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Sea-doo GTX 4-TEC 5573 2002, Shop Manual

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Sea-doo GTX 4-TEC 5573 2002 Shop Manual Download Page 468

Section 14

HULL/BODY

Subsection 02

(ADJUSTMENT AND REPAIR)

14-02-8

SMR2002-092_14_02A.FM

1. Storage cover lateral locking bracket
2. Inner skin lateral locking hook

1. Storage cover back locking hook
2. Inner skin back locking bracket

– Secure the inner skin in the storage cover by

using the rubber hammer.

– Fasten the seven inner skin short screws and

the two inner skin long screws.

STORAGE COVER SHOCK

To remove storage cover shock proceed as follows:

– Unlock shock rod from circlip and remove washer.

1. Shock rod
2. Circlip
3. Washer

– Release the shock from top linkage bracket and

bottom support bracket by inserting a flat screw-
driver in the shock top and bottom locking devices.

1. Top linkage bracket
2. Shock top locking device

1

F18L1VA

2

1

F18L1WA

2

WARNING

Make sure to have a 2x4 piece of wood around
the work bench to support the storage cover
while changing the cover shock.

1

F18L1NA

2

3

2

F18L1YA

1

www.SeaDooManuals.net

Summary of Contents for GTX 4-TEC 5573 2002

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

Page 2: ...2002 Shop Manual Volume 2 GTX DI GTX 4 TEC 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: ...ntents 05 01 1 02 Leak test 05 02 1 03 Intake system 05 03 1 04 Exhaust system 05 04 1 05 Removal and installation 05 05 1 06 PTO housing Magneto 05 06 1 07 Lubrication 05 07 1 08 Cylinder head and valves 05 08 1 09 Engine block 05 09 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 ENGINE ...

Page 5: ...ts 12 01 1 02 Jet pump 12 02 1 03 Drive system 12 03 1 04 Reverse system 12 04 1 13 STEERING SYSTEM 01 Table of contents 13 01 1 02 Steering system 13 02 1 03 Alignment 13 03 1 14 HULL BODY 01 Table of contents 14 01 1 02 Adjustment and repair 14 02 1 15 TECHNICAL DATA 01 GTX DI model 15 01 1 02 GTX 4 TEC model 15 02 1 16 WIRING DIAGRAMS 01 Wiring diagrams 16 01 1 TABLE OF CONTENTS www SeaDooManua...

Page 6: ...mmended 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 fasteners...

Page 7: ...is composed of 12 digits MODELS ENGINE TYPE MODEL NUMBER GTX DI International green 947 DI 5563 GTX DI green 947 DI 5564 GTX 4 TEC International red 1503 5573 GTX 4 TEC red 1503 5574 GTX 4 TEC International blue 1503 5593 GTX 4 TEC blue 1503 5594 GTX DI International blue 947 DI 5595 GTX DI blue 947 DI 5596 1 F18L0ZA Z Z N 1 2 3 4 5 L 4 9 5 Model year Serial number F00A0CB Month of production Year...

Page 8: ...HIS MANUAL The manual is divided into 16 major sections 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE DI 05 ENGINE 4 TEC 06 ENGINE MANAGEMENT DI 07 ENGINE MANAGEMENT 4 TEC 08 COOLING SYSTEM 09 FUEL SYSTEM 10 LUBRICATION SYSTEM DI 11 ELECTRICAL SYSTEM 12 PROPULSION SYSTEM 13 STEERING SYSTEM 14 HULL BODY 15 TECHNICAL DATA 16 WIRING DIAGRAMS Several sections are divided in...

Page 9: ...stration number for publishing process Subsection title indicates beginning of the subsection Dotted box contains parts of a particular model or an exploded view Page numbering system 03 ENGINE section 04 MAGNETO SYSTEM subsection 1 First page of this subsection Italic sub title above exploded view indicate pertaining models Drop represents a liquid product to be applied to a surface In this case ...

Page 10: ...place other wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI Diaph...

Page 11: ...nvironmental Protection Agency USA HP Horse Power KS Knock Sensor LED Light Emitting Diode MAG Magneto MAPS Manifold Air Pressure Sensor MATS Manifold Air Temperature Sensor MPEM Multi Purpose Electronic Module MPH Mile Per Hour MPI Multi Protocol Interface N A Not Applicable OPAS Off Power Assisted Steering OPS Oil Pressure Sensor OPT Optional OSPS Oil Separator Pressure Sensor P N Part Number PF...

Page 12: ...tion in which the proce dure is contained A number of procedures throughout the book re quire the use of special tools Before undertaking any procedure be sure that you have on hand all the tools required or approved equivalents ENGINE EMISSIONS INFORMATION Manufacturer s Responsibility Beginning with 1999 model year engines PWC manufacturers of marine engines must determine the exhaust emission l...

Page 13: ...OURIER MAIL Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403J 501 3rd St NW Washington DC 20001 EPA INTERNET WEB SITE http www epa gov omswww SELF LOCKING FASTENERS PROCEDURE The following describes the most common appli cation procedures when working with self locking fasteners Use a metal brush or a screwtap to clean the hole properly then us...

Page 14: ...P N 293 800 041 on threads and allow to dry 3 Put several drops of proper strength Loctite threadlocker on female threads and in hole 4 Apply several drops of proper strength Loctite on stud threads 5 Install stud 6 Install cover etc 7 Apply drops of proper strength Loctite on un covered threads 8 Tighten nuts as required Preassembled Parts 1 Apply here 2 Do not apply 1 Clean bolts and nuts with s...

Page 15: ...es 3 Twist bolt when inserting it to improve thread conformation NOTE NOT intended for engine stud repairs Repair of Small Holes Fine Threads Option 1 Enlarge damaged hole then follow Stan dard Thread Repair procedure Option 2 Apply FORM A THREAD on the screw and insert in damaged hole Permanent Stud Installation light duty 1 Use a stud or thread on desired length 2 DO NOT apply release agent on s...

Page 16: ...ent point NOTE Retaining compound is always forced out when applied on shaft 3 DO NOT use anti seize Loctite or any similar product 4 No curing period is required Mounting in Tandem 1 Apply retaining compound on internal element bore 2 Continue to assemble as shown above CASE IN COMPONENTS Metallic Gaskets 1 Proper strength Loctite 1 Clean inner housing diameter and outer gasket diameter 2 Spray h...

Page 17: ...4 124 15 133 16 142 17 150 18 159 19 168 N m FASTENER SIZE 8 8 grade Lbf ft 20 15 21 15 22 16 23 M8 17 24 18 25 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 41 30 42 31 43 32 44 32 45 33 46 34 47 35 48 M10 35 49 36 50 37 51 38 52 38 53 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 65 48 66 49 67 49 68 50 69 51 70 52 71 52 72 53...

Page 18: ... 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 N m FASTENER SIZE 8 8 grade Lbf ft 116 86 117 86 118 87 119 88 120 89 121 89 122 90 123 91 124 91 125 92 126 93 127 94 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 147 108 148 109 149 110 150 111 N m F...

Page 19: ...TENTS 0 MANDATORY SERVICE TOOLS 01 02 1 ENGINE 01 02 1 COOLING FUEL OIL SYSTEMS 01 02 4 PROPULSION SYSTEM 01 02 5 STEERING SYSTEM 01 02 7 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 5 SERVICE PRODUCTS 01 04 1 www SeaDooManuals net ...

Page 20: ...4 TEC engine Sleeve set P N 529 035 543 21 mm sleeve F00B0U4 APPLICATION 947 DI engine NEW 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 APPLICATION 947 DI engine Starter drive bearing pusher P N 290 876 502 F06B054 APPLICATION All engines Piston pin p...

Page 21: ... 529 035 507 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 155 6 mm jet pump Alignment shaft P N 295 000 141 F00B0G4 APPLICATION All models Alignment adaptor P N 529 035 719 F18B0C4 APPLICATION GTX 4 TEC models NEW VCK Vehicle Communication Kit P N 529 035 844 Individual B U D S diskettes v1 1 P N ...

Page 22: ...ller tool P N 420 976 235 puller ass y P N 529 035 549 puller bolt F01B294 APPLICATION 947 DI engine Crankshaft protective cap P N 290 877 414 F00B1R4 APPLICATION 947 DI engine Polygonal wrench P N 529 035 505 F00B0Y4 APPLICATION Exhaust system of the 947 DI en gine Intake plug P N 529 035 708 APPLICATION 947 DI engine Oil pressure gauge 1 to 8 bars P N 529 035 709 V00B064 APPLICATION 4 TEC engine...

Page 23: ... 529 035 591 F02B0B4 APPLICATION 4 TEC 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 pressor adapter P N 529 035 712 F12R014 APPLICATION 947 DI engine 1 3 2 4 Oil seal guide P N 529 035 8...

Page 24: ...0W4 APPLICATION GTX DI models Jet pump bearing remover P N 295 000 144 F01J114 APPLICATION GTX DI models Bearing seal installer P N 295 000 107 F01J4K4 APPLICATION GTX DI models Inner seal installer P N 529 035 609 F08B014 APPLICATION GTX DI models Impeller shaft guide P N 295 000 002 F01J1O4 APPLICATION GTX DI models Pliers P N 295 000 054 Caillau F01B1T4 APPLICATION All models NOTE This tool is ...

Page 25: ...haft floating ring P N 529 035 841 F18B044 APPLICATION GTX 4 TEC models Seal bearing pusher P N 529 035 819 F18B0D4 APPLICATION GTX 4 TEC models NEW NEW Shaft pusher P N 529 035 818 F18B0E4 APPLICATION GTX 4 TEC models NEW Pressure cap P N 529 035 843 F18B054 APPLICATION GTX 4 TEC models NEW www SeaDooManuals net ...

Page 26: ...1 SERVICE TOOLS AND PRODUCTS Subsection 02 MANDATORY SERVICE TOOLS SMR2002 054_01_02A FM 01 02 7 STEERING SYSTEM OPAS cylinder nut wrench P N 529 035 840 F18B0A4 APPLICATION All models NEW www SeaDooManuals net ...

Page 27: ...ness P N 295 000 136 F01B284 APPLICATION 947 DI engine Dial indicator TDC gauge P N 295 000 143 A00B4E4 APPLICATION 947 DI engine Digital induction type tachometer P N 529 014 500 F01B1G4 APPLICATION All models Timing mark pointer P N 295 000 135 F01H544 APPLICATION 947 DI engine Crimping tool P N 295 100 164 F00B0E4 APPLICATION Contacts of AMP plug connectors Terminal Packard remover Not sold by ...

Page 28: ...000 132 F01B2A4 APPLICATION All models Engine lifting device Not sold by Bombardier Do it yourself Refer to REMOVAL AND INSTAL LATION section of engine F01D0A4 APPLICATION 947 DI engine Steering cable tool P N 295 000 145 F01B2P4 APPLICATION All models Rubber pad P N 290 877 032 F06B064 APPLICATION 947 DI engine MPEM programmer P N 529 035 878 A01B5B4 APPLICATION 947 DI models Piston ring compress...

Page 29: ...201 2 9 Puller bolt P N 420 940 755 APPLICATION 947 DI engine MAG side PTO side 8 1 5 2 3 4 4 6 8 7 7 9 9 Valve spring compressor clamp P N 529 035 724 V00B044 APPLICATION 4 TEC Engine Valve spring compressor cup P N 529 035 725 V04B094 APPLICATION 4 TEC Engine Ring compressor Not sold by Bombardier Snap on RC980 V04B084 APPLICATION 4 TEC Engine NEW NEW NEW Special pliers for valve stem seal remov...

Page 30: ... mirror Not sold by Bombardier Snap on 50101 F01B1I4 APPLICATION All models Hose pincher P N 529 032 500 F01B234 APPLICATION All models Hose pincher P N 295 000 076 A01B2I4 APPLICATION All models Flexible spout oil P N 414 837 300 F04B044 APPLICATION All models Flushing adapter P N 295 500 473 F00B104 APPLICATION All models Use with coupler hose P N 295 500 258 Test radiator cap P N 295 021 400 F1...

Page 31: ... 6 Claws CJ93 4 F01J0Z4 APPLICATION All 947 DI 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 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 1 50 m 5 ft long P N 295 100 103 F00B014 APPLICATION All models Tie down with ratche...

Page 32: ... 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 33: ...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 Primer for gasket eliminator P N 293 800 041 Loctite 764 A00B3N4 111 Pipe sealant A P N 293 800 013 B P N 293 800 018 A Loctite 567 250 mL B Loctite 592 50 mL A00B2W4 Hylomar sealant P N 293 800 001 PL 32 100 g A00B3F4 Sealant P N 293 530 011 Sikaflex 221 black 350...

Page 34: ...t lubricant P N 293 550 015 200 mL F00B0X4 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 Loctite 82328 V00B0I4 Anti seize lubricant P N 293 800 070 Loctite 76764 454 g 16 oz A00B594 Grease Isoflex P N 293 550 021 50 g A00B554 BOMBARDIER LUBE P N 293 600 016 12 x 14 oz A00B624 NEW www SeaDooManuals net ...

Page 35: ...8 600 236 mL 8 oz A00B604 732 Multi purpose sealant P N 293 800 086 Dow Corning 90 mL clear F01B1C4 Premixed coolant 50 50 37 C 35 F P N 293 600 038 16 x 1 L A00B5X4 Sealant adhesive P N 293 800 086 Loctite 5150 29647 A00B5S4 NEW BOMBARDIER Formula XP S II synthetic injection oil P N 293 600 245 12 x 1 L A00B5T4 P N 293 600 246 3 x 4 L A00B5U4 P N 293 600 247 205 L NEW www SeaDooManuals net ...

Page 36: ...01 04 5 Instant gasket P N 293 800 088 7 oz A02B0C4 Jet pump synthetic oil P N 293 600 011 12 x 6 oz F01B0P4 Jet pump grease P N 293 550 032 110 g NEW NEW 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 37: ...D 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 1 FUEL SYSTEM 02 05 1 ENGINE OIL CHANGE AND FILTER 02 05 2 COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION 02 05 2 ENGINE LUBRICATION 02 05 2 BATTERY 02 05 3 WATERCRAFT CLEANING 02 05 3 ADDITIONAL RECOMMENDED PROTECTION 02 05 3 ANTICORROSION TREATMENT 02 05 5 CHECKLIST 02 05 6...

Page 38: ...ss Exhaust system fasteners RAVE valve cleaning Top end inspection leak test piston and ring clearance Counterbalance shaft oil level Spark plug inspection cleaning and gap adjustment Spark plug replacement TDC setting COOLING SYSTEM Flushing Hose condition and fasteners Inspect clean engine drain tubes Water flow regulator valve inspection FUEL SYSTEM Throttle inspection lubrication Fuel filter a...

Page 39: ...l box es starting system fuel injectors etc MPEM mounting brackets fasteners Digitally Encoded Security System and safety lanyard post condition 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 Drive shaft protection hos...

Page 40: ...ressure test FUEL SYSTEM Throttle cable inspection lubrication Fuel injection system sensors visual inspection Throttle body cleaning and inspection Fault code reading Fuel vent line pressure relief valve inspection Fuel lines connections and fuel system leak test Visual inspection throttle body sensors fuel lines fuel rail and fittings Air intake silencer fit tightness Fuel tank straps visual ins...

Page 41: ...eriode DESCRIPTION FREQUENCY FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR STEERING SYSTEM Inspection and cable adjustment O P A S FUEL SYSTEM Check O P A S system operation and condition including filter PROPULSION SYSTEM Drive shaft protection boot inspection Grease splines in jet pump Shifter system cable adjustment Impeller shaft seal replacemen...

Page 42: ...erely damage engine and or exhaust system 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 Connect a garden hose to the flushing adaptor 1 Flushing adaptor NOTE A quick connect adapter with a flushing adaptor P N 295 500 473 can be used to ease garden hose installa...

Page 43: ...h cylinder NOTE Proceeding in this order no fuel will be inject ed and no ignition will occur in the engine While engine is stopped fully depress throttle lever 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 walls NOTE A 1 second beep every second indicates the drowned mode is active Apply anti seize ...

Page 44: ...upplying water to the exhaust cooling system when wa tercraft is out of water Ensure water flows out of exhaust outlet while flushing Otherwise refer to an authorized Sea Doo dealer for servicing CAUTION Never run engine longer than 5 min utes Drive line seal has no cooling when water craft is out of water Close the water tap then stop the engine CAUTION Always close the water tap before stopping ...

Page 45: ...ailure to remove the air pressure hose from the compressor will result in the bend ing of the compressor connecting rod when cranking the engine 1 Disconnect this hose Remove the flywheel guard and turn the PTO fly wheel several times by hand While engine is stopped fully depress throttle le ver and HOLD for cranking Crank engine several times to drain crankcase NOTE A 1 second beep every second i...

Page 46: ...he engine is stopped all the valves close to prevent water from being ingested in the engine If water is suspected to be in the intake manifold and the exhaust system it must be drained as fol lows Remove the intake manifold and suck out the wa ter from the intake valve ports Refer to subsec tion INTAKE SYSTEM Remove the water from oil air separator breather hose Remove the exhaust pipe the muffle...

Page 47: ...ool and the fitting Rein stall the drain plug NOTE Do not forget to install the sealing washer on the drain plug NOTE If spillage occurs clean immediately with the Pulley flange cleaner P N 413 711 809 to pre vent oil stains 12 Install a new oil filter and reinstall the oil filter cap 13 Fill up the reservoir with fresh oil 14 Boil out the remaining water as follows a Recommended procedure BOIL OU...

Page 48: ... 5 minutes at 3000 RPM 4 With the engine still running at 3000 RPM in stall a hose pincher to the coolant line going to the oil cooler 5 Continue to run the engine at 3000 RPM for 15 more minutes 20 minutes total run time 6 Shut off the engine CAUTION Hose pincher should be remove be fore operating the watercraft engine Failure to do this will result in damage to the engine 7 Remove the hose pinch...

Page 49: ... 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 rubber boot 1 Grease PTO flywheel CAUTION Never leave any clothing tool or oth er objects near PTO flywheel and drive shaft FUEL SYSTEM All Engines Verify fuel system Check fuel lines and injectors for leaks Replace damag...

Page 50: ... spark plugs Otherwise dirt would fall into cylinder and will damage the internal components Remove the spark plugs Apply BOMBARDIER LUBE lubricant into the cylinders Reinstall spark plugs and ignition coils Reconnect ignition coil connector NOTE Prior to inserting the ignition coil to its lo cation apply some BOMBARDIER LUBE lubricant around the seal area that touches the spark plug hole After in...

Page 51: ...ation CAUTION The watercraft must never be Ieft in water for storage Never leave the watercraft stored in direct sunlight ADDITIONAL RECOMMENDED PROTECTION DI Engines NOTE This procedure requires approximately 2 5 L 2 6 U S qt of antifreeze In cool regions where freezing point may be encoun tered coolingsystem shouldbefilledwithwater and antifreeze solution 40 water 60 antifreeze CAUTION Remaining...

Page 52: ...LET hose at engine between T fitting and cylinder head fitting 1 Disconnect this side of the T fitting 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 F18E0FA 1 F18E08A 1 F18E0BA 1 F07E0LA www SeaDooManuals net ...

Page 53: ...eze will drain out when removing the hose pinchers Use a container to recover it DIS POSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS NOTE Although antifreeze will mainly drain out the antifreeze has mixed with the water that was possibly trapped in the cylinder water jackets and thus preventing freezing problems At preseason preparation drain the remaining an tifreeze from cooling system pr...

Page 54: ...l and filter 4 TEC engines Flush the exhaust cooling system by running the engine 4 TEC engines Lubricate the engine Remove clean and store the battery Clean the bilge Wash the body Add antifreeze solution to the cooling system in cool regions DI engines Replace antifreeze Check solution concentration in the cooling system in cool regions 4 TEC engines Spray BOMBARDIER LUBE over all metallic compo...

Page 55: ...YSTEM and ENGINE MANAGEMENT Safety lanyard switch faulty or discon nected or harness damaged Replace Disconnected or faulty DESS auxil liary module 4 TEC models Refer to ENGINE MANAGEMENT Burnt fuse on MPEM or in rear elec trical box battery starting system fuel pump Check wiring then replace fuse Starting system fuse keeps on burning Check wiring starting system solenoid and MPEM Discharged or di...

Page 56: ...y Check charge replace Restriction in jet pump Check clean pump Partial seizure in jet pump Inspect refer to section PROPULSION SYSTEM Partial engine hydrolock Check refer to section MAINTENANCE Partial engine seizure Check compression refer to section ENGINE Worn starter Check refer to section ELECTRICAL SYSTEM Outside temperature too low Oil is too thick Change oil viscosity Battery capacity is ...

Page 57: ...or operation Check output signal from MPEM No spark at the spark plug Check spark plugs condition and replace as necessary Check ignition system and repair Defective MPEM or EMS ECU Replace MPEM or EMS ECU as applicable 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 defec...

Page 58: ...d remove water Refer to intake system in ENGINE MANAGEMENT Water in fuel reservoir or contaminated fuel Flush reservoir and refill with fresh gas Mechanical engine failure Check cylinder compression Check for cylinder head leaks Check starting system Spark plug faulty fouled or worn out Check spark plug condition Low fuel pressure Check fuel pump operation Refer to ENGINE MANAGEMENT Check fuel pre...

