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Sea-doo GTX Limited iS 255 2009, Shop Manual

The Sea-doo GTX Limited iS 255 2009 is a high-performance personal watercraft designed for water enthusiasts. To ensure smooth operation and easy maintenance, it is essential to have a comprehensive Shop Manual. Our website offers a free download of the manual, providing users with detailed instructions and valuable insights.

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Section 02 ENGINE

Subsection 09 (COOLING SYSTEM)

CLOSED LOOP COOLING SYSTEM

Ride plate

(operates as heat

exchanger)

Coolant flows

to ride plate

Coolant housing

including thermostat

opens at 87°C (188°F)

and water 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

smr2009-024-100_en

114

smr2009-024

Summary of Contents for GTX Limited iS 255 2009

Page 1: ......

Page 2: ...2009 Shop Manual RXT iS 255 GTX LIMITED iS 255 ...

Page 3: ...of Bombardier Recreational Products Inc BRP or its affiliates 4 TEC iTC Sea Doo D E S S O T A S Sea Doo Learning Key iBR Rotax VTS Variable Trim System iControl RXT XPS iS This document contains the trademarks of the following companies AMP is a trademark of Tyco Electronics Corporation Gelcote is a trademark of Gelcote International Limited GTX is a trademark of Castrol Ltd Used under license Loc...

Page 4: ...RCRAFT 13 02 ENGINE 01 ENGINE REMOVAL AND INSTALLATION 15 GENERAL 15 PROCEDURES 15 ENGINE 15 ENGINE MOUNTS 23 02 AIR INTAKE SYSTEM 25 GENERAL 27 SYSTEM DESCRIPTION 27 PROCEDURES 27 REAR VENTILATION BOX 27 FRONT VENTILATION BOX 27 AIR INTAKE DUCT 27 AIR INTAKE SILENCER COVER 28 AIR INTAKE SILENCER BAFFLE 28 AIR INTAKE TUBE 28 AIR INTAKE SILENCER 29 SUPERCHARGER AIR INLET HOSE 29 03 INTAKE MANIFOLD ...

Page 5: ... HOUSING AND MAGNETO 69 GENERAL 71 TROUBLESHOOTING 71 PROCEDURES 71 PTO HOUSING 71 PTO SEAL 76 PTO COUPLING 77 STARTER DRIVE BEARING 77 STATOR 78 ROTOR AND TRIGGER WHEEL 81 RING GEAR 82 STARTER DRIVE 83 08 LUBRICATION SYSTEM 85 GENERAL 90 MAINTENANCE 90 ENGINE OIL 90 OIL FILTER 92 INSPECTION 93 ENGINE OIL PRESSURE 93 TROUBLESHOOTING 94 PROCEDURES 95 OIL PRESSURE SWITCH OPS 95 PTO OIL STRAINER 96 S...

Page 6: ...ANIFOLD 132 CYLINDER HEAD COVER 133 SPARK PLUG TUBES 134 ROCKER ARMS 134 CAMSHAFT TIMING GEAR 136 CAMSHAFT 138 CYLINDER HEAD 139 VALVE SPRINGS 141 VALVES 143 VALVE GUIDES 146 11 CYLINDER BLOCK 149 GENERAL 152 TROUBLESHOOTING 152 PROCEDURES 152 TIMING CHAIN 152 CHAIN TENSIONER 153 PISTONS AND CONNECTING RODS 153 PISTON RINGS 158 CRANKSHAFT 159 BALANCER SHAFT 164 CYLINDER BLOCK 167 03 ELECTRONIC MAN...

Page 7: ... DESCRIPTION 220 ADJUSTMENT 221 IDLE SPEED 221 CLOSED THROTTLE RESET 222 TROUBLESHOOTING 222 DIAGNOSTIC TIPS 222 PROCEDURES 223 ENGINE CONTROL MODULE ECM 223 FUEL RAIL 230 FUEL INJECTOR 232 THROTTLE BODY 236 TPS THROTTLE POSITION SENSOR 239 CRANKSHAFT POSITION SENSOR CPS 241 CAMSHAFT POSITION SENSOR CAPS 243 MANIFOLD AIR TEMPERATURE SENSOR MATS 245 COOLANT TEMPERATURE SENSOR CTS 247 MANIFOLD ABSOL...

Page 8: ...289 TROUBLESHOOTING 289 DIAGNOSTIC GUIDELINES 289 IGNITION SYSTEM TESTING 290 PROCEDURES 290 IGNITION COILS 290 SPARK PLUGS 294 04 CHARGING SYSTEM 297 GENERAL 297 SYSTEM DESCRIPTION 297 INSPECTION 298 CHARGING SYSTEM OUTPUT 298 PROCEDURES 300 CHARGING SYSTEM FUSE 300 VOLTAGE REGULATOR RECTIFIER 300 BATTERY 301 05 STARTING SYSTEM 313 GENERAL 313 BASIC STARTING SYSTEM OPERATION 313 TROUBLESHOOTING 3...

Page 9: ...LE 362 HANDLEBAR GRIP 363 HANDLEBAR SWITCH COVER LH OR RH 364 STEERING COVER 364 THROTTLE AND iBR LEVERS 366 STEERING CABLE 366 STEERING COLUMN 368 STEERING COLUMN SUPPORT 369 STEERING TILT ADJUSTMENT HANDLE 369 O T A S SWITCH 370 O T A S MAGNETS 371 02 iBR AND VTS 373 GENERAL 375 SYSTEM DESCRIPTION iBR 375 SYSTEM DESCRIPTION VTS 378 MAINTENANCE 379 iBR GATE BACKLASH CHECK 379 FRICTION SLEEVE REPL...

Page 10: ...TIC TIPS 429 PROCEDURES 430 DRIVE SHAFT 430 SEALING RING 435 07 BODY AND HULL 01 SUSPENSION iS 437 GENERAL 440 SYSTEM DESCRIPTION 440 TROUBLESHOOTING 441 DIAGNOSTIC TIPS 441 DIAGNOSTIC GUIDELINES 441 DIAGNOSTIC FLOW CHARTS 443 PROCEDURES 445 SHOCK ABSORBER 445 SPRINGS 446 SUSPENSION POSITION SENSOR 446 iS MODULE 449 iS BUTTON 451 HYDRAULIC PUMP 453 ACTUATOR 457 LATERAL SUPPORT 458 LATERAL BELLOWS ...

Page 11: ...M 506 DRAIN PLUGS 507 BOW EYELET 507 STERN EYELETS 509 HULL INSERTS 509 08 TECHNICAL SPECIFICATIONS 01 RXT iS 255 GTX LIMITED iS 255 511 09 WIRING DIAGRAM 01 WIRING DIAGRAM INFORMATION 517 GENERAL 517 WIRING DIAGRAM LOCATION 517 WIRING DIAGRAM CODES 517 02 CONNECTOR INFORMATION 519 PROCEDURES 519 MAGNETO AND ENGINE CONNECTOR DEUTSCH 519 ECM CONNECTOR MOLEX 521 BRLS TAS AND STARTER SOLENOID CONNECT...

Page 12: ...ts is most strongly recom mended when considering replacement of any component 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 WARNING Unless otherwise specified engine should be turned OFF and cold for all maintenance and r...

Page 13: ... equipment without incurring obligation VEHICLE INFORMATION HULL IDENTIFICATION NUMBER H I N The hull identification number is composed of 12 digits YDV 12345 L 4 95 Model year Year of production Month of production Serial number a letter may also be used as a digit Manufacturer It is located on footboard at the rear of watercraft smr2009 011 001_a 1 Hull Identification Number H I N ENGINE IDENTIF...

Page 14: ...ion Regulations All new 1999 and more recent SEA DOO wa tercrafts manufactured by BRP are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft engines This certification is contingent on certain adjustments being set to factory standards For this reason the fac tory procedure for servicing the product must be strictly follow...

Page 15: ...ny procedure be sure that you have on hand all the tools required or approved equivalents The use of RIGHT starboard and LEFT port in dications in the text always refers to driving posi tion when sitting on watercraft Besides in the marine industry FRONT is called BOW and REAR is called STERN smr2009 011 002_a 1 Left port 2 Right starboard This manual uses technical terms which may be different fr...

Page 16: ...related positions TYPICAL PAGE Illustration number for publishing process Subsection title Indicates applicable models Document number for publishing process Bold face number is used to identify a part referred to the text Drop represents a service product to be applied Dotted box contains parts applicable to a specific model Page number NEW indicates that the part must be replaced with a new one ...

Page 17: ... exploded views Clean threads before applying a threadlocker Re fer to the SELF LOCKING FASTENERS and LOC TITE APPLICATION sections at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners etc must be replaced with new ones PROCEDURES MAGNETO FLYWHEEL ...

Page 18: ...ue value NOTE Always torque screws bolts and or nuts in a crisscross sequence A00A8BS Property class and head markings Property class and nut markings 5 5 8 8 10 10 12 12 4 8 4 8 4 8 8 8 8 8 8 8 9 8 9 8 9 8 10 9 10 9 10 9 12 9 12 9 12 9 12 9 FASTENER GRADE TORQUE FASTENER SIZE 5 8 Grade 8 8 Grade 10 9 Grade 12 9 Grade M4 1 5 2 N m 13 18 lbf in 2 5 3 N m 22 27 lbf in 3 5 4 N m 31 35 lbf ft 4 5 N m ...

Page 19: ...ads bolt and nut with solvent 2 Apply LOCTITE PRIMER N P N 293 800 041 on threads and allow to dry 3 Choose proper strength Loctite threadlocker 4 Fit bolt in the hole 5 Apply a few drops of threadlocker at proposed tightened nut engagement area 6 Position nut and tighten as required Threadlocker Application for Blind Holes 1 2 lmr2007 040 004_a 1 On threads 2 On threads and at the bottom of hole ...

Page 20: ...ng metal with tip of flask NOTE For preventive maintenance on exist ing equipment retighten nuts and apply proper strength Loctite on bolt nut contact surfaces Threadlocker Application for Adjusting Screw A00A3PA 1 2 1 Apply here 2 Plunger 1 Adjust screw to proper setting 2 Apply drops of proper strength Loctite thread locker on screw body contact surfaces 3 Avoid touching metal with tip of flask ...

Page 21: ... Clean both mating surfaces with solvent 3 Spray Loctite Primer N on both mating surfaces and on both sides of gasket Allow to dry 1 or 2 minutes 4 Apply LOCTITE 518 P N 293 800 038 on both sides of gasket using a clean applicator 5 Place gasket on mating surfaces and assemble immediately NOTE If the cover is bolted to blind holes above apply proper strength Loctite in the hole and on threads Tigh...

Page 22: ...per strength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low strength liquid is recommended as normal strength and gap are required 4 Install according to standard procedure 5 Wipe off surplus 6 Allow it to cure for 30 minutes NOTE Normally used on worn out housings to prevent leaking or sliding It is generally not necessary to remove gask...

Page 23: ...XX smr2009 011 ...

Page 24: ...AR 200 HOURS or 2 YEAR A Adjust C Clean I Inspect L Lubricate R Replace O Operator D Dealer TO BE PERFORMED BY PART TASK NOTE ENGINE Engine oil 1 and filter R R D Rubber mounts I I D Corrosion protection L O Supercharger clutch R 2 D 1 Check level before each ride 2 See NOTE 1 after maintenance schedule EXHAUST SYSTEM Exhaust system I I C 3 D O 3 Daily flushing in salt water or foul water use COOL...

Page 25: ...on before each ride 7 See NOTE 2 after maintenance schedule 10 Check operation PROPULSION SYSTEM Carbon ring and rubber boot drive shaft I I D Impeller boot I I D Impeller shaft seal sleeve and O ring I 4 D Drive shaft impeller splines I L D Sacrificial anode if so equipped 8 D Impeller and impeller wear ring clearance I I D Pump mounts I I D 4 At storage period or after 100 hours of use whichever...

Page 26: ...ENANCE REQUIRED message is displayed on the information center every 100 hours of operation or earlier depending on the riding style speed engine s RPM water conditions This is determined by the engine management system The supercharger clutch will need to be replaced within 5 hours of the message display The supercharger maintenance reminder must be reset using B U D S 2 The iTC and iBR levers sh...

Page 27: ...4 ...

Page 28: ... should be turned off during preseason preparation pro cedure Using the maintenance chart performed items in the columns indicated 100 HOURS OR 1 YEAR and TO BE PERFORMED BY smr2009 013 001_a 1 Use these columns Furthermore proceed with the following Watercraft Prepared as per Storage Procedure Reinstall the battery Test ride watercraft to confirm proper opera tion Watercraft Not Prepared as per S...

Page 29: ...6 ...

Page 30: ... protection against varnish deposits Fill up fuel tank completely Ensure there is no wa ter inside fuel tank WARNING Always stop the engine before refueling Fuel is inflammable and explosive under certain conditions Always work in a well ventilated area Do not smoke or allow open flames or sparks in the vicinity Fuel tank may be pressurized slowly turn cap when open ing When fueling keep watercraf...

Page 31: ...tifreeze should be replaced every 200 hours or every two years to prevent antifreeze deteriora tion NOTICE Failure to replace the antifreeze as recommended may allow its degradation that could result in poor engine cooling If coolant is not replaced test the coolant density using an antifreeze hydrometer Replace coolant if necessary For the coolant re placement procedure refer to COOLING SYSTEM su...

Page 32: ...battery removal cleaning and storage refer to CHARGING SYSTEM subsection VEHICLE Bilge Cleaning Clean the bilge with hot water and mild detergent or with bilge cleaner Rinse thoroughly Lift front end of watercraft to completely drain bilge Body and Hull Cleaning Wash the body with soap and water solution only use mild detergent Rinse thoroughly with fresh water Remove marine organisms from the hul...

Page 33: ...10 ...

Page 34: ...ination If nec essary siphon and refill with fresh fuel WATER FLOODED ENGINE If engine is water flooded it must be serviced within a few hours after the event Otherwise engine will have to be overhauled NOTICE Never try to crank or start the engine Water trapped in the intake manifold would enter the combustion chamber through the intake valves and may cause damage to the engine A water flooded en...

Page 35: ...iphon the contaminated oil from the oil filter reservoir 7 Remove valve cover Refer to CYLINDER HEAD subsection smr2006 006 001_a 1 Valve cover 8 Put a tape at 400 mm 16 in from the end of the suction pump tube 9 Insert the tube in the PTO area until the tape reach the cylinder block edge Then siphon contaminated oil out smr2006 006 003_a TYPICAL 1 Suction pump tube with tape 2 Edge of cylinder bl...

Page 36: ...nlet hose 4 Continue to run the engine at 3500 RPM for 15 more minutes 20 minutes total run time 5 Shut the engine off 6 Remove the hose pincher on the coolant line going to the oil cooler NOTICE Hose pincher must be removed prior to operating the watercraft Failure to do this will result in damage to the engine 7 Change the oil and filter again 8 Procedure is now completed CAPSIZED WATERCRAFT Cap...

Page 37: ...14 ...

Page 38: ... FASTENER and LOCTITE APPLICATION at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pin etc must be replaced with new ones Hoses cables or locking ties removed during a procedure must be reinstalled as per factory stan dards PROCEDURES EN...

Page 39: ...e 4 Blow by valve 5 Exhaust manifold 10 Move muffler rearward 10 1 Unplug the exhaust gas temperature sen sor EGTS smr2009 016 004_a 1 EGTS sensor 2 Exhaust hose 10 2 Disconnect the exhaust hose smr2009 016 005_a 1 Exhaust hose clamp 10 3 Detach retaining strap smr2009 016 006_a 1 Muffler retaining strap 10 4 Unscrew exhaust clamp NOTICE Do not use pneumatic or elec tric tools on exhaust clamp as ...

Page 40: ...ection 17 Cut locking tie securing wiring harness to oil filler tube smr2009 016 010_a 1 Cut this locking tie 2 Oil filler tube 18 Unscrew ground wires from engine smr2009 016 011_a 1 Ground wires 19 On top of engine cut locking ties securing ve hicle harness and engine connector to engine 20 Unplug the B connector from the ECM smr2009 016 012_a 1 Locking tie retaining engine connector 2 Locking t...

Page 41: ...nector 2 Connector housing 24 Disconnect air intake hose from throttle body smr2009 016 016_a 1 Air intake hose 2 Throttle body 25 Disconnect ride plate hoses from water pump housing smr2009 016 017_a 1 Ride plate hoses 2 Water pump housing 26 Install a suitable lifting device smr2009 016 018_a 1 Engine lifting brackets 27 Remove front engine support screw smr2009 016 019_a 1 Front engine support ...

Page 42: ...king tie securing coolant hoses starter cable and ground cable smr2009 016 022_a 1 Rear engine support screw on port side 2 Cut this locking tie 32 Disconnect the water outlet hose from the ex haust manifold smr2009 016 023_a 1 Water outlet hose 2 Exhaust manifold 33 Slightly lift engine to ease the remaining com ponent removal 34 Disconnect the water inlet hose from the ex haust manifold smr2009 ...

Page 43: ...y LOCTITE 243 BLUE P N 293 800 060 on threads of ground cable screw or use a new screw with self locking product Tighten ground cable screw to 23 N m 17 lbf ft Torque starter cable nut to 7 N m 62 lbf in Install protective cap over the starter cable end Connect exhaust manifold water inlet and outlet hoses Tighten clamps to 1 7 N m 15 lbf in Place engine into vehicle Install engine support screws ...

Page 44: ...ubsections To verify alignment proceed as follows 1 Remove the sealing ring and the drive shaft boot Refer to DRIVE SHAFT subsection 2 Install the ALIGNMENT SHAFT SUPPORT P N 529 035 506 on the ENGINE ALIGNMENT PLATE P N 529 036 170 529035506 ALIGNMENT SHAFT SUPPORT 529036170 ENGINE ALIGNMENT PLATE smr2009 016 027_a 1 Engine alignment plate 2 Engine alignment support 3 Secure the tool on ride plat...

Page 45: ...and shim s P N 270 000 762 for the rear engine mounts Shims location is between engine mount and engine mount plate NOTICE Whenever shims are used to correct alignment never install more than 5 shims smr2009 016 032_a REAR STARBOARD ENGINE MOUNT SHOWN 1 Engine mount 2 Engine mount screws 3 Shim 4 Engine mount plate 10 When engine alignment is correct check the longitudinal position of engine Engin...

Page 46: ...check engine alignment ENGINE MOUNTS If engine mounts have been removed apply LOC TITE 243 BLUE P N 293 800 060 on screw threads or use new screws with self locking product Torque all engine mount screws to 25 N m 18 lbf ft 1 Loctite 243 2 1 Loctite 243 2 1 Loctite 243 2 smr2009 016 033_a 1 Torque to 25 N m 18 lbf ft 2 Position conical spring washer with its concave side towards hull smr2009 016 2...

Page 47: ...24 ...

Page 48: ...Section 02 ENGINE Subsection 02 AIR INTAKE SYSTEM AIR INTAKE SYSTEM Blow by valve 1 7 N m 15 lbf in NEW 6 N m 53 lbf in 6 N m 53 lbf in 4 N m 35 lbf in smr2009 017 001_a smr2009 017 25 ...

Page 49: ...Section 02 ENGINE Subsection 02 AIR INTAKE SYSTEM 1 2 N m 11 lbf in 1 2 N m 11 lbf in smr2009 017 002_a 26 smr2009 017 ...

Page 50: ...aining latches smr2009 017 010_a 1 Ventilation box 2 Retaining latches 3 Remove the ventilation box Rear Ventilation Box Installation The installation is the reverse of the removal pro cedure However pay attention to the following Before installing the ventilation box check the condition of its seal If the seal is damaged replace the ventilation box as an assembly FRONT VENTILATION BOX Front Venti...

Page 51: ...reverse of the removal pro cedure However pay attention to the following Check the condition of the seal cover Replace seal as required Tighten clamp to 1 7 N m 15 lbf in AIR INTAKE SILENCER BAFFLE Air Intake Silencer Baffle Removal Remove AIR INTAKE SILENCER COVER see pro cedure in this subsection Pull the baffle out of the air intake silencer smr2009 017 005_a 1 Air intake silencer baffle Air In...

Page 52: ... silencer squeeze the top of the supercharger air inlet hose and move hose out of air intake silencer Air Intake Silencer Installation Squeeze the top of the supercharger air inlet hose and move hose in air intake silencer Install the air intake silencer into hose groove smr2009 017 009_a 1 Air intake silencer 2 Inlet hose groove Install all other removed parts SUPERCHARGER AIR INLET HOSE Supercha...

Page 53: ...30 ...

Page 54: ...3 BLUE 293 800 060 35 18 N m 159 lbf in Loctite 243 9 N m 80 lbf in NEW 9 N m 80 lbf in 9 N m 80 lbf in 5 5 N m 49 lbf in 5 5 N m 49 lbf in Engine oil Loctite 243 Loctite 243 Loctite 243 Loctite 243 See ELECTRONIC FUEL INJECTION See ELECTRONIC FUEL INJECTION See ELECTRONIC FUEL INJECTION smr2009 018 001_a smr2009 018 31 ...

Page 55: ... stan dards PROCEDURES INTAKE MANIFOLD Intake Manifold Removal Remove the moving deck and the deck extension Refer to BODY subsection Remove the air intake silencer Refer to AIR IN TAKE SYSTEM subsection Disconnect the intake hose at intake manifold smr2009 018 020_a 1 Intake hose Move the coolant expansion tank aside to make room Remove the oil dipstick Release the fuel pressure Disconnect fuel h...

Page 56: ...9 018 007_a 1 MAPS connector 2 Engine connector location 3 MATS connector Pull the engine connector out of the ECM support smr2009 018 008_a 1 Engine connector 2 ECM support Unplug the knock sensor KS the magneto and the throttle actuator connectors smr2009 018 009_a 1 KS connector 2 Magneto connector location 3 Throttle actuator connector Pull the knock sensor KS and magneto connec tors out of th...

Page 57: ...ut of the manifold slot R1503motr59A Lift intake manifold up to pull it out of the mount ing brackets 1 R1503motr61A 1 Mounting brackets Pull intake manifold out Intake Manifold Inspection Check intake manifold for cracks warping at flanges or any other visible damage Check if intake manifold gaskets are cracked brit tle or otherwise damaged Replace damaged parts as necessary Intake Manifold Insta...

Page 58: ... in following the tightening sequence as shown in next illustration smr2009 018 013_a Ensure to properly route and secure wiring har ness with locking ties Apply LOCTITE 243 BLUE P N 293 800 060 on the ECM retaining screws and torque them to 9 N m 80 lbf in FLAME ARRESTER Flame Arrester Location The flame arrester is integrated in the intake man ifold smr2009 018 014_a 1 Flame arrester Flame Arres...

Page 59: ...36 ...

Page 60: ...KING TOOL 529 035 839 40 SUPERCHARGER GEAR HOLDER 529 036 025 41 SUPERCHARGER RETAINING KEY 529 036 027 44 46 50 SUPPORT PLATE 529 035 947 41 44 47 48 TORX ADAPTOR 529 035 938 43 51 SERVICE PRODUCTS Description Part Number Page ISOFLEX GREASE TOPAS NB 52 293 550 021 50 LOCTITE 243 BLUE 293 800 060 48 50 51 LOCTITE 5910 293 800 081 51 SUPER LUBE GREASE 293 550 030 51 smr2009 020 37 ...

Page 61: ... 9 N m 80 lbf in Loctite 243 Loctite 243 Engine oil Loctite 5910 29 N m 21 lbf ft 9 N m 80 lbf in NEW Loctite 243 29 N m 21 lbf ft NEW NEW Loctite 243 Engine oil Super Lube grease Engine oil Isoflex grease Topas NB62 Engine oil Isoflex grease Topas NB62 NEW smr2009 020 001_a 38 smr2009 020 ...

Page 62: ...must be reinstalled as per factory stan dards INSPECTION SUPERCHARGER INLET CLEANLINESS NOTE A lower than usual maximum RPM at full throttle might be caused by a dirty supercharger inlet Remove the deck extension Refer to BODY sub section for proper procedure Remove the air intake silencer Refer to AIR IN TAKE SYSTEM subsection Remove the air intake silencer support smr2009 020 010_a 1 Air intake ...

Page 63: ...eck extension Refer to BODY sub section for proper procedure Remove the air intake silencer Refer to AIR IN TAKE SYSTEM subsection Remove the air intake silencer support smr2009 020 010_a 1 Air intake silencer support smr2009 020 011_a MANY PARTS REMOVED FOR CLARITY PURPOSE 1 Support screws Remove the air inlet hose from supercharger smr2009 020 012_a 1 Air inlet hose 2 Hose clamp Remove cylinder ...

Page 64: ...uld start to turn at a torque within the specified values SLIPPING MOMENT NEW SUPERCHARGER 9 N m to 17 N m 80 lbf in to 150 lbf in SLIPPING MOMENT BREAK IN SUPERCHARGER 8 N m to 12 N m 71 lbf in to 106 lbf in If the torque is not within specifications repair supercharger clutch Verify supercharger clutch components as per SUPERCHARGER INSPEC TION in this subsection SUPERCHARGER CLUTCH SLIPPING MOM...

Page 65: ... is a guideline and it should not be assumed to list all possible prob lems Always check for fault codes If a fault code is de tected service the fault code first Refer to MON ITORING SYSTEM AND FAULT CODES subsec tion ENGINE WILL NOT START ENGINE DOES NOT TURN OVER 1 Supercharger seized or obstructed Inspect and repair supercharger ENGINE LACKS ACCELERATION OR POWER DOES NOT REACH MAXIMUM RPM 1 S...

Page 66: ...2 Supercharger Using a marker trace a mark on rubber adapter and exhaust pipe smr2008 012 011_a 1 Rubber adapter 2 Exhaust pipe Loosen clamp securing rubber adapter to exhaust pipe Detach muffler strap Move muffler back 5 cm 2 in Remove retaining screws and pull out the super charger smr2009 020 005_a 1 Retaining screws 2 Upper retaining screw hidden behind the supercharger NOTE To remove the uppe...

Page 67: ...rts may result in damage of the super charger Strictly follow the described proce dures 1 Mount supercharger on the SUPPORT PLATE P N 529 035 947 529035947 2 Take apart supercharger housing 1 F00B28A 3 2 1 1 1 1 Retaining screws 2 Housing half intake side 3 Housing half engine side F00B29A PLASTIC HAMMER 3 Loosen cap nut turn clockwise on super charger shaft turbine side while holding shaft with t...

Page 68: ...ing shaft with the SUPERCHARGER RETAINING KEY P N 529 036 027 2 F00B2BA 1 1 Nut 2 Retaining key NOTE There are 40 loose needle bearings under the gear Do not reuse 6 Remove L ring spring washers lock washer drive gear and needle pins by turning the super charger upside down smr2006 012 008_a 1 Nut 2 L ring 3 Spring washers 5x 4 Lock washer 5 Titanium shims 6 Drive gear 7 Needle bearings 7 Carefull...

