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Section 05 FUEL SYSTEM

Subsection 02 (FUEL TANK AND FUEL PUMP)



WARNING

Use of improper fuel lines could compromise
fuel system integrity.

To remove the darts from the front access panel (if
so equipped), use the pliers Oetiker 1099 (P/N 295
000 070).

F18F0AA

1. Dart

TESTING PROCEDURES

Fuel Pump

When connecting the safety lanyard to the DESS
post, the fuel pump should run for 2 seconds to
build up the pressure in the system.

If the pump does not work, disconnect the con-
nector from the fuel pump.

Install a temporary connector on the fuel pump
with wires long enough to make the connection
outside the bilge.

F18F0TA

BAT

CAUTION:

Running pump a few minutes with

reverse polarity can damage the pump.

If pump does not run, replace the fuel pump mod-
ule.

Otherwise, probe terminals as shown.

F18F0UA

When installing safety lanyard, you should read
battery voltage for approximately 2 seconds (then
voltage will drop to approximately 11 V).

If battery voltage is read, the problem can be in
fuel pump or in harness connector. Repair or re-
place appropriate part.

If battery voltage is not read, probe terminals as
shown.

100

smr2005-053

www.SeaDooManuals.net

Summary of Contents for 105A

Page 1: ...C M Y CM MY CY CMY K www SeaDooManuals net ...

Page 2: ...2005 Vehicle Shop Manual 2 Stroke Models www SeaDooManuals net ...

Page 3: ...rks of Bombardier Recreational Products Inc BRP or its affiliates Trademark of Bombardier Inc used under license SEA DOO BOMBARDIER ROTAX BOMBARDIER LUBE Sea Doo Learning KeyTM DESSTM Rotax O P A S TM TOPSTM This document contains the trademarks of the following companies Knight s Spray Nine is a trademark of Korkay System Ltd Loctite is a trademark of Loctite Corporation Snap on is a trademark of...

Page 4: ...DED ENGINE 20 CAPSIZED ENGINE 22 FUEL FLOODED ENGINE 22 02 TROUBLESHOOTING 01 TROUBLESHOOTING CHART 25 ENGINE WILL NOT START 25 ENGINE HARD TO START 28 ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED 28 ENGINE STARTS BUT RUNS ONLY ON ONE CYLINDER RFI MODELS 28 ENGINE RUNS ON BOTH CYLINDERS AT IDLE AFTER ENGINE IS WARM UP RFI MODELS 29 ENGINE MISFIRES RUNS IRREGULARLY 29 ENGINE CONTINUALLY BACKFIRES 31 E...

Page 5: ...TION SYSTEM 71 GENERAL 74 OIL SYSTEM PRESSURIZATION 74 02 OIL INJECTION PUMP 77 OIL PUMP IDENTIFICATION 80 REMOVAL 80 DISASSEMBLY 80 CLEANING 80 ASSEMBLY 80 ADJUSTMENT 81 CHECKING OPERATION 83 05 FUEL SYSTEM 01 CARBURETOR 85 GENERAL 87 REMOVAL 87 CLEANING 87 INSPECTION 88 ASSEMBLY 90 INSTALLATION 92 ADJUSTMENTS 93 02 FUEL TANK AND FUEL PUMP 95 GENERAL 99 TESTING PROCEDURES 100 REMOVAL 102 INSPECTI...

Page 6: ...TPS 131 TESTING PROCEDURES 131 FUEL PUMP 131 FUEL INJECTOR 132 THROTTLE POSITION SENSOR TPS 135 THROTTLE BODY 136 CRANKSHAFT POSITION SENSOR CPS 136 AIR TEMPERATURE SENSOR ATS 137 WATER TEMPERATURE SENSOR WTS 137 AIR PRESSURE SENSOR APS 138 RAVE SOLENOID 139 PARTS REPLACEMENT 140 ECM AND VCM 140 THROTTLE POSITION SENSOR TPS 141 AIR TEMPERATURE SENSOR ATS 142 AIR PRESSURE SENSOR APS 142 WATER TEMPE...

Page 7: ...ED VIEW 182 STARTING SYSTEM ELECTRICAL DIAGRAM 184 STARTING SYSTEM TROUBLESHOOTING CHART 185 GENERAL 186 TESTING PROCEDURES 186 REMOVAL 190 DISASSEMBLY 190 CLEANING 190 INSPECTION 190 ASSEMBLY 191 INSTALLATION 193 STARTER SPECIFICATION 194 04 INSTRUMENTS AND ACCESSORIES 195 GENERAL 195 FUSES 195 MULTI PURPOSE ELECTRONIC MODULE MPEM 196 INFORMATION CENTER 198 TESTING PROCEDURES 200 POWER SUPPLY CUT...

Page 8: ...49 02 DRIVE SYSTEM 251 GTI SERIES 252 GENERAL 253 REMOVAL 255 INSPECTION 255 INSTALLATION 257 LUBRICATION 257 3D SERIES 258 GENERAL 259 REMOVAL 259 INSPECTION 260 ASSEMBLY 262 INSTALLATION 264 LUBRICATION 266 03 REVERSE SYSTEM 267 DISASSEMBLY 269 INSPECTION 271 ASSEMBLY 271 ADJUSTMENT 272 04 VARIABLE TRIM SYSTEM 273 REMOVAL 275 DISASSEMBLY 275 INSPECTION 275 ASSEMBLY 276 INSTALLATION 276 10 STEERI...

Page 9: ...323 MIRROR 323 INLET GRATE 324 RIDING PLATE 324 JET PUMP SUPPORT 325 DRAIN PLUG 326 SEAT COVER 326 BUMPER 326 SPONSON 327 SPONSON ADAPTOR 327 BAILER PICK UPS 327 THRU HULL FITTING 328 DECALS REPLACEMENT 329 HULL AND BODY REPAIR 330 TOOLS AND MATERIALS LIST 332 02 3D SERIES 333 GENERAL 339 PROCEDURES 339 MOTO SEAT IF SO EQUIPPED 339 KART SEAT IF SO EQUIPPED 341 BILGE VENT TUBES 341 REAR ACCESS COVE...

Page 10: ... LE MODELS 355 03 3D RFI MODEL 357 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS 01 ELECTRICAL CONNECTORS 361 DEUTSCH CONNECTORS 361 PACKARD CONNECTOR 362 AMP CONNECTOR 363 ECM CONNECTORS 366 VCM CONNECTORS 370 BATTERY AND STARTER CABLE CONNECTORS 372 02 WIRING DIAGRAMS 375 WIRE COLOR CODES 375 WIRE DIGIT CODES 375 VII www SeaDooManuals net ...

Page 11: ...ngly recommended 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 repair procedures...

Page 12: ...tains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured BRP reserves the right at any time to discontinue or change specifications designs features mod els or equipment without incurring obligation CAUTION These watercraft are designed with parts dimensioned mostly in the metric sys tem However some co...

Page 13: ...is a table of contents at the beginning of many sections The illustrations show the typical construction of the different assemblies and in all cases may not reproduce the full detail or exact shape of the parts shown however they represent parts which have the same or a similar function As many of the procedures in this manual are inter related we suggest that before undertaking any task you read...

Page 14: ...d positions TYPICAL PAGE F01A0CT Illustration number for publishing process Subsection title indicates beginning of the subsection Dotted box contains parts of a particular model or an exploded view Page number Italic sub title above exploded view indicate pertaining models Drop represents a liquid product to be applied to a surface In this case Loctite 243 to screw threads Bold face number indica...

Page 15: ...ther wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI Diaphragm mu...

Page 16: ... Current VTS Variable Trim System WTS Water Temperature Sensor ENGINE EMISSIONS INFORMATION Manufacturer s Responsibility Beginning with 1999 model year engines PWC manufacturers of marine engines must determine the exhaust emission levels for each engine horse power family and certify these engines with the United States of America Environmental Protec tion Agency EPA An emissions control informa...

Page 17: ...rams and Compliance Division Engine Compliance Programs Group 6403J 401 M St NW Washington DC 20460 VIA EXPRESS or COURIER MAIL Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403J 501 3rd St NW Washington DC 20001 EPA INTERNET WEB SITE http www epa gov omswww SELF LOCKING FASTENERS PROCEDURE The following describes the most common appli cation pr...

Page 18: ...Loctite Primer N P N 293 800 041 on threads and allow to dry Put several drops of proper strength Loctite threadlocker on female threads and in hole Apply several drops of proper strength Loctite on stud threads Install stud Install cover etc Apply drops of proper strength Loctite on un covered threads Tighten nuts as required Pre assembled Parts A00A3OA 1 2 1 Apply here 2 Do not apply 1 Clean bol...

Page 19: ...ces Twist bolt when inserting it to improve thread conformation NOTE NOT intended for engine stud repairs Repair of Small Holes Fine Threads Option 1 Enlarge damaged hole then follow Standard Thread Repair procedure Option 2 Apply FORM A THREAD on the screw and insert in damaged hole Permanent Stud Installation light duty Use a stud or thread on desired length DO NOT apply release agent on stud Do...

Page 20: ...nue to assemble as shown above Case In Components Metallic Gaskets A00A3VA 1 1 Proper strength Loctite Clean inner housing diameter and outer gasket diameter Spray housing and gasket with Loctite Primer N P N 293 800 041 Apply a strip of proper strength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low strength liquid is recommended as norma...

Page 21: ...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 in 4 5 N m 35 44 lbf in M5 3 3 5 N m 27 31 lbf in 4 5 5 5 N m 40 47 lbf in 7 8 5 N m 62 75 lbf in 8 10 N m 71 89 lbf in M6 6 5 8 5 N m 58 75 lbf in 8 12 N m 71 106 lbf in 10 5 15 N m 93 133 lbf ...

Page 22: ... and rubber mount I I Seals and fasteners I I Exhaust system fasteners 5 I I Expansion pipe I RAVE valve 5 C C Counterbalance shaft oil level I I Spark plug 4 5 I R Ignition timing 5 I Air intake silencer fit tightness I I 4 Replace at 150 hours or after 2 years whichever comes first 5 Emission related component COOLING SYSTEM Flushing T 3 Hose and fasteners I I Engine drain tubes I 1 1 Every 10 h...

Page 23: ...ering cable I A L I A L Steering pole I I Handlebar and adjuster operation I I O T A S SYSTEM O T A S system operation I I PROPULSION SYSTEM Drive shaft protection bellows I 2 Seal carrier L L Drive shaft impeller splines L VTS Variable Trim System if so equipped I I Jet pump reservoir oil R I R Anti Rattle Pusher in Jet pump cover I Impeller shaft seal R 4 Impeller and impeller wear ring clearanc...

Page 24: ...omes first 5 Emission related component COOLING SYSTEM Flushing T 3 Hose and fasteners I I Engine drain tubes I 1 Water flow regulator valve if so equipped I 1 Every 10 hours in salt water use 3 Daily flushing in salt water or foul water use FUEL SYSTEM Throttle choke cables carburetor equipped models 1 I A L Fuel filter except RFI models I I R Fuel injection system sensor except throttle body RFI...

Page 25: ...rs I I 5 Emission related component STEERING SYSTEM Steering cable I I O P A S SYSTEM O P A S system if so equipped I I PROPULSION SYSTEM Drive shaft impeller splines I 2 Drive shaft bellow I 2 PTO flywheel L L Shifter system cable if so equipped I I Jet pump reservoir oil and oil level I R Jet pump cover pusher if so equipped I Impeller shaft seal R 4 Impeller and impeller wear ring clearance I 2...

Page 26: ...tem FUEL SYSTEM Carburetor adjustment Throttle and choke cable inspection adjustment 2 Carburetor Fuel filter replacement GTI Fuel tank and fuel pump Throttle cable inspection adjustment Fuel injection sensors verification Engine Management Fuel filter replacement All RFI models Filler neck fuel tank fuel tank straps fuel cap check valves lines fasteners condition and fuel system pressurization 2 ...

Page 27: ...EM Check O T A S system condition 3D Series O T A S PROPULSION SYSTEM Shifter system condition and cable adjustment GTI Series Reverse System Variable Trim System VTS 3D Series VTS System Propulsion system inspection Jet pump oil replacement All models Jet Pump HULL BODY Inspection of bailer pick ups All models Special Procedures Kart seat condition if so equipped Moto seat condition if so equippe...

Page 28: ... Always wipe off any fuel spillage from the watercraft Periodically inspect fuel system Always turn the fuel tank valve if so equipped to OFF position when storing the watercraft Throttle Cable Lubricate the throttle cable with Bombardier Lube P N 293 600 016 Fuel Hoses Carburetor or Injectors Verify fuel system Check fuel hoses and injectors or carburetor for leaks Replace damaged hoses or clamps...

Page 29: ...01I0BA 1 1 Grease PTO flywheel CAUTION Never leave any clothing tool or other objects near PTO flywheel and drive shaft Seal Carrier 3D RFI Models Remove rear access cover Lubricate seal carrier of drive shaft support with synthetic grease P N 293 550 010 Stop lubricat ing when grease is just coming out of seal F22J05A 1 1 Grease seal carrier ENGINE AND EXHAUST SYSTEM Engine Draining Check engine ...

Page 30: ...ine support F17E0AA 1 GTI RFI AND GTI RFI LE 1 Press tabs here and disconnect hose F22E02A 1 3D SERIES 1 Press tabs here and disconnect hose Water should flow out of the fitting magneto cool ing circuit and hose crankcase heat exchanger Push and hold hose against bilge so that draining can take place NOTE It may be necessary to position the end of the hose in a lower area of the bilge to allow pro...

Page 31: ...ng the water tap Open water tap im mediately after engine is started to prevent overheating Proceed as follows Clean jet pump by spraying water in its inlet and outlet and then apply a coating of Bombardier Lube P N 293 600 016 or an equivalent WARNING Always remove safety lanyard cap from post to prevent unexpected engine starting before cleaning the jet pump area Engine must not be running for t...

Page 32: ...flushing adapter after oper ation if used Wipe up any residual water from the engine FINAL ENGINE LUBRICATION Remove spark plug cables and connect them on the grounding device WARNING Always use spark plug cable grounding de vice when removing spark plugs 1 F01H7CA 717 ENGINES 1 Grounding device 1 F01H7DA 787 RFI ENGINES 1 Grounding device Remove both spark plugs and spray Bombardier Lube P N 293 ...

Page 33: ...th remaining water trapped in water jackets Always use ethy lene glycol antifreeze containing corrosion inhibitors specifically recommended for alu minum engines Never use antifreeze for RV recreational vehicles NOTE When available it is recommended to use biodegradable antifreeze compatible with internal combustion aluminum engines This will contribute to protect the environment NOTE The engine w...

Page 34: ...ecover it DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS NOTE Although antifreeze will mainly drain out the antifreeze has mixed with the water that was possibly trapped in the water jackets and thus pre venting freezing problems At preseason preparation drain the remaining an tifreeze from cooling system prior to using the wa tercraft Ensure no hose pincher was forgotten at storage GTI...

Page 35: ...001_a 1 Engine water inlet hose Disconnect hose just above T fitting as shown F15E02A 2 1 TYPICAL 1 Hose connecting to cylinder head inlet fitting 2 Disconnect hose above T fitting Install a large hose pincher P N 529 032 500 just below T fitting Pour approximately 300 mL 10 oz of antifreeze in the water regulator valve supply hose to allow an tifreeze flowing through the valve and into muffler to...

Page 36: ...season preparation drain the remaining an tifreeze from cooling system prior to using the wa tercraft Ensure no hose pincher was forgotten at storage 3D Series Remove rear access panel and engine cover Lock steering pole in upright position with the holder WARNING Always install steering pole holder while working in the engine compartment Using a small hose pincher P N 295 000 076 block heat excha...

Page 37: ...r water antifreeze from this outlet Place a container at rear of watercraft to recov er the water antifreeze from the vehicle hose adapter Remove the 2 small hose pinchers from the en gine drain hoses Most of the antifreeze will drain out when remov ing the hose pinchers Use a container to recover it DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS Install the water supply hose and remove...

Page 38: ...and mild detergent or with bilge cleaner Rinse thoroughly Lift front end of watercraft to completely drain bilge If any repairs are needed to body or to the hull touch up paint and Gelcote repair kit are available Re place damaged labels decals Wash the body with soap and water solution only use mild detergent Rinse thoroughly with fresh water Remove marine organisms from the hull Apply a nonabras...

Page 39: ... fuel system Add fuel stabilizer Flush the cooling system Lubricate the engine Remove clean and store the battery Clean the bilge Wash the body Add antifreeze solution to the cooling system in cool regions Spray Bombardier Lube over all metallic components in engine compartment and in throttle cable Spray Bombardier Lube in oil injection pump cable 18 smr2005 044 www SeaDooManuals net ...

Page 40: ...gine with a large hose pincher P N 529 032 500 529 032 500 This will prevent the exhaust cooling system from filling which may lead to water being injected in to and filling the exhaust system and the engine Without the engine running there isn t any exhaust pressure to carry the water out the exhaust outlet CAUTION Failure to do this may result in dam age to the engine If you tow this watercraft ...

Page 41: ...lidate presence of water CAUTION Never try to crank or start the en gine Water trapped in the engine may cause severe damage to the engine components WATER FLOODED ENGINE If engine is water flooded it must be serviced within a few hours after the event Otherwise en gine will have to be overhauled CAUTION A water flooded engine must be properly lubricated operated then lubricated again otherwise pa...

Page 42: ...Remove safety lanyard from its post Depress and hold the throttle lever at full throttle position Wait 2 seconds then reinstall the safety lanyard cap Press the start stop button to crank the engine during 10 seconds to allow water to escape from spark plug openings All Engines Spray Bombardier Lube P N 293 600 016 into spark plug holes Crank engine again Reinstall spark plugs and spark plug cable...

Page 43: ...ngine is running F01F25A 1 3 2 717 AND 787 RFI ENGINES 1 Air intake silencer 2 Pull plug 3 Spray BOMBARDIER LUBE here CAPSIZED ENGINE If the engine does not cranked after a cap size check for water ingestion Refer to WA TER FLOODED ENGINE above FUEL FLOODED ENGINE 717 Engines Install the safety lanyard cap on its post Ensure choke lever is completely pushed in Fully depress the throttle lever and ...

Page 44: ...CEDURES Remove spark plugs Cover spark plug holes with a rag Crank engine several times while keeping throttle fully depressed on RFI models Install new spark plugs Reconnect cables Start engine as explained above smr2005 045 23 www SeaDooManuals net ...

Page 45: ...ce Burnt fuse battery starting system Also fuel pump on RFI models Check wiring then replace fuse Starting system fuse keeps on burning Check wiring starting system solenoid and MPEM or ECM RFI models Discharged or disconnected battery Check recharge Defective or disconnected start stop switch Check refer to STARTING SYSTEM or ENGINE MANAGEMENT Battery connections Check clean tighten Poor bad or c...