Page 59: ...models Clogged fuel injectors 4 TEC models Remove and clean direct injectors Defective sensor or EMS ECU 4 TEC models MPEM DI models Check faulty codes in EMS ECU or MPEM as applicable memory refer to section ENGINE MANAGEMENT Rich fuel mixture Fouled spark plug Flame arrester dirty or restricted Check replace Improper air fuel rail pressure DI models Check pressures refer to ENGINE MANAGEMENT Fau...

Page 60: ...er to ENGINE MANAGEMENT OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Fouled defective spark plugs Clean replace Spark plugs Ignition coil leads or wiring reversed Check with wiring diagram Ignition timing TDC setting Incorrect setting DI models Check reset refer to section ELECTRICAL SYSTEM Defective encoder wheel Check refer to section ENGINE MANAGEMENT Engine Intake or exhaust valve s leak...

Page 61: ...fer to section CYLINDER HEAD Overheated engine See ENGINE OVERHEATS in this chart Engine revs lower than its maximum operational RPM RAVE valve does not open DI models 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 DI models Check refer to section ENGINE OTHER OBSERVATION POS...

Page 62: ...tch too low Incorrect throttle position sensor TPS adjustment Damaged impeller Check replace refer to section PROPULSION SYSTEM Check and adjust TPS refer to ENGINE MANAGEMENT Replace impeller Refer to PROPULSION Jet pump cavitation Damaged leading or trailing edge of impeller Check replace NOTE Leading edge damage contributes to poor performance from start Trailing edge damage contributes to poor...

Page 63: ...LE CAUSE REMEDY Oil level too low Refill See TECHNICAL DATA for specifications Leaking gasket Replace Oil leaking out of weep hole PTO housing Replace oil seal on pump shaft Oil pressure sensor defective Check replace Oil pump malfunctioning Clean rotor and check wear limits Oil regulator valve sticks open or spring load to small Clean replace Heavy wear on plain bearings Replace OTHER OBSERVATION...

Page 64: ...inside rocker arm s is are worn out valve adjust ment Replace faulty rocker arm s Rocker arm screws not tightened Retorque Heavy wear on crankshaft and or bal ancer shaft bearings Replace Crankshaft and balancer shaft not aligned Check marks and readjust shafts Heavy wear on thrust washers or thrust washers missing Check replace OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weeds debris caught in intake...

Page 65: ... 1 ENGINE REMOVAL 04 03 1 CLEANING 04 03 3 INSTALLATION 04 03 4 MAGNETO SYSTEM 04 04 1 DISASSEMBLY 04 04 2 CLEANING 04 04 3 ASSEMBLY 04 04 3 TOP END 04 05 1 GENERAL 04 05 2 DISASSEMBLY 04 05 3 CLEANING 04 05 6 INSPECTION 04 05 7 USED PISTON MEASUREMENT 04 05 8 ASSEMBLY 04 05 10 BOTTOM END 04 06 1 DISASSEMBLY 04 06 2 CLEANING 04 06 5 INSPECTION 04 06 6 ASSEMBLY 04 06 10 EXHAUST SYSTEM 04 07 1 REMOV...

Page 66: ...ions 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 NOTE If a leak is found it is important to continue testing as there is the possibility of having more than one leak Continue pumping to compensate for t...

Page 67: ...ts If kit components are not leaking and pressure drops verify all external jointed surfaces tem perature sensor and the O ring between the spark plug area and the engine cylinder head cover If none of these components are leaking there is an internal leak and it can be detected with Bottom End and Top End testing Bottom End and Top End Remove throttle bodies Install intake manifold plugs P N 529 ...

Page 68: ...d gasket cylinder base gasket crankcase halves engine plugs exhaust manifold intake flanges Check also small oil injection pump lines and fit tings check for air bubbles or oil column going to ward pump which indicate a defective check valve Check for leak through cournterbalancing shaft seal toward air compressor Air bubbles in lowest fitting oil return line underneath compressor indi cates a sea...

Page 69: ...Section 04 ENGINE DI Subsection 02 LEAK TEST 04 02 4 SMR2002 059_04_02A FM ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 947 DI Engine F00D28T www SeaDooManuals net ...

Page 70: ...nect connectors from fuel injectors and di rect injectors Disconnect connector from knock sensor Disconnect RAVE valve hose where shown Inspect hose If it has hardened or is slit replace hose 1 Disconnect hose here Refer toENGINEMANAGEMENT forlocation ofsen sors and connectors Unplug air compressor lines inlets and outlets cooling oil outlet only and air inlet only on throt tle body side Disconnec...

Page 71: ...ent Remove engine support mount screws FRONT SUPPORT 1 Remove screw REAR SUPPORT 1 Remove screws Lifting Engine 947 DI 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 H...

Page 72: ...0 076 Disconnect RED positive cable from starter post TYPICAL 1 Disconnect RED positive cable Disconnect BLACK negative cable from engine crankcase 1 Positive starter cable 2 Ground cable Carry on engine lifting then tilt engine so that it can be removed from the body opening CAUTION Be careful not to scratch body or to hit any component TYPICAL CLEANING Wipe off any spillage in bilge Clean with a...

Page 73: ...he following illustration TORQUE TO 24 N m 17 lbf ft AS PER SEQUENCE NOTE Remembertoinstallsleevesandflatwashers 1 Sleeves 2 Flat washers Positive Starter Cable Torque nut of positive starter cable to 6 N m 53 lbf in Apply dielectric grease on nut Engine Jet Pump Alignment Alignment is necessary to eliminate possible vi bration and or damage to components Check alignment of engine using the follow...

Page 74: ...gnment 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 never install more than 1 3 mm 0 051 in shim thickness Engine Support Screws Apply Loctite 243 blue P N 293 8...

Page 75: ...ified in OIL INJECTION PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT Check hose condition and pressure test fuel sys tem refer to FUEL CIRCUIT Verify all electrical connections Run engine and ensure there is no leakage CAUTION If watercraft is out of water engine must be cooled using the flush kit WARNING Whenever doing any type of repair on water craft or if any components of t...

Page 76: ...4_04A FM 04 04 1 MAGNETO SYSTEM 0 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 77: ...o 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 assembly unscrew nut no 13 counterclockwise when facing it 1 Nut The magneto rotor is easily freed from crankshaft with puller P N 420 976 235 Install protective cap P N 290 877 414 to cra...

Page 78: ...tor no 9 and trigger coil no 10 from the engine magneto cover 1 Remove screws CLEANING Clean all metal components in a solvent CAUTION Clean coils and magnets using only a clean cloth Clean crankshaft taper and threads using acetone Apply the acetone on a rag first then clean the crankshaft ASSEMBLY Battery Charging Coil Position new coil crimp and solder all wires Prior to assembly apply Loctite ...

Page 79: ...give any protection Magneto Housing Install gasket no 24 between magneto housing no 5 and engine crankcase Install magneto housing and torque screws no 16 to 9 N m 80 lbf in Armature Plate Position the armature plate on the crankcase aligning the marks on both parts When reinstalling armature plate on a new crank case housing proceed as follows Find manufacturer s mark on armature plate In line wi...

Page 80: ...e 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 Rotor and Ring Gear Apply Loctite 648 green on mating surface of the rotor no 8 When reinstalling rotor to ring gear no 3 one of the protrusion end of rotor must b...

Page 81: ...nstall 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 If heat exchanger cover has been removed en sure to align its notch with the emboss in casing 1 Align notch with the emboss 1 F12R0EA www SeaDooManuals net ...

Page 82: ...05 1 TOP END 0 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 83: ...ate the bellows and open the RAVE valves To open the RAVE valves the MPEM activates a so lenoid which directs the pressure from air compres sor to the valves 1 Pressure from solenoid 1 Solenoid 2 Pressure from air compressor 3 Pressure to RAVE valves 4 Vent to air intake silencer 5 Check valve 6 Vent from counterbalancing shaft oil cavity To close the RAVE valves the MPEM deactivates the solenoid ...

Page 84: ... a customer uses a lower quality oil than 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 fi...

Page 85: ...om valve housing 1 Valve piston 2 Valve housing 3 Sliding valve Cylinder Head Cover and Cylinder Head Disconnect temperature sensor wire and spark plug cables Connect spark plug cables on grounding device Disconnect hose of RAVE valves Remove air fuel rail Refer to ENGINE MANAGE MENT Use Snap On Torx socket E12 and unscrew cylin der head screws no 14 following the sequence shown in the next illust...

Page 86: ...AL 1 Piston notch To extract piston pin no 4 use piston pin puller P N 529 035 503 with the appropriate set of sleeves 1 Puller 2 Shoulder sleeve 3 Sleeve Fully thread on puller handle Insert extractor spindle into the piston pin Slide the sleeve and shoulder sleeve onto the spindle Screw in extracting nut with the movable ex tracting ring towards spindle 1 Puller 2 Sleeve 3 Shoulder sleeve 4 Extr...

Page 87: ...er 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 CLEANING Discard all gaskets and O rings Clean all metal components in a solvent Clean water passages and make sure they are not clogged Remove carbon deposits from...

Page 88: ... just below auxiliary transfer port facing exhaust port and just be low the auxiliary transfer port facing the exhaust port Compare readings If the difference 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 cyli...

Page 89: ... Piston Cylinder Wall Clearance Used and New Pistons IMPORTANT Make sure used piston is not worn more than specified See USED PISTON MEA SUREMENT above To determine the piston dimension take the mea surement on the piston dome 1 Piston dome 2 Piston measurement Adjust and lock a micrometer to the specified val ue on the piston dome 1 Micrometer set to the piston dimension With the micrometer set t...

Page 90: ...e indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false Ring Piston Groove Clearance 1 Feeler gauge 2 Rectangular ring bottom 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 cyl...

Page 91: ...ustment of the combustion chamber volume To identify gasket thickness refer to the identifi cation holes on the gasket TYPICAL 1 Identification holes ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following 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...

Page 92: ...ld in place by a lo cating sleeve outside and 2 plastic cage halves inside Push needle bearing together with inner halves out of the locating sleeve into the 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 instal...

Page 93: ...uter 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 hamme...

Page 94: ...rclip installer 1 Circlip installer Remove sleeve from pusher then insert circlip into its bore Reinstall sleeve onto pusher and push until cir clip comes in end of tool TYPICAL 1 Circlip near end of tool Position end of tool against piston pin opening Firmly hold piston against tool and tap tool with a hammer to insert circlip into its groove CAUTION The hand retaining the piston should absorb th...

Page 95: ...holes in cylin der block 1 Dowels To easily slide cylinder block over pistons use ring compressor P N 290 876 965 1 Slide this edge NOTE For each ring make sure to align ring end gap with piston locating pin Install cylinder block Cylinder Screw Apply Molykote 111 below the screw head The blue coating underneath the cylinder screw head can be only used once Either replace with new bolts or remove ...

Page 96: ... 50 50 of gasoline and injection oil 1 Graduated burette 0 50 cc 3 Open burette valve to fill its tip Add liquid in burette until level reaches 0 cc 4 Inject the burette content through direct injec tor hole until liquid touches the top hole 1 Top of spark plug hole NOTE The liquid level in cylinder must not drop for a few seconds after filling If so there is a leak between piston and cylinder The...

Page 97: ...kote 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 sei...

Page 98: ... 2 Breaker bar locking crankshaft Remove the coupler no 20 Install puller plate P N 529 035 533 and extension handle P N 295 000 125 to PTO flywheel NOTE Puller plate can be used without the exten sion handle Loosen bolt no 22 retaining the PTO flywheel to the crankshaft using a suitable socket and breaker bar 1 Puller plate 2 Extension handle 3 Loosen bolt with socket and breaker bar Remove the P...

Page 99: ... assembly Reed Valve Remove both carburetor flanges 1 Carburetor flange Remove reed valves no 28 from crankcase Crankcase Before opening the bottom end remove the fol lowing parts magneto flywheel refer to MAGNETO SYSTEM subsection starter starter drive assembly reed valves air compressor cover Place engine upright on crankcase magneto side Loosen crankcase screws 1 M8 x 45 flanged screws 2 M10 x ...

Page 100: ...onnect the piston as described in ENGINE MANAGEMENT Crankshaft Bearing and Seal If a crankshaft end seal no 5 has to be replaced bottom end must be opened NOTE Do not needlessly remove crankshaft bear ings Remove end seal s TYPICAL 1 End seal To remove end bearings from crankshaft use the following tools 1 Puller P N 420 877 635 2 Protective cap P N 290 877 414 3 Distance ring P N 420 876 569 4 Ri...

Page 101: ...race an index mark Remove seals no 17 Remove bearing no 31 and washer no 32 Use a press to remove gear no 14 CLEANING Discard all oil seals gaskets O rings and sealing rings Clean oil passages and make sure they are not clogged Clean all metal components in a solvent Crankcase mating surfaces are best cleaned using a combination of the chisel gasket remover P N 413 708 500 and a brass brush Brush ...

Page 102: ...bled crankshaft it can become misaligned or deflected Crankshaft can be twist ed on center main journal changing timing of one cylinder in relation with the other 1 Main journal alignment here To accurately check if crankshaft is twisted on cen ter main journal proceed as follows Remove magneto housing cover Remove flywheel nut and magneto rotor Refer to MAGNETO SYSTEM for procedures Install Bomba...

Page 103: ...s worn bearing s bent and or disaligned crankshaft Proceed with the disassem bly of the engine Disassembled Engine The following verifications can be performed with the engine disassembled Crankcase Inspect plane surfaces for warpage Small defor mation can be corrected by grinding surface with a fine sandpaper Install sandpaper on a surface plate and rub part against oiled sand paper Bearing Inspe...

Page 104: ...side deflection in crankcase Remove crankshaft bearings and check deflection again on V shaped blocks as illustrated 1 Measuring MAG side deflection on V shaped blocks 1 Measuring PTO side deflection on V shaped blocks NOTE Crankshaft deflection cannot be correctly measured between centers of a lathe Connecting Rod Big End Axial Play MEASUREMENT MAG SIDE PTO SIDE Crankshaft deflection max 0 050 mm...

Page 105: ...t they can be inserted in end bearing Holding claws turn puller shaft clock wise so that claws open and become firmly tight against bearing Slide puller hammer outwards and tap puller end Retighten claws as necessary to always maintain them tight against bearing Continue this way until bearing completely comes out For installation see below in this section Reed Valve Check reed valve petals no 29 ...

Page 106: ...jection oil on all moving parts when re assembling the engine Crankshaft and Bearing Apply Loctite 767 anti seize on part of crankshaft where bearing fits Prior to installation place bearings no 4 into a container filled with oil previously heated to 75 C 167 F This will expand bearing and ease instal lation To properly position the outer bearing s a dis tance gauge must be temporarily installed a...

Page 107: ... align index marks previously traced Crankshaft and Counterbalance Shaft Install crankshaft no 3 first in crankcase After crankshaft installation install counterbal ance shaft no 13 Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears CAUTION Marks on the crankshaft and coun terbalance shaft must be aligned otherwise en gine will vibrate and premature wear wil...

Page 108: ...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 Loctite 5910 Usingthese productsornonsilicone based sealant over a previously sealed crankcase w...

Page 109: ... following sequence Starter Drive Bearing To install bearing no 23 of starter drive assembly use pusher P N 290 876 502 and handle P N 420 877 650 1 Handle 2 Pusher PTO Flywheel Apply Loctite 243 blue on bolt no 22 Using the same tools as for disassembly proce dure torque bolt no 22 to 115 N m 85 lbf ft Apply Loctite 648 on mating surface of PTO fly wheel and coupler Apply Loctite 243 blue to Alle...

Page 110: ... m 35 lbf ft 7 9 14 N m 124 lbf in 4 15 5 RTV sealant 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 Ultra Cooper sealant RTV sealant RTV sealant 10 4 N m 35 lbf in www SeaDooManuals net ...

Page 111: ...tuned pipe head from the tuned pipe cone using the following pro cedure The second procedure removes the tuned pipe without tuned pipe head and tuned pipe cone separation This procedure is explained further Tuned Pipe Removal with Separation from Tuned Pipe Head and Tuned Pipe Cone 1 Disconnect water return hose at tuned pipe head no 10 1 Water return hose 2 Disconnect small hose from water outlet...

Page 112: ...1 Water injection hose 4 Disconnect the water bleed hose 1 Water bleed hose 5 Loosen clamp no 1 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 1 F06E0AA 1 F06E0BA 1 F06D14A 1 F06D1SA www SeaDooManuals net ...

Page 113: ...lt 11 Remove tuned pipe head no 10 12 Loosen bolt no 6 of tuned pipe cone beside the engine water return hose 1 Loosen bolt 13 Remove tuned pipe cone no 5 14 Block exhaust opening in the manifold to keep debris from entering cylinder during threads cleaning procedure 15 Remove the stud no 21 from Y manifold 16 Use a M10 x 1 5 screw tap to clean the 4 threaded holes on the Y manifold and the 2 thre...

Page 114: ... head above the engine magneto then remove bolts retaining bracket to engine 1 Remove bolt Remove tuned pipe assembly Block exhaust opening in the manifold to keep de bris from entering cylinder during threads cleaning procedure Remove the stud no 21 from Y manifold Use a M10 x 1 5 screw tap to clean the 4 threaded holes on the Y manifold and the 2 threaded holes on tuned pipe Clean out the debris...

Page 115: ...us Test Use compressed air at 124 kPa 18 PSI to pres surize tuned pipe CAUTION Always ensure waterpassages are not blocked partially or completely while welding tuned pipe NOTE Prior to verify leaks plug all holes and pres surize tuned pipe while immerging it in water INSTALLATION Installation is essentially the reverse of removal procedures However pay particular attention to the following Exhaus...

Page 116: ...13 710 300 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 117: ...bf 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 118: ...Section 04 ENGINE DI Subsection 07 EXHAUST SYSTEM SMR2002 065_04_07A FM 04 07 9 Install exhaust hose 1 Torque clamp to 4 N m 35 lbf in 1 F06D14A www SeaDooManuals net ...

Page 119: ...VAL AND INSTALLATION 05 05 1 GENERAL 05 05 1 ENGINE REMOVAL 05 05 1 CLEANING 05 05 2 INSTALLATION 05 05 2 PTO HOUSING MAGNETO 05 06 1 GENERAL 05 06 2 PTO HOUSING 05 06 2 PTO SEAL 05 06 5 COUPLING 05 06 5 STATOR 05 06 6 ROTOR AND ENCODER WHEEL 05 06 7 RING GEAR 05 06 7 STARTER DRIVE ASS Y 05 06 8 LUBRICATION SYSTEM 05 07 1 GENERAL 05 07 3 OIL LEVEL VERIFICATION 05 07 3 ENGINE PRESSURE TEST 05 07 4 ...

Page 120: ...05 08 3 CAMSHAFT TIMING GEAR 05 08 6 TIMING CHAIN 05 08 8 CYLINDER HEAD 05 08 8 CAMSHAFT 05 08 10 VALVE SPRING 05 08 11 VALVE 05 08 12 ENGINE BLOCK 05 09 1 GENERAL 05 09 3 CRANKSHAFT LOCKING 05 09 3 CRANKSHAFT 05 09 3 TIMING CHAIN 05 09 8 CHAIN TENSIONER 05 09 8 BALANCER SHAFT 05 09 9 ENGINE BLOCK 05 09 11 PISTON CONNECTING ROD 05 09 17 PISTON RINGS 05 09 22 www SeaDooManuals net ...

Page 121: ...shaft refer to JET PUMP in PROPULSION SYSTEM coolant tank cap oil dipstick 1 Oil dipstick unplug ignition coil and pull it out spark plug from cylinder head NOTE Ignition coil may be used as an extractor 1 Ignition coil 2 Spark plug WARNING Prevent burning yourself due to handling on the hot engine WARNING Safety lanyard must be removed to prevent engine to be cranked while fuel rail is re moved t...

Page 122: ...ld the crankshaft in this position by using the im peller remover installer tool P N 529 035 820 and a wrench Install gauge adapter into previously cleaned spark plug hole Connect to adequate air supply NOTE Each tester will have specific instruction on the gauge operation and required pressure Set needle of measuring gauge to zero Supply combustion chamber with air 1 Measuring gauge 2 Adequate ad...

Page 123: ...ouches the spark plug hole After installation ensure the seal seats prop erly with the engine top surface General Engine Leakage Spray soap water solution at the indicated location and look and or listen for air bubbles Paying attention to the following checkpoints clamp s tightened coolant hoses air oil escaping from crankcase means damaged gasket s and or loosened screws refer to ENGINE BLOCK ai...

Page 124: ..._05_03A FM 05 03 1 INTAKE SYSTEM 0 4 TEC Engines R1503motr63S 10 N m 88 lbf in Loctite 243 10 N m 88 lbf in 6 N m 53 lbf in 10 N m 88 lbf in Loctite 243 6 N m 53 lbf in 18 N m 159 lbf in 10 N m 88 lbf in Loctite 243 Loctite 243 Oil Loctite 243 www SeaDooManuals net ...

Page 125: ...following illustration to see it 1 Other lock tab under tube Unlock coolant expansion tank pull out then move away Step Push tab each side to release Step Pull tank out Remove vent tube support NOTE Pay attention not to drop the nuts under support when removing screws 1 Vent tube support 2 Remove retaining screws 3 Pay attention to nuts underneath Remove oil dipstick Pull fuel rail cover out Disco...

