly Cover carbon seal ring with a rag or plastic wrap to prevent the protect...

Page 639: ...12 13 16 19 15 20 3 5 N m 31 lbf in 17 18 14 Loctite 243 1 11 4 N m 35 lbf in 3 N m 27 lbf in Loctite 243 10 N m 89 lbf in 2 5 N m 22 lbf in Synthetic grease 2 5 N m 22 lbf in 6 N m 53 lbf in 7 N m 62 lbf in 2 Loctite 243 6 N m 53 lbf in 5 N m 44 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 4 3 N m 27 lbf in Loctite 243 Silicone sealant www SeaDooManuals net ...

Page 640: ... 4 retain ing reverse gate to support no 10 and remove re verse gate Cable Lever Remove Allen screw no 6 and detach cable lever from reverse gate Pawl Lock and Spring To remove pawl lock no 7 and spring no 8 re move roll pin no 9 Reverse Gate Support Unscrew 4 bolts which retain reverse gate support no 10 to venturi Remove reverse gate support from venturi 1 Reverse gate support 2 Remove bolts Int...

Page 641: ...16 to body Remove reverse cable support INSPECTION Visually inspect parts for wear or cracks Replace parts as required ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following CAUTION Refer to the main illustration at the beginning of this subsection for torque specifi cations and service products to be used Spring Make sure to prope...

Page 642: ...e gate pay attention to position its lever behind the reverse gate support stopper 1 Stopper Reverse Cable Install reverse cable to cable lever as per following illustration 1 Bolt 2 Ball joint 3 Cable lever 4 Flat washer 5 Lock nut CAUTION Ensure cable ball joint is parallel to cable lever 90 5 to minimize tension on ca ble Adjust as required ADJUSTMENT Put shift lever in forward position Pull sh...

Page 643: ...en 2 bolts no 18 at reverse cable support no 16 Turn adjustment nut no 23 as required 1 Reverse cable support 2 Loosen bolts 3 Adjustment nut When adjustment is completed there should be gap of 0 to 5 mm 0 to 3 16 in between handle and left cover A 0 to 5 mm 0 to 3 16 in F07J09A 1 2 3 2 F07J0AA A A www SeaDooManuals net ...

Page 644: ...sealant 3 Synthetic grease 2 1 7 N m 62 lbf in 2 5 N m 22 lbf in 10 N m 89 lbf in 4 N m 35 lbf in 2 5 N m 22 lbf in 2 N m 18 lbf in 2 N m 18 lbf in Loctite 243 3 3 N m 29 lbf in 2 N m 18 lbf in 2 5 N m 22 lbf in 11 12 4 9 9 10 Loctite 243 Loctite 243 Loctite 243 2 5 N m 22 lbf in 4 N m 35 lbf in Silicone sealant Silicone sealant GTX series 5 2 5 N m 22 lbf in www SeaDooManuals net ...

Page 645: ...ard the front of the vehicle to get greater access to the interior lever and the reverse cable support To release the vent tube press down its locking tabs and move the tube There are two locking tabes one above and one underneath the hose DO NOT REMOVE the vent tube completely 1 Engine vent tube 2 Vent tube locking tab 3 Interior lever 4 Reverse cable support On the interior lever no 3 unscrew th...

Page 646: ... slots from interior lever tabs then remove the shift lever no 5 1 Shift lever retaining bolt 2 Shift lever slot 3 Interior lever tab 4 Shift lever Reverse Cable Support Remove shift lever interior lever bracket no 6 1 Bracket 2 Reverse cable bolts no 7 Withdraw reverse cable support no 8 Handle Housing Remove shift lever interior lever reverse cable support bolts no 9 Then remove handle housing n...

Page 647: ...e shift lever action is smooth and pre cise Forward and reverse positions should be easy to select with a detent position between each Reverse Gate Refer to JET PUMP section Reinstall glove box and seat ADJUSTMENT Put shift lever in forward position Place reverse gate in the up position Turn the joint at the end of reverse cable and align its hole with hole in pivot arm Secure with bolt washers sp...

Page 648: ... TRIM SYSTEM 0 RX DI Models F16J01U 1 2 3 5 6 7 8 9 10 7 N m 62 lbf in 11 12 14 2 20 N m 15 lbf ft Loctite Primer N 5 N m 44 lbf in 3 N m 27 lbf in Synthetic grease 7 N m 62 lbf in 13 Dielectric grease 7 N m 62 lbf in 4 Loctite 243 20 N m 15 lbf ft Synthetic grease Loctite Primer N www SeaDooManuals net ...

Page 649: ...ls F08J10S 7 Synthetic grease 8 9 10 2 3 2 13 1 14 16 2 5 N m 23 lbf in 10 N m 89 lbf in 15 5 6 12 5 N m 44 lbf in 7 N m 62 lbf in 11 Loctite Primer N Dielectric grease 4 Loctite 243 20 N m 15 lbf ft 7 N m 62 lbf in 20 N m 15 lbf ft 20 N m 15 lbf ft Synthetic grease Loctite Primer N www SeaDooManuals net ...

Page 650: ...VTS rod no 1 to sliding shaft no 10 Remove clamps no 2 Remove boot no 3 RX DI MODELS 1 VTS rod 2 Bolt 3 Lock nut 4 Rubber boot XP DI MODELS 1 VTS rod 2 Bolt 3 Lock nut 4 Rubber boot RX DI Models Disconnect steering cable reverse cable Unscrew the pivot arm bolts one on each side Move the pivot arm backwards All Models To loosen nut no 4 use VTS socket tool P N 295 000 133 Remove sealing washer no ...

Page 651: ... them INSPECTION Boot Make sure boot no 3 is in good condition If it is cracked or torn replace boot Worm Inspect threads and splines of worm no 9 for wear If worm replacement is necessary renew also sliding shaft 1 Inspect threads and splines ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Motor Worm and Sliding Shaft Apply...

Page 652: ...041 to threads of VTS housing and to nut no 4 Apply Loctite 243 blue to nut no 4 Install nut with sealing washer and torque to 7 N m 62 lbf in using the VTS socket tool P N 295 000 133 Apply synthetic grease to sliding shaft Boot and Clamps Install rubber boot no 3 over sliding shaft and se cure with clamps VTS Rod RX DI Models Install pivot arm reverse cable steering cable boot with clamps Secure...

Page 653: ...fere with venturi there should be a gap of 1 mm 039 in NOTE Install safety lanyard to be able to position VTS 1 No interference 2 Nozzle up If an adjustment is necessary loosen jam nut no 16 of VTS rod no 1 Turn adjustment nut of VTS rod to obtain the desired gap between trim ring and venturi TYPICAL 1 Turn adjustment nut of VTS rod Tighten jam nut of VTS rod to 2 5 N m 23 lbf in when adjustment i...