Page 46: ... system RFI models Check for fault codes Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT Engine drowned mode is active RFI models Release throttle lever Low battery voltage Recharge or replace battery Check fuel pump pressure output Check fuel pump fuse Low or no fuel pressure RFI models Check wiring harness Check fuel injector operation Replace as necessary Fuel injectors not working RFI mode...

Page 47: ...k refer to the appropriate ENGINE SHOP MANUAL Internal engine damage Check refer to the appropriate ENGINE SHOP MANUAL Defective trigger wheel RFI models Check refer to MAGNETO SYSTEM in the appropriate ENGINE SHOP MANUAL Incorrectly aligned flywheel and rotor RFI models Properly position flywheel and rotor refer to MAGNETO SYSTEM in the appropriate ENGINE SHOP MANUAL Engine turns over cont d Insu...

Page 48: ...efer to FUEL SYSTEM Low fuel pressure RFI models Check fuel pressure regulator Refer to FUEL SYSTEM Missing shim under CPS RFI models Refer to COMPONENT ADJUSTMENT INSPECTION AND REPLACEMENT ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED OTHER OBSERVATION POSSIBLE CAUSE REMEDY The system is in limp home mode RFI models Refer to ENGINE MANAGEMENT and check the fault codes Broken or loose throttle cable ...

Page 49: ...ATION POSSIBLE CAUSE REMEDY Fouled defective worn spark plugs Check verify heat range gap replace Faulty ECM RFI models Check refer to ENGINE MANAGEMENT Defective trigger wheel CPS RFI models Check refer to ENGINE MANAGEMENT Too much oil supplied to engine Adjust oil injection pump Bad ignition coil wiring Check wiring condition and proper grounding of ignition coil Faulty ignition coil or bad con...

Page 50: ... or ECM RFI models Check faulty codes in ECM memory refer to ENGINE MANAGEMENT Flame arrester dirty or restricted Check replace Partially closed choke carburetor models Check adjust choke cable Loose main jet carburetor models Check refer to FUEL SYSTEM Faulty fuel injector s RFI models Remove and replace fuel injector s refer to ENGINE MANAGEMENT Defective sensor or ECM RFI models Check faulty co...

Page 51: ...before replacing an ECM that could otherwise be good ENGINE CONTINUALLY BACKFIRES OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Fouled defective spark plugs Clean replace Spark plugs Ignition coil leads or wiring reversed Refer to WIRING DIAGRAM Incorrect setting Check reset refer to ELECTRICAL SYSTEM Ignition timing Defective trigger wheel CPS RFI models Check refer to ENGINE MANAGEMENT Rota...

Page 52: ...d Check replace refer to PROPULSION SYSTEM Poor fuel quality Siphon then refill with fresh fuel Clogged fuel injectors RFI models Remove and clean fuel injectors Low fuel pressure RFI models Check fuel line and fuel pump pressure Incorrect throttle position sensor TPS adjustment RFI models Check and adjust TPS refer to ENGINE MANAGEMENT Overheated engine See ENGINE OVERHEATS in this chart RAVE val...

Page 53: ...uel pressure and delivery Engine start but stops after approximately 2 seconds Air in fuel rail RFI models Refill fuel tank ENGINE CANNOT REACH MAXIMUM RPM OTHER OBSERVATION POSSIBLE CAUSE REMEDY RAVE valve does not open if so equipped Check refer to the appropriate ENGINE SHOP MANUAL and to COOLING SYSTEM Faulty water regulator valve if so equipped Check refer to COOLING SYSTEM Low fuel pressure ...

Page 54: ...er pitch Check replace refer to PROPULSION SYSTEM Engine RPM too high Improper impeller pitch Check replace refer to PROPULSION SYSTEM Damaged leading or trailing edge of impeller Check replace NOTE Leading edge damage contributes to poor performance from start Trailing edge damage contributes to poor top performance and stator vanes erosion Jet pump cavitation Sealing of ride plate jet pump suppo...

Page 55: ...eplace refer to PROPULSION SYSTEM Idle speed too low Adjust carbureted models Check fault codes RFI models Broken engine mounts Check replace refer to ENGINE STEERING POLE IS HEAVIER THAN USUAL 3D SERIES OTHER OBSERVATION POSSIBLE CAUSE REMEDY Steering pole return spring adjustment Set the adjuster to reduce the weight at the handlebar Refer to STEERING SYSTEM Steering pole return spring is broken...

Page 56: ... 03 ENGINE SYSTEM Subsection 01 AIR INTAKE SYSTEM AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 41 Loctite 518 293 800 038 41 smr2005 047 37 www SeaDooManuals net ...

Page 57: ...7 Engines F02F2CT 10 N m 89 lbf in 4 5 3 10 N m 89 lbf in 7 8 10 N m 89 lbf in Loctite 518 10 Loctite 518 6 2 1 9 Loctite 243 Loctite 243 11 Loctite 243 Loctite 243 Loctite 243 Loctite 243 4 5 N m 40 lbf in 20 N m 15 lbf ft 38 smr2005 047 www SeaDooManuals net ...

Page 58: ...NGINE SYSTEM Subsection 01 AIR INTAKE SYSTEM 787 RFI Engines F15F01U 3 1 5 2 4 10 N m 89 lbf in 6 10 10 N m 89 lbf in 8 9 10 N m 89 lbf in 7 Loctite 243 Loctite 243 Loctite 243 smr2005 047 39 www SeaDooManuals net ...

Page 59: ...e 6 retaining slides holding air intake si lencer cover no 1 Remove cover and its gasket no 2 F01F2OA 1 2 TYPICAL 1 Air intake silencer cover 2 Unlock Air Intake Silencer Base Remove screws no 3 of retaining plate no 4 Pull out retaining plate and air intake silencer base no 5 F00F02A 1 2 1 Retaining plate 2 Remove screws Flame Arrester Base Remove flame arrester no 6 Remove screws no 7 retaining ...

Page 60: ...torque to 10 N m 89 lbf in Flame Arrester Base Supports On 717 engines before installing arrester sup ports no 11 to flame arrester base no 9 apply Loctite 518 P N 293 800 038 around each holes of retaining plate Apply the product on side to ward the base Flame Arrester Inspect condition of flame arrester no 6 Replace or clean as necessary WARNING Do not operate watercraft without flame ar rester ...

Page 61: ...M Subsection 02 EXHAUST SYSTEM EXHAUST SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 48 Loctite 518 293 800 038 56 silicone sealant clear 293 800 086 56 smr2005 048 43 www SeaDooManuals net ...

Page 62: ... SYSTEM GTI SERIES GTI Model 717 Engine F17D04S 24 N m 17 lbf ft 4 N m 35 lbf in 12 Loctite 243 9 18 19 16 14 5 10 25 N m 18 lbf ft 8 19 Loctite 243 6 4 15 Loctite 30542 1 Loctite 29647 11 2 1 3 4 N m 35 lbf in 44 smr2005 048 www SeaDooManuals net ...

Page 63: ...BS Loctite 518 7 9 16 48 N m 35 lbf ft Loctite 243 14 19 18 19 6 3 10 19 18 19 25 N m 18 lbf ft 13 12 4 N m 35 lbf in 1 20 25 N m 18 lbf ft Loctite 243 2 Silicone sealant 5150 40 N m 30 lbf ft Loctite 243 25 N m 18 lbf ft 1 25 Loctite sealant 1 24 1 Loctite sealant 20 smr2005 048 45 www SeaDooManuals net ...

Page 64: ... Remove screws Tuned Pipe 717 Engine Disconnect water supply hose and water injection hose Disconnect tuned pipe bleed hose F01D8NA 1 2 3 TYPICAL 1 Bleed hose removed 2 Injection hose removed 3 Supply hose removed Loosen exhaust hose collar no 1 at tuned pipe outlet Disconnect strap no 2 retaining muffler no 11 Remove exhaust hose no 3 from tuned pipe by pulling muffler Remove clamp no 4 from tune...

Page 65: ...TI Models Remove vent tube support Upper Type Resonators Detach resonator from body Loosen clamps and disconnect hoses Withdraw resonator from watercraft 2 1 3 F07L1DA TYPICAL 1 Loosen hose clamps 2 Upper type resonator 3 Muffler holding strap Footwell Type Resonators NOTE GTI RFI and GTI RFI LE are equipped with both types of resonators F07L1EA 2 1 TYPICAL 1 Footwell type resonator 2 Upper type r...

Page 66: ...kPa 18 PSI to pres surize tuned pipe CAUTION Always ensure water passages are not blocked partially or completely while weld ing tuned pipe NOTE Prior to verify leaks plug all holes and pres surize tuned pipe while immerging it in water INSTALLATION Installation is essentially the reverse of removal procedures However pay particular attention to the following Exhaust Manifold For installation proc...

Page 67: ...st be no gap between tuned pipe cone and tuned pipe head NOTE Exhaust clamp nuts should be tightened al ternately to assure no leakage and to obtain spec ified torque 787 RFI Engine NOTE Loosen all pipe supports from engine be fore installing tuned pipe Ensure rubber bushings no 19 and sleeve no 18 are not damaged and are properly installed into tune pipe supports CAUTION Damage to bushings and or...

Page 68: ... support on the engine before torquing the pipe support bolts 26 N m 19 lbf ft 1 N m 9 lbf in 40 N m 30 lbf ft 40 N m 30 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 7 3 9 5 6 N m 53 lbf in 48 N m 35 lbf ft 4 8 2 6 26 N m 19 lbf ft 26 N m 19 lbf ft 13 12 10 11 1 15 14 50 smr2005 048 www SeaDooManuals net ...

Page 69: ...Section 03 ENGINE SYSTEM Subsection 02 EXHAUST SYSTEM 3D SERIES smr2005 048 002 smr2005 048 51 www SeaDooManuals net ...

Page 70: ...placed with new ones where specified If the efficiency of a locking device is impaired it must be renewed REMOVAL Tuned Pipe Remove engine cover then lift and lock steering pole Remove air intake silencer NOTE To ease tuned pipe removal the throttle body can be removed from engine Disconnect hoses from tuned pipe smr2005 048 004_A 1 Tuned pipe head water jacket supply hose smr2005 048 005_A 1 Tune...

Page 71: ...ct hose from exhaust manifold smr2005 048 010_A 1 Exhaust manifold 2 Cooling system indicator hose For removal procedure of the exhaust manifold refer to the 717 787 RFI ENGINE SHOP MANUAL Exhaust Bellow Remove tuned pipe Unscrew clamp holding exhaust bellow to water trap smr2005 048 011_A 1 Exhaust bellow 2 Water trap 3 Remove this clamp Remove exhaust bellow Muffler Open rear access panel smr200...

Page 72: ...arward Pull muffler out of vehicle Inspect muffler shell and boot condition Water Trap and Exhaust Pipe Remove tuned pipe and exhaust bellow Unscrew clamps retaining extension pipe to muf fler and water trap smr2005 048 014_A 1 Clamps 2 Extension pipe 3 Muffler 4 Water trap Remove heat shield from extension pipe Detach straps holding water trap against fuel tank smr2005 048 012_A 1 Water trap 2 Ex...

Page 73: ...th chamfer over crack Use pure argon gas with 5 55 mm 3 32 in tungsten electrode puretung green zirtung brown and AC current Use a 5 55 mm 3 32 in aluminum welding rod no 4043 to fill crack Sand welding slightly to remove material sur plus Test Use compressed air at 124 kPa 18 PSI to pres surize tuned pipe CAUTION Always ensure water passages are not blocked partially or completely while weld ing ...

Page 74: ...rque clamp yet Install all other hoses and resonators Torque all clamps and install muffler strap Ensure there is a gap between muffler and drain plug The gap should be 10 mm 3 8 in minimum A smr2005 048 017_a A Gap between muffler and drain plug Exhaust Outlet Prior to installing exhaust outlet apply silicone sealant clear P N 293 800 086 as shown F22D0PA 1 2 1 All around 2 Opposite vertical line...

Page 75: ... engine before torquing the pipe support bolts 26 N m 19 lbf ft 1 N m 9 lbf in 40 N m 30 lbf ft 40 N m 30 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 7 3 9 5 6 N m 53 lbf in 48 N m 35 lbf ft 4 8 2 6 26 N m 19 lbf ft 26 N m 19 lbf ft 13 12 10 11 1 15 14 TUNED PIPE TORQUING SEQUENCE smr2005 048 57 www SeaDooManuals net ...

Page 76: ...L On some models it is not necessary to remove engine from watercraft to service TOP END PTO FLYWHEEL or MAGNETO However engine re moval is necessary to repair BOTTOM END PROCEDURES ENGINE REMOVAL In order to remove engine from watercraft pro ceed as follows First disconnect battery cables from battery WARNING Always disconnect battery cables exactly in the specified order BLACK cable first then t...

Page 77: ...er to JET PUMP CAUTION Whenever removing engine from watercraft engine jet pump alignment must be performed at reinstallation Drive System To withdraw drive shaft s refer to DRIVE SYS TEM Cooling System Disconnect the engine water supply hose Disconnect the engine water return hose NOTE Engine will have to be raised inside bilge to disconnect drain hose before removing from bilge 2 1 3 smr2005 049...

Page 78: ...nect fuel supply hose from fuel rail F07F11A 1 TYPICAL PRESS TABS AND PULL CONNECTOR 1 Fuel rail WARNING The fuel hose may be under pressure Cov er the fuel line connection with an absorbent shop rag Slowly disconnect the fuel hose to release the pressure Wipe off any fuel spillage inside bilge Engine Support NOTE Be careful when removing engine sup port s or rubber mount adapters shims could have...

Page 79: ...830 and the engine lift tool P N 529 035 940 A33B06A LIFTING RING A00B6BA ENGINE LIFT TOOL Remove spark plugs and replace by lifting ring Hook engine lift tool into lifting ring holes Using a chain block a hoist or other suitable equip ment slightly lift engine to ease the remaining component removal CAUTION Take care not to damage cable or oil injection hoses 787 RFI Engines Engine can be easily ...

Page 80: ...2 smr2005 049 008_a TYPICAL 1 Rear support 2 Engine support bolts All Engines Lift up engine slowly until oil injection hoses can be reached Install a small hose pincher P N 295 000 076 to oil supply hoses of oil injection pump and rotary valve shaft then disconnect hoses A01B2JB 1 TYPICAL 1 Small hose pincher Install another small hose pincher P N 295 000 076 to oil return hose of rotary valve sh...

Page 81: ...2 1 1 Positive starter cable 2 Ground cable Carry on engine lifting then tilt engine so that it can be removed from the body opening CAUTION Be careful not to scratch body or to hit any component F01D7RA TYPICAL GTI RFI SHOWN CLEANING Wipe off any spillage in bilge Clean with a bilge cleaner Clean external parts of engine INSTALLATION Installation of engine in watercraft is essentially the reverse...

Page 82: ...o 22 N m 16 lbf ft 2 Torque nuts to 39 N m 29 lbf ft 787 RFI Engines Apply Loctite 243 blue P N 293 800 060 to rear engine support screws and install them with flat washers and torque to 24 N m 17 lbf ft 1 F07F12B TYPICAL 1 Torque engine support screws to 24 N m 17 lbf ft Oil Injection Hoses Make sure to reinstall hoses before completely lowering engine in bilge Positive Starter Cable Torque nut o...

Page 83: ...rt shaft end into PTO flywheel NOTE Ensure the protective hose and carbon ring or seal carrier is removed to check engine align ment NOTE If the alignment is correct the shaft will slide easily without any deflection in PTO fly wheel F07D05A 2 1 TYPICAL 1 Alignment shaft 2 PTO flywheel If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft end NOTE Us...

Page 84: ... 787 RFI ENGINES FRONT SHIM LOCATION SHIM TO BE USED MAXIMUM THICKNESS A shim 1 3 mm 0512 in P N 270 000 446 5 mm 1968 in CAUTION Whenever shims are used to cor rect alignment never install more than 5 mm 1968 in shim thickness B smr2005 049 006_a 787 RFI ENGINES REAR SHIM LOCATION SHIM TO BE USED MAXIMUM THICKNESS B shim 1 3 mm 0512 in P N 270 000 446 5 mm 1968 in CAUTION Whenever shims are used ...

Page 85: ...M Then ensure the mid bearing is loosened to check en gine alignment Carefully slide alignment shaft through shaft sup port and seal carrier F05I08A 1 2 TYPICAL 1 Alignment tool 2 Seal carrier 1 F08I06A 2 1 Alignment shaft 2 Adapter Continue to slide the alignment shaft forward and install PTO adapter on shaft end If the alignment is incorrect loosen engine support screws to enable to align PTO fl...

Page 86: ...nstall nuts Refer to following illustration for tightening se quence Torque 1 to 6 at 3 N m 27 lbf in and then 7 to 12 at 10 N m 89 lbf in NOTE It is very important to tighten nuts of seal carrier in this sequence to maintain its alignment F00B25B 9 4 7 2 11 6 10 3 8 1 12 5 TIGHTENING SEQUENCE Engine Support Screws Apply Loctite 243 blue P N 293 800 060 on screw threads Torque engine support screw...

Page 87: ...OIL INJECTION PUMP and adjust throttle cable as specified in CARBURETOR or ENGINE MANAGEMENT RFI Check hose condition and pressure test fuel sys tem refer to FUEL SYSTEM WARNING Whenever doing any type of repair on wa tercraft or if any components of the fuel sys tem are disconnected a pressure test must be done before starting engine Verify all electrical connections Run engine and ensure there i...

Page 88: ...ION SYSTEM OIL INJECTION SYSTEM SERVICE TOOLS Description Part Number Page pump gauge tester 295 000 114 75 small hose pincher 295 000 076 74 SERVICE PRODUCTS Description Part Number Page Loctite 271 red 293 800 005 74 smr2005 050 71 www SeaDooManuals net ...

Page 89: ...UBRICATION SYSTEM Subsection 01 OIL INJECTION SYSTEM GTI Series 1 2 1 3 4 1 5 N m 13 lbf in 2 N m 18 lbf in 4 N m 36 lbf in 23 N m 17 lbf ft 4 N m 36 lbf in smr2005 050 001_aen 72 smr2005 050 www SeaDooManuals net ...

Page 90: ...TION SYSTEM Subsection 01 OIL INJECTION SYSTEM 3D Series 3 5 3 4 1 5 N m 13 lbf in 2 N m 18 lbf in 3 5 N m 31 lbf in 2 N m 18 lbf in Loctite 271 1 5 N m 13 lbf in smr2005 050 006_aen smr2005 050 73 www SeaDooManuals net ...

Page 91: ...ion Oil Filter Oil filter no 4 should be replaced annually When installing point the arrow toward the engine Oil Reservoir Pad 3D Series When the foam pad under oil reservoir is installed apply Loctite 271 red P N 293 800 005 on screw threads OIL SYSTEM PRESSURIZATION WARNING Whenever oil system components are discon nected or replaced a pressure test must be done before starting engine Ensure to ...

