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SeaDoo 2006 GTI, Shop Manual

The SeaDoo 2006 GTI Shop Manual is now available for download, completely free of charge, from our website. This comprehensive manual provides detailed instructions and valuable insights for maintaining and repairing your SeaDoo 2006 GTI. Enhance your watercraft experience by accessing this essential manual at manualshive.com.

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TABLE OF CONTENTS

ANTICORROSION TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

03

TROUBLESHOOTING

01 – TROUBLESHOOTING CHART . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 49

ENGINE WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ENGINE HARD TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ENGINE MISFIRES, RUNS IRREGULARLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE CONTINUALLY BACKFIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENGINE DETONATION OR PINGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENGINE LACKS ACCELERATION OR POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ENGINE STOPS RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ENGINE CANNOT REACH MAXIMUM RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH ITS TOP SPEED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ENGINE OVERHEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
O.P.A.S. SYSTEM FAULTS (GTX 4-TEC MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
ENGINE SMOKE IN THE EXHAUST (4-TEC SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LOW OR NO ENGINE OIL PRESSURE (4-TEC SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ENGINE OIL CONTAMINATION (MILKY) (4-TEC SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
UNUSUAL ENGINE NOISE AND/OR VIBRATION (4-TEC SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ABNORMAL NOISE FROM PROPULSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

04

ENGINE (2-STROKE)

01 – LEAK TEST .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 63

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

02 – REMOVAL AND INSTALLATION. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 71

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

03 – MAGNETO SYSTEM. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 83

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

04 – TOP END. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 99

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

USED PISTON MEASUREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125

05 – BOTTOM END .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 129

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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II

www.SeaDooManuals.net

Summary of Contents for 2006 GTI

Page 1: ...Smr 2004 ang FH8 Thu Jun 03 14 42 10 2004 Page 1 www SeaDooManuals net ...

Page 2: ...2004 Shop Manual GTI GTI LE GTI RFI GTI LE RFI XP DI GTX 4 TEC Supercharged Limited Supercharged Wakeboard Edition RXP 4 TEC Supercharged BOMBARDIER RECREATIONAL PRODUCTS INC www SeaDooManuals net ...

Page 3: ...BOMBARDIER ROTAX BOMBARDIER LUBE BOMBARDIER ROTAX Formula XP S Synthetic Injection Oil BOMBARDIER Formula XP S DI Synthetic Injection Oil BOMBARDIER ROTAX Injection Oil Sea Doo Synthetic Grease Sea Doo LKTM 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 GTX is a trademark of Castrol Ltd Used un...

Page 4: ...TOOLS AND PRODUCTS 01 MANDATORY SERVICE TOOLS 1 ENGINE 1 COOLING FUEL OIL SYSTEMS 5 PROPULSION SYSTEM 6 STEERING SYSTEM 8 02 OPTIONAL SERVICE TOOLS 9 ENGINE 9 COOLING FUEL OIL SYSTEMS 14 PROPULSION SYSTEM 14 BODY 15 WATERCRAFT HANDLING 15 03 SERVICE PRODUCTS 17 02 MAINTENANCE 01 PERIODIC INSPECTION CHART 21 02 FLUSHING AND LUBRICATION 27 GENERAL 27 PROCEDURE 27 ANTICORROSION TREATMENT 32 03 WATER ...

Page 5: ...NE SMOKE IN THE EXHAUST 4 TEC SERIES 59 LOW OR NO ENGINE OIL PRESSURE 4 TEC SERIES 60 ENGINE OIL CONTAMINATION MILKY 4 TEC SERIES 60 UNUSUAL ENGINE NOISE AND OR VIBRATION 4 TEC SERIES 61 ABNORMAL NOISE FROM PROPULSION SYSTEM 61 04 ENGINE 2 STROKE 01 LEAK TEST 63 GENERAL 63 PREPARATION 63 TESTING PROCEDURE 63 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 69 02 REMOVAL AND INSTALLATION 71 GENERAL 71 ENGINE R...

Page 6: ...TEM 185 INSPECTION 189 REMOVAL 191 DISASSEMBLY 198 ASSEMBLY 201 INSTALLATION 205 03 EXHAUST SYSTEM 209 EXHAUST PIPE 210 EXHAUST MANIFOLD 213 MUFFLER 214 RESONATOR 214 EXHAUST OUTLET 215 04 REMOVAL AND INSTALLATION 217 GENERAL 217 ENGINE REMOVAL 217 CLEANING 221 INSTALLATION 221 05 PTO HOUSING MAGNETO 225 GENERAL 226 PTO HOUSING 226 PTO SEAL 229 COUPLING 229 STATOR 230 ROTOR AND ENCODER WHEEL 231 R...

Page 7: ...ONER 280 BALANCER SHAFT 280 ENGINE BLOCK 283 PISTON CONNECTING ROD 288 PISTON RINGS 294 06 ENGINE MANAGEMENT RFI 01 OVERVIEW 297 AIR INDUCTION 298 FUEL DELIVERY 298 FUEL PUMP 298 FUEL PRESSURE REGULATOR 298 FUEL FILTERS 298 FUEL PUMP MODULE 299 FUEL INJECTORS 299 ELECTRONIC MANAGEMENT 299 ELECTRONIC CONTROL UNIT ECU 299 MPEM MULTI PURPOSE ELECTRONIC MODULE 300 02 DIAGNOSTIC PROCEDURES 303 INTRODUC...

Page 8: ...EVOLUTIONS 320 05 ADJUSTMENT 321 THROTTLE CABLE ADJUSTMENT 321 THROTTLE POSITION SENSOR TPS 321 CLOSED TPS 321 IDLE SPEED 321 06 REMOVAL AND INSTALLATION 323 MPEM ECU 323 THROTTLE POSITION SENSOR TPS 323 AIR TEMPERATURE SENSOR ATS 323 AIR PRESSURE SENSOR APS 323 WATER TEMPERATURE SENSOR WTS 323 CRANKSHAFT POSITION SENSOR CPS 323 FUEL PUMP ASSEMBLY 323 REGULATOR 324 FUEL FILTER 324 FUEL INJECTORS 3...

Page 9: ...ERATURE SENSOR EGTS 364 KNOCK SENSOR KS 364 RAVE SOLENOID 365 IGNITION COIL 366 IGNITION TIMING 368 SPARK PLUGS 372 CRANKING SYSTEM 373 DI SYSTEM TEST SUMMARY 373 03 DIAGNOSTIC PROCEDURES 377 GENERAL 377 FAULT DETECTION AND COMPENSATORY ACTIONS 379 COMPONENT FAILURE WARNING SYSTEM 379 VCK VEHICLE COMMUNICATION KIT 381 DI SYSTEM FAULT CODES 382 08 ENGINE MANAGEMENT 4 TEC 01 OVERVIEW 391 COMPLETE EL...

Page 10: ... CTS 427 MANIFOLD AIR PRESSURE SENSOR MAPS 428 EXHAUST GAS TEMPERATURE SENSOR EGTS 429 KNOCK SENSOR KS 429 OIL PRESSURE SENSOR OPS 431 OIL SEPARATOR PRESSURE SENSOR OSPS 431 TOPS VALVE BLOW BY 433 IGNITION COILS 436 IGNITION TIMING 437 ENGINE START STOP SWITCH VERIFICATION 437 SAFETY LANYARD SWITCH VERIFICATION 437 SPARK PLUGS 438 CRANKING SYSTEM 438 03 DIAGNOSTIC PROCEDURES 439 GENERAL 439 SELF D...

Page 11: ...VAL 520 CLEANING 520 DISASSEMBLY AND INSPECTION 521 ASSEMBLY 523 INSTALLATION 525 ADJUSTMENTS 525 11 LUBRICATION SYSTEM 2 STROKE 01 OIL INJECTION SYSTEM 529 GENERAL 531 OIL SYSTEM PRESSURIZATION 531 02 OIL INJECTION PUMP 533 OIL PUMP IDENTIFICATION 536 REMOVAL 536 DISASSEMBLY 536 CLEANING 536 ASSEMBLY 536 ADJUSTMENT 538 CHECKING OPERATION 541 12 ELECTRICAL SYSTEM 01 IGNITION SYSTEM 543 GENERAL 543...

Page 12: ...F ELECTRICAL ACCESSORIES 600 INSPECTION 600 05 DESS CARBURETED AND RFI ENGINES 609 GENERAL 609 DESS KEY PROGRAMMING 611 13 PROPULSION 01 JET PUMP 615 GENERAL 616 JET PUMP INSPECTION ON WATERCRAFT 616 REMOVAL 618 DISASSEMBLY 620 CLEANING 622 PARTS INSPECTION 623 ASSEMBLY 625 PUMP PRESSURIZATION 633 INSTALLATION 633 GENERAL 637 JET PUMP INSPECTION ON WATERCRAFT 637 REMOVAL 638 DISASSEMBLY 641 CLEANI...

Page 13: ...ORT 704 TIE ROD 705 SEALED TUBE 706 FILTER 706 VALVE 707 WATER HOSE 707 CROSS SUPPORT PLATE 708 02 ALIGNMENT 709 15 SUSPENSION 01 DIRECT ACTION SUSPENSION 711 REMOVAL 712 INSPECTION 713 ASSEMBLY 714 16 HULL BODY 01 ADJUSTMENT AND REPAIR 715 GENERAL 733 GLOVE BOX 733 ENGINE COVER 735 SEAT ADJUSTMENT 736 STORAGE COMPARTMENT INNER SHELL 737 STORAGE COVER SHOCK 744 STORAGE COMPARTMENT COVER ADJUSTMENT...

Page 14: ...TERIALS LIST 760 THRU HULL FITTING INSTALLATION 761 17 TECHNICAL DATA 01 GTI AND GTI LE MODELS 763 02 GTI RFI AND GTI LE RFI MODELS 767 03 XP DI MODEL 771 04 RXP 4 TEC MODELS 775 05 GTX 4 TEC MODELS 781 18 WIRING DIAGRAM 01 WIRING DIAGRAMS 787 WIRE COLOR CODES 787 WIRE DIGIT CODES 787 DEUTSCH CONNECTORS 787 PACKARD CONNECTOR 790 AMP PLUG CONNECTOR 790 IDENTIFICATION OF CONNECTOR PINS 793 ECM CONNE...

Page 15: ...r 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 Torque wrench tightening specifications must be strictly adhered to Locking devices ex lock ing tab self locking fasteners etc must be installed or replaced with new ones If...

Page 16: ... pearl 1503 6142 GTX 4 TEC Supercharged Limited blue pearl 1503 6141 GTX 4 TEC Supercharged yellow 1503 6143 GTX 4 TEC Supercharged International yellow 1503 6144 GTX 4 TEC Wakeboard Edition viper red 1503 6149 GTX 4 TEC Wakeboard Edition International viper red 1503 6150 RXP apple green 1503 6115 RXP International apple green 1503 5599 RXP yellow 1503 6162 RXP International yellow 1503 6163 XP DI...

Page 17: ... the magneto housing 1 F01D01A TYPICAL 1 Engine Identification Number E I N 787 RFI Engines The Engine Identification Number is located on the upper crankcase on PTO side F01D87A 1 1 Engine Identification Number E I N 947 DI Engines The Engine Identification Number is located on the upper crankcase on MAGNETO side F06D15A 1 1 Engine Identification Number E I N 1503 Engines The Engine Identificatio...

Page 18: ... THIS MANUAL The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual Several sections are divided in various subsec tions There is a table of contents at the beginning of many sections XV www SeaDooManuals net ...

Page 19: ...elated 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 i...

Page 20: ...ace other wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4 PSI Diaphra...

Page 21: ...e Sc Supercharger STD Standard ABBREVI ATION DESCRIPTION TBD To Be Determined TDC Top Dead Center TPS Throttle Position Sensor VDC Volt Direct Current VCK Vehicle Communication Kit Vdc Volt Direct Current VTS Variable Trim System WTS Water Temperature Sensor GENERAL INFORMATION The use of RIGHT starboard and LEFT port indi cations in the text always refers to driving position when sitting on water...

Page 22: ...cuted in a manner that maintains emission levels within the prescribed certification standards Dealers are not to modify the engine in any man ner that would alter the horsepower or allow emis sion levels to exceed their predetermined factory specifications Exceptions include manufacturer s prescribed changes such as altitude adjustments for exam ple Owner Responsibility The owner operator is requ...

Page 23: ... 2 1 Apply here 2 Do not apply Clean threads bolt and nut with solvent Apply Loctite Primer N P N 293 800 041 on threads and allow to dry Choose proper strength Loctite threadlocker Fit bolt in the hole Apply a few drops of threadlocker at proposed tightened nut engagement area Position nut and tighten as required Blind Holes A00A3MA 1 2 1 On threads 2 On threads and at the bottom of hole Clean th...

Page 24: ...s Avoid touching metal with tip of flask NOTE for preventive maintenance on exist ing equipment retighten nuts and apply proper strength Loctite on bolt nut contact surfaces Adjusting Screw A00A3PA 1 2 1 Apply here 2 Plunger Adjust screw to proper setting Apply drops of proper strength Loctite thread locker on screw body contact surfaces Avoid touching metal with tip of flask NOTE if it is difficu...

Page 25: ...minants with Loctite Chisel remover P N 413 708 500 Use a mechanical mean if necessary NOTE Avoid grinding Clean both mating surfaces with solvent Spray Loctite Primer N on both mating surfaces and on both sides of gasket Allow to dry 1 or 2 minutes Apply GASKET ELIMINATOR 518 P N 293 800 038 on both sides of gasket using a clean ap plicator Place gasket on mating surfaces and assemble immediately...

Page 26: ...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 normal strength and gap are required Install according to standard procedure Wipe off surplus Allow it to cure for 30 minutes NOTE Normally used on worn out housings to prevent leaking or sliding It is generally ...

Page 27: ...t Torque to the recommended torque value NOTE Always torque screws bolts and or nuts in a criss cross sequence A00A8BS Property class and head markings Property class and nut markings 5 5 10 10 10 10 12 12 4 8 4 8 4 8 8 8 8 8 8 8 9 8 9 8 9 8 10 9 10 9 10 9 12 9 12 9 12 9 12 9 FASTENER GRADE TORQUE FASTENER SIZE 5 8 Grade 8 8 Grade 10 9 Grade 12 9 Grade M4 1 5 2 N m 13 18 lbf in 2 5 3 N m 22 27 lbf...

Page 28: ...on circlip installer a P N 529 035 562 b P N 529 035 765 APPLICATION a 2 stroke engines b 4 TEC engines Sleeve set a P N 529 035 542 20 mm sleeve b P N 529 035 543 21 mm sleeve APPLICATION a 717 and 787 RFI engines b 947 DI engines Air compressor ring compressor P N 529 035 713 APPLICATION 947 DI engines Carbon dam guide P N 529 035 715 APPLICATION 947 DI engines Carbon dam compressor P N 529 035 ...

Page 29: ...TION 717 engines Puller ass y P N 290 876 488 1 Screw P N 290 240 860 2 Hexagonal nut P N 290 242 210 2 1 APPLICATION 717 and 787 RFI engines Alignment support plate kit P N 529 035 506 1 Alignment plates P N 529 035 507 2 Support P N 529 035 511 3 Screw 2 P N 207 182 544 4 Lock washer 2 P N 234 181 601 5 Flat washer 2 P N 234 081 410 APPLICATION All models Alignment shaft P N 295 000 141 APPLICAT...

Page 30: ... supplementary to P N 295 500 352 Handle P N 420 877 650 APPLICATION Use with pushers P N 290 876 609 and P N 290 877 740 Rotary valve shaft pusher P N 290 876 609 APPLICATION 787 RFI engines Use with handle P N 420 877 650 Oil seal pusher P N 290 877 740 APPLICATION 787 RFI engines Use with handle P N 420 877 650 Ring gear puller tool P N 420 976 235 puller ass y P N 529 035 549 puller bolt APPLI...

Page 31: ...39 APPLICATION 4 TEC engines N Drive shaft adaptor a P N 529 035 892 b P N 529 035 985 APPLICATION a GTX 4 TEC engines b RXP 4 TEC engines Torx adapter P N 529 035 938 APPLICATION 4 TEC Supercharged engines Support plate P N 529 035 947 APPLICATION 4 TEC Supercharged engines Retaining key P N 529 035 949 APPLICATION 4 TEC Supercharged engines 4 pin socket P N 529 035 948 APPLICATION 4 TEC Supercha...

Page 32: ...es Fuel pressure gauge P N 529 035 591 APPLICATION 787 RFI and 4 TEC engines 1 Fuel pressure gauge P N 529 035 709 2 Fuel pressure gauge T fitting P N 529 035 710 3 Fuel pressure gauge pressure relief valve P N 529 035 711 4 Fuel pressure gauge air compressor adapter P N 529 035 712 1 3 2 4 APPLICATION 947 DI engines Oil pressure gauge 1 to 8 bars P N 529 035 709 APPLICATION 4 TEC engines Engine o...

Page 33: ... NOTE This tool is also used for the PTO flywheel on some models Pliers P N 295 000 069 APPLICATION All models Impeller shaft holder P N 295 000 082 APPLICATION All 2 stroke models Jet pump bearing remover P N 295 000 144 APPLICATION All 2 stroke models Bearing seal installer P N 295 000 107 APPLICATION All 2 stroke models Inner seal installer P N 529 035 609 APPLICATION 155 6 mm 6 1 8 in jet pump...

Page 34: ...I models PTO seal support P N 529 035 842 APPLICATION GTX 4 TEC models N Drive shaft holder a P N 529 035 871 b P N 529 035 987 APPLICATION a GTX 4 TEC models b RXP 4 TEC models Drive shaft floating ring P N 529 035 841 APPLICATION GTX 4 TEC models N Seal bearing pusher P N 529 035 955 APPLICATION GTX 4 TEC models Shaft pusher P N 529 035 819 APPLICATION GTX 4 TEC models Pressure cap P N 529 035 8...

Page 35: ...E TOOLS AND PRODUCTS Subsection 01 MANDATORY SERVICE TOOLS STEERING SYSTEM O P A S cylinder nut wrench P N 529 035 840 APPLICATION Models equipped with the O P A S system 8 smr2004 Complete Line Up www SeaDooManuals net ...

Page 36: ...ngines Cylinder aligning tool P N 420 876 904 APPLICATION 717 engines Distance gauge a P N 529 034 800 14 mm 551 in b P N 529 034 900 15 4 mm 606 in c P N 529 035 100 11 5 mm 453 in d P N 529 035 000 7 5 mm 295 in APPLICATION a 717 engines b 787 RFI engines c 947 DI engines MAG d 947 DI engines PTO N Spring installer remover P N 529 035 989 APPLICATION GTX 4 TEC models Valve spring compressor clam...

Page 37: ...er P N 529 035 687 APPLICATION 4 TEC engines Torque angle gauge Not sold by Bombardier Snap on TA362 APPLICATION 4 TEC engines Leak test kit pump P N 529 021 800 APPLICATION 4 TEC engines Leak down tester P N 529 035 661 APPLICATION 4 TEC engines Oil VAC P N 529 035 880 APPLICATION 4 TEC engines a Four pin magneto harness P N 295 000 131 b Six pin magneto harness P N 295 000 136 APPLICATION a 717 ...

Page 38: ...er P N 529 014 500 APPLICATION All 2 stroke models Timing mark pointer P N 295 000 130 APPLICATION 717 engines Timing mark pointer P N 295 000 135 APPLICATION 787 RFI 947 DI engines N Crimping tool Crimping tool alone P N 529 035 909 Individual die for Kostal connector ECM P N 529 035 906 for AMP connector MPEM and Deutsch connector P N 529 035 908 APPLICATION Contacts of AMP and ECM plug connecto...

Page 39: ...CJ93 1 Hammer CJ125 6 Claws CJ93 4 APPLICATION 717 and 787 RFI engines NOTE This tool is also used to pull out impeller shaft seal Protective mat P N 295 000 128 APPLICATION All models Gear bearing puller P N 290 877 665 APPLICATION 787 RFI engines Exhaust outlet tool P N 295 000 132 APPLICATION All models Feeler gauge 45 Not sold by Bombardier Snap onFB 300 A APPLICATION 717 and 787 RFI engines S...

Page 40: ...5 868 APPLICATION All models 1 Puller ass y P N 420 877 635 2 Protective cap P N 420 876 557 P N 290 877 414 947 DI engines 3 Ring both ends P N 420 977 490 P N 420 977 480 947 DI engines 4 Ring halves PTO P N 420 977 475 2 P N 420 876 330 947 DI engines 5 Distance ring MAG P N 420 876 569 6 Ring halves MAG P N 420 276 025 2 7 Screw M8 x 40 P N 420 840 681 2 8 Screw M8 x 70 P N 420 841 201 2 9 Pul...

Page 41: ... APPLICATION All models Flushing adapter P N 295 500 473 APPLICATION All models Use with coupler hose P N 295 500 258 N Test radiator cap P N 529 021 991 P A S OUVRIR A CHA U D APPLICATION 4 TEC models NOTE This cap does not require to pinch the overflow hose PROPULSION SYSTEM Fitting P N 295 000 086 APPLICATION All models Slide hammer puller Not sold by Bombardier Snap on Handle CJ93 1 Hammer CJ1...

Page 42: ...TION XP DI models Suction cup P N 295 000 163 APPLICATION 4 TEC models WATERCRAFT HANDLING Dolly with wheels P N 295 000 126 Beach wheels set of 2 wheels P N 295 000 005 APPLICATION Dolly Tie down 1 50 m 5 ft long P N 295 100 103 APPLICATION All models Lift kit a P N 295 100 206 b P N 295 100 205 APPLICATION a 2 stroke models b 4 TEC models smr2004 Complete Line Up 15 www SeaDooManuals net ...

Page 43: ...0 mL High strength threadlocker P N 293 800 005 Loctite 271 red 10 mL High temperature threadlocker P N 420 899 788 Loctite 648 green 5 g High temperature retaining compound P N 293 800 054 Loctite 642 50 mL Retaining compound P N 413 703 100 Loctite RC 609 green 10 mL General purpose instant adhesive P N 293 800 021 Loctite 495 Gasket eliminator P N 293 800 038 Loctite 518 50 mL Flange sealant P ...

Page 44: ...93 800 018 Loctite 592 50 mL b P N 293 800 013 Loctite 567 250 mL Hylomar sealant P N 293 800 001 PL 32 100 g Sealant P N 293 530 011 Sikaflex 221 black 350 mL Dielectric grease P N 293 550 004 Dow Corning 150 g High temperature RTV sealant P N 293 800 090 Ultra Copper 80 mL Grease P N 293 550 005 400 g Synthetic grease P N 293 550 010 400 g Super Lube grease P N 293 550 030 Loctite Anti seize P N...

Page 45: ...711 900 U S 12 x 350 g Sea Doo fuel stabilizer P N 413 408 600 236 mL 8 oz 732 Multi purpose sealant P N 293 800 033 Dow Corning 90 mL clear Premixed coolant 50 50 37 C 35 F P N 293 600 038 16 x 1 L BOMBARDIER FORMULA XP S II synthetic injection oil P N 293 600 045 12 x 1 liter P N 293 600 046 3 x 4 liter P N 293 600 247 205 liter Bombardier 4 stroke oil SAE 10W40 P N 219 700 346 12 x 1 L smr2004 ...

Page 46: ...t gasket P N 293 800 088 7 oz Jet pump oil P N 293 600 011 Sea Doo synthetic jet pump oil 12 x 6 oz Jet pump bearing grease P N 293 550 032 110g Sea Doo Cleaner P N 293 110 001 400 g P N 293 110 002 4 L Pulley flange cleaner P N 413 711 809 N Anti corrosion spray P N 219 700 304 20 smr2004 Complete Line Up www SeaDooManuals net ...

Page 47: ...RIPTION INTERVAL I Inspect verify clean adjust lubricate Replace if necessary C Clean L Lubricate R Replace FIRST 10 HOURS EVERY 25 HOURS OR 3 MONTHS EVERY 50 HOURS OR 6 MONTHS EVERY 100 HOURS OR 1 YEAR GENERAL Lubrication corrosion protection 1 L ENGINE Support and rubber mount I I Exhaust system fasteners 5 I I RAVE valve if so equipped 5 C C Top end leak test piston and ring clearance DI models...

Page 48: ...s 5 6 I I Fuel lines connections RFI and DI models check valve relief valve and fuel system pressurization 5 I I Carburetor throttle body RFI fuel rail and fittings if so equipped 5 I I Air intake silencer fit tightness I I Fuel tank straps I I LUBRICATION SYSTEM Oil injection pump 5 I I Oil lines I I Oil filter I I R Oil reservoir straps I ELECTRICAL SYSTEM Electrical connections and fastening ig...

Page 49: ... I I Jet pump reservoir oil and oil level I R Jet pump cover pusher if so equipped I Impeller shaft seal 7 Impeller and impeller wear ring clearance I 2 Water intake grate I 2 HULL BODY Bailer pick ups check for obstructions I I Hull I I 1 Every 10 hours in salt water use 2 These items have to be initially checked after 25 hours Thereafter servicing to be made as specified in this chart 3 Daily fl...

Page 50: ... I I Exhaust system fasteners 5 I I Spark plug 5 R Supercharger slipping moment if so equipped I Supercharger drive gear shaft and lock washer if so equipped I 10 COOLING SYSTEM Flushing exhaust system C 3 Hose and fasteners I I Coolant 7 Coolant expansion tank cap cooling system pressure test 4 FUEL SYSTEM Throttle cable I Fuel injection system sensors I I Fault code reading 1 5 I Fuel lines conn...

Page 51: ... safety lanyard post I I Monitoring beeper I I Battery and fasteners I I STEERING SYSTEM Steering cable I I O P A S SYSTEM O P A S system including filter if applicable I I 8 I PROPULSION SYSTEM Drive shaft corrosion protection L 9 Drive shaft protection boot I 2 Drive shaft impeller splines GTX 4 TEC Series L Drive shaft impeller splines RXP 4 TEC models L Sacrificial anode I Shifter system cable...

Page 52: ...lly checked after 25 hours Thereafter servicing to be made as specified in this chart 3 Daily flushing in salt water or foul water use 4 Perform every 200 hours or 2 years 5 Emission related component 6 Replace after the vehicle completed 100 hours of use or 2 years 7 Replace for storage period or after 100 hours of use whichever comes first 8 Every 25 hours when riding in weed areas 9 Perform at ...

Page 53: ...ne Make sure engine operates during entire procedure PROCEDURE WARNING Perform this operation in a well ventilated area Do not touch any electrical parts or jet pump area when engine is running Clean jet pump by spraying water in its inlet and outlet and then apply a coating of BOMBARDIER LUBE lubricant WARNING Always remove safety lanyard cap from post to prevent accidental engine starting before...

Page 54: ...r intake silencer NOTE An increase of engine RPM may be no ticed while spraying the lubricant in the air intake silencer F01F25A 1 3 2 717 AND 787 RFI ENGINES 1 Air intake silencer 2 Pull plug 3 Spray BOMBARDIER LUBE here F12F01A 1 947 DI ENGINES 1 Partially pull tube out of air box to inject BOMBARDIER LUBE lubricant or equivalent Push tube in when finished Lubrication of engine should be done fo...

Page 55: ...king Wait 2 seconds then press the start stop button to crank the engine a few turns and distribute the lubricant onto cylinder walls NOTE A 1 second beep every second indicates the drowned mode is active Crank the engine a few turns to distribute the oil on cylinder wall All Models except 4 TEC Apply anti seize lubricant on spark plug threads then reinstall them Properly reconnect spark plug cabl...

Page 56: ...nexpected engine starting before cleaning the jet pump area Engine must not be running for this operation Models without a Flushing Connector in Engine Compartment Connect a garden hose to connector located at the rear of watercraft on jet pump support Do not open water tap yet WARNING When operating the engine while the water craft is out of the water the heat exchanger in the ride plate may beco...

Page 57: ...NING Certain components in the engine compart ment may be very hot Direct contact may re sult in skin burn Do not touch any electrical part or jet pump area when engine is running CAUTION Never flush a hot engine Always start the engine before opening the water tap Open water tap immediately after engine is started to prevent overheating Run the engine about 20 seconds at a fast idle between 4000 ...

Page 58: ... water outlet hose CAUTION Serious damage to exhaust system can occur if hose pincher is not removed NOTE Engine valves fogging should be done whenever the watercraft is to be stored for a long period Refer to STORAGE section ANTICORROSION TREATMENT All Models To prevent corrosion spray a corrosion inhibitor salt water resistant such as BOMBARDIER LUBE lubricant or equivalent over metallic com pon...

Page 59: ...ND GTI LE MODELS 1 Grounding device 1 F01H7DA 787 RFI AND 947 DI MODELS 1 Grounding device Remove spark plugs and dry them with a clean cloth A contact cleaner spray can be used It may be preferable to replace spark plugs Do NOT install spark plugs on engine yet Cover spark plug holes with a rag WARNING Be careful when cranking engine in the fol lowing procedure water will spray out from spark plu...

Page 60: ...r then to lean the vehicle so that water can flow out from throttle bodies All Models except 4 TEC Spray BOMBARDIER LUBE lubricant P N 293 600 016 into spark plug holes Crank engine again Reinstall spark plugs and spark plug cables 947 DI Engines WARNING Always reconnect spark plug cables at the same spark plugs where they come from The cable coming out the edge of the electri cal box must be conn...

Page 61: ...er to ENGINE MANAGE MENT for 947 DI engines Check crankshaft if needed it may be misaligned or deflected Refer to BOTTOM END After engine has started spray BOMBARDIER LUBE lubricant for one minute through air intake silencer while engine is running All Models except 947 DI and 4 TEC Models F01F25A 1 3 2 717 AND 787 RFI ENGINES 1 Air intake silencer 2 Pull plug 3 Spray BOMBARDIER LUBE here 947 DI M...

Page 62: ... recon nected If necessary remove supercharger housing All 4 TEC Engines If water is suspected to be in the intake and the exhaust system it must be drained as follows Remove the intake manifold and drain it Then suck out the water from the intake valve ports Refer to subsection INTAKE SYSTEM Remove the water from oil air separator breather hose Remove the exhaust pipe and drain it Then either rem...

Page 63: ...dure in a Test Tank or Tied to a Trailer with Watercraft in Water Run the engine for 5 minutes at 3500 RPM WARNING Make sure to safely secure the watercraft With the engine still running at 3500 RPM in stall a hose pincher to the coolant line going to the oil cooler WARNING Certain components in the engine compart ment may be very hot Direct contact may re sult in skin burn Do not touch any electr...

Page 64: ...run time Shut off the engine Remove the hose pincher on the coolant line going to the oil cooler CAUTION Hose pincher must be removed pri or to operating the watercraft Failure to do this will result in damage to the engine Change the oil and filter again Move rearward the Ring Seal Carrier and rein stall the C clip Refer to DRIVE SYSTEM sec tion Water in Supercharger Supercharged 4 TEC Engines If...

Page 65: ...damage will occur Check engine drain hose for obstructions F07E0MA 1 TYPICAL 1 Engine drain hose RFI Models Disconnect the water supply hose used to cool the magneto It features a quick connect fitting Press both tabs and pull fitting in order to discon nect hose This hose is located at the bottom of the magneto cover beside the engine support F17E0AA 1 TYPICAL 1 Press tabs here and disconnect hos...

Page 66: ...d and refilled with SEA DOO synthetic 75W90 GL5 polyester oil Refer to JET PUMP for proper procedure CAUTION Use only SEA DOO jet pump oil or equivalent synthetic gear oil otherwise com ponent service life could be reduced Do not mix oil brands or types 4 TEC Models Verify jet pump grease for water contamination Check for the presence of water in cone and bear ing if so replace oil seal and sleeve...

Page 67: ... ventilated area Do not smoke or allow open flames or sparks in the vicinity Fuel tank may be pressurized slowly turn cap when opening Never use an open flame to check fuel level When fueling keep watercraft level Do not overfill or top off the fuel tank and leave watercraft in the sun As tem perature increases fuel expands and might overflow Always wipe off any fuel spillage from the watercraft P...

Page 68: ...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 nonabrasive wax CAUTION Never clean fiberglass and plastic parts with strong detergent degreasing ...

Page 69: ...t DI NOTE This procedure requires approximately 2 5 L 2 6 U S qt of antifreeze Hose Pinchers Installation Some hoses have to be plugged to prevent drain ing before filling cooling system jackets with the antifreeze All 2 Stroke Models except DI Install hose pinchers at the following locations 1 F17E05A GTI AND GTI LE MODELS 717 ENGINES 1 Engine drain hose F15E01A 1 RFI MODELS 787 ENGINES 1 Engine ...

Page 70: ... be disconnected Discon nect hoses at the following location F06E0EB 1 717 AND 787 RFI ENGINES 1 Disconnect engine water inlet hose 717 Engines Temporarily install a short piece of hose to engine water inlet at cylinder head All 2 Stroke Models except DI Insert a funnel into hose and pour antifreeze in engine until the colored solution appears at the cooling system bleed outlet F07E0LA 787 RFI Eng...

Page 71: ...emov ing the hose pinchers Use a container to recover 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 Ensu...

Page 72: ... ft with an internal diameter of 12 7 mm 1 2 in over the previously disconnected hose Antifreeze Insert a funnel into the temporary hose Ensure to hold the funnel approximately 1 m 3 ft above the deck when pouring the antifreeze to create enough pressure so that it flows properly F08E0TA A A 1 m 3 ft to ease antifreeze flow Pour antifreeze in engine until the colored solution appears at cooling sy...

Page 73: ...let Then install a hose pincher on this hose F08E0JA 1 1 Engine drain hose crankcase cooling outlet Continue to pour until antifreeze flows in air com pressor water outlet hose F08E0EA 1 XP DI MODELS 1 Air compressor water outlet hose The pouring operation is over Remove pinchers in this order to allow proper flow of antifreeze smr2004 Complete Line Up 47 www SeaDooManuals net ...