Page 654: ...LY 14 02 3 ASSEMBLY 14 02 8 DISASSEMBLY 14 02 13 ASSEMBLY 14 02 16 OFF POWER ASSISTED STEERING SYSTEM O P A S 14 02 18 GENERAL 14 02 19 SIDE VANE 14 02 19 CYLINDER SUPPORT ASSEMBLY 14 02 20 TIE ROD 14 02 21 SEALED TUBE 14 02 22 FILTER 14 02 22 VALVE 14 02 22 WATER HOSE 14 02 23 CROSS SUPPORT PLATE 14 02 23 ALIGNMENT 14 03 1 www SeaDooManuals net ...

Page 655: ...8 18 16 15 17 9 10 11 10 N m 88 lbf in 10 N m 89 lbf in Loctite 243 4 N m 35 lbf in 13 N m 115 lbf in Loctite 243 5 N m 44 lbf in Loctite 243 6 N m 53 lbf in 6 N m 53 lbf in Loctite 243 6 N m 53 lbf in Loctite 243 26 N m 19 lbf ft 7 N m 62 lbf in 23 22 2 5 N m 22 lbf in 2 5 N m 22 lbf in 19 20 21 25 24 27 26 Carburetor equipped engines 7 Synthetic grease 5 N m 44 lbf in www SeaDooManuals net ...

Page 656: ...89 lbf in 5 N m 44 lbf in 14 12 13 N m 115 lbf in 13 8 18 16 15 17 6 N m 53 lbf in Loctite 243 5 N m 44 lbf in 2 5 N m 22 lbf in 6 N m 53 lbf in 9 Loctite 243 10 24 27 25 10 N m 89 lbf in 19 11 Loctite 243 2 5 N m 22 lbf in 4 N m 35 lbf in 32 33 30 Loctite 243 34 29 Synthetic grease 48 49 50 47 Loctite 767 Loctite 271 26 N m 19 lbf ft GTX 4 TEC Supercharged LTD only 46 Synthetic grease 7 N m 62 lb...

Page 657: ...e 2 Support bushing Hold jam nut no 34 and unscrew adjustment han dle no 30 from adjuster screw no 29 TYPICAL 1 Loosen jam nut All Models Handle Grip and Grip Insert To remove handle grip no 1 pull out cap no 2 and remove screw no 3 Pull out grip and remove grip insert from handlebar no 4 1 Handle grip 2 Remove screw NOTE Verify grip insert for damage Steering Cover Remove grips no 1 Loosen set sc...

Page 658: ...ls and GTX 4 TEC Series Only Remove 2 tapping screws no 42 1 Tapping screw 2 Handle bar housing Remove handlebar housing cover no 8 and throt tle handle housing no 39 Unhook throttle cable from throttle handle no 40 Pry out the throttle cable housing from throttle handle housing no 41 1 Throttle cable 2 Throttle handle housing 3 Throttle cable handle Remove 6 screws no 7 and flat washers no 45 eac...

Page 659: ... upper steering cover no 4 1 DESS switch nut Steering Padding Remove steering cover as mentioned above Remove 2 screws no 35 and flat washers no 36 Remove steering padding no 37 1 Screws 2 Steering padding Handlebar GTX 4 TEC Supercharged Limited Models Only Remove 4 elastic stop nuts M8 retaining steering clamp no 44 TYPICAL 1 Remove nuts 2 Steering clamp 1 F18K0EA 2 1 F18K0FA 1 2 F18K0GA F07K0SA...

Page 660: ...ited Remove steering cover and steering padding as mentioned above Remove 4 nuts no 38 to remove handle bar no 22 from steering stem no 46 and steering clamp no 44 1 Nuts 2 Handlebar 3 Steering stem 4 Steering clamp All Models Cable Support Loosen bolts no 9 and remove retaining block no 10 1 Retaining block Loosen bolts no 11 each side of steering support no 12 1 Steering support 2 Bolt F07K0TA 1...

Page 661: ...ie Disconnect the throttle and choke cables from car buretor levers Disconnect the wiring harnesses leading out of steering stem and cut locking tie ALL OTHER MODELS EXCEPT XP DI 1 Tie rap 2 Connectors Disconnect the steering cable from the steering stem arm no 15 1 Steering stem arm 2 Steering cable Remove bolts no 11 retaining cable support no 8 to steering support no 12 1 2 F07K03A F07K04A 1 2 ...

Page 662: ... from steering stem Unscrew threaded pivots to remove threaded block from steering stem no 49 1 Steering stem 2 Steering support 3 Support bushing 4 Adjuster screw 5 Threaded block 6 Threaded pivots All Models 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 ...

Page 663: ...upport 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 GTX 4 TEC Supercharged Limited Models Only Steering Stem and Steering Support Install support bushings no 50 on steering support Apply Loctite 767 antiseized lubricant P N 413 701 000 on pivot bol...

Page 664: ...ring support Handlebar Before installing handlebar position stopper no 33 and rubber pad no 32 CAUTION Rubber pad must not exceed stop per 1 Pad must not exceed stopper Position handlebar no 22 Install steering clamp no 44 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 All Models Ball Joint Secure the steering cable ball join...

Page 665: ...ING SYSTEM SMR2003 044_14_02A FM 14 02 11 All Models except XP DI TYPICAL 1 Ball joint on top of steering arm 2 Torque nut to 7 N m 62 lbf in STEERING ALIGNMENT For steering alignment procedure refer to ALIGN MENT F06K01A 1 2 www SeaDooManuals net ...

Page 666: ...n 18 8 13 Synthetic grease 7 N m 62 lbf in 7 Loctite 243 10 26 N m 19 lbf ft 13 N m 10 lbf ft Engine cover Loctite 243 2 5 N m 22 lbf in Loctite 243 Loctite 243 20 19 6 N m 53 lbf in 11 24 21 2 5 N m 22 lbf in 23 7 N m 62 lbf in 22 26 25 27 Engine cover 17 6 N m 53 lbf in Loctite 243 16 15 7 N m 62 lbf in Synthetic grease 14 7 10 N m 89 lbf in 12 1 N m 9 lbf in 3 N m 27 lbf in www SeaDooManuals ne...

Page 667: ...ip insert from handle bar NOTE Verify grip insert no 5 for damage Steering Cover To remove the steering cover no 6 loosen set screws no 7 of handlebar housing 1 Set screws Remove 4 screws no 8 and washers TYPICAL 1 Cover 2 Screws Remove 2 screws no 9 and flat washers each side of cover 1 Remove screws Detach upper and lower section of cover from steering 1 Upper section 2 Lower section F00K01A 1 F...

Page 668: ...n Allen screws Lift the top section of the engine cover and discon nect wiring harnesses Remove the top section of the engine compart ment cover Disconnect steering cable no 11 from lever no 10 1 Disconnect steering cable Remove link rod no 12 1 Remove link rod Remove bolt no 13 and washer retaining lever no 10 to steering support no 18 1 Remove bolt and washer 1 F08L0KB 1 1 1 1 F08K05A 1 F08K06A ...

