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Sea-doo GTI 5558, Shop Manual

The Sea-doo GTI 5558 Shop Manual is a must-have resource for all GTI 5558 owners. This comprehensive manual is available for free download on manualshive.com, providing in-depth guidance on maintenance, repairs, and troubleshooting. Maximize your watercraft's performance with this essential manual at your fingertips.

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Section 04

ENGINE

Subsection 05

(TOP END)

SMR2002-024_04_05A.FM

04-05-19

1. Indicator set to zero

Position the dial bore gauge at 16 mm (5/8 in) be-
low cylinder top edge.

1. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)

Read the measurement on the cylinder bore gauge.
The result is the exact piston/cylinder wall clearance.

NOTE:

Make sure the cylinder bore gauge indica-

tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.

Ring/Piston Groove Clearance

717 and 787 RFI Engines

Using a feeler gauge, check clearance between
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 Engines

Due to the semi-trapez rings, it is not possible to
accurately measure ring/piston groove clearance.

Ring End Gap

Position ring halfway between exhaust port and
top of cylinder.

NOTE:

In order to correctly position ring in cylin-

der, use piston as a pusher.

Using a feeler gauge, check ring end gap. If gap
exceeds specified tolerance, rings should be re-
placed.

1. Top of cylinder
2. Ring end gap

F00B0AA

1

F01D0KA

1

A

F01D0XA

1

2

F01D0OA

1

2

www.SeaDooManuals.net

Summary of Contents for GTI 5558

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

Page 2: ...2002 Shop Manual Volume 1 GTI GTI LE GTX GTX RFI XP RX RX DI LRV DI www SeaDooManuals net ...

Page 3: ...hout the prior written permission of Bombardier Inc Bombardier Inc 2002 Technical Publications Bombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc Loctite is a trademark of Loctite Corporation Snap on is a trademark of Snap on Tools Corporation Gelcote is a trademark of Gelcote International Limited www SeaDooManuals net ...

Page 4: ...nts 05 01 1 02 Overview 05 02 1 03 Diagnostic procedures 05 03 1 04 Component inspection 05 04 1 05 Troubleshooting summary 05 05 1 06 Adjustment 05 06 1 07 Removal and installation 05 07 1 06 ENGINE MANAGEMENT DI 01 Table of contents 06 01 1 02 Overview 06 02 1 03 Component inspection and adjustment 06 03 1 04 Diagnostic procedures 06 04 1 07 COOLING SYSTEM 01 Table of contents 07 01 1 02 Circuit...

Page 5: ... 12 02 1 03 Alignment 12 03 1 13 SUSPENSION 01 Table of contents 13 01 1 02 Direct action suspension 13 02 1 14 HULL BODY 01 Table of contents 14 01 1 02 Adjustment and repair 14 02 1 15 TECHNICAL DATA 01 GTI and GTI LE models 15 01 1 02 GTX RFI model 15 02 1 03 XP model 15 03 1 04 RX DI model 15 04 1 05 LRV DI models 15 05 1 06 GTX and RX models 15 06 1 16 WIRING DIAGRAMS 01 Wiring diagrams 16 01...

Page 6: ...commended 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 fastene...

Page 7: ...iolet 717 5558 GTI LE International earthen clay 717 5560 GTI LE earthen clay 717 5561 GTI California ultraviolet 717 6116 GTI LE California earthen clay 717 6117 GTX yellow 947 5588 GTX International yellow 947 5587 GTX RFI blue 787 5566 GTX RFI International blue 787 5565 RX blue 947 5580 RX International blue 947 5579 RX yellow 947 5582 RX International yellow 947 5581 RX DI blue 947 DI 5584 RX...

Page 8: ... RFI Engine The Engine Identification Number is located on the upper crankcase on PTO side 1 Engine Identification Number E I N 947 Engine The Engine Identification Number is located on the upper crankcase on MAGNETO side 1 Engine Identification Number E I N Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number F00A0CB Month of production Year of production A letter may also be used as a digit Manufact...

Page 9: ...ENGINE MANAGEMENT RFI 06 ENGINE MANAGEMENT DI 07 COOLING SYSTEM 08 FUEL SYSTEM 09 LUBRICATION SYSTEM 10 ELECTRICAL SYSTEM 11 PROPULSION SYSTEM 12 STEERING SYSTEM 13 SUSPENSION 14 HULL BODY 15 TECHNICAL DATA 16 WIRING DIAGRAM Several sections are divided in various subsections There is a table of contents at the beginning of many sections INTRODUCTION www SeaDooManuals net ...

Page 10: ...ustration number for publishing process Subsection title indicates beginning of the subsection Dotted box contains parts of a particular model or an exploded view Page numbering system 03 ENGINE section 04 MAGNETO SYSTEM subsection 1 First page of this subsection Italic sub title above exploded view indicate pertaining models Drop represents a liquid product to be applied to a surface In this case...

Page 11: ...place other wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI Diaph...

Page 12: ...ey represent 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...

Page 13: ...rformed 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 water crafts manufactured by Bombardier are certified t...

Page 14: ...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 15: ...rops of proper strength Loctite on bolt nut contact surfaces 5 Avoid touching metal with tip of flask NOTE For preventive maintenance on existing equipment retighten nuts and apply proper strength Loctite on bolt nut contact surfaces Adjusting Screw 1 Apply here 2 Plunger 1 Adjust screw to proper setting 2 Apply drops of proper strength Loctite thread locker on screw body contact surfaces 3 Avoid ...

Page 16: ...nly 1 Remove old gasket and other contaminants with Loctite Chisel remover P N 413 708 500 Use a mechanical mean if necessary NOTE Avoid grinding 2 Clean both mating surfaces with solvent 3 Spray Loctite Primer N on both mating surfaces and on both 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 gas...

Page 17: ...all 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 also...

Page 18: ...2 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 91 124...

Page 19: ...ations 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 INTRODUCTION www SeaDooManuals net ...

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

Page 21: ... 0 6 0 50 40 30 20 10 10 20 30 40 5 0 6 0 7 0 8 0 9 0 1 0 0 1 1 0 1 2 0 1 3 0 1 4 0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 2 0 0 2 1 0 2 2 0 2 3 0 2 4 0 2 5 0 2 6 0 2 7 0 2 8 0 2 9 0 3 0 0 3 1 0 320 330 340 350 360 Air compressor ring compressor P N 529 035 713 F12B0L4 APPLICATION 947 DI engine Carbon dam guide P N 529 035 715 F12B0M4 APPLICATION 947 DI engine Carbon dam compressor P N 529 035 716 F12B0N4 ...

Page 22: ...Screw P N 290 240 860 2 Hexagonal nut P N 290 242 210 F01B0I4 APPLICATION 717 and 787 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 P N 529 035 511 3 Screw 2 P N 207 182 544 4 Lock washer 2 P N 234 181 601 5 Flat washer 2 P N 234 081 410 F00B0F4 APPLICATION All models A 155 6 mm jet pump B 139 5 mm jet pump Alignment shaft P N ...

Page 23: ...77 650 A00C3V4 APPLICATION Use with pushers P N 290 876 609 and 290 877 740 Ring gear puller tool P N 420 976 235 puller ass y P N 529 035 549 puller bolt F01B294 APPLICATION 787 947 and 947 DI engines Crankshaft protective cap A P N 420 876 557 B P N 290 877 414 F00B194 APPLICATION A 717 and 787 engines B 947 and 947 DI engines Polygonal wrench P N 529 035 505 F00B0Y4 APPLICATION Exhaust system o...

Page 24: ... APPLICATION All models NOTE This tool is also used for the propulsion system Fuel pressure gauge P N 529 035 591 F02B0B4 APPLICATION 787 RFI engine Fuel line disconnect tool P N 529 035 714 F12B0G4 APPLICATION 947 DI engine 1 Fuel pressure gauge P N 529 035 709 2 Fuel pressure gauge T fitting P N 529 035 710 3 Fuel pressure gauge pressure relief valve P N 529 035 711 4 Fuel pressure gauge air com...

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

Page 26: ...Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 MANDATORY SERVICE TOOLS 01 02 6 SMR2002 016_01_02A FM OPAS cylinder nut wrench P N 529 035 840 F18B0A4 APPLICATION GTI LE NEW www SeaDooManuals net ...

Page 27: ...ATION A 717 engine B 787 engine C 947 and 947 DI engines MAG D 947 and 947 DI engines PTO Stroboscopic timing light P N 529 031 900 A00B4F4 APPLICATION All models A Four pin magneto harness P N 295 000 131 B Six pin magneto harness P N 295 000 136 F01B284 APPLICATION A 717 engine B 787 947 and 947 DI engines Dial indicator TDC gauge P N 295 000 143 A00B4E4 APPLICATION All models Digital induction ...

Page 28: ... 034 600 F01B244 APPLICATION All models Slide hammer puller Not sold by Bombardier Snap on Handle CJ93 1 Hammer CJ125 6 Claws CJ93 4 F01J0Z4 APPLICATION 717 and 787 engines NOTE This tool is also used to pull out impeller shaft seal Protective mat P N 295 000 128 F02B0A4 APPLICATION All models Gear bearing puller P N 290 877 665 F04B034 APPLICATION 787 engine Exhaust outlet tool P N 295 000 132 F0...

Page 29: ...2 A P N 290 876 965 88 mm B P N 290 876 979 82 mm F01B1T4 APPLICATION A 947 and 947 DI engines B 717 and 787 engines Digital multimeter P N 529 035 868 APPLICATION All models F01D885 1 Puller ass y P N 420 877 635 2 Protective cap P N 420 876 557 P N 290 877 414 947 and 947 DI engines 3 Ring both ends P N 420 977 490 P N 420 977 480 947 and 947 DI engines 4 Ring halves PTO P N 420 977 475 2 P N 42...

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

Page 31: ...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 32: ...WATERCRAFT HANDLING Dolly with wheels P N 295 000 126 F01B014 Beach wheels set of 2 wheels P N 295 000 005 F01B074 APPLICATION Dolly Tie down with ratchet 3 60 m 12 ft long P N 295 100 104 APPLICATION All models Tie down 1 50 m 5 ft long P N 295 100 103 F00B014 APPLICATION All models www SeaDooManuals net ...

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

Page 34: ...02B0B4 NEW Thread sealant P N 293 800 050 Loctite 577 250 mL F00B0W4 Solvent P N 413 711 809 Loctite Safety Solvent 320 g 11 oz A00B4X4 Molykote 111 P N 413 707 000 A00B3W4 111 Primer for gasket eliminator P N 293 800 041 Loctite 764 A00B3N4 Pipe sealant A P N 293 800 018 B P N 293 800 013 A Loctite 592 50 mL B Loctite 567 250 mL A00B2W4 Hylomar sealant P N 293 800 001 PL 32 100 g A00B3F4 Sealant ...

Page 35: ...Ultra Copper 80 mL A00B5A4 Deoxit contact lubricant P N 293 550 015 200 mL F00B0X4 NEW Grease P N 293 550 005 400 g A00B2L4 Synthetic grease P N 293 550 010 400 g F01B154 Super Lube grease P N 293 550 030 A00B474 Anti seize lubricant P N 293 800 070 Loctite 76764 454 g 16 oz A00B594 R Grease Isoflex P N 293 550 021 50 g A00B554 BOMBARDIER LUBE P N 293 600 016 12 x 14 oz A00B624 NEW www SeaDooManua...

Page 36: ...r F01B1C4 Premixed coolant 50 50 37 C 35 F P N 293 600 038 16 x 1 L A00B5X4 BOMBARDIER FORMULA XP S II synthetic injection oil P N 293 600 245 12 x 1 liter A00B5T4 P N 293 600 246 3 x 4 liter A00B5U4 P N 293 600 247 205 liter NEW NEW Sealant adhesive P N 293 800 086 Loctite 5150 29647 A00B5S4 Instant gasket P N 293 800 088 7 oz Ao2B0C4 Jet pump oil P N 293 600 011 12 x 6 oz Sea Doo synthetic jet p...

Page 37: ...E TOOLS AND PRODUCTS Subsection 04 SERVICE PRODUCTS SMR2002 016_01_04A FM 01 04 5 Sea Doo Cleaner P N 293 110 001 400 g P N 293 110 002 4 L F01B2J4 Pulley flange cleaner P N 413 711 809 A00B5V4 NEW www SeaDooManuals net ...

Page 38: ...1 PROCEDURE 02 03 1 WATER FLOODED ENGINE 02 04 1 GENERAL 02 04 1 PROCEDURE 02 04 1 STORAGE 02 05 1 ENGINE DRAINING 02 05 1 PROPULSION SYSTEM 02 05 2 FUEL SYSTEM 02 05 3 COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION 02 05 3 BATTERY 02 05 3 WATERCRAFT CLEANING 02 05 3 ADDITIONAL RECOMMENDED PROTECTION 02 05 3 ANTICORROSION TREATMENT 02 05 9 CHECKLIST 02 05 9 www SeaDooManuals net ...

Page 39: ...uipped FUEL SYSTEM Carburetor adjustment including choke throttle cable adjustments carburetor equipped models Throttle choke cables carburetor equipped models inspection lubrication Fuel filter except RFI models and lines inspection Fuel filter replacement except DI and RFI models Fuel filter replacement DI models only Visually check for oil leakage between cylinder head and injector DI models Fu...

Page 40: ... fasteners Digitally Encoded Security System Monitoring beeper Battery condition and strap s STEERING SYSTEM Inspection and cable adjustment O P A S SYSTEM Check O P A S system operation and condition including filter PROPULSION SYSTEM Drive shaft boot and spline condition if so equipped Drive shaft protection hose inspection PTO flywheel and seal carrier lubrication if so equipped Shifter system ...

Page 41: ...em 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 42: ...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 tube in when finished Close the water tap then stop the engine CAUTION Always close the water tap before stopping the engine Disconnect the garden hose CAUTI...

Page 43: ...nto cylinder walls NOTE Proceeding in this order no fuel will be in jected into the engine DI Models NOTE Proceeding in this order no fuel will be in jected and no ignition will occur in the engine While engine is stopped fully depress throttle le ver and HOLD for cranking Wait 2 seconds then press the start stop button to crank the engine a few turns and distribute the lubricant onto cylinder wal...

Page 44: ...cessary siphon and refill with fresh fluids Turn fuel valve to OFF position carburetor equipped models then drain fuel filter bowl Re fer to FUEL CIRCUIT Drain bilge if water is present Remove spark plug cables and connect them on the grounding device GTI MODELS 1 Grounding device XP MODELS 1 Grounding device RX RX DI GTX AND LRV DI MODELS 1 Grounding device GTX RFI MODELS 1 Grounding device WARNI...

Page 45: ...second indicates the drowned mode is active If water does not completely go out it may be nec essary to remove the air intake silencer then to lean the vehicle so that water can flow out from throttle bodies All Models 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 co...

Page 46: ...to IGNITION SYSTEM Check crankshaft if needed it may be misaligned or deflected Refer to BOTTOM END After engine has started spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running 717 AND 787 RFI ENGINES 1 Air intake silencer 2 Pull plug 3 Spray BOMBARDIER LUBE here Spray BOMBARDIER LUBE lubricant or equiva lent through hole of air intake silencer keeping en gine at fa...

Page 47: ...e 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 1 Disconnect this hose Water should flow out of the fitting magneto cooling circuit and hose c...

Page 48: ...r procedure CAUTION Use only SEA DOO jet pump oil or equivalent synthetic gear oil otherwise com ponent service life could be reduced Do not mix oil brands or types PTO Flywheel All Models except XP Remove PTO flywheel guard Lubricate PTO flywheel at grease fitting with syn thetic grease P N 293 550 010 CAUTION Do not lubricate excessively Imme diately stop when a slight movement is noticed on rub...

Page 49: ... 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 prevent sun rays and grime from affecting the plastic components watercraft finish as well as preventing dust accumulation CAUTION The watercraft must never be Ieft in water for storage Ne...

Page 50: ... except DI GTI MODELS 717 ENGINES 1 Engine drain hose RFI MODELS 787 ENGINE 1 Hose pincher installed on engine drain hose NOTE On RFI models make sure the hose is properly connected to the magneto cover 1 Water supply hose from crankcase heat exchanger 2 Quick connector 3 Magneto heat exchanger 947 CARBURETOR EQUIPPED ENGINES EXCEPT XP 1 Engine drain hose 1 F17E05A 1 F07E0DA 1 F07E0EB 2 3 F07E0JA ...

Page 51: ...ncher installed on engine drain hose Install hose pincher on injection hose going to tuned pipe GTI MODELS 717 ENGINES 1 Hose pincher on injection hose going to tuned pipe 717 AND 787 RFI ENGINES 1 Engine water outlet hose 947 CARBURETOR EQUIPPED ENGINES 1 Engine water outlet hose 1 Tuned pipe bleed hose 1 F08E04A 1 F12E0SA F17E01A 1 F12E02A 1 F12E04A 1 www SeaDooManuals net ...

Page 52: ...ater 40 water 60 antifreeze in engine until the colored solution appears at the cooling sys tem bleed outlet 947 Carburetor Equipped Engines At this point remove the hose pincher at tuned pipe bleed hose If necessary continue to pour anti freeze mix until the colored solution appears at the other cooling system bleed outlet stern eyelet Remove the remaining hose pinchers in this order to allow pro...

Page 53: ...tect it Reconnect hose to T fitting and remove hose pincher if applicable All Models except DI Remove temporary hose on 717 engines and re connect engine water outlet hose Remove hose pinchers DI Models 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 ...

Page 54: ...tting Temporarily install a short piece of hose 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 1 Bleed outlet hose Continue to pour until antifreeze flows in air com pressor water outlet hose F07E0JA 1 F12E0BA 1...

Page 55: ... thus preventing freezing problems At pre season preparation drain the remaining an tifreeze from cooling system prior to using the wa tercraft ANTICORROSION TREATMENT Wipe off any residual water in the engine compart ment Spray BOMBARDIER LUBE lubricant over all me tallic components in engine compartment Lubricate the throttle cable with BOMBARDIER LUBE lubricant The seat should be partially left...

Page 56: ...s Check wiring then replace fuse Starting system fuse keeps on burn ing Check wiring starting system solenoid and MPEM Discharged or disconnected battery Check recharge Defective or disconnected start stop switch Check refer to STARTING SYSTEM or ENGINE MANAGEMENT Battery connections Check clean tighten Water fuel hydrolock Check refer to section MAINTENANCE Starter malfunction Check refer to sect...

Page 57: ... replace as necessary Check ignition system and repair Defective MPEM Replace MPEM Defective crankshaft position sensor Check operation of CPS and replace if necessary Water contaminated fuel Check siphon and refill Dirty fuel filter Clean replace Fouled or defective spark plug Replace Water in engine Check refer to section MAINTENANCE Carburetion carburetor models Check refer to section FUEL SYST...