Page 74: ...usly damage the engine Failure to replace the antifreeze for storage may allow its degradation that could result in poor cooling when engine will be used All Models ANTICORROSION TREATMENT Wipe off any residual water in the engine compart ment Spray BOMBARDIER LUBE lubricant over all metallic components in engine compartment Lubricate the throttle cable with BOMBARDIER LUBE lubricant 4 TEC Models ...

Page 75: ... models Check wiring then replace fuse Starting system fuse keeps on burning Check wiring starting system solenoid and MPEM Discharged or disconnected battery Check recharge Defective or disconnected start stop switch Check refer to STARTING SYSTEM or ENGINE MANAGEMENT Battery connections Check clean tighten Poor bad or corroded ground contacts engine starter etc Check clean repair Water fuel hydr...

Page 76: ...ult codes Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT Engine drowned mode is active fuel injection models Release throttle lever Low battery voltage Recharge or replace battery Check fuel pump pressure output Check air fuel rail DI models Check fuel pump fuse Low or no fuel pressure fuel injection models Check wiring harness Check fuel injector operation Replace as necessary Fuel injectors...

Page 77: ...rrect rotary valve timing if so equipped Check refer to ENGINE Internal engine damage Check refer to ENGINE Defective encoder trigger wheel fuel injection models Check refer to ENGINE MANAGEMENT Incorrectly aligned flywheel and encoder trigger wheel fuel injection models Properly position flywheel and encoder trigger wheel refer to PTO HOUSING MAGNETO Insufficient engine compression Replace defect...

Page 78: ...er in fuel reservoir or contaminated fuel Flush reservoir and refill with fresh gas Check cylinder compression Check for cylinder head leaks Mechanical engine failure Check starting system Spark plug faulty fouled or worn out Check spark plug condition Check fuel pump operation Refer to ENGINE MANAGEMENT Low fuel pressure fuel injection models Check fuel pressure regulator Refer to ENGINE MANAGEME...

Page 79: ...rs or if filter is plugged Replace if necessary Leaking crankshaft seal s or intake manifold carburetor models Pressure check engine to ENGINE Restricted fuel valve carburetor models Check replace Loose carburetor carburetor models Tighten carburetor Stale or water fouled fuel Check siphon and refill Fuel filter dirty or restricted Check clean replace Clogged fuel injectors fuel injection models R...

Page 80: ...ting fuel injection models Inspect fuel pressure regulator and air pressure DI models Refer to ENGINE MANAGEMENT Rich fuel mixture Fouled spark plug cont d High fuel pressure fuel injection models Check pump regulator injectors or if filter is plugged Replace if necessary Check spark plug condition check fault codes check fuel pressure fuel injection models Also check RAVE valves operation 2 strok...

Page 81: ... SYSTEM Engine Intake or exhaust valve s leak 4 TEC models Pressure check engine refer to ENGINE ENGINE DETONATION OR PINGING OTHER OBSERVATION POSSIBLE CAUSE REMEDY Timing too far advanced Check reset except 4 TEC models Ignition Spark plug heat range too high Check change to correct range Engine overheats and exhaust overheats Check see ENGINE OVERHEATS in this section Fuel octane too low of poo...

Page 82: ...hon then refill with fresh fuel Clogged direct injectors DI models Remove and clean direct injectors Clogged fuel injectors fuel injection models Remove and clean fuel injectors Low fuel pressure fuel injection models Check fuel line and fuel pump pressure Incorrect throttle position sensor TPS adjustment fuel injection models Check and adjust TPS refer to ENGINE MANAGEMENT Improper timing chain a...

Page 83: ...ystem for proper fuel pressure and delivery Air in fuel rail RFI and 4 TEC models Refill fuel tank Engine start but stops after approximately 2 seconds Low air pressure DI models Check air system compressor air fuel rail etc ENGINE CANNOT REACH MAXIMUM RPM OTHER OBSERVATION POSSIBLE CAUSE REMEDY RAVE valve does not open if so equipped Check refer to ENGINE and COOLING SYSTEM Faulty water regulator...

Page 84: ... Check reseal refer to section PROPULSION SYSTEM or HULL BODY ENGINE OVERHEATS OTHER OBSERVATION POSSIBLE CAUSE REMEDY Coolant level low Refill check for leaks Coolant leaking out of weep hole PTO housing Replace seal Hoses or clamps missing defective Repair replace Cylinder head gasket leaks white exhaust gas Replace cylinder head gasket Thermostat failure Replace Coolant pump failure Replace Coo...

Page 85: ... cylinder Refer to STEERING SYSTEM ENGINE SMOKE IN THE EXHAUST 4 TEC SERIES OTHER OBSERVATION POSSIBLE CAUSE REMEDY Coolant leak Check repair Refer to LEAK TEST Intercooler leak if so equipped Check repair Refer to INTAKE SYSTEM Damaged cylinder head gasket Check replace cylinder head gasket Water ingestion Inspect intake manifold for water infiltration White smoke Valve guide seals Check replace ...

Page 86: ... OTHER OBSERVATION POSSIBLE CAUSE REMEDY Oil seal and rotary seal on coolant pump shaft leaking Replace both seals Refer to PTO HOUSING Change oil Cylinder head gasket leaking Replace gasket Refer to CYLINDER HEAD Change oil Loose screws on cylinder head PTO housing or oil separator Retorque Change oil Oil contamination due to metal or plastic particles Replace possibly damaged parts Change oil Wa...

Page 87: ... refer to INTAKE Missing defective air intake hose Check replace air intake hose or clamps refer to section INTAKE ABNORMAL NOISE FROM PROPULSION SYSTEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weeds debris caught in intake grate or impeller Check clean Low oil level in jet pump 2 stroke models Check troubleshoot source of leak refill supply refer to PROPULSION SYSTEM Worn anti rattle system 2 stro...

Page 88: ...er on all hoses connections fittings plates etc If there is a leak bubbles will indicate leak location Three areas of the engine will be tested in se quence as per the diagnostic flow chart see the end of this subsection 1 Engine Cooling System 2 Bottom End and Top End 3 Rotary Valve Shaft except DI engine NOTE If a leak is found it is important to continue testing as there is the possibility of h...

Page 89: ...1 Loop hose and use clamps 2 Use two washers with exhaust manifold stud 3 Hose with adapter and nipple 3 2 1 F02E0DA 787 RFI ENGINES REAR VIEW 1 Loop hose and use clamps 2 Hose with clamps Install pump to the end 3 Block engine drain hose with a hose pincher F02D0WA 1 787 RFI ENGINES FRONT VIEW 1 Exhaust manifold plate 64 smr2004 Complete Line Up www SeaDooManuals net ...

Page 90: ...ween the spark plug area and the engine cylinder head cover If none of these components are leaking there is an internal leak and it can be detected with BOTTOM END AND TOP END testing Bottom End and Top End Carburetor Equipped Models Remove the carburetor s and gasket s Make sure the surface of the intake manifold 717 en gines or rotary valve cover 787 RFI engines are clean Install the intake pla...

Page 91: ...tes 3 Pulse hose blocked with a hose pincher 4 Exhaust plate 3 1 2 F08D05A 947 DI ENGINES 1 Exhaust plate 2 Rave valve plates 3 Intake plates Activate pump and pressurize engine to 34 kPa 5 PSI CAUTION Do not exceed this pressure Wait 3 minutes and check if pressure drops if so verify all testing components If kit components are not leaking verify engine jointed surfaces as per following areas spa...

Page 92: ...ter seal If no leak is found on the PTO side outer seal remove magneto flywheel and verify crankshaft outer seals Proceed with the ROTARY VALVE SHAFT testing if so equipped if the crankshaft outer seals are not leaking Rotary Valve Shaft if so equipped NOTE It is mandatory to drain the injection oil from the rotary valve shaft Block oil return hose of the rotary valve shaft with a hose pincher F01...

Page 93: ...ug If pressure drops it indicates a defective MAG side crankshaft inner seal or crankcase is not sealed correctly If the above mentioned components are not leak ing and there is a pressure drops remove the ro tary valve cover Check the seal of the rotary valve shaft If the rotary valve shaft is not leaking it could indicates a defective engine casting Disassem ble engine and carefully check for de...

Page 94: ...ARY VALVE SHAFT IS SEAL LEAKING CAREFULLY INSPECT ENGINE CASTINGS PARTICULARLY THE THREADED HOLE AREAS YES YES NO PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING CHECK TESTING KIT REPLACE O RING OF CYLINDER HEAD AND OR CYLINDER BASE GASKET YES YES NO CHECK TESTING KIT IS RESERVOIR LEAKING PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE REPLACE GASKET OR O RING RE SEAL LEAKING AREA REPLACE C...

Page 95: ...Section 04 ENGINE 2 STROKE Subsection 01 LEAK TEST 947 DI Engines F00D28T 70 smr2004 Complete Line Up www SeaDooManuals net ...

Page 96: ...NAGEMENT sec tion All Models 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 negative cable first then the RED positive battery cable last Electrical Connections It is recommended to disconnect electrical con nections prior to disconnecting fuel lines Disconnect ...

Page 97: ...slit replace hose 1 F16D04A 1 Disconnect hose here Refer to ENGINE MANAGEMENT for location of sensors and connectors Unplug air compressor lines inlets and outlets cooling oil outlet only and air inlet only on throt tle body side Disconnect vent hose from balancing shaft gear housing Jet Pump Removal All Models To withdraw jet pump refer to JET PUMP CAUTION Whenever removing engine from watercraft...

Page 98: ...fuel line connection with an absorbent shop rag Slowly disconnect the fuel hose to release the pressure Wipe off any fuel spillage inside bilge DI Models Remove air fuel rail Refer to ENGINE MANAGE MENT All Models Engine Support NOTE Be careful when removing engine sup port s or rubber mount adapters shims could have been installed underneath Shims control engine jet pump alignment Always note pos...

Page 99: ...9 035 940 into lifting ring holes A00B6BA ENGINE LIFT TOOL 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 and 947 DI Engines Engine can be easily lifted by inserting a hook into exhaust manifold eyelet F01D7OA TYPICAL Using a chain block a hoist or other suita...

Page 100: ...p and rotary valve shaft except the 947 DI engines then disconnect hoses A01B2JB 1 TYPICAL 1 Hose pincher P N 295 000 076 Install a hose pincher to oil return hose of rotary valve shaft except the 947 DI engines then dis connect hose F01D3ZA 2 1 TYPICAL 717 ENGINES 1 Rotary valve oil supply line 2 Hose pincher installed F04D10A 3 2 1 TYPICAL 787 RFI ENGINES 1 Rotary valve oil supply line 2 Hose pi...

Page 101: ...spillage in bilge Clean with a bilge cleaner Clean external parts of engine INSTALLATION Installation of engine in watercraft is essentially the reverse of removal procedures However pay particular attention to the following Rubber Mount Shim and Screw Check tightness and condition of rubber mounts If they have been removed apply Loctite 243 blue on screw threads Torque screws to 25 N m 18 lbf ft ...

Page 102: ...fer to the following illustration 3 F12D13A 1 4 2 5 TORQUE TO 24 N M 17 LBF FT AS PER SEQUENCE NOTE Remember to install sleeves and flat wash ers F12D13B 2 1 2 1 2 1 Sleeves 2 Flats washers Oil Injection Hoses 717 and 787 RFI Engines Make sure to reinstall hoses before completely lowering engine in bilge Positive Starter Cable Torque nut of positive starter cable to 6 N m 53 lbf in Apply dielectri...

Page 103: ... 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 Use shim s P N 270 000 024 or P N 270 000 025 as necessary between engine supports and rubber mounts to correct alig...

Page 104: ... DRIVE SYSTEM Then ensure the mid bearing is loosened to check en gine alignment Carefully slide alignment shaft P N 295 000 141 through shaft support 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 P N 529 035 590 on shaft end If the alignment is incorrect loosen engi...

Page 105: ... 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 All Models Apply Loctite 243 blue on screw threads Torque engine support screws to 25 N m 18 lbf ft whe...

Page 106: ... OIL INJECTION PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT DI models Check hose condition and pressure test fuel sys tem refer to FUEL CIRCUIT 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 is no l...

Page 107: ...Loctite 243 4 6 7 Loctite 243 6 N m 53 lbf in 23 6 N m 53 lbf in 22 Loctite 243 3 6 N m 53 lbf in 15 Loctite 243 14 13 150 N m 110 lbf ft Loctite 648 25 1 12 11 10 N m 89 lbf in Anti seize lubricant 10 N m 89 lbf in 11 Anti seize lubricant 10 N m 89 lbf in 11 2 6 N m 23 lbf in 2 F02D12S smr2004 Complete Line Up 83 www SeaDooManuals net ...

Page 108: ...f in 13 120 N m 89 lbf ft Loctite 243 Loctite 243 14 3 4 N m 35 lbf in 27 9 N m 80 lbf in 9 Dielectric grease 25 1 Molykote 111 11 Ground cable Dielectric grease Anti seize lubricant 6 N m 53 lbf in Anti seize lubricant 26 Anti seize lubricant 4 N m 35 lbf in 20 9 N m 80 lbf in Anti seize lubricant 11 9 N m 80 lbf in Dielectric grease Loctite 243 Anti seize lubricant 84 smr2004 Complete Line Up ww...

Page 109: ...ykote 111 9 N m 80 lbf in Loctite 243 Molykote 111 Loctite 243 13 N m 115 lbf in 9 N m 80 lbf in 5 N m 44 lbf in Loctite 243 Loctite 243 Loctite 243 115 N m 85 lbf ft 3 8 14 21 20 16 29 9 25 1 11 13 17 13 N m 115 lbf in Loctite 648 30 smr2004 Complete Line Up 85 www SeaDooManuals net ...

Page 110: ...ews then secure puller plate on magneto fly wheel so that sleeves are against ring gear no 3 Install extension handle on end of puller plate F01D48A 1 TYPICAL 1 Sleeves on opposite side Using a suitable socket unscrew retaining nut no 13 COUNTERCLOCKWISE when facing it NOTE If socket is found too large to be inserted in puller plate machine or grind its outside diameter as necessary F01D4BA 1 TYPI...

Page 111: ...g procedure is to find a common ref erence point on both crankcases old and new to position armature plate Proceed as follows Before removing the armature plate find a crankcase locating lug the top one in this ex ample Place a cold chisel at the end of chosen lug then punch a mark on armature plate at this point 1 F01D4DA 2 1 Crankcase locating lug 2 Mark armature plate at the end of lug At assem...

Page 112: ...ry charging coil no 7 Heat the armature plate to 93 C 200 F around the screw holes to break the threadlocker bond F00D09A 1 1 Heat the armature plate CAUTION Protect harness from flame Remove screws Uncrimp and unsolder YELLOW and YELLOW BLACK wires from coil Uncrimp and unsolder ground wire BLACK from coil core A25E0SA 1 2 1 Uncrimp and unsolder ground wire BLACK 2 Uncrimp and unsolder YELLOW and...

Page 113: ...locked by using the PTO flywheel extractor tool For procedure refer to BOTTOM END Lock ring gear using special tool P N 529 035 846 F15B01A SPECIAL TOOL P N 529 035 846 1 F15D0AA 1 Special tool P N 529 035 846 Remove crankshaft position sensor no 18 before removing the ring gear Alternatively you can lock ring gear using special tool assembly P N 295 000 155 F01B26A 1 2 1 Ring gear blocking tool P...

Page 114: ...tool locking ring gear Insert crankshaft protector to outer end of crank shaft and fully thread puller in magneto rotor F01D7YA 1 TYPICAL 1 Puller Tighten puller screw and at the same time tap on screw head using a hammer to release magneto rotor from its taper Magneto Housing To remove magneto housing no 5 starter has to be removed Refer to STARTING SYSTEM Unscrew retaining screws no 19 then with...

Page 115: ...L 1 Cover 2 Screw Remove oil pump shaft from magneto rotor nut F06D23A 1 TYPICAL 1 Remove oil pump shaft Rotor and Ring Gear Lock ring gear using special tool P N 529 035 946 F00B2WA SPECIAL TOOL P N 529 035 946 NOTE Crankshaft can also be locked by using the PTO flywheel remover tool For procedure refer to BOTTOM END If necessary the magneto rotor can be removed without removing the ring gear and...

Page 116: ...e not enough threads would be engaged and damage may occur F06D0PA 1 TYPICAL 1 Puller Tighten puller screw and at the same time tap on screw head using a hammer to release magneto rotor from its taper CAUTION Be careful after ring gear removal not to bend the encoder wheel teeth Also pay attention when putting away If you suspect a bent tooth refer to ENGINE MANAGEMENT for inspection procedure Sta...

Page 117: ...ll wires Prior to assembly apply Loctite 243 blue Use magneto coil centering tool P N 420 876 922 and install it so that it fits around armature plate before tightening screws no 23 F00D0AA 1 1 Magneto coil centering tool P N 420 876 922 Magneto Flywheel and Ring Gear Apply Loctite 648 green to magneto flywheel mating surface Lay ring gear on a steel plate then heat with a propane torch in order t...

Page 118: ...te 2 Punch a mark on crankcase lug aligned with plate mark The new mark on crankcase will be used for fur ther assembly positioning as a pre timing position F01D4GA 1 TYPICAL 1 For further assembly use these marks Apply a drop of Loctite 243 blue on threads of screws no 15 and torque to 6 N m 53 lbf in Magneto Flywheel Apply Loctite 243 blue on crankshaft taper Position Woodruff key and magneto fl...

Page 119: ...nkshaft Apply Loctite 243 blue on nut no 13 Install nut with lock washer no 14 and torque to 120 N m 89 lbf ft CAUTION Never use any type of impact wrench at magneto installation Crankshaft Position Sensor Install crankshaft position sensor no 18 on mag neto housing Torque screw to 9 N m 80 lbf in NOTE The crankshaft position sensor is not ad justable Cover Before installing cover make sure oil pu...

Page 120: ... 13 N m 115 lbf in Cover Before installing cover make sure oil pump shaft is properly positioned Before installation properly install O ring no 25 in engine magneto cover no 1 Apply Loctite 767 anti seize compound on screws no 11 Torque screws in a criss cross sequence to 9 N m 80 lbf in Rotor and Ring Gear Install trigger wheel no 30 on ring gear no 3 1 F18D2TA 2 1 Ring gear 2 Trigger wheel Apply...

Page 121: ... use any type of impact wrench Unlock crankshaft Reinstall pulse fitting with washer and torque to 19 N m 14 lbf ft Cover Before installation properly install O ring no 25 in engine magneto cover no 1 Apply Loctite 767 anti seize compound on screws no 11 Torque screws in a criss cross sequence to 9 N m 80 lbf in If heat exchanger cover has been removed en sure to align its notch with the emboss in...

Page 122: ...7 Engines F17D02S 10 11 12 12 14 6 2 13 9 13 5 3 4 3 4 5 6 24 N m 17 lbf ft 24 N m 17 lbf ft 24 N m 17 lbf ft Loctite 243 Loctite 243 Loctite 243 Engine oil Molykote 111 Molykote 111 Molykote 111 Engine oil 8 7 smr2004 Complete Line Up 99 www SeaDooManuals net ...

Page 123: ...8 3 5 4 5 6 34 rollers Engine oil Loctite 243 Molykote 111 14 1 11 12 12 2 13 Loctite 243 Molykote 111 40 N m 30 lbf ft 9 10 30 Molykote 111 10 N m 89 lbf in 15 16 17 19 18 20 Molykote 111 3 N m 27 lbf in 21 29 27 8 26 25 24 23 22 Molykote 111 100 smr2004 Complete Line Up www SeaDooManuals net ...

Page 124: ... lbf ft 7 8 3 4 5 6 Engine oil Loctite 243 Molykote 111 14 13 Loctite 243 Molykote 111 40 N m 30 lbf ft 9 10 34 2 10 N m 89 lbf in 15 16 17 19 18 3 N m 27 lbf in 26 24 23 22 Molykote 111 20 25 F12D0TS Loctite 243 Engine oil smr2004 Complete Line Up 101 www SeaDooManuals net ...

Page 125: ...ustment knob Turning the adjustment in or out changes the preload on the return spring which in turn will change the RPM at which the RAVE valve opens and closes On 947 DI engines the spring preload does not have a significant effect on the valve operation 787 RFI Engines On these engines the RAVE valves are controlled by the Multi Purpose Electronic Module MPEM To open the RAVE valves the MPEM ac...

Page 126: ... 4 2 3 1 Solenoid 2 Pressure from air compressor 3 Pressure to RAVE valves 4 Vent to air intake silencer 5 Check valve 6 Vent from counterbalancing shaft oil cavity To close the RAVE valves the MPEM deactivates the solenoid which blocks the air compressor pressure The RAVE valves are opened to the atmosphere The vent on couterbalancing shaft oil cavity is nec essary to prevent pressure buildup in ...

Page 127: ...f a customer uses a lower than recom mended quality oil more frequent cleaning may be required No special solvents or cleaners are required when cleaning the valve BORING PRECAUTION In its stock configuration the RAVE valve guillo tine has a minimum of 0 5 mm 020 in clearance to the cylinder bore measured at the center line of the cylinder This is the minimum production clearance There is only a f...

Page 128: ... hold cover to valve base The com pression spring inside the valve is applying pressure against the cover F06D0RA 1 1 Spring Remove the compression spring no 19 F06D25A 1 1 Remove spring 787 RFI Engines Remove spring no 30 retaining bellows no 21 to valve piston no 20 F06D0SA 1 1 Spring Free bellows no 21 from valve piston no 20 smr2004 Complete Line Up 105 www SeaDooManuals net ...

Page 129: ...om sliding valve no 22 NOTE Hold the sliding valve to prevent it from turning F06D0TB 2 1 1 Unscrew piston 2 Hold sliding valve Remove compression spring no 29 A06D26A 1 1 Remove spring Remove supporting ring no 28 F06D27A 1 1 Remove supporting ring Remove O ring no 23 106 smr2004 Complete Line Up www SeaDooManuals net ...

Page 130: ... Remove bellows 947 DI Engines Loosen Allen screws no 26 each side of RAVE valve 1 F12D0UA 1 1 Remove screws Remove RAVE valve no 15 Remove the cover no 18 of the valve by releasing the spring no 16 WARNING Firmly hold cover to valve base The com pression spring inside the valve is applying pressure against the cover smr2004 Complete Line Up 107 www SeaDooManuals net ...

Page 131: ... valve housing 1 F12D0YA 2 3 1 Valve piston 2 Valve housing 3 Sliding valve Cylinder Head Cover and Cylinder Head Disconnect temperature sensor wire and spark plug cables Connect spark plug cables on grounding device 717 Engines Remove air intake silencer and support refer to AIR INTAKE 717 and 787 RFI Engines Remove screws no 14 Remove cylinder head cover no 1 If shells sand salt or any other par...

Page 132: ...aking sure con necting rods do not hit crankcase edge WARNING If screws need to be heated for removal when engine is in watercraft fuel system pressur ization must be done first Do not use open flame use a heat gun NOTE Even if only 1 cylinder needs repair both cylinders should be lifted to allow 1 piece cylinder base gasket replacement 947 DI Engines Remove cylinders screws then cylinders no 9 Pi...

Page 133: ... 503 with the appropriate set of sleeves ENGINE SLEEVE SET P N 717 787 RFI 529 035 542 947 DI 529 035 543 F00B0IA 2 3 1 1 Puller 2 Shoulder sleeve 3 Sleeve Fully thread on puller handle Insert extractor spindle into the piston pin Slide the sleeve and shoulder sleeve onto the spindle Screw in extracting nut with the movable ex tracting ring toward spindle F00B0JA 1 2 3 4 1 Puller 2 Sleeve 3 Should...

Page 134: ...move shoulder sleeve Carefully remove the piston no 3 The needles thrust washers and the sleeve re main in the connecting rod bore and may be used again 1 2 F00B0NA 1 Needles and thrust washer 2 Sleeve CLEANING Discard all gaskets and O rings Clean all metal components in a solvent Clean water passages and make sure they are not clogged Remove carbon deposits from cylinder exhaust port RAVE valve ...

Page 135: ...clearance 947 DI engine 0 12 mm 0047 in N A 0 20 mm 008 in Ring piston groove clearance 717 engine 0 025 mm 001 in 0 070 mm 0027 in 0 20 mm 008 in Ring piston groove clearance 787 RFI engine 0 025 mm 001 in 0 070 mm 0027 in 0 24 mm 009 in Ring piston groove clearance 947 DI engine 0 044 mm 002 in 0 089 mm 003 in 0 20 mm 008 in Ring end gap 717 engine 0 25 mm 010 in 0 40 mm 016 in 1 0 mm 039 in Rin...

Page 136: ...90 to it If the difference between readings exceed specification cylinder should be rebored and honed or replaced A F01D8BA A 1 2 1 Measuring in piston pin axis 2 Measuring perpendicularly 90 to piston pin axis A 16 mm 5 8 in USED PISTON MEASUREMENT Note the measurement on the piston dome F00D0EA 2 1 1 Piston dome 2 Piston measurement Using a micrometer measure piston skirt perpen dicularly 90 to ...

Page 137: ...Wall Clearance Used and New Pistons IMPORTANT Make sure used piston is not worn more than specified See USED PISTON MEA SUREMENT above To determine the piston dimension take the mea surement on the piston dome F00D0EA 2 1 1 Piston dome 2 Piston measurement Adjust and lock a micrometer to the specified val ue on the piston dome F00B08A 1 1 Micrometer set to the piston dimension With the micrometer ...

Page 138: ...he exact piston cylinder wall clearance NOTE Make sure the cylinder bore gauge indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false Ring Piston Groove Clearance 717 and 787 RFI Engines Using a feeler gauge check clearance between rectangular ring and groove If clearance exceeds specified tolerance replace piston NOTE Ring piston groove clearance...

Page 139: ...g rods refer to the COMBUS TION CHAMBER VOLUME MEASUREMENT to properly determine the required gasket thickness Different thicknesses of cylinder base gaskets are used for a precise adjustment of the combustion chamber volume To identify gasket thickness refer to the identifi cation holes on the gasket F01D67A 1 TYPICAL 1 Identification holes All Engines GASKET THICKNESS IDENTIFICATION HOLES 0 3 mm...

Page 140: ...linder so that its opening is toward the bottom F01D8JB 1 1 Bottom of valve housing When the valve is mounted onto the cylinder move the valve piston no 20 to ensure the sliding valve no 22 moves easily and does not stick F01D8LA 947 DI Engines Check the piston valve O ring Replace if neces sary F12D0ZA 1 1 Piston valve O ring Check the sliding valve O ring Replace if neces sary smr2004 Complete L...

Page 141: ...irection of the exhaust port A01C01A AUS 1 1 Exhaust side NOTE On the 787 RFI and 947 DI engines the exhaust ports are located on the same side as the intake Carefully cover crankcase opening as for disas sembly Piston Pin and Roller Bearing To install roller bearing no 4 and piston pin no 6 use piston pin puller P N 529 035 503 with the appropriate set of sleeves as for disassembly Replacement be...

Page 142: ...pposite side of the piston pin 2 Tighten extracting nut Rotate handle to pull piston pin carefully into the piston Plastic Mounting Device Method This is an alternate method when no service tool is available Replacement roller bearings are delivered in a con venient plastic mounting device For installation proceed as follows Align replacement roller bearing with connect ing rod bore Carefully push...

Page 143: ... F01D0TA 1 1 Pulling inner sleeve half Circlip Always use new circlips WARNING Always wear safety glasses when installing piston circlips CAUTION Always use new circlips At instal lation take care not to deform them Circlips must not move freely after installation 717 and 787 RFI Engines Secure circlip with its opening located at the bot tom of the piston CAUTION To minimize the stress on the circ...

Page 144: ...ly hold piston against tool and tap tool with a hammer to insert circlip into its groove F00B0RA CAUTION The hand retaining the piston should absorb the energy to protect the con necting rod Cylinder Base Gasket Install new base gasket NOTE The general procedure is to install a new gasket of the same thickness However if you do not know the gasket thickness that was in stalled or if a crankshaft a...

Page 145: ...ston locat ing pin Slide tool over rings F01D0ZA 1 1 Ring end gap aligned with piston locating pin Slide cylinder over piston F01D10A When reassembling cylinders to crankcase it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold 717 Engines The aligning tool P N 420 876 904 or the exhaust manifold can be used to align cylinders F01D44A 1 717 ...

Page 146: ...els To easily slide cylinder block over pistons use ring compressor P N 290 876 965 A01B1TA 1 1 Slide this edge NOTE For each ring make sure to align ring end gap with piston locating pin Install cylinder block Apply Molykote 111 on O ring no 31 and install it CAUTION The O rings must be installed and properly positioned in the cylinder block The O rings are meant to dampen stud vibration Cylinder...

Page 147: ...ing underneath the cylinder screw head can be only used once Either replace with new bolts or remove blue coating and apply Molykote 111 below the screw heads Install and torque screws to 40 N m 30 lbf ft in the indicated order Refer to the following illustra tion F12D07A 7 2 3 5 8 1 4 6 All Engines Cylinder Head Install cylinder head gasket 717 and 787 RFI Engines Make sure to install O rings no ...

Page 148: ... 2 4 6 12 11 3 1 5 9 7 TORQUING SEQUENCE ADJUSTMENT RAVE Valve 787 RFI Engines Turn the red plastic knob no 17 until it is flush to the valve cover F00D0GA 1 1 Knob flush with the cover Combustion Chamber Volume Measurement All Engines NOTE This procedure is required to determine the thickness of the cylinder base gasket to be in stalled if a crank repair has involved replacement of connecting rod...

Page 149: ... 0 50 cc Open burette valve to fill its tip Add liquid in burette until level reaches 0 cc Inject the burette content through the spark plug hole on all engines except 947 DI and through direct injector hole on DI engines until liquid touches the top hole F00D0HA 1 1 Top of spark plug hole NOTE The liquid level in cylinder must not drop for a few seconds after filling If so there is a leak between...

Page 150: ... a thinner gasket A lower volume dictates a thicker gasket All Engines except DI NOTE When the combustion chamber is filled to top of spark plug hole it includes an amount of 2 39 cc corresponding to the spark plug tip The following table of combustion chamber volume in cludes this value All Engines ENGINE COMBUSTION CHAMBER VOLUME 717 31 2 34 0 cc 787 RFI 34 7 37 9 cc 947 DI 45 7 48 4 cc Repeat t...

Page 151: ...i seize lubricant 12 3 110 N m 81 lbf ft 1 6 5 6 Anti seize lubricant Loctite 642 12 4 Anti seize lubricant Loctite 243 6 6 4 5 Loctite 5910 2 11 7 24 N m 17 lbf ft 10 10 N m 89 lbf in Loctite 518 Loctite 518 8 40 N m 30 lbf ft 4 9 F00D0YU Molykote 111 Molykote 111 Molykote 111 smr2004 Complete Line Up 129 www SeaDooManuals net ...

Page 152: ...e 642 Anti seize lubricant Loctite 5910 Loctite 518 40 N m 30 lbf ft Loctite 518 Loctite 518 24 N m 17 lbf ft 30 mL 1 oz SAE 30 motor oil 5 6 12 6 15 16 6 4 6 2 7 11 12 18 11 4 3 4 19 15 14 F07D0VS 9 N m 80 lbf in Anti seize lubricant Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 Molykote 111 8 40 N m 30 lbf ft 8 7 24 N m 17 lbf ft Anti seize lubricant 130 smr2004 Complete Line ...

Page 153: ...bf ft Loctite 5910 6 5 N m 58 lbf in 9 N m 80 lbf in 7 N m 62 lbf in Anti seize lubricant Anti seize lubricant 1 5 N m 13 lbf in Loctite 243 Molykote 111 115 N m 85 lbf ft 6 5 N m 58 lbf in Engine oil 27 N m 20 lbf ft 40 N m 30 lbf ft 20 N m 15 lbf ft Anti seize lubricant 28 5 4 6 16 15 17 29 30 14 13 2 24 25 9 27 23 3 2 4 4 6 6 5 1 22 20 21 7 8 7 7 31 32 15 13 8 XP DI only Loctite 243 23 N m 17 l...

Page 154: ...eel splines F01D1AA 1 TYPICAL 1 PTO flywheel remover P N 295 000 001 Using a suitable wrench or socket with a break er bar unscrew PTO flywheel COUNTERCLOCK WISE when facing it and hold extension handle locking the magneto flywheel F00D0ZA 1 TYPICAL 1 Extension handle locking crankshaft NOTE When splines of PTO flywheel are worn out and special tool cannot be used proceed with the following altern...

Page 155: ...emove Allen screws no 21 re taining coupler no 20 to PTO flywheel F01J0TA PTO FLYWHEEL REMOVER TOOL F06D37A 2 1 1 Loosen Allen screws 2 Breaker bar locking crankshaft Remove the coupler no 20 XP DI Models Remove Allen screws no 21 2 F08D02A 3 1 1 PTO flywheel 2 Coupler 3 Loosen Allen screw Remove coupler no 20 947 DI Engines Install puller plate P N 529 035 533 and extension handle P N 295 000 125...

Page 156: ...9A 2 4 3 1 1 Puller plate 2 Puller 3 Bolt 4 Extension handle Starter Drive Assembly 947 DI Engines Only Loosen 2 Allen screws no 24 retaining starter drive cover no 25 F06D1CA 1 2 1 Cover 2 Allen screw Remove starter drive cover no 25 and spring no 9 Remove starter drive assembly no 27 F06D1DA 1 TYPICAL 947 DI ENGINES 1 Starter drive assembly Reed Valve 947 DI Engines Only Remove reed valves no 28...

Page 157: ...x 73 5 flanged screws 2 M8 x 68 5 flanged screws 3 M8 x 45 socket head screws 2 F15D05A 2 1 1 1 787 RFI ENGINES 1 M10 x 73 5 flanged screws 2 M8 x 53 5 flanged screws 947 DI Engines Place engine upright on crankcase magneto side Loosen crankcase screws F07D09D 1 1 2 947 DI ENGINES 1 M8 x 45 flanged screws 2 M10 x 73 5 flanged screws All Engines Put engine back on a support Insert a pry bar between...