Page 92: ... gauge tester P N 295 000 114 to oil injection reservoir vent check valve 35 4 3 25 2 15 1 5 60 50 4 0 30 2 0 10 295000114 1 F01G0IA TYPICAL 1 Connect pump to check valve Pressurize oil system to 21 kPa 3 PSI The system must maintain a pressure for at least 10 minutes Never pressurize over 21 kPa 3 PSI If pressure is not maintained locate leak and repair replace component leaking To ease leak sear...

Page 93: ...ION PUMP OIL INJECTION PUMP SERVICE TOOLS Description Part Number Page gear holder 420 277 905 80 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 80 Loctite anti seize lubricant 293 800 070 81 smr2005 051 77 www SeaDooManuals net ...

Page 94: ...NJECTION PUMP 717 Engines F00G03T Loctite 243 1 4 5 N m 40 lbf in 8 N m 71 lbf in 8 N m 71 lbf in 2 3 10 N m 89 lbf in 5 Loctite 243 6 N m 53 lbf in 6 4 6 N m 53 lbf in Loctite 243 5 N m 44 lbf in Synthetic grease 78 smr2005 051 www SeaDooManuals net ...

Page 95: ...Section 04 LUBRICATION SYSTEM Subsection 02 OIL INJECTION PUMP 787 RFI Engines F07G0DS 6 6 N m 53 lbf in 4 5 N m 40 lbf in 9 8 7 3 N m 27 lbf in 1 4 5 N m 40 lbf in smr2005 051 79 www SeaDooManuals net ...

Page 96: ...ws no 6 with flat washers re taining oil injection pump to intake manifold no 2 Disconnect oil injection pump cable from oil pump lever Disconnect oil hoses from oil pump fittings Remove pump 787 RFI Engines Disconnect oil injection pump cable no 7 Remove 2 Allen screws no 6 with flat washers no 9 retaining oil injection pump to magneto housing cover Pull pump Disconnect oil hoses from fittings of...

Page 97: ...d of shaft Install pump Secure with flat washers and screws no 6 Torque to 6 N m 53 lbf in Install oil injection pump cable ADJUSTMENT CAUTION As oil injection pump adjustment is dependent on throttle cable position make sure to perform throttle cable adjustment first except if otherwise specified Preliminary Synchronization NOTE To check synchronization of pump as a routine maintenance see FINAL ...

Page 98: ...ARBURETOR NOTE On 787 RFI engines there is no idle speed adjustment to perform Stop engine Final Synchronization Eliminate throttle cable free play by depressing throttle lever until a slight resistance is felt In this position marks on pump body and lever must align If necessary turn cable adjustment nut to obtain pump mark alignment Refer to above illustra tions Tighten jam nut and recheck align...

Page 99: ...leeding procedure above Start engine and run at idle while holding the pump lever in fully open position Oil must advance into small oil lines NOTE The engine should have a rich mixture idling irregularly and emitting smoke at exhaust outlet If not remove pump assembly and check the pump gear 717 engines or shaft 787 RFI en gines for defects replace as necessary Test pump as described below NOTE T...

Page 100: ...al delivery on both ports To obtain a precise result of the oil pump delivery rate rotate it counterclockwise at 1500 RPM for a total time of 5 minutes NOTE To ensure accuracy of test oil lines should be completely filled before starting test Compare the results with the chart below If oil pump is out of specification replace it ENGINE OIL PUMP DELIVERY AT 1500 RPM pump speed FOR 5 MINUTES 717 9 9...

Page 101: ... Part Number Page digital inductive type tachometer 529 014 500 94 pump gauge tester 295 000 114 88 89 91 SERVICE PRODUCTS Description Part Number Page Bombardier Lube 293 600 016 92 93 Loctite 243 blue 293 800 060 90 synthetic grease 293 550 010 92 smr2005 052 85 www SeaDooManuals net ...

Page 102: ... FUEL SYSTEM Subsection 01 CARBURETOR Mikuni BN 40i Loctite 243 Loctite 243 10 19 17 15 18 3 16 13 14 4 8 7 20 9 6 5 20 N m 15 lbf ft Synthetic grease 1 2 smr2005 052 001_aen 86 smr2005 052 www SeaDooManuals net ...

Page 103: ...emove air intake silencer Refer to AIR INTAKE Turn fuel valve to OFF position Disconnect pulse line F06F0LA 1 2 TYPICAL 1 Pulse line 2 Loosen gear clamp Disconnect fuel supply line from fuel pump Disconnect fuel return line Disconnect oil injection pump cable throttle cable and choke cable Remove screws no 1 and lock washers no 2 re taining carburetor Remove carburetor CLEANING The carburetor exte...

Page 104: ...ragm Fuel Pump Valve Check fuel pump valve operation as follows Connect a clean plastic tubing to the inlet nipple of the fuel pump body no 5 and alternately apply pressure and vacuum with the mouth The inlet valve should release with pressure and hold under vacuum WARNING Some fuel may be present in fuel pump Be careful not to swallow fuel when under vacu um F01F0WA 1 2 3 TYPICAL 1 Fuel outlet ni...

Page 105: ...it reaches 28 kPa 4 PSI F06F07A 2 1 3 1 Pump gauge tester 2 Hose installed to inlet nipple 3 Outlet nipple obstructed Diaphragm no 10 must stand pressure for 10 sec onds If pressure drops replace accelerator pump diaphragm Verify accelerator pump check valves operation as follows Connect a clean plastic tubing to the valve inlet nipple and alternately apply pressure and vacuum The check valve shou...

Page 106: ...late and Throttle Plate When installing choke plate no 11 or throttle plate no 12 onto shaft s close plate so that it cen ters into carburetor bore Apply Loctite 243 blue P N 293 800 060 on thread screws then firmly tighten screws Needle Valve Lever Rounded end of needle valve lever no 13 must be flush with surrounding metering chamber floor and not with body assembly Place the end of a ruler over...

Page 107: ...Leak Test Needle valve no 3 must stand a pressure of 69 kPa 10 PSI for 30 seconds Otherwise hold carburetor upside down pour oil over needle valve and apply pressure Check for bubbles If they come from seat or O ring bubbles will exit around seat Retighten as necessary If it still leaks remove needle and seat and replace O ring If bubbles come from needle replace needle and seat Main Jet and Pilot...

Page 108: ...r no 19 is inserted into carburetor notch Fuel Accelerator Pump Lubricate pump plunger roller and cam with syn thetic grease P N 293 550 010 and roller shaft with Bombardier Lube P N 293 600 016 F06F06B 1 2 TYPICAL 1 Apply synthetic grease to plunger 2 Apply Bombardier Lube on roller shaft INSTALLATION Carburetor At installation pay attention to the following Install carburetor with gasket to inta...

Page 109: ...e plate is fully open at full throttle position At this position throttle lever stopper is almost in contact 0 5 mm 1 64 in with carburetor body NOTE Apply a light pressure on the throttle plate a slight play should be obtained CAUTION Improper cable adjustment will cause strain on cable and or damage cable bracket or throttle lever at handlebar To adjust loosen jam nut then turn adjustment nut as...

Page 110: ...p Ensure throttle cable and idle speed are properly adjusted With the engine not running loosen adjustment screw lock nut Use a feeler gauge between lever tab and pump plunger Turn adjustment screw to achieve approximately 0 05 0 15 mm 002 005 in gap Tighten adjustment screw lock nut F02F1QA 1 2 TYPICAL 1 Adjustment screw 2 Small gap NOTE Turning the adjustment screw clockwise will increase the ga...

Page 111: ...D FUEL PUMP SERVICE TOOLS Description Part Number Page engine leak test kit 295 500 352 106 fuel pressure gauge 529 035 591 101 pliers Oetiker 1099 295 000 070 99 100 pressure vacuum pump 529 021 800 106 small hose pincher 295 000 076 106 smr2005 053 95 www SeaDooManuals net ...

Page 112: ...16 1 2 N m 11 lbf in 1 17 2 N m 18 lbf in 3 N m 27 lbf in 15 4 3 1 2 N m 11 lbf in 1 2 22 N m 16 lbf ft 13 4 N m 35 lbf in 14 13 12 18 11 7 18 6 1 1 1 2 N m 11 lbf in Engine 8 10 9 3 N m 27 lbf in Body 4 N m 35 lbf in smr2005 053 001_aen 96 smr2005 053 www SeaDooManuals net ...

Page 113: ...5 FUEL SYSTEM Subsection 02 FUEL TANK AND FUEL PUMP GTI RFI and GTI RFI LE Models 16 4 N m 35 lbf in Body 1 2 22 N m 16 lbf ft 13 14 12 18 18 6 5 1 1 1 17 smr2005 053 002_aen smr2005 053 97 www SeaDooManuals net ...

Page 114: ...Section 05 FUEL SYSTEM Subsection 02 FUEL TANK AND FUEL PUMP 3D Series Hull Body 2 13 14 13 6 18 18 1 1 1 17 1 1 5 12 12 1 16 smr2005 053 003_aen 98 smr2005 053 www SeaDooManuals net ...

Page 115: ...filtration in reservoir Re place any damaged leaking or deteriorated fuel lines When the repair is completed en sure that hoses from fuel rail going to fuel pump are properly secured in their supports Then pressurize the fuel system After per forming a pressure test use the valve on the fuel pressure gauge to release the pressure if so equipped WARNING Ensure to verify fuel line connections for da...

Page 116: ... from the fuel pump Install a temporary connector on the fuel pump with wires long enough to make the connection outside the bilge F18F0TA D A BAT CAUTION Running pump a few minutes with reverse polarity can damage the pump If pump does not run replace the fuel pump mod ule Otherwise probe terminals as shown F18F0UA D A When installing safety lanyard you should read battery voltage for approximate...

Page 117: ... cover 3D Se ries Remove storage basket On GTI RFI Series remove glove box to have ac cess to fuel pump Refer to HULL BODY section Remove air vent tube from front storage area Ensure there is no leak from hoses and fittings Repair any leak Ensure there is enough gas in fuel tank Disconnect outlet hose from fuel pump WARNING The fuel hose may be under pressure Cov er the fuel line connection with a...

Page 118: ...e in the bilge Fu el is flammable and explosive under certain conditions Always work in a well ventilated area Reinstall removed parts REMOVAL Fuel Filter Carburetor Equipped Models Turn the fuel valve OFF then remove the seat WARNING The engine must not be running and fuel valve must be set to OFF position Gasoline is flammable and explosive under certain conditions Always work in a well ventilat...

Page 119: ...no 6 Remove steering assembly Refer to STEERING SYSTEM for procedure Disconnect fuel lines from baffle pick up and loosen lower clamp no 8 NOTE Note fuel lines locations for installation F02F1OA 1 2 TYPICAL 1 Disconnect fuel hoses 2 Loosen lower clamp Disconnect wiring harness of fuel sender Remove baffle from fuel tank Remove upper clamp no 9 from adapter no 10 and slide adapter from baffle Push ...

Page 120: ...m can get stuck and bend which can reduce the fuel sensor capabilities Remove fuel pump assembly from fuel tank WARNING Always wipe off any fuel spillage from the wa tercraft While dealing with fuel or fuel sys tem always work in well ventilated area Fuel Tank The engine removal is necessary to remove fuel tank on all models 3D Series Pull out both vent tubes F22J0AA Remove ignition coils Disconne...

Page 121: ... tightened Torque clamps to 4 N m 35 lbf in Pressure Relief Valve All Models This valve no 16 will eliminate fuel spillage when the watercraft is upside down If pressure is built up in fuel system the valve should open to release the pressure PRESSURE RELIEF VALVE MODELS PRESSURE Carburetor equipped 10 kPa 1 5 PSI RFI 3 5 kPa 0 5 PSI WARNING If pressure relief valve is stuck the pressure in fuel s...

Page 122: ...ank Pressure Test supply and vent circuits WARNING Whenever doing any type of repair on wa tercraft or if any components of the fuel sys tem are disconnected a pressure test must be done before starting engine Ensure to verify fuel line ends for damage Always cut dam aged end before reinstallation Proceed as follows Fill up fuel tank Disconnect air inlet hose of fuel tank from body Install a small...

Page 123: ... pressure is dropping on pump NOTE Pressure drop indicates that relief valve and the outlet fitting are not blocked Remove the pump from the air inlet hose fitting High Pressure Test fuel pump circuit RFI Models Refer to FUEL PUMP PRESSURE TEST INSTALLATION Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Fuel Tank Ensure rubber carpe...

Page 124: ...nsor CPS crankshaft position sensor RV RAVE valve SRV solenoid RAVE valve SP spark plug FI fuel injector IC ignition coil VCM vehicle control module ECM engine control module Bat battery FT fuel tank FP fuel pump FRe fuel regulator FRa fuel rail VCM ECM FRa IC FP FRe FT Bat ATS APS TPS CPS RV RV SP SP FI FI SRV smr2005 054 002_aen smr2005 054 109 www SeaDooManuals net ...

Page 125: ... system 1 air induction 2 fuel system 3 electrical system OPERATING PRINCIPLE AIR INDUCTION A single throttle body 56 mm breath through the air intake silencer to provide a sufficient amount of air for the engine operation F07F1LA THROTTLE BODY FUEL SYSTEM The Rotax Fuel Injection RFI is a semi direct elec tronic fuel injection system The Rotax Fuel Injection RFI is composed of the following main ...

Page 126: ...rmal conditions of use The internal fuel filter is located inside the end cap of the fuel pump module F07F0LA 2 1 1 End cap of fuel pump module removed 2 Internal fuel filter not replaceable This filter is not replaceable If clogged the fuel pump module should be replaced Fuel Injectors The injectors inject a metered quantity of fuel from the fuel rail into the cylinder rear transfer port in ac co...

Page 127: ... is not left on its post after engine is stopped IMPORTANT Leaving the safety lanyard on its post when engine is not running will slowly dis charge the battery Engine Starting If the ECM recognizes a valid safety lanyard it allows engine to start when the start stop button is pressed If start stop button is held after engine has started the ECM automatically stops the starter when the engine speed...

Page 128: ...ion 529 035 981 Vehicle Control Module VCM The VCM is mounted on the same support as the ECM in the front of the engine 1 F22H0NA 1 VCM The VCM is responsible of the following electrical functions Power Distribution A power supply cut off relay isolates the battery from the electrical system to prevent battery drain When the safety lanyard is installed the relay then supplies current to the VCM Th...

Page 129: ...TE The fuel pump will be activated for 2 sec onds to build up pressure in the fuel injection sys tem Low Fuel and Low Oil Level Warning Device When the fuel level in the reservoir is low the fuel level sensor transmits a signal to the VCM The VCM sends out signals to the beeper and to the information center gauge or to the indicator light cluster When the oil level is low in the reservoir the VCM ...

Page 130: ...n required for optimum air fuel ratio To activate an injector the ECM completes the injector circuit to ground IGNITION TIMING The ECM is programmed with data for optimum ignition timing under all operating conditions Us ing data provided by the sensors the ECM con trols the ignition timing for optimum engine oper ation A double ignition coil provides high voltage to each spark plug individually T...

Page 131: ...rs and involves a limp home mode operation the EMS system will reduce engine RPM gradually to the proper level Monitoring System The ECM permanently records and stores some engine operation parameters The ECM monitors the electronic components of the fuel injection system other electrical compo nents When a fault occurs it sends visual mes sages through the information center or indicator light cl...

Page 132: ...tem circuits are referred as 5 32 for instance It means connector no 5 and the circuit wire no 32 as found in the wiring diagram When they are referred as A 41 it means connec tor A on the ECM and the circuit 41 TPS Throttle Position Sensor Faults Faults which are reported in B U D S fall into two groups TPS faults and adaptation faults These are displayed on the B U D S system as TPS OUT OF RANGE...

Page 133: ...ed Throttle Sensor is loose Fix and reset Closed Throttle Throttle bracket is loose Fix and reset Closed Throttle Adjustment screw worn or loose Change throttle body Burnt Fuse and Related Fault Code FUSE NO FUSE CAPACITY AND FUNCTION CODE Main 5 A Accessories None 1 10 A Fuel pump None 2 5 A RAVE solenoid P 0231 3 10 A Ignition coil and starter solenoid P 0079 4 3 A Injector 1 MAG P 0616 P0351 P ...

Page 134: ...Y N When the fault is recovered P 0112 Intake manifold temperature sensor shorted to ground 15 Y N Y N When the fault is recovered P 0113 Intake manifold temperature sensor shorted to 12 V or open circuit 15 Y N Y N When the fault is recovered P 0116 Engine temperature functional problem 15 Y N Y N When the fault is recovered P 0117 Engine temperature sensor short circuit to ground 15 Y N Y N When...

Page 135: ... Y N When engine stop P 0352 Ignition coil 2 open circuit or shorted to ground or to 12 V 15 Y N Y N When engine stop P 0513 DESS incorrect key 15 N Y N A N A N A P 0562 Battery voltage too low 15 N N Y 0 When the fault is recovered At 10 V P 0563 Battery voltage too high 15 N N Y 5128 When the fault is recovered At 18 V P 0601 TPS learns unlikely or checksum fault 15 Y P 0601 Module call monitori...

Page 136: ...el cut off detected 15 Y N Y N When the fault is recovered P 1611 Engine speed rpm detected 15 N Y Y N When the fault is recovered P 1655 DESS line shorted to 12 V 15 Y Y N N When the fault is recovered P 1656 DESS line shorted to ground 15 Y Y N N When the fault is recovered P 1670 Buzzer Short to Battery Voltage 15 N Y Y N When the fault is recovered P 1671 Buzzer short circuit to ground or open...

Page 137: ... electronic equipments inspection diagnostic options and reset such as the Closed Throttle For more information pertaining to the use of the software B U D S use its help which contains de tailed information on its functions WARNING If the computer you are using is connected to the 110 Vac power outlet there is a poten tial risk of electrocution when working in con tact with water Be careful not t...

Page 138: ... VCK Supply The VCK MPI box can use the watercraft power for its supply The safety lanyard must be connected in order to use the watercraft as a power source If watercraft power is used every time the safety lanyard is taken off the DESS post the kW2000 protocol will have to be re activated Changes in ECM Anytime a change is brought in ECM through B U D S there will be an EMS Tracking mes sage tha...

Page 139: ...conditions Always work in a well ventilated area Always disconnect battery prior to work on the fuel system After per forming a pressure test use the valve on the fuel pressure gauge to release the pressure if so equipped When a repair is completed ensure that hose from fuel rail going to fuel pump is properly se cured in his support Then pressurize the fuel system as explained in FUEL SYSTEM sect...

Page 140: ...ays check electri cal connections Make sure that they are very tight and they make good contact and that they are corrosion free A defective module could possibly be repaired simply by unplugging and replugging the ECM The voltage and current might be too weak to go through dirty wire pins Check carefully if posts show signs of moisture corrosion or if they look dull Clean pins properly and then c...