Page 126: ...lve OSPS TPS idle bypass valve engine connector CTS CAPS KS CPS magneto OPS and EGT 1 Ignition coils 2 TOPS 3 TPS hidden behind throttle body 4 Idle bypass valve 5 Engine connector 6 KS 7 CPS 8 Magneto 9 B Kostal connector 10 OSPS For the TOPS valve connector refer to the follow ing illustration 1 Push here and hold while pulling connector out WARNING Always disconnect battery cables exactly in th...

Page 127: ...OPS valve then move away to access the TPS connector Slightly pry locking tab of connector to unlock 1 TOPS hose disconnected and moved away 2 TPS connector 3 Slightly pry tab to unlock 1 CTS connector 1 CAPS connector 1 EGT connector 1 Oil filter housing 2 OPS R1503motr75A 1 3 2 1 R1503motr64A 1 R1503motr65A 1 R1503motr66A 1 F18D0BA 2 www SeaDooManuals net ...

Page 128: ...ay from intake manifold Slacken air intake silencer collar Unlock throttle cable housing from throttle body Cable is to be detached further 1 Air intake silencer collar 2 Unlock throttle cable housing Remove 7 retaining screws and push the oil dip stick tube out of the manifold slot Lift intake manifold up to pull it out of the mount ing brackets just enough to reach throttle cable end 1 R1503motr...

Page 129: ...ar attention to the following CAUTION Do not modify air intake system otherwise calibration will be affected Air Intake manifold Ensure that all gaskets are properly installed and in a good condition INTAKE MANIFOLD 1 Gaskets First position intake manifold on front mounting bracket then push manifold toward engine to thus allow proceeding with rear mounting bracket When installing the intake manif...

Page 130: ... manifold screws Torque them to 10 N m 88 lbf in follow ing the tightening sequence shown Ensure to properly route and resecure wiring har ness with locking ties WARNING Always check O ring for damage such as defor mation at reinstallation Replace the O ring if it is damaged R1503motr59B 1 5 R1503motr210A 3 1 2 6 7 4 www SeaDooManuals net ...

Page 131: ...T SYSTEM SMR2002 068_05_04A FM 05 04 1 EXHAUST SYSTEM 0 9 Loctite 296 11 N m 97 lbf in 8 3 11 2 4 1 5 15 16 6 14 17 15 15 12 7 10 8 N m 71 lbf in 16 N m 142 lbf in 4 N m 35 lbf in 4 N m 35 lbf in Silicone sealant 13 F18D0HS www SeaDooManuals net ...

Page 132: ...between muffler LH no 6 and the exhaust pipe no 1 1 Exhaust hose clamp 2 Exhaust pipe Loosen both exhaust hose clamps no 15 and re move the exhaust hose no 16 between the muf fler LH and the muffler RH 1 Hose clamp 2 Exhaust hose Detach the strap no 11 from the muffler LH using the spring installer remover P N 529 035 559 WARNING Certain components in the engine compartment maybeveryhot Directcont...

Page 133: ...pe Move muffler LH no 6 backward enough to allow the exhaust pipe to be pulled out Squeezetheexhausthoseno 7goingtotheexhaust outlet with one hand and withdraw the exhaust pipe no 1 from the exhaust manifold 1 Exhaust pipe 2 Squeeze this hose to ease removal of pipe Apply sealant P N 413 710 200 on the welds of the exhausttube whiletheexhaustpipeisremovedfrom the muffler LH 1 Sealant P N 413 710 2...

Page 134: ...mp no 5 to the top portion of the hose Thetwoclampsmustbeseparatedby3 5 mm 1 8 3 16 in and the screws must be at least 25 mm 1 in apart 1 Exhaust pipe step 2 Exhaust hose 3 Exhaust hose clamp Pre align the exhaust pipe no 1 by rotating axially and moving longitudinally the muffler LH so that the exhaust pipe flange makes perfect contact with the engine manifold 1 Engine manifold 2 Exhaust pipe fla...

Page 135: ...when engine is running Test run the engine while supplying water to the flushing connector EXHAUST MANIFOLD Removal Disconnect the cooling hoses no 2 and no 3 from the exhaust pipe no 1 Remove the exhaust clamp no 4 and detach the muffler LH from its support Move the muffler LH no 6 rearwards to separate the exhaust pipe from the manifold See above in EXHAUST PIPE Disconnect the cooling system sup...

Page 136: ...ON Never run engine without supplying water to the exhaust cooling system when water craft is out of water After installation ensure there is no coolant or ex haust gas leak when the engine is running Test run the engine while supplying water to the flushing con nector MUFFLER LH Removal Remove the exhaust pipe no 1 See above Disconnect the temperature sensor connector Disconnect the outlet hose 1...

Page 137: ...tach the strap no 12 from the muffler RH using the spring installer remover P N 529 035 559 1 Muffler RH 2 Strap 3 Spring installer remover Carefully pull out the muffler RH no 10 Inspection Inspect parts condition paying attention for cracks or other damage Check hoses Replace any defective part Installation Installation is thereverseofthe removal procedures After installation ensure there is no ...

Page 138: ... no 14 together Detach the adapter no 14 from the exhaust hose no 7 Inspection Inspect parts condition paying attention for cracks or other damage Check hose Replace any defective part Installation Installation is essentially the reverse of the removal procedures However pay particular attention to the following Apply Loctite silicone sealant P N 293 800 086 on the adapter flange to seal the bilge...

Page 139: ...section Jet Pump Removal To withdraw jet pump refer to PROPULSION section CAUTION Whenever removing engine from watercraft engine jet pump alignment must be performed at reinstallation Drive System To withdraw drive shaft refer to PROPULSION section Cooling System To remove cooling system hoses refer to COOL ING SYSTEM section Exhaust Pipe To remove exhaust pipe refer to EXHAUST SYS TEM in ENGINE ...

Page 140: ... of Remaining Components Disconnect RED positive cable from starter post TYPICAL 1 Disconnect RED positive cable Carry on engine lifting to remove from the body opening CAUTION Be careful not to scratch body or to hit any component CLEANING Wipe off any spillage in bilge Clean with a bilge cleaner Clean external parts of engine INSTALLATION Installation of engine in watercraft is essentially the r...

Page 141: ...ectric grease on nut Engine Jet Pump Alignment Alignment is necessary to eliminate possible vi bration and or damage to components Check alignment of engine using the following alignment tools Support plate kit P N 529 035 506 NOTE Use plate P N 529 035 508 for the 139 5 mm 5 1 2 in jet pump and plate P N 529 035 507 for the 155 6 mm 6 1 8 in jet pump 1 Plate 2 Support Alignment shaft P N 295 000 ...

Page 142: ...ment adapter 2 Alignment shaft If the alignment is incorrect loosen engine support screws to enable to align engine alignment adap tor with shaft end NOTE Use shim s P N 270 000 024 or P N 270 000 025 as necessary between engine supports and rubber mounts to correct alignment TYPICAL 1 Shim CAUTION Whenever shims are used to correct alignment never install more than 5 mm 0 196 in shim thickness En...

Page 143: ... its installation properly adjust throttle cable as specified in ENGINE MANAGEMENT Check hose condition and pressure test fuel sys tem refer to FUEL SYSTEM section Verify all electrical connections Run engine and ensure there is no leakage CAUTION If watercraft is out of water engine must be cooled using the flush kit 1 F18D13A 1 F18D14A WARNING Whenever doing any type of repair on water craft or ...

Page 144: ...n 30 N m 22 lbf ft Multi purpose grease 9 24 N m 17 lbf ft 15 14 16 Loctite 243 17 19 20 21 Loctite 5910 Loctite 243 Engine oil Engine oil Loctite 243 Engine oil Loctite 243 10 N m 88 lbf in 18 Loctite anti seize Engine oil 12 250 N m 184 lbf ft 13 10 N m 88 lbf in 8 7 6 Engine oil 18 N m 159 lbf in 12 N m 106 lbf in Loctite 243 5 4 10 N m 88 lbf in 10 11 Engine oil 22 Loctite 243 R1503motr57S www...

Page 145: ...ew 2 Gasket ring 3 Chain tensioner Remove valve cover Refer to CYLINDER HEAD AND VALVES subsection A tube is to be inserted to siphon oil out of PTO housing To ensure tube will be inserted far in enough measure 381 mm 15 3 8 in from tube end the end that will be inserted in engine and trace a mark or put tape on the tube at this loca tion Insert the tube along timing chain as shown until you reach...

Page 146: ... that starter gear disc springs no 6 and washer no 7 do not fall down PTO housing no 5 CAUTION Ensure to use prying lugs to sepa rate PTO housing to prevent damaging contact surface 1 Disc springs 2 Washer 3 Starter drive gear gasket no 9 Inspection Check PTO housing for cracks or other damages Replace if necessary Installation NOTE Clean all metal component in a non ferrous metal cleaner For inst...

Page 147: ...nt 1 Pay attention that gasket remains properly positioned on this surface Refer to the following illustration for proper instal lation of screws 1 Screws M6 x 35 2 Screws M6 x 85 Tightening sequence for screws on PTO housing is as per following illustration Reinstall LH engine support Apply Loctite 243 blue on screw threads then torque to 24 N m 17 lbf ft Remove block under engine Properly reinst...

Page 148: ... the Pul ley flange cleaner P N 413 711 809 to prevent oil stains Remove Oetiker clamp no 11 located close to the PTO housing jet pump refer to JET PUMP in PROPULSION SYSTEM drive shaft refer to DRIVE SYSTEM in PRO PULSION SYSTEM PTO seal no 22 1 Oetiker clamps 2 PTO seal Installation Reinstall removed parts in the reverse order COUPLING Removal Lock crankshaft with locking tool P N 529 035 821 Re...

Page 149: ...ate no 14 with CPS no 15 1 CPS screws 2 Holding plate 3 CPS screws no 16 stator no 17 1 Stator screws 2 Stator Inspection Check stator and CPS condition If damaged re place the faulty part For electrical inspection refer to CHARGING SYS TEM for the stator and to ENGINE MANAGE MENT for the CPS Installation For installation reverse the removal procedure However pay attention to the following NOTE Th...

Page 150: ...th and encoder wheel condi tion If damaged replace faulty part Installation For installation reverse the removal procedure However pay attention to the following Encoder wheel position has to be located with the location pin on the crankshaft gear IMPORTANT If rotor has balancing holes never install it so that they are inside the large gap be tween encoder wheel teeth This would create a non start...

Page 151: ...owing Ring gear and encoder wheel position has to be lo cated with the location pin on the crankshaft gear 1 Location pin 2 Location pin holes Apply Loctite 243 on threads Torque rotor screws to 24 N m 17 lbf ft STARTER DRIVE ASS Y Removal Remove PTO housing and ring gear as described above starter drive ass y no 8 1 Starter drive ass y CAUTION Be careful not to lose the distance washer disc sprin...

Page 152: ... the removal procedure However pay attention to the following Apply some Isoflex Topas NB52 grease P N 293 550 021 on the starter drive bearing located in the engine block and on the starter drive support in the PTO housing cover 1 Starter drive bearing 1 Starter drive support CAUTION Be sure not to forget the distance washer disc springs and washer on the starter drive shaft when assembling 1 R15...

Page 153: ...8 lbf in 10 N m 88 lbf in 28 N m 21 lbf ft Multi purpose grease 24 N m 17 lbf ft Loctite 5910 Loctite 243 Engine oil Engine oil Loctite 243 Engine oil Loctite 243 10 N m 88 lbf in 10 N m 88 lbf in 18 N m 159 lbf in 12 N m 106 lbf in Loctite 243 10 N m 88 lbf in Loctite 243 Loctite 243 1 2 3 4 19 20 25 26 5 18 17 16 15 39 23 24 22 21 6 33 31 32 R1503motr112S www SeaDooManuals net ...

Page 154: ... m 88 lbf in 18 N m 159 lbf in Loctite 243 10 N m 88 lbf in Loctite 243 10 N m 88 lbf in 11 10 10 N m 88 lbf in 5 25 N m 44 221 lbf in Horizontal to exhaust side 9 Loctite 243 Loctite 243 10 N m 88 lbf in Loctite 243 8 Loctite 243 10 N m 88 lbf in Loctite 243 13 14 Loctite 243 10 N m 88 lbf in 18 N m 159 lbf in R1503motr113S Oil Oil Oil Oil Oil Oil Oil 29 30 7 www SeaDooManuals net ...

Page 155: ... Never run engine without supplying water to the exhaust cooling system when wa tercraft is out of water 2 If out of water raise trailer tongue and block in position when bumper rail is level Install a gar den hose to the flushing connector Refer to Flushing in MAINTENANCE and follow the pro cedures CAUTION Failure to flush exhaust cooling sys tem when engine is out of water may severely damage en...

Page 156: ...ssure at different RPM as per following table 1 Oil filter housing 2 Pressure test plug NOTE Oil pressure switch works between 180 kPa 26 PSI and 220 kPa 32 PSI The engine oil pressure should be within the follow ing values If the engine oil pressure is out of specifications check the points described in TROUBLESHOOT ING section Reinstall plug Oil change Engine in vehicle NOTE If water is found in...

Page 157: ... siphon tube out of dipstick hole then crank engine do not start while in engine drown mode fully depress throttle lever and HOLD then crank engine Crank engine for 10 seconds Siphon oil again Re peat the crank siphon cycle 2 3 times Engine removed There are two separate drain plugs on the engine One is located in the lower crankcase half and the other one in the PTO housing 1 Drain plugs Place a ...

Page 158: ...w O ring change if necessary Check and clean the oil filter inlet and outlet area for dirt and other contaminations 1 Inlet bore from the oil pump to the oil filter 2 Outlet bore to the engine oil providing system Installation The installation is the opposite of the removal pro cedure Pay attention to the following details Install a new oil filter Install O ring on oil filter cover Torque oil filt...

Page 159: ... and clean the oil outlet area for dirt and oth er contaminants 1 Oil inlet to the oil pump Installation For installation reverse the removal procedure Refill engine at the proper level with the recom mended oil Refer to TECHNICAL DATA for capacity and OIL LEVEL VERIFICATION above for procedure Suction Pump Oil strainer Removal Remove blow by ventilation hose no 7 1 Blow by ventilation hose Discon...

Page 160: ...nspection Clean oil strainer with a part cleaner then use an air gun to dry it Inspect rubber rings no 13 and no 14 1 O ring 2 Rubber ring gasket If rubber rings are brittle cracked or hard replace them Clean both contact surfaces of oil strainer cover Check and clean the oil inlet and outlet area for dirt and other contaminations 1 Oil inlet to the oil pump WARNING Wear safety glasses and work in...

Page 161: ...lator is located on the bottom of the PTO housing 1 Oil pressure regulator NOTE The oil pressure regulator system opens when the oil pressure exceeds 400 kPa 58 PSI Removal Remove engine oil refer to OIL CHANGE oil pressure regulator plug no 15 compression spring no 16 valve piston no 17 and valve pis ton guide no 18 1 Valve piston guide 2 Valve piston 3 Compression spring 4 Oil pressure regulator...

Page 162: ...in place Torque plug screw to 12 N m 106 lbf in maxi mum Apply Loctite 243 on threads OIL PRESSURE PUMP The oil pressure pump is located in the PTO hous ing and is driven by the balance shaft Removal Remove engine oil refer to OIL CHANGE PTO housing refer to PTO HOUSING MAGNETO section Coolant pump housing no 19 and impeller no 20 refer to COOLING SYSTEM section screws no 21 oil pump cover no 22 1...

Page 163: ...eck oil pump housing and cover and replace if damaged 1 Pittings on the teeth Using a feeler gauge measure the clearance be tween inner and outer rotors 1 Outer rotor 2 Inner rotor If clearance between inner and outer rotors ex ceeds the tolerance replace coolant oil pump shaft assembly Ensure to also check oil pump housing and cover and replace if damaged If clearance between outer rotor and its ...

Page 164: ...ck the inside of oil pump housing and its cover for scoring or other damages and replace if dam aged Installation For installation reverse the removal procedure Pay attention to the following details NOTE Never use oil in the press fit area of the ro tary seal Push coolant oil pump shaft seal in place by using thumb 1 Oil seal Install the new rotary seal by using the rotary seal pusher P N 529 035...

Page 165: ...ide of the engine at the bottom of the oil separator Removal Remove blow by ventilation hose no 7 1 Blow by ventilation hose Disconnect wiring harness from blow by pres sure switch no 9 and blow by valve no 8 Detach air silencer from throttle body Disconnect battery cables and vent tube then remove battery Refer to BATTERY in CHARG ING SYSTEM section for proper procedures Remove retaining screws n...

Page 166: ...eck oil pump housing and cover and replace if damaged 1 Pittings on the teeth Using a feeler gauge measure the clearance be tween inner and outer rotors 1 Outer rotor 2 Inner rotor If clearance between inner and outer rotors ex ceeds the tolerance replace oil pump shaft as sembly Ensure to also check oil pump housing and cover and replace if damaged If clearance between outer rotor and its bore in...

Page 167: ...earance of the oil pump shaft assembly increases the oil pressure de creases Check the inside of oil pump housing and its cover for scoring or other damages and replace if dam aged Installation For installation reverse the removal procedure Pay attention to the following details 1 Screws M6 x 85 2 Screws M6 x 25 Torque oil pump cover screws to 10 N m 88 lbf in Tighten suction pump screws as per fo...

Page 168: ... length Replace parts if important wear or damage are present Clean bore and threads in the PTO housing from metal shavings and other contaminations Installation For installation reverse the removal procedure Pay attention to the following details Torque plug screw to 28 N m 21 lbf ft Apply Loc tite 243 blue on threads OIL COOLER The oil cooler is located below the air intake man ifold 1 Oil coole...

Page 169: ...sconnect wiring harness from blow by valve no 8 and blow by pressure switch no 9 Detach air silencer box from throttle body Disconnect battery cables and vent tube then remove battery Refer to BATTERY in CHARG ING SYSTEM section for proper procedures Remove retaining screws no 42 Place rags under cover to prevent spillage If spillage occurs clean immediately with the pul ley flange cleaner P N 413...

Page 170: ... surfaces of oil separator Check and clean the oil and blow by channels for dirt and other contaminations Installation For installation reverse the removal procedure Pay attention to the following details 1 Screws M6 x 25 2 Screws M6 x 85 Apply grease on O rings and rubber rings Torque screws to 10 N m 88 lbf in Apply Loctite 243 blue on threads 1 R1503motr119A 2 www SeaDooManuals net ...

Page 171: ... ft 120 90 10 N m 88 lbf in Loctite 243 Engine oil 4 5 10 11 10 1 6 8 Loctite 243 10 N m 88 lbf in Engine oil 17 18 19 Loctite 243 10 N m 88 lbf in 26 27 Engine oil 20 Loctite 243 10 N m 88 lbf in 9 18 N m 159 lbf in 24 23 28 29 30 16 2 10 N m 88 lbf in 18 N m 159 lbf in 6 N m 53 lbf in 21 Engine oil 15 13 10 N m 88 lbf in 6 N m 53 lbf in Grease Klueber Isoflex Topas NB52 7 Loctite 243 14 12 25 22...

Page 172: ...could be the cause and it will be easy to know which one among the springs is the cause to replace it if you grouped them at disassembly Besides since used parts have matched together during the engine operation they will keep their matched fit when you reassemble them together within their group SPARK PLUG Removal Remove fuel rail cover from engine Unplug the single spark ignition coil connector ...

Page 173: ...ile sealing ring or the valve cover screw accord ingly Installation For installation reverse the removal procedure NOTE Install the valve cover screws according to following sequence Torque screws first to 40 N m 29 lbf ft and in a second sequence to 55 N m 40 lbf ft ROCKER ARM Removal Lock crankshaft with crankshaft locking tool P N 529 035 821 refer to CRANKSHAFT LOCK ING in ENGINE BLOCK section...

Page 174: ... to the valve adjustment Inspection Spark Plug Tube Check seals on spark plug tube If seals are brittle cracked or hard replace spark plug tube 1 Spark plug tube 2 Seal to the valve cover 3 Seal to the cylinder head Rocker Arm Inspect each rocker arm for cracks and scored fric tion surfaces If so replace rocker arm assembly Check the rocker arm rollers for free movement wear and excessive radial p...

Page 175: ...ion reverse the removal procedure Pay attention to the following details Apply engine oil on rocker arm shaft IMPORTANT The rocker arm shaft can only be installed in one specific position Therefore crank shaft as well as camshaft has to be positioned with their locking pins when the piston of cylinder no 3 is on ignition TDC Refer to CRANKSHAFT LOCKING in ENGINE BLOCK section for crank shaft and t...

Page 176: ...use new screws at assembly Failure to replace screws and to strictly follow the torque proce dure may cause screws to loosen and lead to engine damage Torque screws at first to 10 N m 88 lbf in ac cording to following sequence Torque screws to 20 N m 177 lbf in Finish tightening screws turning an additional 90 rotation with a torque angle gauge 1 Rocker arm shaft screw 2 Torque angle gauge CAMSHAF...