Page 58: ...NGINE MANAGEMENT Check fuel pressure regulator Refer to ENGINE MANAGEMENT Low air pressure DI models Check air fuel rail Refer to ENGINE MANAGEMENT Check air compressor system Refer to ENGINE MANAGEMENT Check RAVE valve for leaks OTHER OBSERVATION POSSIBLE CAUSE REMEDY DI models The system is in limp home mode Broken or loose throttle cable Refer to section ENGINE and check the fault codes in the ...

Page 59: ...Fuel filter dirty or restricted Check clean replace Carburetion dirty or out of adjustment carburetor models Check clean adjust refer to section FUEL SYSTEM Clogged fuel injectors RFI and DI models Remove and clean fuel injectors Clogged direct injectors DI models Remove and clean direct injectors Defective sensor or MPEM RFI and DI models Check faulty codes in MPEM memory refer to section ENGINE ...

Page 60: ...e system DI models Check refer to ENGINE MANAGEMENT Oil injection pump adjustment Check adjust refer to section 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 DI models Inspect fuel pressure regulators Refer to ENGINE MANAGEMENT High fuel pressure RFI and ...

Page 61: ...iming Check reset refer to ENGINE Carburetor if so equipped Carburetion too lean Check adjust refer to section FUEL SYSTEM Engine Intake leak crankshaft seal failure carburetor models Pressure check engine refer to section ENGINE OTHER OBSERVATION POSSIBLE CAUSE REMEDY Ignition Timing too far advanced Check reset Spark plug heat range too high Check change to correct range Engine exhaust high temp...

Page 62: ... DI models Check and adjust TPS refer to section ENGINE MANAGEMENT Overheated engine See ENGINE OVERHEATS in this chart Engine revs lower than its maximum operational RPM RAVE valve does not open if so equipped Limp home mode activated Check refer to section ENGINE Refer to ENGINE MANAGEMENT Peak performance is delayed until higher RPM range is reached RAVE valve is stuck opened if so equipped Che...

Page 63: ...ir OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine RPM too high Faulty rev limiter in MPEM Check refer to section ENGINE MANAGEMENT Improper impeller pitch too low Incorrect throttle position sensor TPS adjustment RFI models Check replace refer to section PROPULSION SYSTEM Check and adjust TPS refer to ENGINE MANAGEMENT Damaged impeller Replace impeller Refer to PROPULSION Jet pump cavitation Damag...

Page 64: ...R OBSERVATION POSSIBLE CAUSE REMEDY Watercraft is more responsive than usual while turning Side vanes do not go up while watercraft is at speed Refer to STEERING SYSTEM Watercraft pulls on one side One side vane does not go up while watercraft is at speed Refer to STEERING SYSTEM O P A S side vanes do not go up while watercraft is at speed Clogged filter square rings damaged leakage in hoses or me...

Page 65: ... 03 6 MAGNETO SYSTEM 04 04 1 DISASSEMBLY 04 04 5 CLEANING 04 04 11 ASSEMBLY 04 04 12 TOP END 04 05 1 GENERAL 04 05 5 DISASSEMBLY 04 05 7 CLEANING 04 05 16 INSPECTION 04 05 16 USED PISTON MEASUREMENT 04 05 17 ASSEMBLY 04 05 20 ADJUSTMENT 04 05 29 BOTTOM END 04 06 1 DISASSEMBLY 04 06 5 CLEANING 04 06 13 INSPECTION 04 06 14 ASSEMBLY 04 06 18 ROTARY VALVE 04 07 1 GENERAL 04 07 2 INSPECTION ON WATERCRA...

Page 66: ...Section 04 ENGINE Subsection 01 TABLE OF CONTENTS 04 01 2 SMR2002 052_04_01ATOC FM EXHAUST SYSTEM 04 08 1 REMOVAL 04 08 7 TUNED PIPE REPAIR 04 08 12 INSTALLATION 04 08 13 www SeaDooManuals net ...

Page 67: ...pplementary 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 all 947 engines N...

Page 68: ... drain hose blocked with a hose pincher 717 ENGINE FRONT VIEW 1 Loop hose and use clamps 2 Use two washers with exhaust manifold stud 3 Hose with adapter and nipple 787 RFI ENGINE REAR VIEW 1 Loop hose and use clamps 2 Hose with clamps Install pump to the end 3 Block engine drain hose with a hose pincher 787 RFI ENGINE FRONT VIEW 1 Exhaust manifold plate F01B2UB 1 F01B2VA 2 3 1 3 2 1 F02E0DA F02D0...

Page 69: ...anifold plate 947 DI ENGINE SIDE VIEW 1 Block engine drain hose with a hose pincher 2 Install pump to water inlet hose 947 DI ENGINE FRONT VIEW 1 Exhaust manifold plate NOTE Water is not required for testing DI models it is not necessary to pressurize the bottom crankcase cover nor the magneto cover There is no possible water leak path toward the internal components of the engine 1 2 F08E06A 1 F08...

Page 70: ...ntake and exhaust plates included in the Supple mentary Engine Leak Test Kit P N 295 500 780 DI Models Remove throttle bodies on DI models Install intake manifold plugs P N 529 035 708 1 Intake manifold plugs All Models On engines with the RAVE system remove the RAVE valves and gaskets Install the RAVE valve plates with fasteners from the kit and tighten adequately NOTE Engines with the RAVE syste...

Page 71: ...ive check valve Check for leak through counterbalancing shaft seal toward air compressor DI engines Air bub bles in lowest fitting oil return line underneath compressor indicates a seal leakage If the above mentioned components are not leak ing block both oil hoses of the rotary valve shaft if so equipped using hose pinchers NOTE If leakage stops at this point proceed with Rotary Valve Shaft testi...

Page 72: ...ective PTO side crankshaft inner seal or crankcase is not sealed correctly Remove 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 lea...

Page 73: ... COVER CHECK SEAL OF ROTARY VALVE SHAFT IS SEAL LEAKING CAREFULLY INSPECT ENGINE CASTINGS PARTICULARLY THE THREADED HOLE AREAS YES YES NO PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING CHECK TESTING KIT REPLACE O RING OF CYLINDER HEAD AND OR CYLINDER BASE GASKET YES YES NO CHECK TESTING KIT IS RESERVOIR LEAKING PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE REPLACE GASKET OR O RING RE SEA...

Page 74: ...Section 04 ENGINE Subsection 02 LEAK TEST 04 02 8 SMR2002 021_04_02A FM 947 Engine F00D28S www SeaDooManuals net ...

Page 75: ...t electrical con nections prior to disconnecting fuel lines Disconnect temperature sensor wire and spark plug cables Disconnect magneto wiring harness 717 ENGINE 1 Unplug connector 787 RFI ENGINE 1 Unplug connector 947 ENGINE 1 Unplug connector GTX RFI Models Disconnect throttle position sensor TPS air pres sure sensor APS and air temperature sensor ATS Disconnect crankshaft position sensor CPS Di...

Page 76: ...VE 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 Carburetor Thr...

Page 77: ...RONT SUPPORT 1 Remove screw 787 RFI AND 947 ENGINES REAR SUPPORT 1 Remove screws Lifting Engine 717 Engine Engine can be easily lifted using the following sug gested tools Cut porcelain from two old spark plugs Weld a lock washer approximately 20 mm 3 4 in diameter on each spark plug as shown 1 Weld a lock washer 2 Old spark plug Remove spark plugs and replace by special tools Hook a sling into ho...

Page 78: ...s 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 pincher to oil supply hoses of oil in jection pump and rotary valve shaft except the 947 engine then disconnect hoses TYPICAL 1 Hose pincher P N 295 000 076 Install a hose pincher to oil return hose of rotary valve shaft excep...

Page 79: ...AL 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 scratch body or to hit any component TYPICAL CLEANING Wipe off any spillage in bilge Clean with a bilge cleaner Clean external parts of engine F04D10A 3 2 1...

Page 80: ...7 Engine 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 and 947 Engines except DI Engine Apply Loctite 243 blue to rear engine support screws and install them with flat washers and torque to 24 N m 17 lbf ft TYPICAL 1 Torque engine support screws to 24 N m 17 lbf ft DI Engine Install and tor...

Page 81: ...9 5 mm 5 1 2 in jet pump and plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plate 2 Support Alignment shaft P N 295 000 141 1 Alignment shaft All Models except XP To verify alignment proceed as follows Install the appropriate plate with the support to hull with four nuts Carefully slide shaft through support Insert shaft end into PTO flywheel NOTE Ensure the protective hose and carbon ...

Page 82: ... mm 0 12 in on the 717 and 787 engines XP Models Use plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plate 2 Support alignment shaft P N 295 000 141 1 Alignment shaft PTO flywheel adapter P N 529 035 590 1 Adapter Install support plate at rear of watercraft Install adapter on shaft NOTE Ensure the mid bearing is loosened to check engine alignment Carefully slide alignment shaft P N 295 ...

Page 83: ...rward and install PTO adapter P N 529 035 590 Insert adapter end into PTO flywheel If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft end NOTE Use shim s P N 270 000 024 or P N 270 000 025 as necessary between engine supports and rubber mounts to correct alignment TYPICAL 1 Shim CAUTION Whenever shims are used to correct alignment neverinstallmore...

Page 84: ... 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 water engine must be cooled using the flush kit F06D35A 1 1 F07F12C WARNING Whenev...

Page 85: ...bf 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 86: ...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 www Se...

Page 87: ...8D0AS Molykote 111 9 Loctite 243 13 N m 115 lbf in 20 Loctite 243 9 N m 80 lbf in 11 Dielectric grease Loctite 243 Dielectric grease 1 25 29 16 5 N m 44 lbf in 10 Loctite 243 21 9 N m 80 lbf in 3 Loctite 648 8 Loctite 648 17 13 N m 115 lbf in 14 Loctite 243 13 115 N m 85 lbf ft Ground cable www SeaDooManuals net ...

Page 88: ...2 023_04_04A FM 947 DI Engines F12D0SS 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 www SeaDooManuals net ...

Page 89: ...sleeves 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 diame ter as necessary TYPICAL 1 ...

Page 90: ...nd crank case to ease reassembly and further ignition timing The following procedure is to find a common ref erence point on both crankcases old and new to position armature plate Proceed as follows Before removing the armature plate find a crankcase locating lug the top one in this exam ple Place a cold chisel at the end of chosen lug then punch a mark on armature plate at this point 1 Crankcase ...

Page 91: ...ness from flame Remove screws Uncrimp and unsolder BLACK RED wire from coil 1 Uncrimp and unsolder wire here Battery Charging Coil To replace battery charging coil no 7 Heatthearmatureplateto93 C 200 F aroundthe screw holes to break the threadlocker bond 1 Heat the armature plate CAUTION Protect harness from flame Remove screws Uncrimp and unsolder YELLOW and YELLOW BLACK wires from coil Uncrimp a...

Page 92: ... rotor nut 1 Oil pump shaft Rotor and Ring Gear Remove starter Refer to STARTING SYSTEM NOTE Crankshaft can also be locked by using the PTO flywheel extractor tool For 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 ...

Page 93: ... P N 420 976 235 and crankshaft protective cap P N 420 876 557 Remove special tool locking ring gear Insert crankshaft protector to outer end of crank shaft and 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 remov...

Page 94: ...emove engine magneto cover no 1 TYPICAL 1 Cover 2 Screw Remove oil pump shaft from magneto rotor nut 1 Remove oil pump shaft Rotor and Ring Gear To remove the rotor no 8 or the ring gear no 3 the crankshaft must be locked For procedure re fer to BOTTOM END If necessary the magneto rotor can be removed without removing the ring gear Remove the six screws no 17 1 Screw To remove the ring gear rotor ...

Page 95: ...rotor from its taper DI Models CAUTION Be careful after ring gear removal not to bend the encoder wheel teeth Also pay attention when putting away If you suspect a bent tooth refer to ENGINE MANAGEMENT for inspection procedure All 947 Engines Stator and Trigger Coil CPS Crankshaft Position Sensor Loosen screws no 20 and no 21 to remove the stator no 9 and trigger coil no 10 from the engine magneto...

Page 96: ...a propane torch in order to install it on magneto flywheel Pay particular attention to position ring gear teeth chamfer side as per following illustration 1 Teeth chamfer NOTE Ensure that ring gear contacts magneto flywheel flange Whenever replacing either ring gear or magneto flywheel Gun Kote must be applied to prevent possible corrosion CAUTION Always assemble magneto flywheel and ring gear pri...

Page 97: ...que to 6 N m 53 lbf in Magneto Flywheel Apply Loctite 243 blue on crankshaft taper Position Woodruff key and magneto flywheel Ap ply Loctite 243 blue on nut no 13 Install nut with lock washer and torque to 145 N m 107 lbf ft CAUTION Never use any type of impact wrench at magneto installation Ignition Timing For ignition timing procedures of the 717 engine refer to IGNITION SYSTEM Magneto Housing C...

Page 98: ...18 on mag neto housing Torque screw to 9 N m 80 lbf in NOTE The crankshaft position sensor is not ad justable Cover Before installing cover make sure oil pump shaft is properly positioned Before installation properly install O ring no 25 in engine magneto cover no 1 Apply Loctite 767 anti seize compound on screws no 11 Torque screws in a criss cross sequence to 9 N m 80 lbf in 947 Engine Stator an...

Page 99: ...d torque screws in a criss cross sequence to 13 N m 115 lbf in Apply Loctite 243 blue on crankshaft taper 1 Loctite 243 blue on crankshaft taper Install flywheel and make sure to align keyway with the crankshaft Woodruff key Apply Loctite 243 blue on nut no 13 Install nut with lock washer and torque to 115 N m 85 lbf ft CAUTION Never use any type of impact wrench Unlock crankshaft Reinstall pulse ...

Page 100: ...5A FM 04 05 1 TOP END 0 717 Engine 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 101: ...D0US 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 102: ...es 30 10 N m 89 lbf in 15 16 17 19 18 20 Molykote 111 3 N m 27 lbf in 21 29 27 26 24 23 22 F08D0BS 15 N m 133 lbf in 4 5 7 8 3 5 6 Engine oil 28 25 Loctite 243 34 N m 25 lbf ft Molykote 111 14 Loctite 243 2 Molykote 111 Loctite 243 34 N m 25 lbf ft 33 34 Molykote 111 31 32 9 10 www SeaDooManuals net ...

Page 103: ...M 947 DI Engine 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 104: ...here 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 engines the spring pre load does not have a significant effect on the valve operation 787 RFI and 947 Carburetor Equipped Engines On these engines the RAVE valves are controlled by the Multi Purpose Electr...

Page 105: ...ssure 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 air c...

Page 106: ...han recom mended more frequent cleaning may be required 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 available for the ...

Page 107: ...rocedures relates the steps for the 787 RFI and 947 carburetor equipped en gines The DI engine is explained below 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 ...

Page 108: ...ng 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 109: ...47 DI Engine 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 110: ...wire and spark plug cables Connect spark plug cables on grounding device 717 Engine 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 particles are pr...

Page 111: ...shown in the next photo UNTORQUING SEQUENCE FOR THE NUTS Remove cylinder head no 2 Remove cylinder head gasket no 34 1 Remove gasket 947 DI Engine Use Snap On Torx socket E12 and unscrew cylin der head screws no 14 following the sequence shown in the next illustration Remove cylinder head no 2 and gasket no 34 Cylinder NOTE When removing cylinder be careful that connecting rods do not hit crankcas...

Page 112: ...der block NOTE To ease removal a plastic tip hammer can be used Remove cylinder base gasket no 10 947 DI Engine 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 sits on pad 1 Rubber pad...

Page 113: ... 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 towards spindle 1 Puller 2 Sleeve 3 Shoulder sleeve 4 Extracting nut WARNING Always wear safety g...

Page 114: ... 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 1 F...

Page 115: ...OLERANCES 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 wall clearance for the 717 engine 0 10 mm 0039 in N A 0 20 mm 008 in Piston cylinder wall clearance for the 787 RFI engine 0 13 mm 005 in N A 0 22 mm 009 in Piston cylinder wall clearance for the 947 engine 0 09 mm 0035 in N A 0 20 mm 008 ...

Page 116: ...nce between read ings exceed specification cylinder should be rebored and honed or replaced 1 Measuring 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...

Page 117: ...pecified 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 the micrometer di mension and set the indicator to ze...

Page 118: ... 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 Engines Due to the semi trapez rings it is not possible to accurately measure ring piston groove clearance Ring End Gap Posi...

Page 119: ...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 Engine Make sure to insert O ring no 23 onto rod of slid ing valve no 22 The TOP position of the sliding valve no 22 is in dicated on one side 1 Sliding valve 2 O ring 3 TOP Install a new gasket no 24 It must be insta...

Page 120: ... 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 Check the O ring under valve housing Replace if necessary 1 Valve housing O ring All RAVE Equipped Engines There is only one way to insert the sliding valve no 22 in valve housing no 25 F01D8LA F06D11A 1 F12D0ZA 1 1 F12D10A 1 F12D11A www Sea...

Page 121: ...g sleeve outside and 2 plastic cage halves inside Push needle bearing together with inner halves out of the locating sleeve into the connecting rod bore Replace the inner halves by the appropriate sleeve tool in the connecting rod bore Insert piston pin into piston until it comes flush with inward edge of piston hub Warm piston to approximately 50 60 C 122 140 F and install it over connecting rod ...

Page 122: ...ter plastic ring will release rollers 1 Outer ring removal after inner sleeve insertion into bore Make sure thrust washers are present each side of rollers 1 Thrust washer each side Insert piston pin into piston until it comes flush with inward edge of piston hub 1 Piston pin flush here 2 Thrust washers Place piston over connecting rod and align bores then gently tap piston pin with a fiber hammer...

Page 123: ...m as described 1 Circlip opening at 6 o clock at bottom 947 Engines Secure circlip in piston groove with its bent end in piston notch as shown 1 Circlip end in piston notch All Engines To easily insert circlip into piston use circlip installer 1 Circlip installer Remove sleeve from pusher then insert circlip into its bore Reinstall sleeve onto pusher and push until cir clip comes in end of tool TY...

Page 124: ...UME MEASUREMENT to properly determine the required gasket thickness Five thicknesses of cylinder base gaskets are available for a precise adjustment of the squish gap To identify gasket thickness refer to the identifi cation holes on the gasket Cylinder 717 and 787 RFI Engines To easily slide cylinder no 9 over piston install on piston ring compressor P N 290 876 979 1 Slide this edge NOTE Ring co...

Page 125: ...E 1 Aligning cylinders using exhaust manifold Cylinder Block 947 Carburetor Equipped Engine Install studs no 32 Apply Molykote 111 to threads and torque studs to 15 N m 133 lbf in Refer to exploded view to see what end to insert in crank case Remove O rings from studs All 947 Engines Install cylinder base gasket no 10 There is only one way to install gasket The cylinder block is positioned with lo...