Page 669: ... nuts and bolts Lift steering support no 18 and slightly pullback steering stem no 14 in order to remove the sup port no 16 and steering stem arm no 15 1 Remove support and steering stem arm Steering Stem Disconnect wiring harnesses choke and throttle cables from engine Remove steering stem no 14 Steering Cable Remove glove box Disconnect steering cable no 11 at lever no 10 1 Disconnect steering c...

Page 670: ...entially the reverse of disassem bly procedure However pay particular attention to the following Lever Prior installing lever no 10 apply synthetic grease to pivot Steering Stem Apply synthetic grease to front and rear thrust bearing surface 1 Apply synthetic grease Steering Stem Arm and Support Position steering stem arm no 15 and support no 16 onto steering stem no 14 Handle Grip and Grip Insert...

Page 671: ...l flat washer other wise screw will damage grip end Ball Joint Secure the steering cable ball joint no 21 to the nozzle as per following illustration CAUTION Ensure the ball joint is parallel 5 to the nozzle arm TYPICAL 1 Ball joint on top of steering arm 2 Torque nut to 7 N m 62 lbf in STEERING ALIGNMENT For steering alignment procedure refer to ALIGN MENT WARNING Correct torque must be strictly ...

Page 672: ...1 24 1 2 N m 10 lbf in 12 22 5 5 N m 49 lbf in 27 Hull 36 25 31 1 7 N m 15 lbf in 32 30 23 6 7 N m 62 lbf in 7 29 28 2 2 N m 19 lbf in 8 2 20 N m 15 lbf ft 3 4 5 1 7 6 7 N m 62 lbf in Hull 8 2 2 N m 19 lbf in 28 29 23 26 34 2 2 N m 19 lbf in 33 35 1 7 N m 15 lbf in 26 36 25 12 1 2 N m 10 lbf in 24 22 5 5 N m 49 lbf in 2 2 N m 19 lbf in 11 9 10 17 16 21 27 21 2 2 N m 19 lbf in www SeaDooManuals net...

Page 673: ...roximately 75 or more RPM the side vanes are automatically raised to upper position since they are not required at that vehicle speed range Between 30 and 75 engine RPM side vanes are gradually raised from lower position to upper position 1 Side vane in upper position When throttle is released and engine RPM drops the side vanes are automatically lowered thus as sisting steering control 1 Side van...

Page 674: ...erse process of disassembly Torque tie rod retaining screw no 10 to 4 5 N m 40 lbf in Torque socket screw no 11 to 2 2 N m 19 lbf in CYLINDER SUPPORT ASSEMBLY Disassembly Removal procedure for RH and LH cylinder sup port assembly is same Remove side vane as mentioned above Unscrew bottom nut using O P A S cylinder nut wrench P N 529 035 840 1 Bottom nut 2 Cylinder support 3 Pivot rod 4 O P A S cyl...

Page 675: ... Replace the cylinder seal ring whenever servicing Torque socket screw no 22 to 5 5 N m 49 lbf in TIE ROD Disassembly Removal procedure for RH and LH tie rod is same Remove side vane and cylinder support assembly as mentioned above Remove O P A S U lever screw no 2 flat wash er no 3 bushing no 4 and venturi bushing no 5 from nozzle Remove jet pump refer PROPULSION SYSTEM Remove screw no 6 and wash...

Page 676: ... rod Assembly Assembly is the reverse process of disassembly Apply silicone grease on the screws before install ing Torque Phillips screws no 28 to 2 2 N m 19 lbf in FILTER For removal and installation procedure refer to PROPULSION SYSTEM O P A S filter is part of plastic elbow no 30 Check for cleanness Replace or clean it as neces sary VALVE Disassembly Remove O P A S U lever screw no 2 flat wash...

Page 677: ...e is same Remove side vane and cylinder support assembly as mentioned above Remove gear clamps no 35 to remove water hose no 26 from valve Pull out the water hose no 26 from exterior Assembly Assembly is the reverse process of disassembly make sure of the following when doing assembly Water hose must be installed from the out side to the inside of hull by turning it oriented to wards valve Tighten...

Page 678: ...sure of the following when doing assembly Check for cracks and deterioration of screw threads on cross support plate change if nec essary Verify the condition of gaskets before installa tion change if necessary 1 Gasket 2 Support plate GASKET INSTALLED ON SUPPORT PLATE Torque screw no 24 to 1 2 N m 10 lbf in 1 F18K1BA 2 F18K1CA www SeaDooManuals net ...

Page 679: ... equalled TYPICAL 1 Measure the distance on each side of the straight edge If necessary steering alignment adjustment should be performed at steering cable support All Models except XP DI Open storage compartment cover and remove bas ket if so equipped Loosen 2 bolts retaining block at cable support Turn adjustment nut as required ALL MODELS EXCEPT XP DI 1 Retaining block 2 Adjustment nut 3 Loosen...

Page 680: ...MODELS 1 Support 2 Adjustment nut 3 Loosen bolts All Models After adjustment torque retaining block bolts to 6 N m 53 Ibf in CAUTION Verify when the handlebar is turned completely to the left or right side that there is no interference with venturi or VTS ring F08K03B 1 2 3 www SeaDooManuals net ...

Page 681: ...n 15 SUSPENSION Subsection 01 TABLE OF CONTENTS SMR2003 049_15_01ATOC FM 15 01 1 TABLE OF CONTENTS 0 DIRECT ACTION SUSPENSION 15 02 1 REMOVAL 15 02 2 INSPECTION 15 02 3 ASSEMBLY 15 02 3 www SeaDooManuals net ...

Page 682: ...N SUSPENSION SMR2003 045_15_02A FM 15 02 1 DIRECT ACTION SUSPENSION 0 XP DI Models 10 11 3 13 12 5 8 6 9 4 7 F08Q02T 34 N m 25 lbf ft 2 1 10 N m 89 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 34 N m 25 lbf ft 5 N m 44 lbf in www SeaDooManuals net ...

Page 683: ... cover Loosen gear clamp no 2 of outer boot no 3 then pull outer boot downward 1 Loosen gear clamp Remove rear access panel from body Loosen lower gear clamp no 4 then push inner boot no 5 upward 1 Loosen gear clamp Remove bolt no 6 and lock nut no 7 from shock absorber lower support no 8 1 Bolt 2 Lock nut F08L11A 1 F08L12A 1 F08I03B 1 F08Q03A 2 1 www SeaDooManuals net ...

Page 684: ...ns of tear renew boot s Shock Absorber Inspect shock absorber for wear Extend and com press the piston several times over its entire stroke it should move smoothly and with uniform resistance Pay attention to the following conditions that will denote a defective shock absorber A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme end of either str...