Page 158: ...nce ring MAG side only P N 420 876 569 4 Ring both sides P N 420 977 490 5 MAG side ring halves P N 420 276 025 6 PTO side ring halves P N 420 977 475 7 Screw M8 x 40 P N 420 840 681 8 Screw M8 x 70 P N 420 841 201 NOTE To facilitate ring or distance ring installa tion lubricate their inside diameters 787 RFI Engines To remove end bearings no 4 from crankshaft use the following tools NOTE The oute...

Page 159: ...Engines F01D1OA 1 TYPICAL 1 Removing crankshaft bearing Or use a bearing extractor such as Proto no 4332 and a press to remove two bearings at a time ex cept on PTO side for the 787 RFI engines F01D1PA 1 2 1 Press bearings out 2 Bearing extractor Crankshaft Gear 787 RFI Engines The crankshaft gear no 18 and bearing no 5 can be removed in one step using the following puller F04B03A 1 1 Puller P N 2...

Page 160: ... removed by using the following tools F00B0CA 1 2 3 4 5 1 Puller P N 420 877 635 2 Protective cap P N 420 876 557 3 Ring P N 420 977 480 4 Ring halves P N 420 876 330 5 Screw M8 x 40 P N 420 840 681 F00D0KA 1 1 Tool installed To remove gear no 14 first trace an index mark on the gear and counterbalance shaft NOTE There is no Woodruff key to position the gear on the counterbalance shaft An index ma...

Page 161: ... press to remove gear no 14 CLEANING All Models Discard all oil seals gaskets O rings and sealing rings Clean oil passages and make sure they are not clogged Clean all metal components in a solvent Crankcase mating surfaces are best cleaned us ing a combination of the chisel gasket remover P N 413 708 500 and a brass brush Brush a first pass in one direction then make the final brushing perpendicu...

Page 162: ...gned or deflected Crankshaft can be twist ed on center main journal changing timing of one cylinder in relation with the other F01D1NA 1 1 Main journal alignment here To accurately check if crankshaft is twisted on cen ter main journal proceed as follows Remove magneto housing cover Remove flywheel nut and magneto rotor for the 787 RFI and 947 DI engines Refer to MAGNETO SYSTEM for procedures Inst...

Page 163: ...reater than specified toler ance this indicates worn bearing s bent and or disaligned crankshaft Proceed with the disas sembly of the engine Disassembled Engine The following verifications can be performed with the engine disassembled Crankcase Inspect plane surfaces for warpage Small defor mation can be corrected by grinding surface with a fine sandpaper Install sandpaper on a surface plate and r...

Page 164: ...lection with crankshaft in crankcase If deflection exceeds the specified tolerance it can be either ball bearings wear bent or twisted crankshaft at connecting rod journal F01D1SA 1 1 Measuring PTO side deflection in crankcase F01D1TA 1 1 Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V shaped blocks as illustrated 1 F01D97A 1 Measuring MAG side...

Page 165: ...1IA 1 1 Bearing of starter drive assembly Removal Starter drive bearing can be easily removed from lower crankcase half using the following suggest ed tool or equivalent Snap on hammer puller including handle CJ93 1 hammer CJ125 6 claws CJ93 4 F01J0ZA Close puller claws so that they can be inserted in end bearing Holding claws turn puller shaft clock wise so that claws open and become firmly tight...

Page 166: ... the oil sys tem will result in serious engine damage ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following NOTE It is recommended to spray BOMBARDIER ROTAX injection oil on all moving parts when reassembling the engine Crankshaft and Bearing Apply Loctite 767 anti seize on part of crankshaft where bearing fits Prior to installati...

Page 167: ...haft Also make sure to align the gear keyway with the Woodruff key on the crankshaft F00D0LA 1 1 Woodruff key on the crankshaft F00D0MA 1 2 1 Keyway 2 Long flange toward the crankshaft counterweight Crankshaft Seal All Models When installing seal assembly no 5 apply a light coat of lithium grease on seal lips 787 RFI Engines Position PTO seal against the retaining shim the gap between the seal no ...

Page 168: ... premature wear will occur Proceed as follows to check if the gear no 14 is properly positioned on the counterbalance shaft Temporarily install the counterbalance shaft in the crankcase Rotate the counterbalance shaft to align the notch of the gear with the crankcase F00D0UA 1 1 Gear notch aligned with the crankcase The notch of the couterweight on the opposite end of the counterbalance shaft must...

Page 169: ...haft no 13 Make sure to properly index crankshaft and counterbalance shaft by gear align ing marks CAUTION Marks on the crankshaft and coun terbalance shaft must be aligned otherwise en gine will vibrate and premature wear will occur F00D0PA 1 787 RFI ENGINES 1 Marks must be aligned F06D1MA 1 947 DI ENGINES 1 Marks must be aligned Turn by hand the crankshaft and counterbalance shaft Make sure they...

Page 170: ...e to get an uniform appli cation without lumps If you do not use the roller method you may use your finger to uniformly dis tribute the sealant unlike the Drei Bond sealing compound using a finger will not affect the adhe sion Use the silicone based Loctite 5910 P N 293 800 081 on mating surfaces NOTE The sealant curing time is similar to the Loctite 518 without using the Primer N CAUTION Do not u...

Page 171: ...4 to 24 hours 947 DI Engines Make sure all locating dowels are in place F06D1PA 1 1 Dowel Counterbalance Shaft Bearing Cover 787 RFI Engines Install the bearing cover no 19 with its hollow side toward the bearing F00D0QA 1 1 Hollow side facing bearing Crankcase Screws 717 Engines Apply Loctite 518 on screw threads and Molykote 111 below head screws Torque crankcase screws to 24 N m 17 lbf ft as pe...

Page 172: ...s Apply Molykote 111 below head of screws and Loctite 518 on threads Torque crankcase screws to 12 N m 106 lbf in as per following sequence Repeat procedure retightening all screws to 27 N m 20 lbf ft F07D09E 7 3 1 16 5 19 22 11 10 8 24 21 15 4 13 2 18 6 23 12 14 9 20 17 As a final step torque only the M10 x 73 5 bolts to 40 N m 30 lbf ft as per following sequence F07D09C 9 7 3 1 5 11 10 8 4 2 6 1...

Page 173: ...ls as for disassembly proce dure torque PTO flywheel to 110 N m 81 lbf ft 947 DI Engines Apply Loctite 243 blue on bolt no 22 Using the same tools as for disassembly proce dure torque bolt no 22 to 115 N m 85 lbf ft Apply Loctite 648 on mating surface of PTO fly wheel and coupler Apply Loctite 243 blue to Allen screws no 21 of coupler and torque to 23 N m 17 lbf ft Final Assembly 717 and 787 RFI E...

Page 174: ... N 293 600 011 or standard gear oil through crankcase ventilation nipple 1 F18D2RA 1 Crankcase ventilation nipple Add approximately 10 mL 3 oz of injection oil in bottom of crankcase for each cylinder This will give an additional lubrication for the first engine startup 152 smr2004 Complete Line Up www SeaDooManuals net ...

Page 175: ... and 787 RFI Engines F00D26T 8 2 20 N m 15 lbf ft Molykote 111 7 10 6 9 5 11 3 4 14 15 717 engines 13 12 1 20 N m 15 lbf ft 9 N m 80 lbf in 2 1 12 787 RFI engines Anti seize lubricant Formula XP Injection Oil Loctite 243 smr2004 Complete Line Up 153 www SeaDooManuals net ...

Page 176: ...ethod the soldering wire method 45 FEELER GAUGE METHOD Remove O ring no 12 from rotary valve cover no 1 Remove intake manifold from rotary valve cover except 787 RFI engines Reinstall cover no 1 in place WITHOUT its O ring and torque screws to 20 N m 15 lbf ft Insert feeler gauge blade through cover inlet ports to verify clearance At least verify clearance at two different places in each port Feel...

Page 177: ... Reverify the clearance At assembly the rotary valve timing must remain as per original setting NOTE If rotary valve crankcase surface is worn it is possible to have it reworked at the factory Rotary Valve Shaft Gear Backlash Remove PTO flywheel guard Remove spark plugs rotary valve cover and valve Manually feel backlash at one position then turn crankshaft about 1 8 turn and recheck Continue this...

Page 178: ... seat no 6 to com press spring and remove circlips no 5 F01D25A 1 2 1 Compress seat 2 Remove circlips Shaft Bearing To remove bearing no 8 use a bearing extractor such as Snap on no CJ 950 or equivalent as il lustrated Slide off distance sleeve no 14 re move snap ring no 7 and washer no 15 then press shaft out F01D4NA 1 2 1 Bearing 2 Bearing extractor Snap on CJ 950 CAUTION Ensure that rotary valv...

Page 179: ... are not clogged Clean rotary valve shaft and inside of distance sleeve no 14 INSPECTION Rotary Valve Cover Inspect rotary valve cover no 1 for warpage Small deformation can be corrected by surfacing with fine sand paper on a surface plate Surface part against oiled sand paper Bearings Inspect bearings no 8 and no 9 Check for scor ing pitting chipping or other evidence of wear Make sure plastic ca...

Page 180: ...attention to the following Bearing To install end bearing no 9 in crankcase use push er P N 420 876 501 F00B07A 1 1 Pusher P N 420 876 501 Position ball bearing shielded side towards rotary valve F01D2DA 1 1 Shield side toward gear Push bearing until it stops on its seat F01D99A Seal Apply Molykote 111 on seal lips Position seal no 11 with shielded portion against shaft splines Bearing Install bal...

Page 181: ...ase halves must be separat ed and crankshaft must not be present to install rotary valve shaft assembly in crankcase 717 Engines To install rotary valve shaft in crankcase use a pusher P N 420 876 605 A00C0YA 1 1 Pusher Push shaft until its stops on bearing seat F01D34A 1 2 1 Rotary valve shaft 2 Push shaft until it stops 787 RFI Engines To install rotary valve shaft in crankcase use a pusher P N ...

Page 182: ... closing of the inlet ports Therefore its efficiency will depend on the precision of its installation IDENTIFICATION OF THE ROTARY VALVE ENGINE ROTARY VALVE P N DURATION 717 787 RFI 420 924 502 159 There is no identification code on the valve To find out the duration place an angle finder on the valve and measure the valve cut out angle or use the following template 160 smr2004 Complete Line Up ww...

Page 183: ...Section 04 ENGINE 2 STROKE Subsection 06 ROTARY VALVE F01D73W 159 smr2004 Complete Line Up 161 www SeaDooManuals net ...

Page 184: ...follows TIMING ENGINE OPENING BTDC CLOSING ATDC 717 147 5 65 5 5 787 RFI 147 5 63 5 5 Timing Procedure The following timing procedure example uses these specifications OPENING 147 BTDC CLOSING 65 ATDC Proceed as follows Turning crankshaft bring MAG side piston to Top Dead Center using a TDC gauge 1 F01D2IA 1 Bring piston to TDC For opening mark first align 360 line of degree wheel with BOTTOM of M...

Page 185: ...lose as possible to these marks with the MAG piston at TDC NOTE Rotary valve is asymmetrical Therefore try flipping it over then reinstall on splines to obtain best installation position Apply Formula XP S injection oil on rotary valve before reassembling rotary valve cover Remove TDC gauge Rotary Valve Cover Install O ring no 12 and rotary valve cover no 1 then torque screws no 2 to 20 N m 15 lbf...

Page 186: ...T SYSTEM 717 Engines GTI and GTI LE models F17D04S 24 N m 17 lbf ft 4 N m 35 lbf in 12 Loctite 243 9 18 19 16 14 5 10 25 N m 18 lbf ft 8 19 Loctite 243 6 4 15 Loctite 30542 1 Loctite 29647 11 2 1 3 4 N m 35 lbf in smr2004 Complete Line Up 165 www SeaDooManuals net ...

Page 187: ...ite 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 20 166 smr2004 Complete Line Up www SeaDooManuals net ...

Page 188: ...ft 18 19 40 N m 30 lbf ft 10 4 14 N m 124 lbf in 16 22 21 47 N m 35 lbf ft 25 N m 18 lbf ft 18 19 6 40 N m 30 lbf ft 5 2 3 4 N m 35 lbf in 1 11 Silicone sealant 23 N m 17 lbf ft 1 48 N m 35 lbf ft 20 14 12 13 7 9 48 N m 35 lbf ft 15 Loctite 243 Loctite 82046 Loctite 82046 smr2004 Complete Line Up 167 www SeaDooManuals net ...

Page 189: ...llar no 1 at tuned pipe outlet Disconnect strap no 2 retaining muffler no 11 Remove exhaust hose no 3 from tuned pipe by pulling muffler Remove clamp no 4 from tuned pipe Remove tuned pipe cone no 5 Remove tuned pipe retaining screw no 6 from exhaust manifold side Remove screws no 12 nut no 8 and flat washers no 9 from tuned pipe flange NOTE Slightly lift tuned pipe to release nut as necessary Be ...

Page 190: ... the tuned pipe head from the tuned pipe cone using the following procedure The second procedure removes the tuned pipe without tuned pipe head and tuned pipe cone separation This procedure is explained further Tuned Pipe Removal with Separation from Tuned Pipe Head and Tuned Pipe Cone 1 Disconnect water return hose at tuned pipe head no 10 1 F18E1WA 1 Water return hose 2 Disconnect small hose fro...

Page 191: ...hose 1 F06E0BA 1 Water bleed hose 5 Loosen clamp no 1 retaining exhaust hose no 3 to tuned pipe cone no 5 1 F06D14A TYPICAL 1 Loosen clamp 6 Loosen and remove clamp no 4 retaining tuned pipe head no 10 to tuned pipe cone no 5 1 F06D1SA 1 Loosen and remove clamp 7 Loosen Allen screw retaining carburetor brack et to tuned pipe head 170 smr2004 Complete Line Up www SeaDooManuals net ...

Page 192: ...0 12 Loosen bolt no 6 of tuned pipe cone beside the engine water return hose 1 F06D1VA 1 Loosen bolt 13 Remove tuned pipe cone no 5 14 Block exhaust opening in the manifold to keep debris from entering cylinder during threads clean ing procedure 15 Remove the stud no 21 from Y manifold 16 Use a M10 x 1 5 screw tap to clean the 4 threaded holes on the Y manifold and the 2 threaded holes on tuned pi...

Page 193: ...ining bracket to engine F06D1UA 1 1 Remove bolt Remove tuned pipe assembly Block exhaust opening in the manifold to keep de bris from entering cylinder during threads cleaning procedure Remove the stud no 21 from Y manifold Use a M10 x 1 5 screw tap to clean the 4 thread ed holes on the Y manifold and the 2 threaded holes on tuned pipe Clean out the debris with a spray cleaner and air pressure CAU...

Page 194: ...fler XP DI Models Remove the VTS motor Refer to VARIABLE TRIM SYSTEM Disconnect the EGT exhaust gas temperature sensor All Models Disconnect hoses from muffler no 11 Disconnect hoses of the water flow regulator valve except 717 engines F01E1FD 1 2 TYPICAL 1 Water supply hose 2 To injection fitting on tuned pipe Disconnect retaining strap no 2 of muffler XP DI Models Disconnect battery cables Refer...

Page 195: ...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 Make sure gasket s no 16 are properly posi tioned prior to finalizing manifold installation 717 Engines Apply Molykote 111 on threads of scre...

Page 196: ...STEM Tuned Pipe 717 Engines CAUTION Torque wrench tightening specifi cations must be strictly adhered to Locking devices ex locking tabs elastic stop nuts self locking fasteners etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be renewed Ensure rubber bushings no 19 and sleeve no 18 are not damaged and are properly installed ...

Page 197: ... spec ified torque 787 RFI Engines CAUTION Torque wrench tightening specifi cations must be strictly adhered to Locking devices ex locking tabs elastic stop nuts self locking fasteners etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be renewed NOTE Loosen all pipe supports from engine be fore installing tuned pipe Ensure rub...

Page 198: ...rt on the engine before torquing the pipe support bolt 25 N m 18 lbf ft 1 N m 9 lbf in 40 N m 30 lbf ft 40 N m 30 lbf ft 6 N m 53 lbf in 48 N m 35 lbf ft 7 3 9 5 6 N m 53 lbf in 48 N m 35 lbf ft 4 8 2 6 25 N m 18 lbf ft 25 N m 18 lbf ft 13 12 10 11 1 15 14 smr2004 Complete Line Up 177 www SeaDooManuals net ...

Page 199: ...l around sealing ring no 15 CAUTION Damage to bushings and or sleeve will eventually cause stress to tuned pipe and may cause cracking CAUTION It is very important that the threads are free of debris before installing new self locking fasteners Refer to removal procedure for the proper thread cleaning procedure Clean the Y manifold and tuned pipe surfaces Screw stud no 21 into the Y manifold Torqu...

Page 200: ... N m 124 lbf in 25 N m 18 lbf ft 25 N m 18 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 3 N m 26 lbf in 48 N m 35 lbf ft 5 15 6 40 N m 30 lbf ft 13 7 3 10 1 2 9 8 6 N m 53 lbf ft 12 14 4 11 smr2004 Complete Line Up 179 www SeaDooManuals net ...

Page 201: ...Section 04 ENGINE 2 STROKE Subsection 07 EXHAUST SYSTEM Install exhaust hose 1 F06D14A 1 Torque clamp to 4 N m 35 lbf in 180 smr2004 Complete Line Up www SeaDooManuals net ...

Page 202: ... engine to be cranked while fuel rail is re moved to prevent fuel to be sprayed out Fuel is flammable jet pump refer to JET PUMP in PROPULSION SYSTEM coolant tank cap WARNING To prevent burning yourself only remove the coolant tank cap by wearing the appropriate safety equipment oil dipstick 1 R1503motr153A 1 Oil dipstick Unplug ignition coil and pull it out spark plug from cylinder head NOTE Igni...

Page 203: ...motr156A 1 Intake rocker arms As the engine is turned over observe the move ment of intake rocker arm of the cylinder to be checked After it completes the cycle and the in take valve closes observe the piston When it reaches its uppermost position that is TDC com pression stroke Protect the hull area then position the wrench lever so that it rest against hull to prevent further crankshaft rotation...

Page 204: ... piston rings INSTALLATION NOTE For installation use the torque values and Loctite products from the exploded views refer to proper engine subsection For installation reverse the preparation proce dure NOTE Prior to inserting the ignition coil in its lo cation apply some Molykote 111 P N 413 707 000 around the seal area that touches the spark plug hole After installation ensure the seal seats prop...

Page 205: ... pump housing means damaged gasket s and or loosened screws refer to COOLING SYSTEM NOTE For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine LEAK TEST PROCEDURE FOR INTERCOOLER Refer to INTAKE SYSTEM 184 smr2004 Complete Line Up www SeaDooManuals net ...

Page 206: ...4 TEC Engines R1503motr63S 10 N m 89 lbf in Loctite 243 10 N m 89 lbf in 6 N m 53 lbf in 10 N m 89 lbf in Loctite 243 6 N m 53 lbf in 18 N m 159 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 Oil Loctite 243 TYPICAL smr2004 Complete Line Up 185 www SeaDooManuals net ...

Page 207: ...gines Supercharger R1503motr357S 30 N m 22 lbf ft Loctite 5910 30 N m 22 lbf ft 30 N m 22 lbf ft 10 N m 89 lbf in Loctite 243 Anti seize lubricant Oil Klueber isoflex 30 N m 22 lbf ft Oil Loctite 243 Loctite 243 Loctite 243 186 smr2004 Complete Line Up www SeaDooManuals net ...

Page 208: ...rcharged Engines Intake Manifold and Throttle Body R1503motr251S 10 N m 89 lbf po Loctite 243 Huile Loctite 243 6 N m 53 lbf po 18 N m 159 lbf po Loctite 243 6 N m 53 lbf po 10 N m 89 lbf po 10 N m 89 lbf po Huile smr2004 Complete Line Up 187 www SeaDooManuals net ...

Page 209: ... Supercharged Intercooled Engines R1503motr358S 10 N m 89 lbf in 10 N m 89 lbf in Loctite 243 Loctite 243 6 N m 53 lbf in Loctite 243 10 N m 89 lbf in 18 N m 159 lbf in 6 N m 53 lbf in Loctite 243 Oil Oil Oil 188 smr2004 Complete Line Up www SeaDooManuals net ...

Page 210: ...ey are not leaking Otherwise remove intercooler from manifold to spray soapy water on it If air bubbles are present replace the intercooler Refer to procedures far ther in this section Properly reinstall removed parts The distance between engine block and intercool er outlet hose must be 3 7 mm 0 12 0 27 in oth erwise the hose would scuff on the engine block 1 R1503motr364A A 1 Outlet hose distanc...

Page 211: ...ith actual torque viewer A mirror is useful to see the viewer 1 R1503motr244A 1 Torque wrench Supercharger should start to turn at a torque be tween 7 to 12 N m 62 to 106 lbf in If the torque is less remove supercharger ass y from engine refer to SUPERCHARGER RE MOVAL elsewhere in this section CAUTION When removing the drive gear with the needle pins be careful not to lose one of the 40 pins Loose...

Page 212: ...washer package on supercharger shaft NOTE Ceramic washers are not affected by wear For assembly refer to SUPERCHARGER ASSEM BLY elsewhere in this section Spring Washer Height Remove supercharger ass y from engine Loosen nut on supercharger shaft engine side Remove L ring and spring washers from shaft Put spring washer package together as it is as sembled on the supercharger shaft Measure the heigh...

Page 213: ...ease Step 2 Pull tank out Remove vent tube support NOTE Pay attention not to drop the nuts under support when removing screws 2 1 F18L1GA 2 3 1 Vent tube support 2 Remove retaining screws 3 Pay attention to nuts underneath RXP 4 TEC Models Remove engine cover Refer to HULL AND BODY All Models Remove oil dipstick Pull fuel rail cover out Release the fuel pressure in the system refer to ENGINE MANAG...

Page 214: ...LLY ASPIRATED ENGINES 1 Cut locking ties to release harness coming from vehicle 1 R1503motr222A 4 TEC SUPERCHARGED ENGINES 1 Cut locking ties to release harness coming from vehicle 4 TEC NA Naturally Aspirated Engines Unplug connectors from ignition coils TOPS valve OSPS TPS idle bypass valve engine con nector CTS CAPS KS CPS magneto OPS and EGTS See following illustrations 5 1 R1503motr60A 9 8 7 ...

Page 215: ...gines For the TOPS valve connector refer to the follow ing illustration 1 R1503motr69A 1 Push here and hold while pulling connector out 4 TEC NA Engines NOTE The TPS connector is hidden behind the TOPS hose Disconnect hose from TOPS valve then move away to access the TPS connector Slightly pry locking tab of connector to unlock R1503motr75A 1 3 2 1 TOPS hose disconnected and moved away 2 TPS conne...

Page 216: ...EGTS connector NOTE On Supercharged models a long screw driver may be used to unlock the connector from the sensor 1 F18D0BA 2 1 Oil filter housing 2 OPS Unplug the B connector from the ECM 1 R1503motr70A 1 Push this end to unlock 1 R1503motr71A 1 Pull here to release smr2004 Complete Line Up 195 www SeaDooManuals net ...

Page 217: ...2 Unlock throttle cable housing 4 TEC Supercharged Engines Remove inlet hose from throttle body Disconnect throttle cable from throttle body R1503motr252A 2 1 1 Detach hose 2 Disconnect cable 4 TEC Supercharged Intercooled Engines Remove the hoses connected to the intercooler 1 R1503motr361A 2 1 Hose from intercooler to exhaust manifold outlet nipple 2 Hose from jet pump All 4 TEC Engines Remove m...

Page 218: ...embly or damage on the parts may result in damage of the supercharg er Strictly follow the described procedures Remove seat GTX 4 TEC Series Remove storage basket vent tube and its support Refer to REMOVAL below RXP 4 TEC Series Remove engine cover Refer to HULL AND BODY All Models Refer to EXHAUST SYSTEM section and remove the following components Cross over hose from LH muffler Detach exhaust pi...

Page 219: ...o remove the upper screw not shown on the picture above use the Torx adapter P N 529 035 938 F00B20A 1 R1503motr250A 1 Upper retaining screws DISASSEMBLY Air Intake Manifold 4 TEC Supercharged Intercooled Engines Intercooler Remove collar from intercooler 1 F19D0DB 2 1 Intercooler 2 Collar Carefully pull intercooler out of air intake manifold 198 smr2004 Complete Line Up www SeaDooManuals net ...

Page 220: ...screws 2 Housing half intake side 3 Housing half engine side F00B29A PLASTIC HAMMER NOTE The cap nut on the supercharger shaft has LH threads Loosen cap nut turn clockwise on supercharger shaft turbine side while holding shaft with a retain ing key P N 529 035 949 1 R1503motr228A 1 Cap nut Remove washer turbine O ring and step collar from supercharger shaft smr2004 Complete Line Up 199 www SeaDooM...

Page 221: ...k washer drive gear and needle pins by turning the supercharger ass y upside down 1 R1503motr359A 2 3 4 5 6 7 1 Nut 2 L ring 3 Spring washers 4 Lock washer 5 Ceramic washers 6 Drive gear 7 Needle bearings Carefully push out supercharger shaft towards en gine side by using a press 1 F00B2CA 1 Supercharger shaft CAUTION Every time when removing the su percharger shaft both ball bearings have to be r...

Page 222: ...36A 2 1 Supercharger housing half engine side 2 Bearing pusher ASSEMBLY All 4 TEC Engines Assembly is essentially the reverse of removal procedures However pay particular attention to the following Air Intake Manifold CAUTION Do not modify air intake system otherwise calibration will be affected Intercooler 4 TEC Supercharged Intercooled Engines Ensure O rings are properly installed on intercool e...

Page 223: ...Every time when supercharger shaft has been removed both ball bearings have to be replaced CAUTION Both ball bearings have to be in stalled with cages facing supercharger impeller side Apply enough engine oil on ball bearing Install ball bearing on supercharger shaft by using support plate P N 529 035 947 to hold bearing CAUTION Ensure to position ball bearing against protrusion of support plate f...

Page 224: ...cker is already applied 1 F00B2IA 2 1 Retaining disc 2 4 pin socket To press supercharger shaft in housing half en gine side properly support bearing using support plate P N 529 035 947 and bearing support push er P N 529 035 950 under supercharger housing half 3 F00B2GA 1 2 1 Support plate 2 Bearing support pusher 3 Protrusion here CAUTION Before pressing in the supercharg er shaft be sure to pro...

Page 225: ...tance that all parts be absolutely clean The compressor shaft spins at up to 45 000 RPM and any debris could cause a failure Install the first ceramic washer NOTE On the RXP 4 TEC supercharged inter cooled engine the ceramic washers differ in their inner diameter Install first the ceramic washer with the bigger inner diameter The ceramic washer with the smaller inner diameter will be installed on ...

Page 226: ...g washers 1 R1503motr359A 2 3 4 5 6 7 1 Nut 2 L ring 3 Spring washers 4 Lock washer 5 Ceramic washers 6 Drive gear 7 Needle bearings Hold the lock washer of the supercharger shaft engine side using the retaining key P N 529 035 949 Tigthen the impeller cap nut to 30 N m 22 lbf ft Apply Loctite 5910 on supercharger housing seal ing surface For correct procedure refer to EN GINE BLOCK Installation i...

Page 227: ... on the intake manifold screws Torque them to 10 N m 89 lbf in fol lowing the tightening sequence shown 5 R1503motr210A 3 1 2 6 7 4 Ensure to properly route and resecure wiring har ness with locking ties WARNING Always check O ring for damage such as deformation at reinstallation Replace the O ring if it is damaged When installing throttle cable ensure cable is in the proper position of bracket an...

Page 228: ...re to install the tool perpendicularly 90 to torque wrench to apply the proper torque to the screw A F00B1UA 1 1 Tool perpendicular 90 to torque wrench A 90 CAUTION Not installing the tool as shown will change the torque applied to the screw Proper torque and tightening sequence are important After complete installation of the supercharger ass y the slipping moment has to be rechecked Refer to SLI...

Page 229: ...4 TEC Subsection 03 EXHAUST SYSTEM EXHAUST SYSTEM F19D02S 6 Loctite 518 2 1 3 7 4 8 5 12 9 11 10 13 Sealant Loctite 5150 High temperature RTV sealant 8 11 N m 97 lbf in smr2004 Complete Line Up 209 www SeaDooManuals net ...

Page 230: ...support 2 Remove screws RXP 4 TEC Models Remove seat Remove engine cover Refer to HULL AND BODY All 4 TEC Engines Disconnect the 3 cooling hoses from exhaust pipe no 1 2 3 F18D0IA 1 1 Exhaust pipe 2 Gear clamp 3 Exhaust clamp Loosen the exhaust hose clamp no 3 to the top portion of the hose between muffler no 4 and the exhaust pipe no 1 1 F18D0RA 2 1 Exhaust hose clamp 2 Exhaust pipe Detach the st...

Page 231: ...edures However pay particular atten tion to the following Apply high temperature RTV sealant P N 293 800 090 on the welds of the exhaust tube while the exhaust pipe is removed from the muffler 1 F18D0TA 2 1 High temperature RTV sealant P N 293 800 090 2 Exhaust pipe Loosely install clamps no 3 on muffler hose Insert the exhaust pipe end in the exhaust hose Align the exhaust pipe flange to the engi...

Page 232: ...nd the screws must be at least 25 mm 1 in apart Tighten both upper clamps 1 F18D0VA 2 3 1 Exhaust pipe step 2 Exhaust hose 3 Exhaust hose clamp 4 5 mm 5 32 3 16 in apart Finalize alignment by rotating axially and mov ing longitudinally the muffler so that the exhaust pipe flange makes perfect contact with the engine manifold A maximum gap of 0 5 mm 1 64 in is allowed Torque the exhaust clamp no 2 ...

Page 233: ... engine while supplying water to the flushing connector EXHAUST MANIFOLD Removal Disconnect the cooling hoses no 2 and no 3 from the exhaust pipe no 1 Remove the exhaust clamp no 4 and detach the muffler from its support Move the muffler no 6 rearwards to separate the exhaust pipe from the manifold See above in EXHAUST PIPE Disconnect the cooling system supply hose no 8 underneath the front part o...

Page 234: ...he exhaust cooling system when wa tercraft is out of water After installation ensure there is no coolant or ex haust gas leak when the engine is running Test run the engine while supplying water to the flush ing connector MUFFLER Removal Remove the exhaust pipe no 1 See above Disconnect the temperature sensor connector Disconnect the outlet hose no 5 Inspection Inspect parts condition paying atten...

Page 235: ...T OUTLET Removal Remove resonator retaining screw no 12 Move resonator forward and disconnect hose no 13 from exhaust outlet no 11 Remove the jet pump as an assembly from pump support Refer to PROPULSION SYSTEM From outside of hull unscrew nut no 10 with the exhaust outlet tool P N 295 000 132 F01B2AA TYPICAL F19D05A 1 2 TYPICAL 1 Exhaust outlet nut 2 Tool From inside the bilge remove exhaust outl...

Page 236: ...ed to disconnect electrical con nections prior to disconnecting fuel lines Disconnect magneto wiring harness Disconnect ground battery cable from engine RXP 4 TEC Models Disconnect ground wires from engine All Models 1 F19D0BA 2 1 Battery ground 2 Engine grounds GTX 4 TEC Series Disconnect the throttle position sensor TPS manifold air pressure sensor MAPS and man ifold air temperature sensor MATS ...

Page 237: ...mp Removal To withdraw jet pump refer to PROPULSION sec tion Drive System To withdraw drive shaft refer to PROPULSION section Cooling System Drain cooling system refer to COOLING SYSTEM section To remove cooling system hoses refer to COOL ING SYSTEM section Disconnect hoses at engine coming from ride plate and coolant expansion tank GTX 4 TEC Series Intake Manifold To remove intake manifold refer ...

Page 238: ...ving engine sup port s or rubber mount adapters shims could have been installed underneath Shims control engine jet pump alignment Always note position of shims for reinstallation to avoid altering engine alignment Remove engine support mount screws 1 F18D13A FRONT SUPPORT 1 Remove screw 1 F18D14A REAR SUPPORT 1 Remove screws Lifting Engine Using a chain block a hoist or other suitable equip ment ...

Page 239: ...the side with the steel rope chain and rotate engine so that it can be pulled out of vehicle 1 F19D09A 2 1 Lift steel rope chain here to rotate engine 2 Usual lifting brackets All Models Removal of Remaining Components Disconnect RED positive cable from starter post 1 F18D12A TYPICAL 1 Disconnect RED positive cable Carry on engine lifting to remove from the body opening CAUTION Be careful not to s...

Page 240: ...orque is important to avoid damaging threads of alu minum insert in bilge Positive Starter Cable and Grounds Connect starter cable before lowering engine Torque nut of positive starter cable to 7 N m 62 lbf in Apply dielectric grease on nut Ensure contact surface is perfectly clean then re connect grounds wires cable to engine Engine Support Do not apply threadlocker to engine support screws and d...

Page 241: ...hout any deflection in engine align ment adapter 1 F18D17A 2 TYPICAL 1 Engine alignment adapter 2 Alignment shaft If the alignment is incorrect loosen engine sup port screws to enable to align engine alignment adapter with shaft end NOTE Use shim s P N 270 000 024 or P N 270 000 025 as necessary between engine supports and rubber mounts to correct alignment 1 F18D15A TYPICAL 1 Shim CAUTION Wheneve...

Page 242: ...ricate it with BOMBARDIER LUBE lubricant After its installation properly adjust throttle cable then perform the TPS reset as specified in EN GINE MANAGEMENT Check hose condition and pressure test fuel sys tem refer to FUEL SYSTEM section 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 en...

Page 243: ...ed only 23 9 17 15 18 14 Loctite 243 10 N m 89 lbf in Loctite 243 6 7 Oil 8 20 21 12 13 19 Oil Loctite anti seize Oil Loctite 5910 16 Loctite 243 10 N m 89 lbf in Loctite 243 12 N m 106 lbf in Oil Loctite 243 10 N m 89 lbf in 3 N m 26 lbf in Left handed thread Oil 11 22 Oil 1 2 Loctite 243 10 N m 89 lbf in 10 smr2004 Complete Line Up 225 www SeaDooManuals net ...