Page 126: ... to the following illustration 787 RFI Engine Prior installation apply Molykote 111 below screw head and Loctite 243 blue on screw threads Install M10 x 105 screws on exhaust side and the M10 x 73 5 on opposite side Torque screws in a criss cross sequence for each cylinder to 20 N m 15 lbf ft Repeat the proce dure retightening all cylinder screws to 40 N m 30 lbf ft 947 DI Engines Apply Molykote 1...

Page 127: ...e Repeat the torquing sequence by retightening to 34 N m 25 lbf ft TORQUING SEQUENCE 947 DI Engine Apply Loctite 243 blue below head of cylinder head bolts no 14 Apply Molykote 111 on threads of cylinder head bolts no 14 Torque bolts to 20 N m 15 lbf ft as per following sequence in the next picture Repeat the torquing sequence by retightening to 40 N m 30 lbf ft Cylinder Head Cover 717 and 787 RFI...

Page 128: ...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 the engine 1 Combustion chamber NOTE When checking...

Page 129: ... 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 change cylinder...

Page 130: ...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 131: ...ant 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 lubricant ww...

Page 132: ...ite 518 Molykote 111 27 N m 20 lbf ft Molykote 111 40 N m 30 lbf ft Loctite 518 Loctite 518 Molykote 111 20 N m 15 lbf ft 27 N m 20 lbf ft 27 N m 20 lbf ft Molykote 111 Loctite 518 Loctite 243 7 N m 62 lbf in Loctite 5910 Anti seize lubricant Anti seize lubricant 40 mL 1 35 oz SAE 30 motor oil 6 16 15 17 14 13 31 32 15 16 4 4 5 6 3 20 N m 15 lbf ft 2 Loctite 243 1 5 N m 13 lbf in 30 29 9 N m 80 lb...

Page 133: ...ote 111 Molykote 111 Loctite 518 27 N m 20 lbf ft Loctite 5910 6 5 N m 58 lbf in 9 N m 80 lbf in 7 N m 62 lbf in Anti seize lubricant Anti seize lubricant 28 5 4 4 6 6 16 15 17 1 5 N m 13 lbf in Loctite 243 29 30 14 13 2 Loctite 243 24 25 9 27 23 Molykote 111 3 2 4 4 6 6 5 1 115 N m 85 lbf ft 22 20 21 6 5 N m 58 lbf in Engine oil 7 8 27 N m 20 lbf ft 40 N m 30 lbf ft 7 20 N m 15 lbf ft 7 Anti seiz...

Page 134: ...tool in PTO flywheel splines TYPICAL 1 PTO flywheel remover P N 295 000 001 Using a suitable wrench or socket with a breaker bar unscrew PTO flywheel COUNTERCLOCK WISE when facing it and hold extension handle locking the magneto flywheel TYPICAL 1 Extension handle locking crankshaft NOTE When splines of PTO flywheel are worn out and special tool cannot be used proceed with the following alternate ...

Page 135: ... facing it 947 Engines except XP Use PTO flywheel remover P N 295 000 001 to hold flywheel and remove Allen screws no 21 re taining coupler no 20 to PTO flywheel PTO FLYWHEEL REMOVER TOOL 1 Loosen Allen screws 2 Breaker bar locking crankshaft Remove the coupler no 20 XP Models Remove Allen screws no 21 1 PTO flywheel 2 Coupler 3 Loosen Allen screw Remove coupler no 20 F06I02A 1 F01J0TA F06D37A 2 1...

Page 136: ...r plate 2 Extension handle 3 Loosen bolt with socket and breaker bar Remove the PTO flywheel using puller plate P N 529 035 533 and puller P N 529 035 547 and bolt P N 529 035 549 1 Puller plate 2 Puller 3 Bolt 4 Extension handle Starter Drive Assembly 947 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 ...

Page 137: ...fer to MAGNETO SYSTEM magneto housing except 947 engines starter rotary valve cover and valve except 947 engines starter drive assembly 947 engines reed valves 947 engines air compressor cover 947 DI engines 717 and 787 RFI Engines Put engine on a stand Loosen crankcase screws 717 ENGINE 1 M10 x 73 5 flanged screws 2 M8 x 68 5 flanged screws 3 M8 x 45 socket head screws 787 RFI ENGINE 1 M10 x 73 5...

Page 138: ...y prying at provided lugs TYPICAL 1 Separate halves by prying at provided lugs Remove crankshaft and counterbalance shaft 787 RFI and 947 engines 947 DI Engines Open air compressor and disconnect the piston as described in ENGINE MANAGEMENT Crankshaft Bearing and Seal All Engines If a crankshaft end seal no 5 has to be replaced bottom end must be opened except for the MAG side seal on the 787 RFI ...

Page 139: ...outer PTO bearing and crankshaft gear can be removed in one step using another puller See Crankshaft Gear no 18 787 RFI ENGINE 1 Puller P N 420 877 635 2 Protective cap P N 420 876 557 3 Distance ring P N 420 876 569 4 Ring P N 420 977 490 5 Ring halves P N 420 977 475 6 Screw M8 x 40 P N 420 840 681 7 Screw M8 x 70 P N 420 841 201 NOTE To facilitate ring or distance ring installa tion lubricate t...

Page 140: ...tractor Crankshaft Gear 787 RFI Engine The crankshaft gear no 18 and bearing no 5 can be removed in one step using the following puller 1 Puller P N 290 877 665 Install the puller as per following illustration 1 Puller 2 Protective cap Secure puller in a vise and remove gear and bearing NOTE If the inner PTO bearing needs to be re placed remove the Woodruff key on the crank shaft F01D1PA 1 2 F04B0...

Page 141: ...g 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 shaft An index mark must be traced to ease assembly procedure 1 Index mark Use a press to remove the gear no 14 from the counterbalance shaft F00B...

Page 142: ...ress 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 direction then make the final brushing per pendicula...

Page 143: ... 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 engines Refer to MAG NETO SYSTEM for procedures Install Bombardier degree wheel P N 529 035 607 on crankshaft end Hand tighten nut only Remove both spark plugs Install a TDC gauge in spark plug hole on MAG side Brin...

Page 144: ...st oiled sand paper Bearing Inspect crankshaft bearings no 4 Check for cor rosion scoring pitting chipping or other evidence of wear Make sure plastic cage is not melted Ro tate and make sure they turn smoothly Crankshaft NOTE If crankshaft and or components are found defective it must be repaired by a specialized shop or replaced Connecting Rod Straightness Align a steel ruler on edge of small en...

Page 145: ...on cannot be correctly measured between centers of a lathe Connecting Rod Big End Axial Play Using a feeler gauge measure distance between thrust washer and crankshaft counterweight 1 Measuring big end axial play 2 Feeler gauge F01D1TA 1 1 F01D97A F01D98A 1 CONNECTING ROD BIG END AXIAL PLAY MODEL NEW PARTS WEAR LIMIT min max 947 engine 0 390 mm 015 in 0 737 mm 029 in 1 2 mm 047 in 787 RFI engine 0...

Page 146: ...ome firmly tight against bearing Slide puller hammer outwards and tap puller end Retighten claws as necessary to always maintain them tight against bearing Continue this way until bearing completely comes out For installation see below in this section Reed Valve 947 Engines Only Check reed valve petals no 29 for cracks or other defects The reed petals must lie completely flat against the reed valv...

Page 147: ...ay 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 bearing s a dis tance gauge must be t...

Page 148: ...ong flange toward the crankshaft counterweight Crankshaft Seal All Models When installing seal assembly no 5 apply a light coat of lithium grease on seal lips 787 RFI Engine 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 Engines Seals are positioned with the outer lip in...

Page 149: ... shaft in the crankcase Rotate the counterbalance shaft to align the notch of the gear with the crankcase 1 Gear notch aligned with the crankcase The notch of the couterweight on the opposite end of the counterbalance shaft must also be aligned with the cranckcase 1 Counterweight notch aligned with the crankcase If notches are not aligned with the crankcase re move the gear and repeat the procedur...

Page 150: ... terbalance shaft must be aligned otherwise en gine will vibrate and premature wear will occur 787 RFI ENGINE 1 Marks must be aligned 947 ENGINES 1 Marks must be aligned Turn by hand the crankshaft and counterbalance shaft Make sure they do not interfere with the crankcase 947 Engines Properly position bearing no 31 and washer no 32 Ensure to position lubrication hole on top if so equipped 1 Beari...

Page 151: ...alant unlike the Drei Bond sealing compound using a finger will not affect the adhe sion Use the silicone based Loctite 5910 P N 293 800 081 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 Loctite5910 Usingtheseproductsornonsilicone based sealant ove...

Page 152: ...ykote 111 below head screws Torque crankcase screws to 24 N m 17 lbf ft as per following illustrated sequence Torque 2 M10 crankcase screws to 40 N m 30 lbf ft 1 Torque to 40 N m 30 lbf ft 787 RFI Engine Apply Loctite 518 on screw threads and Molykote 111 below head screws Torque crankcase screws to 12 N m 106 lbf in as per following sequence Repeat procedure re tightening all screws to 24 N m 17 ...

Page 153: ...quence Oil Fittings 717 and 787 RFI Engines If inlet and outlet oil fittings no 11 of rotary valve shaft have been removed from crankcase rein stall them with their end pointing toward ignition housing Apply Loctite 518 on threads of fittings Stud 717 Engine At assembly in crankcase apply Loctite 518 on threadsof studs no 10 Torque to10N m 89 lbf in Starter Drive Bearing 947 Engines To install bea...

Page 154: ...1 of coupler and torque to 23 N m 17 lbf ft Final Assembly 717 and 787 RFI Engines For rotary valve timing and assembly procedures refer to ROTARY VALVE 787 RFI Engine When engine assembly is completed add 30 mL 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 Carburetor Equipped Engines When engine assembly is c...

Page 155: ..._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 engine 13 12 1 20 N m 15 lbf ft 9 N m 80 lbf in 2 1 12 787 RFI engine Anti seize lubricant Engine oil Loctite 243 www SeaDooManuals net ...

Page 156: ...d the soldering wire method 45 FEELER GAUGE METHOD Remove O ring no 12 from rotary valve cover no 1 Remove intake manifold from rotary valve cover except 787 engine Reinstall cover no 1 in place WITHOUT its O ring and torque screws to 20 N m 15 lbf ft Insert feeler gauge blade through cover inlet ports to verify clearance At least verify clearance at two different places in each port Feeler gauge ...

Page 157: ...ust remain as per original setting NOTE If rotary valve crankcase surface is worn it is possible to have it reworked at the factory Contact your dealer or distributor Rotary Valve Shaft Gear Backlash Remove PTO flywheel guard Remove spark plugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this way to complete one revol...

Page 158: ...ing and remove circlips no 5 1 Compress seat 2 Remove circlips Shaft Bearing To remove bearing no 8 use a bearing extractor such as Snap on no CJ 950 or equivalent as illus trated Slide off distance sleeve no 14 remove snap ring no 7 and washer no 15 then press shaft out 1 Bearing 2 Bearing extractor Snap on CJ 950 CAUTION Ensure that rotary valve shaft is per fectly perpendicular with press tip E...

Page 159: ... 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 smo...

Page 160: ...at 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 Shaft As...

Page 161: ...er 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 VALVE A...

Page 162: ...VALVE 04 07 8 SMR2002 026_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 163: ...l with BOTTOM of MAG side inlet port Then find 147 line on inner scale of degree wheel and mark crankcase at this point OPENING MARK Step Bottom of MAG inlet port Align 360 line of degree wheel Step Find 147 on inner scale of degree wheel and mark here NOTE Do not rotate the crankshaft ENGINE TIMING OPENING BTDC CLOSING ATDC 717 147 5 65 5 5 787 RFI 147 5 63 5 5 360 350 340 330 320 3 1 0 3 0 0 2 9...

Page 164: ... 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 Cover...

Page 165: ...MR2002 027_04_08A FM 04 08 1 EXHAUST SYSTEM 0 717 Engine Model GTI and GTI LE F17D01S 4 N m 35 lbf in 4 N m 35 lbf in 4 N m 35 lbf in 10 7 9 25 N m 18 lbf ft 4 4 N m 35 lbf in 1 4 N m 35 lbf in 2 6 19 25 N m 18 lbf ft 15 5 3 11 www SeaDooManuals net ...

Page 166: ... 35 lbf ft Loctite 243 14 19 18 19 6 Loctite 243 1 3 10 19 18 19 25 N m 18 lbf ft 2 13 12 4 N m 35 lbf in 1 1 20 25 N m 18 lbf ft Loctite 243 22 1 21 1 26 2 27 1 11 28 24 1 4 N m 35 lbf in 1 1 24 Loctite 82046 25 Silicone sealant 40 N m 30 lbf ft 25 N m 18 lbf ft Loctite 82046 Loctite 82046 Loctite 82046 www SeaDooManuals net ...

Page 167: ...U 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 168: ... m 35 lbf ft 7 9 10 14 N m 125 lbf in 4 15 5 25 N m 18 lbf ft 19 18 6 40 N m 30 lbf ft 14 Loctite 243 48 N m 35 lbf ft 9 16 21 22 47 N m 35 lbf ft 25 N m 18 lbf ft 19 18 20 40 N m 32 lbf ft 1 3 4 N m 35 lbf in 1 4 N m 35 lbf in 1 4 N m 35 lbf in 11 2 2 12 13 Loctite 243 Loctite 82046 Loctite 82046 Loctite 296 www SeaDooManuals net ...

Page 169: ... 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 1 1 Loctite 82046 Loctite 243 Silicone sealant F16D05S www SeaDooManuals net ...

Page 170: ...f 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 Body Loctite 243 Loctite 82046 Loctite 82046 Loctite 82046 10 4 N m 35 lbf in Loctite 243 www SeaDooManuals net ...

Page 171: ... TYPICAL 1 Bleed hose removed 2 Injection hose removed 3 Supply hose removed Loosen exhaust hose collar no 1 at tuned pipe outlet Disconnect strap no 2 retaining muffler no 11 Remove exhaust hose no 3 from tuned pipe by pulling muffler Remove clamp no 4 from tuned pipe Remove tuned pipe cone no 5 Remove tuned pipe retaining screw no 6 from ex haust manifold side Remove screws no 7 nut no 8 and fla...

Page 172: ...pipe there 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 p...

Page 173: ... retaining 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 F06E0AA 1 F06E0BA 1 F06D14A 1 F06D1SA 1 F06D3JA www SeaDooManuals net ...

Page 174: ... 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 lockin...

Page 175: ...rom 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 locking fasteners Exhaust Manifold Remove ...

Page 176: ...isconnect hoses from muffler no 11 Disconnect hoses of the water flow regulator valve except 717 engine TYPICAL 1 Water supply hose 2 To injection fitting on tuned pipe Disconnect retaining strap no 2 of muffler Pull muffler no 11 out of bilge NOTE On RX and XP models remove the VTS motor Refer to VARIABLE TRIM SYSTEM TUNED PIPE REPAIR This procedure is given to repair tuned pipe cracks using T I ...

Page 177: ...e properly posi tioned prior to finalizing manifold installation 717 Engine Apply Molykote 111 on threads of screws no 12 Install exhaust manifold no 14 and torque screws no 12 to 24 N m 17 lbf ft as per following illus trated sequence 787 RFI Engine Apply Loctite 518 on 2 screws no 12 On the oth er screws no 12 apply Molykote 111 on threads Install screws Refer to the following illustration for p...

Page 178: ...stalled or re placed with new ones where specified 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 tune pipe and may cause cracking Make sure that gasket no 16 is properly located on exhaust man...

Page 179: ...ctly 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 install tuned pipe Ensure rubber bushings no 19 and sleeve no 18 are not damaged and are properly installed into tune pipe suppo...

Page 180: ... 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 181: ...93 800 090 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 the Y m...

Page 182: ...f ft F07D0SS 14 N m 124 lbf in 6 N m 53 lbf in 25 N m 18 lbf ft 6 N m 53 lbf in 25 N m 18 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 2 5 N m 22 lbf in 48 N m 35 lbf ft 5 16 6 40 N m 30 lbf ft 7 9 15 8 14 3 12 1 10 4 13 2 11 www SeaDooManuals net ...

Page 183: ...Section 04 ENGINE Subsection 08 EXHAUST SYSTEM SMR2002 027_04_08A FM 04 08 19 Install exhaust hose 1 Torque clamp to 4 N m 35 lbf in 1 F06D14A www SeaDooManuals net ...

Page 184: ...CODE TABLES 05 03 2 ECU FAULTS 05 03 2 INPUT SIGNAL FAULTS 05 03 2 OUTPUT SIGNAL FAULTS 05 03 3 COMPONENT INSPECTION 05 04 1 GENERAL 05 04 1 AIR INDUCTION SYSTEM 05 04 3 THROTTLE BODY 05 04 3 FUEL DELIVERY 05 04 3 FUEL FILTER 05 04 3 FUEL PUMP 05 04 3 REGULATOR 05 04 3 FUEL INJECTOR 05 04 4 LEAK TEST SUPPLY AND VENTILATION CIRCUITS 05 04 5 HIGH PRESSURE TEST FUEL PUMP CIRCUIT 05 04 5 ELECTRONIC MA...

Page 185: ...30 SECONDS 05 05 1 ENGINE CANNOT REACH MAXIMUM REVOLUTIONS 05 05 1 ADJUSTMENT 05 06 1 THROTTLE CABLE ADJUSTMENT 05 06 1 THROTTLE POSITION SENSOR TPS 05 06 1 CLOSED TPS 05 06 1 IDLE SPEED 05 06 1 REMOVAL AND INSTALLATION 05 07 1 MPEM 05 07 1 THROTTLE POSITION SENSOR TPS 05 07 1 AIR TEMPERATURE SENSOR ATS 05 07 1 AIR PRESSURE SENSOR APS 05 07 1 WATER TEMPERATURE SENSOR WTS 05 07 1 CRANKSHAFT POSITIO...

Page 186: ...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 187: ...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 188: ...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 189: ...gine operation Maximum 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 net...

Page 190: ...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 191: ...EHICLE By selecting DIAGNOSIS the following message INITIALIZING IN PROCESS will be displayed a few seconds then a new menu will appear on the screen Select READ FAULT and press ENTER 1 BOSCH INFO 2 READ FAULT 3 ERASE FAULT 4 ADJUSTMENT 5 REAL TIME 6 END DIAGNOSIS NOTE Lineno 1 BOSCHINFOwilldisplaytheiden tification of the watercraft and the MPEM ECU By selecting READ FAULT the MPEM program mer wi...

Page 192: ...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 193: ... 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 194: ...al 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 un...

Page 195: ...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 Howeve...

Page 196: ...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 197: ...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 198: ...on 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 replac...

Page 199: ...nd 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 no 4 on the MPEM Using a multimeter check the resistance between terminal 3 PURPLE BROWN wire and terminal 4 BL...