Page 177: ... reverse the removal procedure Pay attention to the following details Using the camshaft locking tool P N 529 035 839 lock camshaft on TDC position 1 Camshaft locking tool 2 Camshaft on TDC position Install the camshaft timing gear with the writing visible i e to be able to see the position lines when looking from outside of engine 1 Good with 1503 aligned 2 Never Install timing chain Refer to ENG...

Page 178: ...nt refer to COOLING SYSTEM Disconnect coolant temperature and cam position sensors CTS and CAPS Remove exhaust manifold refer to EXHAUST MANI FOLD REMOVAL elsewhere in this section engine coolant outlet hose 1 Blow by ventilation hose coolant hose 1 Blow by ventilation hose chain tensioner refer to CHAIN TENSIONER REMOVAL in ENGINE BLOCK section valve cover shield valve cover and profile sealing r...

Page 179: ... gasket Using a gasket twice will cause engine damage even if the engine had not run Install cylinder screws M11 no 17 Torque screws as per following procedure CAUTION This assembly use stretch screws As the screws have been stretched from the previous installation it is very important to measure each screw at assembly If screw is out of specification replace by a new Failure to replace screws and...

Page 180: ...ease the camshaft bearing journals well by us ing the grease Klueber Isoflex P N 293 550 021 or a similar product Install camshaft then place the camshaft lock no 20 in the slot 1 2 R1503motr101A A R1503motr102A B C D A C A B C A C A B C A CAMSHAFT LOBE EXHAUST VALVE NEW MINIMUM 31 699 mm 1 248 in NEW MAXIMUM 31 809 mm 1 252 in SERVICE LIMIT 31 670 mm 1 247 in CAMSHAFT LOBE INTAKE VALVE NEW MINIMU...

Page 181: ...ve spring compressor clamp P N 529 035 724 and valve spring compressor cup P N 529 035 725 1 Valve spring compressor clamp 2 Valve spring compressor cup LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters no 24 WARNING Always wear safety glasses when disassem bling valve springs Be careful when unlock ing valves Components could fly away be cause of the strong spring p...

Page 182: ...verse the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top NOTE Valve cotters must be properly engaged in valve stem grooves 1 Position of the valve spring VALVE Removal Remove valve spring Push valve stem then pull valves no 26 and no 27 out of valve guides 1 Intake valve 38 mm 2 Exhaust valve 31 mm Remove valve stem seal no 28 with s...

Page 183: ...and Valve Guide Clearance Measure valve stem and valve guide in three places using a micrometer and a small bore gauge NOTE Clean valve guide to remove carbon depos its before measuring Change valve if valve stem is out of specification or has other damages such as wear or friction sur face A Valve stem diameter R610motr125A VALVE STEM DIAMETER mm in NEW MINIMUM Exhaust 5 946 mm 2341 in Intake 5 9...

Page 184: ...tion of contact area should be in center of valve seat Measure valve seat width using a caliper If valve seat contact width is too wide or has dark spots replace the cylinder head A Valve face contact width B Valve seat contact width Installation For installation reverse the removal procedure Pay attention to the following details Install thrust washer no 30 valve spring guide no 29 then valve ste...

Page 185: ...aling lips of valve stem seal 1 Sealing lips of valve stem seal To ease installation of cotters apply oil or grease to them so that they remain in place while releas ing the spring After spring is installed ensure it is properly locked by tapping on valve stem end with a soft hammer so that valve opens and closes a few times CAUTION An improperly locked valve spring will cause engine damage 2 R150...

Page 186: ...ngine oil Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Engine oil Engine oil 24 N m 17 lbf ft 18 N m 159 lbf in 24 N m 17 lbf ft 24 N m 17 lbf ft 10 N m 88 lbf in 24 N m 17 lbf ft 10 N m 88 lbf in 18 N m 159 lbf in 18 N m 159 lbf in 24 N m 17 lbf ft 24 N m 17 lbf ft 21 22 20 18 3 2 1 7 17 16 19 40 N m 30 lbf ft 55 N m 41 lbf ft Grease www SeaDooManuals net ...

Page 187: ...otr02S 8 9 10 8 12 11 13 5 14 15 15 6 4 4 Engine oil 45 N m 33 lbf ft 90 260 N m 191 lbf ft Loctite anti seize Engine oil Engine oil Engine oil Engine oil 6 Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil www SeaDooManuals net ...

Page 188: ... and vent tube support air intake manifold refer to AIR INTAKE MANI FOLD REMOVAL in ENGINE section fuel rail cover spark plugs plug screw 1 Plug screw 2 Gasket ring Put a screwdriver or similar into the spark plug hole of cylinder no 3 and feel when the piston reaches TDC 1 Screwdriver In this position the crankshaft can be locked by using crankshaft locking tool P N 529 035 821 When finished rein...

Page 189: ...crews no 3 and no 7 BOTTOM VIEW OF ENGINE 1 Screws bottom engine block half connecting rod screws 1 Connecting rod screws NOTE Before removing the connecting rod bear ing caps mark them to remember the right posi tion when reassembling 1 Mark on connecting rod thrust washers no 4 1 Thrust washer 1 R1503motr05A 1 R1503motr06A 1 R1503motr08A R1503motr07A 1 R1503motr09A 1 www SeaDooManuals net ...

Page 190: ...ace of connecting rod and crankshaft counterweight If the distance exceeds specified tolerance replace the worn part 1 Crankshaft 2 Feeler gauge Crankshaft Radial Play Measure all crankshaft journals Compare to inside diameter of crankshaft bushings elsewhere in this section 1 Micrometer 2 Crankshaft area for bushing 1 R1503motr10A R1503motr11A 1 2 CONNECTING ROD BIG END mm in NEW MINIMUM 0 150 mm...

Page 191: ...s on crankshaft and bal ance shaft 1 Groove on balance shaft 2 Groove on crankshaft For correct installation of the connecting rods refer to CONNECTING ROD INSTALLATION elsewhere in this section CAUTION It is absolutely necessary to follow this procedure Otherwise several engine dam age can occur CAUTION Never forget thrust washers no 4 for axial adjustment on crankshaft center CRANKSHAFT JOURNAL ...

Page 192: ...ewhere in this section for proper procedure to clean surfaces apply Loctite 5910 and proper torquing sequence Install the crankshaft cover before mounting the engine bracket Put some oil on O ring and press the cover in The crankshaft cover has to be even with the engine block surface 1 O ring 2 Crankshaft cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to put crankshaft i...

Page 193: ...se of the re moval procedure but pay attention to the follow ing details Ensure to perform proper valve timing Lock crank shaft and camshaft at TDC refer to CYLINDER HEAD Install chain then install chain tension CAUTION Improper valve timing will damage engine components CHAIN TENSIONER Removal NOTE Removal of the air intake manifold allows easier access to the chain tensioner but is not necessary...

Page 194: ...REMOVAL in PTO HOUSING MAGNETO section starter gear refer to STARTER GEAR REMOV AL in PTO HOUSING MAGNETO section starter drive ass y oil suction pump with oil separator ass y refer to SUCTION PUMP REMOVAL in LUBRICA TION section engine mounting brackets oil tank plug screws no 1 with O ring no 2 ENGINE UPSIDE DOWN 1 Oil tank plug screw with O ring engine block screws no 3 1 Screws bottom engine b...

Page 195: ...or installation reverse the removal procedure Pay attention to following detail CAUTION Balance shaft has to be aligned with crankshaft Grooves on crankshaft and balance shaft 1 Groove on balance shaft 2 Groove on crankshaft CAUTION Never forget thrust washers no 6 for axial adjustment on balance shaft PTO side Insert thrust washers as soon as balance shaft is in place according to following illus...

Page 196: ...C position before installing the camshaft and rock ers refer to CYLINDER AND HEAD 1 Crankshaft locking tool ENGINE BLOCK Removal Remove engine oil refer to OIL CHANGE in LUBRICA TION section engine from vehicle refer to REMOVAL AND INSTALLATION cylinder head refer to CYLINDER HEAD RE MOVAL in CYLINDER HEAD section PTO housing refer to PTO HOUSING REMOVAL in PTO HOUSING MAGNETO section starter gear...

Page 197: ...ft clock wise so that claws open and become firmly tight against bearing Slide puller hammer outwards and tap puller end Retighten claws as necessary to always maintain them tight against bearing Continue this way until bearing completely comes out Inspection Cylinder Check cylinder for cracks scoring and wear ridges on the top and bottom of the cylinder If so replace cylinder Cylinder Taper Measu...

Page 198: ... balance shaft bushings no 15 both engine block halves with OLD bush ings have to be screwed together according to tightening procedure described below Measure the inside diameter of the bushings with a radial gauge ENGINE UPSIDE DOWN 1 Radial gauge ENGINE UPSIDE DOWN 1 Radial gauge Replace bushings if they are out of specifications CYLINDER TAPER IN DIAMETER mm in NEW MAXIMUM 0 038 mm 001 in SERV...

Page 199: ...as they were before Put bushings correctly in place Top crankshaft bushing halves have a bore which has to be placed in the upper engine block 1 Upper engine block half 2 Oil bore in engine block 3 Oil bore in bushing Bushings have to be even with the engine block split surface and their protrusions have to fit in the notched areas in the engine block seat 1 Bushing protrusion in engine block notc...

Page 200: ...Do not use Loctite 515 or 518 to seal crankcase Do not use Loctite Primer N with the Loctite 5910 Using these products or non sili cone based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor ad hesion and possibly a leaking crankcase These products are chemically incompatibles Even af ter cleaning the Loctite 5910 would leave incom patible microscopic particles Use a ...

Page 201: ...ankshaft cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to put crankshaft in TDC position before installing the camshaft and rockers refer to CYLINDER AND HEAD 1 Crankshaft locking tool Install cylinder head PTO housing and the other parts in accordance with the proper installation procedures CRANKSHAFT AXIAL CLEARANCE mm in NEW MINIMUM 0 08 mm 003 in NEW MAXIMUM 0 22 mm ...

Page 202: ...ling Pull piston with connecting rod out of the cylin ders Remove one piston circlip no 8 and discard it 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin no 9 out of piston 1 Piston 2 Piston pin 3 Circlip Detach piston no 10 from connecting rod Inspection Connecting Rod Piston Pin Clearance Measure piston pin Compare to inside diameter...

Page 203: ... Do the torque procedure as described below A Connecting rod big end bushing Use NEW bushings no 12 when connecting rod big end diameter is out of specification CONNECTING ROD SMALL END DIAMETER mm in NEW MINIMUM 23 01 mm 9059 in NEW MAXIMUM 23 02 mm 9063 in SERVICE LIMIT 23 07 mm 908 in PISTON PIN DIAMETER mm in NEW MINIMUM 22 996 mm 9053 in NEW MAXIMUM 23 000 mm 9055 in SERVICE LIMIT 22 990 mm 9...

Page 204: ...o the dimension adjust a cylinder bore gauge to the micrometer dimen sion and set the indicator to 0 zero 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge 62 mm 2 44 in above cylinder base measuring perpendicularly 90 to piston pin axis Read the measurement on the cylinder bore gauge The result is the exact piston ...

Page 205: ...learance Measure inside diameter of connecting rod 1 Bore gauge 2 Connecting rod Replace connecting rod if diameter of connecting rod small end is out of specifications Refer to CRANKSHAFT AND BALANCER SHAFT for removal procedure of connecting rod Installation For installation reverse the removal procedure Pay attention to the following details Apply engine oil on the piston pin Insert piston pin ...

Page 206: ...it surface of the connecting rod 3 Protrusion of bushing in line with connecting rod groove Torque NEW connecting rod screws no 11 as per following procedure Install screws and torque to 45 N m 33 lbf ft Do not apply any thread locker product Finish tightening the screws with an additional 90 turn using an angle torque wrench CAUTION Failure to strictly follow this proce dure may cause screw to lo...

Page 207: ...Installation For installation reverse the removal procedure Pay attention to the following details Install the oil scraper ring first then the taper face ring with the word TO facing up then the rectan gular ring with the word T facing up 1 Rectangular ring 2 Taper face ring 3 Oil scraper ring RING PISTON GROOVE CLEARANCE mm in NEW MINIMUM RECTANGULAR 0 025 mm 001 in TAPER FACE 0 015 mm 0006 in OI...

Page 208: ...reakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after installation Space the piston ring end gaps 120 apart and do not align the gaps with the piston pin bore or the thrust side axis 1 DO NOT align ring gap with piston trust side axis 2 DO NOT align ring gap with piston pin bore axis A 120 A31C2OA 1 2 A A A www SeaDooManuals net ...

Page 209: ...SSURE 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 06 03 22 CRANKSHAFT POSITION SENSOR CP...

Page 210: ...2 SMR2002 095_06 01ATOC FM DIAGNOSTIC PROCEDURES 06 04 1 GENERAL 06 04 1 DESS SYSTEM 06 04 1 FAULT DETECTION AND COMPENSATORY ACTIONS 06 04 3 COMPONENT FAILURE WARNING SYSTEM 06 04 3 VCK VEHICLE COMMUNICATION KIT 06 04 5 DI SYSTEM FAULT CODES 06 04 6 www SeaDooManuals net ...

Page 211: ...Section 06 ENGINE MANAGEMENT DI Subsection 02 OVERVIEW SMR2002 074_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: ...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 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 w...

Page 220: ...y 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 the old ...

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 THROT TLE POSITION SENSO...

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 sealant on idle set screw head 1 Plastic ca...

Page 226: ...ss 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 after...

Page 227: ... work ing adequately If pressure 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 oth...

Page 228: ...s position Remove top end as explained above Remove access plug of air compressor 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 R...

Page 229: ...ston 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 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 sh...

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: ...t is not leaking then replace fuel pressure regulator NOTE 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 in...

Page 232: ... lanyard must be on DESS post Using the vehicle communication 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 valida...

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: ...am it is recom mended to replace it 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 ...

Page 236: ...re the pressure relief valve is installed on the fuel pump return line side 1 Fuel pump outlet hose fuel filter side 2 Fuel pump return line 3 Fuel relief valve on the return line side 4 Pressure gauge between disconnected hose inline 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 fi...

Page 237: ...26 If wiring harness is good try a new MPEM Refer to MPEM REPLACEMENT procedures elsewhere in this section Otherwise repair the wiring harness connectors between AMP plug connector and fuel pump Fuel Pump Replacement Removal Open front storage compartment cover Remove the storage basket Remove glove box see HULL BODY section Remove front vent tubes From glove box opening remove fuel pump retain in...

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: ...epancy 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 Voltage Test Both TPS Check the voltage output from MPEM...

Page 241: ... in this section 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...

Page 242: ...first ensure information center is in tachometer mode If it displays ap proximately 300 RPM the CPS circuitry is properly working Otherwise validate the information center is working by activating the tachometer using the software B U D S under Activation first ensure information center is in tachometer mode If it does not display 3000 RPM the information cen ter may be faulty and needs to be test...

Page 243: ... the voltage readings on the harness side as follows If voltage tests good the CPS is defective and needs replacement If voltage does not test good perform the follow ing tests Resistance Test Check the continuity of the wiring harness Disconnect the AMP 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 C...

Page 244: ...resistance value be tween terminals 16 and 19 If resistance value is correct try a new MPEM Re fer to MPEM REPLACEMENT procedures else where in this section If resistance value is incorrect repair the wiring harness connectors between AMP 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 righ...

Page 245: ...xpected sensor range at idle when it reads the atmospheric pressure Ensure the cor rect connector is plugged and not mixed with the MAG TPS Remove sensor and check for oil or dirt on its end and if problem persists check throttle plate condition position and the wiring harness Perform the following tests Voltage Test Check the voltage output from MPEM to the mani fold air pressure sensor MAPS Disc...

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

Page 248: ...is correct try a new MPEM Refer to MPEM REPLACEMENT procedures elsewhere in this section If resistance value is incorrect repair the wiring harness connectors between AMP 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 ...

Page 249: ...below Measure resistance of the high tension leads They must be as follows Otherwise replace the lead NOTE It is not necessary to remove the spark plug cap IMPORTANT Always replace leads with genuine parts Otherwise fuel injection system operation may be impaired Check continuity between ignition coil ground cir cuits and engine Dynamic Test Use an ignition coil tester available from after market ...

Page 250: ... 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 indica...

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: ...ion Kit P N 295 035 844 Look 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...

Page 253: ... of cir cuits 2 8 and 2 11 using a multimeter If wiring harness tests good it could be the MPEM Try a new MPEM referring to MPEM REPLACE MENT procedures elsewhere in this section Safety Lanyard Switch Verification If 2 short beeps 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...

Page 254: ... dry coating of soot or an oily glossy coating given by an excess either of oil or of oil with soot Such coatings form a conductive 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 A...

Page 255: ...Throttle position sensor PTO TPS TPS 1 and engine ground PU RD 5 V 2 and engine ground BK RD 0 0 5 V 3 and engine ground WH RD 0 V AMP no 4 3 and 18 BK RD and PU RD 1600 2400 ohms 1 and 3 WH RD and BK RD 1000 ohms at idle 1 and 18 WH RD and BK RD 2500 ohms at idle Crankshaft position sensor CPS CPS Deutsche connector Pin 4 and ground BK 0 V with a small mV tolerance Pin 5 and ground GY RD 12 V Pin...

Page 256: ...22 RE GN and WH GN 45 55 ohms primary winding Coil terminal C and coil post 6800 10200 ohms secondary winding w o high tension leads Ignition coil PTO AMP no 3 20 and 23 RE BL and WH BL 45 55 ohms primary winding Coil terminal C and coil post 6800 10200 ohms secondary winding w o high tension leads High tension leads GTX DI models MAG 5700 ohms lead alone PTO White tape 4900 ohms lead alone COMPON...

Page 257: ...safety lanyard on watercraft post Safety lanyard is recognized by the MPEM Good contact between safety lanyard cap and DESS post Ignition is authorized engine can be started normally 1 long beep while installing safety lanyard on watercraft post or when pressing start stop button Badconnection between safe ty lanyard cap and post Remove and replace the safety lanyard on the post until 2 short beep...

Page 258: ...SE 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 m...

Page 259: ...S 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 Engin...

Page 260: ...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 261: ...PORTANT 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 BU...

Page 262: ...l 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 l...

Page 263: ...s loose Yes Fix and reset closed TPS Inspect sensor for damage or corrosion Yes Replace and reset closed TPS Inspect wiring voltage test Failed Repair Inspect wiring and sensor resistance test Failed If bad wiring repair If bad TPS replace and reset closed TPS Test sensor operation wear test Failed Replace and reset closed TPS POSSIBLE CAUSES RESULT ACTION Sensor has been replaced and TPS closed p...

Page 264: ...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 265: ...CU 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 f...

Page 266: ...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 267: ... 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 c...

Page 268: ...ENERAL 07 03 1 FUEL SYSTEM 07 03 1 ELECTRICAL SYSTEM 07 03 2 ENGINE CONNECTOR PIN OUT 07 03 3 CONNECTORS ON ENGINE 07 03 4 AIR INDUCTION SYSTEM 07 03 5 THROTTLE BODY 07 03 5 FUEL DELIVERY 07 03 8 FUEL PUMP 07 03 9 FUEL RAIL 07 03 11 FUEL INJECTOR 07 03 11 ELECTRONIC MANAGEMENT 07 03 13 EMS ECU AND MPEM REPLACEMENT 07 03 13 ENGINE WIRING HARNESS 07 03 14 THROTTLE POSITION SENSOR TPS 07 03 16 IDLE B...

Page 269: ...ING TOP DEAD CENTER 07 03 30 ENGINE START STOP SWITCH VERIFICATION 07 03 30 SAFETY LANYARD SWITCH VERIFICATION 07 03 30 SPARK PLUGS 07 03 31 CRANKING SYSTEM 07 03 31 DIAGNOSTIC PROCEDURES 07 04 1 GENERAL 07 04 1 SELF DIAGNOSTIC MODE 07 04 3 VCK vehicle communication kit 07 04 4 4 TEC SYSTEM FAULT CODES 07 04 4 www SeaDooManuals net ...

Page 270: ...tem Electronic Control Unit MPEM Multi Purpose Electronic Module KS Knock Sensor CPS Cranshaft Position Sensor OSPS Oil Separator Pressure Sensor CTS Coolant Temperature Sensor CAPS Camshaft Position Sensor EGT Exhaust Gas Temperature MAPS Manifold Air Pressure Sensor MATS Manifold Air Temperature Sensor TOPS Tip Over Protection System Con A Connector for Engine Wiring Harness Con B Connector for ...

Page 271: ...cuit by switching it to the ground COMPASS OUTSIDE AIR TEMPERATURE SENSOR VCK COMMUNICATION PORT COMMUNICATION LINK COMMUNICATION LINK POWER TO EMS ECU INFORMATION CENTER SET AND MODE SWITCHES SPEED SENSOR FUEL LEVEL SENDER BEEPER START STOP SWITCH STARTING SOLENOID FUEL PUMP FUEL INJECTORS IGNITION COILS TOPS VALVE TOPS SWITCH CAPS INFORMATION CENTER EMS ECU MPEM TPS MAPS MATS CTS EGT KS OPS OSPS...

Page 272: ...on center or B U D S Refer to DIAGNOSTIC PROCEDURES section MAGNETO SYSTEM AND POWER SUPPLY The magneto is the primary source of electrical energy It transforms magnetic field into electric current AC The magneto has a 3 phases delta wound stator on 18 poles Capacity is 380 watts It supplies DC current to battery after being trans formed by the voltage regulator rectifier Refer to CHARGING SYSTEM ...