Page 244: ... 037 1 F18D19A TYPICAL 1 Scavenge oil pump cover drain plug F18D2PA TYPICAL Connect the oil vac tool Bombardier P N 529 035 880 to the fitting The front of the engine must be tilted down ap proximately 15 degrees to facilitate the removal of the oil Raise the rear of the watercraft ac cordingly Siphon the oil from the fitting When done remove the oil vac tool and the fitting Apply Loctite 243 and ...

Page 245: ... use prying lugs to sepa rate PTO housing to prevent damaging contact surface R1503motr263A 2 1 3 4 1 Disc springs 2 Washer 3 Flange washer 4 Starter drive gear gasket no 9 Inspection Check PTO housing for cracks or other damages Replace if necessary Installation NOTE Clean all metal component in a non ferrous metal cleaner WARNING Wear safety glasses and work in a well venti lated area when worki...

Page 246: ... housing and check oil coolant pump alignment and starter gear alignment 1 F18D2LA 1 Pay attention that gasket remains properly positioned on this surface Refer to the following illustration for proper instal lation of screws R1503motr15A 1 1 1 2 2 2 2 2 TYPICAL 1 Screws M6 x 35 2 Screws M6 x 85 Tightening sequence for screws on PTO housing is as per following illustration R1503motr15B 14 15 16 17...

Page 247: ... 413 711 809 to prevent oil stains Remove Oetiker clamp no 11 located close to the PTO housing jet pump refer to JET PUMP in PROPULSION SYSTEM drive shaft refer to DRIVE SYSTEM in PROPUL SION SYSTEM PTO seal no 22 1 R1503motr47A 2 TYPICAL 1 Oetiker clamps 2 PTO seal Installation Reinstall removed parts in the reverse order CAUTION When installing PTO seal on su percharged models make sure to posit...

Page 248: ... 184 lbf ft Ap ply Loctite anti seize on threads STATOR Removal Remove PTO housing refer to PTO HOUSING RE MOVAL elsewhere in this section holding plate no 14 with CPS no 15 1 R1503motr21A 2 3 TYPICAL 1 CPS screws 2 Holding plate 3 CPS screws no 16 stator no 17 1 R1503motr26A 2 TYPICAL 1 Stator screws 2 Stator Inspection Check stator and CPS condition If damaged re place the faulty part For electr...

Page 249: ... tool P N 529 035 821 Refer to CRANKSHAFT LOCKING in EN GINE BLOCK subsection Remove PTO housing hexagonal screws no 18 retaining rotor Withdraw rotor no 19 with encoder wheel no 20 1 R1503motr53A 2 3 1 TYPICAL 1 Hexagonal screws 2 Rotor 3 Encoder wheel Inspection Check rotor bent teeth and encoder wheel condi tion If damaged replace faulty part Installation For installation reverse the removal pr...

Page 250: ...ing Ring gear and encoder wheel position has to be lo cated with the location pin on the crankshaft gear 1 R1503motr54B 2 TYPICAL 1 Location pin 2 Location pin holes Apply Loctite 243 on threads Torque rotor screws to 24 N m 17 lbf ft STARTER DRIVE ASS Y Removal Remove PTO housing and ring gear as described above starter drive ass y no 8 1 R1503motr55A TYPICAL 1 Starter drive ass y CAUTION Be care...

Page 251: ...sc springs and washer on the starter drive shaft when assembling 4 TEC Supercharged Models OIL SPRAY NOZZLE Removal Remove the PTO housing as described above Turn oil spray nozzle no 23 by using a grip plier to crack the Loctite CAUTION Do not try to pull out the oil spray nozzle with a plier This may damage the force fit in the PTO housing Fix supercharger spray nozzle remover tight on oil spray ...

Page 252: ...NETO Only use supercharger spray nozzle installer to push in the nozzle no 23 Use retaining screw hole to ensure the exact position 1 R1503motr265A 2 1 Spray nozzle installer 2 Screw hole for positioning 234 smr2004 Complete Line Up www SeaDooManuals net ...

Page 253: ...Loctite 243 10 N m 89 lbf in 24 N m 18 lbf ft Loctite 5910 Loctite 243 10 N m 89 lbf in Oil 3 N m 27 lbf in Left handed threads 20 25 26 Loctite 243 10 N m 89 lbf in 18 17 16 Loctite 243 12 N m 106 lbf in 15 Oil 23 24 6 Oil 23 21 Multi purpose grease Loctite 243 10 N m 89 lbf in 1 2 4 3 19 Oil smr2004 Complete Line Up 235 www SeaDooManuals net ...

Page 254: ...59 lbf in Oil 35 37 36 38 28 29 30 13 11 9 27 10 7 8 Loctite 243 10 N m 89 lbf in 18 N m 159 lbf in 10 N m 89 lbf in Loctite 243 12 Loctite 243 10 N m 89 lbf in Oil 5 25 N m 44 221 lbf in Loctite 243 10 N m 89 lbf in Oil Loctite 243 236 smr2004 Complete Line Up www SeaDooManuals net ...

Page 255: ... oil level either with watercraft in water or out of water Engine should be warm CAUTION Never run engine without supplying water to the exhaust cooling system when wa tercraft is out of water If out of water raise trailer tongue and block in position when bumper rail is level Link a gar den hose to the hose adapter Refer to FLUSH ING in MAINTENANCE and follow the proce dures CAUTION Failure to fl...

Page 256: ... go in limp home mode at 2500 RPM or to generate a fault code start en gine THEN ground OPS connector to engine You may find easier on supercharged engines to remove the plug from the end of engine head However the pressure readings will be different Use the proper table below NOTE The pressure may be measured from cylin der head on all 4 TEC engines if desired F18D2ZA 1 1 Remove this plug and ins...

Page 257: ...damage engine and or exhaust system WARNING Engine oil may be hot Certain components in the engine compartment may be very hot Direct contact may result in skin burn CAUTION Never run engine longer than 5 min utes Drive line seal has no cooling when wa tercraft is out of water Run engine for 10 seconds at 4000 RPM and shut it off at this RPM This will move oil from PTO housing to oil tank to allow...

Page 258: ...mmediately with the pul ley flange cleaner P N 413 711 809 to prevent stains WARNING Wear safety glasses and work in a well venti lated area when working with strong chem ical products Also wear suitable non ab sorbent gloves to protect your hands Inspection Check oil filter cover O ring no 4 and oil filter screw O ring change if necessary Check and clean the oil filter inlet and outlet area for d...

Page 259: ...er then use an air gun to dry it WARNING Always wear eye protector Chemicals can cause a rash break out in and an injury to your eyes Check and clean the oil outlet area for dirt and other contaminations 1 R1503motr118A 1 Oil inlet to the oil pump Installation For installation reverse the removal procedure Refill engine at the proper level with the recom mended oil Refer to TECHNICAL DATA for capa...

Page 260: ...nge cleaner P N 413 711 809 to prevent stains WARNING Wear safety glasses and work in a well venti lated area when working with strong chem ical products Also wear suitable non ab sorbent gloves to protect your hands Remove suction pump cover with oil separator Remove oil strainer no 12 1 R1503motr120A TYPICAL GTX 4 TEC ENGINES 1 Oil strainer R1503motr370A 1 TYPICAL RXP 4 TEC ENGINES 1 Oil straine...

Page 261: ...of oil strainer cover Check and clean the oil inlet and outlet area for dirt and other contaminations 1 R1503motr122A TYPICAL 1 Oil inlet to the oil pump Installation For installation reverse the removal procedure Position screws according to their length as shown 1 R1503motr119A 2 TYPICAL 1 Screws M6 x 25 2 Screws M6 x 85 Torque suction pump cover screws to 10 N m 89 lbf in as per sequence illust...

Page 262: ...egulator R1503motr372A 1 TYPICAL RXP 4 TEC ENGINES 1 Oil pressure regulator NOTE The oil pressure regulator system opens when the oil pressure exceeds 400 kPa 58 PSI Removal Remove engine oil refer to OIL CHANGE oil pressure regulator plug no 15 compression spring no 16 valve piston no 17 and valve piston guide no 18 WARNING Oil pressure regulator plug on oil pump hous ing is spring loaded 244 smr...

Page 263: ...0 3 mm 1 980 in Replace parts if important wear or damage are present Clean bore and threads in the PTO housing from metal shavings and other contaminations Installation For installation reverse the removal procedure Pay attention to the following details Be careful that the O ring on plug screw is in place Torque plug screw to 12 N m 106 lbf in maxi mum Apply Loctite 243 on threads OIL PRESSURE P...

Page 264: ...h a screwdriver R1503motr127A TYPICAL CAUTION Be careful not to damage the surface of the rotary seal bore in PTO housing cover oil seal no 26 1 R1503motr128A 1 Oil seal Inspection Inspect oil pump shaft assembly housing and cov er for marks or other damages Check inner rotor for corrosion pin holes or other damages If so replace oil pump shaft assembly Ensure to also check oil pump housing and co...

Page 265: ...eds the tolerance replace the com plete oil pump and the PTO housing Using a vernier depth gauge measure side wear as shown 1 R1503motr131A 2 1 PTO housing surface 2 Vernier depth gauge R1503motr132A 1 2 1 Oil pump outer rotor surface 2 Vernier depth gage Difference between pump housing and outer rotor should not exceed 0 1 mm 004 in If so replace the complete oil pump assembly NOTE When the axial...

Page 266: ... shaft using the rotary seal pusher P N 529 035 823 on the opposite side to support the rotary seal Use the oil seal guide P N 529 035 822 with a press 1 R1503motr142A 2 1 Oil seal guide 2 Coolant oil pump shaft 2 R1503motr143A 1 1 Coolant oil pump shaft with oil seal guide 2 Rotary seal pusher Tighten oil pump cover screws and torque to 10 N m 89 lbf in Apply Loctite 243 on threads Final Test Aft...

Page 267: ...no 42 Place rags under cover to prevent spillage If spillage occurs clean immediately with the pul ley flange cleaner P N 413 711 809 to prevent stains WARNING Wear safety glasses and work in a well venti lated area when working with strong chem ical products Also wear suitable non ab sorbent gloves to protect your hands Remove oil suction pump housing with oil sep arator Remove oil pump screws no...

Page 268: ...ance between inner and outer rotors ex ceeds the tolerance replace oil pump shaft as sembly Ensure to also check oil pump housing and cover and replace if damaged If clearance between outer rotor and its bore in oil pump exceeds the tolerance replace the com plete oil pump and the PTO housing Using a vernier depth gage measure side wear as shown 2 R1503motr139A 1 1 Oil pump housing surface 2 Verni...

Page 269: ...s M6 x 25 Torque oil pump cover screws to 10 N m 89 lbf in Tighten suction pump screws as per following se quence and torque to 10 N m 89 lbf in Apply Loctite 243 blue on threads R1503motr145A 1 4 5 8 6 7 3 2 OIL COOLER The oil cooler is located below the air intake man ifold 1 R1503motr110A TYPICAL 1 Oil cooler Removal Remove cooling hoses no 34 and no 35 retaining screws no 36 oil cooler no 37 1...

Page 270: ...ARATOR Pressure Test Refer to ENGINE MANAGEMENT section Removal Remove TOPS ventilation hose no 7 1 R1503motr133A TYPICAL GTX 4 TEC ENGINES 1 TOPS ventilation hose R1503motr374A 1 TYPICAL RXP 4 TEC ENGINES 1 TOPS ventilation hose Disconnect wiring harness from TOPS valve no 8 and OSPS no 9 Detach air silencer from throttle body Disconnect battery cables and vent tube then remove battery Refer to B...

Page 271: ...ection Completely disassemble oil separator ass y Inspection If O rings and rubber rings are brittle cracked or hard replace them Clean all contact surfaces of oil separator Check and clean the oil and blow by channels for dirt and other contaminations Installation For installation reverse the removal procedure Pay attention to the following details 1 R1503motr119A 2 TYPICAL 1 Screws M6 x 25 2 Scr...

Page 272: ...n Loctite 243 Engine oil 4 5 10 11 10 1 6 8 Loctite 243 10 N m 89 lbf in Engine oil 17 18 19 Loctite 243 10 N m 89 lbf in 26 27 Engine oil 20 Loctite 243 10 N m 89 lbf in 9 18 N m 159 lbf in 24 23 16 2 10 N m 89 lbf in 18 N m 159 lbf in 6 N m 53 lbf in 21 Engine oil 15 13 10 N m 89 lbf in 6 N m 53 lbf in Grease Klueber Isoflex Topas NB52 7 Loctite 243 14 12 25 22 20 N m 14 5 lbf ft 90 smr2004 Comp...

Page 273: ...e easy to know which one among the springs is the cause to replace it if you grouped them at disassembly Besides since used parts have matched together during the engine operation they will keep their matched fit when you reassemble them together within their group SPARK PLUG Removal Remove fuel rail cover from engine Unplug the single spark ignition coil connector on the spark plug you need to re...

Page 274: ...ro file sealing ring or the valve cover screw accord ingly Installation For installation reverse the removal procedure NOTE Install the valve cover screws according to following sequence 3 R1503motr159A 1 5 7 8 2 4 6 Torque screws to 10 N m 89 lbf in ROCKER ARM Removal Lock crankshaft with crankshaft locking tool P N 529 035 821 refer to CRANKSHAFT LOCK ING in ENGINE BLOCK section Remove spark plu...

Page 275: ... the valve adjustment Inspection Spark Plug Tube Check seals on spark plug tube If seals are brittle cracked or hard replace spark plug tube 1 R1503motr86A 2 3 1 Spark plug tube 2 Seal to the valve cover 3 Seal to the cylinder head Rocker Arm Inspect each rocker arm for cracks and scored fric tion surfaces If so replace rocker arm assembly Check the rocker arm rollers for free movement wear and ex...

Page 276: ...CKER ARM BORE DIAMETER NEW MINIMUM 19 980 mm 7866 in NEW MAXIMUM 19 993 mm 7871 in SERVICE LIMIT 19 965 mm 7860 in A R1503motr90A A Measure rocker arm shaft diameter here Any area worn excessively will require parts re placement Installation For installation reverse the removal procedure Pay attention to the following details Apply engine oil on rocker arm shaft IMPORTANT The rocker arm shaft can ...

Page 277: ...ure may cause screws to loosen and lead to engine damage Torque screws at first to 10 N m 89 lbf in according to following sequence R1503motr93A 2 1 3 4 5 6 Torque screws to 20 N m 177 lbf in Finish tightening screws turning an additional 90 rotation with a torque angle gauge 1 R1503motr92A 2 1 Rocker arm shaft screw 2 Torque angle gauge CAMSHAFT TIMING GEAR NOTE Although it is not necessary to po...

Page 278: ... Never Install timing chain Refer to ENGINE BLOCK sec tion Ensure chain guides are in place Loosely install screws Install chain tensioner NOTE There can be 2 different positions to install the timing gear on the camshaft Basically both positions are working well since the camshaft and crankshaft are locked in their proper position Due to some tolerances there could be one position which fits bett...

Page 279: ...connect coolant temperature and camshaft po sition sensors CTS and CAPS Remove exhaust manifold refer to EXHAUST MANI FOLD REMOVAL elsewhere in this section engine hoses 1 R1503motr253A 2 TYPICAL 1 Coolant hose 2 TOPS ventilation hose chain tensioner refer to CHAIN TENSIONER REMOVAL in ENGINE BLOCK section valve cover shield see VALVE COVER RE MOVAL above camshaft timing gear cylinder head screws ...

Page 280: ...owing procedure CAUTION This assembly uses stretch screws As the screws have been stretched from the previous installation it is very important to measure each screw at assembly If screw is out of specification replace by a new Failure to replace screws and to strictly follow the torque procedure may cause screws to loosen and lead to engine damage CYLINDER SCREW M11 SERVICE LIMIT 148 5 mm 5 846 i...

Page 281: ...4 in SERVICE LIMIT 31 450 mm 1 238 in CAMSHAFT BEARING JOURNAL NEW MINIMUM 39 892 mm 1 5705 in NEW MAXIMUM 39 905 mm 1 5711 in SERVICE LIMIT 39 860 mm 1 5693 in CAMSHAFT BEARING JOURNAL ENGINE FRONT NEW MINIMUM 24 939 mm 9818 in NEW MAXIMUM 24 960 mm 9826 in SERVICE LIMIT 24 910 mm 9807 in CAMSHAFT BORE MEASURED IN DIAMETER NEW MINIMUM 40 000 mm 1 5748 in NEW MAXIMUM 40 016 mm 1 5754 in SERVICE LI...

Page 282: ...spring compressor cup P N 529 035 725 WARNING Always wear safety glasses when disassem bling valve springs Be careful when unlock ing valves Components could fly away be cause of the strong spring preload 2 1 R1503motr103A 1 Valve spring compressor clamp 2 Valve spring compressor cup R1503motr104A LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF THE VALVE Remove valve cotters no 24 Withdraw valve...

Page 283: ... NEW NOMINAL 45 45 mm 1 789 in SERVICE LIMIT 43 mm 1 693 in INNER VALVE SPRING FREE LENGTH NEW NOMINAL 41 02 mm 1 615 in SERVICE LIMIT 38 8 mm 1 499 in Installation For installation reverse the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top NOTE Valve cotters must be properly engaged in valve stem grooves 1 R1503motr105B 1 Position o...

Page 284: ...valve guide in three places using a micrometer and a small bore gauge NOTE Clean valve guide to remove carbon de posits before measuring Change valve if valve stem is out of specification or has other damages such as wear or friction sur face A R610motr126A A Valve stem diameter VALVE STEM DIAMETER NEW MINIMUM Exhaust 5 946 mm 2341 in Intake 5 961 mm 2347 in NEW MAXIMUM Exhaust 5 960 mm 2346 in In...

Page 285: ...destroy the cylinder head as the valve guide is removed Use a special reamer as far as the top of the notch 1 R1503motr258A 2 TYPICAL 1 Special reamer 2 Notch Chase valve guide out of the cylinder head to wards combustion chamber by using a suitable punch 1 R1503motr255A TYPICAL 1 Punch Check valve guide bore for abreased material The inlet and exhaust valve guides have the same length and are int...

Page 286: ...ection Ream the new valve guide with a reamer 6 mm diameter Clean cylinder head carefully Check that the valve seat is concentric with the new guide axis check contact surface with engineer s blue Valve Face and Seat 1 2 R1503motr107A 3 1 Valve seat 2 Exhaust valve contaminated area 3 Valve face contact surface to valve seat Check valve face and seat for burning or pittings and replace valve or cy...

Page 287: ...35 80 45 35 R1503motr259A A Valve seat outer diameter EXHAUST R1503motr260A A INTAKE 55 45 55 45 35 35 A Valve seat outer diameter INTAKE VALVE SEAT OUTER DIAMETER Intake 37 35 mm 1 4705 in Exhaust 30 3 mm 1 1929 in Using a 55 stone for the intake and an 80 stone for the exhaust valve reduce the valve seat contact width to the appropriate value mentioned above Finally coat the valve head sealing s...

Page 288: ...en valve stem is passed through sealing lips of valve stem seal R1503motr254B 1 1 Sealing lips of valve stem seal To ease installation of cotters apply oil or grease on them so that they remain in place while releas ing the spring After spring is installed ensure it is properly locked by tapping on valve stem end with a soft hammer so that valve opens and closes a few times CAUTION An improperly l...

Page 289: ... Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Engine oil Engine oil 24 N m 18 lbf ft 24 N m 18 lbf ft 24 N m 18 lbf ft 10 N m 89 lbf in 24 N m 18 lbf ft 10 N m 89 lbf in 18 N m 159 lbf in 18 N m 159 lbf in 24 N m 18 lbf ft 24 N m 18 lbf ft 21 22 20 18 3 2 1 7 17 16 19 40 N m 30 lbf ft 55 N m 41 lbf ft Grease smr2004 Complete Line Up 273 www SeaDooManuals net ...

Page 290: ...5 15 6 4 4 Engine oil 45 N m 33 lbf ft 90 260 N m 191 lbf ft Loctite anti seize Engine oil Engine oil Engine oil Engine oil 6 Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil 23 274 smr2004 Complete Line Up www SeaDooManuals net ...

Page 291: ...OLD REMOVAL in ENGINE section fuel rail cover spark plugs plug screw 2 R1503motr04A 1 TYPICAL 1 Plug screw 2 Gasket ring Put a screwdriver or similar tool into the spark plug hole of cylinder no 3 and feel when the piston reaches TDC 1 R1503motr03A TYPICAL 1 Screwdriver In this position the crankshaft can be locked by using crankshaft locking tool P N 529 035 821 When finished reinstall all remove...

Page 292: ...EW OF ENGINE 1 Screws bottom engine block half connecting rod screws 1 R1503motr08A 1 Connecting rod screws NOTE Before removing the connecting rod bear ing caps mark them to remember the right posi tion when reassembling R1503motr07A 1 1 Mark on connecting rod thrust washers no 4 R1503motr09A 1 1 Thrust washer crankshaft no 5 276 smr2004 Complete Line Up www SeaDooManuals net ...

Page 293: ...g face of connecting rod and crankshaft counterweight If the distance exceeds specified tolerance replace the worn part 1 R1503motr12A 2 1 Crankshaft 2 Feeler gauge CONNECTING ROD BIG END mm in NEW MINIMUM 0 150 06 NEW MAXIMUM 0 302 01 SERVICE LIMIT 0 5 02 Crankshaft Radial Play Measure all crankshaft journals Compare to in side diameter of crankshaft bushings elsewhere in this section 1 R1503motr...

Page 294: ...verse the removal procedure Pay attention to following details NOTE Before installing the crankshaft make sure that the timing chain is on the crankshaft and the chain guide has been installed first Those parts cannot be installed when the crankshaft is in place CAUTION Crankshaft and balancer shaft marks have to be aligned R1503motr17A 1 2 1 Mark on balancer shaft 2 Mark on crankshaft For correct...

Page 295: ...e Install the crankshaft cover before mounting the engine bracket Apply oil on O ring and press cov er in Crankshaft cover has to be flush with engine block surface 1 R1503motr19A 2 1 O ring 2 Crankshaft cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to position crank shaft at TDC before installing the camshaft and rockers refer to CYLINDER HEAD AND VALVES 1 R1503motr18A ...

Page 296: ...s CHAIN TENSIONER Removal NOTE Removal of the air intake manifold allows easier access to the chain tensioner but is not necessary Refer to AIR INTAKE MANIFOLD RE MOVAL in INTAKE section Remove chain tensioner plug screw no 18 with gasket ring no 19 chain tensioner no 20 3 R1503motr39A 1 2 1 Plug screw 2 Gasket ring 3 Chain tensioner Inspection Check chain tensioner for excessive wear or cracks Al...

Page 297: ... thrust washers no 6 1 R1503motr20A 1 Thrust washer balancer shaft Inspection Check balancer shaft and replace if damaged If the gear on the balancer shaft is damaged re place balancer shaft Check gear on the crankshaft at the same time and replace crankshaft if necessary refer to CRANK SHAFT above Balancer Shaft Bushing Seat Play Measure all balancer shaft bushing seats Com pare to in side diamet...

Page 298: ... control axial adjustment on bal ancer Insert thrust washers as soon as balancer shaft is in place as per following illustration 1 R1503motr20B THRUST WASHER INSERT DIRECTION 1 Thrust washer CAUTION Thrust washers have to be flush with the engine block sealing surface 2 R1503motr22A 1 1 Thrust washer 2 Sealing surface Install lower engine block half Refer to ENGINE BLOCK ASSEMBLY elsewhere in this...

Page 299: ...ar refer to STARTER GEAR RE MOVAL in PTO HOUSING MAGNETO section starter drive ass y oil suction pump with oil separator ass y re fer to SUCTION PUMP REMOVAL in LUBRICA TION section balancer shaft refer to BALANCER SHAFT RE MOVAL elsewhere in this section crankshaft refer to CRANKSHAFT REMOVAL elsewhere in this section piston with connecting rod refer to PISTON RE MOVAL elsewhere in this section B...

Page 300: ...re place cylinder Cylinder Taper Measure cylinder bore and if it is out of specifi cations rehone cylinder sleeve and replace piston ass y with first oversize NOTE It is not necessary to have all cylinders rehoned if they are not all out of specification Mixed standard size and oversize cylinders are al lowed Measure cylinder bore at 3 recommended posi tions See the following illustration R1503mot...

Page 301: ...r as per tighten ing procedure described below Measure the inside diameter of the bushings with a bore gauge 1 R1503motr33A ENGINE UPSIDE DOWN 1 Bore gauge CRANKSHAFT BUSHING INSIDE DIAMETER mm in SERVICE LIMIT 50 1 1 9724 R1503motr34A 1 ENGINE UPSIDE DOWN 1 Bore gauge BALANCER SHAFT BUSHING INSIDE DIAMETER mm in SERVICE LIMIT 32 11 mm 1 2642 in Replace bushings if they are out of specifications O...

Page 302: ...ine block seat 1 R1503motr36A 1 Bushing protrusion in engine block notch Apply engine oil on all bushings in the bottom area of the cylinder bore and also on the band of the piston ring compressor tool For proper installation of pistons refer to Piston Installation elsewhere in this section NOTE Before installing the crankshaft make sure that the timing chain is on the crankshaft and the chain gui...

Page 303: ...iglass plate and apply some sealant on it Use a soft rubber roller 50 75 mm 2 3 in available in arts products suppliers for printmak ing and roll the sealant to get a thin uniform coat on the plate spread as necessary When ready apply the sealant on crankcase mating surfaces F12R17A Do not apply in excess as it will spread out inside crankcase NOTE Do not use Loctite Primer N with this sealant The...

Page 304: ... in Crankshaft cover has to be flush with engine block surface 1 R1503motr19A 2 1 O ring 2 Crankshaft cover CAUTION Install crankshaft locking tool P N 529 035 821 right away to position crank shaft at TDC before installing the camshaft and rockers refer to CYLINDER HEAD AND VALVE 1 R1503motr18A 1 Crankshaft locking tool Install cylinder head PTO housing and the oth er parts in accordance with the...

Page 305: ...circlip no 8 and discard it 1 R610motr134A 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin no 9 out of piston 1 R1503motr27A 3 2 1 Piston 2 Piston pin 3 Circlip Detach piston no 10 from connecting rod Inspection Connecting Rod Piston Pin Clearance Measure piston pin Compare to inside diameter of connecting rod no 5 1 R610motr73A 2 1 B...

Page 306: ... connecting rod big end Compare to crankshaft pin To measure the connecting rod big end diameter use the OLD screws no 11 Install the OLD bushings no 12 as they were mounted initially Do the torque procedure as described below R610motr76A A A Connecting rod big end bushing CONNECTING ROD BIG END DIAMETER mm in SERVICE LIMIT 45 080 1 774 CONNECTING ROD BIG END CLEARANCE mm in SERVICE LIMIT 0 09 003...

Page 307: ...ter set to the dimension adjust a cylinder bore gauge to the micrometer dimen sion and set the indicator to 0 zero F00B09A 1 2 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge F00B0AA 1 TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge 62 mm 2 44 in above cylinder base measuring perpendicularly 90 to piston pin axis Read the measurement on the cylinder bore gauge ...

Page 308: ... ROD SMALL END DIAMETER mm in NEW MINIMUM 23 01 9059 NEW MAXIMUM 23 02 9063 SERVICE LIMIT 23 07 908 1 R610motr73A 2 1 Bore gauge 2 Connecting rod Replace connecting rod if diameter of connect ing rod small end is out of specifications Refer to CRANKSHAFT AND BALANCER SHAFT for re moval procedure of connecting rod Installation For installation reverse the removal procedure Pay attention to the foll...

Page 309: ...ne with connecting rod groove Torque NEW connecting rod screws no 11 as per following procedure Install screws and torque to 45 N m 33 lbf ft Do not apply any thread locker product Finish tightening the screws with an additional 90 turn using an angle torque wrench CAUTION Failure to strictly follow this proce dure may cause screw to loosen and lead to en gine damage Knowing that the screws have b...

Page 310: ...ve clearance If the clearance is too large the piston and the piston rings should be replaced RING PISTON GROOVE CLEARANCE mm in NEW MINIMUM RECTANGULAR 0 025 001 TAPER FACE 0 015 0006 OIL SCRAPER RING 0 020 0008 NEW MAXIMUM RECTANGULAR 0 070 0028 TAPER FACE 0 060 0024 OIL SCRAPER RING 0 055 0021 SERVICE LIMIT ALL 0 15 006 2 R1503motr32A 1 1 Piston 2 Filler gauge 294 smr2004 Complete Line Up www S...

Page 311: ...se the removal procedure Pay attention to the following details Install the oil scraper ring first then the taper face ring with the word TO facing up then the rect angular ring with the word T facing up A31C2NA 1 2 3 1 Rectangular ring 2 Taper face ring 3 Oil scraper ring CAUTION Ensure that top and second rings are not interchanged NOTE Use a ring expander to prevent breakage during installation...

Page 312: ...lter 3 Fuel pump 4 Regulator 5 Fuel rail 6 Fuel injector 7 Electronic Control Unit ECU 8 Multi Purpose Electronic Module MPEM 9 Throttle plate 10 Throttle Position Sensor TPS 11 Air Pressure Sensor APS 12 Air Temperature Sensor ATS 13 Crankshaft Position Sensor CPS 14 Water Temperature Sensor WTS 15 Battery 16 Ignition coil smr2004 Complete Line Up 297 www SeaDooManuals net ...

Page 313: ...g the engine power fuel economy and emission con trols under all engine operating conditions by man aging both the fuel injection duration and ignition timing The Rotax Fuel Injection RFI is composed of the 3 following basic systems 1 air induction 2 fuel delivery 3 electronic management AIR INDUCTION A single throttle body 56 mm breath through the air intake silencer to provide a sufficient amoun...

Page 314: ...d in a single module mounted in the fuel tank The fuel gauge sender is also mounted on this module F07F09A FUEL PUMP ASSEMBLY FUEL INJECTORS The injectors inject a metered quantity of fuel from the fuel rail into the cylinder rear transfer port in ac cordance with the signal from the Electronic Con trol Unit ECU F07F0AA INJECTOR ELECTRONIC MANAGEMENT ELECTRONIC CONTROL UNIT ECU The electronic fuel...

Page 315: ...t at 7200 50 RPM Fail Safe Function In the event of a sensor malfunction the ECU will use a default operating mode to ensure driveability to shore A message may be displayed on the Info Center to inform the operator Diagnostic Mode The ECU is able to detect malfunctions in the sen sor network The malfunction is recorded in the memory of the ECU The memory of the ECU can be checked using VCK Vehicl...

Page 316: ...rature Intake air temperature Battery voltage Start stop signal Air Pressure Sensor APS Water Temperature Sensor WTS Air Temperature Sensor ATS Fuel tank Fuel filter Fuel pump Regulator Injectors Multi Purpose Electronic Module MPEM Electronic Control Unit ECU PARAMETERS SENSORS FUEL DELIVERY Throttle Position Sensor TPS To engine F07F0NS SIGNAL MANAGEMENT smr2004 Complete Line Up 301 www SeaDooMa...

Page 317: ...he 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 Electrical Connections DESS Post Connection Through the 6 Pin Connector Disconnect the connector shown in the following picture and install RFI DESS adapter P N 278 001 978 F12H18A 1 1 Connector t...

Page 318: ...5 REAL TIME 6 END DIAGNOSIS NOTE Line no 1 BOSCH INFO will display the identification of the watercraft and the MPEM ECU By selecting READ FAULT the MPEM program mer will display the number of faults in the ECU memory and the codes related with the fault s The programmer will offer PRESS ANY KEY If there is more than 1 fault in the ECU memory the next fault code will be displayed NOTE On this mode...

Page 319: ...too high 02 0A 1D P 0117 Sensor circuit shorted to ground 02 0A 1E P 0118 Signal interruption or short circuit to battery Engine Water Temperature Sensor WTS 02 0A 1B P 0116 Non plausible signal 02 06 1F P 0122 Sensor circuit shorted to ground Throttle Position Sensor TPS 02 06 1C P 0123 Sensor circuit shorted to battery Crankshaft Position Sensor CPS 02 1F 06 02 1F 23 P 0219 Signal exceeding RPM ...

Page 320: ...1200 Interruption or open circuit 04 E2 1C P 0265 Short circuit to battery 04 E2 1D P 0264 Short circuit to ground Injector 2 04 E2 1E P 1201 Interruption or open circuit Fuel pump 04 EB 1C P 0230 Short circuit to battery Not applicable 04 FC N A Not applicable 04 DB 1C P 0478 Short circuit to battery 04 DB 1D P 0477 Short circuit to ground RAVE vacuum solenoid 04 DB 1E P 0479 Interruption or open...

Page 321: ...urize the fuel tank and fuel lines as explained in FUEL SYSTEM section Properly reconnect the battery WARNING Ensure to verify fuel line connections for damage and that NO fuel line is disconnected prior to installing the safety lanyard on the DESS post A pressure test must be done before connecting the safety lanyard The fuel pump is started each time the safety lan yard is installed and it build...

Page 322: ...rly in the ignition system Installing resistive caps non resistive spark plug cables or modified length or non resistive spark plugs may lead to generate fault codes or bad operation NOTE Use the VCK to diagnose fault codes See TROUBLESHOOTING section After a problem has been solved ensure to clear the fault s in the MPEM using the VCK Refer to DIAGNOSTIC PROCEDURES Resistance Measurement When mea...

Page 323: ...operation AIR INDUCTION SYSTEM THROTTLE BODY Check that the throttle plate moves freely and smoothly when depressing throttle lever FUEL DELIVERY FUEL FILTER To inspect the fuel filter the fuel pump assembly has to be removed from the fuel tank See RE MOVAL in this subsection for the procedure FUEL PUMP The fuel pump operation can be checked as fol lows Install the safety lanyard cap on the switch...

Page 324: ...e injector at idle While working at 2500 RPM and below engine gradually goes from two cylinder to one at idle 1 F07F0CA 2 3 4 5 6 7 1 Inlet side 2 Filter 3 Wiring terminal 4 Coil 5 Plunger 6 Needle valve 7 Injection side Touch the injector while cranking the engine to feel the operation of the injector If there is no signal detected from the injector disconnect the plug connector from the injector...