Page 69: ...ssary to heat the housing with a heat gun to release the retaining disc F00B2AA 1 1 4 pin socket 10 Discard the oil seal 11 Remove and discard ball bearing from super charger housing half engine side by using a press and a suitable bearing pusher 1 R1503motr236A 2 1 Supercharger housing half engine side 2 Bearing pusher Supercharger Inspection Supercharger Clutch Components and Gear Check the wear...

Page 70: ... WASHER PACKAGE HEIGHT NEW 10 7 mm to 10 9 mm 4213 in to 4291 in SERVICE LIMIT 10 2 mm 4016 in Supercharger Assembly NOTICE Every time when supercharger shaft has been removed both ball bearings have to be replaced NOTICE Both ball bearings have to be in stalled with cages facing turbine side 1 Apply enough engine oil on NEW ball bearing 2 Install ball bearing on supercharger shaft by us ing the S...

Page 71: ... half engine side on the SUPPORT PLATE P N 529 035 947 529035947 6 Apply LOCTITE 243 BLUE P N 293 800 060 on retaining disc If a new retaining disc is used the threads are coated with a self locking prod uct 7 Install the retaining disc in supercharger hous ing half by using the 4 PIN SOCKET P N 529 035 948 8 Torque retaining disc to 29 N m 21 lbf ft 529035948 1 F00B2IA 2 1 Retaining disc 2 4 pin ...

Page 72: ...aring life 10 Apply heat outside of the housing with a heat gun to expand its diameter prior to inserting the shaft Ensure there is no O ring on the housing half prior to heating 11 Apply engine oil on supercharger shaft Press shaft with thrust washer and distance sleeve together in supercharger housing half smr2006 012 032_a 1 Compressor shaft 2 Ball bearing 3 Supercharger housing half 4 Thrust w...

Page 73: ...e on the shaft titanium shims needle bearings shaft surface and lock washer NOTICE No other grease can be used other wise damage to bearings will occur 17 Install the 40 needle bearings on the compres sor shaft NOTE The 40 needle bearings comes in a wax strip with an adhesive backing 18 Remove the adhesive backing 19 Install the drive gear over the needle bearings 20 Install the second titanium sh...

Page 74: ...nt Refer to SUPERCHARGER CLUTCH SLIPPING MO MENT BENCH TEST in this subsection Supercharger Installation 1 Grease sealing surface between supercharger and PTO housing with SUPER LUBE GREASE P N 293 550 030 NOTE Ensure O rings are installed 1 R1503motr247A 1 Super Lube grease 2 Install supercharger on PTO housing 3 Apply LOCTITE 243 BLUE P N 293 800 060 on the retaining screws 4 Torque retaining sc...

Page 75: ...ll change the torque applied to the screw Proper torque and tightening sequence are important 6 After complete installation of the supercharger the slipping moment has to be rechecked Refer to SUPERCHARGER CLUTCH SLIPPING MOMENT ON ENGINE at the beginning of this subsection 52 smr2009 020 ...

Page 76: ...TERCOOLER INTERCOOLER SERVICE TOOLS Description Part Number Page LARGE HOSE PINCHER 529 032 500 55 VACUUM PRESSURE PUMP 529 021 800 55 4 N m 35 lbf in NEW 4 N m 35 lbf in 8 N m 71 lbf in 8 N m 71 lbf in smr2009 019 001_a smr2009 019 53 ...

Page 77: ... necessary will severely damage engine inter cooler and or exhaust system PROCEDURES INTERCOOLER WARNING Let engine cool down prior to work on or near intercooler Intercooler Cleaning If temperature in intake manifold is too high or if engine is down in performance intercooler may require to be cleaned The exhaust system should be flushed first as it may unclogged the intercooler If not then pro c...

Page 78: ... inlet hose 4 Bleed hose Install the VACUUM PRESSURE PUMP P N 529 021 800 on bleed hose fitting 529021800 BLEED HOSE FITTING Pressurize the intercooler PRESSURE TEST 69 kPa 10 PSI for 10 minutes min If there is a pressure drop first spray tool hoses and adapters with a soapy water solution to en sure they are not leaking Otherwise replace the intercooler Intercooler Removal Open the boarding platf...

Page 79: ...t attachment and iS module support are attached together with rivets Remove the INTERCOOLER see procedure in this subsection Detach iS module from its support and move the module aside to make room smr2009 019 005_a FIXED DECK REMOVED FOR CLARITY PURPOSE 1 iS module 2 Retaining latch Cut locking ties securing wiring harness to iS mod ule support and front attachment smr2009 019 006_a 1 Cut these l...

Page 80: ...AR OPENING 1 Plastic rivet 2 Rubber pad Remove and discard screw securing the attach ment to the hull smr2009 019 051_a THROUGH THE LH REAR OPENING 1 Retaining screw 2 Washer 3 LH rear attachment Install a new attachment using a NEW screw Tighten screw to 8 N m 71 lbf in Install all other removed parts smr2009 019 57 ...

Page 81: ...58 ...

Page 82: ...ubsection 06 EXHAUST SYSTEM EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page FLUSHING CONNECTOR ADAPTER 295 500 473 62 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 67 smr2009 021 59 ...

Page 83: ... 142 lbf in Loctite 567 pipe sealant 11 N m 97 lbf in 7 5 N m 66 lbf in 16 N m 142 lbf in Loctite 518 4 N m 35 lbf in 5 N m 44 lbf in 4 N m 35 lbf in 8 N m 71 lbf in GTX LIMITED 9 N m 80 lbf in Loctite 243 See EFI subsection smr2009 021 001 60 smr2009 021 ...

Page 84: ...ocated at front of manifold Water enters the manifold end and is directed to water jackets of exhaust manifold smr2009 021 002_a 1 Exhaust manifold water inlet 2 Exhaust manifold 3 Exhaust manifold water outlet to pump support 4 Exhaust manifold water outlet to exhaust pipe and muffler Water exits exhaust manifold through 2 hoses at rear manifold smr2008 013 008_a Water exits exhaust pipe through ...

Page 85: ... be used with a quick connect adapter to ease garden hose instal lation 1 F00E05A 2 1 Quick connect adapter 2 Flushing connector adapter To flush the exhaust system start the engine then immediately open the water tap NOTICE Always start the engine before opening the water tap Open water tap im mediately after engine is started to prevent overheating Never run engine without sup plying water to th...

Page 86: ...S sensor 2 Exhaust hose 7 Disconnect the exhaust hose from muffler smr2009 016 005_a 1 Exhaust hose clamp 8 Detach retaining strap smr2009 016 006_a 1 Muffler retaining strap 9 Remove the LH rear storage basket 10 Move muffler backwards and slide it through the rear opening Muffler Inspection Check muffler for Cracks Corrosion Other damages Check if exhaust hose is Brittle Hard Cracked Otherwise d...

Page 87: ...ark is aligned with the mark on the exhaust manifold smr2008 013 025_a 1 Exhaust manifold mark 2 Exhaust pipe mark Tighten exhaust clamp to 11 N m 97 lbf in NOTICE Do not use pneumatic or electric tools as seizure may occur Install the muffler strap NOTICE Ensure not to rotate muffler during strap installation The use of a soapy water so lution on inner side of muffler strap is recom mended Instal...

Page 88: ...ose to res onator and iBR support plate Remove the rear exhaust hose from vehicle When reinstalling rear exhaust hose tighten clamps to 4 N m 35 lbf in Reinstall all other removed parts After installation ensure there is no water or ex haust gas leak when the engine is running Test run the engine while supplying water to the ex haust system NOTICE Never run engine without supplying water to the ex...

Page 89: ...mark previously traced on muffler smr2008 013 037_a 1 Middle of rubber adapter strip 2 Center of the muffler bulge opening Using a caliper measure the distance between the exhaust pipe shoulder and the outside of the muffler bulge Position the muffler to 95 mm 2 mm 3 74 in 079 in Check the distance in several places smr2008 013 039_a 1 Rubber adapter end 2 Outside of the muffler bulge A 95 2 mm 3 ...

Page 90: ...OTE There is no gasket between cylinder block and exhaust manifold Apply LOCTITE 243 BLUE P N 293 800 060 on threads of screws To help holding the manifold while installing screws first insert the exhaust manifold into the exhaust pipe then install the upper front screw Continue with the remaining screws Torque screws to 9 N m 80 lbf in as per follow ing illustrated sequence Repeat the procedure t...

Page 91: ... dures However pay attention to the following After installation ensure there is no water or ex haust gas leak when the engine is running Test run the engine while supplying water to the ex haust system NOTICE Never run engine without supplying water to the exhaust system when watercraft is out of water 68 smr2009 021 ...

Page 92: ...R SET 529 036 117 77 HANDLE 420 877 650 78 IMPELLER REMOVER INSTALLER 529 035 820 77 OETIKER PLIERS 295 000 070 77 STARTER DRIVE SEAL PUSHER 420 876 502 78 SUCTION PUMP 529 035 880 72 SERVICE PRODUCTS Description Part Number Page ISOFLEX GREASE TOPAS NB 52 293 550 021 78 83 LOCTITE 243 BLUE 293 800 060 76 81 LOCTITE 648 GREEN 413 711 400 77 PULLEY FLANGE CLEANER 413 711 809 73 76 smr2009 022 69 ...

Page 93: ...MAGNETO Oil 9 N m 80 lbf in NEW Loctite 243 15 N m 133 lbf in 50 Oil Loctite 648 Isoflex grease Topas NB 52 NEW Oil 9 N m 80 lbf in Loctite 243 9 N m 80 lbf in Loctite 243 Isoflex grease Topas NB 52 250 N m 184 lbf ft smr2008 014 007_b 70 smr2009 022 ...

Page 94: ...osing the probable source of troubles It is a guideline and should not be assumed to list all possible prob lems Always check for fault codes If a fault code is de tected service the fault code first Refer to MON ITORING SYSTEM AND FAULT CODES subsec tion ENGINE WILL NOT START ENGINE DOES NOT TURN OVER 1 Obstructed starter drive gear assembly Check and repair the starter drive ENGINE WILL NOT STAR...

Page 95: ... 003_a 1 Oil siphoning tube 2 Edge of cylinder block 6 Drain engine coolant refer to the COOLING SYSTEM subsection Remove the air intake silencer Refer to AIR IN TAKE SYSTEM subsection Remove the supercharger air outlet hose Move muffler rearwards Refer to EXHAUST SYS TEM subsection Remove the supercharger refer to the SUPER CHARGER subsection smr2009 020 005_b 1 Supercharger Refer to STEERING AND...

Page 96: ... 809 to prevent oil stains Remove both rear engine support screws smr2009 016 020_b RIGHT SIDE OF VEHICLE 1 Rear engine support screw smr2009 016 022_b LEFT SIDE OF VEHICLE 1 Rear engine support screw Slightly lift aft end of engine and insert a safely block under the engine to secure it in this position Remove LH rear engine support 1 R1503motr50A TYPICAL 1 Engine support Remove water pump housin...

Page 97: ...rd PTO Housing Inspection Inspect PTO housing for cracks or any other dam ages Replace if necessary Inspect the needle bearing in the PTO housing used to support the starter drive assembly shaft NOTE Clean all disassembled metal components in a non ferrous metal cleaner WARNING Wear safety glasses and work in a well ventilated area when working with strong chemical products Also wear suitable non ...

Page 98: ... installing it If there is a strong resistance re move housing and check oil water pump shaft alignment and starter gear drive alignment NOTICE Ensure the starter drive gear shaft is well aligned when engaging it in the PTO hous ing needle bearing smr2009 022 002_a 1 Pay attention that gasket remains properly positioned on this surface Refer to the following illustration to identify the locations ...

Page 99: ...pection Inspect the PTO seal on the PTO housing If brit tle hard or damaged or if you see a sign of oil leakage replace it Inspect ball bearing within PTO seal for excessive play and smooth operation Replace PTO seal if oil seal or ball bearing is dam aged smr2009 022 006_a 1 PTO seal PTO Seal Removal Place rags under PTO housing to prevent spillage If spillage occurs clean immediately with PULLEY...

Page 100: ... Impeller removal tool NOTE PTO coupling has left hand threads PTO Coupling Inspection Inspect seal within coupling if it is brittle cracked or hard replace it Check coupling for worn or damaged splines Re place as required R1503motr49A PTO Coupling Installation For installation reverse the removal procedure However pay attention to the following Apply LOCTITE 648 GREEN P N 413 711 400 on threads ...

Page 101: ...onnector is located between the ECM and the throttle body smr2009 016 015_b 1 Magneto connector 2 ECM 3 Throttle body Install the 3 PIN MAGNETO HARNESS ADAPTER P N 529 036 016 onto the magneto connector NOTE Do not connect the magneto harness adapter to the vehicle harness connector 529036016 Set multimeter to Vac scale Start engine Connect multimeter between each pair of YEL LOW wires as per foll...

Page 102: ...ect the magneto harness adapter to the vehicle harness connector Set multimeter to Connect multimeter between each pair of YEL LOW wires smr2009 022 101_b STATOR CONTINUITY TEST 1 Connect adapter to magneto stator connector 2 Leave vehicle harness disconnected Read resistance STATOR CONTINUITY TEST TERMINAL RESISTANCE 20 C 68 F 1 and 2 1 and 3 2 and 3 0 1 1 If any result is out of specification re...

Page 103: ...aced Stator Removal Remove PTO housing see procedure in this sub section Remove stator cable holding plate from PTO hous ing smr2009 022 011_a TYPICAL 1 Screws 2 Holding plate Remove stator retaining screws Remove stator from PTO housing smr2009 022 012_a 1 Stator screws 2 Stator Stator Installation For installation reverse the removal procedure However pay attention to the following NOTE The posi...

Page 104: ... tooth measured reference tooth Gently lift the gauge contact point off the tooth and rotate the flywheel to the next tooth NOTE When lifting contact point off the tooth for flywheel rotation be careful not to move gauge position or test readings taken on next tooth will not be accurate with reference to the reference tooth Gently set the gauge contact point on the next tooth and read the dial ind...

Page 105: ...emove and discard the magneto rotor retaining screws Pull rotor and trigger wheel off crankshaft end Pull rotor trigger wheel and ring gear off crank shaft end 1 R1503motr54A 2 3 4 TYPICAL 1 Magneto rotor retaining screws 2 Rotor 3 Trigger wheel 4 Ring gear Ring Gear Inspection Inspect ring gear for damages Pay particular at tention to teeth condition If badly worn cracked or broken teeth are foun...

Page 106: ...nsure proper operation of the starter drive sprag clutch If any part of the assembly shows signs of ab normal wear cracks broken teeth or malfunction sprag clutch replace the faulty part Starter Drive Installation For installation reverse the removal procedure However pay attention to the following NOTE When installing a new starter drive assem bly oil the shaft gear teeth and splines with en gine...

Page 107: ...84 ...

Page 108: ...P 529 035 880 91 SUPERCHARGER OIL SPRAY NOZZLE TOOL 529 036 134 105 WATER PUMP SEAL PUSHER 529 035 823 101 102 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page FLUKE RIGID BACK PROBES tp88 109 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 111 LOCTITE 243 BLUE 293 800 060 96 98 99 102 104 105 112 LOCTITE 5910 293 800 081 97 PULLEY FLANGE CLEANER 413 711 809 92 ...

Page 109: ... N m 80 lbf in NEW NEW Engine oil 9 N m 80 lbf in Loctite 243 16 N m 142 lbf in Engine oil NEW NEW 9 N m 80 lbf in Loctite 243 Engine oil Engine oil Engine oil 9 N m 80 lbf in Loctite 243 9 N m 80 lbf in Loctite 243 18 N m 159 lbf in smr2009 023 001_a 86 smr2009 023 ...

Page 110: ...3 9 N m 80 lbf in Loctite 243 3 N m 27 lbf in Left hand thread NEW Engine oil Engine oil 11 N m 97 lbf in NEW Loctite 243 NEW Engine oil 13 N m 115 lbf in Loctite 243 Loctite 5910 Engine oil Loctite 243 9 N m 80 lbf in Loctite 243 Loctite 243 9 N m 80 lbf in 9 N m 80 lbf in smr2009 023 002_a smr2009 023 87 ...

Page 111: ...2 13 Legend Pressurized oil Blow by gas Scavenged oil smr2009 023 100_en 1 Oil dipstick 2 Rocker arm intake 3 Rocker arm exhaust 4 Hydraulic valve lifter 5 Camshaft 6 Piston pin 7 Into PTO cover 8 From oil filter 9 Piston cooling 10 Connecting rod 11 Balance shaft 12 Crankshaft 13 Oil tank 88 smr2009 023 ...

Page 112: ...eparator 8 Cylinder head 9 Blow by valve 10 Supercharger if so equipped 11 Oil filter 12 Hydraulic chain tensioner 13 Supercharger bearing if so equipped 14 Friction clutch 15 Piston pin 16 Connecting rod 17 Piston cooling 18 Oil spray nozzle 19 Drive shaft 20 Crankshaft 21 PTO seal 22 Oil pressure switch 23 Balance shaft 24 PTO cover 25 Pressure pump 26 Pressure relief valve 27 Oil strainer press...

Page 113: ... supercharger and eventu ally lead to premature wear For this reason XPS Summer Grade oil or a BRP approved equivalent are the only recommended oils Use of any oil not recommended by BRP may void BRP s limited warranty Oil Level Verification NOTICE Check level frequently and refill if necessary Do not overfill it would make the engine smoke and reduce its power Op erating the engine with an improp...

Page 114: ...ller neck opening and add the recommended oil to the proper level Do not overfill Oil Change NOTE Oil and oil filter must be replaced at the same time Oil change and oil filter replacement should be done with a warm engine Bring engine to its normal operating temperature NOTICE When watercraft is out of water Never run engine without supplying water to the exhaust system Never run engine longer th...

Page 115: ...nstall oil filler cap and dipstick Replace OIL FILTER see procedure in this sub section OIL FILTER Oil Filter Removal Remove Oil filter screw Oil filter cover Oil filter smr2009 023 003_a 1 Oil filter screw 2 Oil filter cover 3 Oil filter NOTE No tools are required to remove the oil fil ter cover as it will pull off when the oil filter screw is unscrewed Place rags in filler area to prevent spilla...

Page 116: ...gine longer than 2 minutes Drive line seal has no cooling when water craft is out of water The oil pressure is measured using the PRESSURE GAUGE P N 529 035 709 and the ADAPTER HOSE P N 529 035 652 A 1 8 NPT pipe extension may ease the installation 529035709 529035652 Use the following table to compare the oil pres sure at different RPM OIL PRESSURE Idle cold 448 kPa 648 kPa 65 PSI 94 PSI for a ve...

Page 117: ...mall Clean oil regulator piston and its bore Replace if necessary Measure spring free length Replace if too small 5 Oil pump s worn or damaged Check oil pump rotors and its bore for wear limits Replace if out of specification 6 Engine oil strainers are clogged Remove and clean engine oil strainers 7 Heavy wear on plain bearings Check radial clearance of plain bearings Replace if out of specificati...

Page 118: ...mation center is present and the beeper sounds Ensure OPS connector is plugged to the switch Check the resistance of the OPS while engine is off and while engine is running Oil Pressure Switch Resistance Test Disconnect the connector from the OPS Use a multimeter to check the resistance as shown ENGINE NOT RUNNING TEST PROBES RESISTANCE OPS connector pin 1 Engine ground Close to 0 normally closed ...

Page 119: ...e Switch Installation Apply LOCTITE 243 BLUE P N 293 800 060 on threads of oil pressure switch Torque oil pressure switch to 9 N m 80 lbf in PTO OIL STRAINER NOTE The oil strainer does not need to be cleaned at every oil change Clean it during other inspections especially when the engine is disas sembled PTO Oil Strainer Removal Remove engine oil See procedure in OIL CHANGE in this subsection Remo...

Page 120: ...L STRAINER NOTE The oil strainer does not need to be cleaned at every oil change Clean it during other inspections especially when the engine is disas sembled Suction Pump Oil Strainer Removal Remove oil filler tube and suction pump cover re fer to OIL SUCTION PUMP in this subsection Remove oil strainer from the suction pump cover smr2006 014 022_a 1 Oil strainer 2 Suction pump cover Suction Pump ...

Page 121: ... 008_a 1 Screws M6 x 25 2 Screws stainless steel M6 x 45 Torque suction pump cover screws as per se quence illustrated below smr2009 023 009_a TIGHTENING SEQUENCE ENGINE OIL PRESSURE REGULATOR The oil pressure regulator is located on the bottom of the PTO housing smr2007 015 005_a TYPICAL 1 Oil pressure regulator NOTE The oil pressure regulator system opens when the oil pressure exceeds 400 kPa 58...

Page 122: ...rocedure Pay attention to the following details Be careful that the O ring on plug screw is in place Apply LOCTITE 243 BLUE P N 293 800 060 on threads of the oil pressure regulator plug Torque plug screw to 13 N m 115 lbf in OIL PRESSURE PUMP The oil pressure pump is located in the PTO hous ing and is driven by the balance shaft Oil Pressure Pump Removal 1 Remove engine oil See procedure in OIL CH...

Page 123: ...l pump housing and cover and re place if damaged 1 R1503motr129A 1 Pittings on the teeth Using a feeler gauge measure the clearance be tween inner and outer rotors 2 R1503motr130A 1 C A B 1 Outer rotor 2 Inner rotor OUTER AND INNER ROTOR CLEARANCE SERVICE LIMIT A B C 0 25 mm 0098 in If clearance between inner and outer rotors ex ceeds the tolerance replace water oil pump shaft Ensure to also check...

Page 124: ...es and replace if dam aged Oil Pressure Pump Installation For installation reverse the removal procedure Pay attention to the following details NOTE Never use oil in the press fit area of the rotary seal Push water oil pump shaft oil seal in place by us ing thumb 1 R1503motr128A 1 Oil seal Install the new rotary seal by using the WATER PUMP SEAL PUSHER P N 529 035 823 529035823 NOTICE Never use a ...

Page 125: ...bottom of the oil filler tube Oil Suction Pump Removal 1 Remove jet pump and drive shaft Refer to STEERING AND PROPULSION section 2 Remove the moving deck Refer to BODY sub section 3 Remove the air intake silencer Refer to AIR IN TAKE SYSTEM subsection 4 Detach the muffler from the exhaust manifold and move muffler backwards Refer to EX HAUST SYSTEM subsection 5 Remove engine support mount screws ...

Page 126: ...ing and cover and re place if damaged 1 R1503motr137A 1 Pittings on the teeth Using a feeler gauge measure the clearance be tween inner and outer rotors R1503motr138A 2 1 C B A 1 Outer rotor 2 Inner rotor OUTER AND INNER ROTOR CLEARANCE SERVICE LIMIT A B C 0 25 mm 0098 in If clearance between inner and outer rotors ex ceeds the tolerance replace oil pump shaft En sure to also check oil pump housin...

Page 127: ...ction Pump Installation For installation reverse the removal procedure Pay attention to the following details Apply LOCTITE 243 BLUE P N 293 800 060 on threads of the suction pump cover screws and tighten them to 9 N m 80 lbf in Position screws according to their length as shown smr2009 023 008_a 1 Screws M6 x 25 2 Screws M6 x 45 Tighten suction pump cover screws as per follow ing sequence smr2009...

Page 128: ... in Adjust the position of the oil spray nozzle by us ing the SUPERCHARGER OIL SPRAY NOZZLE TOOL P N 529 036 134 529036134 The distance between the adjustment tool and oil spray nozzle must be within 1 mm 039 in smr2008 015 008_a A 1 mm 0 039 in NOTE Make sure that the oil spray nozzle is fac ing to the center of the tool Not following this procedure will lead to an insufficient oiling of the supe...

Page 129: ...freely mmr2009 111 049_a 1 Ball 2 Spring 3 Banjo fitting 4 Oil spray nozzle NOTE If the oil spray nozzle is damaged or bent during work in the cylinder block it must be re placed immediately Oil Spray Nozzle Installation NOTICE At assembly make sure the contact surface of the oil spray nozzle is well fitted onto the cylinder block If this is not ensured the oil spray direction will change causing ...

Page 130: ...careful not to break the holding clips from oil separator cover when its removed from the timing gear Oil Separator Cover Inspection Inspect oil separator cover for marks or other dam ages Ensure to check also the holding clips of oil separator cover and for thrust washer If any dam age is visible replace oil separator cover smr2006 014 037_a 1 Holding clips Oil Separator Cover Installation For in...

Page 131: ...take sys tem where they are harmlessly burned The TOPS switch TOPS state is OFF no signal to the ECM smr2009 023 019_a NORMAL OPERATION Tip Over Protection Function If the watercraft tips over gravity causes a valve piston to close and no engine oil will leak out of the blow by valve In this event a pin with magnet opens a gap to the TOPS switch Hall effect sensor and the TOPS changes its state to...

Page 132: ... using the B U D S software Blow By Valve TOPS Switch Output Voltage Test Remove the blow by valve Back probe TOPS connector and check voltage using the FLUKE 115 MULTIMETER P N 529 035 868 NOTE To easily probe wire terminals through the back of the connector use the FLUKE RIGID BACK PROBES P N TP88 or an equivalent smr2009 023 050_a BLOW BY VALVE IN NORMAL POSITION 1 Blow by valve 2 RED probe int...

Page 133: ...tors Blow By Valve TOPS Switch Replacement Remove blow by valve and turn it upside down Insert a small screwdriver between TOPS switch and its retaining tab Twist and hold the TOPS switch then release the other retaining tab smr2009 023 051 When installing the TOPS switch make sure printed information is visible smr2009 023 052_a 1 TOPS valve inscriptions Blow By Valve Removal Remove Deck extensio...

Page 134: ...urfaces of blow by valve Place a clean rag on valve inlet Blow air through inlet port Air must flow freely to the outlet port smr2009 023 023_a Turn valve upside down and blow air again Air must not flow out smr2009 023 024_a If test fails replace blow by valve Blow By Valve Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install the bl...

Page 135: ...re not to lose O rings located between oil cooler and engine 1 R1503motr148A 1 O rings Oil Cooler Inspection If O rings are brittle cracked or hard replace them Clean both contact surfaces of oil cooler Check and clean the oil inlet and outlet area for dirt and other contaminations Oil Cooler Installation For installation reverse the removal procedure Pay attention to the following details Apply e...

Page 136: ...age OETIKER PLIERS 295 000 070 120 OIL SEAL GUIDE 529 035 822 125 TEST CAP 529 035 991 119 VACUUM PRESSURE PUMP 529 021 800 119 WATER PUMP SEAL PUSHER 529 035 823 125 126 SERVICE PRODUCTS Description Part Number Page BRP PREMIXED COOLANT 219 700 362 117 LOCTITE 243 BLUE 293 800 060 122 smr2009 024 113 ...

Page 137: ...ncluding thermostat opens at 87 C 188 F and water 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 smr2009 024 100_en 114 smr2009 024 ...

Page 138: ...ONENTS 1 7 N m 15 lbf in NEW 1 7 N m 15 lbf in 1 7 N m 15 lbf in 1 7 N m 15 lbf in 1 7 N m 15 lbf in NEW NEW 5 N m 44 lbf in 4 N m 35 lbf in 1 7 N m 15 lbf in 4 N m 35 lbf in 4 N m 35 lbf in 1 7 N m 15 lbf in 1 7 N m 15 lbf in smr2009 024 101_a smr2009 024 115 ...