Page 273: ...LD 1 Electronic Control Unit EMS ECU 2 Fuel rail 3 Injector 4 Throttle body 5 Ignition coil 6 Manifold air pressure sensor MAPS 7 Manifold air temperature sensor MATS The intake manifold is mounted on the engine block on the vehicle starboard side It provides support for the fuel injectors the fuel rail the EMS ECU the flame arrester and the throttle body The air intake manifold is a resonator bet...

Page 274: ...the system Fuel Pressure Regulator A fuel pressure regulator controls the pressure in the system and allows the excess of fuel to return to the fuel tank The fuel pressure regulator regu lates the fuel pressure at approximately 303 kPa 44 PSI Fuel Filter A mesh filter is located at the bottom of the fuel pump module inside the fuel tank ELECTRONIC MANAGEMENT EMS engine management system The engine...

Page 275: ...onds after engine is stopped CAUTION Leaving the safety lanyard on its post when engine is not running will slowly dis charge battery Antistart Feature This system allows starting the vehicle only with safety lanyard s that has been programmed to op erate a specific watercraft This functionality is the DESS system See below for details Digitally Encoded Security System DESS The following component...

Page 276: ... start stop switch is pressed If start stop button is held after engine has started the EMS ECU automatically stops the starter when the engine speed reaches 1600 RPM If start button is activated while the throttle lever is depressed more than 65 the engine will not be allowed to start Engine RPM Limiter The EMS ECU will limit the maximum engine speed Engine Stopping There are 2 ways to stop the e...

Page 277: ...Section 07 ENGINE MANAGEMENT 4 TEC Subsection 02 OVERVIEW 07 02 8 SMR2002 077_07 02A FM EMS ENGINE MANAGEMENT FUNCTIONS R1503motr220S www SeaDooManuals net ...

Page 278: ... and firing in order to achieve the proper engine requirements Ignition Coils Three separate ignition coils induce voltage to a high level in the secondary windings to produce a spark at the spark plug The ignition coils receive input from the EMS ECU Each coil provides high voltage to its correspond ing spark plug This ignition system allows spark plugs to spark independently NOTE Ignition coil c...

Page 279: ...lly if the condi tion does not exist anymore Releasing throttle and letting the engine returning at idle speed may allow normal operation to come back If it does not work try removing and rein stalling the safety lanyard on its post Depending on the malfunction the watercraft speed may be reduced and not allowed to reach its usual top speed The engine speed will be lim ited to 2500 or 5000 RPM The...

Page 280: ...Level Warning Device When the fuel level in the reservoir is low the fuel level sensor transmits a signal to the MPEM The MPEM sends out signals for the beeper and to the information center gauge Monitoring System The EMS ECU monitors the electronic compo nents of the fuel injection system and also the en gine components of the electrical system The MPEM monitors the vehicle electrical system and ...

Page 281: ...reconnect the battery WARNING The fuel system of a fuel injection system holds much more pressure than on a carbureted wa tercraft Prior to disconnecting a hose or to re moving a component from the fuel system fol low the recommendation described here 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 li...

Page 282: ...ct and that they are corrosion free Particularly check MPEM and EMS ECU ground connections Ensure that con tacts are good and clean A defective module could possibly be repaired simply by unplugging and replugging the MPEM or EMS ECU The volt age and current might be too weak to go through dirty wire pins Check carefully if pins show signs of moisture corrosion or if they look dull Clean pins prop...

Page 283: ...fler and heated with a heat gun while it is still connected to the harness to see if the EMS ECU will detect the high temperature condition and generate a fault code NOTE In case of overheating EGT and CTS do not generate codes No message will be displayed on the information center The beeper will be acti vated and the EMS will be set in limp home mode ENGINE CONNECTOR PIN OUT Connector Position 1...

Page 284: ...NE Removal To remove connectors from engine connector bracket slide a flat screwdriver between the con nector bracket and the connectors and remove connectors 1 Engine connector bracket 2 Connectors 1 Engine connector bracket 2 Deutsch connector 3 Flat screwdriver To disconnect two connectors slide a flat screw driver between each other to disengage press the release button and disconnect them 1 F...

Page 285: ...ging the idle stop or modifying it in any way will not increase performance or change the idle speed but may cause poor startability and erratic idling Before replacing any part check the following as these could be causing the fault Perform the test while the engine is not running Throttle cable adjustment too tight Not return ing fully to idle stop Throttle body idle set screw is loose or worn T...

Page 286: ...e stop screw CAUTION It is not allowed to perform any change on the idle stop screw The adjustment of the idle stop screw is optimized by the throttle body manufacturer and locked to prevent any modification CAUTION Never attempt to adjust the idle speed through the throttle body tamper proof screw If so it would impair the idle speed sta bility Besides no adjustment could be per formed by the dea...

Page 287: ... contact with throttle body NOTE Apply a light pressure on the throttle plate a slight play should be obtained CAUTION If there is no free play at idle posi tion it may cause poor idling and startability Improper cable adjustment will cause strain on cable and or damage cable bracket or throttle lever at handlebar To adjust loosen jam nut then turn adjustment nut as necessary 1 Adjustment nut 2 Ja...

Page 288: ... safety lanyard connection Check fuel pump operation Repair or replace if necessary Fuel pressure is 303 kPa 44 PSI Fuel pressure more than 303 kPa 44 PSI Fuel pressure less than 303 kPa 44 PSI Perform fuel pump test Check fuel line rail for leaks Crank or start engine Fuel pressure less than 303 kPa 44 PSI Fuel pressure more than 303 kPa 44 PSI Check fuel injector Fails Connect safety lanyard Fue...

Page 289: ...Release pressure using B U D S between tests so that the gauge is reset to zero 0 Crank or start engine and observe fuel pressure The fuel pressure should be the same as above If pressure is within limits fuel pump and pressure regulator are working adequately A rapid pressure drop indicates leakage either from the fuel rail or from the fuel pump check valve Check fuel rail for leaks If it is not ...

Page 290: ...nuity of cir cuit B 29 going towards EMS ECU If it is good try a new EMS ECU b If battery voltage is not read check continuity of circuit 1 26 going towards MPEM If it is good try a new MPEM Fuel Pump Replacement Removal Open front storage compartment cover Remove the storage basket if so equipped Remove front access panel see HULL BODY sec tion Remove front vent tubes Remove glove box see HULL BO...

Page 291: ...following A thin film of injection oil should be applied to O rings of fuel injectors to ease installation in in take manifold Apply Loctite 243 on rail retaining screws then torque to 10 N m 89 lbf in When installing fuel line connector to the fuel rail put some oil on the O ring to ease installation FUEL INJECTOR Leakage Test To perform a leakage test the injectors and fuel rail have to be remov...

Page 292: ...ty of cir cuit as per following table If it is good try a new MPEM Otherwise check the resistance of the fuel injec tor circuit Reconnect the injector and disconnect the EMS ECU connector A EMS ECU Using a multimeter check resistance value be tween terminals as follows ENGINE CONNECTOR EMS ECU CONNECTOR The resistance should be between 11 4 and 12 6 Ω If resistance value is correct try a new EMS E...

Page 293: ...eneral introduction of this section have been followed IMPORTANT When the EMS ECU is replaced the safety lanyard s and the Closed Throttle and Idle Actuator must be reprogrammed reset Re fer to their specific section for adjustment To allow transferring the previous recorded informa tion from the old EMS ECU or MPEM to the new one use the vehicle communication kit VCK with the B U D S software Use...

Page 294: ... display that option If an option is checked in B U D S but not installed in vehicle a fault code will be generated Ensure to clear all faults from the newly replaced MPEM Start engine and ensure no fault is active ENGINE WIRING HARNESS 1 EMS ECU connector 2 CTS connector 3 EGT connector 4 CAPS connector 5 Fuel injector connector cylinder 1 6 Ignition coil connector cylinder 1 7 Fuel injector conn...

Page 295: ... Locking tie Lead the cable bundle with the injector and igni tion coil connectors to the fuel rail and fix it also by using 4 locking ties 1 Locking ties Connect the fuel injectors ignition coils CAPS CTS and EGT to the wiring harness Install the engine connector on the appropriate bracket on the wiring support Then fix the other bundle on the appropriate sup ports on the wiring support and the E...

Page 296: ... BODY in AIR INDUCTION SYSTEM above The EMS may generate several fault codes pertain ing to the TPS Refer to SYSTEM FAULT CODES in DIAGNOSTIC PROCEDURES section for more in formation Wear Test While engine is not running activate throttle and pay attention for smooth operation without physi cal stops of the cable Using the vehicle communication kit VCK with the B U D S software use the Throttle Op...

Page 297: ...on The resistance should be 1000 1100 Ω Check the resistance between terminal A 24 and A 25 with throttle plate in idle position The resistance should be 1000 1100 Ω Now check the resistance with the throttle plate in wide open position The resistance should be 2600 2700 Ω NOTE When measuring between pins A 24 and A 39 resistance value decreases while depress ing throttle lever when measuring betw...

Page 298: ... EMS ECU takes care of that If TPS is not within the allowed range while resetting the Closed Throttle and Idle Actuator the EMS ECU will generate a fault code and will not accept the setting Start engine and make sure it operates normally through its full engine RPM range If fault codes ap pear refer to SYSTEM FAULT CODES in DIAGNOS TIC PROCEDURES section for more information IDLE BYPASS VALVE An...

Page 299: ... Vac Otherwise inspect wiring and replace CPS if wiring is good Resistance Test Disconnect the CPS plug connector from the wir ing harness and check the resistance of the sensor itself The resistance should be between 190 Ω and 290 Ω Otherwise replace the CPS If resistance tests good reconnect the CPS and disconnect the EMS ECU connector A on the EMS ECU Using a multimeter recheck resistance value...

Page 300: ... CAMSHAFT POSITION SENSOR CAPS 1 CAPS Voltage Test harness Disconnect the connector from the wiring harness To see the connector pin out temporarily remove the connector shield joining the harness to ex pose the pin numbers Remove and reinstall safety lanyard to activate the system Probe pin 3 of CAPS connector wiring harness side and battery ground a If 12 V is read check continuity of circuits A...

Page 301: ...s from 12 V to less than 1 V 1 CAPS 2 Conductor If the voltage is not good replace the CAPS Replacement Unscrew the retaining screw and replace the CAPS Ensure to reinstall O ring Apply Loctite 243 blue on thread and torque to 6 N m 53 lbf in MANIFOLD AIR TEMPERATURE SENSOR MATS INTAKE MANIFOLD 1 Manifold air temperature sensor MATS R1503motr184A 1 2 3 CAPS 1200 W 1 2 3 12 V V R1503motr208A Voltme...

Page 302: ...n EMS ECU connector and the MATS Replacement Disconnect the connector of the MATS Screw MATS out and install the new one Torque to 18 N m 159 lbf in COOLANT TEMPERATURE SENSOR CTS 1 Coolant temperature sensor CTS Resistance Test Disconnect the plug connector from the CTS and check the resistance of the sensor itself The resistance should be between 2280 Ω and 2740 Ω at 20 C 68 F Otherwise replace ...

Page 303: ...nd the wiring harness Perform the following tests Voltage Test Check thevoltageoutputfromEMS ECU to theman ifold air pressure sensor MAPS Disconnect plug connector from maps and con nect a voltmeter between pin 1 and 3 and also between pin 1 and 2 of wiring harness Remove and reinstall the safety lanyard to activate the EMS ECU There should be 5 Vdc in each test If voltage test is good replace the...

Page 304: ...nitor the knock sensor using the Faults section Start the engine and bring engine RPM above 5000 RPM If no fault code occurs the knock sen sor is good Otherwise do the following Ensure sensor and head contact surfaces are clean and mounting bolt and washer are correct and prop erly torqued down NOTE It is necessary to remove intake manifold to inspect contact surfaces Refer to INTAKE SYS TEM secti...

Page 305: ...is good check the resis tance of the OPS while engine is off and while engine is running Resistance Test Disconnect the plug connector from the OPS and use a multimeter to check the resistance between OPS pin and engine ground while engine is stopped without oil pressure and while engine is running with oil pressure When engine is stopped the resistance is infinitely high normally open switch When...

Page 306: ...unning with blow by pressure When engine is stopped and the blow by pressure is released the resistance of the OPS is close to 0 Ω normally closed switch When engine is running and the blow by pressure exceeds 40 kPa 6 PSI the resistance is infinitely high If resistance values are incorrect replace OSPS If the values are correct check the continuity of the wiring harness Disconnect the EMS ECU con...

Page 307: ...erated R1503motr206S TOPS DIAGNOSTIC FLOW CHART Connect safety lanyard TOPS valve opens short knocking noise Check TOPS switch Check output voltage on wiring harness Replace TOPS valve Lower than 8 V Greater than 8 V No OK Fails Repair or replace Install oil pressure gauge on oil dipstick tube Start engine Yes No Pressure drops down directly after reaching 40 kPa 5 8 PSI TOPS valve opens again Pre...

Page 308: ...l separator cover Refer to OIL SEP ARATOR REPLACEMENT in the LUBRICATION SYSTEM section 1 Solenoid valve 2 Spring 3 Valve disc 4 Retaining washer Remove the valve disc and the spring on the bot tom of the TOPS valve after removing the retain ing washer Unscrew and remove the TOPS valve Install the new valve with new gasket Apply Loc tite 243 blue on threads and torque to 10 N m 89 lbf in Reinstall...

Page 309: ...ition coil connector on the wiring harness and battery ground The voltage should be 12 V If 12 V is NOT read check continuity of appropri ate circuit 2 16 cylinder 1 2 17 cylinder 2 or 2 18 cylinder 3 If it tests good try a new MPEM If 12 V is read disconnect the EMSECU connector A from the EMS ECU and check the continuity of appropriate circuit 41 cylinder 1 1 cylinder 2 or 29 cylinder 3 EMS ECU ...

Page 310: ... the output side of the starting system MPEM output signal to starting so lenoid wiring harness going to the solenoid and starter motor Refer to STARTING SYSTEM for test ing procedures Otherwise check the input side as follows Disconnect the start stop switch connector Using an ohmmeter connect test probes to YELLOW RED and PURPLE wires Measure resistance it must be an open circuit switch is norma...

Page 311: ...w module Reconnect module If the above procedures did not work refer to elec trical troubleshooting in TROUBLESHOOTING and ENGINE MANAGEMENT sections Safety Lanyard on Switch Connect test probes to switch BLACK and BLACK YELLOW wires Measure resistance it must be close to 0 ohm SPARK PLUGS Disassembly Disconnect the wiring harness from the ignition coil Remove the ignition coil First unscrew the s...

Page 312: ...er P followed by 4 digits P 1234 can be displayed in the information center for troubleshooting With safety lanyard on its post press 5 times the SET button to start the display of P codes onboard diagnostic Press MODE to scroll codes if more than one is present When list is over END will appear When END appears press MODE to exit 1 Press 5 times to activate display of P codes onboard diagnostic 1...

Page 313: ...TWARES MAPS manifold air pressure sensor APS air pressure sensor MATS manifold air temperature sensor ATS air temperature sensor CTS coolant temperature sensor WTS water temperature sensor EGT exhaust gas temperature ETS exhaust temperature sensor TOPS valve tip over protection system Blow by valve Idle bypass valve DLA digital linear actuator Idle actuator Idle valve OSPS oil separator pressure s...

Page 314: ...event battery discharge remove the safety lanyard from its post A 2 seconds beep every minute interval High pressure in oil separator tank Refer to LUBRICATION SYSTEM section Low fuel level Refer to INSTRUMENTS AND ACCESSORIES section Fuel tank level sensor or circuit malfunction Refer to INSTRUMENTS AND ACCESSORIES section A 2 seconds beep every 15 minutes interval Watercraft is upside down Turn ...

Page 315: ...EM If an X is shown the safety lanyard is not in stalled on its post or there is a problem with both ECUs Ensure VCK is working properly and check connections on VCK and watercraft VCK supply The VCK MPI box can use the watercraft power for its supply The safety lanyard must be connected in order to use the watercraft as a power source If watercraft power is used every time the safety lanyard is t...

Page 316: ...al noise might also lead engine to occa sional cutout without generating a fault code when engine is restarted When looking at the fault code pay attention to the count value in the software B U D S A value between 1 and 9 confirms an electrical noise problem A value of 10 and above will generate a fault code When installing a new EMS ECU It is not proper ly programmed from the factory The EMS ECU...

Page 317: ...tor Inspect sensor for damage or corrosion Yes Replace and reset Closed Throttle and Idle Actuator Inspect wiring voltage test Failed Repair Inspect wiring and sensor resistance test Failed If bad wiring repair If bad TPS replace and reset Closed Throttle and Idle Actuator Test sensor operation wear test Replace and reset Closed Throttle and Idle Actuator POSSIBLE CAUSES RESULT ACTION Sensor has b...

Page 318: ...AND CARE 08 02 1 CIRCUIT 08 02 6 COMPONENTS 08 02 8 CARE 08 02 12 CIRCUIT 08 02 13 COOLING SYSTEM LEAK TEST 08 02 13 INSPECTION 08 02 15 DRAINING THE SYSTEM 08 02 15 COOLANT REPLACEMENT 08 02 15 COOLANT PUMP HOUSING 08 02 17 THERMOSTAT 08 02 18 COOLANT PUMP IMPELLER 08 02 18 ROTARY SEAL 08 02 19 CARE 08 02 21 www SeaDooManuals net ...

Page 319: ...PONENTS AND CARE 0 DI engines F18E1NS Pipe sealant Pipe sealant Pipe sealant 1 Pipe sealant Pipe sealant Pipe sealant 2 Pipe sealant Silicone sealant Body Loctite 243 Loctite 243 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 3 4 7 0 11 N m 1 lbf in 8 6 0 6 N m 5 lbf in 5 www SeaDooManuals net ...

Page 320: ...Section 08 COOLING SYSTEM Subsection 02 CIRCUIT COMPONENTS AND CARE 08 02 2 SMR2002 080_08_02A FM 4 TEC Engines Closed loop system F18E0ZS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 www SeaDooManuals net ...

Page 321: ...Section 08 COOLING SYSTEM Subsection 02 CIRCUIT COMPONENTS AND CARE SMR2002 080_08_02A FM 08 02 3 4 TEC Engines Open loop system F18E1DS www SeaDooManuals net ...

Page 322: ...ket Water flows out of exhaust manifold water jacket and through tuned pipe water jacket before exiting the tuned pipe Water injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and performance improvement F12E09S Side of hull RX DI routing GTX DI routing Bleed hose upper point of circuit Air compressor silencer Quick connect hose fitting for easy engine drai...

Page 323: ...ride plate Coolant housing including thermostat opens at 87 c 188 f and coolant pump impeller Bleed hose from cylinder head to expansion coolant tank Expansion coolant tank Coolant temperature sensor CTS activates when temperature exceeds 100 c 212 f Coolant flows to oil cooler Oil cooler Coolant returns from oil cooler Coolant returns from ride plate www SeaDooManuals net ...

Page 324: ...p on the inlet side The reducer is blue on the DI mod els The water is entering the engine by the water inlet fitting at the cylinder head 1 Water supply hose Water from inlet hose also supplies the water reg ulator on muffler and magneto cover and crankcase cover Water then is expulsed through the pump support drain Water circulates through the one piece cylinder head which features improved comb...

Page 325: ... at the tran som Water continues to flow in the crankcase water jacket to cool the crankcase area to then be ex pulsed to the transom area Draining of the cooling system is accomplished by the drain hose connected to a fitting at the bottom of the cylinder block on tuned pipe side 1 Drain hose Bleeding of the cooling system is accomplished by the bleed hose located at the uppermost point of the ci...

Page 326: ...ecure non reusable Oetiker clamps of cooling system hoses use pliers P N 295 000 070 1 Cutting clamp 2 Securing clamp Elbow Fitting Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe The elbow fitting no 1 has a calibrated inside diameter to optimize water flow in tuned pipe The water injection also helps in reducing noise level and coo...

Page 327: ...ion fitting 3 Water injected into the muffler NOTE The water injected into the muffler is not regulated by the valve A calibrated water injection fitting of 4 0 mm 156 in inside diameter limits water flow into the muffler The water flow regulator valve has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe CAUTION Do not change anything on the wa ter flow ...

Page 328: ...alve more restriction 3 Water injected in the muffler Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified NOTE Water flow regulator valves ordered from the parts channel are also calibrated The valve cap on the is sealed and it is not adjustable If the maximum engine speed cannot be attained or if the engine has poor performance the water flow re...

Page 329: ... 6 NOTE Hold the valve to prevent it from turning 1 Tapered needle Remove the tapered needle from valve housing 1 Remove tapered needle Pull the valve slightly Using pliers release the clamp which retains the bellows no 8 Remove valve no 7 and bellows no 8 Loosen clamp to separate valve from bellows 1 Clamp F01E1SA 1 F01E1TA 1 F01E20A 1 F01E21A F01E24A 1 www SeaDooManuals net ...

Page 330: ...watercraft in water Maximum recommended towing speed is 24 km h 15 MPH When towing your watercraft in water pinch the water supply hose from the jet pump housing to the engine with a large Hose Pincher P N 529 032 500 This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system Without the engine run ning there isn t any exhaust press...