Page 325: ...ace each injector in a clean bowl Install the safety lanyard cap on the switch to ac tivate the fuel pump Check for fuel leakage from the injector nozzle There should be less than 1 drop of fuel per minute 2 1 F07F16A 3 1 Fuel injectors 2 Fuel rail 3 Injector nozzles If not within specification replace the fuel injec tor s LEAK TEST SUPPLY AND VENTILATION CIRCUITS Refer to FUEL SYSTEM HIGH PRESSUR...

Page 326: ...ons at fuel pump and at fuel rail ELECTRONIC MANAGEMENT THROTTLE POSITION SENSOR TPS Check the resistance value of the throttle position sensor F07F0EA 1 TYPICAL 1 Throttle position sensor TPS Disconnect the AMP plug connector 4 on the MPEM Using a multimeter check the resistance between terminal 3 PURPLE BROWN wire and terminal 4 BLACK BROWN wire on the AMP plug connec tor The resistance should b...

Page 327: ...tage Test If the sensor resistance value is good check the voltage output from MPEM to throttle position sensor Disconnect plug connector from throttle position sensor and connect a voltmeter between the PUR PLE BROWN wire and the BLACK BROWN wire in the wiring harness Depress the start stop button with the safety lan yard removed to activate the timer There should be 5 Vdc CRANKSHAFT POSITION SEN...

Page 328: ...ATS If resistance is above specifications disconnect the connector of the air temperature sensor and check resistance of wiring harness and terminals between AMP plug connector and ATS sensor connector If there is an open circuit repair or replace the defective wire or terminal Reconnect the air temperature sensor connector and recheck the resistance between terminal 6 and terminal 13 in the AMP p...

Page 329: ...iring harness and pin 12 on the 4 AMP plug connector Remove the TAN ORANGE wire from the 12 po sition on the AMP plug connector install a test connector a female connector with about 25 mm 1 in of wire then reconnect the AMP plug con nector Press the start stop button and check for 5 V on the test wire If none is present replace the MPEM On the WTS connector check for continuity to ground on the B...

Page 330: ...re sensor connector and recheck the resistance value between terminals in the AMP plug connector 4 If not within specification replace the air pressure sensor Voltage Test If the sensor resistance value is within specifica tions disconnect the plug connector from the APS sensor and check the voltage between the PUR PLE BLUE wire and the BLACK BLUE wire in the wiring harness from the MPEM Install s...

Page 331: ...sition sensor 4 and 11 BK BW and WH BW 710 1380 ohms 5 Vdc between PU BW and BK BW Water temperature sensor 5 and 12 BK OR and TA OR 2280 2736 ohms N A Air temperature sensor 6 and 13 BK WH and WH GY 2280 2736 ohms N A Crankshaft position sensor 7 and 14 GY YL and GY RE 774 946 ohms N A Rave solenoid 16 and 23 PU GY and BK GY 30 ohms N A Injector no 1 18 and 20 BL PU and BL BK 2 3 2 5 ohms Injecto...

Page 332: ... spark independent ly on each piston stroke Reversed high tension cables will cause backfires ECU FAULT CODES Fault codes in the ECU memory will identify poten tial problems with the RFI system When check ing fault codes without engine in operation the CPS fault code will always appear Also the 04 FC fault code will always appear Disconnecting the battery will erase the fault codes in the ECU memo...

Page 333: ...attery voltage When voltage is too low the MPEM limits the engine revolutions Recharge or replace battery The RAVE system is not functioning properly The sliding valves do not open Check pressure hoses and check valve from crankcase to RAVE solenoid Check RAVE solenoid 320 smr2004 Complete Line Up www SeaDooManuals net ...

Page 334: ... TPS re setting Reset the TPS value to provide the zero scale value to ECU Using MPEM Programmer Access the BOSCH SYSTEM in the MPEM pro grammer Then select ADJUSTMENT in the sub menu CAUTION Never attempt to adjust the idle speed through the throttle body tamper proof screw If so it would impair the idle speed stability Besides no adjustment could be per formed to correct the idle speed The throt...

Page 335: ...the APS Remove the APS At installation apply Loctite 243 blue on screw threads WATER TEMPERATURE SENSOR WTS Disconnect the connector of the WTS Loosen the WTS from the cylinder head At installation apply Loctite 518 on threads of the WTS CRANKSHAFT POSITION SENSOR CPS Disconnect the connector of the CPS Loosen Allen screw retaining the CPS Remove the CPS At installation apply Loctite 243 blue on t...

Page 336: ... fuel pump assembly has to be removed from the fuel tank to have access to the fuel filter Refer to the section above for more detail Remove fuel pump Turn fuel pump up side down Using a small flat screwdriver remove the fuel filter by prying the inner plastic ring 1 F18R0EA 2 1 Fuel filter 2 Inner plastic ring FUEL INJECTORS Place a suitable container below the quick connect fitting of the fuel r...

Page 337: ...tion 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 immediately stop the en gi...

Page 338: ...e reed valves into the crankcase 1 F12F05A 1 TWIN 46 MM THROTTLE BODIES 1 Throttle position sensor TPS AIR COMPRESSOR SYSTEM The air compressor supplies the compressed air required for fuel atomization in the air injector It is integrated with the engine and mechanically driven by the counterbalance shaft It also sup plies the air pressure required to operate the RAVE valves F12D01A FUEL DELIVERY ...

Page 339: ... pressure increases in the fuel rail the fuel pressure needed to open the regulator will increase equally The differential pressure regulation utilizes the air pressure reference signal to maintain constant pressure drop across fuel injector orifice The initial operating pressure of the regulator is preset by the manufacturer and is not adjustable Direct Injector Also called air injector two direc...

Page 340: ...es and other vehicle information even when the battery is removed from the watercraft MPEM General Functions Safety Lanyard Reminder If engine is not started within 5 seconds after installing the safety lanyard on its post 4 short beeps every 3 second interval will sound for ap proximately 2 hours to remind you to start the en gine or to remove safety lanyard Afterwards the beeps will stop The sam...

Page 341: ...not allowed The MPEM features a self diagnostic mode Re fer to DIAGNOSTIC PROCEDURES subsection for more information The memory of the MPEM is permanent If the battery is disconnected no information is lost When ordering a new MPEM from the regular parts channel the DESS circuitry will be activat ed Gauges Current Supply When installing the safety lanyard it activates the reading of gauges without...

Page 342: ...egrated in the MPEM in fuse holder s close to MPEM or in the electrical box Fuses are identified besides their holder IMPORTANT The sensors and injectors are con tinuously powered with the supply from the bat tery The MPEM switches the ground to com plete the electrical circuits it controls Take this into account when troubleshooting the electrical system smr2004 Complete Line Up 331 www SeaDooMan...

Page 343: ...Section 07 ENGINE MANAGEMENT DI Subsection 01 OVERVIEW MPEM ENGINE MANAGEMENT FUNCTIONS 332 smr2004 Complete Line Up www SeaDooManuals net ...

Page 344: ...os sible conditions Cranking start up idle warm up normal operation Sea Doo LK learning key limited vehicle speed engine speed limiter flooded engine and limp home see below Flooded Engine drowned mode If the engine does not start and it is flooded pro ceed as follows Remove spark plug cables and connect them on the grounding device Remove spark plugs and dry them using a rag Cover spark plug hole...

Page 345: ...ging system A 12 volts battery supplies the Multi Purpose Elec tronic Module MPEM with DC current Refer to CHARGING SYSTEM The following type of ignition system is used Digital Inductive System Magneto System The magneto is the primary source of electrical energy It transforms magnetic field into electric current AC The magneto has a 3 phase delta wound stator on 18 poles Capacity is 270 watts Ign...

Page 346: ... system Wear safety glasses and work in a well ventilated area Do not allow fuel to spill on hot engine parts and or on electrical connectors Proceed with care when removing installing high pressure test equipment or disconnecting fuel line connec tions Use the VCK Vehicle Communication Kit to release fuel pressure prior to removing a hose Cover the fuel line connection with an absorbent shop rag ...

Page 347: ... even when the safety lanyard is removed Always disconnect the battery prior to disconnecting any electric or electronic parts To perform verifications a good quality multimeter such as Fluke 111 P N 529 035 868 should be used Pay particular attention to ensure that terminals are not out of their connectors or out of shape The troubleshooting procedures cover problems not resulting from one of the...

Page 348: ...test good at a certain temperature but it might be defective at other temperatures If in doubt try a new sensor Also remember this validates the operation of the sensor at ambient temperature It does not val idate the over temperature functionality To test it the sensor could be removed from the engine muffler and heated with a heat gun while it is still connected to the harness to see if the MPEM...

Page 349: ...Pressure gauge between disconnected hose inline installation Install safety lanyard and observe fuel pressure Do not crank engine FUEL REGULATOR PRESSURE when installing safety lanyard 185 14 kPa 27 2 PSI If pressure is within limits air fuel rail is working adequately Proceed with the fuel pressure test below If pressure is out of limits refer to FUEL DELIV ERY below and proceed with the tests de...

Page 350: ...to AIR IN TAKE section Disconnect TPS connectors Disconnect throttle cable and oil injection pump cable Detach hoses and remove fasteners retaining throttle bodies and pull out together If only one throttle body replacement is required detach them and remove the sealant on idle set screw head Gently remove the plastic cap from the synchronization screw Remove TPS throttle lever spring and guide fr...

Page 351: ...hronizing screw and spring between levers NOTE The 175 resistance mentioned below is used to open the throttle plates the same amount on each throttle body to obtain the proper synchro nization It is the equivalent of using a drill bit in the throttle bore to open throttle plate on carbure tors Master TPS Snap throttle plate a few times to ensure it is com pletely closed Using an ohmmeter measure ...

Page 352: ...ing removed Snap throttle plate a few times to ensure it is com pletely closed Measure resistance between terminals 2 and 3 Note the resistance value Substract 175 from that value Properly reinstall the spring Ensure that master throttle plate is still closed Turn synchronizing screw clockwise until read ing reaches the computed value above 20 1 2 F12R1CA 1 Measure resistance between terminals 2 a...

Page 353: ...e until throttle opening meter indicates between 95 and 99 Closed TPS Adjustment Perform the CLOSED TPS ADJUSTMENT as de scribed in THROTTLE POSITION SENSOR TPS in ELECTRONIC MANAGEMENT further in this section Injection Oil Pump Cable Adjustment As oil injection cable is throttle dependent always proceed with the oil injection pump cable adjust ment after throttle cable adjustment Refer to LU BRIC...

Page 354: ...air may flow out from it MINIMUM AIR PRESSURE at cranking 621 14 kPa 90 2 PSI If pressure is within limits air compressor is work ing adequately If pressure is below limits ensure inlet hose is not obstructed bent or kinked Otherwise repair the air compressor Remove pressure gauge and reinstall air compres sor hose REPAIR Top End Remove retaining screws Lift cover then remove compressor head Clean...

Page 355: ... Block engine in this position Remove top end as explained above Remove access plug of air compressor connecting rod Remove connecting rod retaining screw As a puller use a M7 x 1 0 x 50 mm screw to release connecting rod crankpin 1 F12R06A 1 Use a M7 x 1 0 x 50 mm screw as a puller Push piston upward with or without the cylinder sleeve Remove rubber plug then push piston pin end to remove from co...

Page 356: ...and needs replacement Otherwise replace piston Ring End Gap Position ring close to top of cylinder top NOTE In order to correctly position ring in cylin der use piston as a pusher Using a feeler gauge check ring end gap If gap exceeds specified tolerance rings should be re placed 2 1 F12R07A 1 Top of cylinder 2 Ring end gap Assembly Apply injection oil in cylinder and on rings prior to installing ...

Page 357: ...ss cov er and install cover Reinstall remaining removed parts Ensure to check engine alignment FUEL DELIVERY FUEL PRESSURE REGULATOR Pressure Test The pressure test will show the available pressure at the air fuel rail It validates the pressure regula tor and leaks in the system IMPORTANT Before checking air fuel rail pres sure make sure the fuel pressure from the fuel pump and the air pressure fr...

Page 358: ...drop indicates leakage either from the fuel injector or from the fuel pressure regulator Check fuel injector for leaks see be low If it is not leaking then replace fuel pressure regulator NOTE Fuel in air compressor outlet line is an in dication of a leaking fuel pressure regulator di aphragm Remove pressure gauge and reinstall fuel hose At installation apply engine oil on O ring WARNING Wipe off ...

Page 359: ...nication kit VCK with the B U D S software energize the fuel injector from the Activation tab If the injector does not work disconnect the con nector from the injector Install a temporary connector to the injector with wires long enough to make the connection out side the bilge and apply voltage 12 V to this test harness This will validate the injector mechanical and elec trical operation If it do...

Page 360: ...If it is not leaking then replace air pressure regulator A higher pressure may be an indication of a pinched or clogged air pressure regulator outlet line Air Pressure Regulator Replacement Removal See FUEL PRESSURE REGULATOR REMOVAL above for procedure Remove the fuel regulator then the air pressure regulator Installation For the installation reverse the removal procedure but pay attention to the...

Page 361: ...e air fuel rail use Loctite Krylox no 29 719 DIRECT INJECTOR When any direct injector is defective while replac ing it make sure to check the other one as well Also check fuel injectors Replace if defective The direct injectors can be replaced by lifting the air fuel rail Leakage Test If direct injector leaks through its large top O ring there will be an air fuel leak between the injector and the ...

Page 362: ...of cylinder head 1 F12R0GA 2 1 Air fuel rail 2 Disconnect and pull injector out Compress the carbon dam using tool P N 529 035 716 Carefully install direct injector in cylinder head paying attention to carbon dam insertion Ensure to position connector pointing toward bottom of cylinder head NOTE A thin film of injection oil may be applied to carbon dam if necessary to ease insertion in cylinder he...

Page 363: ...above Note the arrow on the valve Otherwise air compressor components might be damaged Install pressure gauge between disconnected hoses on fuel pump side closed loop installation on fuel pump Make sure the pressure relief valve is installed on the fuel pump return line side 1 2 3 4 F12R0BA 1 Fuel pump outlet hose fuel filter side 2 Fuel pump return line 3 Fuel relief valve on the return line side...

Page 364: ... section Otherwise repair the wiring harness connectors between AMP connector and fuel pump Fuel Pump Replacement Ensure fuel pressure has been released in the sys tem using the VCK Vehicle Communication Kit Removal Open front storage compartment cover Remove the storage basket Remove glove box see HULL BODY section Remove front vent tubes Remove rear access panel Referring to DIRECT ACTION SUSPEN...

Page 365: ...tall new rubber washers under neath the nuts while installing the fuel pump Apply Loctite 243 on nut threads Install fuel pump on fuel tank and torque nuts to 2 5 N m 22 lbf in Ensure to align the arrow with the dot on the gas ket towards the LH side of fuel tank 10 11 9 2 12 5 1 6 7 3 8 4 13 F18F09B TORQUE AS PER SEQUENCE FUEL FILTERS Fuel Pump Filter Removal The fuel pump assembly has to be remo...

Page 366: ...t pay attention to the following New filter can be pressed back on by hand En sure it is fully seated for complete filtering of the fuel Reinstall fuel pump External Fuel Filter A replaceable in line filter is located near the fuel pump 1 F12R0IB 2 TYPICAL 1 Fuel pump 2 Fuel filter Using low compressed air check if the fuel filter is clogged NOTE Respect the fuel filter flow check the ar row WARNI...

Page 367: ... blockage Check for air leaks Repair leaks Check direct injector yes Perform fuel pump test Replace fuel pump module pass no leaks Check RAVE for air leaks Repair air compressor Air pressure more than 621 kPa 90 PSI OK Replace direct injector Connect safety lanyard Fuel pump does not run Fuel pump runs for 2 sec then stops Check fuses Check lanyard connection Check pump module operation Repair or ...

Page 368: ...Battery BLACK negative cable must always be disconnected first and connected last Disconnect AMP connectors from MPEM Remove MPEM Install the new MPEM on the vehicle Reconnect AMP connectors to MPEM then bat tery cables If the previous MPEM was read with B U D S Transfer the data from the previous MPEM to the new one using B U D S then proceed with the required resets after following the procedure...

Page 369: ...Using the vehicle communication kit VCK with the B U D S software use the Throttle Opening display under Monitoring Slowly and regularly depress the throttle Ob serve the needle movement It must change gradually and regularly as you move the throttle If the needle sticks bounces suddenly drops or if any discrepancy between the throttle move ment and the needle movement is noticed it indicates a wo...

Page 370: ...values are incorrect disconnect the TPS and perform the resistance measurement di rectly to the TPS terminals If TPS is good repair the wiring harness connectors between AMP con nector and the TPS Replacement Remove the air intake silencer Remove the air duct Disconnect the TPS connector Loosen two Allen screws retaining the TPS Remove TPS 2 F12R0LA 1 MAG SIDE THROTTLE BODY 1 Allen screws 2 Thrott...

Page 371: ...ngine first ensure information center is in tachometer mode If it displays ap proximately 300 RPM the CPS circuitry is proper ly working Otherwise validate the information center is working by activating the tachometer using the software B U D S under Activation first ensure information center is in tachometer mode If it does not display 3000 RPM the information center may be faulty and needs to b...

Page 372: ...nals for corrosion or dam age Check the voltage readings on the harness side as follows CONNECTION VOLTAGE Terminal 4 with engine ground 0 V a small mV tolerance Terminal 5 with engine ground 12 V Terminal 6 with engine ground 5 V If voltage tests good the CPS is defective and needs replacement If voltage does not test good perform the follow ing tests Resistance Test Check the continuity of the w...

Page 373: ...the MPEM Using a multimeter recheck resistance value be tween terminals 16 and 19 If resistance value is correct try a new MPEM Refer to MPEM REPLACEMENT procedures else where in this section If resistance value is incorrect repair the wiring harness connectors between AMP connector and the MATS Replacement Remove the air intake silencer Remove the air duct Disconnect the connector of the MATS Pul...

Page 374: ...stalled in elbow adap tor Otherwise the MAPS could generate a fault code for an unexpected sensor range at idle when it reads the atmospheric pressure Ensure the cor rect connector is plugged and not mixed with the MAG TPS Remove sensor and check for oil or dirt on its end and if problem persists check throt tle plate condition position and the wiring harness Perform the following tests Voltage Te...

Page 375: ...and remove EGTS Apply Loctite 518 on threads of the EGTS then install Replug connector KNOCK SENSOR KS 1 F12R0QA 1 Knock sensor KS Dynamic Test Using the vehicle communication kit VCK with the B U D S software monitor the knock sensor using the FAULTS section Start the engine and bring engine RPM above 4500 RPM If no fault code occurs the knock sensor is good Otherwise do the following Ensure sens...

Page 376: ... electronic side However pneumatic test still has to be performed to validate the mechanical operation Leakage Voltage Test NOTE The solenoid activates both RAVE valves at the same time Unplug the RAVE solenoid supply hose from air compressor F12R0RA 1 2 1 Air compressor 2 Disconnect RAVE solenoid supply hose Install leak test pump P N 529 021 800 on hose end and pressurize air line to 69 103 kPa ...

Page 377: ... prevents the pressure from going down into the crankcase Install a hose pincher after the T fitting to adequately pressurize the check valve portion F12R0TB 1 3 2 1 RAVE solenoid 2 Pressure relief hose 3 Install hose pincher here Resistance Test Reconnect the solenoid and disconnect the AMP connector number 4 on the MPEM Using a multimeter check resistance value be tween terminals 20 and 23 The r...

Page 378: ... 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 A dynamic test is more effec tive Remove high tension lead from ignition coil Using a multimeter check the resistance between the terminals C and the coil post The resistance should be between 6800 and 10200 at 20 C 68 F If not within specification repl...

Page 379: ...eral Before checking ignition timing setting with a stro boscopic timing light dynamic test it is manda tory to scribe a timing mark on the PTO flywheel static test corresponding to the engine specifica tion CAUTION The relation between the PTO fly wheel mark position and crankshaft position may change as the PTO flywheel might move on crankshaft when engine is ran This will result in a false igni...

Page 380: ... N 295 000 135 Install and adjust a TDC gauge P N 414 104 700 in MAG side spark plug hole Ensure to install its roller to allow proper reading of the gauge Proceed as follows Rotate magneto flywheel clockwise until piston is just Before Top Dead Center 1 F12R0VA 2 3 4 5 TYPICAL 1 Outer ring 2 Adaptor lock nut 3 Adaptor 4 Roller 5 Roller lock nut Install roller on dial gauge end Ensure to posi tion...

Page 381: ...USTMENT below for more informa tion CAUTION If the spark advance curve is not locked using B U D S then a wrong ignition timing will be seen as the ignition curve does not match the locked ignition timing Start engine and check mark at idle speed Point beam of timing light straight in line with timing mark pointer NOTE Look at the mark at the same angle as it was scribed so that parallax error is ...

Page 382: ...nd to reset the service hours when you per form a service action such as the ignition timing setting NOTE The MPEM features a permanent non volatile memory and keeps the ignition timing set ting programmed even when the watercraft bat tery is disconnected Engine Start Stop Switch Verification A quick operation test can be done using the ve hicle communication kit VCK with the B U D S software usin...

Page 383: ...be continuity Otherwise replace DESS switch If switch tests good in both checks do the follow ing Disconnect the connector on electrical box Using a voltmeter perform the following tests Connect test probes to the small RED wire on the starter solenoid and on the RED PURPLE wire from the cut off relay Reading should be 0 V Oth erwise replace the cut off relay Keeping the test probes on the same wi...

Page 384: ... con nection between the center electrode and ground Spark Plug Installation Prior to installation make sure that contact sur faces of the cylinder head and spark plug are free of grime Using a wire feeler gauge set electrode gap according to the following chart Apply anti seize lubricant over the spark plug threads to prevent possible seizure Hand screw spark plug into cylinder head Then tighten ...

Page 385: ...BK BW 1600 2400 ohms 5 and 14 WH BW and BK BW 2500 ohms at idle Throttle position sensor MAG TPS AMP no 3 5 and 10 WH BW and PU BW 1200 ohms at idle 1 and engine ground PU RD 5 V 2 and engine ground BK RD 0 0 5 V TPS 3 and engine ground WH RD 0 V 3 and 18 BK RD and PU RD 1600 2400 ohms 1 and 3 WH RD and BK RD 1000 ohms at idle Throttle position sensor PTO TPS AMP no 4 1 and 18 WH RD and BK RD 2500...

Page 386: ...uity Exhaust gas temperature sensor EGTS AMP no 4 10 and 12 TA GY and BK TA 2280 2740 ohms Knock sensor KS AMP no 4 2 and 17 BK BL and YL BL 5 M ohms RAVE solenoid RS AMP no 4 20 and 23 PU GY and BK GY 24 ohms AMP no 3 21 and 22 RE GN and WH GN 45 55 ohms primary winding Ignition coil MAG Coil terminal C and coil post 6800 10 200 ohms secondary winding w o high tension leads AMP no 3 20 and 23 RE ...

Page 387: ...ard on watercraft post Good contact between safety lanyard cap and DESS post Bad connection between safety lanyard cap Remove and replace the safety lanyard on the post until 2 short beeps are heard to indicate the system is ready to allow engine starting Unprogrammed or defective safety lanyard Use the safety lanyard that has been programmed for the watercraft If it does not work check safety lan...

Page 388: ... Refer to CHARGING SYSTEM Coolant and exhaust gas temperature sensors or TPS Throttle Position Sensor or CPS Crankshaft Position Sensor malfunction Refer to ENGINE MANAGEMENT A 2 seconds beep every minutes intervals MPEM malfunction Refer to ENGINE MANAGEMENT A 2 seconds beep every 15 minutes intervals Oil injection reservoir level is low Refill Continuous beep Engine overheats Refer to COOLING SY...

Page 389: ...5 if EGTS also fails Direct injector single injector MAINT ON OFF 7 Limited RPM Fuel injector single injector MAINT ON OFF 7 Limited RPM Ignition no firing on one cylinder MAINT ON OFF 7 Limited RPM RAVE solenoid MAINT ON OFF 7 Limited RPM Starter solenoid MAINT ON OFF 7 Engine may not start Fuel pump MAINT ON OFF 7 Limited RPM Exhaust gas temperature sensor EGTS MAINT ON OFF ON 7 5 Limited RPM co...

Page 390: ...ed RPM Sensor supply fault TPS and MAPS MAINT ON ON OFF 5 7 Limited RPM code 7 and idle RPM if both in fault Encoder CPS fault bad pattern MAINT ON OFF 7 Limited RPM Low battery voltage 12 V LOW ON OFF 7 None Very low battery voltage 12 V LOW MAINT ON ON 5 Limited RPM High battery voltage MAINT ON OFF 7 None Very high battery voltage MAINT ON OFF 7 Idle RPM High water temperature HI TEMP ON ON 1 N...

Page 391: ...81 is the primary tool to diagnose fuel in jection related problems B U D S is designed to allow among other things the programming of safety lanyard s entering customer information engine monitoring sensor inspection diagnostic options and adjustment such as the Throttle Position Sensor TPS and the ignition timing setting For more information pertaining to the use of the software B U D S use its ...

Page 392: ... This will also records that the problem has been fixed in the MPEM memory Many fault codes at the same time is likely to be burnt fuse s For more information pertaining to the code faults state count first etc and report refer to B U D S online help Supplemental Information for Some Specific Faults ECU fault code P0606 This code may occur in the following situations Electrical noise is picked up ...

Page 393: ...t sensor for damage or corrosion Yes Replace and reset closed TPS Inspect wiring voltage test Failed Repair Inspect wiring and sensor resistance test Failed If bad wiring repair If bad TPS replace and reset closed TPS Test sensor operation wear test Failed Replace and reset closed TPS TPS ADAPTATION FAILURE Fault It is caused by the idle position moving out of an acceptable range POSSIBLE CAUSES R...

Page 394: ...es damaged connector damaged ECU output pins ECU failure Service action Check for 1 7 1 9 ohm resistance between system circuits 4 13 and 4 7 Check for 12 volts on pin A of injector connector color P0202 Fuel injector PTO FUEL_ INJ_2 Open or short circuit Yes No Return to idle Possible causes Damaged injector damaged circuit wires damaged connector damaged ECU output pins ECU failure Service actio...

Page 395: ... and between 1 and 3 2500 ohms Check for linear resistance rise when opening throttles Check physical stops for wear P0220 TPS MAG TPI_2 Sensor out of range Yes No Return to idle Possible causes Damaged sensor damaged circuit wires damaged connector damaged ECU pins ECU failure damaged or out of alignment throttle bodies or sensor Service action Check for 5 volts on pin 1 and 4 75 5 0 volts on 3 a...

Page 396: ...ice action Check for resistance approx 2280 ohms to 2736 ohms at temperature of 19 to 21 C 66 to 70 F between system circuits 4 16 and 4 19 P0106 MAPS MAP Sensor out of range Yes No Return to idle Possible causes Check sensing port for dirt or blockage Sensor failure unexpected reading at idle Sensor fallen out of housing Leaking Inlet system ECU failure Service action Check system circuits 3 3 3 ...

Page 397: ... output pins ECU failure Service action Check for resistance of 6 8 ohms between system circuits 4 24 and 4 26 P0475 RAVE solenoid RAVE Open or short circuit Yes open and short circuit Yes open circuit Return to idle Possible causes Damaged solenoid damaged circuit wires damaged connector damaged ECU output pins ECU failure Service action Check for resistance of 30 ohms between system circuits 4 2...

Page 398: ... 25 to battery terminal 2 26 to regulator 2 pin connector pin A 2 25 to regulator 2 pin connector pin B P0122 Sensor supply TPS MAG and MAPS XDRP_1 Sensor 5 volt supply failure Yes Yes Return to idle Possible causes Damaged circuit wires associated sensor failure TPI 2 or MAP ECU fault Service action Check for shorts to ground or corrosion on the following system circuits 3 10 or 3 3 P0222 Sensor ...

Page 399: ...500 No Return to idle Possible causes Damaged sensor damaged circuit wires damaged connector damaged ECU pins ECU failure Service action Bring engine to 4500 RPM If fault code appears check for resistance approx 4 8 ohms between system circuits 4 2 and 4 17 P1601 Diagnostic cap COMMS_CAP Diagnostic cap is not installed on wiring harness Yes Yes As soon as fault is not present Possible causes Cap i...

Page 400: ...nd COMPASS OUTSIDE AIR TEMPERATURE SENSOR COMMUNICATION LINK COMMUNICATION LINK POWER TO ECM INFORMATION CENTER SET AND MODE SWITCHES SPEED SENSOR FUEL LEVEL SENDER BEEPER DEPTH GAUGE START STOP SWITCH STARTING SOLENOID FUEL PUMP FUEL INJECTORS IGNITION COILS TOPS VALVE TOPS SWITCH CAPS INFORMATION CENTER ECM MPEM TPS MAPS MATS CTS EGTS KS OPS OSPS CPS DESS IDLE BYPASS VALVE COMMUNICATION LINK WH ...

Page 401: ...trical system is managed by micro controllers working together Overall the MPEM multi purpose electronic module man ages the vehicle electrical system the EMS engine management system controls the en gine management and the information center is used to display information that comes both from MPEM and EMS A communication link is used between the elec tronic modules to communicate with each other ...

Page 402: ...and 3 instead of PTO CENTRE and MAG The numbers are stamped on the valve cover 1 R1503motr218A 2 3 1 Cylinder 1 2 Cylinder 2 3 Cylinder 3 NOTE The EMS includes an ECM engine con trol module sensors injectors electromagnetic valves and ignition system AIR INDUCTION 4 TEC Naturally Aspirated Engine Air for combustion is drawn directly at the front of the engine through one 52 mm throttle body The ai...

Page 403: ...32A 3 2 1 Supercharger 2 Intercooler 3 Throttle body FUEL DELIVERY SYSTEM BASIC OPERATION When the intake valve reaches the correct posi tion the ECM Engine Control Module opens the fuel injector and fuel is discharged into the intake port at the air intake manifold by the high fuel pres sure inside the fuel rail The air fuel mixture enters then the combustion chamber through the open intake valve...

Page 404: ... the cylin der head Fuel Rail The fuel rail is a small tube on which the three injectors are mounted It ensures all the time that enough fuel at the right pressure can be delivered to the fuel injectors The fuel rail is fed by the fuel pump Fuel Injector Three fuel injectors one per cylinder are used to inject fuel into the intake ports of the cylinder head Flame Arrester The flame arrester is a t...

Page 405: ... ulates the fuel pressure at approximately 303 kPa 44 PSI for all 4 TEC Naturally Aspirated super charged engines and at 399 kPa 58 PSI for inter cooled engines Fuel Filter A mesh filter is located at the bottom of the fuel pump module inside the fuel tank ELECTRONIC MANAGEMENT EMS ENGINE MANAGEMENT SYSTEM The EMS is controlled by its ECM Engine Control Module 1 R1503motr215A TYPICAL 1 ECM ECM Eng...

Page 406: ...ntistart Feature This system allows starting the vehicle only with safety lanyard s that has been programmed to op erate a specific watercraft This functionality is the DESS system See below for details Digitally Encoded Security System DESS The following components are specially designed for this system Multi Purpose Electronic Module MPEM ECM safety lanyard cap and safety lan yard post The safet...

Page 407: ...rt stop button is pressed If start stop button is held after engine has started the ECM automatically stops the starter when the engine speed reaches 1600 RPM If start button is activated while the throttle lever is depressed more than 65 the engine will not be allowed to start Engine RPM Limiter The ECM will limit the maximum engine speed Engine Stopping There are 2 ways to stop the engine Press ...

Page 408: ... As shown in the 1503 4 TEC CONTROL SYSTEM illustration the ECM is the central point of the fuel injection system It reads the inputs makes com putations uses pre determined parameters and sends the proper signals to the outputs for proper engine management The ECM also stores the fault codes and general information such as operating conditions vehicle hours serial numbers customer and maintenance...

Page 409: ...hat would be typically generated by en gine detonation If detonation occurs the knock sensor detects it and the ECM retards the ignition advance temporarily it goes in a specific mode until detonation stops The ECM is able to evalu ate the knocking cylinder and modifies the ignition advance just on the detonating one Engine Modes of Operation The ECM controls different operation modes of the engin...

Page 410: ...ng the safety lanyard on its post Depending on the malfunction the watercraft speed may be reduced and not allowed to reach its usual top speed The engine speed will be limited to 2500 or 5000 RPM These performance reduced modes allow the rid er to go back home which would not be possible without this advanced system Refer to the DIAG NOSTIC PROCEDURES for a complete chart If a fault occurs and in...

Page 411: ...cess to most functions of the informa tion center gauge without starting the engine Gauges are supplied with current whenever the safety lanyard cap is installed on its post NOTE The fuel pump will be activated for 2 sec onds to build up pressure in the fuel injection sys tem only when connecting the safety lanyard cap to the post Low Fuel Level Warning Device When the fuel level in the reservoir ...

Page 412: ...s Always proceed with care and use appro priate safety equipment when working on pressurized fuel system Wear safety glass es Do not allow fuel to spill on hot engine parts and or on electrical connectors Pro ceed with care when removing installing high pressure test equipment or discon necting fuel line connections Use the VCK Vehicle Communication Kit to release fuel pressure prior to removing a...

Page 413: ... Always disconnect the battery prior to disconnecting any electrical or electronic parts To perform verifications a good quality multimeter such as Fluke 111 P N 529 035 868 should be used Pay particular attention to ensure that terminals are not out of their connectors or out of shape The troubleshooting procedures cover problems not resulting from one of these causes WARNING Ensure all terminals...

Page 414: ...6 325 280 370 90 194 245 210 280 100 212 195 160 210 110 230 145 125 160 120 248 115 100 125 CONVERSION CHART FOR TEMPERATURE SENSORS The resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures If in doubt try a new sensor Also remember this validates the operation of the sensor at ambient temperature It does not validate the ...

Page 415: ...se this diagram to locate the terminal numbers on the Engine connector of the wiring harness when performing tests CAUTION Before unplugging engine connec tor always remove safety lanyard first then wait 15 seconds Otherwise damage to CAPS may occur 4 R1503motr192A 1 2 3 ENGINE CONNECTOR PIN OUT WIRING HARNESS SIDE CONNECTORS ON ENGINE Removal To remove connectors from engine connector bracket sli...