Page 139: ... 150 lbf in NEW 9 N m 80 lbf in 9 N m 80 lbf in Loctite 243 Left hand threads 3 N m 27 lbf in NEW Loctite 243 NEW Engine oil Loctite 243 Loctite 243 NEW NEW Engine oil NEW Engine oil NEW 9 N m 80 lbf in 9 N m 80 lbf in 9 N m 80 lbf in 9 N m 80 lbf in smr2009 024 001_a 116 smr2009 024 ...

Page 140: ...ylinder head the water channels flow around the exhaust and then the intake valves and leave the engine through a large hose From there the coolant goes back to the water pump hous ing and depending on the engine temperature it flows through the thermostat directly back to the water pump impeller or it takes its way through the heat exchanger Engine coolant is also directed towards the oil cooler ...

Page 141: ... drain plug on ride plate NOTE Raising the front of the watercraft will con tribute to drain the cooling system smr2009 024 102_a 1 Cooling drain plug Dispose coolant as per local regulations Do not reinstall drain plug at this time Cleaning the System NOTICE Cleaning the cooling system as per the following procedure is required when en gine overheats assuming everything else is operating normally...

Page 142: ...l coolant tank and top up if necessary INSPECTION COOLING SYSTEM LEAK TEST WARNING To avoid potential burns do not remove the expansion tank cap or loosen the ride plate drain plug if the engine is hot Remove the deck extension Refer to BODY sub section Install the TEST CAP P N 529 035 991 on the coolant expansion tank 529035991 NOTE It is not necessary to install a hose pincher on overflow hose C...

Page 143: ...cooling system 3 Thermostat defective does not open when en gine gets hot Replace thermostat housing 4 Water pump failure Inspect and replace defective components 5 Water temperature sensor defective Check or replace Refer to ELECTRONIC FUEL INJECTION 6 Ride plate or hoses damaged Check or replace damaged components 7 Exhaust system clogged Flush exhaust system 8 Internal passage blocked in coolin...

Page 144: ...se 2 Intercooler air outlet hose Drain cooling system and engine oil Disconnect the coolant expansion tank hose from water pump housing and move expansion tank aside to make room smr2009 024 105_a 1 Expansion tank hose Disconnect exhaust hose from the resonator Place hose over muffler smr2009 024 106_a 1 Exhaust hose 2 Cut these locking ties 3 Retaining clamp Disconnect ride plate hoses from water...

Page 145: ...er return hose coolant tank hose ride plate return hose and cylin der head return hose with a rag 1 F18E12A 3 2 4 1 Oil cooler return connection 2 Coolant tank hose connection 3 Ride plate return hose connection 4 Cylinder head return hose connection Fill the water pump housing with water If a bigger quantity of coolant leaks out at the ride plate outlet connection replace the water pump housing I...

Page 146: ...nspection Check impeller for cracks or other damage Re place impeller if damaged Water Pump Impeller Installation The installation is the opposite of the removal pro cedure Pay attention to the following details NOTICE Be careful not to damage impeller wings during installation Torque impeller to 3 N m 27 lbf in THERMOSTAT The thermostat is a single action type Thermostat Removal Remove the WATER ...

Page 147: ...cates a faulty oil seal However if seal is disassembled both parts have to be replaced together Rotary Seal Removal Remove WATER PUMP HOUSING see proce dure in this subsection Unscrew the impeller clockwise NOTICE Always unscrew the impeller clock wise otherwise you can damage the compo nents Remove PTO housing Refer to PTO HOUSING AND MAGNETO subsection Remove oil pump cover screws 1 2 F18E14A 1 ...

Page 148: ... pro cedure Pay attention 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 a press and the WATER PUMP SEAL PUSHER P N 529 035 823 529035823 NOTICE Never use a hammer for the rotary seal or water oil pump shaft installation Only use a press to avoid damaging the ...

Page 149: ...otector 2 Coolant oil pump shaft Using the WATER PUMP SEAL PUSHER P N 529 035 823 to support the PTO cover install the coolant oil pump shaft 1 F18E1BA 2 1 Coolant oil pump shaft with oil seal protector 2 Rotary seal installer Install all other removed parts 126 smr2009 024 ...

Page 150: ...DE PUSHER 6 MM 529 036 087 147 VALVE GUIDE REMOVER 6 MM 529 036 086 146 VALVE SPRING COMPRESSOR CUP 529 036 073 141 VALVE SPRING COMPRESSOR 529 035 724 141 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page SNAP ON VALVE STEM SEAL PLIERS YA8230 143 SERVICE PRODUCTS Description Part Number Page ISOFLEX GREASE TOPAS NB 52 293 550 021 139 LOCTITE 243 BLUE 293 800 060 132 137 141 MOLYKOTE G N 4...

Page 151: ...m 80 lbf in Loctite 243 Engine oil NEW 40 N m 30 lbf ft 120 90o NEW 9 N m 80 lbf in Loctite 243 9 N m 80 lbf in 11 N m 97 lbf in 9 N m 80 lbf in Loctite 243 Engine oil Loctite 243 NEW Engine oil NEW Engine oil Loctite 243 9 N m 80 lbf in NEW See LUBRIFICATION SYSTEM See ELECTRONIC FUEL INJECTION Engine oil smr2009 025 001_a 128 smr2009 025 ...

Page 152: ...ssembly installation use torque values and service products as in the exploded view Clean threads before applying a threadlocker Re fer to SELF LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pi...

Page 153: ...roke 1 1 As the engine crankshaft is turned over observe the movement of intake rocker arm of the cylinder to be checked 1 2 After piston completes its cycle and the intake valve closes observe the piston 1 3 When it reaches its uppermost position this is TDC compression stroke 1 R1503motr156A 1 Intake rocker arms 2 Secure the drive shaft adapter with a wrench lever against hull to prevent further...

Page 154: ...olant escaping from water pump housing Damaged gasket and or loosened screws refer to COOLING SYSTEM Coolant escaping from leak indicator hole Damaged rotary seal on water pump shaft refer to COOLING SYSTEM Oily contamination on leak indicator hole Damaged oil seal on water pump shaft Reassembly For reassembly reverse the preparation proce dure Use torque values and service products from the explo...

Page 155: ... Incorrect camshaft timing adjustment Replace damaged components and readjust camshaft timing 2 Intake or exhaust valves are leaking Perform ENGINE LEAK TEST Check if valve seats properly in valve seat Repair or replace damaged components 3 Broken valve spring s Replace defective parts 4 Broken rocker arm s Replace defective parts PROCEDURES EXHAUST MANIFOLD Exhaust Manifold Removal 1 Remove the m...

Page 156: ...er head cover screws 5 Remove the cylinder head cover and its gasket smr2006 016 028_a 1 Cylinder head cover 2 Gasket Cylinder Head Cover Inspection Check if the gasket on the cylinder head cover and the rubber bushing on the cylinder head cover screws are brittle cracked or hard If so replace the gasket or the cylinder head cover screw ac cordingly Cylinder Head Cover Installation For installatio...

Page 157: ... cracked or hard replace spark plug tube smr2005 036 001_a TYPICAL 1 Spark plug tube 2 Seal to the cylinder head cover 3 Seal to the cylinder head Spark Plug Tube Installation For installation reverse the removal procedure Pay attention to the following detail Apply engine oil on seals ROCKER ARMS Rocker Arm Removal 1 Remove the CYLINDER HEAD COVER see procedure in this subsection 2 Remove spark p...

Page 158: ...r arm bore Otherwise replace Rocker Arm Shaft Check for scored friction surfaces if so replace parts Measure rocker arm shaft diameter A R1503motr90A A Measure rocker arm shaft diameter here ROCKER ARM SHAFT DIAMETER NEW 19 980 mm 19 993 mm 7866 in 7871 in SERVICE LIMIT 19 965 mm 786 in Any area worn excessively will require parts re placement Verify and clean oil orifices to ensure a good rocker ...

Page 159: ...6 Torque screws at first to 10 N m 89 lbf in ac cording to following sequence R1503motr93A 2 1 3 4 5 6 7 Retorque screws to 20 N m 15 lbf ft 8 Finish tightening screws turning an additional 90 rotation with a torque angle gauge 1 R1503motr92A 2 1 Rocker arm shaft screw 2 Torque angle gauge CAMSHAFT TIMING GEAR NOTE Although it is not necessary to position crankshaft to TDC for disassembly it is a ...

Page 160: ...en looking from outside of engine 1 R1503motr97A 2 1 Good with 1503 aligned 2 Never Install timing chain Refer to CYLINDER BLOCK subsection Ensure chain guides are in place Loosely install timing chain screws Install chain tensioner NOTE There can be 2 different positions to install the timing gear on the camshaft Basically both positions are working well since the camshaft and crankshaft are lock...

Page 161: ...e in this subsection Remove the ROCKER ARM see procedure in this subsection Remove the camshaft lock to remove the camshaft 1 2 R1503motr101A 1 Camshaft lock 2 Camshaft Camshaft Inspection Check each lobe and bearing journal of camshaft for scoring scuffing cracks or other signs of wear Measure camshaft bearing journal and lobe height using a micrometer Measure clearance between both ends of camsh...

Page 162: ...ar product Install camshaft then place the camshaft lock in the slot 1 R1503motr101B 1 Camshaft lock position For other parts refer to the proper installation pro cedures in this subsection CYLINDER HEAD Cylinder Head Removal Lock crankshaft refer to CYLINDER BLOCK sub section Drain coolant refer to COOLING SYSTEM sub section Unscrew blow by valve from cylinder head Refer to LUBRICATION SYSTEM sub...

Page 163: ... between valve seats or other damages if so replace cylinder head Check cylinder head mating surface for flatness using a straight edge smr2006 016 063_a 1 Cylinder head 2 Flat bar 3 Feeler gauge Check cylinder head warpage CYLINDER HEAD WARPAGE Maximum 0 15 mm 006 in If warpage exceeds specification resurface the cylinder head as follows Use a 400 600 grit wet sandpaper on a surface plate and gen...

Page 164: ... screws to loosen and lead to engine damage Using the following sequence tighten screws as described below smr2005 036 002_a 1 First torque screws M11 to 40 N m 30 lbf ft 2 Then tighten screws M11 turning a 120 rota tion with a torque angle gauge and finish tight ening with an additional 90 rotation 3 Torque screws M6 to 9 N m 80 lbf in 1 R1503motr100A 2 1 Cylinder screws M11 2 Angle torque wrench...

Page 165: ...ction Check valve springs for rust corrosion or other visible damages If so replace faulty valve springs Check valve springs for free length and straight ness Replace valve springs if not within specifications R610motr122A A A Valve spring length OUTER VALVE SPRING FREE LENGTH NEW NOMINAL 45 45 mm 1 789 in SERVICE LIMIT 43 00 mm 1 693 in INNER VALVE SPRING FREE LENGTH NEW NOMINAL 41 02 mm 1 615 in...

Page 166: ... PLI ERS P N YA8230 R610motr125A Valve Inspection Valve Stem Seal Inspection of valve stem seals is not needed because NEW seals should always be installed whenever cylinder head is removed Valve Inspect valve surface check for abnormal stem wear and bending If so replace by a new one Valve Stem and Valve Guide Clearance Measure valve stem and valve guide in three places using a micrometer and a s...

Page 167: ...otr107A 3 1 Valve seat 2 Exhaust valve contaminated area 3 Valve face contact surface to valve seat Check valve face and seat for burning or pittings and replace valve or cylinder head if there are signs of damage Ensure to seat valves properly Apply some lap ping compound on valve face and work valve on its seat with a lapping tool Measure valve face contact width NOTE The location of contact are...

Page 168: ...e 37 35 mm 1 4705 in Exhaust 30 3 mm 1 1929 in 3 Using a 55 stone for the intake and an 80 stone for the exhaust valve reduce the valve seat contact width to the appropriate value mentioned above 4 Finally coat the valve seating surface with a fine paste of valve grinding compound using a manual valve grinding mandrel Lightly grind the valves until a smooth even uniform sealing surface of the appr...

Page 169: ...pping on valve stem end with a soft hammer so that valve opens and closes a few times NOTICE An improperly locked valve spring will cause engine damage VALVE GUIDES Valve Guide Replacement NOTICE Do not heat cylinder head for this procedure NOTICE The sharp edge near the top of the valve guide must be machined away Other wise it will foul the valve guide hole in the cylinder head and destroy the c...

Page 170: ...33 3 R1503motr256A 1 2 TYPICAL 1 Valve guide leading end 2 Cylinder head bore 3 Jig With the VALVE GUIDE PUSHER 6 MM P N 529 036 087 press the valve guide into the COLD cylinder head as shown A R1503motr257A TYPICAL A Protrusion VALVE GUIDE PROTRUSION MINIMUM 12 4 mm 4882 in MAXIMUM 12 8 mm 5039 in NOTE After installing new guides they must be reamed with a standard 6 mm reamer tool These are avai...

Page 171: ...148 ...

Page 172: ...CIRCLIP INSTALLER 529 035 765 157 STARTER DRIVE SEAL PUSHER 420 876 502 169 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page SNAP ON PISTON RING COMPRESSOR PLIERS RC980 157 SNAP ON SMALL SLIDE HAMMER CJ93B 167 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 170 LOCTITE 5910 293 800 081 170 LOCTITE CHISEL GASKET REMOVER 413 708 500 170 smr2009 026 149 ...

Page 173: ... 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Engine oil Engine oil 23 N m 17 lbf ft 23 N m 17 lbf ft 23 N m 17 lbf ft 9 N m 80 lbf in 9 N m 80 lbf in 19 N m 168 lbf in 17 N m 150 lbf in 23 N m 17 lbf ft 23 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 19 23 N m 17 lbf ft Loctite 243 smr2007 018 001_b 150 smr2009 026 ...

Page 174: ...5 15 6 4 4 Engine oil 45 N m 33 lbf ft 90 260 N m 191 lbf ft Loctite anti seize Engine oil Engine oil Engine oil Engine oil 6 Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil 23 smr2009 026 001_a smr2009 026 151 ...

Page 175: ... fault code first Refer to EN GINE MANAGEMENT section UNUSUAL ENGINE NOISE OR VIBRATIONS 1 Heavy wear on plain bearings Check radial play of plain bearings Replace plain bearings if out of specification 2 Crankshaft and balancer shaft are not properly aligned Disassemble cylinder block and check if marks are properly aligned 3 Crankshaft or balancer shaft axial play out of specification Measure cr...

Page 176: ...N TENSIONER Chain Tensioner Removal NOTE Removal of the intake manifold allows easier access to the chain tensioner but is not necessary Refer to INTAKE MANIFOLD subsec tion Remove Chain tensioner plug screw no 18 with gasket ring no 19 Chain tensioner no 20 3 R1503motr39A 1 2 1 Plug screw 2 Gasket ring 3 Chain tensioner Chain Tensioner Inspection Check chain tensioner for excessive wear or cracks...

Page 177: ... pin 5 Push piston pin no 9 out of piston 1 R1503motr27A 3 2 1 Piston 2 Piston pin 3 Circlip 6 Detach piston no 10 from connecting rod no 5 Connecting Rod Inspection Connecting Rod Big End Axial Play Using a feeler gauge measure distance between butting face of connecting rod and crankshaft counterweight If the distance exceeds specified tolerance replace the worn part 1 R1503motr12A 2 1 Crankshaf...

Page 178: ...ADIAL PLAY SERVICE LIMIT 0 080 mm 003 in Connecting Rod Big End Radial Play Measure inside diameter of connecting rod big end Compare to crankshaft pin To measure the connecting rod big end diameter use the OLD screws no 11 Install the OLD bearings no 12 as they were mounted initially Do the torque procedure as described below R610motr76A A A Connecting rod big end bearing CONNECTING ROD BIG END D...

Page 179: ...ring perpendicularly 90 to piston pin axis A 18 mm 709 in The measured dimension should be as described in the subsequent table If not replace piston PISTON MEASUREMENT NEW NOMINAL 99 931 mm 99 949 mm 3 934 in 3 935 in SERVICE LIMIT 99 90 mm 3 933 in Piston Cylinder Wall Clearance Adjust and lock a micrometer to the piston dimen sion F00B08A 1 1 Micrometer set to the piston dimension NOTE Make sur...

Page 180: ...ot all out of specification Mixed standard size and oversize piston are allowed Piston and Connecting Rod Assembly For installation reverse the removal procedure Pay attention to the following details Apply engine oil on the piston pin Insert piston pin into piston and connecting rod Use the PISTON CIRCLIP INSTALLER P N 529 035 765 to assemble the piston circlip 529035765 NOTICE Secure piston pin ...

Page 181: ...ue wrench NOTICE Failure to strictly follow this proce dure may cause screw to loosen and lead to engine damage Knowing that the screws have been stretched from the previous installation it is very important to use new screws at as sembly R1503motr31A 1 1 Angle torque wrench PISTON RINGS Piston Ring Removal Remove piston as described above Remove rings Piston Ring Inspection Ring Piston Groove Cle...

Page 182: ...ace ring with the word TO facing up then the rect angular ring with the word T facing up A31C2NA 1 2 3 1 Rectangular ring 2 Taper face ring 3 Oil scraper ring NOTICE Ensure that top and second rings are not interchanged NOTE Use a ring expander to prevent breakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after installation Space the piston ring en...

Page 183: ...p as shown in the following illus tration smr2009 026 004_a 1 Position lines Use a small screwdriver to check if the groove in the crankshaft is aligned with the hole In this position lock the crankshaft using the CRANKSHAFT LOCKING TOOL P N 529 035 821 529035821 Crankshaft Removal 1 Drain engine oil refer to LUBRICATION SYS TEM subsection 2 Remove engine from vehicle refer to ENGINE REMOVAL INSTA...

Page 184: ...ng rod screws 1 R1503motr08A 1 Connecting rod screws NOTE Before removing the connecting rod caps mark them to remember the right position when reassembling It is recommended to measure connecting rod big end axial play prior to re move connecting rod Refer to PISTONS AND CONNECTING RODS in this subsection for the procedure R1503motr07A 1 1 Mark on connecting rod 13 Remove thrust washers no 4 R150...

Page 185: ... this subsection 1 R1503motr13A 2 1 Micrometer 2 Crankshaft area for bearing CRANKSHAFT JOURNAL DIAMETER NEW 49 991 mm 50 01 mm 1 9681 in 1 9689 in SERVICE LIMIT 49 95 mm 1 9665 in CRANKSHAFT JOURNAL RADIAL CLEARANCE SERVICE LIMIT 0 07 mm 0028 in Crankshaft Pin Measure all crankshaft pin diameters Compare to inside diameter of connecting rod bearings else where in this subsection R1503motr14A 1 2 ...

Page 186: ...de has been installed first Those parts cannot be installed when the crankshaft is in place NOTICE Crankshaft and balancer shaft marks have to be aligned R1503motr17A 1 2 1 Mark on balancer shaft 2 Mark on crankshaft For correct installation of the connecting rods re fer to PISTONS AND CONNECTING RODS in this subsection NOTICE It is absolutely necessary to follow this procedure Otherwise severe en...

Page 187: ...CYLINDER HEAD subsection 529035821 1 R1503motr18A 1 Crankshaft locking tool BALANCER SHAFT Balancer Shaft Removal 1 Drain engine oil refer to LUBRICATION SYS TEM subsection 2 Remove engine from vehicle refer to ENGINE REMOVAL AND INSTALLATION subsection 3 Remove cylinder head refer to CYLINDER HEAD subsection 4 Remove PTO housing refer to PTO HOUSING AND MAGNETO subsection 5 Remove starter gear re...

Page 188: ...er Shaft Bearing Seat Play Measure all balancer shaft bearing seats Com pare to inside diameter of balancer shaft bearings elsewhere in this subsection 1 R1503motr23A 2 1 Micrometer 2 Balancer shaft area for bearing BALANCER SHAFT SEAT DIAMETER NEW 31 984 mm 32 000 mm 1 2592 in 1 2598 in SERVICE LIMIT 31 960 mm 1 2583 in BALANCER SHAFT SEAT RADIAL CLEARANCE SERVICE LIMIT 0 07 mm 0028 in Balancer S...

Page 189: ...20B THRUST WASHER INSERT DIRECTION 1 Thrust washer NOTICE Thrust washers have to be flush with the cylinder block sealing surface 2 R1503motr22A 1 1 Thrust washer 2 Sealing surface Install cylinder block lower half Refer to CYLIN DER BLOCK in this subsection Install the crankshaft cover before mounting the engine bracket Apply engine oil on O ring and press cover in Crankshaft cover has to be flus...

Page 190: ...tion Crankshaft refer to CRANKSHAFT elsewhere in this subsection Piston with connecting rod refer to PISTONS AND CONNECTING RODS elsewhere in this subsection Bearings When bearings need to be removed from the cylinder block mark them to identify the correct position at installation See the following illustra tion for an example 1 R1503motr37A 2 1 Mark on balancer shaft bearings 2 Mark on crankshaf...

Page 191: ...See the following illustration R1503motr24A 3 1 2 B A 1 First measuring diameter 2 Second measuring diameter 3 Third measuring diameter A 60 mm 2 362 in B 110 mm 4 331 in CYLINDER TAPER IN DIAMETER NEW MAXIMUM 0 038 mm 001 in SERVICE LIMIT 0 090 mm 004 in Distance between measurements should not ex ceed the service limit mentioned above Cylinder Out of Round Measure cylinder diameter in piston axi...

Page 192: ...re at the same position as they were before Correctly install bearings Top crankshaft bearing halves have a bore which has to be placed in the upper cylinder block R1503motr35A 3 2 1 1 Cylinder block upper half 2 Oil bore in cylinder block 3 Oil bore in bearing Bearings have to be flush with the cylinder block split surface and their protrusions have to fit in the notched areas in the cylinder blo...

Page 193: ...cts or non sil icone based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor adhesion and possibly a leaking crankcase NOTE Refer to the product label for the sealant curing time Respect the manufacturer s recom mendations prior to start engine Use a plexiglass plate and apply some sealant on it Use a soft rubber roller of 50 mm 75 mm 2 in 3 in available in arts produc...

Page 194: ...lock surface 1 R1503motr19A 2 1 O ring 2 Crankshaft cover Install the CRANKSHAFT LOCKING TOOL P N 529 035 821 right away to position crankshaft at TDC before installing the camshaft and the rocker arms refer to CYLINDER HEAD subsection 529035821 1 R1503motr18A 1 Crankshaft locking tool Install cylinder head PTO housing and the other parts in accordance with the proper assembly pro cedures smr2009 ...

Page 195: ...172 ...

Page 196: ...iring Harness Connector CAPS Camshaft Position Sensor CPS Crankshaft Position Sensor CTS Coolant Temperature Sensor ECM Engine Control Module EGTS Exhaust Gas Temperature Sensor KS Knock Sensor OPS Oil Pressure Sensor MAPS Manifold Absolute Pressure Sensor MATS Manifold Air Temperature Sensor ETA Electric Throttle Actuator TLS Throttle Lever Sensor TOPS Tip Over Protection System ECM ECM OUT IN FR...

Page 197: ...r sensor TAS Crankshaft position CPS Coolant temperature CTS Manifold air temperature MATS Manifold absolute pressure MAPS Oil pressure OPS Camshaft position CAPS ENGINE CONTROL MODULE ECM Exhaust gas temperature EGTS Throttle position sensor TPS Off throttle assisted steering O T A S Controller area network CAN Relay Fuel pump Starter solenoid Fuel injector 3 Ignition coil 3 Controller area netwo...

Page 198: ... start this special mode can be activated to prevent fuel injection and ignition while cranking in order to ventilate the engine to dry the cylinder walls NOTE This mode can also be used if engine is water flooded Proceed as follows to activate it With safety lanyard on its post while engine is stopped press and HOLD throttle lever Press the START STOP button The mode is now on Releasing throttle ...

Page 199: ...Section 03 ELECTRONIC MANAGEMENT SYSTEMS Subsection 01 ENGINE MANAGEMENT SYSTEM in limp home mode Refer to MONITORING SYS TEM AND FAULT CODES subsection for more in formation 176 smr2009 027 ...

Page 200: ...ation center gauge control s For a comprehensive and complete description of the information center refer to GAUGE subsec tion in the ELECTRICAL SYSTEM section iTC INTELLIGENT THROTTLE CONTROL The iTC is an electronic throttle control system that includes a cableless throttle control located on the RH side of handlebar and an electric throt tle actuator ETA located on the throttle body For a compr...

Page 201: ...ROPULSION section iS INTELLIGENT SUSPENSION The intelligent suspension is a mechanical system of one spring and one shock absorber installed in the lower fixed deck connecting to the upper mov ing deck to isolate the riders from the rough water For a comprehensive and complete description of this system refer to its subsection in the BODY and HULL section 178 smr2009 047 ...

Page 202: ...re starting B U D S to allow proper operation MPI 2 Connection Troubleshooting MPI 2 Status Lights The MPI 2 includes 2 status lights to show the connection conditions USB and CAN Both lights must be GREEN so that MPI 2 works properly Otherwise refer to the following charts vdd2006 001 151_b Prerequisite for USB communication PC Computer turned on MPI 2 connected to PC computer USB LIGHT STATUS WH...

Page 203: ...ot be powered or is defective Check to find which module is missing in B U D S The tab of the missing module will not be visible at the bottom of B U D S screen smr2009 028 001_a 1 iS tab not visible meaning this ECU is not communicating If a module is missing check wiring and power supply to that module Message Box No Vehicle Detected If the following message box is displayed in B U D S smr2008 0...

Page 204: ...o acti vate the ECM Do not hold START button to avoid engine starting 3 Click on the Write button in B U D S If message reappears do the following 1 Click on the Cancel button in B U D S 2 Remove the D E S S key 3 Press the vehicle START button to activate the ECM 4 Reinstall the D E S S key and make sure it has a proper contact with its post 5 Click on the Write button in B U D S PROCEDURES MPI 2...

Page 205: ... to vehicle Connect the other end of diagnostic cable to the MPI 2 INTERFACE CARD P N 529 036 018 529036018 NOTE An optional MALE FEMALE EXTENSION SE RIAL CABLE P N DB9 available at electronic retail outlets can be used between diagnostic cable and MPI 2 interface Do not exceed 7 6 m 25 ft 529035697 OPTIONAL MALE FEMALE EXTENSION SERIAL CABLE Connect the MPI 2 INTERFACE CARD P N 529 036 018 to the...

Page 206: ...have been made before starting B U D S to allow proper operation Refer to MPI 2 in this subsection Press the START button to power the ECM Connect D E S S key to vehicle D E S S post Start B U D S and logon IMPORTANT When engine is not started approximately 3 minutes after pressing the START button the ECM will stop communicating with B U D S Therefore operations with B U D S will be interrupted T...

Page 207: ...tion related to the vehi cle is available If so carefully follow the given in structions mmr2009 118 011 SERVICE UNIT HISTORY NOTE When selecting the update menu in B U D S a dialog box will appear and the update file description may give some clue to find the vehicle related information in BOSSWeb mbg2008 022 100_a TYPICAL 1 File description Writing Data in ECM When finished with B U D S save new...