Page 331: ...r A smaller quantity of engine coolant is also direct ed towards the oil cooler which is located under the air intake manifold to increase cooling effi ciency Coolant temperature sensor and bleed nipple are located on the cylinder head 1 Bleed nipple 2 Coolant temperature sensor CTS CAUTION Never modify cooling system arrange ment otherwise serious engine damage could occur Pressure Cap Check if c...

Page 332: ...1 Water coming from exhaust manifold 2 Exhaust pipe 3 Bleed hose Water enters exhaust pipe and flows in the water jacket of pipe 1 Exhaust pipe 2 Outlet holes of exhaust pipe 3 Muffler Bleeding of the exhaust system is accomplished by the bleed hose located at the upper most point of the circuit of the exhaust pipe Water exits exhaust pipe through holes at the end of the water packet and mixes wit...

Page 333: ...ant as per local regulations Do not reinstall drain plug at this time COOLANT REPLACEMENT Recommended Coolant Use a blend of 50 antifreeze with 50 water Premixed antifreeze water is available P N 293 600 038 To prevent antifreeze deterioration always use the same brand Never mix different brands unless cool ing system is completely flushed and refilled Do not reinstall pressure cap CAUTION To prev...

Page 334: ...e Refer to flushing in MAINTENANCE Section Start engine and let run for 2 minutes Stop engine and wait 15 minutes to cool down Refill tank as necessary Repeat this run stop cycle 2 3 times until thermo stat opens and stop engine Last refill expansion tank and install cap When engine has completely cooled down re check coolant level in radiator and coolant tank and top up if necessary Test the dens...

Page 335: ... hard or damaged and replace as necessary 1 Weep hole pump housing gasket Check if thermostat is in good condition Refer to THERMOSTAT elsewhere in this section Installation The installation is the opposite of the removal pro cedure Install screws as per the following illustra tion 1 Screw M6 x 25 2 Screw M6 x 105 CAUTION To prevent leaking take care that the gaskets are exactly in groove when you...

Page 336: ...using Refer to COOLANT PUMP HOUSING in this section If there is no leak check the operation of the ther mostat Dynamic Test To check the operation of the thermostat put it in water and heat water Look inside the cylinder head return hose connection to see the move ment of the thermostat Thermostat should open when water temperature reaches 87 C 188 F If there is no operation replace coolant pump h...

Page 337: ...ut of the hole indicates a defective rotary seal Leaking oil indicates a faulty oil seal However if seal is disassembled both parts have to be replaced together Removal Remove coolant pump housing no 6 CAUTION Always unscrew the impeller clock wise otherwise you can damage the compo nents unscrew the impeller no 8 clockwise remove PTO cover no 10 Refer to PTO HOUS ING MAGNETO Section remove screws...

Page 338: ... to the following details NOTE Never use oil in the press fit area of the oil seal and rotary seal Push water pump shaft oil seal in place by using thumb Install the new rotary seal using the rotary seal in staller P N 529 035 823 CAUTION Never use a hammer for the rotary seal or water oil pump shaft installation Only use a press to avoid damaging the ceramic component 1 Rotary seal 2 Rotary seal ...

Page 339: ... is 24 km h 15 MPH When towing your watercraft in water pinch the water supply hose from the jet pump housing to the engine with a large Hose Pincher P N 529 032 500 This will prevent the exhaust cooling system from filling which may lead to water being injected into and filling the exhaust system and the engine Without the engine running there isn t any ex haust pressure to carry the water out th...

Page 340: ...oolant pump TEMPERATURE CONTROL Thermostat SYSTEM BLEEDING Self bleed type through expansion tank hose at uppermost point of circuit SYSTEM DRAINING Self drain type on the exhaust cooling system hose at lowest point of circuit SYSTEM FLUSHING Required only for exhaust cooling system open loop system MONITORING BEEPER Turns on at 100 C 212 F COOLANT LIFE CYCLE 2 years www SeaDooManuals net ...

Page 341: ...TS SMR2002 095_09 01ATOC FM 09 01 1 TABLE OF CONTENTS 0 FUEL CIRCUIT 09 02 1 GENERAL 09 02 3 REMOVAL 09 02 3 INSPECTION 09 02 5 ASSEMBLY 09 02 6 FUEL SYSTEM PRESSURIZATION 09 02 6 AIR INTAKE 09 03 1 REMOVAL 09 03 3 ASSEMBLY 09 03 4 www SeaDooManuals net ...

Page 342: ...L SYSTEM Subsection 02 FUEL CIRCUIT SMR2002 081_09_02A FM 09 02 1 FUEL CIRCUIT 0 947 DI Engines F12F0ZT 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 2 5 N m 22 12 lbf in www SeaDooManuals net ...

Page 343: ...on 09 FUEL SYSTEM Subsection 02 FUEL CIRCUIT 09 02 2 SMR2002 081_09_02A FM 4 TEC Engines F18F08S 2 5 N m 22 12 lbf in 7 6 5 4 13 22 N m 16 lbf ft 4 N m 35 lbf in 4 4 N m 35 lbf in 14 8 www SeaDooManuals net ...

Page 344: ...e electric fuel pump inlet The pump has to be removed from the fuel tank to have access to its filter Refer to EN GINE MANAGEMENT DI section WARNING The fuel system of a fuel injection system hold much more pressure than on a carburet ed watercraft Prior to disconnecting a hose or to removing a component from the fuel system follow the recommendations de scribed in ENGINE MANAGEMENT under Fuel Sys...

Page 345: ... MPEM connectors Detach MPEM assembly and support from bilge Remove TOPS switch from electrical harness or MPEM bracket Remove air box Refer to AIR INTAKE SYSTEM sub section From storage compartment disconnect fuel pump connections Remove fuel pump from fuel tank Refer to EN GINE MANAGEMENT section Detach reverse system support 1 Screw Remove battery Refer to CHARGING SYSTEM sub section Disconnect...

Page 346: ...low Check Valve Black side of the one way check valve no 7 is the valve outlet It allows air to get in reservoir Fuel Tank Visually inspect the inside and outside of the 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 surfa...

Page 347: ...RESSURIZATION Pressure Test supply and vent circuits Proceed as follows Fill up fuel tank Disconnect air inlet hose of fuel tank from body Install a hose pincher P N 295 000 076 on fuel tank vent hose TYPICAL 1 Disconnect air inlet hose 2 Install a hose pincher to vent hose Connect pump gauge tester P N 529 021 800 to air inlet hose NOTE This pump is included in the ENGINE LEAK TESTER KIT P N 295 ...

Page 348: ...nlet 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 Pressure Test fuel pump circuit Refer to the appropriate ENGINE MANAGEMENT section WARNING If any ...

Page 349: ...Section 09 FUEL SYSTEM Subsection 03 AIR INTAKE SMR2002 082_09_03A FM 09 03 1 AIR INTAKE 0 947 DI Engines 2 Loctite 243 1112 4 Loctite 243 13 3 Super Lube F12F0KT 14 Loctite 243 www SeaDooManuals net ...

Page 350: ...Section 09 FUEL SYSTEM Subsection 03 AIR INTAKE 09 03 2 SMR2002 082_09_03A FM 4 TEC Engines F18F0FS 14 13 7 8 12 9 10 11 10 11 6 5 4 2 2 3 1 4 N m 35 lbf in www SeaDooManuals net ...

Page 351: ...ts retaining bothair ducts toengine both sides 1 Remove bolts Pull air ducts out 1 Air duct 4 TEC Engines Disconnect connectors no 1 no 2 and no 3 Detach straps no 4 using hook tool P N 529 035 559 1 Magneto connector 2 Voltage regulator connector 3 Fuse connector 4 Straps Loosen spring clamp no 2 and remove formed hose no 3 from engine Loosen clamp no 5 and remove intake hose no 6 from engine 2 F...

Page 352: ...ke silencer back in place Properly reinstall hair pin to secure clip no 2 Ensure the elbow adaptor is well inserted and that it has not pushed the gasket inside the air box 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...

Page 353: ...1 TABLE OF CONTENTS 0 OIL INJECTION SYSTEM 10 02 1 GENERAL 10 02 2 OIL SYSTEM PRESSURIZATION 10 02 2 OIL INJECTION PUMP 10 03 1 OIL PUMP IDENTIFICATION 10 03 2 REMOVAL 10 03 2 DISASSEMBLY 10 03 2 CLEANING 10 03 2 ASSEMBLY 10 03 2 ADJUSTMENT 10 03 3 CHECKING OPERATION 10 03 4 www SeaDooManuals net ...

Page 354: ...TEM DI Subsection 02 OIL INJECTION SYSTEM SMR2002 083_10_02A FM 10 02 1 OIL INJECTION SYSTEM 0 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 355: ...ter P N 529 021 800 to disconnected tube at throttle body NOTE Use the same pump included in the EN GINE LEAK TESTER KIT P N 295 500 352 TYPICAL 1 Connect pump to check valve Pressurize oil system to 21 kPa 3 PSI If pressure is not maintained locate leak and repair replace component leaking To ease leak search spray a solution of soapy water on compo nents bubbles will indicate leak location Verif...

Page 356: ... 03 OIL INJECTION PUMP SMR2002 084_10_03A FM 10 03 1 OIL INJECTION PUMP 0 F12G01S 6 N m 53 lbf in 1 Loctite 243 6 4 5 N m 40 lbf in 7 Throttle body 4 5 N m 40 lbf in 8 Molykote 111 To air compressor supply line To crankcase www SeaDooManuals net ...

Page 357: ... retaining oil injection pump to magneto housing cover Pull pump Disconnect oil hoses from fittings of oil injection pump DISASSEMBLY NOTE Some oil pump parts are not available in single parts A gasket set is available for the pump If the pump is found defective it should be replaced by a new one CLEANING Discard all seals and O rings Clean metal compo nents in a solvent ASSEMBLY Oil Injection Pum...

Page 358: ...hrottle body bracket 1 Oil pump cable adjustment 2 Throttle cable Adjust the cable to the rich position Use the long est mark 1 Mark on pump must be facing longest mark on lever Start and bring engine to normal operating temper ature CAUTION If watercraft is out of water engine must be cooled using the flush kit If air bubbles are present in the oil injection system bleed system before operating e...

Page 359: ...eding function that al lows to lock the engine RPM in idle speed while the throttle is fully depressed to ease the bleeding operation Since oil cannot be seen through the small oil lines press and hold the vehicle throttle to wide open position for 45 seconds CAUTION If watercraft is out of water engine must be cooled using the flush kit CHECKING OPERATION On Watercraft NOTE Oil line supply must b...

Page 360: ...n oil container 2 Hold lever in fully open position 3 Counterclockwise reverse rotating drill 4 Oil must drip here For an accurate test each port should be checked separately to ensure equal delivery on both ports To obtain a precise result of the oil pump delivery rate rotate it counterclockwise at 1500 RPM for a total time of 5 minutes NOTE To ensure accuracy of test oil lines should be complete...

Page 361: ...1 02 3 STARTING SYSTEM 11 03 1 GENERAL 11 03 2 STARTING SYSTEM TROUBLESHOOTING 11 03 3 STARTER REMOVAL 11 03 4 STARTER DISASSEMBLY 11 03 4 CLEANING 11 03 7 PARTS INSPECTION 11 03 8 STARTER ASSEMBLY 11 03 9 STARTER INSTALLATION 11 03 9 STARTER SPECIFICATION 11 03 11 INSTRUMENTS AND ACCESSORIES 11 04 1 GENERAL 11 04 1 ADDITION OF ACCESSORIES 11 04 6 INSPECTION 11 04 6 www SeaDooManuals net ...

Page 362: ...e fuse still burns check for a defective wire CAUTION Do not use a higher rated fuse as this could cause severe damage DI A 25 A fuse is mounted on the MPEM and a 30 A fuse is located in the rear electrical box 4 TEC Engines The charging system is protected by 1 fuse 30 A in starter relay TESTING PROCEDURE NOTE First ensure that battery is in good condi tion prior to performing the following tests...

Page 363: ...f the 6 pin magneto harness adapter 4 Ground the multimeter negative probe to the engine or the stator iron core and note the read ing 1 Multimeter 2 Magneto harness adapter 3 Positive probe to YELLOW wire 4 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 ...

Page 364: ...E Hand tighten caps then tighten an addi tional 1 4 turn using a 20 mm 3 4 in socket Using other tool could damage the plastic battery caps All Models Electrolyte Level Check electrolyte level in each cell add distilled wa ter up to upper level line CAUTION Add only distilled water in an activat ed battery SYMPTOM DISCHARGED OR WEAK BATTERY CAUSE REMEDY 1 Battery posts and or cable terminal oxidiz...

Page 365: ...above 21 C 70 F and by subtracting 004 point for every 5 5 C 10 F below 21 C 70 F This chart will be useful to find the correct reading Load Test This is the best test of battery condition under a starting load Use a load testing device that has an adjustable load Apply a load of 3 times the ampere hour rating of the battery At 14 seconds into the test check bat tery voltage if battery is in good ...

Page 366: ...solution of baking soda and water CAUTION Do not allow cleaning solution to en ter battery Rinse battery with clear water and dry well using a clean cloth Store battery in a cool dry place Such conditions reduce self discharging and keep fluid evaporation to a minimum Keep battery away from dew high moisture and direct sunlight During the storage period recheck electrolyte level and specific gravi...

Page 367: ...4 TEC Models NOTE Hand tighten caps then tighten a additional 1 4 turn using a 20 mm 3 4 in socket Using other tool could damage the plastic battery caps All Models Charging a Used Battery For 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...

Page 368: ... flow may not be detect able on some charger ammeters and the bat tery will seem not to accept any charge Exceptionally for this particular case set 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 ...

Page 369: ...bsection 03 STARTING SYSTEM SMR2002 086_11_03A FM 11 03 1 STARTING SYSTEM 0 DI Engines F07H0TT Dielectric grease 2 Loctite 243 1 10 N m 89 lbf in 8 12 10 Ground cable 6 11 7 9 Synthetic grease 3 Synthetic grease www SeaDooManuals net ...

Page 370: ...ECU If 2 short beeps are not heard when installing the safety lanyard refer to ENGINE MANAGEMENT section Engine Start Stop Switch and Safety Lanyard Switch Refer to ENGINE MANAGEMENT section Solenoid NOTE Solenoid is located in the electrical box for the DI engines and besides the MPEM for 4 TEC engines Inspect connections and clean as necessary Static Test Continuity With a multimeter check prima...

Page 371: ...s Check and replace defective parts Open circuit start stop switch or solenoid Check and replace Safety lanyard or MPEM or ECU Refer to ENGINE MANAGEMENT DESS auxiliary module Refer to engine management STARTER ENGAGES BUT DOES NOT CRANK THE ENGINE Poor battery cable connections Clean battery cable connections Poor contact of brush Straighten commutator and brush Burnt commutator Turn commutator o...

Page 372: ...tarter drive assembly mag neto flywheel has to be removed Refer to MAG NETO SYSTEM and BOTTOM END To check and replace the starter end bearing refer to BOTTOM END section 4 TEC Engines Remove retaining screws no 1 from starter Pull starter no 3 out Lift starter enough to reach starter cable then disconnect from starter nut no 2 1 Exhaust manifold 2 Starter 3 Retaining screws 4 Nut STARTER DISASSEM...

Page 373: ... thrust washers no 10 from armature shaft TYPICAL 1 Thrust washers Remove the other end cover no 11 and gasket Remove the three washers no 10 from armature shaft 1 Washers Remove armature no 12 TYPICAL 1 Pull armature shaft Release brush wires of yoke from brush holder no 11 Remove brush holder no 11 1 Remove brush holder F06H1GA 1 F06H1HA 1 F06H1IA 1 F06H1JA 1 F06H1KA 1 www SeaDooManuals net ...

Page 374: ...1 Loosen nut and remove washers Remove brushes To remove bearing and seal in end cover release tabs of retainer 1 Retainer 4 TEC Engines Remove bendix retaining circlip no 4 and starter bendix no 5 1 Retaining circlip 2 Starter bendix Locate index marks on yoke and end covers 1 Index marks F06H1LA 1 F06H1MA 1 1 F18H0NA 2 1 F18H0OA www SeaDooManuals net ...

Page 375: ...y Remove armature TYPICAL 1 Pull armature shaft Remove brushes from brush holder by loosening retaining screws 1 Brushes 2 Retaining screw 3 Brush holder Remove springs CLEANING All Models CAUTION Yoke ass y and drive unit assembly must not be immersed in cleaning solvent Discard all O rings Clean brushes and holders with a clean cloth soaked in solvent Brushes must be dried thorough ly with a cle...

Page 376: ...mica depth If depth is less than 0 20 mm 008 in undercut mica Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed DI Engines 1 Commutator undercut 0 20 mm 008 in Check commutator out of round condition with V shaped blocks and an indicator If commutator out of round is more than 0 40 mm 016 in commu tator should be turned on a lathe ...

Page 377: ... to reassemble starter However attention should be paid to the following operations Install new O rings on 4 TEC engines and gaskets on DI engines Insert thrust washers no 19 onto armature shaft 1 Thrust washers DI Engines Install the three washers no 10 onto armature shaft All Engines When installing end covers no 7 and no 8 to yoke align index marks Apply Loctite 271 red on through bolts no 9 an...

Page 378: ... 243 blue on retaining screws no 1 and torque to 10 N m 89 lb in Nut CAUTION The cable nut features 1 4 20UNC SAE threads If for some reason you replace it DO NOT use a metric one Connect the RED positive cable to the starter and torque nut to 7 N m 62 lbf in Apply dielectric grease on terminal and nut Ensure to slide protector over nut to hide metallic parts 1 Grease on O rings 2 Torque nut to 7 ...

Page 379: ...g 3 7 lb Performance specification at 20 C 68 F No load 10 9 V 45 A max 8600 RPM Load 9 V 120 A max 5350 RPM Stall 2 25 V 390 A max 0 RPM Battery 12 V 19 Ah Nominal output 0 9 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 2 5 kg 5 39 lb Performance specification at 20 C 68 F No load 11 4 V 23 A max 8600 RPM Load 8 5 V 140 A max 5200 RPM Stall 3 75 V...

Page 380: ...ponents Description 1 Speedometer 2 Tachometer 3 Display area 1 Text and numerical area 1 Function buttons Display Area The display area comprises the following 1 Fuel level indicator 2 Numerical section 3 Units and messages section Fuel Level Display Bar gauge continuously indicates the amount of fuel in the fuel tank while riding A low fuel condi tion is also indicated when in the information ce...

Page 381: ...ture Displays the water tempera ture L TEMP in degrees Celsius C or Fahrenheit F Exterior Temperature Displays the exterior air temperature E TEMP in degrees Celsius C or Fahrenheit F Trip Hour Meter TRIPMTR Allows to measure an interval of time in hours and minutes hh mm Function Buttons Different displays and functions can be activated using 2 buttons MODE and SET following specific sequences as...

Page 382: ...ou do not touch any button for 10 seconds When active it becomes the default display until it is changed again When another display mode is chosen the default display will be displayed back after 10 seconds In the event of a warning message the message will blink and override the units display unless MODE button is pressed The display will then dis play the clock compass after 10 seconds If more t...

Page 383: ...FM 1 Press TOGETHER and hold for 2 seconds Clock Adjustment While in the clock compass mode 1 Press TOGETHER and hold for 2 seconds 1 Repeatedly press to adjust HOURS 1 Repeatedly press to adjust MINUTES 1 Press TOGETHER to end F18L09A 1 F18L09A 1 F18L09C 1 F18L09D 1 F18L09A 1 www SeaDooManuals net ...

Page 384: ...essary Except for low liquid levels which can be corrected by refilling NOTE If a fault occurs this system generates num bered fault codes P XXXX that can be displayed through the information center using a special pro cedure In case of a failure refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT Warning Light The red warning LED Light Emitting Diode blinks along with the beeper to catch your att...

Page 385: ...emperature Sensor The water temperature sensor is integrated with the speed sensor located on the ride plate To check if the water temperature sensor is oper ational activate the Info Center and select the lake temperature mode With a garden hose spray the speed sensor with water The temperature reading on the Info Center should adjust to the water temperature If not replace the speed sensor Compa...

Page 386: ...housing of the Info Center Using an appropriate terminal remover remove the PINK wire from the tab housing Reconnect the connector housing Disconnect the 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 resis...

Page 387: ... TEC GTX DI Fuel Baffle Pick Up Sender The fuel pick up system is part of the fuel pump module mounted inside the fuel reservoir The fuel level gauge sender is also mounted on this module TYPICAL FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL PUMP MODULE Refer to ENGINE MANAGEMENT RESISTANCE Ω DISPLAY TEMPERATURE C 25407 3 5 2 19911 1 10 2 15718 0 15 2 12495 0 20 2 10000 0 25 2 8054 9 30 2 6528 3 35 2 RE...

Page 388: ... ON To check the oil sensor unplug its connector and pull sensor out of oil tank Using a multimeter check the continuity between the BLUE and BLUE BLACK terminals When sensor is out of oil tank and its reservoir is empty resistance must be infinite open circuit NOTE Wait about 15 20 seconds before taking any reading to give the oil enough time to flow out or inside sensor reservoir Soak sensor in ...