Page 200: ...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 201: ...s 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 res...

Page 202: ...k 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 5V on the test wire If none is present replace the MPEM On the WTS connector check for continuity to ground on...

Page 203: ...d APS sensor connector Reconnect the air pressure sensor connector and recheck the resistance value between terminals in the AMP plug connector no 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 PURPLE BLUE wire and the BLACK BLU...

Page 204: ...ition 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 1 18 and...

Page 205: ...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 206: ...enu 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 speed screw until it does not con tact the throttle plate stopper Loosen the adjustment of...

Page 207: ...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 208: ...and disconnect the quick con nect fitting Disconnect the wire connectors of both fuel injec tors 1 Press retaining clip to unlock the connector Loosen both screws retaining the fuel rail to the cylinders 1 Loosen screws retaining the fuel rail Remove the fuel rail with both fuel injectors To remove the fuel injector from the fuel rail pry off the retaining clip 1 Pry the clip When reinstalling the...

Page 209: ...ONNECTOR PIN OUT 06 03 3 QUICK FUEL PRESSURE TEST 06 03 4 AIR INDUCTION SYSTEM 06 03 5 THROTTLE BODY 06 03 5 AIR COMPRESSOR 06 03 8 PRESSURE TEST 06 03 8 REPAIR 06 03 9 FUEL DELIVERY 06 03 12 FUEL PRESSURE REGULATOR 06 03 12 FUEL INJECTOR 06 03 14 AIR FUEL RAIL 06 03 15 DIRECT INJECTOR 06 03 16 FUEL PUMP 06 03 17 ELECTRONIC MANAGEMENT 06 03 21 MPEM REPLACEMENT 06 03 21 THROTTLE POSITION SENSOR TPS...

Page 210: ...06 03 35 CRANKING SYSTEM 06 03 36 DI SYSTEM TEST SUMMARY 06 03 36 DIAGNOSTIC PROCEDURES 06 04 1 GENERAL 06 04 1 DESS SYSTEM 06 04 2 FAULT DETECTION AND COMPENSATORY ACTIONS 06 04 4 COMPONENT FAILURE WARNING SYSTEM 06 04 4 VCK VEHICLE COMMUNICATION KIT 06 04 6 DI SYSTEM FAULT CODES 06 04 7 www SeaDooManuals net ...

Page 211: ...Section 06 ENGINE MANAGEMENT DI Subsection 02 OVERVIEW SMR2002 029_06_02A FM 06 02 1 OVERVIEW 0 F12F03T www SeaDooManuals net ...

Page 212: ...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 213: ...pen the regulator will increase equally The differential pressure regulation utilizes the air pressure reference signal to maintain constant pressure drop across fuel injector orifice The initial operating pressure of the regulator is preset by the manufacturer and is not adjustable Direct Injector Also called air injector two direct injectors one per cylinder are used to inject air fuel mixture i...

Page 214: ...atures a permanent memory that will keep the programmed safety lanyard s active fault codes and other vehicle information even when the battery is removed from the watercraft MPEM General Functions Automatic Power Shut Down The MPEM is equipped with an automatic power shut down This feature prevents the battery from losing its charge if the safety lanyard cap is left on the post when the engine is...

Page 215: ...rent Supply The purpose of this function is to allow reading of gauges without the engine running It will give ac cess to most functions of the information center gauge without starting the engine Gauges are supplied with current for 33 seconds when connecting the safety lanyard cap on its post or when pressing the start stop switch without the safety lanyard on the DESS post NOTE The fuel pump wi...

Page 216: ... signal to the information center gauge and the pilot lamp on the gauge will turn on Power Distribution The MPEM distributes power from battery to all accessories Accessories are protected by fuses integrated in the MPEM Fuses are identified be sides their holder IMPORTANT The sensors and injectors are con tinuously powered with the supply from the bat tery The MPEM switches the ground to com plet...

Page 217: ...llow proper operation for all possi ble conditions Cranking flare idle warm up nor mal operation Sea Doo LK learning key limit ed vehicle speed engine speed limiter drowned engine and limp home see below Flooded Engine drowned mode If the engine does not start and it is flooded pro ceed as follows Remove spark plug cables and connect them on the grounding device Remove spark plugs and dry them usi...

Page 218: ... 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 phases delta wound stator on 18 po...

Page 219: ...arbureted wa tercraft Prior to disconnecting a hose or to re moving a component from the fuel system fol low the recommendation described here Pay attention that some hoses may have more than one clamp at their ends Ensure to reinstall the same quantity of clamps at assembly WARNING Fuel lines remain under pressure at all times Al ways proceed with care and use appropriate safety equipment when wo...

Page 220: ... simply by unplugging and replugging the MPEM The voltage and current might be too weak to go through dirty wire pins Check carefully if posts show signs of moisture corrosion or if they look dull Clean pins properly and then coat them with silicon based dielectric grease or other appropriate lubricant except if otherwise speci fied when reassembling them If the newly re placed MPEM is working try...

Page 221: ...onality 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 inje...

Page 222: ...ly Proceed with the fuel pressure test below If pressure is out of limits go to FUEL DELIVERY part 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 and reinstall fuel hose At installation apply engine oil...

Page 223: ...ottle 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 THROTTLE POSITION SENSOR...

Page 224: ...imes to ensure it is com pletely closed Using an ohmmeter measure resistance between pins 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 pins 2 and 3 2 Turn screw clockwise to increase resistance Tighten lock nut Recheck reading and readjust as necessary Slave TPS Inst...

Page 225: ...plate is still closed Turn synchronizing screw clockwise until read ing reaches the computed value above 20 Ω 1 Measure resistance between pins 2 and 3 2 Turn screw clockwise to decrease resistance Ensure spring is still well positioned on stoppers Properly reinstall the plastic cap to the synchroni zation screw Apply Loctite 5900 P N 293 800 066 flange seal ant on idle set screw head 1 Plastic ca...

Page 226: ...b Press throttle lever to reach full throttle Turn cable adjustment until Throttle Opening meter indicates between 95 and 99 Closed TPS Adjustment Perform the CLOSED TPS ADJUSTMENT as de scribed in THROTTLE POSITION SENSOR TPS in ELECTRONIC MANAGEMENT below Injection Oil Pump Cable Adjustment As oil injection cable is throttle dependent always proceed with the oil injection pump cable adjust ment ...

Page 227: ...sure is below limits ensure inlet hose is not obstructed bent or kinked Otherwise repair the air compressor Remove pressure gauge and reinstall air compres sor hose REPAIR Top End Remove retaining screws Lift cover then remove compressor head Clean all parts in a solvent and visually inspect for corrosion damage Check reed valve plates for cracks deformation dirt or other defects The reed plates m...

Page 228: ...ompressor connect ing rod Remove connecting rod retaining screw As a puller use a M7 x 1 0 x 50 mm screw to re lease connecting rod crankpin IMPORTANT Trace a mark on crankpin bush ing outer end This is needed for reinstallation 1 Use a M7 x 1 0 x 50 mm screw as a puller Push piston upward with or without the cylinder sleeve Remove rubber plug then push piston pin end to remove from connecting rod...

Page 229: ...ring end gap If gap exceeds specified tolerance rings should be re placed 1 Top of cylinder 2 Ring end gap Assembly Apply injection oil in cylinder and on rings prior to installing Install the oil ring with the TOP marking on top Identify the correct position by looking at beveled edge of oil ring and while installation make sure that the beveled edge should be towards the top of the piston 1 Beve...

Page 230: ... assembly Also the new screw will have the proper threadlocking coating Ensure to correctly position O ring on access cov er and install cover Reinstall remaining removed parts Ensure to check engine alignment FUEL DELIVERY FUEL PRESSURE REGULATOR Pressure Test The pressure test will show the available pressure at the air fuel rail It validates the pressure regula tor and leaks in the system IMPOR...

Page 231: ...OTE Fuel in air compressor outlet line is an indica tion of a leaking fuel pressure regulator diaphragm Remove pressure gauge and reinstall fuel hose At installation apply engine oil on O ring Fuel Pressure Regulator Replacement Removal Release the fuel pressure in the system Disconnect spark plug cables from spark plugs Disconnect the fuel injector wires if necessary 1 Push clip toward injector t...

Page 232: ...cation kit VCK with the B U D S software energize the fuel injector from the Activation section If the injector does not work disconnect the plug connector from the injector Install a temporary connector to 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 the injector mechanical and elec trical operation If...

Page 233: ...A higher pressure may be an indication of a pinched or clogged air regulator outlet line Air Pressure Regulator Replacement Removal See FUEL PRESSURE REGULATOR REMOVAL above for procedure Remove the fuel regulator then the air regulator Installation For the installation reverse the removal procedure but pay attention to the following NOTE A thin film of injection oil may be applied to O ring to ea...

Page 234: ...leak the high tempera ture from the combustion chamber will make visible overheated area Replace damaged components Electrical Test Using the vehicle communication kit VCK with the B U D S software energize the direct injector in the Activation section If the injector does not work disconnect the plug connector from the injector Install a temporary connector to the injector with wires long enough ...

Page 235: ... on both injectors It is also recommended to replace all O rings When servic ing air fuel rail or direct injectors we recommend replacing carbon dams that have been running for 50 hours or more CAUTION Never reuse a carbon dam after it has been removed from the injector Always install a new one Remove carbon dam and O ring using a small pick Install seal guide P N 529 035 715 on end of injec tor C...

Page 236: ...el relief valve on the return line side 4 Pressure gauge between disconnected hose inline installation Install safety lanyard and observe fuel pressure If pressure is within limits fuel pump is working adequately If pressure is below limits ensure fuel filters are not obstructed There is one in line fuel filter at the fuel pump outlet hose and one filter at the inlet underneath the pump Otherwise ...

Page 237: ...ont storage compartment cover Remove the storage basket Remove glove box see HULL BODY section Remove front vent tubes RX DI Remove tube Y connector Remove tube bracket by unscrewing nuts from bilge front storage area 1 Vent tube bracket 2 Nut All Models From glove box opening remove fuel pump retain ing nuts 1 Fuel pump 2 Retaining screw Disconnect electrical connector Disconnect vent tube from f...

Page 238: ...ine 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 pump module operation Rep...

Page 239: ...not working try to find a previous saved file from B U D S Replacement Disconnect battery cables Disconnect AMP connectors from MPEM Remove MPEM Install the new MPEM to the vehicle Reconnect AMP connectors to MPEM then bat tery cables Transfer the data from the previous MPEM to the new one using B U D S then proceed with the re quired resets after the following verification has been done Select th...

Page 240: ...dle sticks bounces suddenly drops or if any dis crepancy between the throttle movement and the needle movement is noticed it indicates a worn TPS that needs to be replaced NOTE In this particular case by comparing the signals from both sensors the MPEM will gener ate a fault code when the TPS is malfunctioning due to specific spots To isolate the faulty TPS disconnect one and test the other Voltag...

Page 241: ...tion If resistance values are incorrect repair the wiring harness connectors between AMP plug connec tor and the TPS Replacement Remove the air intake silencer Remove the air duct Disconnect the connector of the TPS Loosen two Allen screws retaining the TPS Remove TPS MAG SIDE THROTTLE BODY 1 Allen screws 2 Throttle position sensor TPS Apply Loctite 243 on screw threads install the new TPS NOTE Bo...

Page 242: ...isplays 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 information center is in tachometer mode If it does not display 3000 RPM the information cen ter may be faulty and needs to be tested If the information center correctly displayed 3000 RPM per...

Page 243: ...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 plug connector number 2 on the MPEM Using a multimeter check continuity of circuits 6 7 and 14 If wiring harness is good it could be either the CPS or...

Page 244: ... 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 plug connec tor 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 and left Install the new MATS Reinstall ...

Page 245: ... 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 voltage output from MPEM to the mani fold air pressure sensor MAPS Disconnect plug connector from throttle ...

Page 246: ...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 head contact surfaces are clean ...

Page 247: ...ct RAVE 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 ...

Page 248: ...ue is incorrect repair the wiring harness connectors between AMP plug connec tor 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 Using the vehicle communication kit VCK with the B U D S software energize the ignition coil from the Activation...

Page 249: ...cessary 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 ignition coil removed from craft hook high tension leads from tester to ignition coil h...

Page 250: ...d not 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 indic...

Page 251: ...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 rotate it clockwise to reach 7 87 mm 310 in NOTE Thi...

Page 252: ...ok in Setting section of the software B U D S NOTE For more information on the VCK refer to its online help The MPEM programmer will not work to perform this operation on the DI engines CAUTION If the TDC setting is adjusted too ad vanced this will cause serious damage to the engine Adjustment In this operation the ignition timing light and B U D S are used to synchronize the MPEM TDC reference wi...

Page 253: ...procedures elsewhere in this section Safety Lanyard Switch Verification If 2 short beeps are not heard when installing the safety lanyard refer to DIAGNOSTIC PROCEDURES The following continuity tests can also be per formed using an ohmmeter Disconnect switch wires Safety Lanyard Removed Connect test probes to switch BLACK and BLACK YELLOW wires Measure resistance there should be NO continuity open...

Page 254: ...rm a conductive con nection between the center electrode and ground Spark Plug Installation Prior to installation make sure that contact surfac es of the cylinder head and spark plug are free of grime 1 Using a wire feeler gauge set electrode gap ac cording to the following chart 2 Apply anti seize lubricant over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into cylin...

Page 255: ... and 10 WH BR and PU BR 1200 ohms at 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 conn Pin 4 and ground BK 0 V with a small mV tole...

Page 256: ...N and WH GN 45 55 ohms primary winding Coil terminal C and coil post 6800 10200 ohms secondary winding w o high tension leads Ignition coil PTO AMP no 3 20 and 23 RD 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 models MAG 5700 ohms lead alone PTO White tape 4300 ohms lead alone High tension l...

Page 257: ...rt in TROUBLESHOOTING sec tion to have an overview of problems and sug gested solutions Check if there is a MAINT signal reported by the vehicle information center If so use the VCK Vehicle Communication Kit and look for fault codes to diagnose the trouble Check all fuses Check air fuel rail pressure Check spark plugs condition Check RAVE valves if stuck Check fuel pump pressure Check air compress...

Page 258: ... button Badconnection between safe ty lanyard cap and post Remove and replace the safety lanyard on the post until 2 short beeps are heard to indicate the system is ready to allow engine starting Unprogrammed or defective safety lanyard Use the safety lanyard that has been programmed for the watercraft If it does not work check safety lan yard condition with the programmer Replace safety lanyard i...

Page 259: ...E REMEDY No beep Engine actually starts Everything is correct 1 long and 1 short beeps No safety lanyard has ever been pro grammed in watercraft MPEM Use MPEM programmer or the VCK and program a safety lanyard This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed 2 short beeps MPEM can not read the digital code of the safety lanyard cap or the ma...

Page 260: ... MAINT ON ON 4 Limited RPM idle speed if both TPS s fail Water temperature sensor WTS MAINT ON OFF ON 6 4 Limited RPM code 4 if EGT also fails Direct injector single injector MAINT ON OFF 6 Limited RPM Fuel injector single injector MAINT ON OFF 6 Limited RPM Ignition no firing on one cylinder MAINT ON OFF 6 Limited RPM RAVE solenoid MAINT ON OFF 6 Limited RPM Starter solenoid MAINT ON OFF 6 Engine...

Page 261: ...NT ON ON 3 Limited RPM Throttle position sensor dual TPS MAINT ON ON 4 Idle RPM Throttle position sensor single adaption fault None OFF OFF 6 None Throttle position sensor dual adaption fault MAINT ON OFF 6 Limited RPM Sensor supply fault TPS and MAPS MAINT ON ON OFF 4 6 Limited RPM code 6 and idle RPM if both in fault Encoder CPS fault bad pattern MAINT ON OFF 6 Limited RPM Low battery voltage 12...

Page 262: ...ORTANT When using the software B U D S with the DI engines ensure that the protocol 947 DI is properly selected in MPI under Choose protocol Refer to the tables below for the fault codes you will find in the B U D S F12H13S 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 BUZ...

Page 263: ... connections are in good condition also grounds battery MPEM engine and ignition sys tem they are clean and well tightened and that all electronic components are genuine particularly in the ignition system Installing resistive caps non resistive spark plug cables or modified length non resistive spark plugs or knock sensor wiring routingmayleadtogeneratethisfaultcode Electrical noise might also le...

Page 264: ...r is loose Yes Fix and reset closed TPS Inspect sensor for damage or corrosion Yes Replace and reset closed TPS Inspect wiring voltage test Failed Repair Inspect wiring and sensor resistance test Failed If bad wiring repair If bad TPS replace and reset closed TPS Test sensor operation wear test Replace and reset closed TPS POSSIBLE CAUSES RESULT ACTION Sensor has been replaced and TPS closed posit...

Page 265: ...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 266: ...ECU failure damaged or out of alignment throttle bodies or sensor P1102 TPS PTO TPI_1_ADAP Throttle position adaption failure Yes No Full reset Key off and on Service action Check cable adjustment Check Idle stop for wear check throttle angles at idle Possible causes No initialisation after throttle body or ECU changes throttle idle stop drifted P1103 TPS MAG TPI_2_ADAP Throttle position adaption ...

Page 267: ...s ECU failure P1401 EGT EXH_RED Overheat warning Yes No As soon as fault is not present Service action Check for debris or blockage in cooling system Check tune pipe injection valve Possible causes Exhaust system overheated damaged sensor damaged circuit wires P0460 Fuel level sensor FUEL_SENS Sensorout of range Yes No As soon as fault is not present Service action TBD Possible causes Damaged sens...

Page 268: ...XDRP_1 Sensor 5 volt supply failure Yes Yes Return to idle Service action Check for shorts to ground or corrosion on the following system circuits 3 10 or 3 3 Possible causes Damaged circuit wires associated sensor failure TPI 2 or MAP ECU fault P0222 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 ci...

Page 269: ...7 COOLING SYSTEM Subsection 01 TABLE OF CONTENTS SMR2002 052_07_01ATOC FM 07 01 1 TABLE OF CONTENTS 0 CIRCUIT COMPONENTS AND CARE 07 02 1 CIRCUIT 07 02 10 COMPONENTS 07 02 14 CARE 07 02 17 www SeaDooManuals net ...

Page 270: ...CIRCUIT COMPONENTS AND CARE 0 GTI and GTI LE Models 717 engine 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 271: ...gine F15E04T 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 272: ...02A FM 07 02 3 GTX Models 947 carburetor equipped engine 0 11 N m 1 lbf in 8 4 3 7 6 5 N m 44 lbf in Loctite 567 Loctite 567 Loctite 567 1 2 N m 11 lbf in 1 2 N m 11 lbf in Loctite 567 Loctite 567 F02E09V 1 Loctite 567 Loctite 567 0 6 N m 5 lbf in 5 2 Loctite 567 www SeaDooManuals net ...