Page 208: ... remove D E S S key from watercraft D E S S post to complete the operation Disconnect MPI connections and reconnect vehi cle harness in protective cap ssi2009 002 004_a 1 Diagnostic connector in its cap NOTICE Failure to secure the 6 pin connector in its protective cap would allow corrosion and damage to the terminals NOTE There is a 120 resistor in protective cap to minimize the possibility of co...

Page 209: ...186 ...

Page 210: ...Vehicle speed iBR gate position CAN Lake temperature sensor Information center ECM INFORMATION CENTER MONITORING Information center VTS and iS switch MODE and SET switch Cruise switch CAN GPS Fuel level sensor Depth sounder ECM iBR module iS module iS MONITORING iS module and motor Vehicle speed Suspension position CAN TOPS Information center iBR module When a malfunction is currently detected the...

Page 211: ...jor Fault and Vehicle Reaction The following EMS conditions will trigger a limp home mode ENGINE PROBLEM MAX ALLOWED RPM High engine temperature from 110 C 230 F 3000 High exhaust temperature from 110 C 230 F 3000 Low oil pressure below 180 220 kPa 26 32 PSI 2500 The following conditions will trigger a limp home mode iBR PROBLEM SYSTEM BEHAVIOR iBR gate will be moved and locked in forward position...

Page 212: ... by a scrolling message in the multifunction display MESSAGE DISPLAY INFORMATION RIGHT KEYPAD ERROR Gauge control button malfunction LOW OIL PRESSURE Engine low oil pressure detected HIGH EXHAUST TEMPERATURE High exhaust temperature detected HIGH TEMPERATURE High engine temperature detected CHECK ENGINE Engine management system malfunction or maintenance required HIGH BATTERY VOLTAGE High battery ...

Page 213: ...Refer to COOLING SYSTEM subsection High exhaust temperature Refer to ELECTRONIC FUEL INJECTION Continuously beeps Low oil pressure Turn off engine as soon as possible Check oil level and refill Refer to LUBRICATION subsection FAULT CODES A fault code is an indication that a glitch or mal function is detected by the monitoring system of the vehicle A fault code consists of a letter followed by a nu...

Page 214: ...to enter the function and display the first fault code then press the UP or DOWN arrow but ton repeatedly to display each subsequent code NOTE When the last fault code has been dis played and the button is pressed again the system loops back to the first fault code dis played and all fault codes can again be displayed If there was one active fault code when entering the FAULT CODE mode and it beco...

Page 215: ...n if this fault is active In this case the fault can be ignored The fault will be set to occurred when the iS module will be shut down If suspension does not operate when using the Up Down s refer to SUSPENSION iS subsection Fault Code U0129 CAN communication error between ECM and iBR modules or iBR CAN message timeout or validity This fault may occasionally appear as occurred Normal operation is ...

Page 216: ...f disconnected to pin 15 on the cluster B2220 Cluster Right keypad fault switch kept activated more than 60 seconds Problem with right keypad The switch may be defective verify the functionality of the switch or the wires Refer to the Shop Manual for switch diagnosis testing procedure B2221 Cluster MODE SET switches shorted to ground fault Problem with right keypad Look for pin B if shorted to gro...

Page 217: ...rea Refer to the Service Manual for more details C2110 iBR iBR gate position sensor error iBR malfunction Replace iBR unit Refer to the Service Manual for more details C2110 iBR Angle position sensor warning iBR malfunction Replace iBR unit Refer to the Service Manual for more details C2110 iBR iBR overheat iBR cooling system failure iBR unit failure Check iBR cooling circuit Replace iBR unit Refe...

Page 218: ...ged iBR pins Fault detected when the engine is running or stopped Check system circuits C03 6pos and C01 12pos Check for 0 5 to 3 V on pin F and 0 25 to 1 5 on pin C C2144 iBR Brake Lever Sensor BRLS power shorted to battery Damaged sensor damaged circuit wires damaged connector or damaged iBR pins Fault detected when the engine is running or stopped Check system circuits C03 6pos and C01 12pos Ch...

Page 219: ... Application calibration is corrupted Incompatible firmware or memory failure B U D S should repair that Program calibration with B U D S C2221 iS Application parameters corrupted backup no 1 or no 2 Battery power lost or memory failure Reset after power down up clear fault If happens often verify supply voltage Check power wiring and fuse C2222 iS Last session interrupted Unexpected battery power...

Page 220: ...nd Sensing port dirty or blocked Sensor failure or unexpected reading at idle Sensor fallen out of housing or leaking inlet Check system circuits A B4 A G4 A H2 Make sure that the sensor housing is correctly inserted into the manifold Check sensor connector for a 5 volts on pin 1 b 0 volt on pin 2 c 0 volt on pin 3 Refer to the Service Manual for more details P0108 ECM Manifold absolute pressure s...

Page 221: ...7 ECM Engine temperature sensor voltage too low Damaged sensor damaged circuit wires damaged connector or damaged ECM pins Check for debris or blockage in cooling system Check the sensor for approximately 2280 to 2736 ohms at 19 to 21 C 66 to 70 F Check for approximately 2280 to 2736 ohms at 19 to 21 C 66 to 70 F between ECM connector pins A A1 and A J2 Refer to the Service Manual for more details...

Page 222: ... or damaged ECM output pins Check for 11 4 to 12 6 ohms between engine connector pin 2 and ECM connector pin A K1 Check for 12 volts on pin 2 of injector connector Check fuse 8 refer to WIRING DIAGRAM Check for damaged circuit wires Refer to the Service Manual for more details P0202 ECM Injection Power Stage fault open line Cylinder 2 Damaged injector damaged circuit wires damaged connector or dam...

Page 223: ...or 2 fault short circuit to battery Damaged sensor damaged circuit wires damaged connector or damaged ECM pins Check system circuits B A3 B B3 B J3 Check for 0 volt on sensor connector pin B Check for 5 volts on sensor connector pin A Check for 0 25 to 1 5 volts on sensor connector pin C Refer to the Service Manual for more details P0231 ECM Fuel pump open circuit or short to ground Damaged pump d...

Page 224: ...ircuit or shorted to ground Damaged injector damaged circuit wires damaged connector or damaged ECM output pins Check for 11 4 to 12 6 ohms between engine connector pin 2 and ECM connector pin A K1 Check for 12 volts on pin 2 of injector connector Check fuse 8 refer to WIRING DIAGRAM Check for damaged circuit wires Refer to the Service Manual for more details P0265 ECM Injector 2 shorted to batter...

Page 225: ...imately 5 Mohms between system circuits A C3 and A G2 Refer to the Service Manual for more details P0335 ECM Crankshaft signal error Damaged sensor damaged circuit wires damaged connector damaged ECM pins or damaged tooth wheel For the CPS check for 700 to 900 ohms between terminals A H1 and A K2 of ECM connector Refer to the Service Manual for more details P0340 ECM Camshaft 1 signal error Damage...

Page 226: ...ne connector pin 1 and ECM connector pin A M4 Check for 12 volts on pin 2 of coil connector Check fuse 7 refer to WIRING DIAGRAM Refer to the Service Manual for more details P0355 ECM Ignition Power Stage fault short circuit to GND Cylinder 2 Damaged coil damaged circuit wires damaged connector or damaged ECM output pins Check for 0 85 to 1 15 ohms between engine connector pin 1 and ECM connector ...

Page 227: ...ls P0513 ECM Invalid D E S S Key detected Key not programmed in ECU Program a good key P0520 ECM Oil pressure switch functional problem Engine leak oil pump failure damaged sensor damaged circuit wires damaged connector or damaged ECM pins Check resistance at 0 RPM and above 3500 RPM Switch is normally closed ECM connector pin A E3 When blow by pressure exceeds 40 kPa 6 PSI the resistance is infin...

Page 228: ...ed AC generator or damaged connectors Check fuses 15 refer to WIRING DIAGRAM Check ground continuity to the engine block Refer to the Service Manual for more details P0563 ECM Battery voltage too high Battery failure rectifier failure or battery terminal connection Check for regulator rectifier failure Refer to the Service Manual for more details P0564 Cluster Cruise switch fault The cruise switch...

Page 229: ...amaged circuit wires damaged connector or damaged ECM output pins Check continuity for circuits A C4 A G1 A F4 Refer to the Service Manual for more details P1504 ECM TOPS switch short circuit ground Boat or sensor upside down damaged circuit wires damaged connector or damaged ECM output pins Check continuity for circuits A C4 A G1 A F4 Refer to the Service Manual for more details P1505 ECM TOPS sw...

Page 230: ...maged connector or damaged ECM Check system circuit perform closed throttle with B U D S Replace throttle actuator replace ECM P1614 ECM Throttle Actuator Return Spring check not passed Spring does not close Damaged throttle actuator damaged circuit wires damaged connector or damaged ECM Check system circuit perform closed throttle with B U D S Replace throttle actuator replace ECM P1615 ECM Throt...

Page 231: ...ult of D E S S key communication line Damaged D E S S key switch damaged circuit wires damaged connector or damaged ECM output pins Remove D E S S key and check system circuit B B2 Refer to the Service Manual for more details P1658 ECM Faulty D E S S key communication Damaged D E S S key switch damaged circuit wires damaged connector or damaged ECM output pins Remove D E S S key and check system c...

Page 232: ...k for approximately 2280 to 2736 ohms at temperature of 19 to 21 C 66 to 70 F between system circuits A H4 and A J4 Refer to the Service Manual for more details P2081 ECM Exhaust temperature sensor fault Intremittent connection Damaged sensor damaged circuit wires damaged connector or damaged ECM output pins Check for approximately 2280 to 2736 ohms at temperature of 19 to 21 C 66 to 70 F between ...

Page 233: ...N circuit failure iBR or ECM failure Check CAN circuits wires Replace iBR Refer to the Service Manual for more details U0129 iS iBR CAN messages time out or validity Warning only the iS module lost communication with the iBR If fault ACTIVE verify CAN connection between iBR and iS U016A ECM Loss of vehicle speed Instrument cluster fault detected by ECM CAN circuit failure instrument Cluster or ECM...

Page 234: ...re iBR or ECM failure Check CAN circuits wires Replace iBR Refer to the Service Manual for more details U16A5 ECM iBR CAN Timeout error Missing CAN ID 012h iBR fault detected by ECM CAN circuit failure iBR or ECM failure Check CAN circuits wires Replace instrument iBR Refer to the Service Manual for more details U16A6 ECM Cluster check sum error CAN ID230h Cluster fault detected by ECM CAN circuit...

Page 235: ...212 ...

Page 236: ...er operates the throttle accelera tor sensor TAS It is a double output hall effect sensor The redundancy is used for security pur poses The throttle actuator ETA is a DC motor on the throttle body that regulates the throttle plate via a drive gear Pulse width modulation PWM is used to control the motor In the throttle body there is a double throttle position sensor TPS The redun dancy is used for ...

Page 237: ...he operator to adjust and set idle speed corresponding to a watercraft speed of 1 6 km h to 8 km h 1 MPH to 5 MPH The throt tle lever should not be depressed while operating in slow speed mode The throttle plate will open and close as necessary to maintain the set speed O T A S TM System Off Throttle Assisted Steering The O T A S Off Throttle Assisted Steering system provides additional maneuverab...

Page 238: ...Test on the 8 pin Connector of Diagnostic Harness 8 PIN CONNECTOR IDLE POSITION WIDE OPEN POSITION PIN VOLTAGE Vdc 6 7 4 9 5 1 7 8 0 15 0 35 1 4 1 6 smr2009 030 033_a Test on the 12 pin Connector of Diagnostic Harness 12 PIN CONNECTOR IDLE POSITION WIDE OPEN POSITION PIN VOLTAGE Vdc 10 11 4 9 5 1 11 12 0 4 0 6 2 9 3 1 smr2009 030 033_b Test Results If voltage is as per specification the TAS sensor...

Page 239: ...2009 030 102_a 1 Route harness here When installation is completed ensure throttle lever works properly CRUISE SWITCH Cruise Switch Test If pressing the cruise switch does not engage the CRUISE or SLOW SPEED modes test the cruise switch as per following procedure 1 Connect the watercraft to the latest B U D S software Refer to COMMUNICATION TOOLS AND B U D S SOFTWARE subsection for de tails 2 In B...

Page 240: ... connector NOTICE Pull connector lock out sideways Do not twist the screwdriver smr2009 042 002_a 1 Gauge connector 2 Pull out to unlock connector 6 Use the FLUKE 115 MULTIMETER P N 529 035 868 7 Select the ohm function 8 Test the cruise button switch as per following table CRUISE SWITCH TEST GAUGE CONNECTOR SWITCH POSITION RESISTANCE Switch released OL Pin 7 Pin 10 Switch depressed Close to 0 If ...

Page 241: ...lifting it off its sup port 7 Cut the locking ties from the harness sheath as necessary 8 Carefully pull the wires out of the harness Ensure the string draws through the harness sheath 9 Tie the string to the new cruise switch wire ends and pull the new wires through the har ness 10 Install new switch terminals in the gauge con nector 11 Apply a small amount of DIELECTRIC GREASE P N 293 550 004 on...

Page 242: ... S software to release fuel pressure prior to removing a hose Cover the fuel line connection with an absorbent shop rag Slowly disconnect the fuel hose to minimize spilling Wipe off any fuel spillage in the bilge Fuel is flammable and explosive under certain conditions Al ways work in a well ventilated area Always disconnect battery prior to working on the fuel system When the repair is completed ...

Page 243: ...me and even contradictory demands if the throttle lever is fully depressed and the iBR lever is fully squeezed for example it must priori tize the most important requirement according to predefined conditions and then applies the proper action by triggering the actuators Air Induction Air Intake Silencer Air is drawn through the air intake silencer located above rear part of engine The air entry i...

Page 244: ... 3 Injector 4 Throttle body 5 Ignition coil 6 Manifold absolute pressure sensor MAPS 7 Manifold air temperature sensor MATS Flame Arrester The flame arrester is a tube inside the intake mani fold It prevents flames leaving through the intake system if the engine backfires EFI Sensors The ECM reads the inputs from the sensors makes computations uses pre determined pa rameters and activates the outp...

Page 245: ...ection Install the D E S S key on its post Briefly press the START button to wake up the ECM Engine must not crank In B U D S click on the Reset button smr2009 030 002_a SETTING AND ECM TABS 1 Click Reset button The following message will confirm the operation smr2009 030 003 Reset is completed NOTE It is not necessary to click on the Write button in B U D S Exit B U D S NOTE If throttle valve was...

Page 246: ...g in the elec trical system Battery voltage Fuses Bus bar condition in fuse boxes Ground connections Wiring connectors Ensure that all electronic components are gen uine Any modification on the wiring harness may lead to generate fault codes or bad operation Electrical Connections Pay particular attention to ensure that terminals and pins are not out of their connectors or out of shape When probin...

Page 247: ... the ECM is cut Power is cut on all the electrical system except the GPS supply in the information center When engine is running and the D E S S key is removed from its post ECM stops the engine After 5 seconds the information center turns off After 10 seconds ECM pin B H2 removes the ground to the relay coil Relay contacts open and power to the ECM is cut Power is cut on all the electrical system...

Page 248: ...pecification check the wiring and connections between relay output and F20 output Refer to WIRING DIAGRAM If voltage is as per specification check the conti nuity of wiring and connections between FB2 and ECM as follows 1 Disconnect B connector from ECM 2 Install ECM ADAPTER TOOL P N 529 036 166 on ECM connector smr2009 030 010 3 Use the FLUKE 115 MULTIMETER P N 529 035 868 and select 4 Probe term...

Page 249: ...aust manifold water inlet fitting If everything tests good and ECM does not power up try a new ECM Refer to ECM RE PLACEMENT ECM Removal NOTE If a new ECM is to be installed first read the procedures in the ECM REPLACEMENT in this subsection Disconnect battery cables WARNING Battery BLACK negative cable must always be disconnected first and connected last Disconnect both ECM connectors from ECM Un...

Page 250: ...he data will remain stored in the PC computer as long as B U DS is running Remove the old ECM Refer to ECM REMOVAL in this subsection Install and connect the new ECM Refer to ECM INSTALLATION in this subsection Briefly press the START button to wake up the ECM Engine must not crank From B U D S choose ECM Replace under Module menu smr2009 030 004 B U D S will automatically write the data from the ...

Page 251: ... servicing NOTE The file name structure is as follows BUDS version_VIN_date read yyyymmdd _hour read hhmmss mpem Example P2 3 22 12_2BPSBK8C68V000168_20090206_111640 mpem Therefore B U D S version P2 3 22 12 VIN 2BPSBK8C68V000168 Date 2009 02 06 Hour 11h 16m 40s Go in the Vehicle tab and record the following in formation 1 Vehicle serial number 2 Engine serial number without the leading M 3 Vehicl...

Page 252: ...the Collected Information Into the ECM Remove the faulty ECM Install and connect the new ECM Use the B U D S software Refer to COMMUNI CATION TOOLS AND B U D S SOFTWARE sub section Install the D E S S key on its post Briefly press the START button to wake up the ECM Engine must not crank In B U D S click the Read Data button to read the new empty ECM vmr2006 012 100_aen The following window will p...

Page 253: ...the Closed throttle reset Refer to Closed Throttle Reset TPS in ADJUSTMENTS in this subsection Reinstall remaining removed parts FUEL RAIL Fuel Rail Removal Open seat Remove rear ventilation box Refer to AIR INTAKE SYSTEM Remove deck extension Refer to BODY Pull out relay in fuse box 2 to prevent fuel pump to turn on unexpectedly Refer to POWER DISTRI BUTION Fuel Rail Hose Disconnection 1 Release ...

Page 254: ...el rail side to side wiggle smr2009 030 027_a 1 Fuel rail Unplug all injector connectors Pull fuel rail out with fuel injectors Fuel Rail Installation Reverse the removal procedure However pay at tention to the following Apply LOCTITE 243 BLUE P N 293 800 060 on fuel rail retaining screws Torque fuel rail retaining screws to 9 N m 80 lbf in smr2009 030 026_a 1 Retaining screws Properly install new...

Page 255: ...rt engine 3 Using the B U D S software shut down each engine cylinder one at a time mmr2009 120 006_a MONITORING AND ECM TABS 1 Click on the desired cylinder number If the engine RPM drops when clicking on a cylin der the injector and the ignition of this cylinder are working If the engine RPM does not drop when clicking on a cylinder this cylinder is not working properly Check the following Fuel ...

Page 256: ...click the Fuel Pump button to ac tivate fuel pump smr2009 030 014_a ACTIVATION AND ECM TABS 1 Fuel pump 5 Fuel pressure must be within specification Re fer to FUEL TANK AND FUEL PUMP subsec tion Re activate fuel pump as necessary 6 In B U D S energize the fuel injector no 1 smr2009 030 013_a ACTIVATION AND ECM TABS 1 Injector of cylinder no 1 shown 7 Record the fuel pressure drop for injector no 1...

Page 257: ...Vdc Read voltage of the desired injector INJECTOR CONNECTOR MEASUREMENT VIOLET wire with a tracer and battery ground Battery voltage smr2009 030 029_a If input voltage is good carry out the INJECTOR CONTROL CIRCUIT TEST If input voltage is not good check continuity be tween fuse box 1 and injector as follows Remove cover of fuse box 1 Refer to POWER DISTRIBUTION subsection Remove the long bus bar ...

Page 258: ...rcuit and all tests applicable to the in jector are good try a new ECM Refer to ECM Fuel Injector Resistance Test at ECM Connector Reconnect the injector connector Disconnect the ECM A connector Install ECM ADAPTER TOOL P N 529 036 166 on ECM connector Remove the long bus bar from fuse box 1 smr2009 027 011_f 1 Long bus bar Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Measure resistance...

Page 259: ...l Fuel Injector Installation Reverse the removal procedure Paying attention to the following details If you reinstall a used injector carefully inspect O ring condition before reinstallation Replace O ring with a new one if damaged Apply a thin film of engine oil to O rings Insert the fuel injector in place on fuel rail Secure injector to fuel rail with its clip Install fuel rail Refer to FUEL RAI...

Page 260: ...ng other things a weak or broken spring and a sticky throttle plate carbon build up dried salt water etc are validated by the throttle body diagnostic mode FAULT EFFECT Partial failure of TAS sensor one internal sensor only Limp home mode Engine speed limited to idle ECM will use the remaining TAS sensor Fault code set and beeper activated to emit warning signals Check engine light is turned ON Dr...

Page 261: ... RE MOVAL Look at throttle plate when the engine is stopped Throttle plate should be in the rest position slightly opened Install the D E S S key on its post Ask someone to briefly press the START button to wake up the ECM while watching the throttle plate Do not start engine WARNING Keep your fingers out of the throttle plate area while the ECM turns on The throttle actuator will cycle This could...

Page 262: ...ension using the iS up button to gain access NOTE If more height is required or if the iS can not be used manually lift suspension by the an chor points close to handlebar and safely block in this position Do not lift the watercraft from the anchor points 2 Disconnect inlet hose from throttle body 3 Disconnect throttle body connector smr2009 030 024_a 1 Throttle body 2 Inlet hose 3 Connector 4 Rem...

Page 263: ...ate and this could cause serious finger injuries if you were working in this area smr2009 030 016_b 1 Push here Check needle movement again If needle moves as expected check the throttle accelerator sensor TAS of throttle lever Refer to THROTTLE ACCELERATOR SENSOR TAS in this subsection If needle does not move as expected perform the TPS VOLTAGE TEST and the TPS RESIS TANCE TEST in this subsection...

Page 264: ...heel tooth First check fault codes then CPS as per following procedure if it tests good verify trigger wheel teeth condition Refer to PTO HOUSING AND MAGNETO in the ENGINE section CPS Voltage Test To gain access to the CPS remove the required parts as described in CPS REPLACEMENT Disconnect CPS connector smr2008 023 016_a TYPICAL Install the D E S S key on its post Briefly press the START button t...

Page 265: ...replace the wiring harness between ECM connector and the CPS CPS Replacement Open seat Remove rear ventilation box Refer to AIR INTAKE SYSTEM Remove deck extension Refer to BODY Remove air intake silencer Refer to AIR INTAKE SYSTEM Drain oil from PTO housing Refer to PTO HOUS ING AND MAGNETO NOTE It is not necessary to drain oil from engine Disconnect CPS connector smr2008 023 016_a TYPICAL Remove...

Page 266: ... the START button to wake up the ECM Probe terminals as shown CAPS CONNECTOR MEASUREMENT PIN VOLTAGE 3 1 Battery voltage smr2009 030 035_a If battery voltage is read proceed with CAPS DY NAMIC TEST further If battery voltage is not read probe circuit as shown CAPS CONNECTOR MEASUREMENT PIN VOLTAGE 3 Battery ground Battery voltage smr2009 030 035_b If voltage is now read check ground circuit be twe...

Page 267: ...r and cover CAPS Dynamic Test To gain access to the CAPS remove the required parts as described in CAPS REPLACEMENT Remove CAPS sensor from engine Back probe connector and read voltage as fol lows NOTE To easily probe wire terminals through the back of their connectors FLUKE RIGID BACK PROBE P N TP88 or equivalent can be used vmr2007 050 004 They can be inserted at the end of the standard probes o...

Page 268: ... BODY Remove air intake silencer Refer to AIR INTAKE SYSTEM Detach CPS connector from its holder smr2008 023 016_a TYPICAL Disconnect CAPS connector smr2009 030 034_a 1 CAPS connector Unscrew the retaining screw Pull out CAPS from engine Install the CAPS Ensure to reinstall O ring Apply Loctite 243 blue on thread and torque to 9 N m 80 lbf in MANIFOLD AIR TEMPERATURE SENSOR MATS smr2009 030 036_b ...

Page 269: ... HIGH 30 22 12600 11800 13400 20 4 11400 11000 11800 10 14 9500 8000 11 000 0 32 5900 4900 6900 10 50 3800 3100 4500 20 68 2500 2200 2800 30 86 1700 1500 1900 40 104 1200 1080 1320 50 122 840 750 930 60 140 630 510 750 70 158 440 370 510 80 176 325 280 370 90 194 245 210 280 100 212 195 160 210 110 230 145 125 160 120 248 115 100 125 vmr2008 022 005_a If resistance value is correct check ECM Refer...

Page 270: ...nector A on the ECM Using a multimeter and the ECM ADAPTER TOOL P N 529 036 166 check the circuit resistance as per table ECM ADAPTER MEASUREMENT PIN RESISTANCE A A1 A J2 See table below TEMPERATURE RESISTANCE OHMS C F NOMINAL LOW HIGH 30 22 12600 11800 13400 20 4 11400 11000 11800 10 14 9500 8000 11 000 0 32 5900 4900 6900 10 50 3800 3100 4500 20 68 2500 2200 2800 30 86 1700 1500 1900 40 104 1200...

Page 271: ...nexpected sensor range at idle when it reads the atmospheric pressure Remove sen sor and check for oil or dirt on its end and if prob lem persists check throttle plate condition posi tion and the wiring harness Perform the follow ing tests MAPS Voltage Test To gain access to the MAPS remove the required parts as described in CTS REPLACEMENT Disconnect connector from MAPS smr2009 030 036_d 1 Discon...

Page 272: ...ll appear when ex haust temperature reaches ENGINE TEMPERATURE All 1503 110 C 230 F EGTS Resistance Test To gain access to the EGTS remove the required parts as described in EGTS REPLACEMENT Disconnect the connector from the EGTS and check the resistance of the sensor itself smr2008 023 018_a The resistance should be as per following chart Otherwise replace the EGTS If resistance tests good reconn...

Page 273: ...6 N m 142 lbf in Plug the EGTS connector Install all other removed parts KNOCK SENSOR KS 1 R1503motr174A 1 Knock sensor KS KS Dynamic Test Using the B U D S software monitor the knock sensor using the Faults section Start the engine and bring engine RPM above 5000 RPM If no fault code occurs the knock sensor is good Otherwise do the following Ensure sensor and cylinder head contact surfaces are cl...

Page 274: ... is good check ECM Refer to ENGINE CONTROL MODULE ECM in this sec tion Otherwise repair the connector or replace the wiring harness between ECM connector and knock sensor KS Replacement Open seat Remove rear ventilation box Refer to AIR INTAKE SYSTEM Remove deck extension Refer to BODY Remove air intake silencer Refer to AIR INTAKE SYSTEM Remove the intake manifold Refer to INTAKE MANIFOLD AND INT...

Page 275: ...252 ...

Page 276: ...GNOSTIC HARNESS 529 036 179 271 ECM ADAPTER TOOL 529 036 166 265 FLUKE 115 MULTIMETER 529 035 868 265 272 FUEL HOSE ADAPTER 529 036 023 262 FUEL PUMP MODULE SOCKET 529 036 125 267 OETIKER PLIERS 295 000 070 264 PRESSURE GAUGE 529 035 709 262 SMALL HOSE PINCHER 295 000 076 259 261 VACUUM PRESSURE PUMP 529 021 800 258 smr2009 031 253 ...

Page 277: ...tion 04 FUEL SYSTEM Subsection 03 FUEL TANK AND FUEL PUMP FUEL TANK AND FUEL PUMP 60 N m 44 lbf ft 4 5 N m 39 lbf in NEW NEW NEW NEW NEW NEW NEW NEW NEW 3 5 N m 31 lbf in smr2009 031 001_a 254 smr2009 031 ...