Page 141: ...a heat gun while it is still connected to the harness to see if the ECM will detect the high temperature condition and gener ate a fault code When working with injectors the resistance value might test good while the complete current would not flow through the wire when pulsating current is supplied to the injector in its normal operation A solution would be to use a jumper wire to di rectly suppl...

Page 142: ... of the wiring harness when performing tests R1503motr176A 1 13 28 41 29 14 TERMINAL IDENTIFICATION OF ECM CONNECTOR A WIRING HARNESS SIDE CAUTION Do not disconnect the ECM connec tors needlessly They are not designed to be disconnected reconnected repeatedly NOTE For more details on ECM connectors ser vicing refer to ELECTRICAL CONNECTORS AND WIRING DIAGRAMS section VCM Connectors 32 Pin Connecto...

Page 143: ...BLE GTI RFI Series Fully depress throttle lever Lever must touch handlebar grip without causing strain to cable or brackets F01K08A 1 1 Must touch handlebar grip Ensure throttle plate is fully open Fully depress throttle lever and hold Throttle lever stopper should almost contact throttle body To ensure there is free play apply a light pres sure on the throttle plate a slight play should be obtain...

Page 144: ...ing pole at its lowest position 2 Handlebar at its lowest position and in straight ahead position Fully depress throttle lever and hold Throttle lever stopper should almost contact throttle body To ensure there is free play apply a light pres sure on the throttle plate a slight play should be obtained F22G03A 1 1 Free play here CAUTION If there is no free play at idle posi tion it may cause poor i...

Page 145: ...hen throttle cable is adjusted THROTTLE POSITION SENSOR TPS Closed TPS Reset NOTE This operation performs a reset of the val ues in the ECM To perform the resetting proceed as follows Use the VCK Vehicle Communication Kit P N 295 035 981 with B U D S software 529 035 981 Click Reset button to reset the TPS value to pro vide the zero scale value to ECM NOTE There will be an EMS Tracking message tha...

Page 146: ...Section 06 ENGINE MANAGEMENT RFI Subsection 03 COMPONENT ADJUSTMENT INSPECTION AND REPLACEMENT FUEL INJECTOR smr2005 056 001_en 132 smr2005 056 www SeaDooManuals net ...

Page 147: ...his can damage the injector This will validate the injector mechanical and elec trical operation If it does not work replace it If it works continue procedure Using B U D S activate injector while probing ter minal as shown INJECTOR CONNECTOR MEASUREMENT Pin 1 and battery ground Pulsating voltage approx 9 Vdc BAT Vdc 1 smr2005 056 011_a NOTE Because B U D S sends pulsating voltage to the injector ...

Page 148: ...TOR 5 31 A 15 1 MAG 5 15 A 33 2 PTO smr2005 056 013_a Repair wire connector if defective If wires test good and there was a fault code try a new ECM If wires test good and there was no fault code try a new VCM Resistance Test Ensure injector is connected and safety lanyard is removed from DESS post Disconnect the VCM connectors 5 and 7 Using a multimeter check resistance value be tween terminals a...

Page 149: ...mponents adjustments of throttle body are adequate The EMS may generate several fault codes per taining to the TPS Refer to DIAGNOSTIC PROCE DURES section for more information Wear Test While engine is not running activate throttle and pay attention for smooth operation without physi cal stops of the cable Using the vehicle communication kit VCK with the B U D S software use the Throttle Opening d...

Page 150: ... ECM voltage output to the TPS Disconnect connector from TPS Remove and reinstall the safety lanyard to activate the ECM Check the voltage readings from harness connec tor as follows TPS CONNECTOR VOLTAGE Pin 1 with battery ground 0 V Pin 2 with battery ground 5 V Pin 3 with battery ground 4 5 5 V BAT Vdc smr2005 056 016_a If voltage test is not good try a new ECM If voltage test is good everythin...

Page 151: ...esistance Test Disconnect the A connector from ECM Using a multimeter check the resistance on the ECM connector as per table ECM CONNECTOR MEASUREMENT PIN RESISTANCE 20 C 68 F A 7 A 21 2280 2736 smr2005 056 015_a If not within specification check wiring harness If wiring is faulty repair replace If wiring is good measure resistance of sensor itself If sensor is faulty replace it If sensor is good ...

Page 152: ...M Using a multimeter check the resistance on the ECM connector as per table ECM CONNECTOR MEASUREMENT PIN RESISTANCE 20 C 68 F A 3 A 4 3400 8200 A 4 A 18 2400 8200 smr2005 056 015_a If not within specification check wiring harness If wiring is faulty repair replace If wiring is good measure resistance of sensor itself If sensor is faulty replace it If sensor is good perform the VOLTAGE TEST below ...

Page 153: ...d connector as per table RAVE SOLENOID CONNECTOR MEASUREMENT PIN PIN RESISTANCE 20 C 68 F 1 2 30 smr2005 056 018_a If resistance is incorrect replace RAVE solenoid If resistance is correct proceed with the VOLT AGE TEST below Voltage Test Safety lanyard must be on DESS post Disconnect RAVE solenoid connector Probe terminal as shown BAT Vdc 2 smr2005 056 011_b If 12 V is read check continuity of gr...

Page 154: ...o IGNITION SYSTEM section for the ignition timing NOTE If Closed TPS reset or ignition timing set ting are not performed the engine will run with reduced performance No fault code will be gen erated To allow transferring the previous recorded in formation from the old ECM to the new one use the vehicle communication kit VCK with the B U D S software Use Replace ECM in the Module menu Follows instr...

Page 155: ...part in History Reprogram safety lanyard s NOTE The ECM serial number can be found on the ECM sticker that also shows the P N Continue procedure as per FINALIZING ECM RE PLACEMENT below Finalizing ECM Replacement Perform the required resets then clear all faults from the newly replaced ECM Start the engine and increase engine speed above 5000 RPM to be sure no fault appears VCM Replacement Disconn...

Page 156: ...w threads WATER TEMPERATURE SENSOR WTS Disconnect the WTS connector Loosen the WTS from the cylinder head At installation apply Loctite 518 P N 293 800 038 on threads of the WTS CRANKSHAFT POSITION SENSOR CPS Disconnect the CPS connector Loosen Allen screw retaining the CPS Remove the CPS At installation ensure to reinstall shim between crankcase and CPS smr2005 056 007 1 Shim under CPS Apply Loct...

Page 157: ...pect O rings condition before re installing fuel injectors Replace O rings with new ones if damaged When reinstalling the fuel injector install the re taining clip to the injector then insert the injector into the fuel rail Apply a thin layer of injection oil to O rings of fuel injectors to ease fuel rail installation Check injectors to ensure there is no leak WARNING If a leak is present immediat...

Page 158: ...ing mark pointer tool 295 000 135 155 VCK Vehicle Communication Kit 295 035 981 159 SERVICE PRODUCTS Description Part Number Page Loctite 243 293 800 060 149 717 ENGINE GENERAL The magneto ignition generator coil MPEM and the ignition coil work together in this Digital CDI ignition system Magneto The magneto is the primary source of electrical energy It transforms magnetic field into electric curr...

Page 159: ... timing mark on the PTO flywheel static test corresponding to the specific engine Also the timing mark scribed on the PTO flywheel can be used to troubleshoot a broken magneto woodruff key CAUTION The relation between the PTO flywheel mark and crankshaft position may change as the PTO flywheel might move on crankshaft when engine is ran This will result in false ignition timing readings If timing ...

Page 160: ... 1 2 TYPICAL 1 Tool slot 2 Flywheel mark NOTE This mark becomes the reference when verifying the ignition timing dynamic test Remove TDC gauge Reinstall spark plug and connect wire Ignition Timing Verification Dynamic Test To check ignition timing use a timing light avail able at local facilities NOTE Ensure to use a timing light capable to work with 2 stroke engines and rated up to 6000 RPM Other...

Page 161: ...sing the flush kit Check if PTO flywheel mark aligns with timing tool slot NOTE On this system timing advance decreases as engine speed increases If timing mark aligns with tool slot timing is prop erly set If mark does not align with tool slot recheck PTO flywheel mark static test before ad justing ignition timing to ensure PTO flywheel has not loosen or tightened Ignition Timing Adjustment Remov...

Page 162: ... advanced timing F01H5UA 1 1 Too advanced timing In this case turn armature plate clockwise when facing it Example 2 When PTO flywheel mark is on left side of timing tool slot it indicates retarded timing F01H5VA 1 1 Retarded timing In this case turn armature plate counterclockwise when facing it After adjustment tighten armature plate retaining screws CAUTION Armature plate screws must have Locti...

Page 163: ...harness connector Install the 4 pin magneto harness adapter P N 295 000 131 F01B28A TYPICAL Check resistance with a multimeter Refer to the following table for values and wire colors PART NAME ADAPTER WIRE RESISTANCE Generating coil BLACK with RED BLACK 40 76 F01H5WA 2 1 3 4 1 Multimeter 2 4 pin magneto harness adapter 3 RED BLACK wire 4 BLACK wire Dynamic Test 1 Connect spark plug cables to groun...

Page 164: ...014 500 start engine and check its maximum speed MODEL RPM LIMITER SETTING 717 7100 50 IGNITION COIL Static Test NOTE An ignition coil with good resistance mea surement can still be faulty Voltage leak can oc cur at high voltage level which is not detectable with an ohmmeter Primary Winding 3 1 F17H04A 2 3 1 Primary side 2 Secondary side 3 Ground plate Disconnect the wire connectors on primary sid...

Page 165: ...k high tension leads from tester to ignition coil high tension cables Connect 2 smaller tester leads to primary of ignition coil F00H14A 1 2 TYPICAL 1 Leads to secondary 2 Leads to primary Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm 276 to 311 in If there is no spark if it is weak or intermittent the coil is defective and should be replace...

Page 166: ...Section 07 ELECTRICAL SYSTEM Subsection 01 IGNITION SYSTEM 787 RFI ENGINE smr2005 057 003_aen IGNITION SYSTEM ELECTRICAL DIAGRAM smr2005 057 153 www SeaDooManuals net ...

Page 167: ...and ECM with DC current Crankshaft Position Sensor The CPS is an inductive speed sensor located on the magneto housing and is working in conjunc tion with a trigger wheel F07H0CA 1 1 Crankshaft position sensor CPS An AC voltage is generated by the sensor and is sent to the ECM to calculate the crankshaft posi tion and the engine speed For troubleshooting the CPS refer to ENGINE MANAGEMENT Engine C...

Page 168: ...k does not align with pointer tool when checking the ignition timing with an appropriate timing light dynamic test verify timing mark again static test to ensure flywheel has not moved NOTE Do not use the factory mark found on the PTO flywheel to check ignition timing or trou bleshoot any problems Normally ignition timing adjustment should not be required It has been set at factory and it should r...

Page 169: ... counterclockwise when facing it until piston is at top dead center 9 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 1 F01H4LA TYPICAL 1 Adjust gauge dial at zero From this point rotate flywheel clockwise to reach proper specification according to engine Refer to the following chart ENGINE IGNITION TIMING BTDC 787 RFI 1 02 mm 040 in Scribe a thin mark on PTO flywheel aligned with timing mark pointer tool 156...

Page 170: ...OTE Ensure to use a timing light capable to work with 2 stroke engines Connect an induction type tachometer P N 529 014 500 to spark plug wire F06H06A 1 1 Tachometer pick up Connect timing light pick up to MAG side spark plug wire F00H0HA 1 1 Timing light pick up IMPORTANT To properly check the ignition tim ing the APS and WTS must be disconnected and the timing tool installed so that timing advan...

Page 171: ... WTS water temperature sensor F07F0GA 1 1 Water temperature sensor WTS Install 787 RFI Timing tool P N 529 036 017 on WTS open connector smr2005 057 001 smr2005 057 002_a 1 WTS connector 2 Timing tool Start engine and point the beam of a timing light on mark smr2005 057 014_a 1 Timing light straight in line with tool end 158 smr2005 057 www SeaDooManuals net ...

Page 172: ... timing correction under Offset angle See illustration below smr2005 057 004_a 1 Actual angle 2 Activate arrow to change ancle When the desired offset angle has been set click the WRITE DATA button NOTE There will be an EMS Tracking message that will say Remove key from vehicle When this occurs remove the safety lanyard from its post and wait until the message disappears it lasts approximately 15 ...

Page 173: ...n still be faulty Voltage leak can occur at high voltage level which is not detectable with an ohmmeter Replacing the ignition coil may be necessary as a test Using a multimeter check the resistance in prima ry windings smr2005 057 018 PRIMARY CIRCUIT CIRCUIT TERMINAL RESISTANCE 20 C 68 F 1 and 2 Primary 2 and 3 0 3 6 If any resistance is not good replace ignition coil Secondary Winding Due to the...

Page 174: ...n ground circuit as follows Resistance Test NOTE For this test use the ECM adapter P N 420 277 010 to probe ECM connector Refer to ENGINE MANAGEMENT for more infor mation 420277010 COMPONENT IGNITION COIL CONNECTOR ECM CONNECTOR RESISTANCE 20 C 68 F Cylinder 1 MAG Pin 1 A 41 Cylinder 2 PTO Pin 3 A 1 Close to 0 If wiring connector is defective repair replace If wiring connectors are good try a new ...

Page 175: ...ed due to misfiring reduced performance and in creased fuel consumption This is due to a loss of compression Other possible causes are pro longed idling or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel The plug face of a fouled spark plug has either a dry coating of soot or an oily glossy coating given by an excess either of oil or of oil with soot Such coat...

Page 176: ...A00E0BA 2 1 1 Proper socket 2 Improper socket Spark Plug Chart ENGINE SPARK PLUG TORQUE GAP 717 and 787 RFI engines BR8ES 24 N m 17 lbf ft 0 4 0 5 mm 016 020 po NOTE Refer to next page for NGK SPARK PLUG SYMBOL EXPLANATION smr2005 057 163 www SeaDooManuals net ...

Page 177: ...2 mm 8 mm 12 mm x 19 mm Reach A B C D E J Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V Grooved Center Electrode A GV B C G L S V X Y Blank 18 mm ø 12 mm 31 64 14 mm ø 9 5 mm 3 8 F02H0MS Compact Type Projected Insulator Type Resistor Type Surface Discharge ...

Page 178: ...nto direct current DC The regulator included in the same unit limits voltage at a maximum level 14 5 to 14 8 volts to prevent any damage to components A half wave rectifier receives magneto current and transforms it into regulated current to allow bat tery charging Battery The battery is the DC source for the electric starter the Multi Purpose Electronic Module and all accessories Fuse If the batt...

Page 179: ...STEM F17H02A 1 TYPICAL 1 MPEM F17H01A FUSE IDENTIFICATION 5 A MPEM AND 15 A BATTERY F06H39A 1 2 1 TYPICAL 1 Vent tubes removed 2 Electrical box smr2005 059 006_a TYPICAL 1 Fuse Step 1 Pull tab Step 2 Pull fuse housing 166 smr2005 058 www SeaDooManuals net ...

Page 180: ... would be accurate in assuming the problem to be in the rectifier regulator If there is no charging at the battery with the pre ceding voltage test the following test can also be performed Disconnect the connector housing of the rectifier regulator Using an appropriate terminal remover Snap on TT600 4 remove the RED and BLACK wires from the tab housing of the rectifier regulator Reconnect the conn...

Page 181: ...ive probe to ground Repeat test with the other two YELLOW BLACK wires of the 4 pin magneto harness adapter NOTE There should be no continuity infinity be tween the stator insulated coils and ground If there is a reading the stator coils and or the wiring from the coils is grounded and needs to be re placed or repaired Dynamic Test AC Voltage Disconnect the voltage regulator rectifier con nector Di...

Page 182: ...Section 07 ELECTRICAL SYSTEM Subsection 02 CHARGING SYSTEM 787 RFI ENGINE Ignition System Electrical Diagram smr2005 058 001_aen smr2005 058 169 www SeaDooManuals net ...

Page 183: ...1 Rectifier regulator The rectifier receives AC current from the magne to and transforms it into direct current DC The regulator included in the same unit limits voltage at a maximum level 14 5 to 14 8 volts to prevent any damage to components The unit is using a 3 phase in series rectifier regulator which transforms AC from the magne to into DC to allow battery charging Battery The battery is the...

Page 184: ... 529 035 868 BATTERY Refer to BATTERY at the end of this section for the battery verifications RECTIFIER REGULATOR Static Test Continuity Due to internal circuitry there is no continuity test available Dynamic Test DC Current Test Proceed as follows Remove charging system fuse smr2005 058 004 Connect probes to fuse holder terminals Set multimeter to Adc Start engine Read current TEST ENGINE SPEED ...

Page 185: ...ttery will not stay charged the problem can be any of the charging system components If these all check good try a new rectifier regulator STATOR Static Test Continuity Disconnect the magneto wiring harness con nector smr2005 058 006_a Install the 4 pin magneto harness adapter P N 295 000 131 between unplugged connec tors F01B28A TYPICAL smr2005 058 006_b 1 Install adapter here between connectors ...

Page 186: ...ORTANT Leave wiring harness side dis connected 1 smr2005 058 008_a 1 Do not plug these connectors Set multimeter to Connect multimeter between YELLOW wires TERMINAL RESISTANCE 20 C 69 F Any YELLOW wire and engine ground infinity open circuit Read resistance If there is a resistance or continuity the stator coils and or the wiring is grounded and needs to be repaired or replaced Replug connectors p...

Page 187: ...rness adapter P N 295 000 131 between unplugged connec tors Connect test probes of the multimeter between YELLOW wires smr2005 058 007_b Set multimeter to Vac scale Start engine Connect multimeter between YELLOW wires TEST ENGINE SPEED TERMINAL VOLTAGE 1 and 2 1 and 3 3500 RPM 2 and 3 45 70 Vac Read voltage If voltage is out of specification replace stator Replug connectors properly 174 smr2005 05...

Page 188: ...and battery posts using a solution of baking soda and water CAUTION Do not allow cleaning solution to en ter battery Remove corrosion from battery cable terminals and battery posts using a firm wire brush Rinse with clear water and dry well Inspection Visually inspect battery casing for cracks or other possible damage If casing is damaged replace battery and thoroughly clean battery tray and close...

Page 189: ... battery condition under a starting load Use a load testing device that has an adjustable load Apply a load of 3 times the ampere hour rating of the battery At 14 seconds into the test check battery voltage if battery is in good condition it will have at least 10 5 Vdc Battery Storage CAUTION Battery storage is critical for battery life Regularly charging the battery during stor age will prevent c...

Page 190: ... fresh dry charged For storage purposes it is fitted with a temporary seal ing tube CAUTION Do not remove the sealing tube or loosen battery caps unless activation is de sired NOTE In case of accidental premature removal of caps or sealing tube battery should be given a full charge Perform the following operations anytime a new battery is to be installed Remove the sealing tube from the vent elbow...