Page 685: ...29 INFO CENTER LCD gauges 16 02 29 DEFLECTOR AND OR UPPER GRID 16 02 30 FINITION PLATE 16 02 30 INLET GRATE 16 02 31 RIDING PLATE 16 02 32 JET PUMP SUPPORT 16 02 33 DEFLECTOR 16 02 34 DRAIN PLUG INSTALLATION 16 02 35 SEAT REMOVAL 16 02 35 SEAT COVER REPLACEMENT 16 02 37 BUMPER REPLACEMENT 16 02 37 WAKE PYLON 16 02 38 SPONSON REPLACEMENT 16 02 39 ENGINE COMPARTMENT COVER REMOVAL 16 02 41 DECALS REP...

Page 686: ...AIR SMR2003 046_16_02A FM 16 02 1 ADJUSTMENT AND REPAIR 0 GTI GTI LE RFI and GTI LE Models bow F17L14S Loctite 29647 5 N m 44 lbf in 3 N m 26 lbf in 8 N m 71 lbf in 7 N m 62 lbf in 8 N m 71 lbf in Loctite 29647 15 N m 133 lbf in Body www SeaDooManuals net ...

Page 687: ...TMENT AND REPAIR 16 02 2 SMR2003 046_16_02A FM GTI GTI LE RFI and GTI LE Models stern F17L15S Silicone sealant 2 5 N m 22 lbf in 15 N m 133 lbf in 8 N m 71 lbf in Silicone sealant 15 4 5 5 Silicone sealant Dart fastex 12 www SeaDooManuals net ...

Page 688: ...16 02 3 GTI GTI LE RFI and GTI LE Models cover F17L16S Loctite 243 4 N m 35 lbf in 1 4 N m 35 lbf in 5 N m 44 lbf in Loctite 243 Loctite 454 15 N m 133 lbf in GTI LE Loctite 243 Synthetic grease 4 N m 35 lbf in 3 N m 26 lbf in 8 N m 71 lbf in 4 N m 35 lbf in www SeaDooManuals net ...

Page 689: ...Section 16 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 16 02 4 SMR2003 046_16_02A FM GTI GTI LE RFI and GTI LE Models seats F07L2OS GTI seats Loctite 414 www SeaDooManuals net ...

Page 690: ...NT AND REPAIR SMR2003 046_16_02A FM 16 02 5 RX DI bow F16L11S Silicone sealant 5 N m 44 lbf in 3 N m 26 lbf in 8 N m 71 lbf in 8 N m 71 lbf in 7 N m 62 lbf in Loctite 271 15 N m 133 lbf in Loctite 271 Body Silicone sealant www SeaDooManuals net ...

Page 691: ... ADJUSTMENT AND REPAIR 16 02 6 SMR2003 046_16_02A FM RX DI stern 2 5 N m 22 lbf in Loctite 271 12 13 4 Loctite 271 5 12 14 12 12 4 5 15 N m 133 lbf in 15 Silicone sealant 2 2 N m 19 lbf in F16L12S Silicone sealant www SeaDooManuals net ...

Page 692: ... RX DI cover F16L13S Loctite 243 5 N m 44 lbf in 5 N m 44 lbf in Loctite 243 Loctite 243 Loctite 454 2 5 N m 22 lbf in 8 N m 71 lbf in 2 5 N m 22 lbf in 8 N m 71 lbf in 8 N m 71 lbf in Synthetic grease 3 N m 26 lbf in 4 N m 35 lbf in 8 N m 71 lbf in 4 N m 35 lbf in www SeaDooManuals net ...

Page 693: ...Section 16 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 16 02 8 SMR2003 046_16_02A FM RX DI seat F16L14S 5 5 N m 49 lbf in www SeaDooManuals net ...

Page 694: ...tion 02 ADJUSTMENT AND REPAIR SMR2003 046_16_02A FM 16 02 9 LRV DI bow F11L0LS Loctite 271 8 N m 71 lbf in Loctite 243 5 N m 44 lbf in 5 N m 44 lbf in Loctite 29647 15 N m 133 lbf in Loctite 29647 Body 10 6 www SeaDooManuals net ...

Page 695: ...AND REPAIR 16 02 10 SMR2003 046_16_02A FM LRV DI stern F11L0MS Loctite 271 8 N m 71 lbf in 13 Loctite 29647 Icebox foam Loctite 243 15 N m 133 lbf in Loctite 243 Body Icebox foam Loctite 29647 2 2 N m 19 lbf in 4 5 12 12 12 5 www SeaDooManuals net ...

Page 696: ...IR SMR2003 046_16_02A FM 16 02 11 LRV 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 ...

Page 697: ...DY Subsection 02 ADJUSTMENT AND REPAIR 16 02 12 SMR2003 046_16_02A FM LRV DI seat F11L0NS Loctite 414 Loctite 243 Loctite 414 Loctite 243 4 N m 35 lbf in 5 N m 44 lbf in Loctite 243 5 N m 44 lbf in www SeaDooManuals net ...

Page 698: ...ODY Subsection 02 ADJUSTMENT AND REPAIR SMR2003 046_16_02A FM 16 02 13 XP DI Models bow F08L1JT Loctite 243 Silicone sealant 10 6 Loctite 243 Silicone sealant Body 15 N m 11 lbf ft Loctite 271 8 7 www SeaDooManuals net ...

Page 699: ...REPAIR 16 02 14 SMR2003 046_16_02A FM XP DI Models stern and rear 23 4 4 5 5 12 13 12 3 5 N m 44 lbf in Loctite 243 Front tray Body Loctite 243 4 N m 35 lbf in 4 N m 35 lbf in Loctite 243 Body 5 N m 44 lbf in Loctite 243 3 F12L0KS www SeaDooManuals net ...

Page 700: ...TMENT AND REPAIR SMR2003 046_16_02A FM 16 02 15 XP DI Models seat F12L0LS Loctite 243 15 N m 11 lbf ft 17 5 N m 44 lbf in Loctite 271 13 N m 10 lbf ft 3 N m 27 lbf in 23 22 21 20 19 18 3 N m 27 lbf in 24 Synthetic grease www SeaDooManuals net ...

Page 701: ...IR 16 02 16 SMR2003 046_16_02A FM XP DI Models suspension and engine cover F08L1KT Loctite 243 4 N m 35 lbf in Loctite 243 8 N m 71 lbf in Loctite 243 4 N m 35 lbf in Loctite 243 4 N m 35 lbf in Loctite 648 8 N m 71 lbf in Loctite 243 www SeaDooManuals net ...

Page 702: ...Y Subsection 02 ADJUSTMENT AND REPAIR SMR2003 046_16_02A FM 16 02 17 XP DI Models front cover Engine cover Synthetic grease 3 N m 27 lbf in Loctite 271 2 N m 18 lbf in Loctite 243 Loctite 243 F12L0MS www SeaDooManuals net ...

Page 703: ...on 16 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 16 02 18 SMR2003 046_16_02A FM GTX DI and GTX 4 TEC Models seats F18L1HS Loctite 414 Loctite 414 Loctite 414 Loctite 414 Loctite 414 www SeaDooManuals net ...