Page 278: ...ure more than 303 kPa 44 PSI or 399 kPa 58 PSI Fuel pressure less than 303 kPa 44 PSI or 399 kPa 58 PSI Perform fuel pump test Check fuel line rail for leaks Fuel pressure less than 303 kPa 44 PSI or 399 kPa 58 PSI Fuel pressure more than 303 kPa 44 PSI or 399 kPa 58 PSI Check fuel injector Fails Press Start button Fuel pump runs Fuel pressure is 303 kPa 44 PSI or 399 kPa 58 PSI OK OK Yes No Check...

Page 279: ...ressure very quickly Prior to pressing the START button ensure there are no disconnected or damaged fuel lines that may leak fuel in the vehicle A high pressure leak test must be carried out whenever a fuel system component has been disconnected WARNING Ensure wires and hoses are routed and se cured away from any vibrating rotating moving or hot components or sharp edges Use appropriate shields an...

Page 280: ... fuel level sensor It then displays the proper fuel level bars and a low fuel warning message when required The information center will also trigger the beeper which produces the appropriate beep signal to warn the driver of a low fuel condition The fuel level sensor resistance is at its lowest value when the fuel tank is full and at its highest value when the tank is empty Refer to the FUEL LEVEL...

Page 281: ... Close fuel tank cap Open front storage compartment cover and re move storage bin Remove front ventilation box smr2009 031 008_a 1 Ventilation box Visually inspect condition of hoses and clamps Pull out inlet valve from its grommet smr2009 031 009_a 1 Pull out inlet valve Make sure that grommets of inlet and outlet valves are not plugged Use the VACUUM PRESSURE PUMP P N 529 021 800 529021800 NOTE ...

Page 282: ...n a few strokes of pump inlet valve is likely clogged Refer to INLET CHECK VALVE TEST in this sub section When pressure has reached 2 8 kPa 7 6 kPa 4 PSI 1 1 PSI the pressure relief valve should open preventing a further increase in pressure When valve opens pressure must drop at pump gauge If pressure increases above specification or gauge does not drop to zero replace outlet valve Install a SMAL...

Page 283: ... will indicate leak location s NOTE If pressure does not stand and no leak has been found it is likely a leaking fuel injector Refer to ELECTRONIC FUEL INJECTION NOTICE When the fuel system leak test is complete thoroughly rinse all components of the soapy water solution with clear water A soapy water residue may cause premature deterioration and must be rinsed away WARNING If a leak is found do n...

Page 284: ... Air should be drawn in freely and vacuum pres sure indication on gauge should remain at zero If vacuum value rises replace inlet valve Set vacuum pressure pump to pressure smr2009 031 012_a 1 Pressure selected Squeeze the vacuum pressure pump handle sev eral times to pressurize air to the inlet valve smr2009 031 015_b TEST SETUP Valve should hold 34 5 kPa 5 PSI without leak age Otherwise replace ...

Page 285: ... engine can be started FUEL PUMP PRESSURE TEST Preparation Before proceeding ensure the battery is fully charged The pressure test will show the available pressure at the fuel pump outlet It validates the pressure regulator the fuel pump and tests for leaks in the system Release fuel pressure Refer to FUEL PUMP in this subsection Open front storage compartment cover Remove the storage basket Remov...

Page 286: ...he fuel pump check valve Check fuel rail for leaks If leak occurs while pressing the START button and fuel rail is not leaking then replace fuel pump module A slow pressure drop indicates leakage either from a fuel injector or from the fuel pressure regulator in the fuel pump module To check fuel injectors for leaks refer to the ELECTRONIC FUEL INJECTION EFI subsection If injectors are not leaking...

Page 287: ...s on fuel lines use OETIKER PLIERS P N 295 000 070 F01B03A 1 1 Cutting clamp F01B04A 1 1 Securing clamp F01B05A 1 1 Securing clamp in limited access FUEL PUMP How to Release Fuel Pump Pressure Connect to the latest B U D S software refer to COMMUNICATION TOOLS AND B U D S SOFT WARE subsection Select the Activation tab then the ECM tab On the RH side of the activation page click Fuel Press Relief b...

Page 288: ...oltage Test Disconnect fuel pump harness connector Refer to FUEL PUMP REMOVAL Use the FLUKE 115 MULTIMETER P N 529 035 868 Select Vdc Press START button Read voltage at fuel pump harness connector as per following table INPUT VOLTAGE TEST TEST PROBES VOLTAGE Pin B probe Battery ground probe Battery voltage smr2008 022 017_b If battery voltage is read power circuit is good Test the fuel pump circui...

Page 289: ...TEST WIRING ONLY TEST PROBES RESISTANCE 20 C 68 F Pump harness connector pin B Fuse box 1 terminal C1 Pump harness connector pin A ECM connector B pin B M1 Close to 0 continuity smr2009 031 021_a smr2009 031 021_b Repair or replace wiring as required If every test succeeded and fuel pump still does not work try a new ECM Refer to ELECTRONIC FUEL INJECTION subsection Fuel Pump Removal Release fuel ...

Page 290: ...DULE SOCKET P N 529 036 125 smr2009 031 022_a 1 Fuel pump module socket 2 Fuel pump retaining nut NOTICE While pulling out the fuel pump module pay attention to the corrugated tubes and fuel sensor float arm Float arm can get caught up and bend which will reduce fuel sen sor accuracy If fuel pump module is dropped or damaged it must be replaced Slowly pull fuel pump module up through opening until...

Page 291: ...MODULE INDEXING 1 IAlign marks Apply torque values as per exploded view Carry out a FUEL TANK LEAK TEST and a FUEL SYSTEM HIGH PRESSURE LEAK TEST See pro cedures in this subsection FUEL FILTER Fuel Filter Inspection Check if fuel filter is dirty If so replace it smr2009 031 025_a 1 Fuel filter Fuel Filter Removal NOTE The lower fuel filter on the fuel pump mod ule does not require replacement unde...

Page 292: ...r crack s If crack s are found replace fuel tank With your fingers feel the inside and outside sur faces of fuel tank especially near the filler neck Flex fuel tank necks to ensure there are no hidden cracks NOTE A fuel tank is comprised of 2 components the tank and the filler neck The necks are injec tion molded and the tank is then blow molded over the necks During the molding process a small mo...

Page 293: ...view Reinstall fuel pump if it was removed Refer to FUEL PUMP in this subsection Ensure flotation foams are properly positioned Insert fuel tank in hull Place fuel tank retaining strap ends in anchoring clips Temporarily use tape to hold straps on the top of fuel tank smr2009 031 027_a 1 Fuel tank retaining strap 2 Clip anchor securing strap to hull Secure a long retaining strap end with a short s...

Page 294: ...TING SYMPTOM POSSIBLE CAUSE Fuel gauge always display EMPTY Wiring connectors Fuel level sensor Float stuck in low position Fuel gauge always display FULL Water in fuel pump connector Float stuck in full position Fuel level sensor fault code Wiring connectors Fuel level sensor Fuel gauge displays wrong level Low battery voltage Fuel level sensor fault Use B U D S to check for a fault code Refer to...

Page 295: ...N CENTER as described in this sub section Remove diagnostic harness and reconnect con nector Fuel Level Sensor Resistance Test at Information Center Disconnect information center multifunction gauge connector Refer to GAUGE subsection Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Alternately drain then fill fuel tank and measure the sensor resistance between pins 19 and 20 as follows RES...

Page 296: ... Removal smr2008 022 029 FUEL LEVEL SENSOR Remove fuel pump module from fuel tank see FUEL PUMP REMOVAL in this subsection WARNING The upper filter and fuel pump reservoir on the fuel pump module contain fuel which will drain out when fuel pump module is not in an upright position Drain all fuel from the upper fuel filter and fuel pump reservoir in an appropriate container NOTE Note routing of fue...

Page 297: ...king tab 2 Pressure regulator rotated clockwise over locking tab Once the pressure regulator is rotate over the locking tab pull up on it to remove it from the pump reservoir cover smr2008 022 025_a 1 Pressure regulator alignment tabs 2 Fuel pump reservoir alignment tabs NOTE The pressure regulator cover must not be removed from the pressure regulator housing as sembly smr2008 022 028_a 1 Do not r...

Page 298: ...pump reservoir smr2008 022 026_b 1 Ensure engagement of sensor locking pins Align the fuel pressure regulator tabs into the pump reservoir cover and turn it counterclock wise until it locks properly smr2008 022 025_b PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR COVER 1 Pressure regulator alignment tabs 2 Fuel pump reservoir alignment tabs smr2008 022 030_a TAB UP WHEN PRESSURE REGULATOR PROPER...

Page 299: ...ensor connector is locked into the module flange connector smr2008 022 021_a 1 Fuel level sensor connector Carry out a FUEL LEVEL SENSOR RESISTANCE TEST as described in this subsection Reinstall the fuel pump module Refer to FUEL PUMP INSTALLATION in this subsection 276 smr2009 031 ...

Page 300: ...ach component and they are in constant communication with each other at a rate of about every 10 or 20 milliseconds depending on the component CAN lines consist of a pair of wires WHITE BLACK and WHITE RED The CAN is also used to communicate with the B U D S software Refer to COMMUNICATION TOOLS AND B U D S SOFTWARE CAN BUS HI FUSE BOX 2 CAN BUS LOW FUSE BOX 2 ECM GAUGE iS iBR DEPTH SOUNDER DIAGNO...

Page 301: ...cluster CAN problem ECM Engine Control Module Engine is set to limp home mode Check engine light is ON iBR light is ON iBR gate locked in neutral Some functions not displayed such as engine hours RPM 3 modules instead of 4 will be active ECM tab and its data will not be present iBR and iS will report an ECM CAN problem iBR intelligent Brake and Reverse Engine is set to limp home mode iBR gate will...

Page 302: ...bsection Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Refer to the CAN BUS DIAGRAM above and read wire resistance between the proper bus bar termi nal and the component terminal Check the con tinuity of the WHITE RED wire and the continuity of the WHITE BLACK wire The following gives an example between the CAN LO wire and the ECM NOTE When working with the ECM install the ECM ADAPTER TO...

Page 303: ...280 ...

Page 304: ...M Subsection 02 POWER DISTRIBUTION POWER DISTRIBUTION SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER 529 035 868 287 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE 293 550 004 286 smr2009 049 281 ...

Page 305: ...oil No 3 Fuel injector Ignition coil No 2 F15 30 A F18 30 A F16 30 A F21 3 A F22 15 A F23 3 A F17 30 A F20 15 A F5 5 A F11 5 A F4 5 A F3 3 A F2 15 A F9 10 A F1 3 A F8 10 A F7 10 A F10 3 A F6 10 A Fuel pump CAPS Camshaft Position Sensor ECM Electronic Control Module iBR Intelligent Brake and Reverse Module iS Intelligent Suspension GPS Global Positioning System A6 D11 A5 A3 A1 A7 A8 B5 D1 B6 E3 D4 ...

Page 306: ... gives the coordinates as seen from the front smr2009 027 011_d TYPICAL CONTACT COORDINATES FRONT VIEW FB1 Coordinates are used to identify the terminal po sition in the fuse box For example if B5 or FB1 B5 is given to reference a terminal it would be located at the intersection of row B and column 5 in fuse box 1 NOTE Contact coordinates in FB2 are identified using the same method NOTE Although t...

Page 307: ...s them to the en gine grounds through terminal E5 in fuse box 2 FB2 E5 smr2009 016 011_a FRONT OF ENGINE 1 Engine grounds A cable connected to the engine behind the ex haust manifold is connected at the other end to the battery ground post to complete the ground circuit smr2009 016 026_b LH SIDE OF ENGINE 1 Battery ground cable 2 Exhaust manifold water inlet fitting CAN Distribution Bus bars The C...

Page 308: ...tes the bat tery from the electrical components including the ECM therefore preventing excessive battery drain The only current drain on the battery when power is switched off by the ECM is for the GPS in the information center It receives power through pin 1 of the information center not illustrated This is used to maintain the GPS memory of the satellite locations for approximately two hours Ele...

Page 309: ...dullness Clean pins properly and coat them with DIELEC TRIC GREASE P N 293 550 004 or other appropri ate lubricant except if otherwise specified when reassembling them Pay attention to ground wires Fuse Inspection If an electrical system fault occurs check the fuses If a fuse is burnt replace it with a fuse of the same rating Keep in mind that an electrical component may require more than one fuse...

Page 310: ...CUIT CONTINUITY If voltage is read at contact A12 but not at B12 check fuse box jumper between B12 and B7 Power Relay Output Voltage Test The power relay output voltage is applied to the short bus bar in FB1 To check for relay output voltage slightly lift the short bus bar in FB1 and test for battery voltage at a bus bar contact If no voltage is measured test the wire jumper between FB1 D6 and FB2...

Page 311: ...Section 05 ELECTRICAL SYSTEM Subsection 02 POWER DISTRIBUTION smr2007 027 060_a TERMINAL RESISTANCE 30 87 0 5 max continuity 288 smr2009 049 ...

Page 312: ... is not adjustable The ECM is programmed with data ignition map pings which it uses along with data it receives from a variety of sensors to establish optimum ignition timing under all engine operating condi tions The firing of each spark plug is independent of the others Knock Sensor A knock sensor is mounted on the cylinder block behind the intake manifold It detects specific vi brations that wo...

Page 313: ...tware as a first trou bleshooting step Refer to COMMUNICATION TOOLS AND B U D S SOFTWARE subsection If a primary winding of an ignition coil or a circuit is at fault a fault code will be set Refer to MON ITORING SYSTEM AND FAULT CODES subsec tion Ignition System Testing Sequence Ensure fuses 7 8 and 9 in fuse box 1 are good If a fuse is burnt test for a short circuit or faulty component on that fu...

Page 314: ...ON COIL INPUT VOLTAGE TEST Ignition Coil Input Voltage Test Disconnect the desired ignition coil connector Remove safety lanyard from the D E S S post Press the START button to activate the ECM Use the FLUKE 115 MULTIMETER P N 529 035 868 Select Vdc Measure voltage as per following table TEST PROBES VOLTAGE VI BU wire ignition coil no 1 VI GN wire ignition coil no 2 VI OR wire ignition coil no 3 B...

Page 315: ...2 Cylinder 3 BR YL A M1 Close to 0 continuity smr2007 023 003_d IGNITION COIL CONTROL CIRCUIT TEST If test failed repair the connector or replace the engine wiring harness If test succeeded wiring and connectors are func tional Ignition Coil Resistance Test An ignition coil with a good resistance measure ment can still be faulty Current leakage can occur at high voltage levels which is not detecta...

Page 316: ...rior to inserting the ignition coil on its spark plug apply sealant as described in following procedure 1 Pull rubber seal down sbs2009 011 002_a 1 Rubber seal pulled down 2 Apply DOW CORNING 111 P N 413 707 000 to rubber seal seat as shown sbs2009 011 001_a 1 Apply product here 3 Pull rubber seal back on its seat making sure the tabs on the ignition coil and the slots in the seal properly match t...

Page 317: ...ug then use the ignition coil to take spark plug out of spark plug hole smr2009 032 003_a 1 Ignition coil 2 Spark plug Troubleshooting a Fouled Spark Plug Fouling of the spark plug is indicated by irregular running or misfiring of the engine decreased engine speed due to misfiring reduced perfor mance and increased fuel consumption Other possible causes are a incorrect or bad fuel defective igniti...

Page 318: ... gauge set electrode gap as specified in the following chart ENGINE SPARK PLUG TORQUE GAP mm in 1503 NGK DCPR8E Hand tighten 1 4 turn with a socket 0 75 030 2 Apply anti seize lubricant over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into cylinder head Then tighten the spark plug clockwise an ad ditional 1 4 turn with an approved spark plug socket Install ignition c...

Page 319: ...296 ...

Page 320: ...equired electrical power for normal vehicle operation Magneto The magneto is the primary source of electrical energy It transforms a magnetic field into an elec tric current AC The magneto has a 3 phase delta wound 18 pole stator that is rated at 380 watts F18H1RA TYPICAL Voltage Regulator Rectifier The rectifier receives AC current from the mag neto and transforms it into direct current DC The vo...

Page 321: ...r output and wiring harness prior to concluding that voltage regulator rectifier is defective Refer to PTO HOUSING AND MAGNETO subsection Output Voltage Test Using a Multimeter Set multimeter to Vdc Connect multimeter to battery posts smr2009 033 002_a CHARGING SYSTEM VOLTAGE TEST AT BATTERY POSTS Start engine NOTE Connect a garden hose to cool exhaust system Refer to EXHAUST SYSTEM subsection Bri...

Page 322: ...s the battery recovers its charge If current reading is far below specification test stator output and wiring harness prior to conclud ing that voltage regulator rectifier is faulty NOTE If battery is in poor condition or is not at a full state of charge current reading will be above specification Refer to BATTERY in this section for battery testing Output Current Test with a Multimeter NOTICE Cha...

Page 323: ...sibility simply disconnect the voltage regula tor rectifier from the circuit and install a new fuse If the fuse still burns check for a shorted wire or connector pins NOTICE Do not use a fuse of a higher rating as this can cause severe electrical system and component damage VOLTAGE REGULATOR RECTIFIER Voltage Regulator Continuity Test Due to internal circuitry there is no static test available to ...

Page 324: ...k fuse s If in good condition check voltage regulator rectifier Faulty stator Test stator and replace as required Parasitic or Key Off current loads Isolate reduce or eliminate such loads recharge battery as recommended if vehicle is not used for extended periods of time NOTE Key Off or parasitic loads may be loads due to installed accessories Parasitic loads may also be due to water infiltration ...

Page 325: ...air flow out smr2009 033 010_a AIR MUST FLOW OUT Set vacuum pressure pump to VACUUM smr2009 031 013_a 1 Vacuum selected Squeeze the vacuum pressure pump handle sev eral times to draw air in through the check valve Check valve must hold air with 10 in Hg 34 kPa of vacuum without leaking smr2009 033 010_b MUST HOLD AIR IN THIS POSITION If any test failed check the vent hose and if good replace check...

Page 326: ...the boarding platform ssi2009 002 002_a 1 Boarding platform 2 Remove the starboard RH storage bin ssi2009 002 003_a 1 Storage bin 3 Disconnect the diagnostic connector from its holder ssi2009 002 004_a 1 Disconnect 4 Disconnect the BLACK battery cable WARNING Always disconnect battery cables exactly in the specified order BLACK battery cable first then the RED cable last 5 Disconnect the RED cable...

Page 327: ...t the vent hose from battery smr2009 033 009_a 1 Disconnect here 9 Install a piece of hose same type as vent hose with a cap or small hose pincher onto the bat tery vent to prevent electrolyte spillage when removing the battery 10 Remove battery with battery holder from ve hicle CAUTION Be careful not to disconnect the hose from the battery vent and cause an elec trolyte spill in the watercraft sm...

Page 328: ...solution of baking soda and water NOTICE Do not allow cleaning solution to en ter battery Remove corrosion from battery cable terminals and battery posts using a firm wire brush Rinse with clear water then dry well Battery Inspection Visually inspect battery casing for cracks or other possible damages If casing is damaged or shows signs of acid leaking replace battery and thoroughly clean battery ...

Page 329: ...eck battery voltage BATTERY VOLTAGE TEST LOAD APPLIED TIME TO MEASURE INTO TEST VOLTAGE 14 seconds 10 5 Vdc min If battery voltage has dropped below specifica tion the battery storage capacity has decreased appreciably and the battery should be replaced Battery Voltage Test No Load NOTE Be aware that the voltage test can indi cate that the battery is in good condition even though the battery does ...

Page 330: ...h cell Add distilled water up to upper level line as nec essary NOTICE Do not overfill The battery must always be stored fully charged If required recharge until the recommended spe cific gravity obtained prior to storage NOTICE Battery electrolyte temperature must not exceed 50 C 122 F during charging The battery casing should not feel hot to the touch Clean battery terminals and cable connection...

Page 331: ...A17E0GA 1 1 30 minutes 3 Readjust the electrolyte level to the UPPER LEVEL line A17E0RB 1 2 1 Battery electrolyte 2 Upper level line 4 Connect a 2 A battery charger for 3 to 5 hours A17E0IA 2 1 3 Step 1 Connect lead to battery post Step 2 Connect lead to battery post Step 3 Connect battery charger to AC outlet WARNING Gases given off by a battery being charged are highly explosive Always charge in...

Page 332: ... let it thaw out before charging WARNING Always charge a battery in a well ventilated area The time required to charge a battery will vary de pending on several factors such as Battery temperature The charging time is in creased for a cold battery as charging current accepted by a cold battery will be lower than for a warm battery As the battery warms up it will accept a higher rate of charge Stat...

Page 333: ...0 hour period the battery is good and charging should be completed at a lower rate as specified in ACTIVATION OF A NEW BATTERY 6 It is recommended that any battery recharged using this procedure be tested under load prior to returning it to service Battery Installation 1 Install battery in its holder and lock holder 2 Secure battery holder with its retaining screws if they were present at removal ...

Page 334: ...CHARGING SYSTEM ssi2009 002 005_a 1 BLACK cable 2 RED cable 10 Apply dielectric grease on battery posts 11 Verify cable routing and attachments 12 Insert diagnostic connector in its holder 13 Install remaining removed components smr2009 033 311 ...

Page 335: ...312 ...

Page 336: ...the starter if engine speed reached at least 1400 RPM If the START STOP button is pressed when en gine is running the engine will be shut down TROUBLESHOOTING DIAGNOSTIC TIPS NOTE It is a good practice to check for fault codes using B U D S software as a first trou bleshooting step Refer to MONITORING SYS TEM FAULT CODES section Starting system failures are not necessarily re lated to the starter ...

Page 337: ...tch or solenoid Check Replace if necessary STARTER TURNS BUT STARTER DRIVE DOES NOT MESH WITH RING GEAR 1 Worn starter drive gear Replace starter drive Refer to PTO HOUSING AND MAGNETO 2 Defective drive Replace starter drive Refer to PTO HOUSING AND MAGNETO 3 Poor movement of drive on splines Clean and correct Refer to PTO HOUSING AND MAGNETO 4 Worn starter drive bushing Replace clutch Refer to PT...

Page 338: ...r here Connect the DIAGNOSTIC HARNESS P N 529 036 179 to make an in line connection between the disconnected connector 529036179 NOTE Plug only the connector that has been dis connected Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Measure resistance through switch as per follow ing table START STOP SWITCH OPERATION TEST SWITCH POSITION 8 PIN CONNECTOR OF DIAGNOSTIC HARNESS RESISTANCE Re...

Page 339: ..._e If test failed problem is in the power circuit com ing from fuse box 2 Perform the START STOP SWITCH POWER CIRCUIT TEST If test succeeded problem is in the control circuit going to ECM Perform the START STOP SWITCH CONTROL CIRCUIT TEST Start Stop Switch Power Circuit Test Keep the same test setup as for the START STOP SWITCH OPERATION TEST Remove cover from fuse box 2 Refer to POWER DISTRIBUTIO...

Page 340: ...ector from ECM Install ECM ADAPTER TOOL P N 529 036 166 on ECM connector 529036166 Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Test continuity of the circuit as per following table CONTROL CIRCUIT TEST 8 PIN CONNECTOR OF DIAGNOSTIC HARNESS ECM CONNECTOR B RESISTANCE Pin 1 B D1 Close to 0 continuity smr2009 030 033_g If test succeeded circuit is functional If test failed repair harness ...

Page 341: ...test succeeded carry out a SOLENOID CON TROL CIRCUIT TEST If test failed carry out a POWER CIRCUIT TEST as follows Solenoid Power Circuit Test Remove relay in fuse box 2 Set multimeter to Test continuity of wiring as per following table SOLENOID POWER CIRCUIT TEST SOLENOID CONNECTOR FUSE BOX 2 TERMINAL RESISTANCE Pin A A10 Close to 0 continuity smr2009 034 006_b If test failed repair or replace wi...

Page 342: ...Set multimeter to setting Measure solenoid coil resistance as per following table SOLENOID COIL RESISTANCE TEST FUSE BOX 2 ECM CONNECTOR B RESISTANCE Terminal A10 B L4 Close to 0 continuity smr2009 034 008_a If test failed replace solenoid If test succeeded perform the following test Disconnect battery negative cable Test solenoid main contacts as per following table SOLENOID MAIN CONTACTS TEST SO...

Page 343: ...T ENGINE CRANKING TEST PROBES VOLTAGE DC Solenoid battery post Battery ground Battery voltage M 1 2 smr2009 034 010_b 1 Starter motor 2 Starter solenoid If test failed replace solenoid If test succeeded continue with next test SOLENOID DYNAMIC TEST ENGINE CRANKING TEST PROBES VOLTAGE DC Solenoid battery post Solenoid starter post 0 2 Vdc max M 1 2 smr2009 034 010_c 1 Starter motor 2 Starter soleno...

Page 344: ...smr2009 034 003_a 1 Locking tab 8 Slide solenoid out smr2009 034 004_a 1 Solenoid 9 Disconnect solenoid cables smr2009 034 005_a 1 Cables Solenoid Installation Revert removal operations and pay attention to the following Connect cables to solenoid as shown smr2009 034 005_b 1 Cable from battery 2 Cable to starter motor Ensure to push solenoid until a click is heard locking tab engagement smr2009 0...

Page 345: ...a spark Failure to follow this procedure may result in an explosion WARNING Always wear safety glasses when working with or around batteries Connect booster cables in this strict order RED booster cable Connect one clip to the starter post on the starter solenoid Connect the other clip to the positive terminal on the external battery BLACK booster cable Connect one clip to the negative battery ter...

Page 346: ... pay particular attention to the fol lowing Ensure starter and engine mating surfaces are free of debris Serious problems may arise if starter is not properly aligned Apply ISOFLEX GREASE TOPAS NB 52 P N 293 550 021 on starter O rings smr2007 025 009_a 1 Apply Isoflex grease Topas NB 52 Install starter NOTE If starter does not mesh properly with the intermediate gear Pull starter out slightly rota...

Page 347: ...BLACK battery cable is discon nected Apply DIELECTRIC GREASE P N 293 550 004 on ter minal and nut Ensure to install rubber protector over starter power cable retaining nut smr2007 025 008_b 1 Torque power cable retaining nut to 7 N m 62 lbf in and apply dielectric grease 2 Install rubber protector A 10 N m 89 lbf in Reinstall remaining removed parts 324 smr2009 034 ...

Page 348: ...system is quite flexible Up to 10 dif ferent keys may be programmed in the memory of the ECM They can also be erased individually The memory of the ECM is programmed to rec ognize the digital code of the D E S S key The programming is achieved with the B U D S soft ware D E S S Key Types For best results it is recommended to use the D E S S key with the oval shaped float It is iden tified as the i...

Page 349: ... proper connection instructions Use the latest B U D S software available from BOSSWeb IMPORTANT Ensure all connections have been made before starting B U D S to allow proper operation Briefly press START button to power the ECM Install a D E S S key to be added or erased on watercraft D E S S post smr2009 035 005_a 1 Key to be added or erased Start B U D S and logon IMPORTANT Approximately 3 minu...