Page 191: ...e Disconnect battery charger A17E0IB 1 3 2 Step 1 Unplug battery charger Step 2 Disconnect lead Step 3 Disconnect lead Test battery state of charge Use a hydrometer A17E0JA 1 1 Specific gravity 1 265 If electrolyte level has dropped after charging fill with distilled water to UPPER LEVEL line After water is added continue charging for 1 to 2 hours to mix water with electrolyte Reinstall caps and c...

Page 192: ...he charging rate increases Such low current flow may not be detectable on some charger ammeters and the battery will seem not to accept any charge Exceptionally for this particular case set the charger to a high rate NOTE Some chargers have a polarity protection feature which prevents charging unless the charg er leads are connected to the correct battery ter minals A completely discharged battery...

Page 193: ...7 ELECTRICAL SYSTEM Subsection 03 STARTING SYSTEM STARTING SYSTEM SERVICE PRODUCTS Description Part Number Page dielectric grease 293 550 004 193 Loctite 271 293 800 005 193 smr2005 059 181 www SeaDooManuals net ...

Page 194: ...LECTRIC STARTER EXPLODED VIEW 717 Engine F00H1PS 16 Loctite 243 15 Loctite 271 14 Ground cable 17 22 N m 16 lbf ft Loctite 243 13 22 N m 16 lbf ft 22 N m 16 lbf ft 5 N m 44 lbf in Dielectric grease 1 12 2 3 5 4 6 11 10 7 8 9 182 smr2005 059 www SeaDooManuals net ...

Page 195: ...YSTEM Subsection 03 STARTING SYSTEM 787 RFI Engine F15H01S Loctite 243 6 7 8 9 10 11 4 1 2 3 5 5 N m 44 lbf in 12 22 N m 16 lbf ft 13 17 Dielectric grease Loctite 243 16 22 N m 16 lbf ft smr2005 059 183 www SeaDooManuals net ...

Page 196: ...Section 07 ELECTRICAL SYSTEM Subsection 03 STARTING SYSTEM STARTING SYSTEM ELECTRICAL DIAGRAM RFI Models smr2005 059 001_aen 184 smr2005 059 www SeaDooManuals net ...

Page 197: ...ten commutator and brush Burnt commutator Turn commutator on a lathe Worn commutator segments Undercut mica Shorted armature Repair or replace armature Weak brush spring tension Replace brush holder or spring Weak magnet Replace yoke assembly Worn bushings Replace clutch STARTER ENGAGES BUT DOES NOT CRANK THE ENGINE Weak battery Recharge or replace battery Worn clutch pinion gear Replace clutch De...

Page 198: ...tarting system Do not place tools on battery If no beep is heard when installing the safety lan yard and gauges are not powered check the fol lowing battery voltage connections refer to CHARG ING SYSTEM fuses Power supply cut off relay 717 engine grounds safety lanyard DESS switch MPEM 717 engine ECM 787 RFI engine If other than 2 beeps are heard when installing the safety lanyard refer to DESS se...

Page 199: ...m the cut off relay to the battery ground Measure voltage Reading should be 12 V Oth erwise check wiring and if it is good replace the cut off relay If there is no current supply to the electrical com ponents while the DESS switch and the cut off relay test good check the wiring harness and connections If everything test good the MPEM could be suspected Engine Start Stop Switch Disconnect start st...

Page 200: ... measure resistance SWITCH CONNECTOR WIRE RESISTANCE 20 C 68 F BLACK BLACK YELLOW close to 0 smr2005 057 010_a If any resistance test fails replace DESS switch Solenoid 717 Engine The Solenoid is located inside the rear electrical box smr2005 059 002_a 1 Solenoid 787 RFI Engine Solenoid is located above ECM VCM smr2005 058 002_b 1 Solenoid Inspect connections and clean as necessary All Engines Sta...

Page 201: ...ug cables and connect them on grounding device NOTE This is done to avoid engine starting 1 F01H7DA 1 Grounding device Depress start stop button and while engine is cranking measure the voltage drop as follows with a multimeter SOLENOID CONNECTOR MEASUREMENT PIN VOLTAGE Post coming from battery Post going to starter 0 2 Vdc max smr2005 059 005_a TYPICAL If voltage is out of specification replace s...

Page 202: ...llar no 7 using a screw driver Remove circlip no 6 Disassemble pinion stop collar no 7 and spring no 8 A03E04A 1 1 Pinion stop collar Turn clutch assembly no 9 clockwise to remove it from armature assembly no 11 Pull housing from armature CLEANING Starter Parts CAUTION Yoke ass y and drive unit assembly must not be immersed in cleaning solvent Discard all O rings Clean brushes and holders with a c...

Page 203: ...or replaced Brush Measure brush length If less than 8 5 mm 335 in replace them NOTE New brush length is 12 mm 472 in A03E05A 1 2 1 New 2 Wear limit 8 5 mm 335 in Overrunning Clutch Pinion of overrunning clutch should turn smooth ly in clockwise direction and should not slip in a counterclockwise direction If defective replace Check pinion teeth for wear and damage If de fective replace NOTE Always...

Page 204: ... 1 TYPICAL 1 Align marks Open brushes no 4 and slide over commutator Align end frame locating notch with yoke locating protrusion and properly sit brush holder no 2 into yoke no 1 F01H0SA 1 1 Locating protrusion is the higher one F01H0TA 1 1 Brush holder locating notch To ease end frame installation retain brush hold er with a small screwdriver while installing end frame 192 smr2005 059 www SeaDoo...

Page 205: ... RED Positive Cable Retaining Nut Connect the RED positive cable to the starter and torque nut no 17 to 6 N m 53 lbf in Apply dielectric grease P N 293 550 004 on terminal and nut BLACK Negative Cable Retaining Screw and Teeth Washer Apply Loctite 271 P N 293 800 005 to screw Connect BLACK negative cable to starter using flat washer teeth washer no 15 and screw no 14 Torque screw to 22 N m 16 lbf ...

Page 206: ...6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight Approx 2 kg 4 4 lb No load 11 5 V 20 A max 5500 RPM Load 8 5 V 170 A max 2200 RPM Performance specification at 20 C 68 F Stall 5 V 350 A max 0 RPM Battery 12 V 19 Ah 194 smr2005 059 www SeaDooManuals net ...

Page 207: ...edures that requires the device to be supplied with electricity To perform verifications a good quality multimeter such as Fluke 111 P N 529 035 868 should be used 529 035 868 FUSES GTI Models Fuse are located on the Multi Purpose Electronic Module MPEM and in the rear electrical box Multi Purpose Electronic Module MPEM F17H02A 1 TYPICAL 1 MPEM Fuse identification is beside the fuse holder SPR mea...

Page 208: ... MULTI PURPOSE ELECTRONIC MODULE MPEM NOTE For models with a 787 RFI Engine refer to ENGINE MANAGEMENT for more information on VCM ECM GTI Models The MPEM is directly powered by the battery through the cut off relay It has a micro processor inside of its sealed case The MPEM features a permanent memory that will keep the programmed safety lanyard s active and other vehicle information even when th...

Page 209: ...m engine speed Digitally Encoded Security System DESS When connecting a safety lanyard cap on the switch the DESS system inside the MPEM is activated and will emit audible signals 2 short beeps indicate a right safety lanyard is being used and gauges are supplied with cur rent for 33 seconds The MPEM will thus allow the engine to start 1 long beep indicates a wrong safety lanyard is being used or ...

Page 210: ... as the chronometer dis tance etc press and hold the SET button for 2 seconds while in the appropriate mode The information center includes the following dis play areas F00L3JA 3 4 1 2 1 General display 2 Message units display 3 Warning light 4 Fuel level display General Display Repeatedly pressing the MODE button scrolls the following displays compass tachometer speedometer average speed trip met...

Page 211: ...ept for low fuel and low oil which can be cor rected by refilling it is recommended to see an au thorized SEA DOO dealer when other messages occur The warning light will blink at the same time Warning Light The red warning LED Light Emitting Diode blinks along with the message display to catch your at tention Fuel Level Display Bar gauge continuously indicates the amount of fuel in the fuel tank w...

Page 212: ...E wire which supplies the MPEM and all the electrical components When the safety lanyard is NOT on its switch the relay cuts the current supply from the bat tery to the MPEM and the electrical components thus preventing current drain that would slowly discharge the battery The relay is located in cover of electrical box First ensure the DESS switch works properly Re fer to STARTING SYSTEM Test the...

Page 213: ...E Power and speedometer signal PURPLE YELLOW Power supply 12Vdc PURPLE Ground BLACK Compass North GREEN WHITE Compass West GREEN RED Compass South GREEN YELLOW Compass East GREEN BLUE Compass supply PURPLE GREEN Compass ground BLACK GREEN Exterior temperature ground BLACK WHITE Exterior temperature signal TAN WHITE The accuracy of some features of the Information Center can be checked with a poten...

Page 214: ...ety lanyard to DESS post 6 Read fuel gauge 7 Repeat steps 1 to 6 for each potentiometer setting If out of specification check wiring harness con nectors If wiring connectors are good try a new Information Center If everything test good and fuel gauge still does not work verify continuity of circuit inside VCM as follows VCM CONNECTOR MEASUREMENT PIN RESISTANCE 20 C 68 F 5 5 5 21 Closed circuit max...

Page 215: ...below Adjust potentiometer to the resistance values as per following chart to test the accuracy of the In formation Center smr2005 060 003_b MAIN HARNESS CONNECTOR RESISTANCE TEMPERATURE C 25407 5 2 19911 10 2 15718 15 2 12495 20 2 10000 25 2 8054 30 2 6528 35 2 RESISTANCE TEMPERATURE F 22799 45 4 17262 55 4 13470 65 4 10496 75 4 8264 85 4 6528 95 4 If out of specification check wiring harness con...

Page 216: ...to end of temporary wires SENSOR TEST WIRES MEASUREMENT PIN RESISTANCE 20 C 68 F A B Resistance according to the ambient temperature See table below smr2005 060 005_b 1 Sensor test wires Remove test wires If resistance is out of specification replace sensor Otherwise perform the following procedure Exterior Temperature Input Unplug connector from temperature sensor Connect potentiometer test probe...

Page 217: ...0 007_a Remove the compass from the support Change the direction of the compass and keep it horizontal 10 There should be a change of direction on the Information Center NOTE To check the accuracy of the compass you can use a portable compass and point it in the same direction Compare the given directions they should be the same If it does not work check wiring connectors If good try a new compass...

Page 218: ...hly 5L 1 3 U S gal is left When roughly 3 L 8 U S gal is left the light will turn off The beeper will remain on until tank is refilled Refer to DIAGNOSTIC PROCEDURES for the coded sig nals The warning light will turn on whenever there is a problem with the engine management system It will blink when there is a problem with the O T A S TM system or the electric bilge pump NOTE When engine is not ru...

Page 219: ... connector and if good replace the indicator light cluster FUEL GAUGE LOW OIL WARNING LIGHT All GTI Models except GTI LE RFI The fuel gauge has a pointer which indicates fuel level in the tank The fuel level sender monitors the fuel level The low oil warning light is part of the gauge It will light when injection oil level is low The oil sensor monitors the oil level F07H0OA TYPICAL FUNCTION WIRE ...

Page 220: ... gauge If it still does not work try a new MPEM RFI Models The fuel level sender is part of the fuel pump mod ule mounted inside the fuel reservoir F07F09A TYPICAL FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL PUMP MODULE Refer to FUEL SYSTEM for fuel pump testing For fuel level sender follow procedures below Disconnect fuel pump connector Measure resistance as per table FUEL LEVEL SENDER CONNECTOR MEAS...

Page 221: ...side the oil tank and therefore in the sensor reservoir the sensor de tects the liquid and the light DOES NOT turn on When the oil level goes at critical LOW level inside the oil tank and therefore in sensor reservoir the sensor detects the absence of liquid and the light TURNS ON Unplug sensor connector Using a multimeter check the continuity as per table NOTE Wait about 15 20 seconds before taki...

Page 222: ...de bilge Using an appropriate terminal remover Snap on TT600 4 remove wires from position A and C in tab housing of speed sensor Reconnect wires in receptacle housing Connect multimeter to speed sensor wires and set it to Vdc smr2005 060 010_a 1 Wires from sensor 2 Wires to gauge SENSOR CONNECTOR TEST CONDITION PIN READING Vdc Slowly rotate paddle wheel A C Fluctuation within 5 5 8 5 ELECTRIC BILG...

Page 223: ... AND ACCESSORIES smr2005 060 012_a Using a voltmeter measure voltage as shown Battery voltage should be read smr2005 060 011_a If so replace bilge pump Otherwise check wiring connectors If they test good try a new VCM smr2005 060 211 www SeaDooManuals net ...

Page 224: ... has a magnet and a ROM chip The chip has a unique digital code The DESS circuitry in the watercraft MPEM ECM is activated at the factory Therefore a safety lanyard must be programmed to start the engine NOTE Actually it is the memory of the MPEM ECM which is programmed to recognize the digital code of the safety lanyard cap The system is quite flexible Up to eight safety lanyards may be programme...

Page 225: ...ed safety lanyard Dried salt water or dirt in safety lanyard cap Clean safety lanyard cap to remove dried salt water or dirt 1 long beep while installing safety lanyard on watercraft post or when pressing start stop button Defective DESS post Improper operation of MPEM or defective wiring harness Verify harness and connectors Try a new MPEM 787 RFI Engines CODED SIGNAL POSSIBLE CAUSE REMEDY 2 shor...

Page 226: ...de tailed information on its functions WARNING If the computer you are using is connected to the 110 Vac power outlet there is a poten tial risk of electrocution when working in con tact with water Be careful not to touch water while working with the VCK 717 Engines The MPEM programmer P N 529 035 878 is an alternative tool to communicate with the MPEM For a complete overview of this tool refer to...

Page 227: ...ram other key s install a new key on MPI DESS post and click again on ADD KEY tab Ensure to save new data in MPEM using WRITE DATA button 787 RFI Engines Locate communication connector in bilge smr2005 055 006_a 3D MODELS smr2005 055 005_a GTI RFI MODELS Unplug communication connector and plug VCK connector Connect the safety lanyard to the DESS post to activate the communication Ensure that the p...

Page 228: ...ace Possible causes are ECM is not powered up wrong protocol is used bad connection between MPI and module Read ECM using READ DATA button Click on KEYS tab smr2005 072 001_en Install key on MPI DESS post smr2005 072 002 Click on ADD KEY button on bottom of screen smr2005 072 003_Aen 1 Click on this tab A new key is now saved in the computer NOTE To program other key s install a new key on MPI DES...

Page 229: ...S A N Y K E Y PGMR indicates to plug a new key NOTE After each key entry a new number appears 2 8 3 8 Press or any key to continue K E Y O K U N P L U G K E Y The 2 beep sound indicates that key electronic number has been transferred to vehicle MPEM Unplug KEY 2 P R O G R A M K E Y 2 E R A S E K E Y S 3 S A V E Q U I T S A V E Q U I T 1 A D D K E Y S Scroll to select SAVE QUIT item Press to contin...

Page 230: ...Section 08 COOLING SYSTEM Subsection 01 COMPONENTS AND CIRCUIT COMPONENTS AND CIRCUIT SERVICE TOOLS Description Part Number Page pliers Oetiker 1099 295 000 070 228 smr2005 061 219 www SeaDooManuals net ...

Page 231: ...717 Engines F17E0ES Loctite 567 Loctite 567 Bleed hose Water injection hose Tuned pipe water inlet hose Loctite 567 Engine drain hose Engine water supply hose Engine water return hose 1 2 N m 11 lbf in Pump support Loctite 567 220 smr2005 061 www SeaDooManuals net ...

Page 232: ...O used as flushing connector Cooling System Indicator CSI Small stream of water flows out of bleed outlet located under bumper line on front port side Engine water hose outlet Pressure zone Calibrated outlet fitting limits water flow Tuned pipe bleed hose injects water into muffler to cool exhaust components Lowest point of circuit allows draining whenever engine is stopped Water injected directly...

Page 233: ...ctite 592 Loctite 592 1 2 N m 11 lbf in Water injection hose Tuned pipe water inlet hose 1 2 N m 11 lbf in Regulator valve water supply hose 2 Loctite 592 Engine drain hose Inlet Outlet 4 3 7 8 6 0 6 N m 5 lbf in 5 5 N m 44 lbf in 0 11 N m 1 lbf in Inlet Outlet Loctite 567 Loctite 567 222 smr2005 061 www SeaDooManuals net ...

Page 234: ... the tuned pipe and manifold water jackets then to the cylinder water jackets Engine water supply hose Engine heat exchanger water outlet hose exits at the exhaust outlet for noise reduction Serial cooling system cylinder head combustion chambers are cooled with the water from the jet pump Engine heat exchanger outlet Engine drain hose from cylinder heat exchanger Magneto heat exchanger outlet hos...

Page 235: ...ed pipe water jacket supply hose Cooling system indicator hose C S I Cylinder head outlet hose Engine water supply hose Engine drain hose from cylinders Engine water outlet hose Hose adaptor flushing Crankcase heat exchanger outlet hose smr2005 061 001_aen 224 smr2005 061 www SeaDooManuals net ...

Page 236: ...change inlet Cylinder head outlet hose Magneto heat exchange inlet hose Anti rollover bypass hose CAUTION Do not modify routing or hose length Engine drain hose from cylinders Crankcase heat exchange outlet hose Tuned pipe water jacket supply hose Cooling system indicator hose C S I Engine water outlet hose Engine water supply hose smr2005 061 002_aen smr2005 061 225 www SeaDooManuals net ...

Page 237: ...st manifold and cylinders 4 Water from cylinder water jackets exiting engine The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation Water is pre heated by the exhaust system before entering the cylinder cooling jackets Water enters cylinder cooling jacket through pas sages located below exhaust ports from tuned pipe F01D7HB 1 1 Water passages No water enters...

Page 238: ... water coming out of the engine heat exchang er is evacuated at the exhaust outlet for noise re duction All Models CAUTION Never modify cooling system ar rangement otherwise serious engine damage could occur Flushing Procedure Refer to STORAGE for flushing procedure of cool ing system Storage Procedure Refer to STORAGE for winterization procedure of cooling system Hull Servicing 717 Engines When s...

Page 239: ...6 94 C 187 201 F COMPONENTS Temperature Sensor NOTE This procedure must be used with 717 en gines only For the 787 RFI engines refer to EN GINE MANAGEMENT RFI The temperature sensor is located on the top of cylinder head smr2005 061 003_A 1 Temperature sensor To test the sensor unplug and remove it from en gine Put in water and heat water The temperature sensor should operate when wa ter temperatu...