Page 704: ... SMR2003 046_16_02A FM 16 02 19 GTX DI and GTX 4 TEC Models front storage compartment F18L34S Body 4 TEC Limited and Wakeboard Edition only Synthetic grease Loctite 243 5 N m 44 lbf in 3 N m 26 lbf in Loctite 271 Loctite 243 Loctite 243 www SeaDooManuals net ...

Page 705: ...ADJUSTMENT AND REPAIR 16 02 20 SMR2003 046_16_02A FM GTX 4 TEC Models and GTX DI Models body front view F18L1JS GTX 4 TEC only Body GTX DI only 10 11 8 12 9 7 7 N m 62 lbf in Loctite 29647 Loctite 29647 Loctite 243 www SeaDooManuals net ...

Page 706: ...s body rear view F18L35S 2 5 N m 22 lbf in 6 GTX 4 TEC Limited only GTX 4 TEC or GTX DI Loctite 29647 Loctite 29647 1 2 3 1 4 15 7 5 N m 13 lbf in GTX 4 TEC Wakeboard Edition only Loctite 29647 15 N m 11 lbf in Loctite 29647 10 N m 88 lbf in Loctite 243 8 N m 70 lbf in Loctite 5900 21 23 25 20 26 24 www SeaDooManuals net ...

Page 707: ...TI LE GTI LE RFI and RX DI Models Removal Remove handle from shift lever 1 Unscrew Remove darts and then remove side panels 1 Unscrew the darts GTI GTI LE and RX DI Models Open front storage cover and remove the access panel Detach the latch retaining vent tube to bracket 1 Unlatch Pull vent tube out From the engine compartment insert a hand through the vent tube hole and press glove box lock tabs...

Page 708: ...n are coated with a self locking prod uct do not apply Loctite 243 on threads TYPICAL GTX DI GTX 4 TEC SERIES AND LRV DI FRONT SEAT 1 Lock pin 2 Adjustment nut Loctite 243 Torque to 5 N m 44 lbf in A 33 1 mm 1 35 64 3 64 in TYPICAL GTX DI GTX 4 TEC SERIES AND LRV DI REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 243 Torque to 5 N m 44 lbf in A 35 1 mm 1 5 16 3 64 in GTI AND GTI LE MODELS FRON...

Page 709: ...ll end front See illustration 1 Gently pull starting this end 2 Finish with this end For installation proceed as follows Sand both inner and outer shells in area to be glued except GTI Clean to remove any dust with isopropylic alco hol Let dry Apply a 2 mm 3 32 in bead of Loctite 454 Reinstall inner shell with its retaining screws Tighten screws starting with the one at the small end front and fin...

Page 710: ...ven inner skin short screws flanged screws Remove two long inner skin screws hex screws 1 Storage cover 2 Inner skin 3 Inner skin short screws x 7 4 Inner skin long screws x 2 Use a rubber hammer to remove the inner skin from the cover If the inner skin is too stiff in stall a piece of 2 x 4 against the inner skin and hit it with the rubber hammer 1 Storage cover 2 Inner skin 3 Rubber hammer Remov...

Page 711: ...ature sensor in grommet Install the tie raps around wire harnesses Align inner skin with storage cover and make sure that the lateral locking hooks in the inner skin get engaged in the storage cover locking bracket If the two lateral locking hooks get properly aligned and engaged the storage cover back locking hook will be engaged properly in the inner skin back locking bracket 1 Inner skin latera...

Page 712: ...move storage cover shock proceed as fol lows Unlock shock rod from circlip and remove wash er 1 Shock rod 2 Circlip 3 Washer Release the shock from top linkage bracket and bottom support bracket by inserting a flat screwdriver in the shock top and bottom locking devices 1 Top linkage bracket 2 Shock top locking device 1 Bottom support bracket 2 Shock bottom locking device WARNING Make sure to have...

Page 713: ...s per following specifica tions FIXED TYPE LOCK PIN 1 Lock pin apply Loctite 243 2 Adjustment nut Torque to 5 N m 44 lbf in A 34 1 mm 1 11 32 3 64 in FLOATING TYPE 1 Lock pin apply Loctite 243 2 Rubber washer 3 Lock nut Torque to 5 N m 44 lbf in A 39 2 1 mm 1 35 64 3 64 in NOTE Some models have a floating type lock pin It is normal to have a front and aft play of the lock pin To adjust tighten loc...

Page 714: ...nd Installation To remove mirror proceed as follows Remove storage compartment inner shell from storage cover as described earlier in this sec tion Remove two hexagonal screws and flat wash ers Remove defective mirror with a spatula 1 Mirror 2 Spatula Place the mirror frame in hot water to soften the material to allow mirror installation in its frame Reinstall storage compartment inner shell INFO ...

Page 715: ...and Installation GTX 4 TEC Supercharged Limited To remove the deflector and or the upper grid pro ceed as follows Remove storage from storage cover compart ment inner shell as described earlier in this sec tion to get access Remove the defective deflector and or the up per grid from plastic retaining clip Use two screwdrivers to release the deflector or the grid 1 Inner skin 2 Deflector retaining ...

Page 716: ...T GRATE Removal and Installation Loosen screws and remove inlet grate NOTE An impact screwdriver should be used to loosen tight screws GTI LE RFI and LRV DI When reinstalling inlet grate apply Loctite 271 on threads and torque screws to 11 N m 8 lbf ft GTX DI GTX 4 TEC Series GTI GTI LE XP DI and RX DI When reinstalling inlet grate apply Loctite 271 on threads Follow this sequence referring to the...

Page 717: ...ate TYPICAL 1 Hydraulic bottle jack 2 Steel plates Cleaning Scrape off all excess of sealant from riding plate and hull Clean hull surface with acetone based solvent to eliminate grease dust and any residue of sealant Installation All Models except GTX DI and GTX 4 TEC Models Apply Loctite The Right Stuff Gasket as indicated by the shaded areas in the next illustrations Fol low also the torquing s...

Page 718: ...ndicated by the shaded area JET PUMP SUPPORT Removal Remove jet pump Refer to JET PUMP Remove inlet grate and riding plate Remove ball joint boot nut half rings and O rings from steering cable TYPICAL 1 Unscrew nut Remove ball joint boot nut half rings and O rings from reverse cable Remove boot and nut from VTS sliding shaft RX DI and XP DI models Disconnect water supply hose water return hose and...

Page 719: ...93 800 066 for GTX DI and GTX 4 TEC Series as indicated by the shaded areas in the next illustrations Follow also the torquing se quence as shown in the same illustrations GTI GTI LE GTI LE RFI RX DI AND XP DI MODELS LRV DI MODELS GTX DI AND GTX 4 TEC MODELS DEFLECTOR GTI LE RFI and LRV DI Removal Using a heat gun heat deflector and pry it using a piece of wood Installation Apply Loctite The Right...