Page 416: ... button 2 Connectors F18Z0NA 1 2 1 Connectors 2 Release button AIR INDUCTION SYSTEM THROTTLE BODY IMPORTANT Never mix up throttle bodies of nat urally aspirated and supercharged 4 TEC engines Doing so will automatically lead to a misfunction of the EMS and will cause a bad engine calibration 6 R1503motr160A 5 4 3 1 2 TYPICAL 1 Throttle body 2 Throttle cable attachment 3 Throttle plate 4 TPS 5 Idle...

Page 417: ...ed or damaged wiring or connectors Throttle body has been replaced and the Closed Throttle and Idle Actuator reset has not been performed ECM has been replaced and the Closed Throt tle and Idle Actuator reset has not been per formed Electrical Inspection Refer to THROTTLE POSITION SENSOR TPS and IDLE BYPASS VALVE in ELECTRONIC MAN AGEMENT below To verify the engine RPM with tachometer P N 529 014 ...

Page 418: ...ever attempt to adjust the idle speed through the throttle body tamper proof screw If so it would impair the idle speed stability Besides no adjustment could be performed by the dealer or the factory to cor rect the idle speed The throttle body would need to be replaced Also take into account that it might change the engine emission level and the engine might not meet the EPA CARB requirements CAU...

Page 419: ...N If there is no free play at idle posi tion it may cause poor idling and startability Improper cable adjustment will cause strain on cable and or damage cable bracket or throttle lever at handlebar To adjust loosen jam nut then turn adjustment nut as necessary 1 F18F07A 2 3 1 Adjustment nut 2 Jam nut 3 Throttle lever stopper Tighten jam nut and recheck adjustment WARNING Make sure idle speed stop...

Page 420: ...r 399 kPa 58 PSI Fuel pressure more than 303 kPa 44 PSI or 399 kPa 58 PSI Fuel pressure less than 303 kPa 44 PSI or 399 kPa 58 PSI Perform fuel pump test Check fuel line rail for leaks Fuel pressure less than 303 kPa 44 PSI or 399 kPa 58 PSI Fuel pressure more than 303 kPa 44 PSI or 399 kPa 58 PSI Check fuel injector Fails Connect safety lanyard Fuel pump runs Fuel pressure is 303 kPa 44 PSI or 39...

Page 421: ...P N 529 035 591 1 F18R08A 2 1 Hose disconnected from fuel pump 2 In line installation of fuel pressure gauge Install safety lanyard and observe fuel pressure Do not crank engine Repeat twice Release pressure using B U D S between tests so that the gauge is reset to zero 0 MODELS FUEL PRESSURE when installing safety lanyard 4 TEC naturally aspirated supercharged 303 kPa 44 PSI 4 TEC supercharged in...

Page 422: ...ltage is read check continuity of circuit B 29 going towards ECM If it is good try a new ECM b If battery voltage is not read check continuity of circuit 1 26 going towards MPEM If it is good try a new MPEM Fuel Pump Replacement Removal Open front storage compartment cover Remove the storage basket if so equipped Remove front access panel see HULL BODY sec tion Remove front vent tubes Remove glove...

Page 423: ...he fuel filter by prying the inner plastic ring 1 F18R0EA 2 1 Fuel filter 2 Inner plastic ring Inspection Check if particles are present in fuel filter If so replace it Installation For installation reverse the removal process but pay attention to the following New filter can be pressed back on by hand En sure it is fully seated for complete filtering of the fuel Reinstall fuel pump FUEL RAIL Pres...

Page 424: ...bove Run engine and check for leaks FUEL INJECTOR IMPORTANT Never mix up fuel injectors of nat urally aspirated and supercharged 4 TEC engines Doing so will automatically lead to a misfunction of the EMS and will cause a bad engine calibration Leakage Test To perform a leakage test the injectors and fuel rail have to be removed from the engine Refer to REMOVAL in FUEL RAIL REPLACEMENT for the proc...

Page 425: ...2 17 2 2 18 3 Resistance Test Reconnect the injector and disconnect the ECM connector A Remove safety lanyard and wait 15 seconds Dis connect engine connector CAUTION Before unplugging engine connec tor always remove safety lanyard and wait 15 seconds Otherwise damage to CAPS may oc cur Using a multimeter check resistance value be tween terminals as follows 4 R1503motr192A 1 2 3 ENGINE CONNECTOR R...

Page 426: ...ONIC MANAGEMENT ECM AND MPEM REPLACEMENT General Prior to replacing a suspected ECM or MPEM en sure that all the recommendations in the general introduction of this section have been followed IMPORTANT When the ECM is replaced the Closed Throttle and Idle Actuator must be re set Refer to its specific section for adjustment To allow transferring the previous recorded infor mation from the old ECM o...

Page 427: ... to be sure no fault appears MPEM Replacement Disconnect battery cables WARNING Battery BLACK negative cable must always be disconnected first and connected last Disconnect AMP connectors from MPEM Re move retaining nuts on top Pull MPEM out Install the new MPEM in vehicle Reconnect AMP connectors to MPEM If the previous MPEM was read with B U D S Transfer the data from the previous MPEM to the ne...

Page 428: ...TS connector 4 CAPS connector 5 Fuel injector connector cylinder 1 6 Ignition coil connector cylinder 1 7 Fuel injector connector cylinder 2 8 Ignition coil connector cylinder 2 9 Fuel injector connector cylinder 3 10 Ignition coil connector cylinder 3 11 TOPS valve connector 12 OSPS connector 13 TPS connector 14 Idle bypass valve connector 15 MATS connector 16 Engine connector 17 MAPS connector 1...

Page 429: ...s 1 R1503motr202A 1 1 Locking ties Connect the fuel injectors ignition coils CAPS CTS and EGTS to the wiring harness WARNING Pay attention not to mix injectors or ignition coils wires between cylinders The location of the splice connectors indicate which cylin der wires belong to Install the engine connector on the appropriate bracket on the wiring support Then fix the other bundle on the appropri...

Page 430: ...EM above The EMS may generate several fault codes per taining to the TPS Refer to SYSTEM FAULT CODES in DIAGNOSTIC PROCEDURES 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 display under Monitori...

Page 431: ...ould be approximately 2500 Check the resistance between terminal A 24 and terminal A 39 with the throttle plate in wide open position The resistance should be 1000 1100 Check the resistance between terminal A 24 and A 25 with throttle plate in idle position The resistance should be 1000 1100 Now check the resistance with the throttle plate in wide open position The resistance should be 2600 2700 N...

Page 432: ... U D S NOTE No message will be displayed if operation is good If operation is wrong an error message will be displayed NOTE There is no idle speed adjustment to perform The ECM takes care of that If TPS is not within the allowed range while resetting the CLOSED THROTTLE AND IDLE ACTUATOR the ECM will generate a fault code and will not accept the setting Start engine and make sure it operates norma...

Page 433: ...ace CPS if wiring is good Resistance Test Disconnect the CPS connector from the wiring harness and check the resistance of the sensor itself The resistance should be between 190 and 290 Otherwise replace the CPS If resistance tests good reconnect the CPS and disconnect the ECM connector A on the ECM Using a multimeter recheck resistance value be tween terminals 5 and 19 R1503motr182A 5 19 If resis...

Page 434: ... connector from the wiring har ness To see the connector pin out temporarily remove the connector shield joining the harness to ex pose the terminal numbers Remove and reinstall safety lanyard to activate the system Probe terminal 3 of CAPS connector wiring har ness side and battery ground If 12 V is read check continuity of circuits A 20 and A 34 If they test good perform the CAPS voltage test as...

Page 435: ... es from 12 V to less than 1 V 2 R1503motr207A 1 Pin 1 Pin 2 1200 W resistor Pin 3 V 1 CAPS 2 Conductor If the voltage is not good replace the CAPS Replacement Unscrew the retaining screw and replace the CAPS Ensure to reinstall O ring Apply Loctite 243 blue on thread and torque to 6 N m 53 lbf in MANIFOLD AIR TEMPERATURE SENSOR MATS 1 R1503motr171A TYPICAL INTAKE MANIFOLD 1 Manifold air temperatu...

Page 436: ...nnector and the MATS Replacement Disconnect the connector of the MATS Screw MATS out and install the new one Torque to 18 N m 159 lbf in COOLANT TEMPERATURE SENSOR CTS 1 R1503motr172A 1 Coolant temperature sensor CTS Resistance Test Disconnect the connector from the CTS and check the resistance of the sensor itself The resistance should be between 2280 and 2740 at 20 C 68 F Otherwise replace the C...

Page 437: ...heck for oil or dirt on its end and if prob lem persists check throttle plate condition posi tion and the wiring harness Perform the follow ing tests Voltage Test Check the voltage output from ECM to the mani fold air pressure sensor MAPS Disconnect connector from MAPS and connect a voltmeter to the terminals of the wiring harness as per the following table CONNECTION VOLTAGE Terminal 1 with engin...

Page 438: ...acement Disconnect EGTS connector and remove EGTS Apply Loctite 518 on threads of the EGTS then install Replug connector KNOCK SENSOR KS 1 R1503motr174A 1 Knock sensor KS Dynamic Test Using the vehicle communication kit VCK with the B U D S software monitor the knock sensor using the FAULTS section Start the engine and bring engine RPM above 5000 RPM If no fault code occurs the knock sensor is goo...

Page 439: ...ness is good test the sensor adaptor Using an ohmmeter measure the resistors as shown in the following illustration F19H04A 1 YELLOW GREEN 19 000 21 000 W 1710 1890 W 1 Knock sensor adaptor Replace sensor adaptor if resistors are not within values If sensor adaptor is good try a new ECM Refer to ECM REPLACEMENT procedures elsewhere in this section Otherwise repair the connector or replace the wiri...

Page 440: ...sistance Test Disconnect the connector from the OPS and use a multimeter to check the resistance between OPS terminal and engine ground while engine is stopped without oil pressure and while engine is running with oil pressure When engine is stopped the resistance is infinitely high normally open switch When engine is running and the oil pressure reach es 180 220 kPa 26 32 PSI the resistance of th...

Page 441: ...es and pump from dip stick tube WARNING Stop the engine and wait at least 30 seconds before removing the pump and tubes so that pressure drops Otherwise check the resistance of the OSPS while engine is off and while engine is running Resistance Test Disconnect the connector from the OSPS and use a multimeter to check the resistance between OSPS terminal and engine ground while engine is stopped wi...

Page 442: ...t voltage on wiring harness Replace TOPS valve Lower than 8 V Greater than 8 V No OK Fails Repair or replace Install engine leak test pump gauge on oil dipstick tube Start engine Yes No Pressure drops down directly after reaching 40 kPa 5 8 PSI TOPS valve opens again TOPS OK Yes Check OSPS Fails OK Fails Yes No OK Fails Replace OSPS Retest Retest OK Try a new MPEM Check wiring harness Retest Worki...

Page 443: ...1 R1503motr179A TYPICAL 4 TEC ENGINE 1 TOPS valve R1503motr351A 1 TYPICAL 4 TEC SUPERCHARGED ENGINES 1 TOPS valve Resistance Test Disconnect the connector from the TOPS valve and check the resistance of the solenoid itself The resistance should be between 1 27 and 2 47 Otherwise replace the TOPS valve Dynamic Test Activate the TOPS valve by installing the safety lanyard on the DESS post If you can...

Page 444: ...ate switch as it would do in vehicle Switch should remain closed up to approximately 120 from the vertical axis in either direction Other wise replace switch NOTE Since this is a mercury switch dispose it properly according to the environmental regula tions in your area Farther than 120 and when switch is upside down switch should be open and resistance will be infinite Limp Home Mode due to OSPS ...

Page 445: ...NING Never make a spark test with spark plug re moved Flammable vapors may be present in the bilge and ignited which could cause an explosion Voltage Test WARNING When disconnecting coil from spark plug al ways disconnect coil from main harness first Never check for engine ignition spark from an open coil and or spark plug in the engine compartment as spark may cause fuel vapor to ignite Disconnec...

Page 446: ...d to prevent a cable mixing by using different cable lengths IGNITION TIMING The ECM is able to determine the exact position of camshaft and crankshaft That means that no ignition timing setting has to be performed ENGINE START STOP SWITCH VERIFICATION A quick operation test can be done using the ve hicle communication kit VCK with the B U D S software using the Monitoring tab Press the start butt...

Page 447: ...e wiring harness from the ignition coil Remove the ignition coil First unscrew the spark plug one turn Clean the spark plug and cylinder head with pres surize air then completely unscrew Spark Plug Installation Prior to installation make sure that contact sur faces of the cylinder head and spark plug are free of grime 1 Using a wire feeler gauge set electrode gap according to the following chart 2...

Page 448: ...an be displayed in the informa tion center for troubleshooting With safety lan yard on its post press 5 times the SET button to start the display of P codes onboard diagnostic Press MODE to scroll codes if more than one is present When the list is over END will appear When END appears press MODE to exit F18L09D 1 1 Press 5 times to activate display of P codes onboard diagnostic F18L09C 1 1 Press t...

Page 449: ...rature Sensor ECM ECU Module EGTS Exhaust Gas Temperature sensor ETS Exhaust Temperature Sensor Idle bypass valve DLA Digital Linear Actuator Idle actuator Idle valve Information center Cluster MAPS Manifold Air Pressure Sensor APS Air Pressure Sensor or Atmospheric Pressure Sensor MATS Manifold Air Temperature Sensor ATS Air Temperature Sensor or Intake manifold Temperature Sensor Oil separator O...

Page 450: ...check safety lanyard condition with B U D S Replace safety lanyard if reported defective Defective safety lanyard Use another programmed safety lanyard Dried salt water or dirt in safety lanyard cap Clean safety lanyard cap to remove salt water Defective DESS post Refer to ENGINE MANAGEMENT section 1 long beep while installing safety lanyard on post Improper operation of ECM or defective wiring ha...

Page 451: ...it malfunction Refer to ENGINE MANAGEMENT section Starter solenoid circuit malfunction Refer to ENGINE MANAGEMENT section Communication link fault detected by MPEM Refer to ENGINE MANAGEMENT section ECM communication link message missing detected by MPEM Refer to ENGINE MANAGEMENT section Information center communication link message missing detected by MPEM Refer to ENGINE MANAGEMENT section 2 se...

Page 452: ...U D S version 2 or above NOTE For 4 TEC inter cooled models B U D S version G 2 1 1 is required B U D S Bombardier utility and diagnostic soft ware is designed to allow among other things the programming of safety lanyard s entering customer information engine monitoring allow ing actuators sensors and electronic equipments inspection diagnostic options and reset such as the closed throttle and id...

Page 453: ...rking properly and check connections on VCK and watercraft VCK Supply The VCK MPI box can use the watercraft power for its supply The safety lanyard must be connected in order to use the watercraft as a power source If watercraft power is used every time the safety lanyard is taken off the DESS post the kW2000 protocol will have to be re activated Changes in ECM Anytime a change is brought in ECM ...

Page 454: ...that all electronic components are genuine particularly in the ignition system Installing resistive caps non resistive spark plugs or im proper knock sensor wiring routing may lead to generate this fault code Electrical noise might also lead engine to oc casional cutout without generating a fault code when engine is restarted When looking at the fault code pay attention to the count value in the s...

Page 455: ...ctuator Test sensor operation wear test Failed Replace and reset Closed Throttle and Idle Actuator TPS ADAPTATION FAILURE Fault It is caused by the idle position moving out of an acceptable range Following failures can be effected by a TPS Adaption Failure Idle speed is out of range Engine stops when throttle is released quickly Engine runs inconsistent in low partload or low RPM POSSIBLE CAUSES R...

Page 456: ... system circuits A 12 A 28 and A 40 Make sure that the sensor housing is correctly inserted into the manifold Check sensor connector for a 5 volts on pin 1 b 0 volt on pin 2 c 0 volt on pin 3 Manifold atmospheric pressure sensor shorted to ground 15 Flash CHK ENG N Y N Fault is recovered P0107 Manifold barometric pressure sensor shorted to ground 15 Flash CHK ENG Y N N Fault is recovered Possible ...

Page 457: ...NG N Y N Fault is recovered Possible cause Damaged sensor damaged circuit wires damaged connector or damaged ECM pins Service action Check the sensor for approximately 2280 to 2736 ohms at 19 to 21 C 66 to 70 F Check for approximately 2280 to 2736 ohms at 19 to 21 C 66 to 70 F between ECM connector pins 7 and 21 P0112 Intake manifold temperature sensor shorted to ground 15 Flash CHK ENG N Y N Faul...

Page 458: ...e temperature sensor short circuit to ground 5 Flash CHK ENG N Y N Fault is recovered Possible cause Damaged sensor damaged circuit wires damaged connector or damaged ECM pins Service action Check for debris or blockage in cooling system Check the sensor for approximately 2280 to 2736 ohms at 19 to 21 C 66 to 70 F Check for approximately 2280 to 2736 ohms at 19 to 21 C 66 to 70 F between ECM conne...

Page 459: ...le Check physical stops for wear P0123 Throttle position sensor out of range short circuit to 12 V or open circuit 15 Flash CHK ENG N Y N Key is removed Possible cause Damaged sensor damaged circuit wires damaged connector or damaged ECM pins Damaged or out of alignment throttle bodies or sensor Service action Check for 0 volt on sensor connector pin 1 Check for 5 volts on sensor connector pin 2 C...

Page 460: ... ohms between engine connector pin 1 and ECM connector pin 15 Check for 12 volts on pin 2 of injector connector P0262 Inj 1 short circuit to 12 V 15 Flash CHK ENG N Y N Fault is recovered Possible cause Damaged injector damaged circuit wires damaged connector or damaged ECM output pins Service action Check for 11 4 to 12 6 ohms between engine connector pin 1 and ECM connector pin 15 Check for 12 v...

Page 461: ...d sensor damaged circuit wires damaged connector or damaged ECM output pins Service action Bring engine to 5000 RPM If fault code appears then check for approximately 5 Mohms between system circuits A 9 and A 23 P0336 Crank position sensor wrong engine RPM detected 15 Flash CHK ENG Possible cause Damaged sensor damaged circuit wires damaged connector damaged ECM pins or damaged tooth wheel Service...

Page 462: ...ck for 12 volts on sensor connector pin 3 Check continuity for circuits A 20 A 34 and terminal 4 on engine connector P0351 Ignition coil 1 open circuit or shorted to ground or to 12 V 15 Flash CHK ENG N Y 5000 Engine is stopped Possible cause Damaged coil damaged circuit wires damaged connector or damaged ECM output pins Service action Check for 0 85 to 1 15 ohms between engine connector pin 1 and...

Page 463: ...4 Flash SENSOR Y Y N Fault is recovered Possible cause Damaged sensor damaged circuit wires damaged connector or damaged MPEM output pins Service action Check voltage between system circuit 1 21 and battery ground DLA output stage cutoff memory difference 15 Off CHK ENG DLA output stage fault 15 Off N A Y N N Fault is recovered DLA open circuit 15 Off N A Y N N Fault is recovered P0505 DLA short c...

Page 464: ...cuits A 10 and A 26 P0545 Exhaust gas temperature sensor shorted to ground 5 Flash CHK ENG Y N Y N Fault is recovered Possible cause Damaged sensor damaged circuit wires damaged connector or damaged ECM output pins Service action Check for approximately 2280 to 2736 ohms at temperature of 19 to 21 C 66 to 70 F between system circuits A 10 and A 26 Exhaust gas temperature sensor shorted to 12 V 5 F...

Page 465: ...ed connector damaged ECM output pins Diagnostic connector cap not connected Service action Check system circuits 1 16 1 17 1 10 1 11 2 10 2 11 Connect diagnostic connector cap P0600 CAN communication problem MPEM message missing 15 Flash N A Y Y N Fault is recovered Possible cause Damaged circuit wires damaged connector or damaged ECM output pins Service action Check system circuits 2 10 2 11 P060...

Page 466: ...ymptom 136 P0605 EEPROM faulty 15 Flash CHK ENG Possible cause Damaged ECM Service action No service action available for fault P0605 symptom 137 P0605 Checksum fault EEPROM 15 Flash CHK ENG Possible cause Damaged ECM Service action No service action available for fault P0605 symptom 143 P0605 Coding ID checksum fault 15 Flash CHK ENG Possible cause Damaged ECM Service action No service action ava...

Page 467: ...rter relay shorted to ground 5 Flash CHK ENG N fault detected while cranking Y N Fault is recovered P0616 Starter relay open circuit 5 Flash CHK ENG Y Y N Key is removed Possible cause Damaged solenoid damaged circuit wires damaged connector or damaged ECM output pins Service action Verify 10 A fuse Check for 12 volts on pin 2 of the starter relay P0617 Starter relay shorted to 12 V 5 Flash CHK EN...

Page 468: ... battery voltage Replace TPS Replace idle bypass valve P1200 Blow by valve shorted to ground or open circuit 5 Flash CHK ENG Y N Y 5000 Fault is recovered Possible cause Blow by valve failure damaged circuit wires damaged connector damaged ECM pins or ECM failure Service action Check for 1 27 to 2 47 ohms on component P1201 Blow by valve shorted to 12 V 5 Flash CHK ENG N N N N A Possible cause Blo...

Page 469: ...k for no continuity between system circuit 2 13 and battery ground Connect or disable lake water temperature sensor in setting page P1511 Lake temperature sensor circuit high voltage 15 Off SENSOR Y Y N N A Possible cause Damaged sensor damaged circuit wires damaged connector or damaged MPEM output pins Service action Check for 6528 3 to 25403 3 ohms between system circuits 2 13 and 2 4 Connect or...

Page 470: ...ms between system circuits 2 8 and 2 9 Connect or disable VTS in setting page P1591 VTS Position Sensor Circuit Low Voltage 15 Off SENSOR N Possible cause Damaged sensor damaged circuit wires damaged connector or damaged MPEM output pins Service action Check for 24 to 167 5 ohms between system circuits 2 8 and 2 9 Connect or disable VTS in setting page P1592 VTS Position Sensor Circuit High Voltag...

Page 471: ...SS key and check for an open circuit on system circuit B 38 P1656 DESS line shorted to ground 15 Flash CHK ENG Y N N N A Possible cause Damaged safety switch damaged circuit wires damaged connector or damaged ECM output pins Service action Remove DESS key and check for an open circuit on system circuit B 38 P1660 Bilge pump shorted to ground or open circuit 5 N A N A Y N N N A Possible cause Damag...

Page 472: ... Possible cause Damaged component damaged circuit wires damaged connector or damaged MPEM output pins Service action Connect component or disable spare output 2 in setting page P1679 Spare output 2 shorted to 12 V 15 N A N A Y Y N N A Possible cause Damaged component damaged circuit wires damaged connector or damaged MPEM output pins Service action Connect component or disable spare output 2 in se...

Page 473: ... cause Damaged VTS damaged circuit wires damaged connector or damaged MPEM output pins Service action Check for 12 volts between system circuits 2 7 and 2 1 when VTS UP is activated P1691 VTS control up circuit shorted to battery 15 Off N A Y Y N N A Possible cause Damaged VTS damaged circuit wires damaged connector or damaged MPEM output pins Service action Check for 12 volts between system circu...

Page 474: ...iagnostic connector 3 P0616 Y Spare fuse 5 P1678 Y Electric starter fuel pump 10 P0231 Y MPEM 2 P0600 N VTS if so equipped 7 5 P1690 P1692 N EMS start stop circuit 5 None N 10A 2A 10A 1A 10A 10A 3A 5A 10A 2A 7 5A 5A 10A 2A 10A 1A 10A 10A 3A 5A 10A 2A 7 5A 5A 10A 2A 10A 1A 10A 10A 3A 5A 10A 2A 7 5A 5A Depth gauge if so equipped or spare fuse TOPS Cylinder 3 ignition coil and injection Information c...

Page 475: ... AND CARE 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 smr2004 Complete Line Up 467 www SeaDooManuals net ...

Page 476: ...ed 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 int...

Page 477: ...92 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 smr2004 Complete Line Up 469 www SeaDooManuals net ...

Page 478: ... 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 hose su...

Page 479: ...567 1 Loctite 567 2 Body Loctite 243 Loctite 518 4 7 0 11 N m 1 lbf in 8 6 0 6 N m 5 lbf in 5 5 N m 44 lbf in 3 Loctite 567 Loctite 567 Loctite 567 Loctite 296 Silicone sealant Loctite primer N Loctite 567 Loctite 567 Loctite 567 Loctite 567 TYPICAL smr2004 Complete Line Up 471 www SeaDooManuals net ...

Page 480: ...haust manifold water jacket and through tuned pipe water jacket before exiting the tuned pipe Water injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and performance improvement Side of hull Air compressor silencer Quick connect hose fitting for easy engine draining Temperature sensor activates monitoring beeper when temperature exceeds 100 C 212 F Air com...

Page 481: ...ust 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 enter...

Page 482: ...ing out of the engine heat exchang er is evacuated at the exhaust outlet for noise re duction DI Engines The water supply is provided by a pressurized area in the jet pump between the impeller and venturi The water is entering the engine by the water inlet fitting at the cylinder head F08E05A 1 1 Water supply hose Water from inlet hose also supplies the water regulator on muffler and magneto cover...

Page 483: ...e air silencer at the tran som Water continues to flow in the crankcase water jacket to cool the crankcase area to then be routed to the transom area Draining of the cooling system is accomplished by the drain hose connected to a fitting at the bottom of the cylinder block on tuned pipe side F06E0IA 1 1 Drain hose Bleeding of the cooling system is accomplished by the bleed hose located at the uppe...

Page 484: ...Engines CAUTION Never modify cooling system ar rangement otherwise serious engine damage could occur TECHNICAL DATA TYPE TLCS Total Loss Cooling System COOLANT FLOW Flow from impeller housing no water pump TEMPERATURE CONTROL Calibrated outlet fittings no thermostat SYSTEM BLEEDING Self bleed type hose at uppermost point of circuit SYSTEM DRAINING Self drain type hose at lowest point of circuit SY...

Page 485: ...e fitting or by measuring its inside diameter Refer to the following illustra tion and chart 16 A 1 B F00E04A 1 Stamped number A Outlet diameter 4 6 mm 181 in B Inlet diameter 5 5 mm 219 in STAMPED NUMBER ON FITTING FITTING P N INLET DIAMETER OUTLET DIAMETER 16 293 700 016 5 5 mm 219 in 4 6 mm 181 in 18 293 710 018 4 0 mm 157 in 5 5 mm 217 in 23 293 700 023 8 5 mm 374 in 8 7 mm 343 in 48 293 710 0...

Page 486: ...en gine damage can occur In many countries it is illegal to tamper with this valve as this will af fect the EPA certification At low speed water pressure in the supply hose of the regulator valve is not sufficient to overcome the spring of the regulator valve more water is being delivered to the injection fitting at the tuned pipe 1 F15E0AA 3 2 LOW SPEED OPERATION 1 Water entering regulator valve ...

Page 487: ...e has poor performance the water flow regulator valve should be considered in the troubleshooting of the problem Disassembly Remove the cover no 4 of the valve by releasing the spring no 3 WARNING Firmly hold cover to valve base The spring inside the valve is applying a pressure against the cover F01E1RA 1 2 1 Spring 2 Cover Remove fitting no 5 from valve housing F01E1SA 1 1 Fitting Unscrew the ta...

Page 488: ... operation a coupler hose is available unnecessary for models with the hose adapter to connect to the fitting spigot A garden hose is used to flush the whole system by backwash For flushing procedure refer to FLUSHING AND LUBRICATION For winterization of cooling system refer to STORAGE 717 Engines When servicing the hull always rotate watercraft counterclockwise seen from the rear Rotating watercr...

Page 489: ...ling which may lead to water being injected into and filling the exhaust system 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 must tow a strand ed watercraft in water and do not have a hose pincher be sure to stay well below the maxi mum towing speed of 24 km h 15 MPH Snugl...

Page 490: ...owards rear 2 Hose coming from engine 3 Install hose pincher here on this side of the T fitting 1 F08E08A 947 DI ENGINES XP DI MODELS 1 Hose pincher on water supply hose CAUTION When finished towing the wa tercraft the hose pincher must be removed before operating it 482 smr2004 Complete Line Up www SeaDooManuals net ...

Page 491: ...Section 09 COOLING SYSTEM Subsection 01 CIRCUIT COMPONENTS AND CARE 4 TEC Engines Engine Components F18E0ZS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 smr2004 Complete Line Up 483 www SeaDooManuals net ...

Page 492: ...sing including thermostat opens at 87 C 188 F and coolant pump impeller Bleed hose from cylinder head to expansion coolant tank Expansion coolant tank Coolant temperature sensor CTS activates when temperature exceeds 100 C 212 F Coolant flows to oil cooler Oil cooler Coolant returns from oil cooler Coolant returns from ride plate 484 smr2004 Complete Line Up www SeaDooManuals net ...

Page 493: ...Section 09 COOLING SYSTEM Subsection 01 CIRCUIT COMPONENTS AND CARE 4 TEC Naturally Aspirated Engines Vehicle Connections F18E22S smr2004 Complete Line Up 485 www SeaDooManuals net ...

Page 494: ...Section 09 COOLING SYSTEM Subsection 01 CIRCUIT COMPONENTS AND CARE 4 TEC Supercharged Engines Vehicle Connections F18E23S LTD Models 486 smr2004 Complete Line Up www SeaDooManuals net ...

Page 495: ...ion 09 COOLING SYSTEM Subsection 01 CIRCUIT COMPONENTS AND CARE 4 TEC Supercharged Intercooled Engines Vehicle Connections F18E24S Intercooler Loctite 567 smr2004 Complete Line Up 487 www SeaDooManuals net ...

Page 496: ...ride plate which operates as a heat exchanger A smaller quantity of engine coolant is also direct ed towards the oil cooler which is located under the air intake manifold to increase cooling effi ciency Coolant temperature sensor and bleed nipple are located on the cylinder head 1 F18E0XA 2 1 Bleed nipple 2 Coolant temperature sensor CTS CAUTION Never modify cooling system ar rangement otherwise s...

Page 497: ...haust manifold Water exits exhaust manifold through 2 hoses at rear manifold 1 F18E1EA 2 3 TYPICAL 1 Water coming from exhaust manifold 2 Exhaust pipe 3 Bleed hose Water enters exhaust pipe and flows in the water jacket of pipe 2 F18E1GA 1 3 TYPICAL 1 Exhaust pipe 2 Outlet holes of exhaust pipe 3 Muffler Bleeding of the exhaust system is accomplished by the bleed hose located at the upper most poi...

Page 498: ...spose coolant as per local regulations Do not reinstall drain plug at this time CLEANING Cleaning the cooling system as per the following procedure is required when engine overheats as suming everything else is operating normally or each time coolant is replaced Drain the cooling system Clean thoroughly using the Valvoline Zerex Super Cleaner or equivalent Add the cleaning product in coolant expan...

Page 499: ...ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum en gines Using water tap instead of demineral ized water would contribute to make deposits in cooling system and to reduce antifreeze effi ciency This could lead to engine overheating System Capacity Refer to TECHNICAL DATA Coolant Replacement Procedure WARNING To prevent burning yourself do not remove...

Page 500: ...tank and top up if necessary Test the density of the coolant using an antifreeze hydrometer NOTE Follow hydrometer manufacturer instruc tions for proper use The reading should be some degrees below the coldest temperature you expect in the area where the watercraft is to be used Add demineralized water or antifreeze accordingly Refill to the prop er level CAUTION Pure antifreeze will freeze at a h...

Page 501: ...y 1 F18E11A 1 Weep hole pump housing gasket Check if thermostat is in good condition Refer to THERMOSTAT elsewhere in this section Installation The installation is the opposite of the removal pro cedure Install screws as per the following illus tration 1 2 F18E10A 1 1 1 1 2 1 1 Screws M6 x 25 2 Screws M6 x 105 CAUTION To prevent leaking take care that the gaskets are exactly in groove when you rei...

Page 502: ... and heat water Look inside the cylin der head return hose connection to see the move ment of the thermostat Thermostat should open when water temperature reaches 87 C 188 F If there is no operation replace coolant pump housing and thermostat Installation For installation reverse the removal procedure paying attention to the following details Refer to COOLANT PUMP HOUSING REPLACE MENT in this sect...

Page 503: ...otherwise you can damage the compo nents unscrew the impeller no 8 clockwise remove PTO cover no 10 refer to PTO HOUS ING MAGNETO section remove screws no 11 retaining oil pump cover 1 2 F18E14A 1 Retaining screws 2 Oil pump cover remove oil pump cover no 12 remove outer oil pump rotor no 13 1 F18E15A 1 Outer oil pump rotor extract the coolant oil pump shaft no 9 from outside PTO housing cover wit...

Page 504: ...tallation On ly use a press to avoid damaging the ceramic component 1 F18E19A 2 1 Rotary seal 2 Rotary seal installer Install the coolant oil pump shaft using the rotary seal installer P N 529 035 823 on the opposite side to the rotary seal and the oil seal protector P N 529 035 822 with a press 1 F18E1AA 2 1 Oil seal protector 2 Coolant oil pump shaft 1 F18E1BA 2 1 Coolant oil pump shaft with oil...

Page 505: ... 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 must tow a strand ed watercraft in water and do not have a hose pincher be sure to stay well below the maxi mum towing speed of 24 km h 15 MPH Snugly install the hose pincher on the...

Page 506: ...hose at uppermost point of circuit SYSTEM DRAINING Self drain type on the exhaust cooling system hose at lowest point of circuit SYSTEM FLUSHING Required for exhaust cooling system open loop system Required for engine closed loop system if engine overheats or when replacing coolant MONITORING BEEPER Turns on at 100 C 212 F COOLANT LIFE CYCLE 100 hours or 1 year Should be replaced before storage 49...