Page 350: ...ogramming is complete write the changes to the ECM Refer to WRITING CHANGES TO ECM in this subsection Erasing One Key Install the key to be erased to the watercraft D E S S post smr2009 035 005_a 1 Key to be erased Click on Erase Key button at bottom of B U D S screen smr2009 035 004_a 1 Click on this button After approximately 10 seconds the following message will appear smr2009 035 007 The key i...

Page 351: ...king Click the Write Data button vmr2006 012 100_ben NOTE If for some reason the writing operation fails exit B U D S Restart B U D S and reenter all the previously lost information After the write operation remove key from D E S S post Try the key s on the watercraft Setting Maximum Speed for Learning and Rental Keys NOTE The maximum speed setting chosen will be applicable to any programmed Learn...

Page 352: ... 002 114_c NOTE Pressing the SET button twice will enable the Rental key setting function 6 Press the UP or DOWN arrow button to tog gle the key setting between 1 and 5 Refer to MAXIMUM WATERCRAFT SET SPEED TABLE smo2009 002 114_ii EXAMPLE LEARNING KEY SET TO 5 7 Press the SET button once to save the setting twice to exit the function or simply wait for the function to time out The change will be ...

Page 353: ...ubleshooting If no beep is heard when installing the D E S S key on the post and engine can be started refer to GAUGE to check the beeper operation If no beep is heard when installing the D E S S key on the post and engine can NOT be started refer to ELECTRONIC FUEL INJECTION D E S S POST D E S S Post Continuity Test NOTE For the following tests the DIAGNOSTIC HARNESS P N 529 036 179 can be used t...

Page 354: ...g Close to 0 smr2009 035 001_b D E S S Key on Post Probe D E S S post terminals to check continuity as follows 8 PIN CONNECTOR D E S S POST HARNESS RESISTANCE 20 C 68 F Pin 3 Pin 5 Close to 0 smr2009 035 002_a Reconnect D E S S post connectors If any continuity test fails replace D E S S post D E S S Post Vehicle Harness Continuity Test Disconnect the 8 pin connector attached to the vehicle harnes...

Page 355: ... ECM ADAPTER TOOL RESISTANCE 20 C 68 F 5 B E4 4 B B2 3 B F2 Close to 0 smr2009 035 009_a Reinstall removed components If any continuity test failed check wiring harness between D E S S connector and ECM connector If problem persists and all tests have been per formed try a new ECM Refer to FUEL INJEC TION section 332 smr2009 035 ...

Page 356: ... approximately three minutes after the START button was depressed 2 Install safety lanyard D E S S key to activate ECM and Information Center when testing pro cedures require the device or system to be sup plied with electrical power IMPORTANT When B U D S is being used the ECM will stop communicating with B U D S approximately 3 minutes after the START but ton was pressed Therefore operations wit...

Page 357: ...als into the appropriate gauge display The inputs to the gauge include but are not limited to the VTS iS MODE SET UP DOWN arrows cruise and fuel level sensor The gauge incorporates a GPS Global Positioning System that it uses for compass and speedome ter indications and to provide speed signals to other systems as required for their operation The beeper is also incorporated in the information cent...

Page 358: ...hin the informa tion center An indicator light seen in the tachometer lights up when the GPS is receiving a good signal See COMPASS for illustration If for some reason the GPS signal is lost a de fault mode is used whereby the speed is calcu lated using information received from other sys tems to provide an estimated watercraft speed 2 Tachometer The tachometer provides an analog indication of the...

Page 359: ...stem overheating CHECK ENGINE or LIMP HOME MODE Check engine minor fault req maint or LIMP HOME MODE major eng fault LOW OIL PRESSURE Low oil pressure PILOT LAMPS ON MESSAGE DISPLAY DESCRIPTION _ CRUISE mode or SLOW SPEED MODE engaged _ iBR system fault _ O T A S system fault _ Good GPS uplink 5 Fuel Level A bar gauge located in the bottom RH side of the digital screen continuously indicates the a...

Page 360: ...de of operation The AUTO indication disap pears and a single segment of the bar gauge is turned on to indicate the position of the suspen sion Refer to SUSPENSION iS for more details 8 Numerical Display A numerical display is used to provide a variety of indications as selected by the operator Engine RPM Watercraft speed Lake temperature Water depth GTX LTD iS 1 2 smo2009 002 114_n EXAMPLE NUMERIC...

Page 361: ...N message when the function is active The display also allows for the selection of vari ous functions which permit changing the numeri cal display indication system modes of operation settings and displaying system fault codes used for troubleshooting WARNING Selecting various numerical displays sys tem modes of operation or changing settings should only be carried out with the watercraft stopped ...

Page 362: ... VTS MODE VTS preset menu PRESET 1 For changing PRESET 1 PRESET 2 For changing PRESET 2 FAULT CODE Fault code menu for viewing codes NO ACTIVE FAULT CODE No active fault code to display KEY MODE Key mode menu MESSAGE DISPLAY INFORMATION L KEY For changing learning key setting R KEY For changing rental key setting SETTINGS For accessing DOCK MODE and iBR OVR settings DOCK MODE Dock mode function me...

Page 363: ...GING NUMERICAL DISPLAY INDICATION in this subsection 1 2 smo2009 002 114_r 1 Depth sounder indicator 2 Water depth indication NOTE The DEPTH sounder indicator is only on when a depth sounder is installed and detected WARNING Never use the depth gauge as a warning de vice to ride in shallow water 11 Water Temperature Display Continuously displays surface water temperature in degrees Celsius C or Fa...

Page 364: ...Compass active indicator WARNING Use the compass as a guide only Not to be used for precision navigation purposes Setting Language and Units of Measurement Connect vehicle to the latest applicable B U D S software refer to the COMMUNICATION TOOLS AND B U D S SOFTWARE subsection 1 Press the START STOP button to energize the electrical system NOTE You will need to press the START button every three ...

Page 365: ...and prevent the reminder from appearing prematurely smr2009 036 011_a TYPICAL 1 Read Data 2 Vehicle tab 3 Reset Service Maint button 4 Reset Supercharger Maintenance button Information Center Pin Out INFORMATION CENTER PIN OUT PIN NO FUNCTION 1 GPS back up power 2 CAN HI 3 CAN LOW 4 Spare Buzzer external GND 5 Spare Buzzer external GND 6 Not used 7 Cruise switch signal Vdc 8 Spare digital input 9 ...

Page 366: ...ing Fuel level ON iBR fault indicator light ON Indicated speed No other indications visible There is no communication between the informa tion center and all other modules ECM iS iBR Carry out a continuity check of the CAN bus wires from the CAN bus bars in FB2 to the information center pins 2 and 3 Refer to the WIRING DIA GRAM for more details If an open circuit is detected carry out same test fr...

Page 367: ... contact B4 of FB2 NOTE This circuit provides 12 Vdc to the GPS in the information center so that it memorizes the satellites it was linked to for a period of two hours This allows the indications to be available within a few seconds of restarting the watercraft hot start After a two hour period the GPS will have to reestablish new satellite links Beeper Does Not Function The beeper is incorporate...

Page 368: ...teering connector 3 Press the START STOP switch and install the safety lanyard on the D E S S post 4 Carry out an input voltage test at the steering connector vehicle harness side as per follow ing table INFORMATION CENTER INPUT VOLTAGE TEST STEERING CONNECTOR INFORMATION CENTER STEERING CONNECTOR VOLTAGE Pin 7 Violet Pin 6 Black Pin 7 Violet Battery ground Battery voltage smr2009 036 005_a PIN OU...

Page 369: ...tery Vdc smr2009 027 011_g VOLTAGE TEST AT FUSE CONTACTS smr2009 027 011_d TYPICAL CONTACT COORDINATES FRONT VIEW FB1 If battery voltage is measured at A12 but not at A11 with fuse installed replace the fuse If no voltage is measured at fuse contact A12 slightly lift one corner of the long bus bar 12 contacts long 10 Measure for battery Vdc between the bus bar and battery ground smr2009 036 007_a ...

Page 370: ... pin steering connector 4 Remove the gauge fuse in FB1 smr2009 027 011_e FB1 1 Remove gauge fuse F1 5 Set multimeter to setting 6 Test the information center power wire continu ity as per following table CONTINUITY TEST OF GAUGE POWER WIRE GAUGE CONNECTOR STEERING CONNECTOR FUSE BOX 1 READING Pin 12 Violet Pin 7 Violet Close to 0 Pin 12 Violet A11 Close to 0 Pin 7 Violet A11 Close to 0 10 1 12 11 ...

Page 371: ...t ventilation box 2 12 pin steering connector Open the boarding platform refer to BODY sub section Remove the RH rear storage bin refer to BODY subsection Remove the cover from fuse box 2 2009 027 009_a 1 Fuse box 1 2 Fuse box 2 Remove the ground bus bar smr2009 027 010_e FB2 1 Ground bus bar Set multimeter to selection and carry out a con tinuity test as per following table Refer to the WIRING DI...

Page 372: ...TES FRONT VIEW FB2 Repair wiring and connectors as required Information Center Removal 1 Open the front cover 2 Move the steering to its highest position refer to BODY subsection 3 Using a long flat screwdriver insert the blade between the lower locking tabs one each side of the gauge support cover and carefully pry the tabs outwards to release them from the gauge support smr2009 042 001_a 1 Long ...

Page 373: ... support and push it in until it snaps back in place 3 Apply a small amount of DIELECTRIC GREASE P N 293 550 004 to the gauge connector pins NOTE If you are installing a replacement informa tion center refer to INFORMATION CENTER RE PLACEMENT in this subsection Information Center Replacement NOTICE Before replacing the information center it is very important to retrieve the approximate time left t...

Page 374: ... message comes on as per normal in tervals Refer to CLEARING MAINTENANCE REMINDER INDICATORS in this subsection smr2009 036 011_c 1 Reset Supercharger maintenance button NOTE Replacement information centers are de livered already programmed After the information center has been replaced connect the watercraft to the latest applicable B U D S software and carry out any updates if required Refer to ...

Page 375: ...PEED func tions increasing or decreasing speed when the functions are active and by the iBR for iBR gate positioning in SLOW SPEED mode of operation NOTE The above stated voltages vary slightly de pending on the actual voltage applied to the circuit and the current flow through the diodes When using a Fluke 115 multimeter for testing in diode test mode the voltage and current applied by the multim...

Page 376: ...ad Pin 17 Pin 18 Approx 1 1 Vdc MODE depressed Black lead Red lead Pin 17 Pin 18 OL Black lead Red lead Pin 17 Pin 18 Approx 1 6 Vdc SET depressed Black lead Red lead Pin 17 Pin 18 OL UP DOWN ARROW SWITCH TEST SWITCH POSITION FLUKE 115 GAUGE CONNECTOR VOLTAGE Red lead Black lead Pin 16 Pin 18 Approx 2 Vdc Switch released Black lead Red lead Pin 16 Pin 18 OL Red lead Black lead Pin 16 Pin 18 Approx...

Page 377: ... amount of DIELECTRIC GREASE P N 293 550 004 on switch contact pins 6 Install connector on new switch assembly 7 Insert switch assembly in switch support 8 Install steering cover refer to STEERING AND O T A S WATER TEMPERATURE SENSOR The water temperature sensor is located within the iBR module that is part of the iBR actuator It cannot be tested or replaced separately Water from the jet pump pass...

Page 378: ...k wires Check WHITE BLACK and WHITE RED wires to CAN bus bars in FB1 Watercraft is not in water Launch watercraft in water and recheck There is air between gel pad and depth sounder or between depth sounder and battery holder base Remove depth sounder Replace gel pad ft or m is displayed Depth sounder is defective Try a new depth sounder smr2009 027 011_c 1 Depth sounder 3A fuse FB1 Depth Sounder ...

Page 379: ...3 Clean the concave surface of depth sounder 4 Remove both protectors from the gel pad 5 Apply gel pad on depth sounder NOTICE Make sure do not trap air between gel pad and depth sounder Otherwise the de vice will not work ssi2009 002 013_a 1 Gel pad 2 Depth sounder Depth Sounder Installation 1 Insert the depth sounder in the battery holder base while paying attention to the position of the wiring...

Page 380: ...operation The depth sounder icon is visible in the information center when the depth sounder is detected ssi2009 002 018_a 1 Depth sounder icon 4 Reinstall all other removed parts 5 Launch watercraft in water and check depth sounder operation Refer to INFORMATION CENTER for instructions on how to select the DEPTH indication in numerical display WARNING Never use the depth gauge as a warning de vic...

Page 381: ...358 ...

Page 382: ...S Description Part Number Page D E S S POST REMOVER 529 035 943 364 ECM ADAPTER TOOL 529 036 166 370 FLUKE 115 MULTIMETER 529 035 868 370 STEERING CABLE TOOL 295 000 145 367 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 363 XPS SYNTHETIC GREASE 293 550 010 366 smr2009 037 359 ...

Page 383: ...rease 6 N m 53 lbf in 2 5 N m 22 lbf in 7 N m 62 lbf in 16 N m 142 lbf in 10 N m 89 lbf in 5 N m 44 lbf in 7 N m 62 lbf in 7 N m 62 lbf in 0 7 N m 6 lbf in 0 7 N m 6 lbf in 7 N m 62 lbf in 6 N m 53 lbf in 7 N m 62 lbf in 7 N m 62 lbf in 7 N m 62 lbf in smr2009 037 001_a 360 smr2009 037 ...

Page 384: ... is activated when the follow ing conditions are achieved The engine speed must be above 4000 RPM for at least 1 5 second approximately The throttle lever must be released completely The steering must be fully turned within approx imately 4 seconds after throttle release The O T A S will stay activated for a random period of time as long as the O T A S switch is closed O T A S will be deactivated ...

Page 385: ...e throttle while steering is in the straight ahead position Within 1 to 3 seconds turn handlebar all the way to one side The O T A S should come on by keeping or increasing engine speed to approximately 3000 RPM Immediately look in B U D S to see if the O T A S system LED turns on smr2009 037 034_a MONITORING AND IBR TABS 1 O T A S LED Then engine speed will gradually decrease to idle speed within...

Page 386: ...ction HANDLEBAR GRIP Handlebar Grip Removal To remove handlebar grip pull out cap and remove screw smr2009 037 006_a 1 Handlebar grip 2 Handlebar grip screw Pull out handlebar grip and remove grip insert from handlebar smr2009 037 007_a 1 Grip insert NOTE Verify grip insert for damage Handlebar Grip Installation When installing the grip insert in the handlebar ensure that it is properly inserted i...

Page 387: ...urn screwdriver to open cover 3 Remove the switch cover Handlebar Switch Cover Installation LH or RH Install the round rubber button in the cover Insert the front tab and tilt the cover over the switches smr2009 037 012_a RH SIDE SHOWN 1 Front tab Press on the cover to lock it STEERING COVER Steering Cover Removal 1 Using the D E S S POST REMOVER P N 529 035 943 remove the nut retaining the D E S ...

Page 388: ...ty 3 3 Release the five retaining tabs at the rear of steering smr2009 037 016_a 1 Retaining tabs 3 4 Remove foam inside the steering cover 3 5 Remove D E S S post from steering cover Steering Cover Installation 1 Install the D E S S post 1 1 Index the alignment pin of the D E S S post with the notch of steering cover smr2009 037 017_a 1 Steering cover notch 1 2 Press the D E S S post until retain...

Page 389: ... subsection 2 Remove the screw and washer securing throt tle lever 3 Remove throttle lever and its bushings smr2009 037 031_a 1 Retaining screw 2 Washer 3 Bushings 4 Throttle lever 4 Clean throttle lever area from dust or any de posits 5 Apply XPS SYNTHETIC GREASE P N 293 550 010 on shaft that receives throttle lever and on the end of the return tab smr2009 037 032_a 1 Apply grease here 6 Install ...

Page 390: ... PUMP AND IBR SYSTEM REMOVED FOR CLARITY PURPOSE ONLY 1 Steering cable 2 Steering cable nut 3 Half rings 4 O ring 7 Remove the adjusting nut from the new steer ing cable 8 Using a piece of hose attach one end of each cable together NOTE Ensure to attach different ends together to avoid installing the new cable in the wrong way 9 Pull the old cable slowly through the vehicle then separate cable end...

Page 391: ...subsection for complete procedure 14 Check steering alignment STEERING COLUMN Steering Column Removal 1 Open the front storage cover and remove the storage basket 2 Remove the gauge support Refer to GAUGE subsection 3 Disconnect the four connectors under moving deck smr2009 042 005_a 1 Disconnect these connectors 4 Remove both screws securing the steering col umn smr2009 037 027_a 1 Steering colum...

Page 392: ...ont grille Body covers 2 Remove the gauge support Refer to GAUGE subsection 3 On both side of vehicle remove both pivot bushings steering column support and steer ing adjustment handle smr2009 037 033_a 1 Pivot bushing of steering column support 2 Pivot bushing of steering adjustment handle NOTE Pivot bushings retaining steering column could be hard to remove in this case remove the retaining scre...

Page 393: ...ge If there is voltage present carry out the O T A S switch continuity test If there is no voltage check continuity of the O T A S switch power wire O T A S Switch Power Wire Continuity Test Check continuity between O T A S switch 3 pin connector and fuse block FB1 3 PIN CONNECTOR FUSE BLOCK FB1 RESISTANCE PIN A C3 5 If there is no continuity check fuse 6 FB1 wiring connector and terminals If cont...

Page 394: ...t 1 Remove STEERING COLUMN SUPPORT see procedure in this subsection 2 Remove steering column from its support by removing both retaining screws smr2009 037 027_a 1 Steering column screws 3 Using a small screwdriver unlatch the switch from steering support smr2009 037 038_a 1 Switch retaining tabs Reverse removal procedure to reinstall the O T A S switch O T A S MAGNETS Magnets Replacement 1 Remove...

Page 395: ...372 ...

Page 396: ...D VTS SERVICE TOOLS Description Part Number Page DIAGNOSTIC HARNESS 529 036 179 384 386 FLUKE 115 MULTIMETER 529 035 868 384 389 390 404 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE 293 550 004 392 405 LOCTITE 243 BLUE 293 800 060 392 smr2009 037 373 ...

Page 397: ... m 53 lbf in 10 N m 88 lbf in 12 N m 106 lbf in 12 N m 106 lbf in NEW Silicone sealant 5150 NEW 4 N m 35 lbf in NEW 24 N m 18 lbf ft NEW NEW 12 N m 106 lbf in NEW 4 N m 35 lbf in NEW 24 N m 18 lbf ft NEW 24 N m 18 lbf ft NEW 8 N m 71 lbf in Loctite 243 12 N m 106 lbf in 12 N m 106 lbf in 24 N m 18 lbf ft smr2009 038 100_a 374 smr2009 037 ...

Page 398: ...ust or the iBR lever for neutral reverse and for the braking function The iBR lever is located on the LH side of the han dlebar sdd2009 001 036_a 1 iBR lever intelligent Brake and Reverse sdd2009 001 039_b 1 iBR gate 2 iBR module and motor 3 Jet pump When the iBR lever is pulled in it operates the brake and reverse lever sensor BRLS It is a dou ble output hall effect sensor The redundancy is used ...

Page 399: ... in Maximum engine RPM in reverse is 5000 RPM Braking Mode If the watercraft speed is 8 km h 5 MPH per hour and above when the iBR lever is pulled in braking mode is engaged When the iBR lever is pulled in to engage braking the following occurs Engine RPM is reduced to idle The iBR gate moves to the maximum down po sition Engine RPM ramps up to the engine power commanded by the iBR lever When oper...

Page 400: ...he START STOP button 2 Install the D E S S key sdd2009 001 019_g Step 1 Press START STOP button Step 2 Install D E S S key NOTE Do not start the engine The D E S S key must be installed to ensure the information cen ter will not shut off all indications after its self test function Electrical power will stay ON for approx imately 3 minutes 3 Press the Mode button on the RH handlebar re peatedly un...

Page 401: ... iBR system It provides watercraft pitch trim adjustments by adjusting the vertical position of the jet nozzle The VTS can be manually trimmed to desired atti tude or to one of two preset trim positions Press VTS control button up or down arrow to adjust riding attitude of the watercraft sdd2009 001 019_c TYPICAL VTS CONTROL 1 Bow up 2 Bow down The VTS switch sends command signals to the gauge The...

Page 402: ... gate moved to up position 2 Take hold of the lower edge of the iBR gate and pull down on it slightly then release it smr2009 038 026_a PULL DOWN SLIGHTLY ON iBR GATE 3 Using a machinists ruler measure the distance between the bottom of the guard and the trailing edge of the iBR gate example 48 mm 1 89 in Note as measurement A smr2009 038 018_a 1 iBR guard 2 Measurement A 4 Without using excessive...

Page 403: ... not within specification af ter replacing the iBR locking sleeve continue dis assembly of the iBR gate replacing the previously listed parts as required NOTE If the contact points on the VTS trim ring and U arm are excessively worn or the friction sleeve cams in the U arm are worn replace them as required 7 Check iBR gate backlash and gate operation af ter parts replacement and reassembly FRICTIO...

Page 404: ...ls and one person to observe iBR gate movement 1 Provide adequate ventilation of exhaust gases or move watercraft outside NOTICE Do not install an exhaust ventilation hose in the iBR gate area or damage may oc cur when the iBR gate moves downward dur ing operation 2 Connect a water hose to the watercraft to pro vide exhaust system cooling when operating engine Refer to EXHAUST SYSTEM subsec tion f...

Page 405: ...r ward thrust allow to run at idle RPM 5 Push the VTS up and down arrow button alter nately to check VTS operation Confirm nozzle movement and VTS position indication change in the information center 6 Double click the VTS UP and DOWN button al ternately to test the VTS preset trim positions If double clicking the VTS UP and DOWN button does not cause the nozzle position or indication to change na...

Page 406: ...ll ef fect sensor A resistance test of the sensor can not be carried out 1 Connect watercraft to the latest B U D S soft ware refer to COMMUNICATION TOOLS AND B U D S SOFTWARE 2 Check for an applicable fault code refer to MONITORING SYSTEM AND FAULT CODES 3 If a fault is indicated follow service actions as indicated in B U D S BRLS Voltage Test Test for BRLS input voltage as well as BRLS signal vo...

Page 407: ...IAGNOSTIC HARNESS P N 529 036 179 in series between the disconnected steer ing connectors 529036179 NOTE Connect only the test harness 12 and 6 pin connectors to both sides of same steering har ness connectors smr2009 042 005_e 1 6 pin connector 2 12 pin connector 8 Press the START STOP button to wake up the electrical system 9 Install the D E S S key on its post sdd2009 001 019_g Step 1 Press STA...

Page 408: ...voltage change should increase or decrease in a steady linear fashion 12 If voltage is out of specification carry out a continuity test of the wiring between the iBR module and the BRLS sensor refer to CONTI NUITY TEST OF BRLS WIRING HARNESS Continuity Test of BRLS Wiring Harness 1 Ensure the steering connector C01 12 POS and C03 6 POS pins are clean make good contact and properly connected 2 Remo...

Page 409: ... tests to find the problem wire or connection From the BRLS to the steering connectors C01 12 POS and C03 6 POS From the steering connectors to the iBR actua tor 12 pin connector smr2009 036 004_c 1 Forward ventilation box 2 12 pin steering connector to disconnect 3 6 pin steering connector to disconnect NOTE Connecting the DIAGNOSTIC HARNESS P N 529 036 179 to the steering connectors steering sid...

Page 410: ...ring harness is properly routed through slot provided in sensor support be fore installing steering cover smr2009 038 001_b 1 Wire harness routed in slot 3 Ensure there are no fault codes Connect wa tercraft to the latest B U D S software refer to MONITORING SYSTEM AND FAULT CODES 4 Carry out an iBR SYSTEM FUNCTIONAL TEST using the iBR lever engine must be running iBR ACTUATOR NOTICE The iBR actua...

Page 411: ... Current Test Using B U D S 1 On the iBR activation page in B U D S note the iBR Position Deg indication smr2009 038 029_a 1 iBR position indication 2 Press and hold the VTS UP button on the LH handlebar to position the iBR to the full up po sition and look for the iBR Motor Current indi cation in B U D S Also look for a change of iBR Position Deg indication NOTE Current draw indication will not b...

Page 412: ...e debris replace iBR gate components or replace the iBR actuator as applicable iBR Motor Voltage Test 1 Disconnect the iBR actuator motor connector from the electronic module on the actuator smr2009 038 030_a 1 iBR motor harness connector 2 iBR motor module connector 2 Set the FLUKE 115 MULTIMETER P N 529 035 868 to Vdc selection 3 Install insulated clips on the multimeter leads and clip leads to ...

Page 413: ... VOLTAGE TEST in this subsection If battery voltage is measured and test light is dim in one direction replace the iBR actuator iBR Power Test Using a Test Light 1 Connect the clip of a 12 Vdc test light to the battery ground or engine ground 2 Touch the test light probe to each pin of the motor output connector on the iBR module as you select the iBR up and down alternately The test light should ...

Page 414: ...1 Ground post Battery voltage NOTE The 5 A switched power to the iBR actua tor is for the iBR electronic module and BRLS If battery voltage is not measured at all check the following 5 A iBR control CRTL fuse in FB1 Battery voltage at fuse contact A4 of FB1 Wire continuity pin 1 iBR 12 pin connector to A3 of FB1 Jumper continuity fuse contact FB1 A4 to FB1 C2 of 12 Vdc accessory bus bar If voltage...

Page 415: ... tuator smr2009 038 002_a 1 Hexagonal screw s 2 Locking sleeve 6 Remove the five hexagonal screws securing the iBR actuator to the LH support plate smr2009 038 005_a 1 Hexagonal screws to remove 1 screw not visible 7 Pull the iBR actuator from the support plate iBR Actuator Installation Installation is the reverse of the removal proce dure however pay attention to the following Clean all actuator ...

Page 416: ...e area 2 Remove the hexagonal screw s securing the iBR gate locking sleeve iBR key and remove the sleeve from the iBR U arm and actuator smr2009 038 002_a 1 Hexagonal screw s 2 Locking sleeve 3 Using your hand move the iBR gate to the down position 4 Disconnect the iBR gate at the linkage arms that connect the gate to the U arm by remov ing hexagonal screws one each side smr2009 038 006_a 1 Discon...

Page 417: ...e removed Secure the assembly with one hand as you remove the spacer sleeves iBR Gate and VTS Trim Ring Disassembly VTS Trim Ring Removal Remove the two hexagonal screws securing the iBR gate to the VTS trim ring smr2009 038 011_a 1 iBR gate retaining hexagonal screws to remove Trim Ring Inspection 1 Inspect trim ring and metal spacers for cracks oblong holes evidence of wear and deforma tion 2 In...

Page 418: ...WEAR MARK ON VTS RING AND iBR GATE CONTACT POINTS 1 Wear mark on VTS ring 2 Wear mark on iBR gate smr2009 038 025_a TYPICAL WEAR MARK ON VTS RING AND iBR GATE CONTACT POINTS 1 Wear mark on VTS ring 2 Wear mark on iBR gate NOTE Wear marks on VTS ring and iBR gate con tact points are normal up to 3 175 mm 125 in This wear affects nozzle backlash not iBR gate backlash 4 Replace parts as required Stee...