Page 720: ...plug no 15 1 Drain plug 2 Silicone sealant P N 293 800 086 around the middle hole and in the screw holes 3 Torque screws to 2 2 N m 19 lbf in SEAT REMOVAL XP DI Models Loosen 4 screws and remove bottom cover no 17 of seat 1 Remove cover Loosen gear clamp of outer boot then pull outer boot downward 1 Loosen gear clamp F07L2NA 2 F00L2RA 3 3 1 F08L11A 1 F08L12A 1 www SeaDooManuals net ...

Page 721: ... Loosen screws of eyelet Remove cup no 21 on each side of seat Loosen nut no 23 on each side of seat 1 Loosen nut Tilt seat Loosen screws no 24 on each side of seat retain ing the side covers Lower seat Remove side covers Pull seat frame out of pivots Remove seat Seat installation is essentially the reverse of re moval procedure Refer to the main illustration of seat at the beginning of this subse...

Page 722: ...im no 5 from side bumper rail no 4 2 Drill pop rivets no 12 to remove side bumper rail no 4 3 Mark hole positions on body straight and bow sections TYPICAL 1 Front bumper 2 Corner bumper 3 Straight section 4 Bow section 4 Slide bumper rail no 4 under front bumper no 13 5 Using a 4 80 mm 3 16 in drill bit drill first hole through bumper rail no 4 at front of bow sec tion Use locating mark as a guid...

Page 723: ...eat and storage basket under it Remove nuts no 24 and 26 1 Screws to be removed 1 U clamp Remove finition U clamp no 21 and screws no 25 and pull out wake post no 20 Disassembly Loosen the stopper screw 1 Stopper screw Pull the safety lock pin to unlock and pull out the cylinder 1 Safety lock pin 1 F18L37A 1 F18L38A 1 F18L39A 1 F18L3AA www SeaDooManuals net ...

Page 724: ...r rail no 2 Remove screws no 4 to remove side bumper rail no 2 Mark hole positions on body straight and bow sec tions TYPICAL 1 Front bumper 2 Corner bumper 3 Straight section 4 Bow section Slide bumper rail no 2 under front bumper no 6 Using a 4 80 mm 3 16 in drill bit drill first hole through bumper rail no 2 at front of bow section CAUTION When drilling be careful not to damage bumper rail and ...

Page 725: ...cover for the XP DI mod els Remove seat support GTI GTI LE GTI LE RFI and LRV DI 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 293 800 086 around sponson studs Apply Loctite 243 blue on sponson ...

Page 726: ... located Remove half of the decal back protective film and align decal with marks Start sticking it from center and remove the other half of the film to stick it completely Carefully squeegee decal beginning at center and working outward using firm short overlapping strokes DECALS HAVING A PROTECTIVE FILM ON BOTH SIDES These decals usually contain graphics and are used on gelcoat or plastic INSTAL...

Page 727: ...required amount while making sure there are no air bubbles in the mixture With a putty knife fill the repair area and cover with plastic film Curing time may depend on tempera ture amount of putty and percentage of catalyst After 2 hours press lightly on the surface with fin gers to test the hardness When the area becomes hard remove the plastic film SANDING Begin block sanding the patch with 320 ...

Page 728: ...polyvinyl alcohol PVA to seal off the air and protect the gelcoat surface from dust PVA speeds up the curing process because gelcoat will not cure properly when exposed to air SANDING Wash the polyvinyl alcohol off with water De pending on the size of the area repaired you can either block sand as per previous procedure or you may use an air sander Sand the surface down with progressively finer gr...

Page 729: ...ior repair If the size of the opening is too large for the pieces to maintain the proper shape you will have to use a backing support It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side It is held in place by tape or a support Inside Wipe down the area with acetone on a cloth Ap ply the same procedure as for outside repair when lamin...

Page 730: ...r instructions Apply epoxy glue on aluminum insert P N 292 000 075 knurled surface and on plastic insert inner bore CAUTION If you notice any clearance between plastic insert and aluminum insert fill gap with epoxy glue to obtain good adhesion of alumi num insert 1 Knurled surface 2 Inner bore Install aluminum insert into plastic hull insert NOTE Align aluminum insert as much as possible with PTO ...

Page 731: ...olume 42 4 0 4 cc Cylinder head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular Ring end gap New 0 25 0 40 mm 010 016 in Wear limit 1 00 mm 039 in Ring piston groove clearance New 0 025 0 070 mm 001 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 10 mm 0039 in Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 mm 004 in Cylin...

Page 732: ...EM 5 A Main electrical system 15 A Charging system 15 A ADDITIONAL INFORMATION Engine cold 6000 RPM CARBURETION GTI GTI LE Carburetor Type Mikuni BN 40i diaphragm fuel accelerator pump Quantity 1 Main jet 167 5 Pilot jet 75 Spring 130 g 4 6 oz 115 g 4 1 oz Adjustment Low speed screw 1 turn 1 4 High speed screw 0 Idle speed in water 1500 100 RPM Idle speed out of water 3000 RPM Fuel Type Regular un...

Page 733: ... 4 mm 000 016 in Wear limit 1 00 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTI GTI LE Number of passenger driver included 3 Overall length 307 cm 121 in Overall width 120 cm 47 in Overall height 104 cm 41 in Dry weight 272 kg 6...

Page 734: ...lastic Flame arrester Multi layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTI GTI LE Estimated pump power 26 1 kW 35 HP Maximum fuel consumption at wide open throttle 33 5 L h 8 8 U S gal h Cruising time at full throttle Fuel tank without reserve 1 21 hour Fuel tank reserve 21 m...

Page 735: ...on ratio 6 0 1 Cylinder head volume 47 7 0 4 cc Cylinder head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular Ring end gap New 0 40 0 55 mm 016 022 in Wear limit 1 00 mm 039 in Ring piston groove New 0 025 0 070 mm 001 003 in Wear limit 0 24 mm 009 in Piston cylinder wall clearance New minimum 0 13 mm 005 in Wear limit 0 22 mm 009 in Cylinder taper maximum ...

Page 736: ... center Not applicable Fuel pump 10 A ADDITIONAL INFORMATION FUEL SYSTEM GTI LE RFI Fuel injection type Rotax Fuel Injection semi direct single throttle body 56 mm Idle speed in water 1500 100 RPM Throttle Position Sensor TPS 1 6 kΩ 2 4 kΩ terminals 1 2 710 Ω 1380 Ω terminals 2 3 Crankshaft Position Sensor CPS 774 Ω 946 Ω Air Temperature Sensor ATS 2 280 kΩ 2 74 kΩ Water Temperature Sensor WTS 2 2...

Page 737: ...16 in Wear limit 1 00 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTI LE RFI Number of passenger driver incl 3 Overall length 307 cm 121 in Overall width 120 cm 147 in Overall height 104 cm 41 in Dry weight 315 kg 695 lb Load lim...