Page 273: ...07 02 4 SMR2002 032_07_02A FM XP and RX Models 947 carburetor equipped engine F08E07T 1 2 3 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 Loctite 567 Loctite 567 Loctite 567 Loctite 567 Loctite 567 Loctite 567 Loctite 567 Loctite 567 www SeaDooManuals net ...

Page 274: ...and LRV DI 947 DI engines 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 275: ...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 276: ...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 277: ... components Engine water supply hose fitting Temperature sensor activates monitoring beeper when temperature exceeds 86 94 C 187 201 F Water flows out of tuned pipe water jacket Water flows out of exhaust manifold water jacket and through tuned pipe water jacket before exiting the tuned pipe Water injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and perfo...

Page 278: ...ipe 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 F12E0WS Side of hull Air compressor silencer Quick connect hose fitting for easy engine draining Temperature sensor activate monitoring beeper...

Page 279: ...ed 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 ent...

Page 280: ... water coming out of the engine heat exchang er is evacuated at the exhaust outlet for noise re duction 947 Engines The 947 engines has a conventional cooling sys tem The water is entering the engine by the water inlet fitting at the cylinder head As with other models the water supply is provid ed by a pressurized area in the jet pump between the impeller and venturi Water is directed to the water...

Page 281: ...er jacket from upper fitting of tuned pipe and is expulsed to the cooling system indicator DI Models Water flows out of tuned pipe water jacket from upper fitting of tuned pipe and is directed to the air compressor then to the air silencer at the tran som Water continues to flow in the crankcase water jacket to cool the crankcase area to then be ex pulsed to the transom area All 947 Engines Draini...

Page 282: ... Regulated water is injected in the tuned pipe by a calibrated fitting 1 Injection fitting All Models 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 SYST...

Page 283: ...ot 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 m...

Page 284: ...tor valve otherwise serious en gine damage can occur In many 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 re...

Page 285: ...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 286: ...s 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 GTI and GTI LE Models When servicing the hull always rotate watercraft counterclockwise seen from the rear Rotating watercraft on the oppo...

Page 287: ...injected into and filling the exhaust system Without the engine run ning there isn t any exhaust pressure to carry the water out the exhaust outlet CAUTION Failure to do this may result in dam age to the engine If you must tow a stranded 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 w...

Page 288: ...ARE SMR2002 032_07_02A FM 07 02 19 TYPICAL RX SERIES AND LRV DI MODELS 1 Hose pincher on water supply hose on this side of the T fitting CAUTION When finished towing the watercraft the hose pincher must be removed before oper ating it F12E01A 1 www SeaDooManuals net ...

Page 289: ...RAL 08 02 7 REMOVAL 08 02 7 INSPECTION 08 02 9 ASSEMBLY 08 02 10 FUEL SYSTEM PRESSURIZATION 08 02 11 AIR INTAKE 08 03 1 REMOVAL 08 03 5 ASSEMBLY 08 03 6 CARBURETOR 08 04 1 GENERAL 08 04 2 REMOVAL 08 04 2 CLEANING 08 04 3 DISASSEMBLY AND INSPECTION 08 04 3 ASSEMBLY 08 04 5 INSTALLATION 08 04 7 ADJUSTMENTS 08 04 7 www SeaDooManuals net ...

Page 290: ...odels F06F18S 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 14 13 1 2 N m 11 lbf in Engine Dielectric grease 4 GTI GTI LE www SeaDooManuals net ...

Page 291: ...m 11 lbf in 2 N m 18 lbf in 6 N m 53 lbf in 1 2 N m 11 lbf in 7 6 22 N m 16 lbf ft 4 N m 35 lbf in 3 N m 27 lbf in 5 4 N m 35 lbf in Dielectric grease 4 14 9 8 10 11 12 1 2 N m 11 lbf in 1 2 N m 11 lbf in Engine Body 4 1 2 N m 11 lbf in 1 2 N m 11 lbf in 4 N m 35 lbf in 1 2 N m 11 lbf in 13 F06F0RS www SeaDooManuals net ...

Page 292: ... SMR2002 033_08_02A FM 08 02 3 XP Models F08F06S Engine 1 2 N m 11 lbf in 1 2 6 N m 53 lbf in 2 N m 18 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 1 2 N m 11 lbf in 6 7 12 11 13 9 8 10 14 13 4 5 4 22 N m 16 lbf ft 4 N m 35 lbf in www SeaDooManuals net ...

Page 293: ...Section 08 FUEL SYSTEM Subsection 02 FUEL CIRCUIT 08 02 4 SMR2002 033_08_02A FM GTX 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 294: ... N m 11 lbf in 2 N m 18 lbf in 6 N m 53 lbf in 1 2 N m 11 lbf in 22 N m 16 lbf ft 4 N m 35 lbf in 3 N m 27 lbf in 4 N m 35 lbf in Dielectric grease 1 2 N m 11 lbf in 1 2 N m 11 lbf in Engine Body 1 2 N m 11 lbf in 1 2 N m 11 lbf in 4 N m 35 lbf in 1 2 N m 11 lbf in F06F0RV 3 1 2 7 6 5 4 14 9 8 10 11 12 4 13 www SeaDooManuals net ...

Page 295: ...Section 08 FUEL SYSTEM Subsection 02 FUEL CIRCUIT 08 02 6 SMR2002 033_08_02A FM DI Models 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 296: ... Open storage compartment cover Remove basket XP Models Open engine cover and remove basket 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 MANAGEMENT DI under FUEL SYSTEM WARNING Whenever repairing the fu...

Page 297: ...sec tion CAUTION A pressure test needs to be com plete after replacement Fuel Baffle Pick Up All Models except GTX RFI and DI NOTE The baffle pick up has an integrated fuel sender for the fuel gauge 1 Pick up tube 2 Fuel sensor 3 Baffle pick up Disconnect BLACK negative cable then RED pos itive cable of battery RX GTI AND GTI LE Models Open storage compartment cover Remove storage basket from wate...

Page 298: ...he baffle in order to remove the filter Pry base off using a small slotted screwdriver if necessary Electric Fuel Pump RFI and DI Models Refer to appropriate ENGINE MANAGEMENT section Fuel tank All Models NOTE On all models except GTX GTX RFI and LRV DI it is necessary to remove the engine Re fer to REMOVAL and INSTALLATION section Siphon fuel tank Remove fuel baffle pick up or electric fuel pump ...

Page 299: ...fuel tank necks for crack s If crack s are existing re place fuel tank no 14 Check with your finger to feel the inside and out side surfaces of fuel tank Flex fuel tank necks to ensure there are no hidden cracks 1 Tank upper surface 2 Inspect outside above upper surface 3 Normal molding seam 4 Inspect inside above upper surface 5 Base of the neck A Approx 4 mm 5 32 in NOTE A fuel tank is comprised...

Page 300: ...a pressure of 34 kPa 5 PSI during 10 minutes Never pressurize over 34 kPa 5 PSI Reconnect air inlet hose of fuel tank to body NOTE Before removing the hose pincher block with your finger the outlet fitting to feel if air is coming out when removing hose pincher This will indicate that pressure relief valve and the outlet fitting are not blocked Remove hose pincher from fuel tank vent hose High Pre...

Page 301: ... 03 AIR INTAKE SMR2002 034_08_03A FM 08 03 1 AIR INTAKE 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 302: ...08 FUEL SYSTEM Subsection 03 AIR INTAKE 08 03 2 SMR2002 034_08_03A FM 787 RFI Engine 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 303: ...Section 08 FUEL SYSTEM Subsection 03 AIR INTAKE SMR2002 034_08_03A FM 08 03 3 947 Carburetor Equipped Engines F08F0DT 2 Loctite 243 11 12 3 4 Loctite 243 3 13 14 www SeaDooManuals net ...

Page 304: ...Section 08 FUEL SYSTEM Subsection 03 AIR INTAKE 08 03 4 SMR2002 034_08_03A FM 947 DI Engines 2 1112 4 13 3 Super Lube 14 Loctite 243 F12F14S Loctite 243 Loctite 243 www SeaDooManuals net ...

Page 305: ...ncer base no 4 1 Retaining plate 2 Remove screws Flame Arrester Base Remove flame arrester no 5 Remove screws no 8 retaining support no 6 of flame arrester base to the cylinder head cover 717 engine or to the exhaust manifold 787 engine TYPICAL 1 Remove support Remove screws no 10 from flame arrester base then withdraw base NOTE On GTI and GTI LE models withdraw both arrester supports no 15 All 94...

Page 306: ...ilencer forward to remove it from the lower bracket no 4 and remove it in a rotating move ment XP MODEL The air intake silencer is a molded piece and it can not be opened It has an integrated flame arrester ASSEMBLY Assembly is essentially the reverse of removal procedures However pay particular attention to the following CAUTION Do not modify air intake system otherwise calibration will be affect...

Page 307: ...Engines Ensure the elbow adaptor is well inserted and that it has not pushed the gasket inside the air box All 947 Engines 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 bracket eyelet Side tongue of protector pad should be toward outside of vehi cle and bent downward toward the exhaust flange P...

Page 308: ...uel system on RFI and DI models refer to appropriate ENGINE MANAGEMENT section Mikuni BN 40i and BN 46i F02F1ZT Loctite 243 11 9 12 20 21 13 14 6 7 4 19 5 15 2 13 8 3 20 18 17 16 1 20 N m 15 lbf ft Anti seize lubricant Synthetic grease Loctite 243 PTO PTO MAG Synthetic grease www SeaDooManuals net ...

Page 309: ...ge A metering jet in the fuel inlet hose controls fuel flow to the pump A check valve on the fuel outlet hose helps to prime the system REMOVAL To remove carburetor s from engine proceed as follows Remove air vent tube support GTI 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 Disconnec...

Page 310: ...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 311: ...lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on inlet nipple of accelerator pump no 20 Obstruct outlet nipple with a finger and hold while pumping Pump tester until it reaches 28 kPa 4 PSI 1 Pump gauge tester 2 Hose installed to inlet nipple 3 Outlet nipple obstructed Diaphragm must stand pressure for 10 seconds If pressure drops replace accelerator pump dia phragm V...

Page 312: ...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 313: ...d 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 to su...

Page 314: ...allation pay attention to the following Install carburetor s with gasket s to intake mani fold rotary valve cover for the 787 RFI engine 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 pressuri...

Page 315: ...lates must open simulta neously otherwise this will cause engine to vi brate and or misfire Throttle Cable Adjustment NOTE Do not activate throttle lever unnecessari ly Carburetors are equipped with fuel accelerator pump This pump is injecting fuel into carburetors each time throttle lever is depressed 717 Engine Lubricate cable with BOMBARDIER LUBE lubricant Throttle lever must reach handlebar gr...

Page 316: ...e Throttle cable is equipped with a sensor which will send a signal to the MPEM at 80 throttle open ing in order to control the spark advance THROTTLE CABLE ASSEMBLY 1 Sensor 2 Throttle lever section 3 Carburetor section 4 Oil pump section NOTE Always perform the throttle cable adjust ment in the specified order as described in follow ing procedure Unscrew idle adjustment screw to obtain a small g...

Page 317: ...cable prior to finalize adjustment of throttle cable CAUTION Improper oil injection pump syn chronization with carburetor throttle opening can cause serious engine damage Adjust throttle cable to obtain proper lever position at full throttle Turn adjuster knob as required to obtain proper throttle lever adjustment 1 Jam nut 2 adjustment nut 3 Throttle cable Throttle lever must reach handlebar grip...

Page 318: ...djust low speed screw 1 4 turn NOTE On twin carburetor engines both low speed screws must be adjusted exactly the same way Never adjust screws more than 1 4 turn at a time All models except GTI LE California High Speed Screw The high speed screw no 14 is sealed with a plas tic cap that allows an adjustment of 1 4 turn NOTE Turning screw 1 4 turn counterclockwise en riches mixture and turning screw...

Page 319: ...lerator Pump All Engines Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM for the 717 engines and 1400 RPM for the 947 engines in water With the engine not running loosen adjustment screw lock nut Use a feeler gauge between lever tab and pump plunger Turn adjustment screw to achieve approximately 0 05 0 15 mm 002 005 in gap Tighten adjustment screw lock nut TYPICAL 1 Ad...

Page 320: ...TABLE OF CONTENTS 0 OIL INJECTION SYSTEM 09 02 1 GENERAL 09 02 6 OIL SYSTEM PRESSURIZATION 09 02 6 OIL INJECTION PUMP 09 03 1 OIL PUMP IDENTIFICATION 09 03 5 REMOVAL 09 03 5 DISASSEMBLY 09 03 5 CLEANING 09 03 5 ASSEMBLY 09 03 6 ADJUSTMENT 09 03 7 CHECKING OPERATION 09 03 10 www SeaDooManuals net ...

Page 321: ...section 02 OIL INJECTION SYSTEM SMR2002 036_09_02A FM 09 02 1 OIL INJECTION SYSTEM 0 GTI and GTI LE Models 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 322: ...Section 09 LUBRICATION SYSTEM Subsection 02 OIL INJECTION SYSTEM 09 02 2 SMR2002 036_09_02A FM XP Models F08G03S 4 3 Steering harness Oil pump www SeaDooManuals net ...

Page 323: ...09 LUBRICATION SYSTEM Subsection 02 OIL INJECTION SYSTEM SMR2002 036_09_02A FM 09 02 3 GTX Models F07G0CS Dielectric grease 27 N m 20 lbf ft 3 5 N m 31 lbf in 3 5 N m 31 lbf in 1 3 2 1 2 4 www SeaDooManuals net ...

Page 324: ...N SYSTEM Subsection 02 OIL INJECTION SYSTEM 09 02 4 SMR2002 036_09_02A FM GTX RFI Models F15G01S 1 3 5 N m 31 lbf in 2 1 2 N m 11 lbf in 3 5 N m 31 lbf in 27 N m 20 lbf ft 1 2 N m 11 lbf in 4 3 1 FRONT www SeaDooManuals net ...

Page 325: ...TION SYSTEM Subsection 02 OIL INJECTION SYSTEM SMR2002 036_09_02A FM 09 02 5 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 326: ...quipped Models Connect pump gauge tester P N 529 021 800 to check valve of oil injection reservoir vent DI Models Connect pump gauge tester P N 529 021 800 to disconnected tube at throttle body All Models NOTE Use the same pump included in the EN GINE LEAK TESTER KIT P N 295 500 352 TYPICAL 1 Connect pump to check valve Pressurize oil system to 21 kPa 3 PSI All Models If pressure is not maintained...

Page 327: ...2002 037_09_03A FM 09 03 1 OIL INJECTION PUMP 0 717 Engine 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 328: ... 09 LUBRICATION SYSTEM Subsection 03 OIL INJECTION PUMP 09 03 2 SMR2002 037_09_03A FM 787 RFI Engine 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 329: ...on 03 OIL INJECTION PUMP SMR2002 037_09_03A FM 09 03 3 947 Carburetor Equipped Engines F07G0ES To carburetor 6 N m 53 lbf in 6 Loctite 243 6 4 5 N m 40 lbf in 6 N m 53 lbf in 1 8 Molykote 111 To MPEM 4 5 N m 40 lbf in www SeaDooManuals net ...

Page 330: ...STEM Subsection 03 OIL INJECTION PUMP 09 03 4 SMR2002 037_09_03A FM DI Models 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 331: ...r P N 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 Engine Remove tuned pipe head Refer to EXHAUST SYS TEM DI Models The cable end has a slight press fit in the lever Using a small screwdriver pry cable end out 787 RFI and 947 Engines Disconnect oil injection pump cable no 7 Remo...

Page 332: ... 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 Engines Oil Injection Pump and Shaft Make sure shaft no 8 is installed in crankshaft end Install pump Secure wit...

Page 333: ...ified 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 Models 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 align re...

Page 334: ...ne NOTE The adjuster knob and jam nut for the oil injection pump cable are located on the oil pump cable 1 Adjuster knob 2 Jam nut 947 DI Engines Loosen jam nut and turn cable adjustment nut to obtain pump mark alignment Refer to following photos The adjustment is located under the throttle body bracket 1 Oil pump cable adjustment 2 Throttle cable Adjust the cable to the rich position Use the long...

Page 335: ...a slight resistance is felt In this position marks on pump body and lever must align If necessary turn cable adjustment nut to obtain pump mark alignment Refer to above illustrations Tighten jam nut and recheck alignment marks CAUTION Proper oil injection pump adjustment is very important Any delay in the opening of pump can result in serious engine damage Bleeding CAUTION Oil injection system mus...

Page 336: ...st advance into small oil lines NOTE The engine should have a rich mixture idling irregularly and emitting smoke at exhaust outlet If not remove pump assembly and check the pump gear 717 engine or shaft 787 RFI and 947 engines for defects replace as necessary Test pump as described below NOTE Through normal use oil level must not drop in small tubes If oil drops verify check valve operation Replac...

Page 337: ...3A FM 09 03 11 Compare the results with the chart below If oil pump is out of specification replace it ENGINE OIL PUMP FLOW RATE AT 1500 RPM 5 minutes 717 9 9 12 1 mL each port 787 RFI 5 7 6 9 mL each port 947 8 3 10 1 mL each port 947 DI 7 5 9 1 mL each port www SeaDooManuals net ...

Page 338: ... 10 02 18 CHARGING SYSTEM 10 03 1 GENERAL 10 03 1 TESTING PROCEDURE 10 03 1 BATTERY 10 03 5 STARTING SYSTEM 10 04 1 GENERAL 10 04 4 STARTING SYSTEM TROUBLESHOOTING 10 04 5 STARTER REMOVAL 10 04 6 STARTER DISASSEMBLY 10 04 6 CLEANING 10 04 8 PARTS INSPECTION 10 04 9 STARTER ASSEMBLY 10 04 9 STARTER INSTALLATION 10 04 11 STARTER SPECIFICATION 10 04 13 INSTRUMENTS AND ACCESSORIES 10 05 1 GENERAL 10 0...

Page 339: ...ct Current Digital Capacitor Discharge Igni tion DC CDI Digital Inductive System Magneto System The magneto is the primary source of electrical energy It transforms magnetic field into electric current AC 717 Engines The flywheel contains 4 permanent magnets and spins around the generating coil This electric cur rent flows to the Multi Purpose Electronic Module GTI and GTI LE models 1 Flywheel 2 G...

Page 340: ...gnetic field outside of coil 5 Magnetic field crossing coil 6 Current to MPEM 7 Rotor Ignition Coil Ignition coil induces voltage to a high level in sec ondary windings to produce a spark at spark plug GTI and GTI LE Models The ignition coil steps up the voltage input from the Multi Purpose Electronic Module to high volt age current for both spark plugs The ignition coil is located in the rear ele...

Page 341: ...NIC MODULE MPEM The MPEM is directly powered by the battery It has a micro processor inside of its sealed case The MPEM is responsible of the following electri cal functions interpreting information distributing information start stop function timer Digitally Encoded Security System ignition timing curve engine rev limiter Some fuses are directly mounted onto the MPEM All the electrical system is ...