Page 419: ... and its plastic liner for cracks out of round holes evidence of wear deformation and other damages 2 Inspect plastic bushings x4 for cracks wear and deformation 3 Replace as required smr2009 038 014_a 1 Plastic liner 2 Plastic bushings iBR Gate and VTS Ring Reassembly Install all parts removed in the reverse order of re moval however pay attention to the following Install new friction sleeves as ...

Page 420: ...TRIM RING procedure as detailed in this sub section 2 Remove the RH U arm retaining hexagonal screw and washer 3 Secure the U arm with one hand and remove the RH spacer sleeve 4 Remove U arm from actuator shaft smr2009 038 015_a 1 U arm 2 Hexagonal screw and washer 3 Spacer sleeve 4 Actuator shaft U Arm Inspection 1 Inspect U arm and linkage arms x2 for cracks wear and signs of twisting and bendin...

Page 421: ... 001_a 1 Exhaust hose 2 Clamp to loosen 4 Remove and discard the 2 hexagonal screws securing the outer support plate to the inner support plate smr2009 043 002_a 1 Support plate retaining screws NOTE Two locking tabs on the inner plate locks it to the outer plate exhaust nozzle 5 Using a small screwdriver or a scriber lift the upper locking tab slightly to help release the plates and avoid breakin...

Page 422: ...x2 2 Intercooler bleed hose 3 Pump water pressure hose 6 Remove the FITTING PLATE from the support plate as described in this subsection this step is only applicable to models with a metal re tainer on the support plate 7 Remove and discard the 5 hexagonal screws securing the outer support plate to the inner support plate smr2009 043 011_a TYPICAL MODEL WITH PLASTIC RETAINING TABS ILLUSTRATED 1 He...

Page 423: ...roperly installed on each support plate 2 Position the LH inner support plate in front of its mounting position in the hull 3 As you hold the inner support plate insert the round extension on the outer support plate through the hull Push the outer plate in until it snaps onto the inner plate 4 Install 5 new hexagonal screws to secure iBR support plates and torque as per exploded view 5 Install the...

Page 424: ...ide Models With Plastic Retaining Tabs on Fitting Plate NOTE On models with plastic retaining tabs on the fitting plate the procedure is the same as models with a metal retaining tab except for the following 1 Compress the fitting plate retaining tab and pull the fitting plate from the outer support plate smr2009 043 012_a 1 Fitting plate tabs 2 Discard the fitting plate NOTICE When the fitting pl...

Page 425: ...ndition 2 Insert the fitting plate through the outer iBR support plate 3 Install the metal retainer and tighten the hexag onal screw until it is snug NOTICE Do not attempt to torque the hexag onal screw or screw threads in the plastic fit ting plate will be damaged smr2009 043 005_a 1 Hexagonal screw 2 Metal retainer 4 Install the four hoses on the inner fitting plate Torque gear clamps to 1 7 N m...

Page 426: ...is pressed 1 diode is by passedby the closed switch The remaining three diodes in the circuit drop 1 8 Vdc at pin A The gauge senses these voltages through pin 13 of its connector and interprets them as signals that tell it which is activated VTS UP or VTS DOWN Since the command generated by the closure of a VTS switch concerns the VTS module a circuit within the gauge will translate it to CAN pro...

Page 427: ...s to come on in the Cluster Lamp Active field smr2009 036 002_c 1 Read Data button 2 Monitoring tab 3 Cluster tab 4 Cluster Lamp Active field smr2009 041 051_b 1 VTS UP and VTS Down indicator lights If each of the gauge button indicator lights come on when the applicable switch is closed the VTS control button switches and wiring are good The problem may be related to the information center or iBR...

Page 428: ...itch assembly If any reading is significantly different than speci fied carry out the same test at the switch connec tor refer to the wiring diagram If you obtain the same results replace the switch assembly If voltages measured on the VTS UP and DOWN switch are as specified or very close to it the switches and the wiring harness are good The fault may be within the gauge Replace the gauge and car...

Page 429: ...itch 2 Wiring routed in slot provided in support 3 VTS iS switch connector 4 Insert switch assembly in switch support 5 Install steering cover refer to STEERING AND O T A S 6 Carry out an operational test of the VTS and iS systems to ensure proper operation of new switch assembly 406 smr2009 037 ...

Page 430: ...ER SHAFT PUSHER 529 035 955 420 422 PRESSURE CAP 529 036 172 410 SEAL BEARING PUSHER 529 035 819 423 VACUUM PRESSURE PUMP 529 021 800 410 SERVICE PRODUCTS Description Part Number Page JET PUMP BEARING GREASE 293 550 032 415 422 424 LOCTITE 243 BLUE 293 800 060 413 414 LOCTITE 577 THREAD SEALANT 293 800 050 418 LOCTITE 767 ANTISEIZE LUBRICANT 293 800 070 417 PULLEY FLANGE CLEANER 413 711 809 413 XP...

Page 431: ...te 767 antiseize lubricant 125 N m 92 lbf ft Jet pump bearing grease 4 ml 14 U S oz Jet pump bearing grease 24 ml 81 U S oz Jet pump bearing grease 23 ml 78 U S oz NEW 7 5 N m 66 lbf in 21 N m 16 lbf in Loctite 243 1 7 N m 15 lbf in 10 N m 89 lbf in 4 5 N m 40 lbf in NEW NEW NEW NEW See iBR AND VTS subsection 21 N m 16 lbf ft 30 N m 22 lbf ft smr2009 039 001_a 408 smr2009 039 ...

Page 432: ...neath the watercraft With the vehicle on the trailer use a flashlight to visually inspect them through the inlet grate smr2007 028 001_a TYPICAL UNDERNEATH HULL 1 Impeller 2 Impeller boot 3 Wear ring IMPELLER WEAR RING CLEARANCE This clearance is critical for jet pump performance To check clearance remove jet pump Using a feeler gauge measure clearance between impeller blade tip and wear ring Meas...

Page 433: ...36172 3 Connect the VACUUM PRESSURE PUMP P N 529 021 800 to the pressure cap fitting 5290218002 smr2008 029 005 TYPICAL 4 Pressurize pump LEAK TEST PRESSURE Maximum 70 kPa 10 PSI 5 Pump must maintain this pressure for at least 5 minutes NOTICE Repair any leak Failure to correct a leak will lead to premature wear of pump com ponents NOTE If there is a pressure drop spray soapy water around cover If...

Page 434: ...pplicable to detect excessive wear SACRIFICIAL ANODE Sacrificial Anode Inspection Check for wear If worn more than half replace anode smr2009 039 009_a 1 Sacrificial anode location Sacrificial Anode Removal Unscrew sacrificial anode hexagonal screw and remove anode smr2006 027 009 Sacrificial Anode Installation Installation is the reverse of the removal proce dure Torque anode retaining screw as s...

Page 435: ...he pump support Jet Pump Housing Inspection and Cleaning 1 Visually inspect jet pump housing Pay atten tion to the stator Ensure the assembly is clean and free of any debris and defects 2 Blow low pressure compressed air through the pressure outlet fitting and make sure it is clear 3 Ensure the neoprene seal is in good condition Replace as required smr2009 039 005_a 1 Pressure hose fitting 2 Neopr...

Page 436: ... jet pump housing as speci fied in the exploded view 4 Remove the jet pump housing from the spare ride plate and install it on the watercraft ride plate Jet Pump Housing Installation Brush and clean impeller splines and drive shaft splines with PULLEY FLANGE CLEANER P N 413 711 809 or equivalent Splines must be free of any residue Lubricate drive shaft splines impeller splines and the inside of th...

Page 437: ... the reverse of the removal pro cedure Pay attention to the following Apply LOCTITE 243 BLUE P N 293 800 060 on threads of venturi screws or install new self lock ing screws Install venturi screws and flat washers Torque venturi hexagonal screws to 21 N m 15 lbf ft Ensure bailer hoses and fittings are in good condi tion IMPELLER COVER Impeller Cover Removal 1 Remove the venturi 2 With pump housing...

Page 438: ...ace O rings and or impeller cover smr2009 006 002_a 1 Seal on impeller side smr2009 006 003_a 1 Cover O rings Check impeller boot and O rings condition on im peller Replace as required smr2009 006 004_a 1 Impeller boot 2 Impeller O ring 3 Pump housing O ring Impeller Cover Installation 1 Install O rings in their respective groove F18J0NA TYPICAL 2 Put 23 ml 8 U S oz of JET PUMP BEARING GREASE P N ...

Page 439: ...fer to LEAK TEST in this subsection IMPELLER Impeller Removal NOTE If impeller shaft is to be disassembled loosen the impeller shaft nut prior to removing the impeller 1 Remove jet pump from the watercraft Refer to JET PUMP HOUSING in this subsection 2 Remove impeller cover Refer to IMPELLER COVER in this subsection 3 Remove impeller boot by turning it clockwise LH threads F19J06A 1 TYPICAL 1 Unsc...

Page 440: ...006_b TYPICAL 7 To pull impeller out of the pump apply a rotating movement as you pull on the impeller Impeller Installation 1 Mount the flat sides of the impeller shaft in a vise smr2009 006 005_a TYPICAL 1 Flat side 2 Apply LOCTITE 767 ANTISEIZE LUBRICANT P N 293 800 070 on threads of impeller shaft smr2009 006 002_b TYPICAL 1 Antiseize lubricant 3 Apply XPS LUBE P N 293 600 016 on the wear ring...

Page 441: ... of this subsection Wear Ring Removal 1 Remove the iBR gate VTS trim ring and the steering nozzle as an assembly See procedure in IBR AND VTS subsection 2 Remove jet pump from watercraft Refer to JET PUMP HOUSING in this subsection 3 Remove impeller from jet pump housing refer to IMPELLER in this subsection 4 Place jet pump housing in a vise with soft jaws It is best to clamp housing using a lower...

Page 442: ... 2 Rounded edge 3 Wear ring IMPELLER SHAFT AND BEARING Impeller Shaft and Bearing Removal 1 Remove impeller cover Refer to IMPELLER COVER in this subsection 2 Mount in a vise the appropriate impeller re mover installer tool according to engine type MODEL TOOL 130 and 155 engines IMPELLER REMOVER INSTALLER P N 529 035 820 215 and 255 engines IMPELLER REMOVER INSTALLER P N 529 035 956 1 F18J0PB TYPI...

Page 443: ...impeller side remove circlip seals spacer and O ring smr2006 027 007_b TYPICAL 1 Circlip 2 Seal 8 Use the IMPELLER SHAFT PUSHER P N 529 035 955 to press impeller shaft out of pump hous ing NOTE Bearing will come out with the impeller shaft 529035955_a smr2009 006 010_a TYPICAL smr2009 006 011 TYPICAL 9 Use the IMPELLER SHAFT BEARING TOOL P N 529 036 168 to press bearing off impeller shaft 420 smr2...

Page 444: ... N 529 035 820 215 and 255 engines IMPELLER REMOVER INSTALLER P N 529 035 956 3 Torque impeller more than impeller shaft nut smr2009 006 006_a TYPICAL 4 Turn pump upside down and retry unscrewing impeller shaft nut smr2009 006 009_a TYPICAL 5 If impeller still loosens instead of nut retighten impeller more and retry Repeat until nut loosens 6 Remove impeller as described in this subsec tion 7 Retu...

Page 445: ...09 006 013_a TYPICAL 1 Impeller shaft bearing tool on INNER race 2 Impeller shaft and bearing 3 Impeller shaft installer pusher tool 3 Press bearing until it bottoms Impeller Shaft Installation NOTE Ensure there is no O ring in pump housing on the cover side 1 From the outlet side of pump press impeller shaft assembly into housing using the IM PELLER SHAFT BEARING TOOL P N 529 036 168 smr2009 006 ...

Page 446: ...eal lip are facing upwards smr2009 006 015_a 1 Seal lip up 1 F18J13A 1 Seal lip facing up 1 F18J14B TYPICAL 1 Seal bearing pusher 8 Install spacer and then the other seal thin En sure seal lip is facing up smr2009 006 016_a 1 Seal lip facing up 9 Install circlip smr2006 027 007_c TYPICAL 1 Circlip 10 Turn pump upside down 11 Install the two O rings in pump housing smr2009 039 423 ...

Page 447: ...er installer tool according to engine type MODEL TOOL 130 and 155 engines IMPELLER REMOVER INSTALLER P N 529 035 820 215 and 255 engines IMPELLER REMOVER INSTALLER P N 529 035 956 1 F18J0PB 1 Impeller remover installer tool 15 Install jet pump housing over this tool F18J0QA TYPICAL 16 Using a 30 mm socket screw the impeller shaft nut on clockwise 17 Torque nut as specified in exploded view smr2009...

Page 448: ...Section 06 STEERING AND PROPULSION Subsection 03 JET PUMP 19 Install the impeller cover Refer to IMPELLER COVER in this subsection smr2009 039 425 ...

Page 449: ...426 ...

Page 450: ...HAFT SERVICE TOOLS Description Part Number Page DRIVE SHAFT ADAPTER 529 035 985 431 433 DRIVE SHAFT WRENCH 529 036 167 431 434 SERVICE PRODUCTS Description Part Number Page LOCTITE 577 THREAD SEALANT 293 800 050 433 PULLEY FLANGE CLEANER 413 711 809 432 smr2009 040 427 ...

Page 451: ...Section 06 STEERING AND PROPULSION Subsection 04 DRIVE SHAFT 125 N m 92 lbf ft LH threads XPS synthetic grease Loctite 577 thread sealant Engine oil 8 turns NEW smr2009 040 001_a 428 smr2009 040 ...

Page 452: ...ocking fasteners cotter pins etc must be replaced with new ones TROUBLESHOOTING DIAGNOSTIC TIPS Leaks at PTO Seal If water enters engine or oil leaks from engine at PTO seal check if drive shaft is fully engaged in sealing ring Compress the drive shaft boot to visually check for proper contact smr2009 010_a 1 Drive shaft boot Rubber sealing lip of drive shaft must be fully en gaged into flange of ...

Page 453: ... deck forward fir access Refer to BODY subsection 3 Remove the aft ventilation box located above the engine smr2009 016 001_a 1 Vent box 2 Retaining latches 4 Remove the deck extension Refer to BODY subsection smr2009 016 002_a 1 Deck extension 5 Lower the moving deck onto the fixed deck and install a few hexagonal screws on the aft con trol arm to hold the deck steady for the duration of the proc...

Page 454: ...n for drive shaft removal 11 In engine compartment install the DRIVE SHAFT WRENCH P N 529 036 167 on the hexagon of sealing ring smr2009 007 002_a TYPICAL 1 Drive shaft wrench 12 From rear of watercraft install the DRIVE SHAFT ADAPTER P N 529 035 985 on drive shaft end smr2009 007 003_a TYPICAL 1 Drive shaft adapter 13 While a coworker holds the drive shaft wrench in the engine compartment unscrew...

Page 455: ...rubber sealing lip is critical for proper sealing of engine at drive shaft con nection into engine 3 Inspect the rubber coating of drive shaft If cracked or otherwise damaged shaft corrosion will occur smr2009 007 006_a 1 Splines 2 Threads 3 Taper 4 Rubber sealing lip 5 Rubber coating 4 Measure drive shaft deflection Excessive de flection could cause vibration and damage to drive shaft splines imp...

Page 456: ...ds as shown smr2009 007 010_a LOCTITE 577 APPLICATION A First 5 threads B 3 mm 1 8 in 8 From rear of watercraft engage drive shaft through the drive shaft boot 9 Continue pushing drive shaft towards engine carefully guiding it through the sealing ring the PTO seal and finally into the crankshaft splines NOTE It may be necessary to move sealing ring and PTO seal up and down to position them in the ...

Page 457: ...ling ring smr2009 007 002_a TYPICAL 1 Drive shaft wrench 15 While a coworker holds the drive shaft wrench in engine compartment continue turning drive shaft counterclockwise LH threads to a total of 8 turns 16 IMPORTANT The number of turns is only a reference to give you an idea of the drive shaft engagement in the sealing ring It is useful if you suspect cross threading When the num ber of turns ...

Page 458: ...ing Ring Inspection Inspect condition of threads tapered surfaces carbon seal contact surface and seal lip contact surface If damage is found replace sealing ring Sealing Ring Cleaning Clean the following sealing ring surfaces and threads smr2009 007 004_a 1 Seal lip contact surface 2 Threads inside 3 Carbon seal contact surface smr2009 007 005_a 1 Tapered surfaces Sealing Ring Installation 1 Care...

Page 459: ...Section 06 STEERING AND PROPULSION Subsection 04 DRIVE SHAFT smr2009 007 008_a WRONG 1 Sealing ring incompletely inserted into PTO seal 436 smr2009 040 ...

Page 460: ...ption Part Number Page FLUKE 115 MULTIMETER 529 035 868 447 449 450 452 MAGNETO HARNESS 6 PINS 295 000 136 447 SUPERTITANIUM DRILL BIT 3 16 529 031 800 459 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE 293 550 004 441 LOCTITE 243 BLUE 293 800 060 456 458 smr2009 041 437 ...

Page 461: ... ft 85 N m 18 lbf ft 10 N m 89 lbf in 8 N m 71 lbf in 4 N m 35 lbf in 25 N m 18 lbf in 10 N m 89 lbf in 10 N m 89 lbf in 10 N m 89 lbf in 6 N m 53 lbf in 25 N m 18 lbf ft 25 N m 18 lbf ft 75 N m 55 lbf ft 25 N m 18 lbf ft 25 N m 18 lbf ft 12 N m 106 lbf in NEW 25 N m 18 lbf ft 10 N m 89 lbf in 25 N m 18 lbf ft NEW 75 N m 55 lbf ft 10 N m 89 lbf in NEW NEW 12 N m 106 lbf in smr2009 041 001_a 438 sm...

Page 462: ... SUSPENSION iS REAR 25 N m 18 lbf ft 12 N m 106 lbf in NEW NEW 12 N m 106 lbf in NEW 25 N m 18 lbf ft NEW 25 N m 18 lbf ft 25 N m 18 lbf ft NEW 10 N m 89 lbf in NEW 10 N m 89 lbf in NEW 25 N m 18 lbf ft NEW smr2009 041 002_a smr2009 041 439 ...

Page 463: ... the moving deck to isolate the riders from the rough water smr2009 041 080 MOVING DECK sdd2009 001 202 FIXED DECK sdd2009 001 206_b 1 Rear suspension arm 2 Front suspension arm 3 Springs 4 Shock absorber An actuator is mounted underneath springs to control the spring preload and therefore the sus pension height smr2009 041 038_a 1 Springs 2 Actuator The iS module controls the electric motor of th...

Page 464: ... electrical power NOTE When using B U D S briefly press the START STOP button to initiate back the commu nication after the electrical system has shutt off Circuit Testing Check the related circuit fuse condition with a fuse tester or ohmmeter relying solely on a visual inspection could lead to an incorrect con clusion Electrical Connection Inspection When replacing an electric or electronic compo...

Page 465: ...aft in its supports SUSPENSION NOISE FRONT OF SEAT 1 Screws retaining holders are loosened Tighten shock absorber and actuator holder screws to recommended torque 2 Shock absorber screws are loosened Tighten shock absorber screws to recommended torque 3 Link under actuator holder loosened or not in stalled Install link properly Tighten bolts to recommended torque SUSPENSION IS LOWER THAN THE DOCK ...

Page 466: ...on steering Install the latest version of B U D S softward and check fault codes Is there a fault code Follow service action In B U D S activation page activate iS UP and iS DOWN buttons Suspension moves Check the suspension position sensor and the iS buttons Suspension moves YES System is ok Perform hydraulic pump operation test Hydraulic pump can be activated NO YES YES NO System is OK Perform i...

Page 467: ...r the hydraulic pump running when pressing iS button s on steering Is there something stuck under moving deck Suspension moves Is vehicle level Is fluid level good Is there visual leak s Is cylinder good Replace hydraulic pump Check for an electrical problem see iS electrical troubleshooting flow chart System is OK iS Hydraulic Mechanical Troubleshooting Suspension moves System is OK Suspension mo...

Page 468: ...or fall into the hull 6 Remove and discard the bolt securing shock ab sorber to shock holder smr2009 041 005_a 1 Shock absorber lower bolt discard 2 Shock holder 7 Detach the top of shock absorber from mount ing plate Discard bolt smr2009 041 006_a 1 Shock absorber upper bolt discard 2 Mounting plate Shock Absorber Inspection NOTE Because of gas pressure strong resis tance is felt when compressing...

Page 469: ...wing damage is detected Crack in the paint Rust Other visible damages Replace spring if one of these problems is de tected NOTE If rust is present ONLY on the first 1 4 of coil the spring should not be replaced smr2009 041 090_a 1 Zone where presence of rust is normal Check the curve line of long spring LONG SPRING SHAPE Maximum 7 mm 9 32 in smr2009 041 041_a A 7 mm 9 32 in maximum Replace spring ...

Page 470: ...s located in front of the bat tery in the same compartment smr2009 041 009_a 1 Suspension position sensor connector on iS module 4 Connect the MAGNETO HARNESS 6 PINS P N 295 000 136 to iS module for voltage checks 295000136 5 Using the FLUKE 115 MULTIMETER P N 529 035 868 check voltage as per the following table 529035868 SUSPENSION POSITION in B U D S MAGNETO HARNESS wire lead color VOLTAGE Vdc A...

Page 471: ...e deck extension Refer to BODY subsection 2 Remove the air intake tube Refer to AIR IN TAKE SYSTEM subsection 3 Unplug the suspension position sensor connec tor smr2009 041 011_a 1 Sensor connector 2 Hydraulic pump reservoir 4 Remove screws securing the suspension posi tion sensor smr2009 041 012_a 1 Retaining screws 5 Remove bolts securing the sensor and its cover to the sensor support and the se...

Page 472: ...cal system Install the D E S S key Using the FLUKE 115 MULTIMETER P N 529 035 868 perform the following test MULTIMETER LEAD POSITION VOLTAGE VDC Pin 1 of iS Module 6 pin connector Negative battery post Battery voltage smr2009 041 055_a Repeat the test using a test light TEST LIGHT POSITION RESULT Pin 1 of iS Module 6 pin connector Negative battery post Bright light If the input voltage test is go...

Page 473: ... continuity of the iS module battery power wire Continuity Test of iS Module Battery Power Wire iS MODULE 3 PIN CONNECTOR FUSE BOX FB1 RESISTANCE Pin 2 A4 5 smr2009 041 057_c PIN 2 TO FUSE BOX PIN A4 FUSE BOX FB2 RESISTANCE A3 A4 5 FUSE BOX FB2 STARTER SOLENOID RESISTANCE A3 Battery terminal connection 5 iS Module Output Voltage Test At the 2 pin connector connect multimeter leads Activate the iS ...

Page 474: ...s pins A and B act as signal wires for each set of switches to the gauge They actually each form one branch of an electronic circuit within the gauge Each diode in circuit drops a nominal 0 6 Vdc when conducting electricity If the circuit current passes through all four diodes if the iS switch is open a drop of 2 4 Vdc would be measured across the 4 the diodes pin B to pin C This 2 4 Vdc at pin B ...

Page 475: ...kely be slightly lower than nominal values stated iS Button Operation Test If iS UP or DOWN switches do not allow the se lection test the switches as follows Check the iS button operation using B U D S software Refer to COMMUNICATION TOOLS AND B U D S SOFTWARE subsection to con nect B U D S Check if there is any occurred or active fault code s If not proceed with the following test Depress the iS ...

Page 476: ... the previous tables or very close to it the switches and the wiring harness are good The fault may be within the gauge or in the circuit or component the function applies to HYDRAULIC PUMP Hydraulic Pump Recommended Fluid Always use automatic transmission fluid ATF Dexron III NOTICE To avoid serious damage to hy draulic pump and actuator use only ATF Dexron III Do not use fluids other than the re...

Page 477: ...nsion by pressing iS up and iS Down s and check voltage smr2009 041 053_a ACTIVATION AND IS TABS 1 B U D S ammeter 2 iS UP 3 iS down CURRENT iS UP 16 20 A iS Down 15 18 A If values is near specifications check connections and wires If wires and connectors are good perform the iS module output voltage test Refer to IS MODULE in this subsection If the current draw is excessive replace the hy draulic...

Page 478: ...N m 18 lbf ft NOTICE Failure to do so might result in spring failure Hydraulic hose routing is very critical to avoid problems with hydraulic unit Use the following illustration to route and attach the hydraulic hose properly smr2009 041 045_a VIEW FROM THE REAR OF VEHICLE 1 Secure hydraulic hose to hydraulic pump 2 Secure hydraulic hose fuel hose and vehicle wiring harness smr2009 041 046_a VIEW ...

Page 479: ...k smr2009 041 019_a 1 Socket screw 2 Hydraulic hose lock 9 Remove hose from pump and plug hose to avoid oil spillage 10 Place your finger on pump opening and re move pump from vehicle NOTE Wipe any oil spillage Hydraulic Pump Installation Without Actuator 1 Install hydraulic hose on pump and secure hose using the the hydraulic hose lock NOTE The hose must turn freely Do not inserted hose into lock...

Page 480: ...nd around inner piston Replace actuator if any leak is detected Actuator Removal 1 Refer to HYDRAULIC PUMP REMOVAL AS A UNIT WITH ACTUATOR and remove the pump from the vehicle 2 Remove and discard the screw securing actua tor link to alignment support smr2009 041 047_a 1 Actuator link 2 Retaining screw 3 Alignment support 3 Remove the alignment support from actuator holder Discard screws smr2009 0...

Page 481: ...e following instruction can be used for RH or LH support 1 Remove the moving deck Refer to BODY sub section 2 Cut the Oetiker clamp retaining lateral bellows to lateral support smr2009 041 022_a 1 Lateral support 2 Oetiker clamp 3 Remove the lateral support screw smr2009 041 023_a 1 Lateral support screw 4 Remove lateral support from lateral bellows Lateral Support Installation The installation is...

Page 482: ...ateral support can be inserted in one position only Install the retaining ring Align the ring pin with holes in bellows and body smr2009 041 026_a 1 Ring pin 2 Bellows alignment hole 3 Body hole Install new rivets If the head of rivet tool can not be inserted in ring opening use the sleeve P N 707 000 181 to offset the rivet tool and well lean the rivet head against ring Index lateral supports wit...

Page 483: ...en loosen from the suspension arm shaft see SUSPENSION ARM SHAFTS for proper installation procedure smr2009 041 063_a 1 Shaft support one on each side SUSPENSION BASE Suspension Base Removal 1 Refer to the appropriate procedures and re move the following parts Moving deck Engine Shock absorber and springs Hydraulic pump with actuator Suspension position sensor 2 Using a marker trace the shape of s...

Page 484: ...ont arm on suspension base and tighten screws to 25 N m 18 lbf ft use the OLD screws 3 Install lateral supports 3 1 Index lateral supports with the front sus pension shaft ends Lateral supports can be inserted in one position only 3 2 Tighten lateral support screws to 48 N m 35 lbf ft 4 Align suspension base in vehicle 4 1 On both sides measure the distance be tween the end of lateral support and ...