Page 240: ...models so that they can produce the maximum horsepower output and yet maintain the neces sary diameter of the injection fitting at the tuned pipe head for unobstructed water flow The water flow regulator valve no 2 is mounted directly onto the muffler F01E1FA 1 2 3 TYPICAL 1 Water supply hose of regulator valve 2 Regulated water to injection fitting 3 Water injected into the muffler NOTE The water...

Page 241: ...ator valve more restriction 3 Water injected in the muffler Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified NOTE Water flow regulator valves ordered from the parts channel are also calibrated If the maximum engine speed cannot be attained or if the engine has poor performance the water flow regulator valve should be considered in the troubles...

Page 242: ...t from turning F01E1TA 1 1 Tapered needle Remove the tapered needle from valve housing F01E20A 1 1 Remove tapered needle Pull the valve slightly Using pliers release the clamp which retains the bellows no 8 Remove valve no 7 and bellows no 8 F01E21A Loosen clamp to separate valve from bellows F01E24A 1 1 Clamp smr2005 061 231 www SeaDooManuals net ...

Page 243: ...TEM Subsection 01 COMPONENTS AND CIRCUIT Inspection Inspect parts for damage Verify especially bel lows for cracks Assembly Assembly is essentially the reverse of disassem bly procedures 232 smr2005 061 www SeaDooManuals net ...

Page 244: ...aring installer tool 529 035 609 245 lift kit 295 100 206 235 pressure vacuum pump 529 021 800 249 SERVICE PRODUCTS Description Part Number Page BOMBARDIER LUBE 293 600 016 247 249 jet pump bearing grease 293 550 032 236 248 jet pump synthetic oil 293 600 011 237 246 249 Loctite 243 blue 293 800 060 236 249 Loctite 518 293 800 038 244 Loctite 567 pipe sealant 293 800 013 236 237 249 Loctite 767 an...

Page 245: ...icant Jet Pump Bearing Grease 4 10 10 20 Loctite 567 Pipe Sealant 5 Jet Pump Synthetic Oil 6 18 9 22 19 Loctite 243 21 Loctite 243 115 N m 85 lbf ft 7 5 N m 66 lbf in Synthetic Grease 21 N m 16 lbf ft 6 N m 53 lbf in 3 N m 27 lbf in Jet Pump Synthetic Oil smr2005 062 001_aen 234 smr2005 062 www SeaDooManuals net ...

Page 246: ... JET PUMP INSPECTION ON WATERCRAFT To work on watercraft securely install it on a stand Thus if access is needed to water inlet area it will be easy to slide underneath watercraft A lift kit P N 295 100 206 can be used to install watercraft on a stand F01J42A 1 2 TYPICAL 1 Lift kit 2 Work stand Impeller Condition Condition of impeller no 1 boot no 2 and wear ring no 3 can be quickly checked from u...

Page 247: ...il indicates water contamination This may involve defective impeller shaft seal no 7 and or O ring no 8 of cover Jet pump unit should be overhauled to replace seal If everything is correct apply Loctite 567 pipe sealant P N 293 800 013 on filler plug threads and reinstall it on cover Properly reinstall re moved parts Oil Replacement Remove venturi no 4 Refer further for complete procedure Remove 3...

Page 248: ...e cables re verse spring and screw retaining U lever on noz zle smr2005 062 005_A 1 Steering cable 2 Reverse cable 3 Reverse spring 4 U lever 5 Nozzle All Models In all other situations use the following procedure Remove reverse gate GTI Series refer to RE VERSE SYSTEM Remove retaining screws no 10 and withdraw venturi no 4 with nozzle Jet Pump Housing Remove venturi with nozzle Loosen 4 hexagonal...

Page 249: ...J0TA Insert the impeller remover tool in impeller splines F00J08A 1 1 Impeller remover tool Rotate impeller remover tool counterclockwise and unscrew completely impeller CAUTION Never use any impact wrench to loosen impeller To remove impeller apply a rotating movement and pull at same time Slide impeller out of hous ing Remove tool from impeller Wear Ring Remove the 4 screws no 12 retaining the w...

Page 250: ...bearings no 16 and no 17 at the same time using the bearing seal remover tool P N 295 000 144 F01J11A Insert bearing remover then press tool using a ar bor press until seal and bearings are out How ever care should be taken not to damage bearing journals F00J0MA 1 1 Bearing seal remover tool NOTE It is always recommended to renew both bearings even if only one bearing needs to be replaced CLEANING...

Page 251: ...ped or broken Such impeller is unbalanced and will vi brate and damage wear ring impeller shaft shaft seal or bearings Renew if damaged F02J0VB 1 1 Replaced if blunted round or damaged Check impeller for cavitation damage deep scratches or any other damage F02J0UA 1 1 Check for cavitation deep scratches or other damage Wear Ring Check wear ring no 3 for deep scratches irregular surface or any appa...

Page 252: ...auge 2 Measure close to threads at shaft end To check both bearings proceed the same way with other shaft end Position gauge tip on diam eter close to flats on shaft F01J19A 1 2 TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1 Dial gauge 2 Measure close to flats at shaft end Excessive play can come either from worn bear ings or impeller shaft or damaged jet pump hous ing bearing surfaces Measuring s...

Page 253: ... that lips are not worn distorted cracked or show signs of any other damage Replace after 150 hours even if it seems good ASSEMBLY Wear Ring To install ring in housing use a square steel plate of approximately 180 x 180 mm x 6 mm thick 7 x 7 in x 1 4 in and a press Manually engage ring in housing making sure it is equally inserted all around Press ring until it seats into bottom of housing F01J5DA...

Page 254: ... deformation Install screws and torque to 6 N m 53 lbf in F08J06B 1 1 Screws Seal and Needle Bearing Impeller Side Bearing no 16 and seal no 7 on impeller side will be properly installed in housing using the bear ing seal installer tool P N 295 000 107 F01J4KA 2 1 BEARING SEAL INSTALLER TOOL 1 Seal side 2 Bearing side Stamped end of bearings showing identification markings must be located toward o...

Page 255: ...o following illustration F01J5YA A 1 2 1 Seal seat 2 Stamped end of bearing A 1 5 2 5 mm 060 100 in Apply Loctite 518 P N 293 800 038 to seal hous ing all around outer diameter and on seal seat Properly insert seal on tool NOTE Apply synthetic grease P N 293 550 010 on tool to ease seal insertion Install seal with the spring toward the outside F01J1KA 1 1 Spring of seal facing tool CAUTION Prevent...

Page 256: ...housing CAUTION Never hammer the bearing into its housing F16J09A 1 1 Press on tool until it stops CAUTION These tools have been designed to properly position bearing thus provid ing space for lubrication purposes The tool flanges allow this If a different pusher type is being used components must be properly positioned as follows Bearing on venturi side must be 2 to 4 mm 080 157 in inside reservo...

Page 257: ...To prevent seal lip damage when inserting im peller shaft no 13 use the impeller shaft guide P N 295 000 002 F01J1OA Insert tool onto shaft end then carefully install shaft in jet pump housing F00J0FA 1 2 1 Impeller shaft 2 Impeller shaft guide NOTE If jet pump housing rest against a table raise it slightly to allow complete shaft insertion with the shaft guide Remove shaft guide Impeller Apply Lo...

Page 258: ...es on impeller shaft threads Carefully engage threads making sure they are well aligned Install the impeller remover installer tool P N 295 000 001 into impeller splines and tighten F00J08A 1 1 Impeller remover installer tool CAUTION Make sure thrust washer and bear ing are not wedged in shaft groove To check manually pull and push jet pump housing some axial play must be felt Torque impeller to 1...

Page 259: ...ther plastic tool in the hole and push on the slider tab CAUTION Do not use a metal tool to push the tab It is possible to damage the inner threads Hold tab and torque screws Remove pencil or tool to release locking mecha nism Check if the mechanism worked properly Push tab with the pencil or tool if there is a small play the installation is correct If not redo the proce dure Verify if the impelle...

Page 260: ...ller plug then secure it in cover INSTALLATION Jet Pump Housing Generously apply synthetic grease P N 293 550 010 on drive shaft splines Make sure rubber damper is on drive shaft end Install jet pump If necessary wiggle jet pump to engage drive shaft splines in impeller CAUTION Some watercraft require a shim between hull and pump if shim has been re moved at pump removal be sure to reinstall it ot...

Page 261: ...09 PROPULSION Subsection 01 JET PUMP F02J0TA 1 1 1 Torque screws to 21 N m 16 lbf ft Steering Cable Refer to STEERING SYSTEM Reverse Gate and Cable Refer to REVERSE SYSTEM 250 smr2005 062 www SeaDooManuals net ...

Page 262: ...r tool 295 000 107 262 263 bearing seal remover tool 295 000 144 260 Caillau pliers 295 000 054 254 Oetiker pliers 1090 295 000 069 253 support plate kit 529 035 570 264 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 265 266 Loctite 518 293 800 038 263 synthetic grease 293 550 010 257 263 266 smr2005 063 251 www SeaDooManuals net ...

Page 263: ...9 PROPULSION Subsection 02 DRIVE SYSTEM GTI SERIES Synthetic grease 1 2 N m 18 lbf in 2 3 8 6 14 11 12 7 10 4 5 13 9 13 Synthetic grease Synthetic grease smr2005 063 001_aen 252 smr2005 063 www SeaDooManuals net ...

Page 264: ...000 069 F01J0GA Insert pointed tips of pliers in closing hooks 1 F01J2AA TYPICAL 1 Closing hooks Squeeze pliers to draw hooks together and dis engage windows from locking hooks 1 F01J29A TYPICAL 1 Locking hooks Secure large clamp as follows Manually engage holding hook in large window This is a pre clamping position only F01J23A 1 2 PRE CLAMPING POSITION 1 Holding hook 2 Large window Insert pointe...

Page 265: ...irection of engine rotation F01J23B 1 2 1 Engine rotation counterclockwise 2 Tail in opposite direction Small Clamp Unfasten small clamp no 3 of PTO flywheel boot as follows Use Caillau pliers P N 295 000 054 F01B1TA To open clamp place flat side of pliers on clamp embossment squeeze and twist pliers F02J0PA To secure small clamp do the following Place notch side of pliers on clamp embossment and ...

Page 266: ...o 11 from hull insert Carbon Ring Loosen gear clamp no 12 then pull carbon ring no 11 from boot no 7 INSPECTION Drive Shaft Inspect condition of drive shaft and PTO flywheel splines Inspect condition of groove With your finger nail feel machined surface of drive shaft If any irregular surface is found re new drive shaft F01I0FA 3 2 1 1 Surface condition 2 Groove condition 3 Splines condition Exces...

Page 267: ...t must be installed Measure boot length when normally installed on drive shaft Ensure circlip no 8 is properly in stalled into groove F00J03A 1 A 1 Boot A Measure here Push floating ring no 6 to compress boot no 7 then remove circlip no 8 out of drive shaft groove F06I06A 1 2 1 Push floating ring 2 Remove circlip Slide floating ring far enough forward in order to release it from carbon ring no 11 ...

Page 268: ...to install floating ring before inserting the drive shaft in the PTO flywheel While holding jet pump guide and engage drive shaft splines in PTO flywheel Rotate shaft to properly index splines Make sure boot no 2 is well positioned over shaft end Circlip Push the floating ring no 6 to compress the boot no 7 Insert the circlip no 8 in the drive shaft groove F06I06A 1 2 1 Push floating ring 2 Insert...

Page 269: ... in 15 28 19 Loctite 271 Loctite 243 Loctite 243 27 22 N m 16 lbf in Bilge pump support 20 26 Loctite 518 31 17 18 14 18 16 Loctite 518 See sequence inside 8 6 25 22 23 7 21 10 24 2 N m 18 lbf in Synthetic grease Synthetic grease Synthetic grease Synthetic grease Synthetic grease 9 N m 80 lbf in Synthetic grease Synthetic grease smr2005 063 002_aen 258 smr2005 063 www SeaDooManuals net ...

Page 270: ...e is held with 2 hexagonal bolts M6 no 3 and the flywheel with 2 wing nuts no 4 and on the top with an hexagonal screw no 5 1 3 2 4 5 4 smr2005 063 003_a 1 Link plate 2 Flywheel guard 3 Link plate bolt 4 Wing nuts 5 Flywheel guard bolt Circlip and Floating Ring Remove the rear access panel Remove clamps from exhaust hoses where shown F22D06A 1 1 1 Disconnect those clamps Pull out T fitting with ho...

Page 271: ...Bearing To remove the seal carrier housing no 14 from support no 15 loosen the 6 nuts no 16 F05I05A 1 TYPICAL 1 Nut 6 Bearing no 17 and seals no 18 can be easily removed using the bearing seal remover tool P N 295 000 144 F01J11A NOTE The same tool is used for bearing and seals removal of jet pump Properly support seal carrier housing no 14 when removing seals and bearing Remove bushings no 19 fro...

Page 272: ...15A MEASURING DRIVE SHAFT DEFLECTION 1 Dial gauge 2 V blocks Front Drive Shaft Check condition of front drive shaft no 13 Check condition of couplers Replace front drive shaft if necessary Damper Visually inspect shape of damper no 24 for defor mation or other damage Floating Ring and O Ring Inspect condition of O rings no 25 and contact surface of floating ring no 6 F01I0GA 1 2 1 O rings 2 Floati...

Page 273: ...install a spacer P N 293 250 017 between boot and hull fitting F00J04B 1 1 Spacer NOTE Drive shaft must be removed to install spacer Seal Carrier of Mid Bearing Inspect seal carrier needle bearing no 17 Check parts for scoring pitting chipping or other evi dence of wear Inspect seals no 18 for deterioration or excessive wear Replace if necessary ASSEMBLY Seal Carrier of Mid Bearing Properly suppor...

Page 274: ...sed edge of lip must be located outwards of seal carrier F01J2FA 2 1 3 4 3 TYPICAL 1 Double lip seal toward engine 2 Double lip seal with protector toward jet pump 3 Raised edge of lip outwards 4 Seal carrier Apply Loctite 518 P N 293 800 038 all around seals outside diameter Seals no 18 can be carefully installed in housing using the bearing seal installer tool P N 295 000 107 Push seals until to...

Page 275: ...roperly index alignment washers no 20 together Install the large washer no 26 and nuts no 16 Slightly tighten nuts but keep loose so that the as sembly still can move and self adjust when insert ing the alignment shaft further in this procedure NOTE Completely tightening nuts would make the alignment more difficult Align the seal carrier using the following tools support plate kit P N 529 035 570 ...

Page 276: ...a criss cross sequence For horizontal alignment loosen shaft support screws no 29 and move the support no 15 sideways as necessary 2 1 F00B26A TYPICAL 1 Shaft support 2 Loosen screws on both sides When done ensure to apply Loctite 243 blue P N 293 800 060 on screw threads then torque screws to 22 N m 16 lbf ft in a criss cross se quence NOTE Ensure the alignment washers are still loose Check engin...

Page 277: ...blue P N 293 800 060 on studs and install nuts no 16 Refer to following illustration for tightening se quence Torque 1 to 6 at 3 N m 27 lbf in and then 7 to 12 at 10 N m 89 lbf in NOTE It is very important to tighten nuts of seal carrier in this sequence to maintain its alignment F00B25B 9 4 7 2 11 6 10 3 8 1 12 5 TIGHTENING SEQUENCE Reinstall shaft guard no 9 Apply Loctite 243 blue P N 293 800 06...

Page 278: ...Section 09 PROPULSION Subsection 03 REVERSE SYSTEM REVERSE SYSTEM SERVICE PRODUCTS Description Part Number Page synthetic grease 293 550 010 271 smr2005 064 267 www SeaDooManuals net ...

Page 279: ...f in 24 Synthetic grease 28 30 29 Loctite 243 2 N m 18 lbf in 2 5 N m 22 lbf in 26 25 Loctite 243 20 19 10 N m 89 lbf in 14 11 2 5 N m 22 lbf in 15 18 17 15 16 7 N m 62 lbf in 7 5 4 2 2 5 N m 22 lbf in 4 1 32 3 31 10 12 24 N m 17 lbf ft 13 9 6 8 2 5 N m 22 lbf in 2 5 N m 22 lbf in 2 5 N m 22 lbf in 27 Loctite 243 smr2005 064 001_en 268 smr2005 064 www SeaDooManuals net ...

Page 280: ...Pivot bolt 2 Pivot support 3 Reverse gate 4 Pivot support bolt Withdraw pivot support no 5 Connecting Rod Remove reverse gate pivot bolt no 6 holding connecting rod no 7 to pivot triangle no 8 Withdraw connecting rod Pivot Triangle Remove reverse gate connecting rod pivot triangle bolts no 9 Withdraw pivot triangle no 8 Pivot Arm Position shift lever in forward Remove reverse gate connecting rod r...

Page 281: ... rings no 20 Remove the seat and the glove box Refer to HULL BODY On the interior lever no 21 unscrew the elastic stop nut no 22 and remove the washer no 23 retaining the reverse cable Remove the retaining bracket no 24 NOTE Before removing reverse cable no 11 from hull note cable routing for reinstallation 1 F18J1JA 2 3 4 1 Interior lever 2 Elastic stop nut and washer 3 Reverse cable 4 Retaining ...

Page 282: ...reverse cable support no 28 bolts no 29 Then remove handle housing no 30 INSPECTION Visually inspect parts for wear or cracks on friction parts Replace all defective parts ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Insert interior lever cursor into reverse cable sup port slider and make sure that the cursor slides freel...

Page 283: ... the pivot triangle turns freely Reverse Gate Install reverse gate with spacers no 31 and wash ers no 32 Torque reverse gate bolts no 3 to 20 N m 15 lbf ft ADJUSTMENT Put shift lever in forward position WARNING When adjusting reverse cable make sure lever is well engaged into the spring slot Place reverse gate in the up position Turn the joint no 18 at the end of reverse cable and align its hole w...

Page 284: ...Section 09 PROPULSION Subsection 04 VARIABLE TRIM SYSTEM VARIABLE TRIM SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 276 smr2005 065 273 www SeaDooManuals net ...

Page 285: ...9 PROPULSION Subsection 04 VARIABLE TRIM SYSTEM 3D PREMIUM F22J07S 6 7 8 9 5 4 3 2 1 3 10 12 11 12 10 N m 89 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 24 N m 18 lbf ft 274 smr2005 065 www SeaDooManuals net ...

Page 286: ...turi smr2005 065 003 Adjustment System Remove nut no 1 bolt no 2 flat washers no 3 and bushing no 4 from pivot no 5 smr2005 065 001 Unscrew the upper right venturi bolt then remove the adjustment system DISASSEMBLY Adjustment System Loosen nut no 6 from support no 9 Remove rubber spacer no 7 and half bushings no 8 Unscrew adjustment knob no 10 from pivot no 5 INSPECTION Inspect each parts for crac...