Page 507: ...quipped Models F17F02S 17 1 2 N m 11 lbf in 1 18 2 N m 18 lbf in 3 N m 27 lbf in 14 4 3 1 2 N m 11 lbf in 1 2 22 N m 16 lbf ft 16 4 N m 35 lbf in 15 16 13 19 12 8 19 6 1 1 1 2 N m 11 lbf in Engine 9 11 10 3 N m 27 lbf in Body 4 N m 35 lbf in smr2004 Complete Line Up 499 www SeaDooManuals net ...

Page 508: ...17 22 N m 16 lbf ft Loctite 243 F12F18S Body 1 1 18 2 4 N m 35 lbf in 16 15 6 19 19 13 13 5 Loctite 243 25 N m 18 lbf ft 7 Silicone sealant Primer N Loctite 243 8 N m 71 lbf in 7 N m 62 lbf in Anti seize lubricant 500 smr2004 Complete Line Up www SeaDooManuals net ...

Page 509: ...on 10 FUEL SYSTEM Subsection 01 FUEL CIRCUIT GTI RFI and GTI LE RFI Models 17 4 N m 35 lbf in Body F17F03S 1 2 22 N m 16 lbf ft 16 15 13 19 19 6 5 1 1 1 18 smr2004 Complete Line Up 501 www SeaDooManuals net ...

Page 510: ...TEM Subsection 01 FUEL CIRCUIT GTX 4 TEC and GTX 4 TEC Wakeboard Edition F18F0QS 17 22 N m 16 lbf ft 1 1 18 1 1 2 16 4 N m 35 lbf in 15 5 13 19 16 4 N m 35 lbf in 6 19 1 502 smr2004 Complete Line Up www SeaDooManuals net ...

Page 511: ...on 01 FUEL CIRCUIT GTX 4 TEC Supercharged and GTX 4 TEC Limited Supercharged 2 22 N m 16 lbf ft F18F0RS 4 N m 35 lbf in 16 15 4 N m 35 lbf in 16 13 5 19 19 6 13 Engine 18 1 1 17 1 1 smr2004 Complete Line Up 503 www SeaDooManuals net ...

Page 512: ...0 FUEL SYSTEM Subsection 01 FUEL CIRCUIT RXP 4 TEC Supercharged IC 2 4 N m 35 lbf in F19F01S 22 N m 16 lbf ft 16 15 4 N m 35 lbf in 16 13 5 1 18 17 1 19 6 13 19 504 smr2004 Complete Line Up www SeaDooManuals net ...

Page 513: ...l venti lated area Always wipe off any fuel spillage from the watercraft To secure or cut Oetiker clamps no 1 on fuel lines use pliers P N 295 000 070 F01B03A 1 1 Cutting clamp F01B04A 1 1 Securing clamp F01B05A 1 1 Securing clamp in limited access When replacing the vent hose on all SEA DOO models be sure to use B1 hoses when replac ing the fuel supply line to the fuel rail on RFI and 4 TEC model...

Page 514: ...move any fuel pressure in system Unscrew the fuel filter bowl no 3 counterclock wise then pull toward the bottom F01F01B 1 2 TYPICAL 1 Loosen counterclockwise 2 Pull Pull fuel filter no 4 toward the bottom F01F04A TYPICAL RFI and 4 TEC Models The fuel pump assembly no 5 has to be removed from the fuel tank no 6 to have access to the fuel filter Refer to the appropriate ENGINE MANAGE MENT section I...

Page 515: ...Loosen lower clamp Disconnect wiring harness of fuel sender Remove baffle from fuel tank Remove upper clamp no 10 from adapter no 11 and slide adapter from baffle Push inward on the 3 clips at the base of the baffle in order to remove the filter no 12 Pry base off using a small slotted screwdriver if necessary Electric Fuel Pump DI RFI and 4 TEC Models Refer to appropriate ENGINE MANAGEMENT sectio...

Page 516: ...Filter Bowl Check filter bowl no 3 for water contamination or other damages Gasket Inspect gasket condition Make sure gasket no 14 is well positioned into the filter bowl F01F02A 1 1 Gasket in bowl WARNING Ensure that there is no leakage from the fuel filter Fuel Filler Hose All Models Verify fuel filler hose no 15 for damage Always ensure that clamps no 16 are well positioned and tightened Torque...

Page 517: ... ly 4 mm 5 32 in from the base of the neck It is a normal situation to have a molding seam and it should not be confused with a crack ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Fuel Tank Ensure rubber carpets no 19 are in place All Models except 4 TEC Insert fuel tank in the vehicle and place straps in bottom clips Use ...

Page 518: ...a solution of soapy water on com ponents bubbles will indicate leak location NOTE The system must maintain a pressure of 34 kPa 5 PSI during 10 minutes Never pressur ize over 34 kPa 5 PSI Reconnect air inlet hose of fuel tank to body WARNING If any leak is found do not start the engine and wipe off any fuel leakage Do not use electric powered tools on watercraft unless system has passed pressure t...

Page 519: ... 717 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 smr2004 Complete Line Up 511 www SeaDooManuals net ...

Page 520: ...TEM Subsection 02 AIR INTAKE 2 STROKE 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 243 512 smr2004 Complete Line Up www SeaDooManuals net ...

Page 521: ...MOVAL Air Intake Silencer Cover 717 and 787 RFI Engines Unlock the 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 Arres...

Page 522: ...ected Flame Arrester Base On 717 engines apply Loctite 518 on mating sur faces of flame arrester base no 9 Apply Loctite 243 blue on screws no 10 and torque to 10 N m 89 lbf in Flame Arrester Inspect condition of flame arrester no 6 Replace or clean as necessary WARNING Do not operate watercraft without flame ar rester Gasket Inspect condition of gasket no 2 Make sure to properly install gasket 51...

Page 523: ...Section 10 FUEL SYSTEM Subsection 02 AIR INTAKE 2 STROKE 947 DI Engines 8 Crankcase F12F17S 7 9 6 5 4 1 4 5 3 2 smr2004 Complete Line Up 515 www SeaDooManuals net ...

Page 524: ...08A 1 1 1 Remove bolts Pull air ducts out with their protector pads no 5 1 F08F09A 1 Air duct NOTE Do not disconnect oil lines Push the air intake silencer out of the throttle body Detach 2 straps from the oil reservoir using spring remover tool P N 529 035 989 F12F16B 529 035 989 Unclip oil filter Pull oil reservoir out Remove foam under the oil tank Pull the air silencer forward to remove it fro...

Page 525: ...g pliers until you feel that the clip is tight enough Properly reinstall hair pin to secure clip no 1 Ensure the elbow adaptor is well inserted and that it has not pushed the gasket inside the air intake silencer NOTE Make sure the air intake silencer is re tained by the lower bracket no 6 Place protector pads on duct supports Use slot in rubber to insert pad on bracket eyelet Side tongue of prote...

Page 526: ...r fuel system on RFI DI and 4 TEC models refer to appropriate ENGINE MANAGEMENT section Mikuni BN 40i F17F04S 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 smr2004 Complete Line Up 519 www SeaDooManuals net ...

Page 527: ...ls Remove 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 ...

Page 528: ...ssure drops replace diaphragm 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...

Page 529: ...until 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 valv...

Page 530: ... Plate When installing choke plate no 11 or throttle plate no 12 onto shaft s close plate so that it centers into carburetor bore Firmly tighten screws CAUTION Always apply Loctite 243 blue on screw threads prior to installing screws Needle Valve Lever Rounded end of needle valve lever no 13 must be flush with surrounding metering chamber floor and not with body assembly Place the end of a ruler o...

Page 531: ...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 Jet Pilot jet no 15 and mai...

Page 532: ...t installation pay attention to the following Install carburetor with gasket to intake manifold rotary valve cover Apply synthetic grease on screws no 1 Then install screws with lock washers no 2 and torque to 20 N m 15 lbf ft Fuel Lines and Hose Clamps If fuel line ends are damaged cut damaged end before reinstallation Properly install clamps WARNING Make sure there is no leak in fuel system For ...

Page 533: ...jection pump cable adjustment Re fer to OIL INJECTION PUMP CAUTION Improper oil injection pump syn chronization with carburetor can cause serious engine damage Idle Speed Screw Turning screw no 20 clockwise increases engine idle speed and turning screw counterclockwise decreases engine idle speed F01G0YD 1 1 Idle speed screw Connect an induction type tachometer P N 529 014 500 on spark plug cable ...

Page 534: ...increase the gap Choke Cable Ensure choke lever has a free play of 0 5 to 2 0 mm 1 64 to 5 64 in 1 F07F02A A TYPICAL 1 Choke lever A Free play of 0 5 to 2 0 mm 1 64 to 5 64 in To adjust loosen jam nut on carburetor bracket then turn adjustment nut as necessary Tighten jam nut and recheck adjustment smr2004 Complete Line Up 527 www SeaDooManuals net ...

Page 535: ...2 STROKE Subsection 01 OIL INJECTION SYSTEM OIL INJECTION SYSTEM GTI Models F17G03S 27 N m 20 lbf ft 3 5 N m 31 lbf in 1 2 3 5 N m 31 lbf in 3 4 1 2 N m 11 lbf in Dielectric grease smr2004 Complete Line Up 529 www SeaDooManuals net ...

Page 536: ...Section 11 LUBRICATION SYSTEM 2 STROKE Subsection 01 OIL INJECTION SYSTEM XP DI Models F08G06S Steering harness Oil pump 4 3 Synthetic injection oil 530 smr2004 Complete Line Up www SeaDooManuals net ...

Page 537: ...urn hose except 947 DI engines Install a hose pincher to oil injection pump sup ply hose XP DI Model Install a hose pincher to compressor return line lower hose of the vent adapter on top of oil in jection tank Disconnect oil tank vent line on PTO side throttle body GTI Models Connect pump gauge tester P N 529 021 800 to oil injection reservoir vent check valve XP DI Model Connect pump gauge teste...

Page 538: ...P OIL INJECTION 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 smr2004 Complete Line Up 533 www SeaDooManuals net ...

Page 539: ...LUBRICATION SYSTEM 2 STROKE 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 534 smr2004 Complete Line Up www SeaDooManuals net ...

Page 540: ... STROKE Subsection 02 OIL INJECTION PUMP 947 DI Engines Throttle cable Oil pump 1 6 N m 53 lbf in 8 6 N m 53 lbf in 4 5 N m 40 lbf in 6 6 Molykote 111 Loctite 243 Loctite 243 F12G08S smr2004 Complete Line Up 535 www SeaDooManuals net ...

Page 541: ... 6 with flat washers re taining oil injection pump to intake manifold no 2 Remove pump 947 DI Engines Remove tuned pipe head Refer to EXHAUST SYSTEM The cable end has a slight press fit in the lever Using a small screwdriver pry cable end out 787 RFI and 947 DI Engines Disconnect oil injection pump cable no 7 Remove 2 Allen screws no 6 with flat washers retaining oil injection pump to magneto hous...

Page 542: ...n each side of gear Install intake manifold no 2 to rotary valve cover and torque screws no 5 to 10 N m 89 lbf in F01D4RC A TYPICAL A 10 N m 89 lbf in 787 and 947 DI Engines Oil Injection Pump and Shaft Make sure shaft no 8 is installed in crankshaft end Install pump Secure with flat washers and screws no 6 Torque to 6 N m 53 lbf in Install oil injection pump cable 947 DI Engines F12G02A F12G03A s...

Page 543: ...NAL SYNCHRONIZA TION Make sure idle speed screw on carburetor is properly set on 717 engines Refer to CARBURETOR for throttle cable adjust ment procedure NOTE On a twin carburetor engine make sure carburetors are properly synchronized Turn oil pump cable adjustment nut to align refer ence marks on pump NOTE A mirror may be used to facilitate this ver ification 717 Engines F01D4RE 2 3 1 TYPICAL 1 J...

Page 544: ...erating temper ature CAUTION If watercraft is out of water engine must be cooled using the flush kit If air bub bles are present in the oil injection system bleed system before operating engine Adjust idle speed to specification on 717 Engines Refer to CARBURETOR NOTE On RFI and DI engines there is no idle speed adjustment to perform Stop engine Final Synchronization Eliminate throttle cable free ...

Page 545: ...iciently filled Install a dry rag below oil injection pump Loosen bleed screw to allow oil to flow 1 F01D4SC 717 ENGINES 1 Bleed screw F07G02A 1 787 RFI ENGINES 1 Bleed screw 1 F16G02A 947 DI ENGINES 1 Bleed screw Keep bleeding until all air has escaped from line Make sure no air bubbles remain in oil supply line Tighten bleed screw Wipe any oil spillage Check small oil lines of the pump They must...

Page 546: ...pump gear 717 engine or shaft 787 RFI and 947 DI engines for defects replace as necessary Test pump as described below NOTE Through normal use oil level must not drop in small tubes If oil drops verify check valve operation Replace as necessary Bench Test Connect a hose filled with injection oil to main line fitting Insert other hose end in an injection oil container Using a counterclockwise rever...

Page 547: ...the charging system The resulting regulated DC is used to charge the battery The CPS MPEM ECU and the ignition coil work together in this Digital Inductive ignition system All Engines A 12 volts battery supplies the Multi Purpose Elec tronic Module MPEM with DC current Refer to CHARGING SYSTEM Magneto System The magneto is the primary source of electrical energy It transforms magnetic field into e...

Page 548: ... scribe a 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 fly wheel mark position and crankshaft position may change as the PTO flywheel might move tighten loosen on the crankshaft As an exam ple on threaded flywheels when ...

Page 549: ...er tool on engine using wing nuts previously removed F01H5SA 1 TYPICAL 1 Timing mark pointer tool P N 295 000 130 787 RFI Engines Remove middle screw securing the engine to the rear engine mount Reinstall screw with timing mark pointer tool F06H05A 1 1 Timing mark pointer tool P N 295 000 135 All Engines Install and adjust a TDC gauge P N 295 000 143 in MAG side spark plug hole F01H5TA 1 TYPICAL 1...

Page 550: ... light CAUTION The static test cannot be used as a timing procedure therefore always check the timing with a stroboscopic timing light Remove TDC gauge Reinstall spark plug and connect wire 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 717 Engines NOTE To perform this procedure make su...

Page 551: ... engine must be cooled using 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 before adjusting igni tion timing to ensure PTO flywheel has not loosen 787 RFI Engines Connect an induct...

Page 552: ... more than a few seconds engine must be cooled using the flush kit NOTE If mark on PTO flywheel is perfectly aligned with timing mark pointer no adjustment is required If mark does not align with pointer recheck PTO flywheel mark before adjusting igni tion timing to ensure PTO flywheel has not loosen or moved Ignition Timing Adjustment 717 Engines Remove magneto housing cover and wire sup port For...

Page 553: ...se cured Reinstall removed parts Refer to MAGNETO SYSTEM Recheck ignition timing make sure engine is cold Repeat armature plate positioning procedure if timing mark position is not adequate 787 RFI Engines CAUTION If the ignition timing is adjusted too advanced this will cause serious damage to the engine VCK Vehicle Communication Kit For the 787 RFI engines use the VCK Vehicle Communication Kit P...

Page 554: ...8 DESS MPEM Programmer As an alternate method to correct the ignition tim ing the data of the MPEM can be changed using the MPEM programmer P N 529 035 878 NOTE For more information on the MPEM pro grammer refer to the MPEM programmer guide P N 219 700 138 Refer to the TIMING CORRECTION CHARTS used per MPEM programmer to find the number corresponding to the timing correction needed The Fixed Timin...

Page 555: ...justment is required refer to following procedure Timing Adjustment Unlike the other models the ignition timing cor rection can be made from 4 5 advanced to 2 25 retarded VCK Vehicle Communication Kit The VCK will display directly the timing correction under Offset angle See illustration below F17H08A 1 2 3 4 5 1 Setting tab 2 Ignition offset section 3 Locked box 4 Current angle in MPEM 5 Arrows t...

Page 556: ...STRUMENTS AC CESSORIES for its testing procedure If 2 short beeps are not heard when installing the safety lanyard refer to DIGITALLY ENCODED SE CURITY SYSTEM The following continuity tests can also be per formed using an ohmmeter Disconnect switch wires Safety Lanyard Removed Connect test probes to switch BLACK and BLACK YELLOW wires Measure resistance there should be no continuity open circuit C...

Page 557: ...eto harness adapter 6 Set multimeter to Vac scale 7 Crank engine and note result The obtained value should be between 18 and 25 Vac 8 If the generating coil is out of specification re place it NOTE If the generating coil tests good discon nect the primary wires of the ignition coil Crank engine and check voltage at primary wires It should be at least 20 Vac If there is insufficient or no voltage e...

Page 558: ...on the primary side Disconnect the ignition coil 3 pin connector Check to see if there is approximately 6 Vdc between the red wire and engine ground If there is no voltage either the MPEM or the wiring harness is defective Secondary Winding Due to the integrated diode it is not possible to take any resistance measurement of the sec ondary winding on the 787 RFI models DYNAMIC TEST All Models Use a...

Page 559: ... cause pre ignition or detonation Fouling Fouling of the spark plug is indicated by irregular running of the engine decreased engine speed due to misfiring reduced performance and in creased fuel consumption This is due to a loss of compression Other possible causes are pro longed idling or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel The plug face of a fou...

Page 560: ...A 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 556 smr2004 Complete Line Up www SeaDooManuals net ...

Page 561: ... 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 Induct...

Page 562: ...ge to components 717 Engines A half wave rectifier receives magneto current and transforms it into regulated current to allow bat tery charging 787 RFI and 947 DI and 4 TEC Engines 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 DC source for the electric starter the Multi Purpose Electroni...

Page 563: ...1 2 1 TYPICAL 1 Vent tubes removed 2 Electrical box F18H1BA 2 1 1 TYPICAL 1 Fuse 787 RFI Engines The main electric system fuse is 20 A and locat ed on the cut off relay Also another 20 A fuse is mounted on the MPEM bracket to protect the rec tifier regulator 560 smr2004 Complete Line Up www SeaDooManuals net ...

Page 564: ...rotected by 2 fuses A 25 A fuse is mounted on the MPEM and a 25 A fuse is located in the rear electrical box on the cut off relay F08H0JA 1 1 MPEM F1 FP 15A F2 ACC 2A F3 REG 25A F4 VTS 7 5A F5 BAT 25A F6 INJ 15A F1 F2 F3 F4 F5 F6 F18H06A 2 1 1 Fuse identification 2 Fuse description REG Regulator charging system smr2004 Complete Line Up 561 www SeaDooManuals net ...

Page 565: ...ing the following tests Rectifier Regulator STATIC TEST CONTINUITY Due to internal circuitry there is no static test avail able DYNAMIC TEST Current Test 717 947 DI and 4 TEC Engines Proceed as follows Start engine Lay an inductive ammeter on positive cable of battery Bring engine to approximately 6000 RPM Current reading should be approximately 4 am peres for the 717 engine and 5 amperes for the ...

Page 566: ...ent If still out of specification the fuel pump or the MPEM current draw is too high If charging current exceeds specification replace the rectifier regulator DC Voltage Test All Models Proceed as follows Start engine Connect a multimeter to battery posts Set multimeter to Vdc scale Bring engine to approximately 5500 RPM If multimeter reads over 15 volts regulator is de fective Replace it NOTE If ...

Page 567: ... short circuit will read 0 ohm or close to on ohmmeter F02H0KA 1 2 3 1 Multimeter 2 Magneto harness adapter 3 YELLOW and BLACK YELLOW wires STATIC TEST INSULATION Disconnect the magneto wiring harness con nector Install the 4 pin magneto harness adapter P N 295 000 131 to the magneto wiring har ness Leave wiring harness side disconnected Insert multimeter positive probe to the YELLOW wire of the 4...

Page 568: ...ctor Install the 6 pin magneto harness adapter P N 295 000 136 to the magneto wiring har ness Leave wiring harness side disconnected Insert multimeter positive probe to one of the YELLOW wire of the 6 pin magneto harness adapter Ground the multimeter negative probe to the engine or the stator iron core and note the read ing F01H60A 1 3 2 4 TYPICAL 1 Multimeter 2 Magneto harness adapter 3 Positive ...

Page 569: ...g from the coils is grounded and needs to be re placed or repaired DYNAMIC TEST AC Voltage Disconnect the voltage regulator rectifier con nectors Disconnect the magneto wiring harness con nector Install the 4 pin magneto harness adapter P N 295 000 131 between connectors Connect test probes of the multimeter to the BLACK YELLOW and RED BLACK wires of the 4 pin magneto harness adapter Set multimete...

Page 570: ...ly inspect battery casing for cracks or other possible damage If casing is damaged replace battery and thoroughly clean battery tray and close area with water and baking soda Inspect battery posts for security of mounting Inspect for cracked or damaged battery caps re place defective caps 4 TEC Models NOTE Hand tighten caps then tighten an addition al 1 4 turn using a 20 mm 3 4 in socket Using oth...

Page 571: ... 27 1 27 1 28 75 1 21 1 22 1 22 1 23 50 1 16 1 17 1 17 1 18 25 1 12 1 13 1 13 1 14 0 1 10 or less 1 11 or less Load Test This is the best test of battery condition under a starting load Use a load testing device that has an adjustable load Apply a load of 3 times the ampere hour rating of the battery At 14 seconds into the test check battery voltage if battery is in good condition it will have at ...

Page 572: ...hile installed in watercraft A new battery is factory 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 ...

Page 573: ...the casing feels hot discontinue charging temporarily or reduce the charging rate 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 conti...

Page 574: ... an am meter capable of accurately measuring current of less than 1 ampere Unless this procedure is properly followed a good battery may be needlessly replaced Measure the voltage at the battery posts with an accurate voltmeter If it is below 10 volts the battery will accept current at very low rate in term of milliamperes because electrolyte is nearly pure water as explained above It could be som...

Page 575: ...length using a wire stripping tool or sharp blade knife A32E2QA A A 10 mm 3 8 in NOTE Make sure not to cut wire strands while stripping the wire Install the appropriate terminal on the wire accord ing to the requirement Refer to appropriate parts catalog A32E2RA INSTALLATION OF TERMINAL Follow the instructions provided with the crimp pli er P N 529 035 730 to select the proper position of the tool...

Page 576: ...re to the terminal Welding can change the property of the wire and it can become brittle and break Install the protective heat shrink rubber tube P N 278 001 692 on the terminal Heat the heat shrink rubber tube using the heat gun so that it grasps the 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 smr20...

Page 577: ...TARTING SYSTEM 717 Engines F00H1PS 16 Loctite 243 15 Loctite 271 14 Ground cable 17 22 N m 16 lbf ft Loctite 243 13 22 N m 16 lbf ft 22 N m 16 lbf ft 5 N m 44 lbf in Dielectric grease 1 12 2 3 5 4 6 11 10 7 8 9 smr2004 Complete Line Up 575 www SeaDooManuals net ...

Page 578: ...ubsection 03 STARTING SYSTEM 787 RFI Engines F15H01S Loctite 243 6 7 8 9 10 11 4 1 2 3 5 5 N m 44 lbf in 12 22 N m 16 lbf ft 13 17 Dielectric grease Loctite 243 16 22 N m 16 lbf ft 576 smr2004 Complete Line Up www SeaDooManuals net ...

Page 579: ...TEM Subsection 03 STARTING SYSTEM 947 DI Engines F07H0TS Dielectric grease 17 Loctite 243 16 10 N m 89 lbf in Synthetic grease Synthetic grease 18 10 11 19 Ground cable 1 2 3 5 smr2004 Complete Line Up 577 www SeaDooManuals net ...

Page 580: ... MPEM The solenoid may be the cause of a burnt fuse If the solenoid checks good one of the accessory may be defective Battery To check battery condition refer to CHARGING SYSTEM MPEM or ECM on 4 TEC engines If 2 short beeps are not heard when installing the safety lanyard refer to DIGITALLY ENCODED SE CURITY SYSTEM or ENGINE MANAGEMENT Engine Start Stop Switch and Safety Lanyard Switch Refer to IG...

Page 581: ...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 582: ...NETO SYSTEM and BOTTOM END To check and replace the starter end bearing refer to BOTTOM END section 4 TEC Engines NOTE To facilitate starter removal on RXP mod els remove engine cover Refer to BODY section Remove retaining screws from starter Pull starter out Lift starter enough to reach starter cable then disconnect from starter 1 F18H0UA 2 4 3 1 Exhaust manifold 2 Starter 3 Retaining screws 4 Nu...

Page 583: ...llar Turn clutch assembly no 9 clockwise to remove it from armature assembly no 11 Pull housing from armature 947 DI Engines Locate index marks on yoke no 1 and end covers no 3 and no 10 F06H1FA 1 1 Index marks Loosen through bolts no 5 F06H1GA 1 1 Through bolts Remove end cover no 3 and gasket on armature shaft side Remove thrust washers no 19 from armature shaft F06H1HA 1 1 Thrust washers Remove...

Page 584: ...emove brush holder no 2 F06H1KA 1 1 Remove brush holder To remove brushes from yoke no 1 loosen nut and remove washers F06H1LA 1 1 Loosen nut and remove washers Remove brushes To remove bearing and seal in end cover release tabs of retainer F06H1MA 1 1 Retainer 4 TEC Engines Remove bendix retaining circlip no 4 and starter bendix no 5 582 smr2004 Complete Line Up www SeaDooManuals net ...

Page 585: ...arks on yoke and end covers 1 F18H0OA 1 Index marks Loosen through bolts 1 F18H0PA 1 Through bolts Remove end cover Remove thrust washer from armature shaft F06H1HA 1 TYPICAL 1 Thrust washers Remove the other end cover with brushes and brush holder assembly Remove armature smr2004 Complete Line Up 583 www SeaDooManuals net ...

Page 586: ... Bushings or bearings must not be cleaned with grease dissolving agents Immerse all metal components in cleaning solu tion Dry using a clean dry cloth PARTS INSPECTION Armature NOTE An ohmmeter may be used for the follow ing testing procedures except for the one con cerning shorted windings in armature Check commutator for roughness burnt or scored surface If necessary turn commutator on a lathe e...

Page 587: ...kwise 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 check engine ring gear teeth for wear and damage If defective replace ring gear Refer to MAGNETO STARTER ASSEMBLY All Engines Reverse the order of disassembly to reassemble starter However attention should be paid to the following operati...

Page 588: ...ICAL 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 586 smr2004 Complete Line Up www...

Page 589: ... sure that starter and engine mating surfaces are free of debris Serious trouble may arise if starter is not properly aligned 717 and 787 RFI Engines Screw Apply service products as per the exploded view given at the beginning of the section on threads and torque starter screws no 13 and no 16 to 22 N m 16 lbf ft Nut Connect the RED positive cable to the starter and torque nut no 17 to 6 N m 53 lb...

Page 590: ...ic shock 4 TEC Engines Apply grease Isoflex Topas NB52 P N 293 550 021 on O rings of starter Install starter NOTE If starter does not mesh properly try to pull it out and slightly rotate the starter gear then re install starter One could also temporarily remove both O rings properly mesh gears then remove starter to reinstall O rings being careful not to ro tate gear to keep its position to finall...

Page 591: ...output 8 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 1 7 kg 3 7 lb No load 10 9 V 45 A max 8600 RPM Load 9 V 120 A max 5350 RPM Performance specification at 20 C 68 F Stall 2 25 V 390 A max 0 RPM Battery 12 V 19 Ah 4 TEC Engines Nominal output 0 9 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise viewed from pinion side Weight 2 5 kg...

Page 592: ...d on the RED PURPLE wire from the cut off relay Reading should be 0 V Oth erwise replace the cut off relay Keeping the test probes on the same wires con nect a jumper wire between the BLACK PURPLE wire from the cut off relay to the battery ground Measure voltage Reading should be 12 V Oth erwise check wiring and if it is good replace the cut off relay If there is no current supply to the electrica...

Page 593: ...as started the MPEM automatically stops the starter when the engine speed reaches 1000 RPM Engine RPM Limiter The MPEM will limit the maximum engine speed Engine Stopping There are two ways to stop the engine Press start stop switch or remove the safety lan yard cap from the switch Low Fuel Level Warning Device When the fuel level in the reservoir is low the fuel level sensor transmits a signal to...

Page 594: ... chosen display will come back Compass if so equipped Displays the cardinal points to indicate the orientation of the watercraft WARNING Use the compass as a guide only Not to be used for navigation purposes Tachometer Indicates the revolutions per minute RPM of the engine Speedometer Indicates the speed of watercraft in kilometers per hour KPH or miles per hour MPH Average Speed The information c...

Page 595: ...riding A low fuel con dition is also indicated when it occurs See MES SAGE DISPLAY above VTS Position Indicator XP DI Models The VTS position indicator shows the riding angle of the watercraft F00L2DA 1 2 3 1 Position indicator 2 Bow up 3 Bow down Display Priorities As a self test all LCD segments and the LED will turn on for 3 seconds each time the informa tion center is activated when safety lan...

Page 596: ...BC 1 1 Press to start or stop chronometer F00L2BC 1 1 Press and hold for 2 seconds to reset Chronometer is reset every time engine is turned off Maintenance Information When the watercraft is due for a maintenance in spection the message MAINT will blink To clear the warning message while it is blinking F00L2BC 1 1 Press and hold for 2 seconds to reset NOTE If maintenance message MAINT contin ues ...

Page 597: ...d in the information center when only one bar is displayed See MESSAGE DISPLAY below Numerical Section This section shows the digits of the function dis played such as the speedometer trip hour meter etc Units and Messages Section This section shows the units related to the num bers displayed Units such as KMH MPH HOUR etc are displayed This section also display navigational and system fault infor...

Page 598: ...S Hour Meter Displays the time in hours of the watercraft usage HOUR Water Temperature Displays the water temper ature of the water surface L TEMP in degrees Celsius C or Fahrenheit F Exterior Temperature Displays the exterior air temperature E TEMP in degrees Celsius C or Fahrenheit F Trip Hour Meter TRIPMTR Allows to measure an interval of time in hours and minutes hh mm VTS Position Indicator R...

Page 599: ...aximum position all LCD segments and the LED will turn on for 3 seconds each time the infor mation center is activated when safety lanyard is installed This allows the driver to validate they are all working properly When the information center is activated the last function set will be displayed In the event of a warning message the message will blink and override the units display unless MODE bu...

Page 600: ... F18L09D 1 1 Press to start or stop trip hour meter F18L09D 1 1 Press and hold for 2 seconds to reset engine is turned off Trip hour meter is reset every time engine is turned off Message Display The information center features a display area that blinks a message whenever one of the follow ing circumstances occurs The abbreviations be tween parenthesis here are the code displayed engine or exhaus...

Page 601: ...U D S to activate it in the MPEM If an option is installed but not checked in B U D S the information center will not display that option If an option is checked in B U D S but not installed in vehicle a fault code will be generated Use the OPTIONS area in the Setting tab in B U D S INSPECTION Information Center GTI LE RFI and XP DI Models The PURPLE wire is the 12 Vdc power source of the Informat...

Page 602: ...at sensor has 3 wires instead of 2 Disconnect the AMP connector 1 from the MPEM Using an appropriate terminal remover remove the BLACK ORANGE and TAN ORANGE wires from the AMP connector Connect potentiometer test probes to the BLACK ORANGE and TAN ORANGE wires Adjust potentiometer to the resistance values as per following chart to test the accuracy of the In formation Center RESISTANCE DISPLAY TEM...

Page 603: ...tic mode Check if wires are swapped unconnected or short circuit One faulty wire will cause a longer delay to perform the self test when safety lanyard is installed If everything tests good try a new information center Fuel Oil Gauge Low Oil Warning Light GTI GTI LE and GTI RFI Models The fuel gauge has a pointer which indicates fuel level in the tank The low oil warning light is part of the gauge...

Page 604: ...vel sensor follow procedures below The resistance measured between PINK BLACK and PINK wires must be in accordance with fuel level measured from under the flange as speci fied in the following charts RFI Models RESISTANCE FLOAT HEIGHT bottom of float with bottom the sensor sends the signal to the low oil level of pump module mm 4 8 2 2 228 5 0 17 8 2 2 186 5 0 27 8 2 2 164 5 0 37 8 2 2 139 5 0 47 ...

Page 605: ...nce should be approximately 2 closed circuit TEST CONDITION READING Sensor OUT of oil open circuit Sensor soaked IN oil 2 max closed circuit F03H0BA 1 2 1 Measure resistance here 2 Sensor reservoir To Reinstall Sensor Remove rubber seal from sensor Install seal in oil tank hole Push sensor in seal Plug connector NOTE This sensor turns the LED to ON if the connector has been forgotten unconnected e...

Page 606: ...tion until motor stops Read the resistance on the ohmmeter it should indicate a resistance of 167 ohms 1 RESISTANCE NOZZLE POSITION 167 1 24 1 UP DOWN NOTE If the VTS control module passes this re sistance test it doesn t mean it is in perfect con dition Water Temperature Sensor GTI LE RFI and 4 TEC Models The water temperature sensor is integrated with the speed As a result that sensor has 3 wire...

Page 607: ...s you can use a portable compass and point it in the same direction Compare the given directions they should be the same Speedometer GTI LE GTI LE RFI and XP DI Models F07H0LA TYPICAL The PURPLE wire is the 12 Vdc power source of the speedometer The BLACK wire is the ground The PURPLE YELLOW wire is the pulse signal from the speed sensor Speed Sensor GTI LE GTI LE RFI XP DI and 4 TEC Models The sp...

Page 608: ...d fluctuate between 5 5 and 8 5 Vdc Depth Gauge GTX 4 TEC Limited Supercharged Models TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Nothing is displayed in the information center The depth gauge is not activated in the MPEM Activate the depth gauge in Options under Setting tab in B U D S Connector of the depth gauge is not connected Connect it properly There is not 12 V or ground is open at the de...

Page 609: ... the silicone pad is in good condition There must be no air between the bottom of the depth gauge and the hull Otherwise the gauge will not work If silicone pad is damaged replace it Installation Ensure O ring is in good condition and in place After installation try pulling the gauge out to en sure it is properly locked Test run gauge 608 smr2004 Complete Line Up www SeaDooManuals net ...

Page 610: ... watercraft MPEM is ac tivated at the factory Therefore a safety lanyard must be programmed to start the engine NOTE Actually it is the memory of the MPEM which is programmed to recognize the digital code of the safety lanyard cap The system is quite flexible Up to eight safety lanyards may be programmed in the memory of the watercraft MPEM They can also be erased NOTE If desired a safety lanyard ...