Page 485: ...arm brackets in accordance with the reference marks previously draw on fixed deck NOTICE If no mark was traced refer to REAR SUSPENSION ARM INSTALLATION WITHOUT REFERENCE MARKS for proper procedure to install and align the rear sus pension arm 3 2 Install NEW screws to secure rear suspen sion arm brackets 3 3 Tighten screws to 25 N m 18 lbf ft Rear Suspension Arm Installation Without Reference Mar...

Page 486: ... the support pin into suspension base hole 4 Tighten the LH support screws to 25 N m 18 lbf ft 5 Apply a force on the RH support to move it on the left side NOTICE Make sure arm shaft is fully inserted it must lean against the arm shaft support smr2009 041 067_a 1 Arm shaft against its support 6 InstallNEW support screws and tighten them to 25 N m 18 lbf ft 7 Secure both supports to shaft using NE...

Page 487: ...t its support 6 Install NEW support screws and tighten them to 25 N m 18 lbf ft 7 Secure both supports to shaft using NEW socket screws Tighten them to 12 N m 106 lbf in smr2009 041 079_a 1 Bar clamp 2 New socket screws Removal of Rear Suspension Arm Lower Shaft 1 Open the boarding platform 2 Remove bolts securing both rear suspension arm covers smr2009 041 072_a 1 Rear suspension arm cover 3 Mark...

Page 488: ...side smr2009 041 070_a 1 Circlip Installation of Rear Suspension Arm Lower Shaft 1 When reassembly the rear bracket on shaft end press bracket on bushing to install the circlip 2 When both brackets are installed on shaft pull brackets outside to position circlips against brackets smr2009 041 071_a 1 Bad installation 2 Good installation 3 Lower the rear suspension arm on fixed deck 4 Tighten NEW so...

Page 489: ...466 ...

Page 490: ... plastic cracks or other damage WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pins etc must be replaced with new one Hoses cables or locking ties removed during a procedure must be reinstalled as per factory stan dards PROCEDURES BOARDING PLATFORM Boarding Platform Removal 1 Unlatch the b...

Page 491: ... is properly inserted in its slots smr2009 042 039_a 1 Upper attachment 9 Close boarding platform to lock the bottom of the gas shock 10 Lock boarding platform SPLASH DEFLECTOR Splash Deflector Removal sdd2009 001 052_a 1 To remove the splash deflector drill out the 4 rivets securing the splash deflector to the fixed deck 2 Pull the deflector from the fixed deck NOTICE A molded location pin at eac...

Page 492: ... could turns and screw will be hard to remove 4 Install coolant reservoir screws and tighten them to 5 N m 44 lbf in 5 Reposition moving deck Refer to MOVING DECK in this subsection MOVING DECK smr2009 042 008_a 1 Moving deck The moving deck is comprised of Front storage cover Front body module Steering Seat Foot wells The moving deck is attached to the intelligent sus pension and moves as a singl...

Page 493: ...curing rear sus pension arm to fixed deck smr2009 042 011_a 1 Rear suspension arm 2 Reinstallation marks 3 Screws discard 5 Lift the rear suspension arm against seat handle and attach it with locking tie or strap smr2009 042 012_a 1 Seat handle 2 Ski wakeboard attachment 3 Locking tie 6 Install two pieces of wood 4 x 4 under mov ing deck front area as shown to avoid potential damage when lifting t...

Page 494: ...bsection for proper pro cedure to install and align the rear suspen sion arm 1 2 Install NEW screws to secure rear suspen sion arm brackets 1 3 Tighten screws to 25 N m 18 lbf ft 2 Detach lifting device 3 Remove pieces of wood located under the front of moving deck Removing the Moving Deck for Servicing Watercraft 1 Open the front storage cover and remove the front basket 2 Remove the BOARDING PLA...

Page 495: ... 8 Detach moving deck from lateral supports 8 1 Remove front carpet of foot wells and pro tective caps on both sides of the moving deck Discard the front carpets smr2009 042 014_a RH SIDE SHOWN 1 Front carpet discard 2 Protective cap 8 2 Remove and discard screws securing moving deck to lateral supports smr2009 042 015_a RH SIDE SHOWN 1 Retaining screws discard 9 Open seat 10 Remove and discard M8...

Page 496: ...Using both mooring cleats under steer ing install two lifting straps smr2009 042 079_a 1 Front lifting strap hooks into steering mooring cleats 15 2 Install another lifting strap on seat handle 16 Attach all lifting straps to an lifting device to lift the moving deck Make sure lifting device is located at the center of the vehicle to rise moving deck horizontally 17 Raise moving deck slowly and dr...

Page 497: ...nectors 5 Lower the front of moving deck and secure it on both lateral supports using NEW screws smr2009 042 015_a RH SIDE SHOWN 1 Retaining screws new 6 Remove pieces of wood located under lateral supports and reposition one under moving deck front area smr2009 042 090_a 1 Install piece of wood here 7 Remove the front lifting straps 8 Open seat 9 Raise rear of moving deck until suspension is clea...

Page 498: ... If no mark was trace refer to iS SUSPENSION subsection for proper pro cedure to install and align the rear sus pension arm 16 2 Install NEW screws to secure rear sus pension arm brackets 16 3 Tighten screws to 25 N m 18 lbf ft 17 Remove rear lifting strap 18 Attach steering cable to steering column 19 Install gauge support Refer to GAUGE sub section 20 Install NEW front carpets on foot wells and ...

Page 499: ...tment Cover Installation The installation is the reverse of the removal pro cedure However pay attention to the following Remove gas shock attachment from cover Apply LOCTITE 243 BLUE P N 293 800 060 on threads of shock absorber body Tighten manually the attachment on gas shock Install the bellows and secure it using a locking tie Install the gas shock on cover NOTE The corrugated section of bello...

Page 500: ... Unscrew wing nut and spring securing mirror smr2009 042 040_a 1 Wing nut 2 Spring 3 Mirror 3 Install the new mirror and tighten wing nut 3 1 The mirror adjustment is correct when the spring length is between 10 mm and 12 mm 13 32 in and 15 32 in smr2009 042 041_a A 10 mm to 12 mm 13 32 in to 15 32 in 4 Install the mirror trim 4 1 Install the front locating tabs smr2009 042 043_a 1 Front locating ...

Page 501: ...Pull the bottom of cover gently to release hinges Glove Box Cover Installation Reverse the removal procedure FRONT GRILLE smr2009 042 056_a LOCATED UNDER STORAGE COMPARTMENT COVER 1 Front grille Front Grille Removal 1 Remove the STORAGE COMPARTMENT COVER see procedure in this subsection 2 Press on both tabs securing front grille to front body module smr2009 042 054_a 1 Front grille 2 Retaining tab...

Page 502: ... and remove them ssi2009 003 003_a LH SIDE SHOWN 1 LH upper trim 5 Remove the plastic push in clips retaining the LH and RH trims ssi2009 003 004_a LH SIDE SHOWN 1 Remove this plastic push in clip 6 Open seat and using a 3 16 drill bit drill the rivets securing the seat trims ssi2009 003 008_b LH SIDE SHOWN 1 Remove these rivets 7 Remove seat trim and drill the front rivet secur ing the body cover...

Page 503: ...le Front Body Module Removal 1 Refer to appropriate procedures and remove the following parts Storage compartment cover Storage bin Glove box cover Body covers and front grille Steering and steering lock Speed Tie unit if equipped 2 Remove both screws and washers located be tween seat and glove box smr2009 042 061_a 1 Rear retaining screws 3 On each side of front body module remove both retaining ...

Page 504: ...allation The installation is the reverse of the removal pro cedure However pay attention to the following Install seat to central arm Tighten bolts to 4 N m 35 lbf in Secure lateral arms to moving deck Install parts as shown smr2009 042 032_a 1 Allen socket screw 2 Stainless steel flat washers 3 Sleeve 4 RH lateral arm 5 Rubber grommet in moving deck Tighten screws to 1 5 N m 13 lbf in NOTICE Do n...

Page 505: ...ent marker E B C Spray paint B B D Wipe or scrape off excess chill gum with ice before hand Suntan lotion A B Tar asphalt D B Yellow mustard A B C E Denatured alcohol rinse dry Suntan lotion tree pollen wet leaves and some other products can contain dyes that stain permanently All cleaning methods must be followed by a thor ough rinse with warm water Certain household cleaners powdered abrasives s...

Page 506: ...4 Remove front bumper from vehicle Rear Bumper 1 Remove both protective caps one on each side smr2009 042 048_a 1 Rear bumper 2 Protective cap 2 Remove side screws securing rear bumper to body smr2009 042 049_a FROM RH SIDE OF VEHICLE 1 Rear bumper 2 Retaining screw 3 Side bumper 3 Remove screws located under rear bumper smr2009 042 050_a 1 Retaining screws 4 Remove rear bumper from vehicle Side B...

Page 507: ... of the mounting tape 2 Clean bumper area using isopropyl alcohol 3 Remove the protective skin on mounting tape smr2009 042 053_a 1 Protective skin 4 Insert bumper over body lip 4 1 Insert lower section first 4 2 Insert upper section last smr2009 042 052_b 1 Make sure bumper is positioned correctly NOTE A heat gun can be used to soften side bumper SPEED TIE UNIT Front Speed Tie Unit Removal 1 Open...

Page 508: ...emove this rivet 3 Seat trim 6 Remove front trim by releasing both retaining tabs smr2009 042 034_a 1 Retaining tabs 7 Using a small screwdriver release both retain ing hooks securing the cam trim on locking mechanism ssi2009 003 015_a 1 Retaining hooks 8 Remove the four screws retaining the Speed Tie unit 9 Position the reel of Speed Tie unit to the bottom of its cavity 10 Remove the locking mech...

Page 509: ...rding platform 2 Remove rear trim by releasing retaining tabs smr2009 042 035_a 1 Retaining tabs 3 Remove screws securing the locking mecha nism to the boarding platform smr2009 042 036_a 1 Retaining screws 4 Remove the Speed Tie unit from vehicle Front Speed Tie Unit Installation 1 Ensure both double cage nuts are correctly in serted into Speed Tie unit cavities ssi2009 003 007_a 1 Double cage nu...

Page 510: ...en reel and locking mechanism 4 Position the reel to the bottom of its cavity ssi2009 003 012_a 1 Push in the reel 5 Lift the lever and insert the locking mechanism so that the lever is pointing toward the front of vehicle ssi2009 003 013_a 1 Locking lever 2 Rope 6 Align the reel with the locking mechanism and secure them using four M6 x 45 tapered screws 7 Tighten screws to 4 N m 1 N m 35 lbf in ...

Page 511: ...009 003 101_a 1 Locking mechanism A 200 mm 8 in 3 Insert the locking mechanism in boarding plat form opening Position the locking lever toward the slot ssi2009 003 102_a 1 Locking lever 2 Boarding platform slot 4 Position a double cage nut on the locking mech anism ssi2009 003 103_a 1 Double cage nut 5 Secure it using two M6 x 45 tapered screws ssi2009 003 104_a 1 M6 x 45 tapered screws 6 Install ...

Page 512: ... trim 12 1 Align tabs and alignment pin with corre sponding openings ssi2009 003 109_a 1 Tabs 2 Alignment pin 12 2 Press trim in place 13 Test Speed Tie operation Speed Tie Unit Cleaning A minimum of maintenance is required to keep the Speed Tie unit and the rope in serviceable con dition Clean the locking mechanism and rope with fresh water to remove salt sand or other deposits NOTICE Do not use ...

Page 513: ...2009 003 020_a 1 Rewind unit 7 Turn the unit upside down and remove the re taining screw ssi2009 003 021_a 1 Retaining screw 8 Split the rewind unit and remove damaged rope ssi2009 003 022_a 9 Before discarding rope remove and keep the inner stopper ssi2009 003 023_a 1 Inner stopper 10 Insert the inner stopper on new rope and tie a knot near the end of the line Position the inner stopper in order ...

Page 514: ...e as shown ssi2009 003 027_a 1 Short tongue 13 Install the rewind unit cover 13 1 Align the cover notch and the rope ssi2009 003 028_a 1 Cover notch 13 2 Press in the cover until both parts are completely pressed together ssi2009 003 029_a 13 3 Install the retaining screw ssi2009 003 021_a 1 Retaining screw 13 4 Tighten screw to 1 1 N m 0 1 N m 10 lbf in 1 lbf in 14 Turn rope clockwise Check indic...

Page 515: ..._a 18 Unlock the end of the rope and pull it out by the housing opening NOTE Be careful not to release the rope and the spring Otherwise you will need to remove drum and repeat the cranking operation 19 Install locking mechanism and rope 19 1 Pull out rope end 19 2 Insert end of rope through locking mech anism ssi2009 003 034_a 1 Locking mechanism 19 3 Pass rope end through the rope button and tie...

Page 516: ...ace and dry thoroughly 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 surface where decal will be installed Remove back protective film from decal and align decal with marks When well aligned squeegee decal beginning at ce...

Page 517: ...n the kit when preparing the gelcoat putty Carefully mix the required amount while making sure there are no air bubbles in the mixture With a putty knife fill the repair area and cover with plastic film Curing time may depend on tempera ture amount of putty and percentage of catalyst After 2 hours press lightly on the surface with fingers to test the hardness When the area be comes hard remove the...

Page 518: ...d Finish off using a fine compound While buffing pay close attention to avoid overheating the surface Compound Fractures Repair 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 structur...

Page 519: ...t is held in place by tape or a support Inside Wipe down the area with acetone on a cloth Apply the same procedure as for outside repair when laminating the alternating pieces of fiberglass material If a backing support was used remove it before starting the repair After the area has hardened remove sharp edges of material from surface If required paint the sur face Sanding Outside This surface wi...

Page 520: ... HULL SERVICE PRODUCTS Description Part Number Page BRP HEAVY DUTY CLEANER 293 110 001 502 503 505 LOCTITE 5150 SILICONE SEALANT 293 800 086 508 509 LOCTITE 577 THREAD SEALANT 293 800 050 507 LOCTITE 5900 293 800 066 502 503 505 smr2009 042 497 ...

Page 521: ...5 N m 18 lbf ft DEVCON HP250Q Loctite 5900 16 N m 142 lbf in 10 N m 89 lbf in 14 5 N m 128 lbf in NEW 25 N m 18 lbf ft DEVCON HP250Q 50 N m 37 lbf ft DEVCON HP250Q 25 N m 18 lbf ft 25 N m 18 lbf ft inside hull DEVCON HP250Q 25 N m 18 lbf ft Loctite 5150 silicone sealant Loctite 5150 silicone sealant GTX Limited iS model Loctite 577 thread sealant smr2009 043 101_a 498 smr2009 042 ...

Page 522: ... All Models 35 N m 25 lbf ft Loctite 5900 300 ml 5 N m 44 lbf in NEW 7 N m 62 lbf in Loctite 5900 300 ml NEW 35 N m 25 lbf ft 8 N m 71 lbf in NEW 35 N m 25 lbf ft 5 N m 44 lbf in Loctite 567 pipe sealant 250 ml smr2009 043 100_a smr2009 042 499 ...

Page 523: ... specifications must be strictly adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pins etc must be replaced with new ones Hoses cables or locking ties removed during a procedure must be reinstalled as per factory stan dards PROCEDURES INLET GRATE Inlet Grate Removal 1 Remove inlet grate retaining screws using an impact tool and remove inlet grate Discard ...

Page 524: ...oolant hoses and fittings 6 Reach in between the exhaust system res onator and hull to loosen the gear clamps and disconnect both coolant hoses from the ride plate smr2009 043 016_a 1 Exhaust system resonator 2 Gear clamps 3 Coolant hoses 7 Remove excess sealant from around the coolant hose fittings 8 Unscrew both hose fittings from the ride plate smr2009 043 014_a 1 Hose fittings NOTICE Removing ...

Page 525: ...s Ride Plate Installation 1 Install the jet pump support on the ride plate see procedure in this section NOTE The jet pump support must be installed on the ride plate before installation of the ride plate on the watercraft 2 Reinstall hose fittings on ride plate and torque to 7 N m 62 lbf in 3 Apply LOCTITE 5900 P N 293 800 066 sealant on ride plate and jet pump support circumference as seen in th...

Page 526: ...ning the pump support to the ride plate smr2009 043 019_a TYPICAL TOP VIEW RIDE PLATE AND PUMP SUPPORT 1 Pump support retaining screws 3 Sealant is applied between the jet pump sup port and the ride plate Using a heat gun heat the base of the pump support to soften the sealant and carefully pry the pump support off the ride plate smr2009 043 019_b APPLY HEAT HERE Jet Pump Support Cleaning 1 Scrape...

Page 527: ...ng that screws onto the outer fitting after the outer fitting is inserted in the hull smr2009 043 024_a 1 Outer fitting 2 Inner fitting Thru Hull Fitting Removal Inner Fitting Removal 1 Remove drive shaft refer to DRIVE SHAFT sub section 2 Using a heat gun heat the glue at the joint be tween the hull and the inner thru hull fitting to soften the glue applied smr2009 043 022_a 1 Heat here 3 Careful...

Page 528: ...l Outer Fitting Installation 1 Apply a bead of LOCTITE 5900 P N 293 800 066 sealant completely around the outer edge of the fitting pointed end and another bead across the top of the fitting smr2009 043 029_a 1 Apply Loctite 5900 here 2 Insert the outer fitting into the hull from the jet pump side of the hull towards the inside En sure fitting is pushed in against the hull 3 Continue with INNER FI...

Page 529: ...craft when it is in operation The bailer pick ups are connected through a hose system to two syphon tubes mounted in the jet pump venturi that draw the water out of the bilge through the bailer pick ups The bailers are also connected to the bilge drain plugs in the stern Bailer Pick Up Inspection 1 Open boarding platform and remove the stor age bins 2 Inside hull check holes in the bailer pick ups...

Page 530: ...rom the drain neck and pull the drain plug out or the neck smr2009 043 032_a DRAIN PLUG REMOVAL 1 Drain plug 2 Drain neck 4 Using a ratchet handle and extension of appro priate size unscrew the drain neck from the hull smr2009 043 033 DRAIN NECK REMOVAL Drain Plug Neck Installation 1 Apply LOCTITE 577 THREAD SEALANT P N 293 800 050 on the drain neck threads 2 Install drain neck and torque to 16 N ...

Page 531: ...rom falling through the hole on installation and increase the contact area for the repair NOTICE Do not cut hole opening larger than etched line to prevent weakening of fixed deck and to ensure proper sealing of splash deflec tor on installation smr2009 043 027_a CUT HERE AT AN INWARD ANGLE 4 Unscrew and discard both elastic stop nuts holding the bow eyelet in place smr2007 034 109_a TYPICAL 1 Ela...

Page 532: ...ern eyelet to hull 3 Pull stern eyelet to remove it from watercraft 4 Clean any residue of silicone sealant from the hull Stern Eyelet Installation 1 Install small washers and nylon washers to stern eyelet and insert it through the hull 2 Inside hull apply LOCTITE 5150 SILICONE SEALANT P N 293 800 086 all around holes 3 Install eyelet and other parts using NEW elastic stop nuts as per following il...

Page 533: ... from the hull NOTE An impact tool may be used to facilitate removal of the insert Insert Installation 1 Clean the insert hole in the hull to remove any dirt or loose glue using clean dry oil free fil tered air NOTICE Do not use a metal tool to clean or remove the glue inside the hull insert hole to prevent damaging the threads in the hull ma terial The glue that is properly bonded to the hull doe...

Page 534: ...ing 0 BTDC Intake valve closing 50 ABDC Exhaust valve opening 50 BBDC Exhaust valve closing 0 ATDC New 5 961 mm to 5 975 mm 2347 in to 2352 in Intake Wear limit 5 930 mm 233 in New 5 946 mm to 5 960 mm 2341 in to 2346 in Valve stem diameter Exhaust Wear limit 5 930 mm 233 in New 5 990 mm to 6 010 mm 2358 in to 2366 in Valve guide diameter Wear limit 6 060 mm 2386 in New 41 02 mm 1 615 in Inner Wea...

Page 535: ... in to 1 5709 in Camshaft bearing journal diameter PTO and center Wear limit 39 880 mm 1 5701 in New 25 000 mm to 25 010 mm 9843 in to 9846 in Front Wear limit 25 020 mm 985 in New 40 000 mm to 40 010 mm 1 5748 in to 1 5752 in Camshaft bearing inner diameter PTO and center Wear limit 40 020 mm 1 5756 in New 31 690 mm to 31 800 mm 1 2476 in to 1 252 in Intake Wear limit 31 650 mm 1 2461 in New 31 4...

Page 536: ...Supercharger spring washer package height not compressed Wear limit 10 200 mm 4016 in AIR INTAKE SYSTEM Intake spark arrester Tubular wire screen COOLING SYSTEM Type Closed loop cooling system Coolant Ethylene glycol and distilled water 50 50 Use premix coolant from BRP or a coolant specially formulated for aluminum engines Cooling system capacity 5 5 L 5 8 qt U S liq total Thermostat 87 C 189 F M...

Page 537: ...R power 30 A 20 ECM 15 A 21 START STOP switch 3 A 22 Diag connector 15 A Fuses and relay Fuse box 2 23 GPS 3 A Magneto generator output 360 W 6000 RPM Stator 0 1 to 1 0 Battery 12 V 30 A h Anti start system D E S S Digitally Encoded Security System with selectable max vehicle speed settings for RK rental key and LK learning key Ignition system type IDI inductive discharge ignition Ignition timing ...

Page 538: ...on Intelligent Brake and Reverse activated by a LH lever Electronically controlled iBR gate to provide brake reverse neutral and forward position Forward Approx from 8 to 5 Neutral Approx 54 Braking Approx 74 Gate angle from horizontal line of watercraft Reverse Approx from 54 to 74 VTS system Electronically controlled with manual and 2 preset positioning VTS range angle 8 up 5 down Actuator 12 V ...

Page 539: ...luggage 227 kg 500 lb DIMENSIONS Overall length 354 cm 139 in Overall width 122 cm 48 in Overall height with keel horizontal suspension extended 128 cm 50 in Overall height with keel horizontal suspension collapsed 111 cm 44 in MATERIALS Hull Composite fiberglass Inlet grate Aluminum Steering cover Thermoplastic Impeller material Stainless steel Impeller housing stator Aluminum aluminum Venturi Al...

Page 540: ...CK CAN HI wires CAN LO wires Terminal Identification on Connector On the wiring diagram a letter or a digit is used to identify the terminal position in a connector smr2009 045 005_a 1 Terminal position On a connector a letter or a digit is usually molded on the connector to identify the terminal position F04H6LA 1 1 TYPICAL 1 Wire identification numbers Terminal Identification on Wiring Diagram I...

Page 541: ...FB2 Fuse box 2 C7 Terminal C7 in fuse box 2 On the wiring diagram corresponding CAN links are identified in fuse box 2 using the following coding smr2009 045 008_a 1 CAN wire 2 Wire origin 3 Destination terminal was referenced at ECM Fuse Box Terminal Reference Refer to POWER DISTRIBUTION subsection 518 smr2009 044 ...

Page 542: ...RMINAL EXTRACTOR 12094430 524 PROCEDURES MAGNETO AND ENGINE CONNECTOR DEUTSCH Connector Removal from its Support Magneto Connector Insert a small flat screwdriver between the sup port and the Deutsch connectors Pry while slid ing out connectors in the direction shown smr2009 045 009_a MALE CONNECTOR REMOVED FOR CLARITY PURPOSE 1 Insert screwdriver here To disconnect the Deutsch connectors twist a ...

Page 543: ...onnectors in the direction shown smr2009 045 010_a MALE CONNECTOR REMOVED FOR CLARITY PURPOSE 1 Insert screwdriver here Connector Disassembly F00H1CA 1 3 4 2 3 1 Male connector 2 Female connector 3 Secondary lock 4 Sealing cap NOTICE Do not apply dielectric grease on ter minal inside connector To remove terminals from connector proceed as follows Using a long nose pliers pull out the lock 1 V01G0O...

Page 544: ...nto appropriate cavity and push as far as it will go 5 Pull back on the terminal wire to be sure the retention fingers are holding the terminal 6 After all required terminals have been inserted the lock must be installed F04H6LA 1 1 1 Wire identification numbers ECM CONNECTOR MOLEX There are 2 connectors on the ECM The engine wiring harness connector is connected on the ECM connector A and the veh...

Page 545: ...e that they are very tight and they make good contact and that they are corrosion free Check if wiring harness shows any signs of scoring Particularly check ECM ground connections Ensure that contacts are good and clean A defective module could possibly be repaired simply by unplugging and re plugging the ECM Or if a newly replaced ECM is working try the old one and recheck if it works The voltage...

Page 546: ...terminals directly in the tool holes vmr2008 139 016_a TYPICAL 1 ECM connector 2 ECM adapter NOTICE Never probe directly on ECM har ness connector This could change the shape or enlarge the terminals and create intermit tent or permanent contact problems ECM Terminal Removal Harness Connector To remove a signal terminal from ECM harness connector use the ECM TERMINAL REMOVER 2 25 P N 529 036 175 T...

Page 547: ...l such as the DELPHI TERMINAL EXTRAC TOR P N 12094429 NOTE Grinding the tool end to make it smaller is required smr2009 045 014_a 1 Unlock terminal here smr2009 045 015_a WARNING Before terminal installation ensure all ter minals are properly crimped on wires After plugging connectors ensure they are prop erly fastened iBR AND iS POWER CONNECTORS DELPHI To remove a terminal from connector use a sp...

Page 548: ... terminal installation ensure all ter minals are properly crimped on wires After plugging connectors ensure they are prop erly fastened INFORMATION CENTER CONNECTORS DELPHI To remove a terminal from connector first remove the locking cap smr2009 045 020_a 1 Pry out locking cap smr2009 045 021_a 1 Unlock here smr2009 045 022_a WARNING Before terminal installation ensure all ter minals are properly ...

Page 549: ... 3 8 in in length using a wire stripping tool or sharp blade knife A32E2QA A A 10 mm 3 8 in NOTE Make sure not to cut wire strands while stripping the wire Install the appropriate terminal on the wire ac cording to the requirement Refer to appropriate PARTS CATALOG A32E2RA INSTALLATION OF TERMINAL Follow the instructions provided with the CRIMP ING TOOL HEAVY GAUGE WIRE P N 529 035 730 to select t...

Page 550: ...mped apply some pulling force on wire and the terminal at the same time from both directions NOTICE Never weld the wire to the terminal Welding can change the property of the wire and it can become brittle and break Install the protective heat shrink rubber tube on the terminal Heat the heat shrink rubber tube us ing the heat gun so that it grasps the wire and the terminal NOTICE Make sure that th...

Page 551: ......

Page 552: ...NOTES ...

Page 553: ...NOTES ...

Page 554: ...2009 Sea Doo 4 TEC iTC iS Series RXT iS 255 GTX Limited iS 255 smr2009 045 001 ...

Page 555: ...IGNITION SYSTEM CHARGING SYSTEM STARTING SYSTEM smr2009 045 002 ...

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