Page 342: ...RE section A light pressure on the safety lanyard is required to allow the MPEM to read and validate the safety lanyard the engines can then be started 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 eng...

Page 343: ...tion coil when to fire TYPICAL 947 Engines The 947 engine has a digital Direct Current Capacitor Discharge Ignition DC CDI system within the MPEM which receives the input from the trigger coil and signals the ignition coils when to fire TYPICAL 1 MPEM Compared to the magneto system the DC CDI system offers a more powerful and stable ignition at low RPM Electrical Box The high amperage voltage comp...

Page 344: ...dels it is located near the oil tank On the GTX models remove the glove box to have access to connector refer to HULL BODY section For the RX models it is located on the LH side of fuel tank Install a test wire in the BLACK wire connector and an other in the WHITE BROWN wire connector going to the MPEM Start the vehicle and hold RPM at 3500 The first timing mark should be lined up if not adjust th...

Page 345: ...ry and it should remain correctly adjusted since every part is fixed and not adjustable The only time the ignition timing might have to be changed would be when replacing the crankshaft the magneto rotor the trigger coil on 947 engines or the CPS on RFI models and the MPEM or the ECU on the RFI models If the ignition timing is found incorrect you should first check for proper crankshaft alignment ...

Page 346: ...illustration Un screw the first screw at right of middle screw securing the engine to the rear engine mount Reinstall screw with the special timing mark pointer tool All Engines 6 Install and adjust a TDC gauge P N 295 000 143 in MAG side spark plug hole TYPICAL 1 TDC gauge on MAG side 7 Rotate PTO flywheel counterclockwise when facing it until piston is at Top Dead Center TYPICAL 1 Adjust gauge d...

Page 347: ...oscopic timing light 9 Remove TDC gauge 10 Reinstall spark plug and connect wire Dynamic Test To check ignition timing use Bombardier timing light P N 529 031 900 717 Engines NOTE To perform this procedure make sure to use a stroboscopic timing light rated up to 6000 RPM Otherwise an inaccurate reading will be ob tained The ignition components are affected by temper ature variation therefore timin...

Page 348: ...g to ensure PTO flywheel has not loosen 787 RFI and 947 Engines 1 Connect an induction type tachometer P N 529 014 500 to spark plug wire 1 Tachometer pick up 2 Connect timing light pick up to MAG side spark plug wire 1 Timing light pick up IMPORTANT On 787 RFI engines to check the ig nition timing the timing advance curve must be locked first This allows to perform ignition timing at any RPM by k...

Page 349: ...or removal of magneto refer to MAGNETO SYS TEM Timing is performed by moving armature plate clockwise to retard spark occurrence or counter clockwise to advance TYPICAL 1 To retard 2 To advance To adjust loosen 3 armature plate retaining screws and slightly rotate armature plate in proper direction NOTE As a guideline turn the armature plate the same amount needed to align mark on PTO flywheel TYP...

Page 350: ...he safety lan yard switch on the craft 2 Press the ON C button on programmer and enter your password 3 Press 3 to choose Vehicle info in programmer 4 Press 8 to choose Bosch system 5 Press 1 to choose Diagnosis 6 Press 4 to choose Adjustment 7 Press 4 to choose Fixed timing 8 The programmer display Timing 12 00 deg 9 Press any key to continue Programmer will go back one level to Adjustment 10 Pres...

Page 351: ... not the real spark advance just a cor rection for the tolerances of the mechanical com ponents Knowing that you select with the programmer the higher or lower number to advance or retard the actual timing correction by referring to the follow ing chart Examples a You found the flywheel mark advanced You must retard the ignition timing The programmer gives you the number 3 Re ferring to the chart ...

Page 352: ...en press Enter 8 Now punch in the number that corresponds to the degree you want for the ignition timing then press Enter 9 Press Menu to go back one level 10 Press 8 to choose Save Quit even if item no 8 is not visible on the display it is active when you select it 11 Press Enter to confirm yes you want to save modifications to the MPEM 12 You must see Operation successful This con firms that the...

Page 353: ...yard on Switch Connect test probes to switch BLACK and BLACK YELLOW wires Measure resistance it must be close to 0 ohm Timer Verification The timer is integrated into the MPEM Always confirm first that the fuses are in good condition To confirm operation of timer remove safety lan yard from switch After a 5 seconds delay depress start stop button once The timer should stay on for about 33 seconds ...

Page 354: ...e is insufficient or no volt age either the MPEM or wiring harness is defec tive Trigger Coil Verification 947 Engines STATIC TEST CONTINUITY 1 Disconnect magneto wiring harness connector 2 Install the 6 pin magneto harness adapter P N 295 000 136 3 Connect one of the multimeter probes to the WHITE wire of the 6 pin magneto harness adapt er 4 Connect the other multimeter probe to the BLACK YELLOW ...

Page 355: ...between the two high tension leads with the spark plug caps removed The resistance should 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...

Page 356: ...nch Follow manufacturer instructions 1 With ignition coil removed from craft discon nect spark plug caps from high tension cables 2 Hook high tension leads from tester to ignition coil high tension cables 3 Connect 2 smaller tester leads to primary of ig nition coil TYPICAL 1 Leads to secondary 2 Leads to primary 4 Turn power switch to 12 volts and you should observe spark jumping at a predetermin...

Page 357: ...lar running of the engine decreased engine speed due to misfiring reduced performance and in creased fuel consumption This is due to a loss of compression Other possible causes are prolonged idling or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel The plug face of a fouled spark plug has either a dry coating of soot or an oily glossy coating given by an exces...

Page 358: ...gap ac cording to the following chart 2 Apply anti seize lubricant over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into cylinder head and tighten with a torque wrench and a proper socket 1 Proper socket 2 Improper socket Spark Plug Chart NOTE Refer to next page for NGK SPARK PLUG SYMBOL EXPLANATION ENGINE SPARK PLUG TORQUE N m lbf ft GAP mm inch All models except DI...

Page 359: ...Cold 18 mm 14 mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach A B C D E J Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V Grooved Center Electrode A GV B C G L S V X Y Blank 18 mm ø 12 mm 31 64 14 mm ø 9 5 mm 3 8 F02H0MS Compact Type Projected Insulator Type Resistor...

Page 360: ...to DC to allow battery charging Battery The battery is the DC source for the electric start er the Multi Purpose Electronic Module and all ac cessories Fuse If the battery is regularly discharged check fuse condition The rectifier regulator could be the culprit of a blown fuse To check simply disconnect the rectifier regulator from the circuit If the fuse still burns check for a defective wire CAU...

Page 361: ...he electrical box 1 RED PURPLE wire Connect an ammeter across the fuse holder Start engine Bring engine to approximately 6000 RPM Note the reading This is the current actually consumed Reinstall fuse Substract the consumed current from the regu lator current This gives the actual charging cur rent It should be within 3 4 A Charging current Current from regulator Consumed current If charging curren...

Page 362: ...r is within the specifi cation either the MPEM or wiring harness between the rectifier and battery is defective If the rectifier regulator is out of specification and the battery charg ing coil or stator test good the rectifier regulator is defective Battery Charging Coil 717 Engine STATIC TEST CONTINUITY 1 Disconnect the magneto wiring harness connec tor 2 Installthe4 pinmagnetoharnessadapter P N...

Page 363: ...r negative probe to the engine or the stator iron core and note the read ing 1 Multimeter 2 Magneto harness adapter 3 Positive probe to YELLOW wire 4 Negative probe to ground 5 Repeat test with the other two YELLOW wires of the 6 pin magneto harness adapter NOTE There should be no continuity infinity be tween the stator insulated coils and ground If there is a reading the stator coils and or the w...

Page 364: ...epaired 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 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 th...

Page 365: ...ttery cable terminals and battery posts using a firm wire brush Rinse with clear water and dry well Inspection Visually inspect battery casing for cracks or other possible damage If casing is damaged replace battery and thoroughly clean battery tray and close area with water and baking soda Inspect battery posts for security of mounting Inspect for cracked or damaged battery caps re place defectiv...

Page 366: ...g occurs A discharged battery will freeze and break in area where freezing point is experi enced Electrolyte leakage will damage sur rounding parts Always remove battery from ve hicle for storage and regularly charge to keep an optimal condition Disconnect and remove battery from watercraft as explained in REMOVAL Check electrolyte level in each cell add distilled water up to upper level line CAUT...

Page 367: ...ed For storage purposes it is fitted with a temporary seal ing tube CAUTION Do not remove the sealing tube or loosen battery caps unless activation is desired NOTE In case of accidental premature removal of caps or sealing tube battery should be given a full charge Perform the following operations anytime a new battery is to be installed 1 Remove the sealing tube from the vent elbow 2 Remove caps ...

Page 368: ...or best results battery should be charged when the electrolyte and the plates are at room temper ature A battery that is cold may not accept current for several hours after charging begun Do not charge a frozen battery If the battery charge is very low the battery may freeze If it is suspected to be frozen keep it in a heated area for about 2 hours before charging The time required to charge a bat...

Page 369: ...the charger to a high rate NOTE Some chargers have a polarity protection feature which prevents charging unless the charg er leads are connected to the correct battery ter minals A completely discharged battery may not have enough voltage to activate this circuitry even though the leads are connected properly This will make it appear that the battery will not accept a charge Follow the charger man...

Page 370: ...R2002 040_10_04A FM 10 04 1 STARTING SYSTEM 0 717 Engine F00H1PS 16 Loctite 243 15 Loctite 271 14 Ground cable 17 22 N m 16 lbf ft Loctite 243 13 22 N m 16 lbf ft 22 N m 16 lbf ft 5 N m 44 lbf in Dielectric grease 1 12 2 3 5 4 6 11 10 7 8 9 www SeaDooManuals net ...

Page 371: ...ubsection 04 STARTING SYSTEM 10 04 2 SMR2002 040_10_04A FM 787 RFI Engine F15H01S Loctite 243 6 7 8 9 10 11 4 1 2 3 5 5 N m 44 lbf in 12 22 N m 16 lbf ft 13 17 Dielectric grease Loctite 243 16 22 N m 16 lbf ft www SeaDooManuals net ...

Page 372: ...STEM Subsection 04 STARTING SYSTEM SMR2002 040_10_04A FM 10 04 3 947 Engine F07H0TS Dielectric grease 17 Loctite 243 16 10 N m 89 lbf in Synthetic grease Synthetic grease 18 10 11 19 Ground cable 1 2 3 5 www SeaDooManuals net ...

Page 373: ...ENCODED SE CURITY SYSTEM or ENGINE MANAGEMENT Engine Start Stop Switch and Safety Lanyard Switch Refer to IGNITION SYSTEM or ENGINE MANAGE MENT Solenoid NOTE Solenoid is located in the electrical box Inspect connections and clean as necessary Static Test Continuity With a multimeter check primary winding resis tance It should be approximately 5 ohms There should be no continuity between the posi t...

Page 374: ...ections Clean battery cable connections Poor contact of brush Straighten commutator and brush Burnt commutator Turn commutator on a lathe Worn commutator segments Undercut mica Shorted armature Repair or replace armature Weak brush spring tension Replace brush holder or spring Weak magnet Replace yoke assembly Worn bushings Replace clutch Weak battery Recharge or replace battery STARTER TURNS BUT ...

Page 375: ...ion STARTER DISASSEMBLY 717 and 787 RFI Engines Before disassembling trace index marks on yoke no 1 and clutch housing no 10 to ease further assembly TYPICAL 1 Trace indexing marks Remove starter support nuts no 12 then through bolts no 5 Separate end frame no 3 from yoke assembly no 1 Withdraw yoke assembly from ar mature no 11 Brush holder no 2 can be removed from end frame no 3 by unscrewing nu...

Page 376: ...sen through bolts no 5 1 Through bolts Remove end cover no 3 and gasket on armature shaft side Remove thrust washers no 19 from armature shaft 1 Thrust washers Remove the other end cover no 10 and gasket Remove the three washers no 18 from armature shaft 1 Washers Remove armature no 11 1 Pull armature shaft F06H1FA 1 F06H1GA 1 F06H1HA 1 F06H1IA 1 F06H1JA 1 www SeaDooManuals net ...

Page 377: ...ed 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 Bushings or bearin...

Page 378: ...sh holder plate If continuity is found brush holder has to be repaired or replaced Brush Measure brush length If less than 8 5 mm 335 in replace them NOTE New brush length is 12 mm 472 in 1 New 2 Wear limit 8 5 mm 335 in Overrunning Clutch Pinion of overrunning clutch should turn smoothly in clockwise direction and should not slip in a counterclockwise direction If defective replace Check pinion t...

Page 379: ...h with yoke locating protrusion and properly sit brush holder no 2 into yoke no 1 1 Locating protrusion is the higher one 1 Brush holder locating notch To ease end frame installation retain brush holder with a small screwdriver while installing end frame Step Retaining brush holder with a screwdriver Step Align here Align end frame notch with brush holder notch yoke protrusion CAUTION Make sure en...

Page 380: ...no 13 and no 16 to 22 N m 16 lbf ft Nut Connect the RED positive cable to the starter and torque nut no 17 to 6 N m 53 lbf in Apply di electric grease on terminal and nut Screw and Teeth Washer Apply Loctite 271 red to screw Connect BLACK negative cable to starter using flat washer teeth washer no 15 and screw no 14 Torquescrew to 22 N m 16 lbf ft Apply dielectric grease on terminal and screw 717 ...

Page 381: ...EL 1 Torque nut to 6 N m 53 lbf in apply dielectric grease and install protection cover 2 Negative BLACK cable 3 Apply Loctite 243 to threads and torque screw to 10 N m 89 lbf in WARNING Always connect RED positive cable first then BLACK negative cable last Whenever con necting the RED positive cable to the starter motor make sure the battery cables are dis connected to prevent electric shock F06H...

Page 382: ...Approx 2 kg 4 4 lb Performance specification at 20 C 68 F No load 11 5 V 20 A max 5500 RPM Load 8 5 V 170 A max 2200 RPM Stall 5 V 350 A max 0 RPM Battery 12 V 19 Ah Nominal output 0 8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 1 7 kg 3 7 lb Performance specification at 20 C 68 F No load 10 9 V 45 A max 8600 RPM Load 9 V 120 A max 5350 RPM Stall ...

Page 383: ...T following specific se quences as described below 1 To change display mode 2 To set or reset a function Resetting a Function To reset a function such as the chronometer dis tance etc press and hold the SET button for 2 sec onds 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...

Page 384: ...low ing circumstances occurs compass error COMPAS maintenance MAINT engine overheating H TEMP low fuel FUEL LO low oil OIL LOW low voltage 12 V LOW fuel injection system sensors and major compo nents DI models Except for low fuel and low oil which can be cor rected by refilling refer to DIAGNOSTIC PROCE DURES section when other messages occur The warning light will blink at the same time Warning L...

Page 385: ...conds Other Functions The following describes how to select other avail able functions Language Option While in the clock 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 1 Press TOGETHER and hold for 2 seconds Clock Adjustment While in the clock compass mode 1 Press TOG...

Page 386: ...r Temperature Sensor GTX GTX RFI and LRV DI Models The temperature sensor is located in the storage cover Remove the back panel of the storage cover to access the temperature sensor 1 Temperature sensor To check if the temperature sensor is operational activate the Info Center and select the exterior temperature mode Use a heat gun to warm up the sensor The tem perature should raise rapidly on the...

Page 387: ...ter gives a reading through a speed sensor Speed sensor 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 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 ...

Page 388: ...he 2 circuit connector housing which contains a PURPLE and BLACK wires Remove the BLACK wire from the receptacle hous ing Reconnect the connector housing Connect potentiometer test probes to the PINK and BLACK wires Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge NOTE The gauge must be activated to obtain a reading VTS RX and RX DI Disconnect ...

Page 389: ...HITE wires Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge NOTE The gauge must be activated to obtain a read ing Fuel Oil Gauge Low Oil Warning Light GTI GTI LE and XP Models The fuel gauge has a pointer which indicates fuel level in the tank The low oil warning light is part of the gauge It will light when injection oil level is low TYPICAL R...

Page 390: ...er to the resistance values as per following chart to test accuracy of gauge NOTE Gauge must be activated to obtain a read ing If gauge is not within the specifications replace it Fuel Baffle Pick Up Sender All Models except RFI and DI Models The baffle pick up has an integrated fuel sender To verify fuel sender a resistance test should be performed with a multimeter allowing the float to move up ...

Page 391: ...signal to the low oil level light in the fuel gauge or the LED in the Info Center 1 Oil sensor FUEL LEVEL AND RESISTANCE GTI GTI LE AND GTX FUEL LEVEL mm RESISTANCE Ω From 248 9 5 and more 0 2 2 From 234 4 to 248 8 5 17 8 2 2 From 200 9 to 234 3 5 27 8 2 2 From 167 4 to 200 8 5 37 8 2 2 From 134 0 to 167 3 5 47 8 2 2 From 100 5 to 133 9 5 57 8 2 2 From 67 0 to 100 4 5 67 8 2 2 From 40 1 to 66 9 5 ...

Page 392: ...nector has been forgotten unconnected even when there is enough oil in tank VTS Switch if so equipped Always confirm first that the fuse is in good con dition Disconnect BLACK wire BLUE WHITE wire and GREEN WHITE wire of VTS switch Using a multimeter connect test probes to switch BLACK and BLUE WHITE wires then connect test probes to switch BLACK and GREEN WHITE wires Measure resistance in both te...

Page 393: ...ire of VTS con trol module NOTE To permit VTS actuation when engine is not running remove safety lanyard from switch and depress start stop button to activate MPEM timer Push on VTS switch down position until motor stops Read the resistance on the ohmmeter it should indicate a resistance of 24 ohms 1 Push on VTS switch up position until motor stops Read the resistance on the ohmmeter it should ind...

Page 394: ...is ac tivated at the factory Therefore a safety lanyard must be programmed to start the engine NOTE Actually it is the memory of the MPEM which is programmed to recognize the digital code of the safety lanyard cap This is achieved with the VCK P N 529 035 676 or with the MPEM pro grammer P N 529 035 718 Refer to Guide to pro gram a safety lanyard The system is quite flexible Up to eight safety lan...

Page 395: ...e the safety lanyard on the switch until 2 short beeps are heard to indicate the system is ready to allow engine starting Unprogrammed or defective safety lanyard Use the safety lanyard that has been programmed for the watercraft If it does not work check safety lanyard condition with the programmer Replace safety lanyard if reported defective If it still does not work enable advanced diagnostic m...

Page 396: ...re resolved SIGNAL CAUSE REMEDY No beep Engine actually starts Everything is correct 1 long and 1 short beeps No safety lanyard has ever been programmed in watercraft MPEM Use programmer and program a safety lanyard This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed 2 short beeps MPEM can not read the digital code of the safety lanyard cap or ...