Page 738: ...lame arrester Multi layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTI LE RFI Estimated pump output 30 4 kW 40 76 HP Maximum fuel consumption at wide open throttle 41 5 L h 11 U S gal h Cruising time at full throttle Fuel tank without reserve 1 hour 5 minutes Fuel tank reserve 17...

Page 739: ...m 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 22 mm 0087 in Piston cylinder wall clearance New minimum 0 12 mm 0047 in Wear limit 0 22 mm 0087 in Cylinder taper maximum 0 10 mm 004 in Cylinder out of round maximum 0 ...

Page 740: ... INJ 15 A Charging system REG 25 A Information center ACC Not applicable Fuel pump FP 15 A Battery 25 A VTS system VTS Installed but not in use 7 5 A 7 5 A ADDITIONAL INFORMATION FUEL SYSTEM GTX DI RX DI XP DI Fuel injection type Orbital Direct Fuel Injection twin throttle body 46 mm 1 81 in Fuel pressure 105 2 PSI 108 PSI Idle speed in water out of water 1450 50 RPM Throttle Position Sensor TPS 1...

Page 741: ... mm 040 in Impeller shaft end play new 0 Impeller shaft side play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTX DI RX DI XP DI Number of passenger driver incl 3 2 2 Overall length 331 cm 130 in 285 cm 112 in 272 cm 107 in Overall width 122 cm 48 in 120 cm 47 in 112 cm 44 in Overall height 113 ...

Page 742: ...Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTX DI RX DI XP DI Estimated pump power 51 kW 68 4 HP 53 6 kW 71 9 HP 53 7 kW 72 HP Maximum fuel consumption at wide open throttle 47 L h 12 4 U S gal h Cruising time at full throttle Fuel tank without reserve 60 minutes Fuel tank ...

Page 743: ...ize Not applicable Stroke 78 20 mm 3 079 in Displacement 951 2 cm 58 in Corrected compression ratio 6 0 1 Cylinder head volume 50 76 0 6 cc Cylinder head warpage maximum 0 10 mm 004 in total Piston ring type and quantity 2 semi trapez Ring end gap New 0 55 0 7 mm 022 028 in Wear limit 1 10 mm 043 in Ring piston groove clearance New 0 044 0 089 mm 002 004 in Wear limit 0 22 mm 009 in Piston cylinde...

Page 744: ...ut 270 W 6000 RPM Ignition system type Digital Inductive Spark plug Make and type NGK ZFR4F Gap 1 1 mm 04 in Ignition timing BTDC mm in 5 39 mm 212 in direct measured through direct injector hole 7 87 310 indirect measured through spark plug hole Degrees 27 1 5 1450 RPM Generating coil Not applicable Battery charging coil 0 1 1 Ω Trigger coil Not applicable Ignition coil Primary 0 45 0 55 Ω Second...

Page 745: ... kΩ Water Temperature Sensor WTS 2 280 kΩ 2 74 kΩ Exhaust Gas Temperature Sensor EGT 2 280 kΩ 2 74 kΩ Manifold Air Pressure Sensor MAPS 3 4 kΩ and 8 2 kΩ terminals 9 2 2 4 kΩ and 8 2 kΩ terminals 1 2 Knock Sensor KS 5 MΩ RAVE solenoid 24 Ω Fuel injector 1 7 Ω 1 9 Ω Direct injector 1 0 Ω 1 6 Ω Fuel Type Regular unleaded gasoline Minimum octane no 87 Fuel return line orifice Not applicable ADDITIONA...

Page 746: ...016 in Wear limit 1 0 mm 040 in Impeller shaft end play new 0 Impeller shaft side play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS LRV DI Number of passenger driver incl 4 Overall length 396 cm 156 in Overall width 155 cm 61 in Overall height 108 cm 42 5 in Dry weight 432 kg 960 lb Load limit pa...

Page 747: ... arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE LRV DI Estimated pump power 50 2 kW 67 3 HP Maximum fuel consumption at wide open throttle 47 L h 12 4 U S gal h Cruising time at full throttle Fuel tank without reserve 1 hour Fuel tank reserve from low level signal 12 m...

Page 748: ...pulsion unit Intake valve opening 10 BTDC Intake valve closing 45 ABDC Exhaust valve opening 50 BBDC Exhaust valve closing 5 ATDC 0 ATDC Starting system Electric start Valve stem diameter Intake Minimum new 5 961 mm 2347 in Maximum new 5 975 mm 2352 in Wear limit 5 930 mm 2330 in Exhaust Minimum new 5 946 mm 2341 in Maximum new 5 960 mm 2346 in Wear limit 5 930 mm 2330 in Valve guide diameter Mini...

Page 749: ...mm 0003 in Camshaft bearing journal Front Minimum new 24 939 mm 9818 in Maximum new 24 960 mm 9827 in Wear limit 24 930 mm 9815 in PTO and center Minimum new 39 892 mm 1 5705 in Maximum new 39 905 mm 1 5711 in Wear limit 39 885 mm 1 5703 in Camshaft bore Front Minimum new 25 000 mm 9842 in Maximum new 25 013 mm 9848 in Wear limit 25 025 mm 9852 in PTO and center Minimum new 40 000 mm 1 5748 in Max...

Page 750: ...imum new 31 984 mm 1 2592 in Maximum new 32 000 mm 1 2598 in Wear limit 31 950 mm 1 2579 in Balance shaft radial clearance Wear limit 0 07 mm 0028 in Balance shaft axial clearance Minimum new 0 02 mm 0008 in Maximum new 0 25 mm 0098 in Supercharger shaft driven plate journal depth Minimum new Not applicable 9 960 mm 3921 in Maximum new Not applicable 10 0 mm 3937 in Wear limit Not applicable 9 700...

Page 751: ... 0 75 mm 030 in Generating coil N A Battery charging coil 0 1 1 0 Ω Ignition coil Primary 0 45 0 55 Ω Secondary 6 8 10 2 kΩ Engine RPM limiter setting 7650 RPM Battery 12 V 30 A h Fuse TOPS 10 A Battery fuse 30 A Cylinder 1 ignition coil and injection 10 A Cylinder 2 ignition coil and injection 10 A Cylinder 3 ignition coil and injection 10 A Electric bilge pump optional 3 A Starting system electr...

Page 752: ...ween terminals 3 and 1 Knock Sensor KS 5 MΩ Oil Pressure Switch OPS 0 Ω if oil pressure is greater than 26 32 PSI Oil Separator Pressure Switch OSPS 0 Ω if blow by pressure is less than 6 PSI TOPS valve 1 27 Ω 2 47 Ω Fuel injector 11 4 Ω 12 6 Ω Fuel Type Regular unleaded gasoline with 87 octane Ron Mon 2 specification Recommended Premium unleaded gasoline with 91 octane Ron Mon 2 specification for...