Page 287: ...eginning of this subsection as a guideline and for torque specification INSTALLATION The installation is the reverse of the removal pro cedure Trim Ring During trim ring installation apply Loctite 243 blue P N 293 800 060 on socket screw threads Torque socket screws no 12 to 24 N m 18 lbf ft Adjustment Screw Torque screws no 2 to 10 N m 89 lbf in 276 smr2005 065 www SeaDooManuals net ...

Page 288: ...on 01 STEERING SYSTEM STEERING SYSTEM SERVICE TOOLS Description Part Number Page steering cable tool 295 000 145 282 292 SERVICE PRODUCTS Description Part Number Page synthetic grease 293 550 010 300 smr2005 066 277 www SeaDooManuals net ...

Page 289: ... m 35 lbf in 5 N m 44 lbf in Loctite 243 6 N m 53 lbf in 6 N m 53 lbf in Loctite 243 Loctite 243 26 N m 19 lbf ft 7 N m 62 lbf in 4 5 2 5 N m 22 lbf in 30 10 11 32 29 34 33 9 2 5 N m 22 lbf in 5 N m 44 lbf in Synthetic grease 22 26 25 13 N m 115 lbf in Loctite 243 8 N m 71 lbf in 7 N m 62 lbf in 13 14 15 17 18 16 1 N m 9 lbf in 31 smr2005 066 001_aen 278 smr2005 066 www SeaDooManuals net ...

Page 290: ...TE Verify grip insert for damage Steering Cover Remove grips no 1 Loosen set screws no 6 of handlebar housings no 7 and no 8 F00K01A 1 1 Set screw Remove 4 screws no 9 F00K02A 2 1 TYPICAL 1 Cover 2 Screws Remove 2 screws no 10 and flat washers no 11 each side of cover no 12 1 F07K0JA 1 Remove screws Remove cover Steering Padding Remove steering cover no 12 Remove 2 screws no 13 and flat washers no...

Page 291: ...remove handle bar no 5 from steering stem no 17 and steering clamp no 18 2 F18K0HA 3 4 1 1 1 Nuts 2 Handlebar 3 Steering stem 4 Steering clamp Steering Cable Support Loosen bolts no 19 and remove retaining block no 20 1 F18K0IA 1 Retaining block Loosen bolts no 21 each side of steering support no 22 F07K02A 1 2 LEFT SIDE 1 Steering support 2 Bolt 280 smr2005 066 www SeaDooManuals net ...

Page 292: ...ke cables from carburetor or disconnect throttle cable from throttle body Disconnect the wiring harnesses leading out of steering stem no 17 and cut locking tie F07K05A 2 1 1 Tie rap 2 Connectors Disconnect the steering cable from the steering stem arm no 24 F07K06A 1 2 1 Steering stem arm 2 Steering cable Remove bolts no 21 retaining cable support no 23 to steering support no 22 Remove bolts no 2...

Page 293: ... 33 and O ring no 34 NOTE To loosen nut use the steering cable tool P N 295 000 145 Remove steering cable from watercraft Note its routing for proper installation Nozzle Disconnect steering cable from jet pump nozzle Remove reverse gate refer to REVERSE SYSTEM U lever bolt located under nozzle smr2005 062 003 nozzle bolts retaining nozzle to venturi nozzle Remove nozzle ASSEMBLY Assembly is essent...

Page 294: ...ke sure the integrated flat keys of the steer ing stem arm and support are properly seat ed in steering stem keyways Steering stem arm must be locked in place before torquing the bolts F07K09A 2 1 2 1 Keyways 2 Integrated flat key Replace lock nuts no 35 by new ones Torque bolts no 19 of steering stem arm to 6 N m 53 lbf in Handlebar Position handlebar no 5 Install steering clamp no 18 and secure ...

Page 295: ...e distance from handlebar grip end to floorboard F01K07A 1 TYPICAL 1 Measuring handlebar grip end floorboard distance Check jet pump nozzle position by placing a straight edge on nozzle outer end Measure the distance on each side of the straight edge It must be equalled F01J5ZA 1 TYPICAL 1 Measure the distance on each side of the straight edge If necessary steering alignment adjustment should be p...

Page 296: ...ERING SYSTEM After adjustment torque retaining block bolts no 19 to 6 N m 53 lbf in CAUTION Verify when the handlebar is turned completely to the left or right side that there is no interference with venturi smr2005 066 285 www SeaDooManuals net ...

Page 297: ... 10 N m 89 lbf in 16 18 27 19 10 N m 89 lbf in 50 11 20 23 22 21 13 49 Loctite 243 33 21 N m 15 lbf ft 28 7 N m 62 lbf in 36 34 21 N m 15 lbf ft 26 25 48 4 31 7 N m 62 lbf in 35 50 44 14 3 43 45 3 10 N m 89 lbf in 2 5 N m 22 lbf in 47 46 2 5 N m 22 lbf in Synthetic grease Synthetic grease smr2005 066 002_aen 286 smr2005 066 www SeaDooManuals net ...

Page 298: ...Section 10 STEERING SYSTEM Subsection 01 STEERING SYSTEM 11 N m 97 lbf in 38 42 41 39 2 37 24 19 N m 168 lbf in 5 40 smr2005 066 003_aen smr2005 066 287 www SeaDooManuals net ...

Page 299: ...nd smoothly without resistance If steer ing pole feels too heavy it can be adjusted with the return spring no 2 If it does not help the re turn spring no 2 could be broken F22L0BA 1 1 Steering pole Lower steering pole to the lowest position and try moving it from side to side to detect any excessive play If excessive play is felt check bushings no 3 in steering support no 4 and or bushings no 5 ne...

Page 300: ...set screws no 11 of handlebar housings no 12 and no 13 F22K0MA 1 2 1 2 1 Cover 2 Screw RH Cover Unhook throttle cable F22K0NA F22K0OA Pull out throttle housing no 12 Remove cover no 14 LH Cover Pull out start stop switch housing no 13 Remove switches from housing Remove cover no 15 smr2005 066 289 www SeaDooManuals net ...

Page 301: ... Adjuster Lift cover of steering padding support no 16 F22K0QA Remove screws no 17 upper clamps no 18 and handlebar no 1 F22K0RA Remove screws no 19 of adjuster blocks no 20 F22K0SA Remove spring no 21 steering padding support no 16 then latch lever no 22 F22K0UA 290 smr2005 066 www SeaDooManuals net ...

Page 302: ...3 for wear or other damage F22K0TA Steering Stem and Support Remove top cover no 24 F22K0YA Detach steering cable switch harness and throttle cable from steering support Remove OTAS switch F22K0CA Raise steering pole Unbend lock tab no 25 then unscrew steering stem screw no 26 smr2005 066 291 www SeaDooManuals net ...

Page 303: ... nozzle then from cable Use the steering cable tool P N 295 000 145 and remove nut no 34 then remove half rings no 35 and O ring no 36 Raise steering pole Cut locking ties as required to allow puling out steering cable Remove steering pole to be able to pull steering cable out of bilge See below Steering Pole Raise and lock steering pole with its retainer Cut locking ties as required then pull thr...

Page 304: ...ng pole Remove front cover in the following step order CAUTION Work carefully when releasing lock ing tabs from cover to avoid damaging cover Remove side screws F22K14A Release rear metal tabs F22K15A INNER FOAM REMOVED FOR CLARITY PURPOSE Using the provided openings release side metal tabs while pulling cover outward smr2005 066 293 www SeaDooManuals net ...

Page 305: ...Section 10 STEERING SYSTEM Subsection 01 STEERING SYSTEM F22K1CS 1 1 Side opening Push cover forward then lift front part to unlock cover 294 smr2005 066 www SeaDooManuals net ...

Page 306: ...Section 10 STEERING SYSTEM Subsection 01 STEERING SYSTEM F22K1DS 2 1 For the center rear locks push plastic tabs rearward to release F22K1JS smr2005 066 295 www SeaDooManuals net ...

Page 307: ...ally the reverse of disassem bly procedures However pay particular attention to the following CAUTION Apply all specified torques and ser vice products as per main illustration at the be ginning of this subsection Nozzle Install nozzle trim ring assembly Torque screws to 24 N m 17 lbf ft NOTE Trim ring has a tight fit to install insert both sides at the same time taking care not to break plastic b...

Page 308: ...y in bilge Steering Stem and Support Position steering support no 4 onto steering pole Lubricate moving parts and bushings no 3 Position washers no 43 against top nuts no 44 Install steering pole retainer no 45 on bottom screws F22K1SA 1 2 1 Washers against nuts here 2 Steering pole retainer against nuts here Torque screws no 28 of steering support in a criss cross sequence Ensure spring washer no...

Page 309: ...1 Rounded edge on backside 2 Small tab into hole of washer Torque screw no 26 then bend tab lock edge against a flat side of screw head 1 F22K0ZA 1 Tab lock edge against flat side of screw head Properly route wiring harness and steering cable in steering support notches First install latch lever no 22 then steering padding support no 16 F22K1VA 298 smr2005 066 www SeaDooManuals net ...

Page 310: ...tle cable to steering support with clamp no 49 F22K25A Handlebar and Adjuster When installing blocks no 20 on handlebar en sure to position block pin into handlebar hole NOTE Block must be centered on handlebar If not it is in reverse position F22K1WA Torque screws no 19 as per the following se quence smr2005 066 299 www SeaDooManuals net ...

Page 311: ...22K1YA Install pin no 23 Hold latch lever depressed F22K1ZA Install handlebar on steering support then upper clamps no 18 Position pin no 23 into slots of blocks no 20 F22K20A Using synthetic grease P N 293 550 010 lubricate pin no 23 and the notches on blocks no 20 Position handlebar vertically then torque screws no 17 in a criss cross sequence Snap cover of steering padding support no 16 on scre...

Page 312: ...screw no 8 Torque screw to 7 N m 62 lbf in Install cap no 7 F02K0KA 1 2 4 5 3 TYPICAL 1 Grip insert 2 Grip 3 Flat washer 4 Screw Torque to 7 N m 62 lbf in 5 Cap CAUTION Ensure to install flat washer other wise screw will damage grip end Ball Joint Secure the steering cable ball joint no 33 to the nozzle as per following illustration CAUTION Ensure the ball joint is parallel to the nozzle arm withi...

Page 313: ...ring each side the distance from handlebar grip end to floorboard F22J06A 1 1 Measuring handlebar grip end floorboard distance Check jet pump nozzle position by placing a straight edge on nozzle outer end Measure the distance on each side of the straight edge It must be equalled F01J5ZA 1 TYPICAL 1 Measure the distance on each side of the straight edge If necessary steering alignment adjustment sh...

Page 314: ...justment nut 3 Loosen bolts After adjustment torque retaining block bolts to 5 N m 44 lbf in CAUTION Verify when the handlebar is turned completely to the left or right side that there is no interference with venturi or VTS ring Reinstall top cover smr2005 066 303 www SeaDooManuals net ...

Page 315: ...EERING O P A S OFF POWER ASSISTED STEERING O P A S SERVICE TOOLS Description Part Number Page O P A S cylinder nut wrench 529 035 840 308 SERVICE PRODUCTS Description Part Number Page silicone sealant clear 293 800 086 309 310 smr2005 067 305 www SeaDooManuals net ...

Page 316: ...Section 10 STEERING SYSTEM Subsection 02 OFF POWER ASSISTED STEERING O P A S GTI Models 2 9 22 23 21 18 20 19 17 19 14 15 16 13 12 11 10 smr2005 039 002_Ben 306 smr2005 067 www SeaDooManuals net ...

Page 317: ...ne Removal Removal procedure for RH and LH side vane no 1 is same Remove socket screw no 2 1 F18K0MA TYPICAL 1 Socket screw Remove the tie rod screw no 3 1 2 F18K0LA 4 3 TYPICAL 1 Tie rod screw 2 Side vane 3 Cylinder support 4 Tie rod fitting Lift pivot shaft no 4 while holding top of side vane Pull side vane out Adjustment During tie rod fitting adjustment tie rod screw no 3 must be loosed and so...

Page 318: ...for RH and LH cylinder sup port assembly is same Remove side vane as mentioned above NOTE To disassemble the cylinder it is not re quired to remove it from vehicle See DISASSEM BLY AND ASSEMBLY procedure Unscrew tie rod fitting no 5 from tie rod no 7 Unscrew 4 socket screws no 8 Discard them F18K0PA 1 1 1 Socket screws Disassembly and Assembly Unscrew cylinder cap no 9 using the O P A S cylinder n...

Page 319: ...rod Installation Installation is the reverse process of removal Torque screw no 14 to 7 N m 62 lbf in Torque O P A S U lever screw no 10 to 20 N m 15 lbf ft Sealed Tube Removal Removal procedure for RH and LH sealed tube no 18 is the same Remove side vane no 1 cylinder housing no 6 and O P A S U lever no 16 as mentioned above Remove jet pump refer to JET PUMP Remove Phillips screws no 19 and remov...

Page 320: ...oss support plate from the inside of bilge Inspection Check for cracks and deterioration of screw threads on cross support plate replace if neces sary Verify the condition of gasket no 23 before instal lation change if necessary 1 F18K1BA 2 1 Gasket 2 Support plate Installation Assembly is the reverse process of disassembly make sure of the following when doing assembly Install the gasket on the c...

Page 321: ...h the watercraft in the water regular riding or jet pump in water with watercraft attached on a trailer and using the digital tachometer P N 529 014 500 Make sure the path ahead is clear Raise engine RPM higher than 4000 RPM for more than 1 second Release 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 o...

Page 322: ...r Perform the following tests for left and right sides Using the multimeter FLUKE 111 P N 529 035 868 measure the resistance between the BLACK WHITE and BLACK wires of switch while steering is roughly at its center position Resistance should be between 446 5 and 493 5 Otherwise check wiring harness and if good re place switch Turn steering until it is blocked by its stopper Keep steering in this p...

Page 323: ...rottle Opening under Monitoring tab Position and hold the mouse pointer over the nee dle of the throttle opening to get the actual value The value should be 17 3 1 If not adjust ca ble at solenoid bracket to get the value F22H0HA Value 17 3 MIN MAX Throttle Opening THROTTLE OPENING GAUGE IN BUDS If B U D S is not available resistance can be mea sured with an ohmmeter on wires going to the TPS Disc...

Page 324: ...Section 10 STEERING SYSTEM Subsection 03 OFF THROTTLE ASSISTED STEERING O T A S F22H0BB 2 1 1 O T A S solenoid 2 Adjust here 314 smr2005 068 www SeaDooManuals net ...

Page 325: ...ERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 321 323 327 Loctite 271 red 293 800 005 324 Loctite 518 293 800 038 325 Loctite 5900 293 800 066 324 325 silicone sealant clear 293 800 086 326 327 smr2005 069 315 www SeaDooManuals net ...

Page 326: ... GTI SERIES Bow Silicone sealant 8 N m 71 lbf in 4 N m 36 lbf in 8 N m 71 lbf in 8 N m 71 lbf in 8 N m 71 lbf in Silicone sealant 15 N m 133 lbf in Body 4 5 3 5 N m 44 lbf in 22 smr2005 069 001_aen 316 smr2005 069 www SeaDooManuals net ...

Page 327: ...lbf in 16 Silicone sealant 18 17 17 19 8 N m 71 lbf in 15 N m 133 lbf in 2 2 N m 19 lbf in Loctite 5900 10 N m 89 lbf in Loctite 243 8 N m 71 lbf in 21 20 8 N m 71 lbf in Silicone sealant Silicone sealant 2 smr2005 069 002_aen smr2005 069 317 www SeaDooManuals net ...

Page 328: ... 36 lbf in 7 5 N m 44 lbf in Loctite 243 15 N m 133 lbf in LE models Loctite 243 Synthetic grease 4 N m 36 lbf in 3 N m 26 lbf in 8 N m 71 lbf in 4 N m 36 lbf in 4 N m 36 lbf in 6 12 13 8 8 N m 71 lbf in 8 N m 71 lbf in 15 10 11 9 1 smr2005 069 003_aen 318 smr2005 069 www SeaDooManuals net ...

Page 329: ...Section 11 HULL BODY Subsection 01 GTI SERIES Seats F07L2OS GTI seats Loctite 414 smr2005 069 319 www SeaDooManuals net ...

Page 330: ...o plas tic cracks or other damage PROCEDURES GLOVE BOX Removal Remove handle from shift lever 1 F16L07A 1 Unscrew Remove darts and then remove side panels 1 F16L08A 1 Unscrew the darts Open front storage cover no 1 and remove the access panel no 2 Detach the latch no 3 retaining vent tube no 4 to bracket no 5 1 F17L0OA 1 Unlatch Pull vent tube out From the engine compartment insert a hand through ...

Page 331: ...h a self locking product do not apply Loctite 243 on threads A 2 F17L0PA 1 FRONT SEAT 1 Lock pin 2 Adjustment nut apply Loctite 243 Torque to 8 N m 71 lbf in A 34 1 mm 1 11 32 3 64 in A 2 F17L0QA 1 REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 243 Torque to 8 N m 71 lbf in A 34 1 mm 1 11 32 3 64 in STORAGE COMPARTMENT INNER SHELL Removal To remove inner shell no 6 proceed as follows CAUTION ...

Page 332: ...ge cover shock no 8 proceed as follows WARNING Make sure to have a 2 x 4 piece of wood around the work bench to support the stor age cover while changing the cover shock Unlock shock rod no 9 from circlip no 10 and remove washer no 11 F18L1NA 1 3 2 1 Shock rod 2 Circlip 3 Washer Release the shock from top linkage bracket no 12 and bottom support bracket no 13 by inserting a flat screwdriver in the...

Page 333: ...ly Loctite 243 Torque to 4 N m 36 lbf in A 13 6 1 mm 1 17 32 3 64 in NOTE Before torquing move pin forward until it s rested against the body MIRROR Removal and Installation To remove mirror proceed as follows Remove storage compartment inner shell no 6 from storage cover no 1 as described earlier in this section Remove two hexagonal screws no 15 and flat washers Remove defective mirror with a spa...

Page 334: ...smr2005 069 008_a RIDING PLATE Removal Remove inlet grate Remove jet pump Refer to JET PUMP Remove the speed sensor from the riding plate if applicable Loosen riding plate screws NOTE An impact screwdriver should be used to loosen tight screws Using a low height hydraulic bottle jack and 2 steel plates pry out riding plate F05J03A 2 1 TYPICAL 1 Hydraulic bottle jack 2 Steel plates Cleaning Scrape ...

Page 335: ...move nuts lock washers and flat washers re taining jet pump support F07L0AA 1 TYPICAL 1 Remove nuts Using a heat gun heat jet pump support until it is possible to pull it NOTE Shims may have been installed between support and body Do not remove these shims otherwise jet pump alignment will be altered Installation Ensure to position the longest threaded portion of studs towards the jet pump Apply L...

Page 336: ... Remove the old seat cover Check the foam and replace it if necessary Install staples with an electric tacker such as Ar row tacker no ETN 50 or with a manual tacker such as Arrow tacker no T 50 NOTE For an easier installation it s highly recom mended to use an electric tacker Ensure that the seat rest firmly against a hard sur face such as a piece of wood This is done to get the staples completel...