Page 397: ...02 21 INSTALLATION 11 02 21 DRIVE SYSTEM 11 03 1 GENERAL 11 03 3 REMOVAL 11 03 3 INSPECTION 11 03 7 ASSEMBLY 11 03 8 INSTALLATION 11 03 10 LUBRICATION 11 03 12 REVERSE SYSTEM 11 04 1 DISASSEMBLY 11 04 2 INSPECTION 11 04 3 ASSEMBLY 11 04 3 ADJUSTMENT 11 04 4 DISASSEMBLY 11 04 8 INSPECTION 11 04 9 ASSEMBLY 11 04 9 ADJUSTMENT 11 04 9 VARIABLE TRIM SYSTEM 11 05 1 GENERAL 11 05 3 REMOVAL 11 05 3 DISASS...

Page 398: ...t 38 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 399: ...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 SeaDooManuals ne...

Page 400: ...h watercraft A lift kit P N 295 100 044 can be used to install watercraft on a stand F00J0SA 5 2 1 6 3 4 F02J0VA 1 WATERCRAFT MODEL IMPELLER P N MATERIAL PITCH XP 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 271 001 128 Stainless steel Progressive pitch 15 21 GTX RFI 271 001 ...

Page 401: ... side However the last method requires more work To check clearance from water inlet side remove inlet grate To check clearance from venturi side remove ven turi nozzle assembly as described in OIL INSPEC TION 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 m...

Page 402: ... 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 cover and reinstall it with its O ...

Page 403: ...GTX RFI 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 GTX RFI Remove reverse gate Unscrew pivot support bolts no...

Page 404: ...8 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 GTX RFI and XP 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 GTX RFI Models Disconnect steering cable from jet pump nozzle Remove ...

Page 405: ...o 24 and remove flat washers and lock washers from jet pump housing Remove jet pump with a wiggle movement CAUTION When removing pump unit a shim could have been installed between hull and pump housing Be sure to reinstall it otherwise engine and jet pump alignment will be altered NOTE After jet pump removal if drive shaft re mains in the PTO flywheel except XP simply pull it out If drive shaft is...

Page 406: ...N 295 000 082 on impeller shaft flat end Using 2 screws previously removed from venturi secure shaft holder to housing 1 Shaft holder Heat impeller shaft end with a propane torch to approximately 150 C 300 F to break the Loctite bond before to remove impeller Do not heat im peller directly Install shaft holder in a vice 1 Shaft holder Impeller is loosened using impeller remover tool P N 295 000 00...

Page 407: ...ring can be cut using a jigsaw a small grinder or a low clearance hacksaw such as Snap on HS3 or equivalent TYPICAL TYPICAL 1 Snap on HS3 After cutting ring insert a screwdriver blade be tween jet pump housing and ring outside diameter Push ring so that it can collapse internally Pull ring out Impeller Shaft Remove shaft holder tool Remove impeller shaft no 28 with thrust washer and thrust bearing...

Page 408: ...sages 2 Oil passages Brush and clean impeller shaft threads impeller and drive shaft splines with Loctite Parts Cleaner P N 413 711 809 or equivalent Free threads and splines from any residue CAUTION Be careful not to damage impeller shaft diameter PARTS INSPECTION Impeller Visually inspect impeller splines Check for wear or deformation Renew parts if damaged NOTE Check also PTO flywheel and drive...

Page 409: ... onto shaft end close to end of threads Move shaft end up and down Difference between highest and lowest dial gauge reading is radial play Maximum permissible radial play is 0 05 mm 002 in TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to threads at shaft end To check both bearings proceed the same way with other shaft end Position gauge tip on diam eter close to flats o...

Page 410: ...sher 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 GTX RFI These models are equipped with la...

Page 411: ...l 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 GTX RFI 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 GTX RFI Bearing no...

Page 412: ...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 413: ...r side All Models except GTX RFI 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 Neverhammerthebearingintoitshous ing 1 Press on tool until it stops CAUTION These tools have been designed to properly position beari...

Page 414: ... 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 415: ...ng 2 screws previously removed from venturi secure impeller shaft holder tool P N 295 000 082 to housing Install shaft holder tool in a vice 1 Impeller shaft holder secured in a vice To ease impeller installation 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 ...

Page 416: ...enter hole of the cover Install pusher no 36 into cover Place the flat side in front of slider tab Install O ring no 37 to cover Apply Loctite 518 on O ring Install cover to jet pump housing making sure to properly position filler plug on top side Do not torque yet keep a small gap Insert a pencil or any other plastic tool in the hole and push on the slider tab CAUTION Do not use a metal tool to p...

Page 417: ... a few minutes add more oil until it is level with bottom of filler hole CAUTION This is a synthetic oil Do not mix with mineral based oil Do not mix oil brands NOTE When filling reservoir oil must be poured into cover quite slowly to allow complete housing fill Apply Loctite pipe sealant P N 293 800 018 on plug threads and reinstall it on cover NOTE The plug threads are perpendicular to the impel...

Page 418: ...ster and remove fit ting Check oil level Refill as necessary Apply Loctite Pipe sealant P N 293 800 018 to threads of filler plug then secure it in cover NOTE The plug threads are perpendicular to the impeller shaft INSTALLATION Jet 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 en...

Page 419: ...e reverse gate support stopper 1 Stopper XP 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 lbf...

Page 420: ...YSTEM Subsection 03 DRIVE SYSTEM SMR2002 044_11_03A FM 11 03 1 DRIVE SYSTEM 0 All Models except XP 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 421: ... m 16 lbf ft Loctite 271 Loctite 518 Synthetic grease 23 15 17 16 15 14 Loctite 518 21 10 N m 89 lbf in 5 6 8 9 10 7 11 12 13 Synthetic grease Synthetic grease Right Stuff sealant 31 N m 23 lbf ft Right Stuff sealant Loctite 518 Loctite 243 31 N m 23 lbf ft Loctite 243 Synthetic grease Synthetic grease Loctite 243 22 N m 16 lbf ft 2 N m 18 lbf in www SeaDooManuals net ...

Page 422: ...el guard from engine and with draw from bilge XP 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 Unfasten large clamp of PTO flywheel boot no 3 as follows Use pliers P N 295 000 069 Insert pointed tips of pliers in closing hooks TYPICAL 1 Closing hooks Squeeze pliers to draw hooks togeth...

Page 423: ...make the following tool and use it in con junction with the jet pump housing remover P N 295 000 113 to withdraw drive shaft Raw Material 1 aluminum alloy square of 51 mm 2 in x 305 mm 12 in 2 aluminum rods of 28 5 mm 1 1 8 in dia x 30 mm 1 3 16 in 1 Use ball end mill for radius This section of the slot should be 38 mm 1 15 32 in deep 2 Drill 25 mm 1 in hole in center to remove material 3 Weld all...

Page 424: ...ction or engine rubber mounts XP Models Rear Drive Shaft Remove rear access panel Remove protective plate no 18 1 Remove protective plate Pull rear drive shaft until coupler no 19 is disen gage from splines 1 Pull drive shaft to disengage coupler from splines Remove rear drive shaft Remove coupler no 19 Front Drive Shaft Remove PTO flywheel guard no 1 Remove bolts lock nuts and sleeves from sup po...

Page 425: ...1 Remove bolts and lock nuts Loosen 4 screws and remove bottom cover of seat 1 Remove cover Loosen gear clamp retaining the outer boot of the shock absorber 1 Loosen gear clamp Tilt seat Remove front drive shaft Seal Carrier of Mid Bearing To remove the seal carrier from support loosen the 6 nuts no 21 1 Nut 6 F08Q01A 1 F08L11A 1 F08L12A 1 F05I05A 1 www SeaDooManuals net ...

Page 426: ...e With your finger nail feel machined surface of drive shaft If any irregular surface is found renew drive shaft 1 Surface condition 2 Groove condition 3 Splines condition Excessive deflection could cause vibration and damage to drive shaft splines impeller flywheel or floating ring seal carrier depending upon the model Place drive shaft on V blocks and set up a dial gauge in center of shaft Slowl...

Page 427: ...e boot free length Subtract the installed length measurement from the free length measurement A difference of 4 mm to 12 mm 5 32 in to 15 32 in should be obtained If the length is less than 4 mm 5 32 in install a spacer P N 293 250 017 between boot and thru hull fitting 1 Spacer NOTE Driveshaftmustberemovedtoinstall spacer XP Models Seal Carrier of Mid Bearing Inspect seal carrier needle bearing n...

Page 428: ...o 15 with protector toward jet pump On both seals no 15 raised edge of lip must be located outwards of seal carrier 1 Double lip seal toward engine 2 Double lip seal with protector toward jet pump 3 Raised edge of lip outwards 4 Seal carrier Apply Loctite 518 all around seals outside diameter Seals no 15 can be carefully installed in housing using bearing seal installer tool P N 295 000 107 Push s...

Page 429: ... 8 in jet pump 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 support plate and seal carrier Insert adapter end into PTO flywheel NOTE Ensure the mid bearing is loosened TYPICAL 1 Alignment tool 2 Seal carrier Place grease fitting on the top and torque seal car rier nuts n...

Page 430: ... lbf in All Models except XP Drive Shaft and Dampers Install dampers no 13 on drive shaft no 12 NOTE Make sure dampers were not left in PTO flywheel or impeller Install drive shaft and jet pump at the same time Insert drive shaft 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...

Page 431: ...n clamp tail should be in op posite direction of engine rotation 1 Engine rotation counterclockwise 2 Tail in opposite direction Small Clamp To secure small clamp no 4 place notch side of plier on clamp embossment and squeeze plier 1 Squeeze plier LUBRICATION PTO Flywheel All Models except XP Using a grease gun carefully lubricate PTO fly wheel with synthetic grease P N 293 550 010 until boot is j...

Page 432: ...on 03 DRIVE SYSTEM SMR2002 044_11_03A FM 11 03 13 Seal Carrier of Mid Bearing XP Models Using a grease gun lubricate seal carrier of mid bearing with synthetic grease P N 293 550 010 TYPICAL 1 Grease fitting F05I09A 1 www SeaDooManuals net ...

Page 433: ... 3 23 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 434: ... 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 435: ...N Visually inspect parts for wear or cracks Replace parts as required ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following CAUTION Apply all specified torques and ser vice products as per main illustration Spring Make sure to properly install spring no 15 into in terior lever no 11 as per following illustration 1 Spring Interior ...

Page 436: ...opper 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 shift lever approximately 50 mm 2 in and push it back slowly in forward positio...

Page 437: ...o 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 All models except GTX RFI and LRV DI To remove reverse gate refer to JET PUMP section F07J09A 1 2 3 2 F07J0AA A A www SeaDooManuals net ...

Page 438: ...RX DI Models F16J0BT 5 Loctite 243 4 10 9 8 6 2 7 9 Loctite 243 7 Silicone 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 www SeaDooManuals net ...

Page 439: ...M 11 04 7 GTX Models 5 2 5 N m 22 lbf in Synthetic Grease F02J12S 10 9 7 11 3 2 6 2 1 4 8 Loctite 296 1 N m 9 lbf in 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 3 N m 27 lbf in Loctite 243 Loctite 243 3 N m 27 lbf in 3 5 N m 31 lbf in www SeaDooManuals net ...

Page 440: ...no 3 unscrew the elastic stop nut and the washer retaining the reverse cable Remove the bracket no 6 NOTE Before removing reverse cable from hull note cable routing for reinstallation Interior Lever Detach the reverse cable from interior lever no 3 Unscrew the shift lever retaining bolt no 4 wash er and nut then remove interior lever 1 Reverse cable 2 Interior lever Shift Lever Unscrew the shift l...

Page 441: ...er Apply synthetic grease on the interior lever pivot and in the reverse cable support hole Install the interior lever in a rotating movement Engage properly the interior lever tabs in the shift lever slots Make sure the 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 Reinsta...

Page 442: ...M SYSTEM 0 RX and 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 443: ...s 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 444: ...1 to sliding shaft no 10 Remove clamps no 2 Remove boot no 3 RX AND RX DI MODELS 1 VTS rod 2 Bolt 3 Lock nut 4 Rubber boot XP MODELS 1 VTS rod 2 Bolt 3 Lock nut 4 Rubber boot RX and RX DI Models Disconnect steering cable reverse cable Unscrew the pivot arm bolts one on each side Move the reverse pivot arm backwards All Models To loosen nut no 4 use VTS socket tool P N 295 000 133 Remove sealing wa...

Page 445: ...them INSPECTION Boot Make sure boot no 3 is in good condition If it is cracked or teared 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 Appl...

Page 446: ... P N 293 800 041 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 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 and RX DI Models Install pivot arm reverse cable steering cable boot with clamps Sl...

Page 447: ...must not interfere with venturi there should be a gap of 1 mm 039 in NOTE Activate timer to be able to position VTS 1 No interference 2 Nozzle up If an adjustment is necessary loosen jam nut no 16 of 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 adjust...

Page 448: ...LY 12 02 2 ASSEMBLY 12 02 4 DISASSEMBLY 12 02 7 ASSEMBLY 12 02 10 OFF POWER ASSISTED STEERING SYSTEM O P A S 12 02 12 GENERAL 12 02 13 SIDE VANE 12 02 13 CYLINDER SUPPORT ASSEMBLY 12 02 14 TIE ROD 12 02 15 SEALED TUBE 12 02 16 FILTER 12 02 16 VALVE 12 02 16 WATER HOSE 12 02 17 CROSS SUPPORT PLATE 12 02 17 ALIGNMENT 12 03 1 www SeaDooManuals net ...

Page 449: ...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 3 N m 26 lbf in Loctite 243 6 N m 53 lbf in 6 N m 53 lbf in Loctite 243 6 N m 53 lbf in Loctite 243 26 N m 19 lbf ft 7 N m 62 lbf in 23 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 450: ...om handlebar no 22 NOTE Verify grip insert for damage Steering Cover Remove grips no 1 Loosen set screws no 5 of handlebar housings no 6 1 Set screw Remove 4 screws no 7 TYPICAL 1 Cover 2 Screws Remove 2 screws no 20 and flat washers no 21 each side of cover 1 Remove screws Remove cover Cable Support Loosen bolts no 9 and remove retaining block no 10 1 Retaining block F00K01A 1 F00K02A 2 1 1 F07K0...

Page 451: ... Remove cable support no 8 Steering Support All Models except XP Cut locking tie securing wiring harness boot 1 Boot 2 Locking tie 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 1 Tie rap 2 Connectors F07K02A 1 2 1 2 F07K03A F07K04A 1 2 F07K05A 2 1 www SeaDooManuals net ...

Page 452: ... stem arm 2 Bolts Remove steering stem arm and support Steering Cable Disconnect steering cable no 24 from steering stem arm no 15 Remove retaining block no 10 Disconnect ball joint no 19 from jet pump nozzle Remove ball joint no 19 and jam nut from cable Loosen nut no 25 then remove half rings no 26 and O ring no 27 NOTE To loosen nut use steering cable tool P N 295 000 145 Remove steering cable ...

Page 453: ...Stem Arm and Support Position steering stem arm no 15 and support no 16 onto steering stem 1 Keyways 2 Integrated flat key Replace lock nuts no 18 by new ones Torque bolts no 17 of steering stem arm to 6 N m 53 lbf in Ball Joint Secure the steering cable ball joint no 19 to the nozzle as per following illustrations CAUTION Ensure the ball joint is parallel 5 to the nozzle arm All Models except XP ...

Page 454: ...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 net ...

Page 455: ...p 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 F0...

Page 456: ...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 457: ... 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 458: ...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 459: ...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 460: ... 2 N m 19 lbf in 11 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 www SeaDooManuals net...

Page 461: ...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 462: ...ess 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 cylinder nut...

Page 463: ...enever servic ing 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 washer no 3 bushing no 4 and venturi bushing no 5 from nozzle Remove jet pump refer PROPULSION SYSTEM Remove screw no 6 and washers no 7 to remove U lever no 1 fr...

Page 464: ... Assembly Assembly is the reverse process of disassembly Apply silicone grease on the screws before installing 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 washer no...

Page 465: ...edure for RH and LH water hose 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 or...

Page 466: ...sembly is the reverse process of disassembly make sure of the following when doing assembly Check for cracks and deterioration of screw threads on cross support plate change if nec essary Apply silicone sealant on cross support plate when servicing or changing 1 Apply silicone sealant Torque screw no 24 to 1 2 N m 10 lbf in 1 F18K10A 1 www SeaDooManuals net ...

Page 467: ...st be equalled TYPICAL 1 Measure the distance on each side of the straight edge If necessary steering alignment adjustment should be performed at steering cable support All Models except XP 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 1 Retaining block 2 Adjustment nut 3 Loosen ...

Page 468: ...ODELS 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 469: ...n 13 SUSPENSION Subsection 01 TABLE OF CONTENTS SMR2002 052_13_01ATOC FM 13 01 1 TABLE OF CONTENTS 0 DIRECT ACTION SUSPENSION 13 02 1 REMOVAL 13 02 2 INSPECTION 13 02 3 ASSEMBLY 13 02 3 www SeaDooManuals net ...

Page 470: ...ION SUSPENSION SMR2002 048_13_02A FM 13 02 1 DIRECT ACTION SUSPENSION 0 XP Model 10 11 3 13 12 5 8 6 9 4 7 F08Q02T 34 N m 25 lbf ft 2 1 10 N m 89 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 34 N m 25 lbf ft 5 N m 44 lbf in www SeaDooManuals net ...

Page 471: ... 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 472: ...tear re new boot s Shock Absorber Inspect shock absorber for wear Extend and com press the piston several times over its entire stroke it should move smoothly and with uniform resistance Pay attention to the following conditions that will denote a defective shock absorber A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme end of either stroke O...

Page 473: ...SS PANEL ADJUSTMENT 14 02 22 MIRROR 14 02 23 INLET GRATE 14 02 23 RIDING PLATE 14 02 23 JET PUMP SUPPORT 14 02 25 DEFLECTOR 14 02 26 DRAIN PLUG INSTALLATION 14 02 27 SEAT REMOVAL 14 02 27 SEAT COVER REPLACEMENT 14 02 29 BUMPER REPLACEMENT 14 02 29 SPONSON REPLACEMENT 14 02 29 ENGINE COMPARTMENT COVER REMOVAL 14 02 30 DECALS REPLACEMENT 14 02 30 HULL AND BODY REPAIR 14 02 31 TOOLS AND MATERIALS LIS...

Page 474: ...R2002 049_14_02A FM 14 02 1 ADJUSTMENT AND REPAIR 0 GTI and GTI LE Models bow F17L0RS Loctite 271 8 N m 71 lbf in 5 N m 44 lbf in Loctite 271 6 N m 53 lbf in Loctite 271 Silicone sealant 15 N m 133 lbf in Loctite 271 Silicone sealant Body www SeaDooManuals net ...