Page 753: ...e New 0 0 0 4 mm 000 016 in Wear limit 1 0 mm 040 in Impeller shaft end play new 0 Impeller shaft side play 0 75 mm 029 in Impeller material Stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTX 4 TEC GTX 4 TEC VANS TRIPLE CROWN EDITION GTX 4 TEC SUPERCHARGED GTX 4 TEC SUPERCHARGED LIMITED Number of passenger driver incl 3 Overall length 331 cm 130 in Overa...

Page 754: ...screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTX 4 TEC GTX 4 TEC VANS TRIPLE CROWN EDITION GTX 4 TEC SUPERCHARGED GTX 4 TEC SUPERCHARGED LIMITED Estimated pump power 52 6 kW 70 54 HP 61 7 kW 82 74 HP Maximum fuel consumption at wide open throttle 43 1 L h 11 4 U S gal h 62 L h 16 4 U S ga...

Page 755: ...ircuit with an other wire s bearing the same letter g in the cir cuit EMS ECU GTX 4 TEC Models On the EMS ECU circuits are identified by a letter followed by a number The letter indicates in which connector the wire is plugged in The number indicates the position of the wire in the connector The connector A is connected to the engine wir ing harness The connector B is connected to the watercraft w...

Page 756: ...wdriver To disconnect the two Deutsch connectors slide a flat screwdriver between each other to disen gage press the release button and disconnect them 1 Flat screwdriver 2 Deutsch connectors 1 Release button 2 Deutsch connectors 1 Deutsch connectors 2 Press release button 1 F18Z0KA 2 3 1 F18Z0LA 2 2 F18Z0MA 2 1 F18Z0NA 1 2 www SeaDooManuals net ...

Page 757: ...k FEMALE CONNECTOR 1 Female lock MALE CONNECTOR 1 Male lock NOTE Before extraction push wire forward to re lieve pressure on retaining tab Insert a 4 8 mm 189 in wide screwdriver blade inside the front of the terminal cavity Pry back the retaining tab while gently pulling wire back until terminal is removed FEMALE CONNECTOR 1 Retaining tab To install For insertion of a terminal make sure the lock ...

Page 758: ...letters To remove terminal from Packard connector use Snap on TT600 4 tool AMP PLUG CONNECTOR These connectors are found on the MPEM When servicing electrical system special care must be taken when working with AMP plug connectors in order to prevent any malfunction of the system Description AMP PLUG CONNECTOR 1 Male connector 2 Cover assembly 3 Mating seal 4 Wedge lock 5 MPEM connector 6 Seal plu...

Page 759: ...n the pins of the MPEM connector only 1 Apply a thin coat of DEOXIT contact lubricant CAUTION Do not apply lubricant excessively Care must be taken so that the lubricant will not come in contact with the mating seal the seal may lose its sealing capacities Do not apply lubricant on terminals inside plug connector Each male connector is mechanically keyed to mate only with identical mechanical keye...

Page 760: ...ween wedge lock and connector 2 Locking tab Repeat the same steps for the other locking tab retaining the wedge lock The wedge lock is now in the open position 1 Wedge lock opened While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the terminal is removed 1 Rotate wire back and forth 2 Pull wire POWER WIRE TERMINAL NOTE The wedge lock must ...

Page 761: ... sur face within 25 mm 1 in from the tip of the termi nal must be smooth All terminals in AMP plug connectors must be crimped using the crimping tool P N 295 100 164 CAUTION If terminals are not crimped using the proper crimping tool the wire seal may be damaged CRIMPING TOOL P N 295 100 164 All circuits are sealed by a diaphragm in the rubber wire seal When installing a terminal in connector the ...

Page 762: ...losed to its locked posi tion IDENTIFICATION OF CONNECTOR PINS AMP Connectors of MPEM AMP Connectors of Wiring Harness EMS ECU CONNECTORS 4 TEC Models Only There are two EMS ECU connectors used on the 4 TEC models and they are connected on the EMS ECU The engine harness female connector is connected on the module male connector A and the watercraft system control harness female connector is connec...

Page 763: ...screwdriver to be able to flip the top cover up 1 Push in tab Lift the cover by pushing it forward 1 Cover Cut both tie raps that secure the harness to the connector 1 Tie raps Turn the connector over and remove the orange locking tab by pushing and then pulling toward the wire harness A terminal remover such as Snap On TT600 1 or a 0 76 mm 030 in oxyacetylene torch tip cleaner or a 68 drill bit m...

Page 764: ...ondition but the terminal is rusted or corroded remove defective terminal and crimp a new one If wire and terminal are defec tive replace with a new genuine wire and new terminal and crimp them together as explained be low IMPORTANT Use genuine wires only Otherwise wires will not fit properly When re inserting the terminal the locking tab must be installed facing the smaller cutout of the terminal...

Page 765: ...er is located in the rear electrical box 1 Main fuse holder joint connector NOTE In the following illustrations the joint insu lator has been removed for clarity purpose only It is not necessary to remove it to separate the joint The same procedure is to be used each side of the joint Insert the Deutsch joint connector tool no 114010 on the wire and push tool toward the joint to re lease it While ...

Page 766: ...e until terminal releases 2 Joint connector For installation simply push the wire in the con nector You should hear a locking click Try to pull the wire out to ensure terminal is properly locked If not remove the wire and bend the tabs inside the joint connector to allow proper locking Recheck 1 F12H12A 2 www SeaDooManuals net ...

Page 767: ...NOTE www SeaDooManuals net ...

Page 768: ...NOTE www SeaDooManuals net ...

Page 769: ...F00Z0D 2003 GTI MODEL WARNING www SeaDooManuals net ...

Page 770: ...F00Z0C 2003 GTI LE MODEL WARNING www SeaDooManuals net ...

Page 771: ...F00Z0E 2003 GTI LE RFI MODEL WARNING www SeaDooManuals net ...

Page 772: ...F00Z0J 2003 RX DI MODEL WARNING www SeaDooManuals net ...

Page 773: ...F00Z0I 2003 GTX DI MODEL WARNING www SeaDooManuals net ...

Page 774: ...F00Z0K 2003 XP DI MODEL WARNING www SeaDooManuals net ...

Page 775: ...F00Z0F 2003 GTX 4 TEC MODEL WARNING www SeaDooManuals net ...

Page 776: ...F00Z0G 2003 GTX 4 TEC MODEL WITH AUXILIARY DESS MODULE WARNING www SeaDooManuals net ...

Page 777: ...F00Z0B 2003 GTX 4 TEC AND GTX 4 TEC SUPERCHARGED MODELS WARNING www SeaDooManuals net ...

Page 778: ...B A B A 2003 LRV DI MODELS F11Z03 INJ BATT 25A BILGE 3A REG 25A ACC 2A FP 15A N S E W RE PU RE GY RE GY RE WARNING www SeaDooManuals net ...

Page 779: ...www SeaDooManuals net ...

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Sea-doo 2003 GTI LE RFI, Shop Manual

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