Page 337: ...ponson is same Removal Unscrew sponson bolts then remove sponson no 22 smr2005 024 014_A 1 Sponson 2 Bolts Clean any residues of silicone sealant on hull and sponson Installation Apply silicone sealant clear P N 293 800 086 around sponson adaptors Apply Loctite 243 blue P N 293 800 060 on sponson bolt threads Install sponson and torque sponson bolts to 7 N m 62 lbf in SPONSON ADAPTOR NOTE Removal ...

Page 338: ...ITTING For hull insert repair proceed as follows Cut plastic hull insert flush with hull using a saw F01L2UA 1 2 1 Hull 2 Plastic hull insert Mix epoxy glue 3M 05895 follow manufacturer instructions Apply epoxy glue on aluminum insert P N 292 000 075 knurled surface and on plastic insert inner bore CAUTION If you notice any clearance between plastic insert and aluminum insert fill gap with epoxy g...

Page 339: ...cal will be located Remove half of the decal back protective film and align decal with marks Start sticking it from cen ter and remove the other half of the film to stick it completely Carefully squeegee decal beginning at center and working outward using firm short overlapping strokes DECALS HAVING A PROTECTIVE FILM ON BOTH SIDES These decals usually contain graphics and are used on gelcoat or pl...

Page 340: ...If needed sand the cavity itself These areas must have a rough surface to allow the gelcoat putty to bond properly FILLING THE CAVITY The prepared surface must be cleaned with ace tone on a cloth Use a gelcoat repair kit Follow the mixing instructions in 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...

Page 341: ...dust PVA speeds up the curing process because gel coat will not cure properly when exposed to air SANDING Wash the polyvinyl alcohol off with water De pending on the size of the area repaired you can either block sand as per previous procedure or you may use an air sander Sand the surface down with progressively finer grits of sandpaper until the desired finish is achieved BUFFING AND WAXING Buff ...

Page 342: ...pening is too large for the pieces to maintain the proper shape you will have to use a backing support It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side It is held in place by tape or a support Inside Wipe down the area with acetone on a cloth Ap ply the same procedure as for outside repair when laminating the alternating pieces of...

Page 343: ... tool 529 034 600 340 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 345 Loctite 271 red 293 800 005 342 Loctite 518 293 800 038 344 Loctite 5900 293 800 066 342 344 Scratch Remover Kit 861 774 800 341 silicone sealant clear 293 800 086 344 346 smr2005 069 333 www SeaDooManuals net ...

Page 344: ...ction 02 3D SERIES Hull 8 15 N m 133 lbf in 15 N m 133 lbf in 2 N m 18 lbf in 7 15 14 5 N m 44 lbf in Silicone sealant Silicone sealant Silicone sealant Silicone sealant smr2005 069 011_aen 334 smr2005 069 www SeaDooManuals net ...

Page 345: ...243 2 N m 18 lbf in 4 5 N m 40 lbf in 4 5 N m 40 lbf in 4 5 N m 40 lbf in 1 7 N m 15 lbf in See inside for torque and sequence 12 2 5 N m 22 lbf in 13 5 N m 120 lbf in 11 11 N m 97 lbf in 13 11 13 9 10 11 smr2005 069 012_aen smr2005 069 335 www SeaDooManuals net ...

Page 346: ...Section 11 HULL BODY Subsection 02 3D SERIES Engine Cover 5 N m 44 lbf in 4 N m 36 lbf in smr2005 069 013_aen 336 smr2005 069 www SeaDooManuals net ...

Page 347: ...N m 44 lbf in 4 15 N m 133 lbf in 5 7 N m 62 lbf in Loctite 243 Loctite 243 4 2 N m 37 lbf in 7 N m 62 lbf in 5 N m 44 lbf in Loctite 243 5 5 N m 49 lbf in Synthetic grease Synthetic grease Synthetic grease 7 N m 62 lbf in smr2005 069 014_aen smr2005 069 337 www SeaDooManuals net ...

Page 348: ...ction 11 HULL BODY Subsection 02 3D SERIES Kart Seat 10 N m 89 lbf in Loctite 243 Loctite 243 5 5 N m 49 lbf in 7 N m 62 lbf in 4 5 N m 40 lbf in smr2005 069 015_aen 338 smr2005 069 www SeaDooManuals net ...

Page 349: ...hile rotating Check for excessive lateral play Also check for excessive play of seat post in seat F22L0SA 1 2 4 3 1 Latch mechanism 2 Seat structure 3 Check play of seat post 4 Check lateral play of seat structure Inspect the seat post receiver in the deck Check for dirt sand or other debris Check for excessive wear Ensure that the cover moves freely Inspect post knuckle condition Check for wear c...

Page 350: ...ng the DESS switch tool P N 529 034 600 1 F18K0FA TYPICAL 1 DESS switch nut Pull plastic rivet no 2 out F22K0GA Position seat post in the receiver Using a plastic hammer push moto seat axle no 3 out while holding seat F22K0HA Post Partially peel seat cover to expose screw no 4 340 smr2005 069 www SeaDooManuals net ...

Page 351: ...h will turn to a dull appearance CAUTION Never clean plastic parts or en gine cover with strong detergent degreasing agent paint thinner acetone products con taining chlorine etc To clean the carpets use 3M Citrus Base Clean er 24 oz spay can or the equivalent KART SEAT if so equipped Check seat tab and anchor plate for wear or dam age Check latch mechanism for tightness wear cracks or other damag...

Page 352: ... 15 14 1 smr2005 069 023_a Step 1 Install screws sequence 1 to 4 Step 2 Install rivets sequence 5 to 26 INLET GRATE Removal and Installation Loosen screws and remove inlet grate NOTE An impact screwdriver should be used to loosen tight screws When reinstalling inlet grate apply Loctite 271 red P N 293 800 005 on threads Apply Loctite 5900 P N 293 800 066 on the small part of inlet grate as indicat...

Page 353: ...aning Scrape off all excess of sealant from riding plate and hull Clean hull surface with solvent to eliminate grease dust and any residue of sealant Clean fitting threads Installation Apply Loctite 5900 P N 293 800 066 as indicated by the shaded areas in the next illustration Follow also the torquing sequence as shown in the same illustration Torque screws to 26 N m 19 lbf ft F08L1TA 6 4 8 2 7 1 ...

Page 354: ... portion of studs towards the jet pump Apply Loctite 518 P N 293 800 038 against contact surface of studs with jet pump support Apply Loctite 5900 P N 293 800 066 as indicated by the shaded areas in the next illustrations smr2005 069 019 Torque nuts to 31 N m 23 lbf ft as per the fol lowing sequence 1 5 4 6 2 3 smr2005 069 020_a DRAIN PLUG Installation Before installation of drain plug no 7 clean ...

Page 355: ...nd or hull Position bumper rail no 10 properly onto body and cut excess length if necessary Slide bumper rail no 10 in corner bumper no 13 Using hole positions previously marked on body drill holes in bumper rail no 10 and install rivets no 11 Install trim no 9 using soapy water Repeat procedure for the other side When installing front bumper no 12 note that bumper screws are installed with a thre...

Page 356: ... in good condition If not replace by a new one smr2005 045 002_A 1 Check valves near elbow fittings Attach elbow fittings at the highest position that you can on the inlet hose smr2005 045 003 THRU HULL FITTING For hull insert repair proceed as follows Cut plastic hull insert flush with hull using a saw F01L2UA 1 2 1 Hull 2 Plastic hull insert Mix epoxy glue 3M 05895 follow manufacturer instructio...

Page 357: ...ING A PROTECTIVE FILM ON BACK SIDE ONLY These decals usually contain written information e g warning and are used on gelcoat or metal Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equiva lent refer to manufacturer instructions Using a pencil and the decal as a template mark the area where decal will be located Remove half of the decal back protective film and align decal...

Page 358: ...esin hardeners and gelcoat A barrier skin cream may also be used Do not expose area to open flame or lit cigarette Some of the materials are flammable Protect eyes wear safety glasses when grinding sanding or spraying Use a dust mask when sanding or grinding When spraying wear a respi rator or paint mask Always read warning labels on products Air Bubbles Possible cause Air pocket trapped between l...

Page 359: ...all Fractures Refer to the same procedure as in the AIR BUB BLES Numerous Fractures Over Large Surface Prepare the area for spray application of liquid gel coat Wipe down the surface with acetone Mask the area off to protect the watercraft from over spray Mix the needed quantity of gelcoat and catalyst ac cording to suppliers recommendations The gel coat can be thinned with acetone up to 10 If it ...

Page 360: ...sk off area For a small crack use an epoxy filler in the same way you would use gelcoat repair putty When laying up a larger area you will use mat cloth and fiberglass resin and catalyst Use a clean contain er to mix the resin mix only what you will need Follow the recommended catalyst ratio Using a clean paintbrush brush the mixed resin on the surface Place the smallest piece of mat over the frac...

Page 361: ...ower sander paint brush spray gun plastic squeegee cover sheets for Sea Doo plastic container mixing Materials fiberglass mat gelcoat putty fiberglass cloth liquid gelcoat polyester resin acetone cardboard epoxy filler masking tape wax 24 grit sanding disks cabosil fine compound white medium compound white sandpaper 100 grit 220 grit 320 grit 400 grit 600 grit 1000 grit smr2005 069 351 www SeaDooM...

Page 362: ...y 15 A ADDITIONAL INFORMATION 1 Engine cold 6000 RPM FUEL SYSTEM GTI Type Mikuni BN 40i diaphragm fuel accelerator pump Carburetor Quantity 1 Main jet 167 5 Pilot jet 75 Spring 130 g 4 6 oz Low speed screw No adjustment High speed screw No adjustment Idle speed in water 1500 100 RPM Adjustment Idle speed out of water 3000 RPM Type Regular unleaded gasoline Fuel Minimum octane no Inside North Ameri...

Page 363: ...7 cm 121 in Overall width 120 cm 47 in Overall height 104 cm 41 in Dry weight 274 kg 604 lb Load limit passenger and 10 kg 22 luggage 243 kg 536 lb ADDITIONAL INFORMATION CAPACITIES GTI Fuel tank including reserve 56 5 L 15 U S gal Fuel tank reserve 11 4 L 3 U S gal Oil injection reservoir 6 L 1 6 U S gal Capacity 100 mL 3 38 U S oz Jet pump impeller shaft reservoir Oil level height Up to plug ADD...

Page 364: ...VE solenoid 5 A Fuse Fuel pump 10 A ADDITIONAL INFORMATION FUEL SYSTEM GTI RFI GTI RFI LE Fuel injection type Rotax Fuel Injection semi direct single throttle body 56 mm Idle speed in water 1550 100 RPM Throttle Position Sensor TPS 1 6 k 2 4 k terminals 1 2 710 1380 terminals 2 3 Crankshaft Position Sensor CPS 774 946 Air Temperature Sensor ATS 2 28 k 2 74 k Water Temperature Sensor WTS 2 28 k 2 7...

Page 365: ...dth 120 cm 47 in Overall height 104 cm 41 in Dry weight 300 kg 661 lb 302 kg 666 lb Load limit passenger and 10 kg 22 lb luggage 243 kg 536 lb ADDITIONAL INFORMATION CAPACITIES GTI RFI GTI RFI LE Fuel tank including reserve 56 5 L 15 U S gal Fuel tank reserve from low level signal 11 4 L 3 U S gal Oil injection reservoir 6 L 1 6 U S gal Capacity 100 mL 3 38 U S oz Jet pump impeller shaft reservoir...

Page 366: ...e Open 470 5 Steering switch resistance Close 82 5 5 O T A S Solenoid resistance 14 9 5 ADDITIONAL INFORMATION FUEL SYSTEM 3D RFI 3D RFI PREMIUM Fuel injection type Rotax Fuel Injection semi direct single throttle body 56 mm Fuel pressure 56 PSI 60 PSI Idle speed in water 1550 100 RPM Throttle Position Sensor TPS 1 6 k 2 4 k terminals 3 4 710 1380 terminals 4 11 Crankshaft Position Sensor CPS 774 ...

Page 367: ...DIMENSIONS 3D RFI 3D RFI PREMIUM Number of passenger driver incl 1 Overall length 272 cm 107 in Overall width 112 cm 44 in Overall height Vert 92 cm 36 25 in Moto 112 cm 44 25 in Kart 96 cm 37 75 in Dry weight Vert 257 kg 565 lb Moto 266 kg 585 lb Kart 273 kg 600 lb Load limit passenger and luggage 10 kg 22 lb 114 kg 250 lb ADDITIONAL INFORMATION CAPACITIES 3D RFI 3D RFI PREMIUM Fuel tank includin...

Page 368: ... PREMIUM Estimated pump power 42 6 kW 57 HP Maximum fuel consumption at wide open throttle 38 L h 10 U S gal h Fuel tank without reserve 47 minutes Cruising time at full throttle Fuel tank reserve from low level signal 8 minutes ADDITIONAL INFORMATION smr2005 070 359 www SeaDooManuals net ...

Page 369: ... CONNECTORS Deutsch connectors are used to connect wiring harness to the magneto the electrical box some models and the VCK RFI models Connector Disassembly F00H1CA 1 3 4 2 3 1 Male connector 2 Female connector 3 Secondary lock 4 Sealing cap CAUTION Do not apply dielectric grease on terminal inside connector To remove terminals from connector proceed as follows Using a long nose pliers pull out th...

Page 370: ...To install For insertion of a terminal make sure the lock is removed Insert terminal into appropriate cavity and push as far as it will go Pull back on the terminal wire to be sure the retention fingers are holding the terminal After all required terminals have been inserted the lock must be installed F04H6LA 1 1 1 Wire identification numbers PACKARD CONNECTOR Packard connectors are used to connec...

Page 371: ...ystem Description F00H0WB 2 3 4 5 6 7 8 9 9 1 AMP CONNECTOR 1 Male connector 2 Cover assembly 3 Mating seal 4 Wedge lock 5 MPEM connector 6 Seal plug 7 Power wire 8 Signal wire 9 Locking tab Removal To remove the male connector from the MPEM press both tabs and pull connector F00H0NA 1 2 Step 1 Press tabs both sides Step 2 Pull male connector Installation Do not apply any product to the pins of th...

Page 372: ... locking tab retaining the wedge lock The wedge lock is now in the open position F00H0PA 1 1 Wedge lock opened While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the terminal is removed F00H0QA 1 2 Step 1 Rotate wire back and forth Step 2 Pull wire POWER WIRE TERMINAL NOTE The wedge lock must be removed to ex tract power terminal Open the ...

Page 373: ...s in AMP connectors must be crimped using the crimping tool P N 529 035 909 and crimper die P N 529 035 908 CAUTION If terminals are not crimped using the proper crimping tool the wire seal may be damaged F00B0EA CRIMPING TOOL All circuits are sealed by a diaphragm in the rubber wire seal When installing a terminal in connector the diaphragm is pierced as the terminal passes through it If the diap...

Page 374: ... are holding the con tact properly After all required terminals have been inserted the wedge lock must be closed to its locked po sition Terminal Identification AMP Connectors of MPEM 26 25 24 23 15 8 16 9 1 F04H6RA AMP Connectors of Wiring Harness F04H6GA 9 ECM CONNECTORS GTI Series with 787 RFI Engine There are two ECM connectors used on the RFI models and they are connected on the ECM The engin...

Page 375: ... reconnected frequently CAUTION For adequate probing techniques and tool refer to ENGINE MANAGEMENT sec tion Terminal Removal Unlock the connector cover by pushing in the tabs on top of the connector with a flat screwdriver to be able to flip the top cover up 1 F18Z0RA 1 Push in tab Lift the cover by pushing it forward 1 F18Z06A 1 Cover Cut both tie raps that secure the harness to the connector sm...

Page 376: ...t the tool tip into the terminal cavity as shown and locate its wire in the back of the con nector You may have to pry the tool tip against the locking tab to release it then remove the terminal from the connector F18Z0UA F18Z0VA Check the locking tab on the terminal it may have to be bent out a little so it will lock in its cavity when it is re inserted F18Z0WA If the wire is in good condition bu...

Page 377: ...ing Kostal To crimp a new connector terminal use the crimp ing tool P N 529 035 909 and the crimper die P N 529 035 906 529035909 529035906 To properly crimp the wires strictly follow this pro cedure Strip the wire to a maximum of 3 mm 1 8 in A32E2QA A TYPICAL A 3 mm 1 8 in max Position wire in terminal Squeeze the terminal tabs with your fingers to temporarily retain terminal in place A32E3YA Ins...

Page 378: ...ny product to the pins of the con nector on the ECM VCM CONNECTORS GTI Series with 787 RFI Engine 32 Pin Connector Firmly push down tab and hold to unlock connec tor while pulling it out A34E0KA 1 TYPICAL 1 Firmly push tab and hold while pulling connector out NOTE A small screw driver may be used to re lease locking tab while pulling connector out smr2005 073 001_a Push on both tabs to remove reta...

Page 379: ...female terminal to unlock from the housing and push out of housing A32E3XA 2 1 TYPICAL 1 Lift and hold plastic lock 2 Lift to unlock and push out 7 Pin Connector Firmly push down tab and hold to unlock connec tor while pulling it out F22H0JA 1 2 TYPICAL 1 VCM vehicle control module 2 Firmly push down this tab and hold while pulling out connector Refer to the illustration for the connector pinout s...

Page 380: ...INSTALLATION OF TERMINAL Follow the instructions provided with the crimping pliers P N 529 035 730 to select the proper posi tion of the tool 529 035 730 NOTE Different wires require different crimping pliers settings so make sure to follow the instruc tion supplied with the tool 2 A32E2SA 1 POSITIONING THE CRIMPING PLIERS Step 1 Press Step 2 Rotate After positioning the crimping pliers crimp the ...

Page 381: ...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 CAUTION Make sure that the protective heat shrink rubber tube has been properly installed and no part of wire is exposed smr2005 073 373 www SeaDooManuals net ...

Page 382: ...ber indicates in which connector the wire is plugged in Second number indicates the position of the wire in the connector The letter at the end of the number if applicable indicates a common circuit in the MPEM printed circuit with another wire bearing the same letter The first number indicates that the wire is posi tioned in the connector no 2 of the MPEM The second number indicates that the wire...

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Page 387: ...smr2005 071 100_aen 2005 3 D MODEL www SeaDooManuals net ...

Page 388: ...smr2005 071 101_aen 2005 GTI MODEL www SeaDooManuals net ...

Page 389: ...smr2005 071 102_aen 2005 GTI RFI MODEL www SeaDooManuals net ...

Page 390: ...smr2005 071 103_aen 2005 GTI LE RFI MODEL www SeaDooManuals net ...

Page 391: ...C M Y CM MY CY CMY K www SeaDooManuals net ...

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