Page 475: ...ND REPAIR 14 02 2 SMR2002 049_14_02A FM GTI and GTI LE Models stern F17L0ST 13 15 N m 133 lbf in Loctite 271 Loctite 271 Silicone sealant Loctite 243 4 5 12 12 12 12 4 5 14 Silicone sealant Silicone sealant 15 2 2 N m 19 lbf in www SeaDooManuals net ...

Page 476: ...tion 14 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2002 049_14_02A FM 14 02 3 GTI and GTI LE Models cover F17L0TT Loctite 243 GTI LE 5 N m 44 lbf in Loctite 243 3 N m 26 lbf in www SeaDooManuals net ...

Page 477: ...Section 14 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 14 02 4 SMR2002 049_14_02A FM GTI and GTI LE Models seats F17L0US www SeaDooManuals net ...

Page 478: ...MENT AND REPAIR SMR2002 049_14_02A FM 14 02 5 RX Series bow F16L0WS Loctite 271 8 N m 71 lbf in 5 N m 44 lbf in Loctite 271 6 N m 53 lbf in Loctite 271 Silicone sealant 15 N m 133 lbf in Loctite 271 Silicone sealant Body www SeaDooManuals net ...

Page 479: ...2 ADJUSTMENT AND REPAIR 14 02 6 SMR2002 049_14_02A FM RX Series stern Loctite 271 12 13 Loctite 243 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 F16L0ST Silicone sealant www SeaDooManuals net ...

Page 480: ...Section 14 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2002 049_14_02A FM 14 02 7 RX Series cover F16L03S 5 N m 44 lbf in Loctite 243 3 N m 26 lbf in Loctite 243 www SeaDooManuals net ...

Page 481: ...Section 14 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 14 02 8 SMR2002 049_14_02A FM RX Series seat F16L04S www SeaDooManuals net ...

Page 482: ... and LRV DI bow F07L2DS 8 N m 71 lbf in 5 N m 44 lbf in Loctite 243 5 N m 44 lbf in 3 Loctite 243 10 Loctite 271 Loctite 243 5 N m 44 lbf in 10 5 N m 44 lbf in Silicone sealant Loctite 243 7 8 6 Right side only Loctite 271 15 N m 133 lbf in Body Silicone sealant 8 N m 71 lbf in www SeaDooManuals net ...

Page 483: ...T AND REPAIR 14 02 10 SMR2002 049_14_02A FM GTX GTX RFI and LRV DI stern F07L2FT 13 12 8 N m 71 lbf in 8 N m 71 lbf in Loctite 271 12 4 5 14 12 12 4 5 Silicone sealant Silicone sealant 15 N m 133 lbf in 15 2 2 N m 19 lbf in www SeaDooManuals net ...

Page 484: ...02 049_14_02A FM 14 02 11 GTX GTX RFI and 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 485: ...L BODY Subsection 02 ADJUSTMENT AND REPAIR 14 02 12 SMR2002 049_14_02A FM GTX GTX RFI and LRV DI seat F07L1NT Loctite 243 4 N m 35 lbf in Loctite 243 5 N m 44 lbf in Loctite 243 5 N m 44 lbf in www SeaDooManuals net ...

Page 486: ... BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2002 049_14_02A FM 14 02 13 XP 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 487: ...TMENT AND REPAIR 14 02 14 SMR2002 049_14_02A FM XP Models stern F08L1RT 15 2 2 N m 19 lbf in Body 4 5 12 14 5 13 12 5 N m 44 lbf in Loctite 243 3 Loctite 243 3 Body Body Silicone sealant Silicone sealant 5 N m 44 lbf in www SeaDooManuals net ...

Page 488: ...AIR SMR2002 049_14_02A FM 14 02 15 XP Models seat F08L16T Loctite 243 15 N m 11 lbf ft 17 5 N m 44 lbf in Loctite 243 4 N m 35 lbf in Loctite 271 13 N m 10 lbf ft 3 N m 27 lbf in 23 22 21 20 19 18 3 N m 27 lbf in 24 Synthetic grease www SeaDooManuals net ...

Page 489: ...AIR 14 02 16 SMR2002 049_14_02A FM XP 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 490: ...Section 14 HULL BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2002 049_14_02A FM 14 02 17 XP Models front cover Loctite 271 3 N m 27 lbf in F08L18S 2 N m 18 lbf in Engine cover www SeaDooManuals net ...

Page 491: ...HULL BODY Subsection 02 ADJUSTMENT AND REPAIR 14 02 18 SMR2002 049_14_02A FM XP Models rear cover Loctite 243 4 N m 35 lbf in F08L19T 22 N m 16 lbf ft 4 N m 35 lbf in Loctite 243 Loctite 243 www SeaDooManuals net ...

Page 492: ... 1 Unscrew Unscrew retaining screws then remove side pan els 1 Unscrew GTI GTI LE and RX Series Open front storage cover and remove the access panel Detach the latch retaining vent tube to bracket 1 Unlatch GTI GTI LE and RX Series Pull vent tube out From the engine compartment insert a hand through the vent tube hole and press glove box lock tabs to release 1 Insert your hand here to release the ...

Page 493: ...eads on new lock pin are coated with a self locking prod uct do not apply Loctite 243 on threads GTX GTX RFI AND LRV DI FRONT SEAT 1 Lock pin 2 Adjustment nut Loctite 243 Torque to 5 N m 44 lbf in A 39 1 mm 1 35 64 3 64 in GTX GTX RFI AND LRV DI REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 243 Torque to 5 N m 44 lbf in A 33 5 1 mm 1 5 16 3 64 in GTI AND GTI LE MODELS FRONT SEAT 1 Lock pin 2...

Page 494: ...towards the small 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 en...

Page 495: ...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 lock pin until any vertical play is eliminated Make sure a front and aft play re mains when pressing by hands XP MODELS 1 Lock pin Torque to 4 N m 35 lbf in A 13 4 mm 17 32 in ACCESS PANEL ADJUSTMENT XP Models Adjust lock pin no 3 of access panel as per follow ing specif...

Page 496: ...hen reinstalling inlet grate apply Loctite 271 on threads and torque screws to 11 N m 8 lbf ft GTI GTI LE XP and RX Series When reinstalling inlet grate apply Loctite 271 on threads Follow this sequence referring to the illustration Hand tighten screw numbers then Torque screw numbers and to 11 N m 97 lbf in Torque screw number to 26 N m 19 lbf ft RIDING PLATE Removal All Models Remove inlet grate...

Page 497: ...sidue of sealant Installation All Models Apply Loctite The Right Stuff Gasket as indicated by the shaded areas in the next illustrations Fol low also the torquing sequence as shown in the same illustrations NOTE Apply Loctite The Right Stuff Gasket as in dicated by the shaded area GTI GTI LE LRV DI RX AND RX DI MODELS NOTE Apply Loctite The Right Stuff Gasket as in dicated by the shaded area XP MO...

Page 498: ...O rings from steering cable TYPICAL 1 Unscrew nut Remove ball joint boot nut half rings and O rings from reverse cable GTI GTI LE RX series GTX GTX RFI and LRV DI Remove boot and nut from VTS sliding shaft RX series and XP models Disconnect water supply hose water return hose and bailer hoses Remove nuts lock washers and flat washers re taining jet pump support TYPICAL 1 Remove nuts Using a heat g...

Page 499: ...he same illustrations GTX RFI MODELS GTX MODELS GTI GTI LE RX RX DI AND XP MODELS LRV DI MODELS DEFLECTOR GTX GTX RFI and LRV DI Removal Using a heat gun heat deflector and pry it using a piece of wood Installation Apply Loctite The Right Stuff Gasket as indicated by the shaded area in the following illustrations GTX AND LRV DI MODELS F15L05A 4 N m 35 lbf in 1 2 4 3 F07L2LA 1 2 4 3 4 2 1 F08L1OA 3...

Page 500: ...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 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 501: ... 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 502: ...nt 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 guide Then install a rivet no 12 CAUTION When drilling be careful not to dam age bumper rail and or hull 6 Position bumper rail no 4 properly onto body and cut exces...

Page 503: ...r torque specifications and ser vice products to be used DECALS REPLACEMENT Removal Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off If decal tears while pulling off it has to be heated for a few seconds longer If decal tends t...

Page 504: ... and body of a Sea Doo watercraft It also provides a protective barri er against water and sun It consists of a mixture of resin pigment coloring fillers monomers and catalyst which is sprayed into the mold The body and hull of the Sea Doo are constructed of chopped fiberglass saturated with resin It is sprayed on the layer of gelcoat along with pieces of fiberglass mat cloth and woven rowing whic...

Page 505: ...e repair concerns the gelcoat only If flex cracking or impact are evident then additional reinforcement may be necessary This subject will be covered in Compound Frac tures PREPARING THE SURFACES Small Fractures Open the cracks up with a sharp triangular can opener or preferably a carbide tipped die grinder The V groove will provide a good bonding area for the gelcoat With 220 grit sandpaper sand ...

Page 506: ...backing support to cover the opening Cut alternat ing pieces of fiberglass mat and cloth in overlap ping sizes PATCHING THE REPAIR AREA Outside The outside should be done first Wipe clean the area with acetone on a cloth then mask off area For a small crack use an epoxy filler in the same way you would use gelcoat repair putty When lay ing up a larger area you will use mat cloth and fiberglass res...

Page 507: ...600 grit 1000 grit 24 grit sanding disks gelcoat putty liquid gelcoat acetone cabosil epoxy filler medium compound white fine compound white wax THRU HULL FITTING INSTALLATION For hull insert repair proceed as follows Cut plastic hull insert flush with hull using a saw 1 Hull 2 Plastic hull insert Mix epoxy glue 3M 05895 follow manufacturer instructions Apply epoxy glue on aluminum insert P N 292 ...

Page 508: ...D REPAIR SMR2002 049_14_02A FM 14 02 35 Install aluminum insert into plastic hull insert NOTE Align aluminum insert as much as possible with PTO flywheel 1 Aluminum insert NOTE The epoxy glue curing time is 30 minutes F01L2WA 1 www SeaDooManuals net ...

Page 509: ... 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 Cylinder out of round maximum 0 080 ...

Page 510: ...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 511: ...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 60...

Page 512: ...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 25 2 kW 34 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 513: ...io 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 0 10 m...

Page 514: ...o center 1 A Fuel pump 10 A ADDITIONAL INFORMATION FUEL SYSTEM GTX 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 2 280 kΩ 2 74 kΩ...

Page 515: ...6 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 GTX RFI Number of passenger driver incl 3 Overall length 315 cm 124 in Overall width 122 cm 48 in Overall height 104 cm 41 in Dry weight 292 kg 644 lb Load limit pa...

Page 516: ...lame arrester Multi layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTX RFI Estimated pump output 30 6 kW 41 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 minut...

Page 517: ...Cylinder head volume 51 34 0 6 cc Cylinder head warpage maximum 0 10 mm 0039 in total Piston ring type and quantity 2 semi trapez Ring end gap New 0 45 0 60 mm 018 024 in Wear limit 1 00 mm 039 in Ring piston groove New 0 048 0 075 mm 002 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 09 mm 0035 in Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 mm 004 in Cylind...

Page 518: ...A Main electrical system 15 A Charging system 15 A VTS system 7 5 A Bilge pump 3 A ADDITIONAL INFORMATION CARBURETION XP Carburetor Type Mikuni BN 46i diaphragm fuel accelerator pump Quantity 2 Main jet MAG and PTO 162 5 Pilot jet 75 Spring 95 g Adjustment Low speed screw 1 1 2 turn 1 4 High speed screw 0 Idle speed in water 1400 100 RPM Idle speed out of water 3000 RPM Fuel Type Regular unleaded ...

Page 519: ...New 0 0 0 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 XP Number of passenger driver incl 2 Overall length 272 cm 107 in Overall width 112 cm 44 in Overall height 104 cm 41 in Dry weight 255 kg 562 ...

Page 520: ... Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE XP Estimated pump output 53 1 kW 71 1 HP Maximum fuel consumption at wide open throttle 55 L h 14 5 U S gal h Cruising time at full throttle Fuel tank without reserve 48 minutes Fuel tank reserve 11 minutes ADDITION...

Page 521: ... 3 474 in Second oversize Not applicable Stroke 78 20 mm 3 079 in Displacement 951 2 cm 58 in Corrected compression ratio 6 1 1 6 0 1 Cylinder head volume 51 4 0 6 cc 50 76 0 6 cc Cylinder head warpage maximum 0 10 mm 0039 in total Piston ring type and quantity 2 semi trapez Ring end gap New 0 55 0 70 mm 022 028 in Wear limit 1 10 mm 043 in Ring piston groove New 0 044 0 089 mm 002 004 in Wear lim...

Page 522: ... 5582 Magneto generator output 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 coi...

Page 523: ...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 RAVE solenoid 24 Ω Knock sensor KS 5 MΩ Fuel injector 1 7 Ω 1 9 Ω Direct injector 1 0 Ω 1 6 Ω Fuel Type Premium unleaded gasoline Regular unleaded gasoline Minimum octane no 91 87 Fuel return line orifice Not applicable ADDITIONA...

Page 524: ...0 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS RX DI 5591 5592 RX DI 5583 5580 5581 5582 Number of passenger driver incl 2 Overall length 285 cm 112 in Overall width 120 cm 47 in Overall height 104 cm 41 in Dry weight 285 kg 628 l...

Page 525: ...stic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE RX DI 5591 5592 RX DI 5583 5580 5581 5582 Estimated pump output 50 2 kW 67 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 ...

Page 526: ...ze 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 cylinder...

Page 527: ...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 528: ...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 ADDITIONAL...

Page 529: ...16 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 pas...

Page 530: ...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 mi...

Page 531: ...on ratio 6 1 1 Cylinder head volume 51 34 0 6 cc Cylinder head warpage maximum 0 10 mm 0039 in total Piston ring type and quantity 2 semi trapez Ring end gap New 0 45 0 60 mm 018 024 in Wear limit 1 00 mm 039 in Ring piston groove New 0 048 0 075 mm 002 003 in Wear limit 0 2 mm 008 in Piston cylinder wall clearance New minimum 0 09 mm 0035 in Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 m...

Page 532: ...xide Fuses MPEM 5 A Main electrical system 15 A VTS system Not applicable 7 5 A Charging system 15 A ADDITIONAL INFORMATION CARBURETION GTX RX Carburetor Type Mikuni BN 46i diaphragm fuel accelerator pump Quantity 2 Main jet MAG and PTO 162 5 Pilot jet 75 Spring 95 g Adjustment Low speed screw 1 1 2 turn 1 4 High speed screw 0 Idle speed in water 1400 100 RPM Idle speed out of water 3000 RPM Fuel ...

Page 533: ... 1 00 mm 040 in Impeller shaft end play new 0 Impeller shaft radial play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTX RX Number of passenger driver incl 3 2 Overall length 315 cm 124 in 285 cm 112 in Overall width 122 cm 48 in 120 cm 47 in Overall height 104 cm 41 in Dry weight 301 kg 664 lb ...

Page 534: ...lastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTX RX Estimated pump output 51 kW 68 HP Maximum fuel consumption at wide open throttle 55 L h 14 5 U S gal h Cruising time at full throttle Fuel tank without reserve 49 minutes Fuel tank reserve 13 minutes AD...

Page 535: ...he first number indicates that the wire is posi tioned in the connector no 2 of the MPEM The second number indicates that the wire is po sitioned in the terminal no 18 The letter g indicates a common circuit with an other wire s bearing the same letter g in the cir cuit DEUTSCH CONNECTORS Deutsch connectors are used to connect wiring harness to magneto and to electrical box some models and to the ...

Page 536: ...ure the re tention fingers are holding the contact After all required contacts have been inserted the lock must be installed 1 Wire identification numbers PACKARD CONNECTOR Packard connectors are used to connect electrical harnesses and gauges VIEW OF A 3 POSITION PACKARD CONNECTOR 1 Identification letters To remove terminal from Packard connector hous ing use Snap on TT600 4 tool AMP PLUG CONNECT...

Page 537: ...on Apply a thin coat of DEOXIT contact lubricant P N 293 550 015 to the pins of the header on the MPEM only 1 Apply a thin coat of DEOXIT contact lubricant CAUTION Do not apply lubricant excessively Care must be taken so that the lubricant will not come in contact with the mating seal the seal may loose its sealing capacities Do not apply lubricant on contacts inside plug connector Each plug assem...

Page 538: ...een 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 contact is removed 1 Rotate wire back and forth 2 Pull wire POWER WIRE CONTACT NOTE The wedge lock must be ...

Page 539: ...tion sur face within 25 mm 1 in from the tip of the con tact must be smooth All contacts in AMP plug connectors must be crimped using the crimping tool P N 295 100 164 CAUTION If contacts are not crimped using the proper crimping tool the wire seal may be dam aged CRIMPING TOOL P N 295 100 164 All circuits are sealed by a diaphragm in the rubber wire seal When installing wire contacts in plug conn...

Page 540: ...lustrations 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 holding the joint insulator push the tool until it bottoms It is now unlocked Maintain ing the press...

Page 541: ...2002 GTI MODEL www SeaDooManuals net ...

Page 542: ...SMR2002 051_16_00A FM 2002 GTI MODEL F17Z01 www SeaDooManuals net ...

Page 543: ...2002 GTI LE MODEL www SeaDooManuals net ...

Page 544: ...SMR2002 051_16_00A FM 2002 GTI LE MODEL F11Z02 www SeaDooManuals net ...

Page 545: ...2002 GTX MODEL www SeaDooManuals net ...

Page 546: ...SMR2002 051_16_00A FM 2002 GTX MODEL F07Z01 www SeaDooManuals net ...

Page 547: ...2002 GTX RFI MODEL www SeaDooManuals net ...

Page 548: ...SMR2002 051_16_00A FM 2002 GTX RFI MODEL F15Z04 www SeaDooManuals net ...

Page 549: ...2002 XP MODEL www SeaDooManuals net ...

Page 550: ...SMR2002 051_16_00A FM 2002 XP MODEL F08Z02 www SeaDooManuals net ...

Page 551: ...2002 RX MODEL www SeaDooManuals net ...

Page 552: ...SMR2002 051_16_00A FM 2002 RX MODEL F16Z03 www SeaDooManuals net ...

Page 553: ...2002 RX DI MODEL www SeaDooManuals net ...

Page 554: ...SMR2002 051_16_00A FM 2002 RX DI MODEL F16Z04 www SeaDooManuals net ...

Page 555: ...2002 LRV DI MODEL www SeaDooManuals net ...

Page 556: ...SMR2002 051_16_00A FM 2002 LRV DI MODEL F11Z02 B A INJ BATT 25A BILGE 3A REG 25A ACC 2A FP 15A N S E W RE PU RE GY RE GY RE www SeaDooManuals net ...

Page 557: ...www SeaDooManuals net ...

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