Page 389: ... PRESSURIZATION 12 02 19 INSTALLATION 12 02 20 GENERAL 12 02 23 JET PUMP INSPECTION ON WATERCRAFT 12 02 23 REMOVAL 12 02 24 DISASSEMBLY 12 02 27 CLEANING 12 02 30 PARTS INSPECTION 12 02 30 ASSEMBLY 12 02 31 PUMP PRESSURIZATION 12 02 36 INSTALLATION 12 02 36 DRIVE SYSTEM 12 03 1 GENERAL 12 03 3 REMOVAL 12 03 3 INSPECTION 12 03 7 INSTALLATION 12 03 9 LUBRICATION 12 03 14 REVERSE SYSTEM 12 04 1 DISAS...

Page 390: ... N and Pipe sealant 567 Primer N and Pipe sealant 592 3 N m 27 lbf in Loctite 243 21 N m 16 lbf ft Loctite 243 7 5 N m 66 lbf in 3 2 1 31 29 30 38 40 41 25 38 44 30 32 33 28 36 35 37 13 26 34 24 39 42 20 43 21 24 N m 18 lbf ft 23 22 2 5 N m 22 lbf in 15 20 N m 15 lbf ft 20 N m 15 lbf ft 2 5 N m 22 lbf in 19 14 16 18 17 6 7 13 13 5 4 8 Loctite 518 6 N m 53 lbf in 45 www SeaDooManuals net ...

Page 391: ...us if access is needed to water inlet area it will be easy to slide underneath watercraft A lift kit can be used to install watercraft on a stand TYPICAL 1 Lift kit 2 Work stand Impeller Condition Condition of impeller no 1 boot no 2 and ring no 3 can be quickly checked from underneath of the watercraft Remove grate and look through water inlet opening TYPICAL 1 Inspect impeller and boot WATERCRAF...

Page 392: ...t its center Clear ance should not exceed 1 0 mm 040 in If clear ance is greater disassemble jet pump and inspect impeller and wear ring Renew worn parts TYPICAL MEASURING FROM WATER INLET SIDE 1 Feeler gauge TYPICAL MEASURING FROM VENTURI SIDE 1 Feeler gauge Oil Inspection Remove reverse gate cable steering cable screws no 10 retaining venturi to the housing Pull venturi Remove plug from cover TY...

Page 393: ...ecessary Apply a thin layer of Loctite 518 on mating surface of cover and reinstall it with its O ring Apply Loctite 243 on threads and torque screws to 7 N m 62 lbf in Remove plug from cover Pour oil through hole until oil reaches the bottom of hole threads Use SEA DOO JET PUMP SYN THETIC OIL P N 293 600 011 only Oil will drain slowly into center area of housing wait a few min utes and readjust o...

Page 394: ...riangle bolts no 15 Withdraw pivot triangle no 16 Pivot Arm Position shift lever in forward Remove reverse gate connecting rod spring no 17 reverse cable pivot arm bolts no 18 Take note of bushing size for reinstallation Withdraw pivot arm no 19 1 Pivot bolts each side 2 Spring 3 Pivot arm Nozzle Remove reverse gate Disconnect steering cable from jet pump nozzle Remove OPAS U lever screw washer an...

Page 395: ...ing 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 simply pull it out If drive shaft is seized in the PTO flywheel refer to DRIVE SYSTEM DISASSEMBLY NOTE Wheneve...

Page 396: ...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 397: ...gsaw 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 Seal and Needle Bearing R...

Page 398: ...2 Oil passages Brush and clean impeller shaft threads impeller and drive shaft splines with Pulley flange 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 shaft...

Page 399: ... 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 400: ...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 OPAS Filter OPAS filter is part of plastic elbow no 45 Check for cleanness Replace or ...

Page 401: ...d Press ring until it seats into bottom of housing 1 Seal lip 2 Press wear ring If a press is not readily available a piece of wood such as a 2 x 4 in x 12 in long can be used Manually engage ring in housing making sure it is equally inserted all around Place wood piece over ring Using a hammer strike on wood to push ring Strike one side then rotate wood piece about 90 and strike again Frequently ...

Page 402: ...eller Side Stamped end of bearings showing identification markings must be located toward outside of hous ing Properly insert bearing on tool Using an arbor press only push tool until tool flange contacts housing 1 Stamped end this side CAUTION Never hammer the bearing into its housing 1 Press on tool until it stops 2 Bearing CAUTION These tools have been designed to properly position bearings and...

Page 403: ...r diameter and on seal seat Properly insert seal on tool NOTE Apply synthetic grease on tool to ease seal insertion Install seal with the spring toward the outside 1 Spring of seal this side CAUTION Prevent sealant from contacting any needles of bearing Push on tool end with a press until tool flange con tacts housing 1 Press on tool until it stops Apply synthetic grease P N 293 550 010 between se...

Page 404: ...esigned to properly position bearing thus providing space for lubrication purposes The tool flanges allow this If a different pusher type is being used components must be properly positioned as fol lows Bearing on venturi side must be 2 to 3 mm 078 118 in inside reservoir measured from thrust wash er seat Refer to following illustration 1 Thrust washer seat 2 Stamped end of bearing A 2 3 mm 078 11...

Page 405: ...g 1 Impeller shaft 2 Impeller shaft guide NOTE If jet pump housing rest against a table raise it slightly to allow complete shaft insertion with the shaft guide Remove shaft guide Impeller Apply Loctite primer N P N 293 600 012 on threads of impeller shaft no 28 Allow to dry for 2 minutes NOTE Loctite primer is used to reduce Loctite 243 curing time and to activate stainless steel and aluminum sur...

Page 406: ...eads making sure they are well aligned Install impeller remover installer tool into impeller splines and tighten 1 Impeller remover installer tool CAUTION Make sure thrust washer and bear ing are not wedged in shaft groove To check manually pull and push jet pump housing some axial play must be felt Torque impeller to 115 N m 85 lbf ft then remove tools CAUTION Never use any impact wrench to tight...

Page 407: ... installation is correct If not redo the proce dure Verify if the impeller is rotating freely Add oil Oil Fill NOTE It is highly recommended to perform a leakage test prior adding the oil See PUMP PRES SURIZATION in this subsection Place housing horizontally as in its operating posi tion so that filler plug is located on top Remove filler plug from cover Pour SEA DOO JET PUMP SYNTHETIC OIL P N 293...

Page 408: ...should be done to check for leakage Proceed as follows Remove drain plug from cover Apply Loctite Pipe sealant on threads of fitting tool P N 295 000 086 then secure on cover Connect pump gauge tester P N 529 021 800 to fitting Pressurize pump to a maximum of 70 kPa 10 PSI Pump must maintain this pressure for at least 10 minutes CAUTION Repair any leak failure to correct a leak will lead to premat...

Page 409: ...ing Install flat washers no 40 lock washers no 41 and nuts no 25 Tighten nuts of jet pump housing in a criss cross sequence and torque to 31 N m 23 lbf ft NOTE SlightlylubricatewearringwithBOMBARDIER LUBE lubricant to minimize friction during initial start Nozzle Insert bushing no 42 in nozzle no 20 Insert bushing no 43 in nozzle no 20 with its off set pointing rearward 1 Bushing offset Position t...

Page 410: ...reverse gate with spacer and washer Torque to 20 N m 15 lbf ft NOTE When installing the reverse gate pay atten tion to position its lever behind the reverse gate support stopper 1 Stopper Steering Cable Refer to section STEERING SYSTEM Reverse Cable Refer to REVERSE SYSTEM F07J07A 1 www SeaDooManuals net ...

Page 411: ...te 243 Pipe sealant 592 Loctite 243 21 N m 16 lbf ft 7 5 N m 66 lbf in 3 1 31 40 41 25 38 44 30 46 32 33 28 37 13 26 39 42 20 43 21 24 N m 18 lbf ft 23 22 2 5 N m 22 lbf in 15 20 N m 15 lbf ft 2 5 N m 22 lbf in 19 14 16 18 17 6 7 13 13 5 4 8 Loctite 518 6 N m 53 lbf in 2 31 N m 23 lbf ft 34 35 36 Alsaco grease 45 24 www SeaDooManuals net ...

Page 412: ...MP INSPECTION ON WATERCRAFT To work on watercraft securely install it on a stand Thus if access is needed to water inlet area it will be easy to slide underneath watercraft A lift kit can be used to install watercraft on a stand TYPICAL 1 Lift kit 2 Work stand Impeller Condition Condition of impeller no 1 boot no 2 and ring no 3 can be quickly checked from underneath of the watercraft Remove grate...

Page 413: ... cm 12 in blades measure clearance between impeller blade tip and wear ring Measure each blade at its center For GTX 4 TEC clearance should not exceed 0 35 mm 014 in If clearance is greater disassemble jet pump and inspect impeller and wear ring Renew worn parts TYPICAL MEASURING FROM WATER INLET SIDE 1 Feeler gauge TYPICAL MEASURING FROM VENTURI SIDE 1 Feeler gauge REMOVAL Pump Assembly Remove OP...

Page 414: ... Reverse gate 4 Pivot support bolt no 13 Withdraw pivot support Connecting Rod Remove reverse gate pivot bolt no 14 Withdraw connecting rod Pivot Triangle Remove reverse gate connecting rod pivot triangle bolts no 15 Withdraw pivot triangle no 16 Pivot Arm Position shift lever in forward Remove reverse gate connecting rod spring no 17 reverse cable pivot arm bolts no 18 Take note of bushing size f...

Page 415: ...hers no 23 Remove nozzle Venturi Remove reverse gate nozzle pivot arm Unplug OPAS hose from plastic elbow Remove 4 retaining screws no 39 and withdraw venturi no 24 It s possible to remove the venturi without remov ing the reverse gate and the nozzle see the fol lowing instructions Disconnect steering cable 1 Steering cable OPAS hose reverse cable Remove 4 retaining screws no 39 and withdraw ventu...

Page 416: ...er to DRIVE SYSTEM DISASSEMBLY NOTE Whenever removing a part visually check for damage such as corrosion crack split break porosity cavitation deformation distortion heat ing discoloration wear pattern missing plating missing or broken balls in ball bearing water dam age diagnosed by black colored spots on metal parts etc Renew any damaged part As a quick check manually feel clearance and end play...

Page 417: ...35 820 in a vise Install pump over this tool Using a 12 mm Allen key unscrew the impeller NOTE It may be needed to heat the impeller to break Loctite bond CAUTION Never use any impact wrench to loos en impeller To remove impeller apply a rotating movement and pull at same time Slide impeller out of housing Pull pump housing out 529 035 820 F18J0PA F18J0QA F18J0RA F18J0SA www SeaDooManuals net ...

Page 418: ...pusher P N 529 035 819 to press out the oil seal no 35 Remove large O ring no 36 from pump housing Wear Ring Remove the screws retaining wear ring in the jet pump housing Place jet pump housing in a vise with soft jaws It is best to clamp housing using a lower ear Cut wear ring at two places CAUTION When cutting ring be careful not to damage jet pump housing NOTE Wear ring can be cut using a jigsa...

Page 419: ...e clear 1 Water passages Brush and clean impeller shaft threads impeller and drive shaft splines with Pulley flange cleaner P N 413 711 809 or equivalent Free threads and splines from any residue PARTS INSPECTION Impeller Visually inspect impeller splines Check for wear or deformation Renew parts if damaged NOTE Check also PTO flywheel and drive shaft con dition Refer to BOTTOM END and DRIVE SYSTE...

Page 420: ...and position its tip onto metal 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 75 mm 029 in MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to threads at shaft end Excessive play can come either from worn bearing or damaged jet pump housing bearing surface Seal Car...

Page 421: ...into bottom of housing 1 Seal lip 2 Press wear ring If a press is not readily available a piece of wood such as a 2 x 4 in x 12 in long can be used Manually engage ring in housing making sure it is equally inserted all around Place wood piece over ring Using a hammer strike on wood to push ring Strike one side then rotate wood piece about 90 and strike again Frequently rotate wood piece so that ri...

Page 422: ... sure to reassemble bear ing parts to their original position The bearing no 33 can be installed either side Install spacer no 32 on shaft no 28 Install O ring no 46 in sleeve no 30 1 O ring Coat shaft surface with jet pump bearing grease P N 293 550 032 then install sleeve no 30 on impeller shaft no 28 From the outlet side of pump press impeller shaft assembly into housing using shaft pusher P N ...

Page 423: ...ATION below On the impeller side install shield no 34 Apply Loctite 243 on impeller shaft and impeller threads Apply BOMBARDIER Lube on the wear ring sur face Start screwing the impeller on its shaft If impeller is too tight use impeller tool to turn im peller to machine wear ring before installing on ve hicle Make sure to turn it smooth enough so that engine starter should turn it Mount impeller ...

Page 424: ...ler cover with new self locking screws Torque to 7 N m 62 lbf in Venturi If needed install new O rings no 38 around bailer passages 1 O rings Position venturi no 24 with bailer passages on top ApplyLoctite 243 blue onthreadsof screws no 39 Install screws no 39 lock washers and flat wash ers then torque to 21 N m 16 lbf ft 1 Torque screws to 21 N m 16 lbf ft O Rings Install O rings no 38 around bai...

Page 425: ...s from other areas must be repaired Disconnect pump gauge tester and remove pres sure cap Reinstall impeller cover no 13 with 3 new self locking screws INSTALLATION Jet Pump Housing Make sure that black rubber covered reducer no 44 is installed as shown CAUTION Misinstallation can cause overheating and damage to exhaust system 1 Black rubber covered reducer Generously apply synthetic grease on dri...

Page 426: ...rque to 24 N m 18 lbf ft OPAS Reconnect OPAS hose Torque clamp screw to 1 7 N m 15 lbf in Fasten OPAS U lever to nozzle Apply Loctite 243 blue on screw threads or use new self locking screws Torque screw to 20 N m 15 lbf ft Pivot Triangle Install head bolts toward inside NOTE Make sure the pivot triangle turn freely Reverse Gate Install reverse gate with spacer and washer Torque to 20 N m 15 lbf f...

Page 427: ... SYSTEM Subsection 03 DRIVE SYSTEM SMR2002 089_12_03A FM 12 03 1 DRIVE SYSTEM 0 GTX DI Models F18I0LS 1 2 3 4 5 6 7 8 9 10 11 13 12 13 2 N m 18 lbf in 2 N m 18 lbf in Synthetic grease Synthetic grease www SeaDooManuals net ...

Page 428: ...Section 12 PROPULSION SYSTEM Subsection 03 DRIVE SYSTEM 12 03 2 SMR2002 089_12_03A FM GTX 4 TEC MOdels F18I01S 5 6 7 8 9 10 11 15 16 12 Synthetic grease Loctite antiseize lubricant www SeaDooManuals net ...

Page 429: ...aining PTO flywheel guard no 1 to engine support Detach PTO flywheel guard from engine and with draw from bilge Large Clamp GTX DI Models Unfasten large clamp of PTO flywheel boot no 3 as follows Use pliers P N 295 000 069 Insert pointed tips of pliers in closing hooks TYPICAL 1 Closing hooks Squeeze pliers to draw hooks together and dis engage windows from locking hooks TYPICAL 1 Locking hooks Sm...

Page 430: ...nt it start engine run at 4000 RPM for 10 seconds and stop engine at this RPM This will move oil out of PTO housing into oil tank Remove seat Detach coolant expansion reservoir from vent tube support then move away 1 Detach expansion reservoir 2 Remove vent tube support Detach vent tube Remove vent tube support Floating Ring and PTO Seal CAUTION Strictly follow this procedure other wise damage to ...

Page 431: ...drive shaft holder P N 529 035 871 on pump support as shown NOTE This is necessary so the drive shaft cannot move rearwards when using the drive shaft floating ring tool 1 Drive shaft holder Disconnect EGT sensor to make room Install drive shaft floating ring tool P N 529 035 841 as shown DRIVE SHAFT FLOATING RING TOOL F18I04A 1 F18B02A 1 F18B03A F18B04A www SeaDooManuals net ...

Page 432: ...haft Remove drive shaft floating ring tool and drive shaft holder Reinstall drive shaft floating ring tool as shown 1 Largest opening here 2 Lubricate both O rings Turn screw clockwise so that the tool pushes the PTO seal forward and the drive shaft to the rear to expose both O rings Lubricate O rings with BOMBARDIER LUBE P N 293 600 016 NOTE This is necessary to ease drive shaft re moval later Re...

Page 433: ...er PTO housing to prevent spillage If spillage occurs clean immediately with the pul ley flange cleaner P N 413 711 809 to prevent oil stains NOTE It may require a slight jerk to the rear to remove the O rings from the PTO seal assembly All Models Boot Loosen gear clamp no 11 holding boot then care fully pull boot and carbon ring no 8 from hull in sert Carbon Ring Loosen gear clamp no 9 then pull ...

Page 434: ...eflection is 0 5 mm 020 in MEASURING DRIVE SHAFT DEFLECTION 1 Dial gauge 2 V blocks Damper GTX DI Models Visually inspect shape of dampers no 13 for de formation or other damage 4 TEC Models Discard damper to install a new one Floating Ring and O Ring Inspect condition of O rings no 7 and floating ring contact surface 1 O rings 2 Floating ring contact surface Boot Inspect the condition of boot If ...

Page 435: ...ustberemovedtoinstallspacer 4 TEC Models InspectPTOsealassembly RefertoPTO HOUSING MAGNETO section All Models INSTALLATION Installation is essentially the reverse of removal procedure However pay particular attention to the following Drive Shaft and Dampers GTX DI Models Install dampers no 13 on drive shaft no 12 NOTE Make sure dampers were not left in PTO flywheel or impeller Install drive shaft ...

Page 436: ...s is a pre clamping position only PRE CLAMPING POSITION 1 Holding hook 2 Large window Insert pointed tips of pliers first in closing hooks TYPICAL 1 Closing hooks Squeeze pliers When both large and small win dows are directly over the 2 locking hooks press those windows down to engage hooks in windows NOTE At installation clamp tail should be in op posite direction of engine rotation 1 Engine rota...

Page 437: ...ION 1 Inner sleeve flush with outer circumference WRONG INSTALLATION 1 Inner sleeve not flush with outer circumference Slightly apply BOMBARDIER LUBE P N 293 600 016 on O rings of drive shaft Apply a thin coat of synthetic grease P N 293 550 010 on the O rings of floating ring and on splines going in impeller Do not get grease on it s sealing surface 1 Synthetic grease 2 No lubrication CAUTION Not...

Page 438: ...float ing ring rearward and guide drive shaft in PTO seal assembly It may be necessary to move PTO seal assembly up and down to position it in the same axis as the drive shaft When properly aligned maintain PTO seal assembly in the proper position and tap shaft end until it bot toms against engine At this time the tell tale MUST NOT be visible This validate the correct position 1 PTO seal support ...

Page 439: ...lder then PTO seal support NOTE Pushing boot no 10 rearwards will ease removal of PTO seal support tool Now ensure everything is properly positioned Tell tale is not exposed inner sleeve is flush with outer circumference of PTO seal assembly and C clip is not exposed If tell tale mark is exposed push PTO seal assem bly rearwards to fully extend it If inner sleeve is not flush gently tap it until i...

Page 440: ...14 SMR2002 089_12_03A FM LUBRICATION PTO Flywheel GTX DI Models Using a grease gun carefully lubricate PTO fly wheel with synthetic grease P N 293 550 010 until boot is just beginning to expand At this point immediately stop greasing F01I0BB www SeaDooManuals net ...

Page 441: ...se F18J1GS 1 2 11 12 4 9 9 7 10 7 6 8 5 10 3 2 5 N m 22 lbf in Loctite 243 Loctite 243 Loctite 243 2 5 N m 22 lbf in 4 N m 35 lbf in 10 N m 89 lbf in 2 6 N m 23 lbf in 3 3 N m 29 lbf in 2 2 5 N m 22 lbf in Loctite 243 2 5 N m 22 lbf in Loctite 243 Silicone sealant Silicone sealant Silicone sealant www SeaDooManuals net ...

Page 442: ...e in terior lever and the reverse cable support To release the engine cooling air intake hose press down the air intake locking devices and move the hose There are two air intake locking devices one above and one underneath the hose DO NOT REMOVE the engine cooling air intake hose completely 1 Engine cooling air intake hose 2 Air intake locking device 3 Interior lever 4 Reverse cable support On th...

Page 443: ...le support bolts no 9 Then remove handle housing no 10 INSPECTION Visually inspect parts for wear or cracks on friction parts Replace all defective parts ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Insert interior lever cursor into reverse cable sup port slider and make that the cursor slides freely in the slider 1 Inter...

Page 444: ...ion Place reverse gate in the up position Turn the joint at the end of reverse cable and place the hole in pivot arm and joint face to face Secure with bolt washers spacer and elastic stop nut Torque to 7 N m 62 lbf in WARNING When adjusting reverse cable assure that le ver is well engaged into the spring slot www SeaDooManuals net ...

Page 445: ...TEM 13 02 1 DISASSEMBLY 13 02 2 ASSEMBLY 13 02 5 OFF POWER ASSISTED STEERING SYSTEM O P A S 13 02 7 GENERAL 13 02 8 SIDE VANE 13 02 8 CYLINDER SUPPORT ASSEMBLY 13 02 9 TIE ROD 13 02 10 SEALED TUBE 13 02 11 FILTER 13 02 11 VALVE 13 02 11 WATER HOSE 13 02 12 CROSS SUPPORT PLATE 13 02 12 ALIGNMENT 13 03 1 www SeaDooManuals net ...

Page 446: ...3 5 6 7 8 2 37 1 36 7 N m 62 lbf in 3 26 N m 19 lbf ft 21 19 4 6 Loctite 243 17 18 22 20 Synthetic grease 10 N m 89 lbf in 29 26 Body 27 38 31 28 6 N m 53 lbf in Loctite 243 30 3 N m 26 lbf in 2 5 N m 22 lbf in Loctite 243 23 24 6 N m 53 lbf in Loctite 243 2 5 N m 22 lbf in 31 32 33 34 10 N m 89 lbf in 35 6 N m 53 lbf in 25 www SeaDooManuals net ...

Page 447: ...move grips no 1 Loosen set screws no 5 of handlebar housings no 6 1 Set screw Remove 4 tapping screws no 7 1 Tapping screw 2 Handle bar housing Remove handlebar housing cover no 8 and throt tle handle housing no 11 Unhook throttle cable from throttle handle no 9 Pry out the throttle cable housing from throttle handle housing no 10 1 Throttle cable 2 Throttle handle housing 3 Throttle cable handle ...

Page 448: ... steering cover as mentioned above Remove 2 screws no 16 and flat washers no 18 Remove steering padding no 17 1 Screws 2 Steering padding Handlebar Remove steering cover and steering padding as mentioned above Remove 4 nuts no 20 to remove handle bar no 4 from steering stem no 22 and steering clamp no 21 1 Nuts 2 Handlebar 3 Steering stem 4 Steering clamp Cable Support Loosen bolts no 22 and remov...

Page 449: ... 1 Steering support 2 Bolts Remove cable support no 27 Steering Support 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 1 Tie rap 2 Connectors 1 F18K0IA F07K02A 1 2 1 2 F07K03A F07K04A 1 2 F07K05A 2 1 www SeaDooManuals net ...

Page 450: ...t no 31 1 Steering stem arm 2 Bolts Remove steering stem arm and support Steering Cable Disconnect steering cable no 31 from steering stem arm no 28 Remove retaining block no 24 Disconnect ball joint no 35 from jet pump nozzle Remove ball joint no 35 and jam nut from cable Loosen nut no 34 then remove half rings no 33 and O ring no 32 NOTE Toloosennut usesteeringcabletool P N 295 000 145 Remove st...

Page 451: ...ering 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 38 by new ones Torque bolts no 30 of steering stem arm to 6 N m 53 lbf in Ball Joint Secure the steering cable ball joint no 35 to the nozzle as per following illustrations CAUTION Ensure the ball joint is parallel 5 to the nozzle arm TYPICAL 1 Ball ...

Page 452: ... 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 453: ...ximately 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 vane ...

Page 454: ...process of disassembly Torque tie rod retaining screw no 10 to 4 5 N m 40 lbf in Torque socket screw no 11 to 2 2 N m 19 lbf in CYLINDER SUPPORT ASSEMBLY Disassembly Removal procedure for RH and LH cylinder sup port assembly is the same Remove side vane as mentioned above Unscrew bottom nut using OPAS cylinder nut wrench P N 529 035 840 1 Bottom nut 2 Cylinder support 3 Pivot rod 4 OPAS cylinder n...

Page 455: ...henever servicing Torque socket screw no 22 to 5 5 N m 49 lbf in TIE ROD Disassembly Removal procedure for RH and LH tie rod is the same Remove side vane and cylinder support assembly as mentioned above Remove OPAS 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 f...

Page 456: ...od 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 OPAS filter is part of plastic elbow no 30 Check for cleanness Replace or clean it as necessary VALVE Disassembly Remove OPAS U lever screw no 2 flat washer no 3 bu...

Page 457: ...for RH and LH water hose is the 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 orie...

Page 458: ...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 2N m 10 lbf in 1 F18K10A 1 www SeaDooManuals net ...

Page 459: ...L 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 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 1 Retaining block 2 Adjustment nut 3 Loosen bolts All Models After adjustment torque ...

Page 460: ...RAGE COMPARTMENT COVER ADJUSTMENT 14 02 9 MIRROR 14 02 10 INFO CENTER LCD GAUGES 14 02 10 DEFLECTOR AND OR UPPER GRILL 14 02 10 FINITION PLATE 14 02 11 INLET GRATE 14 02 11 RIDING PLATE 14 02 11 JET PUMP SUPPORT 14 02 12 DRAIN PLUG INSTALLATION 14 02 13 SEAT COVER REPLACEMENT 14 02 13 BUMPER REPLACEMENT 14 02 14 SPONSON REPLACEMENT 14 02 14 DECALS REPLACEMENT 14 02 15 HULL AND BODY REPAIR 14 02 15...

Page 461: ...BODY Subsection 02 ADJUSTMENT AND REPAIR SMR2002 092_14_02A FM 14 02 1 ADJUSTMENT AND REPAIR 0 GTX DI and GTX 4 TEC Models seats F18L1HS Loctite 414 Loctite 414 Loctite 414 Loctite 414 Loctite 414 www SeaDooManuals net ...

Page 462: ... AND REPAIR 14 02 2 SMR2002 092_14_02A FM GTX DI and GTX 4 TEC Models Front storage compartment F18L1IS Body 4 TEC Limited Only Synthetic Grease Loctite 243 5 N m 44 lbf in 3 N m 26 lbf in Loctite 271 Loctite 243 Loctite 243 www SeaDooManuals net ...

Page 463: ...tion 02 ADJUSTMENT AND REPAIR SMR2002 092_14_02A FM 14 02 3 GTX 4 TEC Model and GTX DI Model Body Front View F18L1JS GTX 4 TEC Only Body GTX DI Only 10 11 8 12 9 7 Loctite 29647 7 N m 62 lbf in Loctite 29647 www SeaDooManuals net ...

Page 464: ...4_02A FM GTX 4 TEC Model and GTX DI Model Body Rear View F18L1KS 2 5 N m 22 lbf in 6 GTX 4 TEC Limited Only GTX 4 TEC or GTX DI Loctite 29647 Loctite 29647 Loctite 5900 Loctite 29647 10 N m 88 lbf in Loctite 243 8 N m 70 lbf in 1 2 3 1 4 15 7 5 N m 13 lbt in www SeaDooManuals net ...

Page 465: ...ES FRONT SEAT 1 Lock pin 2 Adjustment nut Loctite 243 Torque to 6 N m 53 lbf in A 33 1 mm 1 30 3 64 in GTX SERIES REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 243 Torque to 6 N m 53 lbf in A 33 5 1 mm 1 5 16 3 64 in STORAGE COMPARTMENT INNER SHELL GTX DI and GTX 4 TEC Removal and Installation To remove inner shell proceed as follows CAUTION Failure to follow this order may lead to damaging ...

Page 466: ...anged screws Remove two long inner skin screws hex screws 1 Storage cover 2 Inner skin 3 Inner skin short screws x7 4 Inner skin long screws x2 Use a rubber hammer to remove the inner skin from the cover If the inner skin is too stiff install a piece of 2x4 against the inner skin and hit it with the rubber hammer 1 Storage cover 2 Inner skin 3 Rubber hammer Remove connector harness from the inner ...

Page 467: ...re it with the two darts Install the temperature sensor in grommet Install the tie raps around wire harnesses Align inner skin with storage cover and make sure that the lateral locking hooks in the inner skin get engaged in the storage cover locking bracket If the two lateral locking hooks get properly aligned and engaged the storage cover back locking hook will be engaged properly in the inner sk...

Page 468: ...skin long screws STORAGE COVER SHOCK To remove storage cover shock proceed as follows Unlock shock rod from circlip and remove washer 1 Shock rod 2 Circlip 3 Washer Release the shock from top linkage bracket and bottom support bracket by inserting a flat screw driver in the shock top and bottom locking devices 1 Top linkage bracket 2 Shock top locking device 1 F18L1VA 2 1 F18L1WA 2 WARNING Make su...

Page 469: ...reads on new lock pin are coated with a self locking product do not apply Loctite 243 on threads Adjust lock pin no 3 as per following specifica tions FLOATING TYPE 1 Lock pin apply Loctite 243 2 Rubber washer 3 Lock nut Torque to 5 N m 44 lbf in A 39 2 1 mm 1 35 64 3 64 in NOTE Floating type lock pin is used for these mod els It is normal to have a front and aft play of the lock pin To adjust tig...

Page 470: ...Speedometer and LCD Info gauge proceed as follows Remove storage compartment inner shell from storage as described earlier in this section to get access Push Info Center LCD Gauges from the stor age cover If the Info center does not come out easily use liquid soap Refer to ELECTRICAL section to unplug gauges from harnesses Reinstall new Info center Reinstall storage compartment inner shell DEFLECT...

Page 471: ...me Finition plate is mounted on deflector Remove three darts holding deflector and grill INLET GRATE Removal and Installation Loosen screws and remove inlet grate NOTE An impact screwdriver should be used to loosen tight screws 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...

Page 472: ...d by the shaded areas in the next illustra tions Follow also the torquing sequence as shown in the same illustrations GTX 4 TEC MODEL GTX DI MODEL NOTE Apply Loctite RTV silicone sealant P N 293 800 066 as indicated by the shaded area JET PUMP SUPPORT Removal Remove jet pump Refer to JET PUMP Remove inlet grate and riding plate Remove ball joint boot nut half rings and O rings from steering cable ...

Page 473: ... sequence as shown in the same illustrations GTX DI AND GTX 4 TEC MODELS DRAIN PLUG INSTALLATION Refer to the following illustration to install drain 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 COVER REPLACEMENT Install staples with an electric tacker such as Arrow tacker no ETN 50 or with a manu...

Page 474: ...if necessary Slide bumper rail no 2 in corner bumper no 3 Install trim no 1 using soapy water Repeat procedure for the other side SPONSON REPLACEMENT Removal and installation procedure for RH and LH sponson is same Remove screws no 11 Pryout sponson cover from backend with screw driver 1 Sponson 2 Sponson cover Slide sponson cover towards front to about 15 mm and pull it out from sponson Unscrew n...

Page 475: ... few seconds when the activator evapo rates the surface is ready Using a pencil and the decal as a template mark the area where decal will be located For better adhesion a dry application is recom mended however to ease decal installation a mild solution of soapy water can be sprayed over sur face where decal will be installed Remove back protective film from decal and align decal with marks When ...

Page 476: ...00 grit BUFFING AND WAXING Buff the surface using a heavy duty polisher with a buffing pad Make sure the pad is free of dirt or you may damage the gelcoat Carefully begin buff ing with a white medium compound Finish off us ing a fine compound While buffing pay close at tention to avoid overheating the surface Blisters Possible causes Insert catalyst Improper catalyst gelcoat ratio A blister is a v...

Page 477: ...a fine compound While buffing pay close at tention to avoid overheating the surface Compound Fractures Possible causes Thickness of fiberglass laminate Direct result of impact Compound fractures are those that have gone past the gelcoated surface and in through the lay ers of fiberglass laminate Two types of repairs have to be performed The first is to restore the structural integrity of the damag...

Page 478: ...dure as for outside repair when laminating the alternating pieces of fiberglass ma terial If a backing support was used remove it before starting the repair After the area has hard ened remove sharp edges of material from sur face If required paint the surface SANDING Outside This surface will have to be prepared for applica tion of gelcoat The size of the area will determine the gelcoating proced...

Page 479: ...total Piston ring type and quantity 2 semi trapez chrome coated steel rings Ring end gap New 0 55 0 7 mm 022 028 in Wear limit 1 1 mm 043 in Ring piston groove clearance New 0 044 0 089 mm 002 003 in Wear limit 0 22 mm 0087 in Piston cylinder wall clearance New minimum 0 12 mm 0047 in Wear limit 0 22 mm 0087 in Cylinder taper maximum 0 10 mm 004 in Cylinder out of round maximum 0 08 mm 003 in Conn...

Page 480: ...in 30 A Injection system INJ 15 A Charging system REG 25 A Information center ACC 2 A Fuel pump FP 15 A Battery 25 A VTS system VTS Not applicable ADDITIONAL INFORMATION FUEL SYSTEM GTX DI Fuel injection type Orbital Direct Fuel Injection twin throttle body 46 mm 1 81 in Fuel pressure 105 2 PSI 108 PSI Idle speed in water out of water 1450 50 RPM Throttle Position Sensor TPS 1 6 kΩ 2 4 kΩ Cranksha...

Page 481: ... diameter 155 6 mm 6 126 in Impeller wear ring clearance New 0 0 0 4 mm 000 016 in Wear limit 1 0 mm 040 in Impeller shaft end play new 0 Impeller shaft side play 0 05 mm 002 in Impeller pitch material Progressive pitch stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTX DI Number of passenger driver incl 3 Overall length 331 cm 130 in Overall width 122 c...

Page 482: ...arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTX DI Estimated pump power 52 2 kW 70 HP Maximum fuel consumption at wide open throttle 47 L h 12 4 U S gal h Cruising time at full throttle Fuel tank without reserve 60 minutes Fuel tank reserve from low level signal 12 ...

Page 483: ...in New maximum 5 975 mm 2352 in Wear limit 5 930 mm 2330 in Exhaust New minimum 5 946 mm 2341 in New maximum 5 960 mm 2346 in Wear limit 5 930 mm 2330 in Valve guide diameter New minimum 5 994 mm 2360 in New maximum 6 018 mm 2369 in Wear limit 6 060 mm 2386 in Valve spring free length Inner New nominal 41 02 mm 1 615 in Wear limit 38 8 mm 1 499 in Outer New nominal 45 45 mm 1 789 in Wear limit 43 ...

Page 484: ...ximum 39 905 mm 1 5711 in Wear limit 39 885 mm 1 5703 in Camshaft bore Front New minimum 25 000 mm 9842 in New maximum 25 013 mm 9848 in Wear limit 25 025 mm 9852 in PTO and center New minimum 40 000 mm 1 5748 in New maximum 40 016 mm 1 5754 in Wear limit 25 025 mm 1 5758 in Cam lobe Intake New minimum 31 480 mm 1 2394 in New maximum 31 590 mm 1 2437 in Wear limit 31 430 mm 1 2374 in Exhaust New m...

Page 485: ...mm 0008 in New maximum 0 25 mm 0098 in ADDITIONAL INFORMATION ENGINE GTX 4 TEC ELECTRICAL GTX 4 TEC Magneto generator output 380 W 6000 RPM Ignition system type DI Digital Induction Ignition timing Not adjustable Spark plug Make and type NGK DCPR8ES Gap 0 75 mm 030 in Generating coil N A Battery charging coil 0 1 1 0 Ω Ignition coil Primary 0 45 0 55 Ω Secondary 6 8 10 2 kΩ Engine RPM limiter sett...

Page 486: ...4 kΩ Exhaust Gas Temperature Sensor EGT 2 28 kΩ 2 74 kΩ Manifold Air Pressure Sensor MAPS 0 Ω continuity between terminals 3 and 1 Knock Sensor KS 5 MΩ Oil Pressure Switch OPS 0 Ω if oil pressure is greater than 26 32 PSI Oil Separator Pressure Switch OSPS 0 Ω if blow by pressure is less than 6 PSI TOPS valve 1 27 Ω 2 47 Ω Fuel injector 11 4 Ω 12 6 Ω Fuel Type Super unleaded gasoline Minimum octan...

Page 487: ...3 0 3 mm 6 122 0118 in Impeller wear ring clearance New 0 0 0 4 mm 000 016 in Wear limit 1 0 mm 040 in Impeller shaft end play new 0 Impeller shaft side play 0 75 mm 029 in Impeller material Stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS GTX 4 TEC Number of passenger driver incl 3 Overall length 331 cm 130 in Overall width 122 cm 48 in Overall height 113...

Page 488: ...ilencer N A Flame arrester Tubular wire screen Steering padding N A Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE GTX 4 TEC Estimated pump power 57 kW 76 44 HP Maximum fuel consumption at wide open throttle 41 1 L h 10 8 U S gal h Cruising time at full throttle Fuel tank without reserve 55 minutes Fuel tank reserve from low le...

Page 489: ...econd 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 EMS ECU GTX 4 TEC Models On the EMS ECU circuits are identified by a letter followed by a number The letter indicates in which connector the wire is plugged in The number indicates the position of the wire in the connector ...

Page 490: ...her to disengage press the release button and disconnect them 1 Flat screwdriver 2 Deutsch connectors 1 Release button 2 Deutsch connectors 1 Deutsch connectors 2 Press release button All Models Deutsch connectors are used to connect wiring harness to the magneto and to the VCK 1 Male housing 2 Female housing 3 Secondary lock 4 Sealing cap 1 F18Z0KA 2 3 1 F18Z0LA 2 2 F18Z0MA 2 1 F18Z0NA 1 2 F00H1C...

Page 491: ...8 mm 189 in wide screwdriver blade inside the front of the contact cavity Pry back the retaining tab while gently pulling wire back until contact is removed FEMALE CONNECTOR HOUSING 1 Retaining tab To install For insertion of signal contact make sure the lock is removed Insert contact into appropriate circuit cavity and push as far as it will go Pull back on the contact wire to be sure the re tent...

Page 492: ... on TT600 4 tool AMP PLUG CONNECTOR All Models These connectors are found on the MPEM When servicing electrical system special care must be taken when working with AMP Plug Con nectors in order to prevent any malfunction of the system Description AMP PLUG CONNECTOR 1 Plug assembly 2 Cover assembly 3 Mating seal 4 Wedge lock 5 Header assembly 6 Seal plug 7 Power wire 8 Signal wire 9 Locking tab 1 F...

Page 493: ...contact with the mating seal the seal may loose its sealing capacities Do not apply lubricant on contacts inside plug connector Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header on the MPEM 1 Mechanically keyed Contact Removal Signal Wire Insert a screwdriver blade between the connector and the wedge lock tab Release the locking tab and at the same time p...

Page 494: ... removed 1 Rotate wire back and forth 2 Pull wire Power Wire Contact NOTE The wedge lock must be removed to ex tract power contact Open the wedge lock Pull both locking tabs and remove wedge lock from plug assembly 1 Pull locking tab both sides Before extraction push wire forward to relieve pres sure on retaining tab Insert a 4 8 mm 189 in wide screwdriver blade inside the front of the contact cav...

Page 495: ...When installing wire contacts in plug connector the diaphragm is pierced as the contact passes through it If the diaphragm is pierced and the cavity is not used install a seal plug large end first into circuit cavity as far as it will go NOTE It is suggested that all unused circuit cavi ties be sealed with a seal plug even if they are not pierced 1 Seal plug 2 Wire seal CAUTION Do not pierce the d...

Page 496: ...oved 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 pressure with the tool pull the wire out 1 Deutsch...

Page 497: ...dule male connector A and the watercraft system control harness female connector is connected to the module male con nector B The engine connector has 41 pins 1 EMS ECU 2 A connector engine harness 3 B connector watercraft system harness Crimping and Installation Tools Required To install EMS ECU connector terminal pins or ter minal wire three tools are required EMS ECU crimping tool EMS ECU extra...

Page 498: ...ns are splited in three groups 1 to 13 14 to 28 and 29 to 41 Make sure you have located the proper terminal 1 Wire harness 2 Terminal pinout numbers Once the defective terminal is identified unlock the red terminal locking plate by using the flat screwdriver and release the locking device at each end of the connector Remove the red terminal locking plate by sliding it outside the connector 1 First...

Page 499: ... 1 Red terminal locking plate 2 EMS ECU extraction tool Release the defective terminal from connector with the extraction tool Align the extraction tool pin properly with the terminal cavity and push the tool downward That will release the wire with the terminal 1 Terminal cavity 2 Extraction tool 3 Extraction tool pin 1 Extraction tool 2 Connector terminal housing 1 F18Z0AA 2 1 F18Z0BA 1 F18Z0CA ...

Page 500: ... ECU crimping tool Install the new termi nal in the crimping tool swivel Close the swivel in place Place the wire on terminal barrel and crimp the wire firmly 1 New terminal 2 Crimping tool swivel 3 Crimping tool 1 Crimping tool swivel 2 Crimping tool 3 Wire CAUTION Probe on top of terminal only Do not try to probe inside terminal or to use a paper clip to probe inside terminal it can damage the s...

Page 501: ...GTX DI MODEL www SeaDooManuals net ...

Page 502: ...F18Z0P MODEL GTX DI 2002 12 VOLTS DISTRIBUTION www SeaDooManuals net ...

Page 503: ...GTX 4 TEC MODEL www SeaDooManuals net ...

Page 504: ...LVE OSPS NORMALY CLOSED CPS COMMUNICATION LINK COMMUNICATION LINK COMMUNICATION LINK D E S S AUXILIARY MODULE OPS NORMALY OPEN OSPS NORMALY CLOSED CPS IDLE BY PASS VALVE EGT MATS CTS MAPS TPS TOPS VALVE ENGINE CONNECTOR EMS ECU TOPS VALVE INFORMATION CENTER 12 VOLTS DISTRIBUTION TOPS VALVE www SeaDooManuals net ...

Page 505: ...www SeaDooManuals net ...

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