Page 611: ... the safety lanyard from its post Continuous beep Engine overheats Refer to COOLING SYSTEM Bad connection between safety lanyard cap Remove and replace the safety lanyard on the post until 2 short beeps are heard to indicate the system is ready to allow engine starting Unprogrammed or defective safety lanyard Use the safety lanyard that has been programmed for the watercraft If it does not work ch...

Page 612: ...native tool to communicate with the MPEM For a complete overview of this tool refer to the MPEM Programmer Guide Programming Keys with B U D S Connect VCK components and open the software B U D S 2 F12H0BA 1 1 6 pin adapter P N 529 035 679 2 DESS adapter P N 529 035 684 RFI Models It is also possible to disconnect the connector shown in the following picture and install the RFI DESS adapter P N 27...

Page 613: ... on ADD NORMAL KEY button on bottom of screen NOTE The learning key mode is only for DI or 4 TEC models 1 F12R1PA 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 DESS post and click again on ADD NOR MAL KEY tab Ensure to save new data in MPEM using WRITE MPEM button 612 smr2004 Complete Line Up www SeaDooManuals net ...

Page 614: ... 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 continue 3 S A V E Q U I...

Page 615: ...e 518 7 36 20 N m 15 lbf ft XP DI 20 21 22 35 Jet pump bearing grease 12 13 14 16 17 7 5 N m 66 lbf in 3 N m 27 lbf in Pipe sealant 15 18 19 21 N m 16 lbf ft Loctite 243 All models except XP DI 32 31 33 2 5 N m 22 lbf in 34 30 23 20 N m 15 lbf ft 29 20 N m 15 lbf ft 24 25 26 2 5 N m 22 lbf in 29 28 27 2 5 N m 22 lbf in smr2004 Complete Line Up 615 www SeaDooManuals net ...

Page 616: ...rogressive pitch 10 20 GTI RFI GTI LE RFI 271 001 370 Stainless steel Progressive pitch 11 21 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 Co...

Page 617: ...EC TION in this subsection Using a feeler gauge with 30 cm 12 in blades measure clearance between impeller blade tip and wear ring Measure each blade at its center Clearance should not exceed 1 0 mm 040 in If clearance is greater disassemble jet pump and inspect impeller and wear ring Renew worn parts F01J0EA 1 TYPICAL MEASURING FROM WATER INLET SIDE 1 Feeler gauge F01J0FA 1 TYPICAL MEASURING FROM...

Page 618: ... gently tap cover to release it from housing cover Thoroughly clean reservoir and inside of cover with a solvent Check O ring condition Replace as necessary Apply jet pump bearing grease on mating surface of cover and reinstall it with its O ring Apply Loctite 243 on threads and torque screws to 7 5 N m 66 lbf in Remove plug from cover Pour oil through hole until oil reaches the bottom of hole thr...

Page 619: ...ing Rod Remove reverse gate pivot bolt no 26 Withdraw connecting rod Pivot Triangle Remove reverse gate connecting rod pivot triangle bolts no 31 Withdraw pivot triangle no 32 Pivot Arm Remove reverse gate connecting rod reverse cable spring no 30 pivot arm bolts no 23 Take note of bushing size for reinstallation Withdraw pivot arm no 34 F16J06A 2 3 1 1 Pivot bolts each side 2 Spring 3 Pivot arm N...

Page 620: ...crews Jet Pump Housing Remove nozzle venturi Loosen 4 hexagonal nuts and remove flat washers and lock washers from jet pump housing Remove jet pump with a wiggle movement NOTE After jet pump removal if drive shaft re mains in the PTO flywheel except XP DI simply pull it out If drive shaft is seized in the PTO fly wheel refer to DRIVE SYSTEM DISASSEMBLY NOTE Whenever removing a part visually check ...

Page 621: ...r 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 retaining the wear ring in the jet pump housing Place jet pump housing in a vise with soft jaws It is best...

Page 622: ... 8 at the same time using 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 Properly clean all thread...

Page 623: ... 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 4 for deep scratches irregular surface or any apparent d...

Page 624: ...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 shaft di...

Page 625: ...ips 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 1 2 1 ...

Page 626: ...6 N m 53 lbf in F08J06B 1 1 Screws Seal and Needle Bearing Bearing no 6 and seal no 5 on impeller side will be properly installed in housing using bearing seal installer tool P N 295 000 107 F01J4KA 2 1 BEARING SEAL INSTALLER TOOL 1 Seal side 2 Bearing side For the bearing no 8 on venturi side use inner bearing installer tool P N 529 035 609 F08B01A CAUTION Failure to use this tool will cause majo...

Page 627: ...mpeller side must be 1 5 to 2 5 mm 060 100 in inside reservoir measured from seal seat Refer to 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 on tool to ease seal insertion Install seal with the sp...

Page 628: ...y push tool until tool flange contacts housing F01J1HA 1 1 Stamped end this side 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 fo...

Page 629: ...hrust Bearing Apply Sea Doo jet pump synthetic oil P N 293 600 011 on both sides of thrust bearing Position thrust bearing no 10 on thrust washer no 9 F00J0EA 1 1 Thrust bearing on top of thrust washer Impeller Shaft To prevent seal lip damage when inserting im peller shaft use impeller shaft guide P N 295 000 002 F01J1OA Insert tool onto shaft end then carefully install shaft in jet pump housing ...

Page 630: ...cant on wear ring Insert impeller into wear ring Manually rotate im peller and push so that it slides on impeller shaft threads Carefully engage threads making sure they are well aligned Install impeller remover installer tool into impeller splines and tighten F00J08A 1 1 Impeller remover installer tool CAUTION Make sure thrust washer and bear ing are not wedged in shaft groove To check manually p...

Page 631: ...y position filler plug on top side Do not torque yet keep a small gap Insert a pencil or any other plastic tool in the hole and push on the slider tab CAUTION Do not use a metal tool to 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 ther...

Page 632: ...fill Apply Loctite pipe sealant P N 293 800 018 on plug threads and reinstall it on cover NOTE The plug threads are perpendicular to the impeller shaft F00J0JA 1 TYPICAL 1 Pour oil slowly until it is level with bottom of filler hole Venturi If needed install new O rings no 38 around bailer passages F00J0KA 1 1 O rings Apply Loctite 518 Gasket Eliminator on mating surface Position venturi no 18 wit...

Page 633: ...al Let soak and recheck Disconnect pump gauge tester and remove fit ting Check oil level Refill as necessary Apply Loctite Pipe sealant P N 293 800 018 to threads of filler plug then secure it in cover NOTE The plug threads are perpendicular to the impeller shaft INSTALLATION Jet Pump Housing Generously apply synthetic grease on drive shaft splines Make sure rubber damper is on drive shaft end Ins...

Page 634: ...N m 15 lbf ft Pivot Triangle if so equipped Install head bolts toward inside NOTE Make sure the pivot triangle turn freely Reverse Gate if so equipped Install reverse gate with spacer and washer Torque to 20 N m 15 lbf ft NOTE When installing the reverse gate pay at tention to position its lever behind the reverse gate support stopper F07J07A 1 1 Stopper Steering Cable Refer to STEERING SYSTEM Tri...

Page 635: ...18 20 30 29 42 Jet pump bearing grease 37 38 39 2 5 N m 22 lbf in 25 42 17 20 N m 15 lbf ft 32 31 34 33 2 5 N m 22 lbf in 36 35 1 2 3 6 7 8 11 6 N m 53 lbf in 12 21 22 7 5 N m 66 lbf in 28 27 26 23 24 21 N m 16 lbf ft Loctite 243 Jet pump bearing grease 2 5 N m 22 lbf in Synthetic grease 24 N m 18 lbf ft smr2004 Complete Line Up 635 www SeaDooManuals net ...

Page 636: ...ealant 3 5 7 6 4 8 9 10 Loctite 518 40 41 12 30 29 28 27 26 37 Loctite 243 24 21 N m 16 lbf ft 23 13 22 21 7 5 N m 66 lbf in 18 20 Loctite antiseize 16 15 14 37 38 39 2 5 N m 22 lbf in 25 42 17 32 31 34 33 2 5 N m 22 lbf in 36 35 Jet pump bearing grease 42 80 N m 59 lbf ft 20 N m 15 lbf ft 636 smr2004 Complete Line Up www SeaDooManuals net ...

Page 637: ...71 001 386 Stainless steel Progressive pitch 13 23 GTX 4 TEC Supercharged 267 001 091 Stainless steel Progressive pitch 13 23 RXP 267 001 096 Stainless steel Progressive pitch 10 21 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 295 100 205 can be used ...

Page 638: ... from venturi side remove ven turi nozzle assembly Using a feeler gauge with 30 cm 12 in blades measure clearance between impeller blade tip and wear ring Measure each blade at its center MODEL MAXIMUM WEAR CLEARANCE mm in All 4 TEC 0 35 014 If clearance is greater disassemble jet pump and inspect impeller and wear ring Renew worn parts F01J0EA 1 TYPICAL MEASURING FROM WATER INLET SIDE 1 Feeler ga...

Page 639: ...Remove pump retaining nuts screws Pull out pump Reverse Gate To remove reverse gate no 31 put shift lever in reverse position Unscrew pivot bolt no 33 F16J04A 2 1 1 Pivot bolt 2 Screw Remove both reverse gate screws no 32 Pivot Support Remove reverse gate Unscrew pivot support bolts no 34 1 F18J0JA 2 3 4 1 Pivot bolt 2 Pivot support 3 Reverse gate 4 Pivot support bolt Withdraw pivot support smr200...

Page 640: ...ze for reinstallation Withdraw pivot arm no 25 2 F18J1AA 3 1 1 Pivot bolts each side 2 Spring 3 Pivot arm Nozzle Remove reverse gate Disconnect steering cable from jet pump nozzle Remove O P A S U lever screws and pull out lever 1 F18J0DB TYPICAL 1 U lever screws RXP Models Disconnect VTS link rod F19J05A 1 1 Link rod Remove side screws no 37 from nozzle Pull out nozzle and VTS ring Remove VTS rin...

Page 641: ...ould have been installed between hull and pump housing Be sure to reinstall it otherwise engine and jet pump alignment will be altered NOTE If drive shaft is seized in the PTO flywheel refer to DRIVE SYSTEM DISASSEMBLY NOTE Whenever removing a part visually check for damage such as corrosion crack split break porosity cavitation deformation distortion heat ing discoloration wear pattern missing pl...

Page 642: ...ip F18J0NA F18J0OA Impeller Remove ring no 1 and impeller boot no 2 RXP Models Unscrew boot no 1 CLOCKWISE F19J06A 1 1 Unscrew clockwise All Models Replace ring or boot if damaged Mount impeller remover installer in a vise MODEL TOOL P N GTX 4 TEC and Supercharged 529 035 820 RXP 529 035 956 1 F18J0PB 1 Impeller remover installer 642 smr2004 Complete Line Up www SeaDooManuals net ...

Page 643: ...haft sleeve no 14 and O ring no 15 in position The impeller shaft push er will work against sleeve to properly push bear ing out Use the impeller shaft pusher P N 529 035 955 to press out impeller shaft no 18 of pump housing Bearing no 16 will come out with the impeller shaft 1 F18J0UB 1 Impeller shaft pusher CAUTION Bearing inner race being in 2 parts bearing may fall apart during removal Use the...

Page 644: ...me ter Push ring so that it can collapse internally Pull ring out CLEANING Properly clean all threads Remove all O rings and clean parts in a solvent Carefully check water passages Blow low pres sure compressed air through them and make sure they are clear 1 F18J0XA 1 Water passages Brush and clean impeller shaft threads impeller and drive shaft splines with pulley flange cleaner P N 413 711 809 o...

Page 645: ... feel contact surface of sleeve If any irregular surface is found renew sleeve no 14 and seal Install bearing then install impeller shaft and ro tate it Make sure it turns smoothly RADIAL PLAY Radial play is critical for jet pump unit life span Radial play of impeller shaft is checked with shaft in housing with impeller Retain housing in a soft jaw vise making sure not to damage housing lug Set a ...

Page 646: ...1 0 mm 039 in It may be positioned up to 2 0 mm 078 in from housing edge A F18J0EA B C A 20 B 2 0 mm 078 in C 1 0 mm 039 in Wear Ring Position wear ring so that its rounded edge is out wards 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 ...

Page 647: ...to 6 N m 53 lbf in F08J06A Bearing Using the seal bearing pusher P N 529 035 819 press the bearing no 16 by its inner race on the impeller shaft no 8 Be careful when removing the plastic retainer from the bearing no 16 to avoid the inner races from falling apart Make sure to reassemble bear ing parts to their original position The bearing no 16 can be installed either side 1 F18J0YB 1 Seal bearing...

Page 648: ...ip no 4 On the outlet side install 2 O rings no 20 in their respective groove Before installing any other parts pump can be pressurized to insure proper seal installation See PUMP PRESSURIZATION below Apply Loctite antiseize on impeller shaft Apply BOMBARDIER LUBE on the wear ring sur face Start screwing the impeller on its shaft If impeller is too tight use impeller tool to turn im peller to mach...

Page 649: ...18A TYPICAL Install impeller cover with new self locking screws Torque to 7 5 N m 66 lbf in Venturi If needed install new O rings no 13 around bailer passages F00J0KA 1 1 O rings Position venturi no 23 with bailer passages on top Apply Loctite 243 blue on threads of screws no 24 Install screws no 24 lock washers and flat wash ers then torque to 21 N m 16 lbf ft F02J0TA 1 1 1 Torque screws to 21 N ...

Page 650: ...cover against pump housing while tightening screws INSTALLATION Jet Pump Housing The water flow is controlled by a reducer located between the jet pump support and the jet pump on the inlet side The reducer is color coded ac cording to watercraft model See table below MODEL REDUCER COLOR GTX 4 TEC and RXP Yellow GTX 4 TEC Supercharged Red Make sure that the reducer is installed as shown CAUTION Mi...

Page 651: ...or use new self locking screws Install screws no 30 and washer no 29 then torque to 24 N m 18 lbf ft WARNING Screws must be torqued as specified O P A S Reconnect O P A S hose if applicable Torque clamp screw to 1 7 N m 15 lbf in Fasten O P A S U lever to nozzle and side levers Apply Loctite 243 blue on screw threads or use new self locking screws Torque center screw to 20 N m 15 lbf ft and side s...

Page 652: ...PULSION Subsection 01 JET PUMP Steering Cable Refer to STEERING SYSTEM Reverse Cable Refer to REVERSE SYSTEM Jet Pump Support and Riding Plate Refer to HULL AND BODY 652 smr2004 Complete Line Up www SeaDooManuals net ...

Page 653: ...OPULSION Subsection 02 DRIVE SYSTEM DRIVE SYSTEM GTI Series F02I0AS 2 3 4 5 6 8 7 9 2 N m 18 lbf in 10 11 13 Synthetic grease 12 Synthetic grease 13 2 N m 18 lbf in smr2004 Complete Line Up 653 www SeaDooManuals net ...

Page 654: ... 243 22 N m 16 lbf ft Loctite 271 Loctite 518 Synthetic grease 23 15 17 16 15 14 Loctite 518 21 10 N m 89 lbf in 5 6 8 9 10 7 11 12 13 Synthetic grease Synthetic grease Loctite 243 Synthetic grease Synthetic grease Loctite 243 22 N m 16 lbf ft 2 N m 18 lbf in 28 27 30 31 32 29 654 smr2004 Complete Line Up www SeaDooManuals net ...

Page 655: ...Section 13 PROPULSION Subsection 02 DRIVE SYSTEM 4 TEC Models F18I0MT 5 6 7 8 9 10 11 25 26 12 Anti corrosion spray Anti corrosion spray smr2004 Complete Line Up 655 www SeaDooManuals net ...

Page 656: ...ge XP DI Models Open engine compartment cover Remove storage basket Remove vent tubes from PTO flywheel guard Remove PTO flywheel guard Large Clamp GTI Series Unfasten large clamp of PTO flywheel boot no 3 as follows Use pliers P N 295 000 069 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 l...

Page 657: ...t this RPM This will move oil out of PTO housing into oil tank If engine cannot be started refer to the procedure in PTO HOUSING MAGNETO section and look for PTO HOUSING REMOVAL Remove seat RXP 4 TEC Models Remove engine cover GTX 4 TEC Models Detach coolant expansion reservoir from vent tube support then move away 2 F18L1GB 1 1 Detach expansion reservoir 2 Remove vent tube support Detach vent tub...

Page 658: ...ve shaft cannot move rearwards when using the drive shaft float ing ring tool F18B02A 1 TYPICAL 1 Drive shaft holder F18B03A Disconnect EGTS sensor to make room For the following operations use the drive shaft floating ring tool MODEL TOOL P N GTX 4 TEC 529 035 841 RXP 4 TEC 529 035 987 NOTE Note that there is a large opening and a small opening on the tool Depending on the step involved in the pr...

Page 659: ...ng here 2 Floating ring Turn screw clockwise so that the tool pushes the floating ring rearwards to expose the circlip Do not remove circlip at this time NOTE This step is done to ensure floating ring is free and not stuck on the drive shaft Remove drive shaft floating ring tool and drive shaft holder Reinstall drive shaft floating ring tool as shown 1 F18I0OA TYPICAL 1 Largest opening on PTO seal...

Page 660: ...re is a distance of 18 mm 71 in between the tell tale groove and the tool edge Lubricate O rings contact area with BOM BARDIER LUBE P N 293 600 016 NOTE This is necessary to ease drive shaft re moval later in this procedure Remove drive shaft floating ring tool and PTO seal support Reinstall drive shaft holder tool F18B03A Reinstall drive shaft floating ring tool as shown Push floating ring rearwa...

Page 661: ... to prevent spillage If spillage occurs clean immediately with the pul ley flange cleaner P N 413 711 809 to prevent oil stains Remove drive shaft NOTE It may require a slight jerk to the rear to re move the drive shaft from the PTO seal assembly Rear Drive Shaft XP DI Models Remove rear access panel Remove protective plate no 18 F08I03B 1 1 Remove protective plate Pull rear drive shaft until coup...

Page 662: ...AL 1 Remove bolts and lock nuts Loosen 4 screws and remove bottom cover of seat F08L11A 1 1 Remove cover Loosen gear clamp retaining the outer boot of the shock absorber F08L12A 1 1 Loosen gear clamp Tilt seat Remove front drive shaft Seal Carrier of Mid Bearing XP DI Models To remove the seal carrier from support loosen the 6 nuts no 21 662 smr2004 Complete Line Up www SeaDooManuals net ...

Page 663: ...els 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 Excessive deflection could cause vibration and damage to drive shaft splines impeller flywheel or floating ring seal carrier depending upon the model Place drive shaft on V blocks and...

Page 664: ...To verify the boot preload and free length jet pump and drive shaft must be installed Measure boot length when normally installed on drive shaft Ensure circlip no 5 is properly in stalled into groove F00J03A 1 A 1 Boot A Measure here Push floating ring to compress boot then remove circlip out of drive shaft groove F06I06A 1 2 1 Push floating ring 2 Remove circlip Slide floating ring far enough for...

Page 665: ...installing seals and bearing CAUTION Ensure to install stamped end of bearing showing identification markings first on tool Never hammer the bearing into its housing Install bearing no 16 with the bearing seal in staller tool P N 295 000 107 F01J51A 1 1 Press bearing in its housing NOTE Bearing can also be installed with the same driver used at disassembly Center bearing in lon gitudinal axis of h...

Page 666: ...Pack seals and bearing with synthetic grease P N 293 550 01 INSTALLATION Installation is essentially the reverse of removal procedure However pay particular attention to the following Seal Carrier of Mid Bearing XP DI Models Install any of the alignment washers no 22 as shown Insert bushings no 27 in washer 2 F00B22A 1 1 Alignment washer 2 Bushings Insert seal carrier housing no 17 in remaining al...

Page 667: ...tall support plate at rear of watercraft Carefully slide shaft through seal carrier and shaft support Ensure that shaft goes farther than shaft support F05I08A 1 2 TYPICAL 1 Alignment tool 2 Seal carrier If alignment tool does not slide easily through seal carrier perform the alignment as follows For vertical alignment loosen damping support nuts no 30 and move the support no 29 up and down as nec...

Page 668: ...oose Install damper no 13 to rear drive shaft no 12 Install drive shaft and jet pump at the same time Insert drive shaft through carbon ring no 8 and floating ring no 6 Insert drive shaft through seal carrier no 14 and into the coupler assembly Be careful not to dam age seals CAUTION When sliding the drive shaft through seal carrier the double lip seal can be folded over This would cause a seal ca...

Page 669: ...over shaft end Circlip All Models except 4 TEC Models Push the floating ring to compress the boot In sert the circlip no 5 in the drive shaft groove F06I06A 1 2 1 Push floating ring 2 Insert circlip in the groove Slide the floating ring onto the circlip Large Clamp GTI Series Secure large clamp no 2 as follows Use pliers P N 295 000 069 as for removal Manually engage holding hook in large window T...

Page 670: ...ive shaft in PTO seal assembly Before installing drive shaft inspect PTO seal as sembly The inner sleeve must be flush with outer circumference of the assembly Otherwise gen tly push or tap on inner sleeve until flush F18I0EA 1 CORRECT INSTALLATION 1 Inner sleeve flush with outer circumference F18I0FA 1 WRONG INSTALLATION 1 Inner sleeve not flush with outer circumference Apply a thin coat of synth...

Page 671: ... application instructions on product can Wait 2 hours prior to using the watercraft to allow protectant to dry CAUTION Note that drive shaft features a tell tale groove If exposed after installation the installation is wrong and PTO seal assembly will be pressed into crankshaft splines which could rub a hole in seal thus creating an oil leak F18I0QA 1 1 Tell tale groove Install PTO seal assembly I...

Page 672: ... in the proper position and tap shaft end until it bottoms against engine At this time the tell tale MUST NOT be visible This validate the correct position F18I0HA 1 2 3 1 PTO seal support 2 Drive shaft end 3 Insert floating ring on shaft end 3 F18I0IA 2 1 GOOD INSTALLATION 1 PTO seal assembly 2 Shaft pushed in hiding tell tale groove 3 Inner sleeve flush with outer circumference 3 F18I0JA 2 1 WRO...

Page 673: ...ed Tell tale is not exposed inner sleeve is flush with outer circumference of PTO seal assembly and C clip is not exposed If tell tale mark is exposed push PTO seal assem bly rearwards to fully extend it If inner sleeve is not flush gently tap it until it is flush Reposition splash guard Reconnect EGTS sensor Install jet pump Refer to JET PUMP section Check engine oil level Refill as necessary Run...

Page 674: ... the excess of sprayed corrosion protectant From underneath hull spray the corrosion protec tant through the intake grate all over the visible portion of drive shaft Dispose of the soiled plastic sheet as per your lo cal environmental regulations NOTE On Supercharged models remove inlet hose from supercharger to gain access From inside bilge lift splash guard to expose PTO seal assembly Cover carb...

Page 675: ... N m 62 lbf in 2 5 N m 22 lbf in 10 N m 89 lbf in 4 N m 35 lbf in 2 5 N m 22 lbf in 2 N m 18 lbf in 2 N m 18 lbf in Loctite 243 3 3 N m 29 lbf in 2 N m 18 lbf in 2 5 N m 22 lbf in 11 12 4 9 9 10 Loctite 243 Loctite 243 Loctite 243 2 5 N m 22 lbf in 4 N m 35 lbf in Silicone sealant Silicone sealant GTX series 5 2 5 N m 22 lbf in smr2004 Complete Line Up 675 www SeaDooManuals net ...

Page 676: ...rage compartment and remove basket Remove nut of front vent tube unsnap wiring har ness and separate vent tube 2 F19J04A 1 1 Remove nut 2 Separate bottom and top parts Pull out bottom part first then top part GTX Series Push the vent tube toward the front of the vehicle to get greater access to the interior lever and the reverse cable support To release the vent tube press down its locking tabs an...

Page 677: ...or lever no 3 Unscrew the shift lever retaining bolt no 4 wash er and nut then remove interior lever 1 F16J0DA 2 1 Reverse cable 2 Interior lever Shift Lever Unscrew the shift lever retaining bolt no 4 wash er and nut Disengage the shift lever slots from interior lever tabs then remove the shift lever no 5 4 F18J1KA 3 1 2 1 Shift lever retaining bolt 2 Shift lever slot 3 Interior lever tab 4 Shift...

Page 678: ... synthetic grease on the interior lever pivot and in the reverse cable support hole Install the interior lever in a rotating movement Engage properly the interior lever tabs in the shift lever slots Make sure the shift lever action is smooth and precise Forward and reverse positions should be easy to select with a decent position between each Reverse Gate Refer to JET PUMP section Reinstall remove...

Page 679: ... 1 2 3 5 6 7 8 9 10 7 N m 62 lbf in 11 12 14 2 20 N m 15 lbf ft Loctite Primer N 5 N m 44 lbf in 3 N m 27 lbf in Synthetic grease 7 N m 62 lbf in 13 Dielectric grease 7 N m 62 lbf in 4 Loctite 243 20 N m 15 lbf ft Synthetic grease Loctite Primer N smr2004 Complete Line Up 679 www SeaDooManuals net ...

Page 680: ... 10 2 3 2 13 1 14 16 2 5 N m 23 lbf in 10 N m 89 lbf in 15 5 6 12 5 N m 44 lbf in 7 N m 62 lbf in 11 Loctite Primer N Dielectric grease 4 Loctite 243 20 N m 15 lbf ft 7 N m 62 lbf in 20 N m 15 lbf ft 20 N m 15 lbf ft Synthetic grease Loctite Primer N 680 smr2004 Complete Line Up www SeaDooManuals net ...

Page 681: ...o 13 retaining VTS rod no 1 to sliding shaft no 10 Remove clamps no 2 Remove boot no 3 1 F16J0AA 3 4 2 RXP MODELS 1 VTS rod 2 Bolt 3 Lock nut 4 Rubber boot F06J01E 1 2 3 4 XP DI MODELS 1 VTS rod 2 Bolt 3 Lock nut 4 Rubber boot To loosen nut no 4 use VTS socket tool P N 295 000 133 F01B2PA Remove sealing washer no 5 All Models Disconnect wiring harnesses Pull out VTS assembly no 6 from bilge DISASS...

Page 682: ...t is cracked or torn replace boot Worm Inspect threads and splines of worm no 9 for wear If worm replacement is necessary renew also sliding shaft F01J25A 1 1 Inspect threads and splines ASSEMBLY Assembly is essentially the reverse of disassem bly procedures However pay particular attention to the following Motor Worm and Sliding Shaft Apply synthetic grease to worm Screw worm no 9 to sliding shaf...

Page 683: ...d to nut no 4 Apply Loctite 243 blue to nut no 4 Install nut with sealing washer and torque to 7 N m 62 lbf in using the VTS socket tool P N 295 000 133 Apply synthetic grease to sliding shaft Boot and Clamps Install rubber boot no 3 over sliding shaft and se cure with clamps VTS Rod Install rubber boot no 3 over sliding shaft and secure with clamps RXP Models Secure the VTS rod onto the sliding s...

Page 684: ...E Install safety lanyard to be able to position VTS F01J3IA 1 2 8 1 No interference 2 Nozzle up If an adjustment is necessary loosen jam nut no 16 of VTS rod no 1 Turn adjustment nut of VTS rod to obtain the desired gap between trim ring and venturi F06J01A 1 TYPICAL 1 Turn adjustment nut of VTS rod Tighten jam nut of VTS rod to 2 5 N m 23 lbf in when adjustment is completed 684 smr2004 Complete L...

Page 685: ... N m 35 lbf in 13 N m 115 lbf in Loctite 243 5 N m 44 lbf in Loctite 243 6 N m 53 lbf in 6 N m 53 lbf in Loctite 243 6 N m 53 lbf in Loctite 243 26 N m 19 lbf ft 7 N m 62 lbf in 23 22 2 5 N m 22 lbf in 2 5 N m 22 lbf in 19 20 21 25 24 27 26 Carburetor equipped engines 7 Synthetic grease 8 N m 71 lbf in 7 N m 62 lbf in 21 35 36 37 46 44 38 smr2004 Complete Line Up 685 www SeaDooManuals net ...

Page 686: ... N m 53 lbf in Loctite 243 5 N m 44 lbf in 2 5 N m 22 lbf in 6 N m 53 lbf in 9 Loctite 243 10 24 27 25 10 N m 89 lbf in 19 11 Loctite 243 6 N m 53 lbf in 2 5 N m 22 lbf in 4 N m 35 lbf in 32 33 30 Loctite 243 34 29 Synthetic grease 48 49 50 47 Loctite 767 Loctite 271 26 N m 19 lbf ft GTX 4 TEC Supercharged LTD only 46 Synthetic grease 7 N m 62 lbf in 31 Loctite 243 10 N m 89 lbf in RXP 4 TEC Model...

Page 687: ...YPICAL 1 Adjustment handle 2 Support bushing Hold jam nut no 34 and unscrew adjustment han dle no 30 from adjuster screw no 29 1 F07K0NA TYPICAL 1 Loosen jam nut Handle Grip and Grip Insert To remove handle grip no 1 pull out cap no 2 and remove screw no 3 Pull out grip and remove grip insert from handlebar no 22 1 F18K0AA 2 1 Handle grip 2 Remove screw NOTE Verify grip insert for damage Steering ...

Page 688: ...emove 2 tapping screws no 42 2 F18K0CA 1 1 Tapping screw 2 Handle bar housing Remove handlebar housing cover no 8 and throt tle handle housing no 39 Unhook throttle cable from throttle handle no 40 Pry out the throttle cable housing from throttle handle housing no 41 2 F18K0DA 1 3 1 Throttle cable 2 Throttle handle housing 3 Throttle cable handle Remove 6 screws no 7 and flat washers no 45 each si...

Page 689: ...ing cover as mentioned above Remove 2 screws no 35 and flat washers no 36 Remove steering padding no 37 1 2 F18K0GA 1 Screws 2 Steering padding Handlebar GTX 4 TEC Supercharged Limited Models Only Remove 4 elastic stop nuts M8 retaining steering clamp no 44 F07K0SA 1 2 TYPICAL 1 Remove nuts 2 Steering clamp Detach steering clamp no 44 and remove handle bar no 22 Withdraw rubber pad no 32 and stop ...

Page 690: ...o remove handle bar no 22 from steering stem no 46 and steering clamp no 44 2 F18K0HA 3 4 1 1 1 Nuts 2 Handlebar 3 Steering stem 4 Steering clamp Cable Support RXP 4 TEC Models Remove front vent tube All Models Loosen bolts no 9 and remove retaining block no 10 1 F18K0IA 1 Retaining block Loosen bolts no 11 each side of steering support no 12 F07K02A 1 2 1 Steering support 2 Bolt 690 smr2004 Compl...

Page 691: ... Fuel Injection Models Disconnect the throttle cable from throttle body All Models Disconnect the wiring harnesses leading out of steering stem and cut locking tie F07K05A 2 1 1 Tie rap 2 Connectors Disconnect the steering cable from the steering stem arm no 15 F07K06A 1 2 1 Steering stem arm 2 Steering cable Remove bolts no 11 retaining cable support no 8 to steering support no 12 Remove bolts no...

Page 692: ... pivots to remove threaded block from steering stem no 49 F07K0PA 2 3 1 5 4 6 1 Steering stem 2 Steering support 3 Support bushing 4 Adjuster screw 5 Threaded block 6 Threaded pivots Steering Cable Disconnect steering cable no 24 from steering stem arm no 15 Remove retaining block no 10 Disconnect ball joint no 19 from jet pump nozzle Remove ball joint no 19 and jam nut from cable Loosen nut no 25...

Page 693: ...port Position steering stem arm no 15 and support no 16 onto steering stem WARNING Make 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 18 by new ones Torque bolts no 17 of steering stem arm to 6 N m...

Page 694: ... TEC Supercharged Limited Models Only Before installing handlebar position stopper no 33 and rubber pad no 32 CAUTION Rubber pad must not exceed stop per F07K0UA 1 1 1 Pad must not exceed stopper All Models Position handlebar no 22 Install steering clamp no 44 and secure with new elastic stop nuts M8 Torque nuts to 26 N m 19 lbf ft as per the fol lowing sequence F07K0VA 1 3 2 4 TORQUE SEQUENCE Bal...

Page 695: ...ection 01 STEERING SYSTEM 1 F19J0CA 2 TYPICAL 1 Ball joint below steering arm 2 Torque nut to 7 N m 62 lbf in STEERING ALIGNMENT For steering alignment procedure refer to ALIGN MENT smr2004 Complete Line Up 695 www SeaDooManuals net ...

Page 696: ... N m 62 lbf in 7 Loctite 243 10 26 N m 19 lbf ft 13 N m 10 lbf ft Engine cover Loctite 243 2 5 N m 22 lbf in Loctite 243 Loctite 243 20 19 6 N m 53 lbf in 11 21 2 5 N m 22 lbf in 23 7 N m 62 lbf in 22 26 25 27 Engine cover 17 6 N m 53 lbf in Loctite 243 16 15 7 N m 62 lbf in Synthetic grease 14 7 10 N m 89 lbf in 12 1 N m 9 lbf in 3 N m 27 lbf in 696 smr2004 Complete Line Up www SeaDooManuals net ...

Page 697: ...ring cover no 6 loosen set screws no 7 of handlebar housing F00K01A 1 1 Set screws Remove 4 screws no 8 and washers F00K02A 2 1 TYPICAL 1 Cover 2 Screws Remove 2 screws no 9 and flat washers each side of cover 1 F07K0JA 1 Remove screws Detach upper and lower section of cover from steering 2 F07K0KA 1 1 Upper section 2 Lower section Lever Open engine compartment cover Remove the top section of the ...

Page 698: ...rt ment cover Disconnect steering cable no 11 from lever no 10 F08K05A 1 1 Disconnect steering cable Remove link rod no 12 F08K06A 1 1 Remove link rod Remove bolt no 13 and washer retaining lever no 10 to steering support no 18 F08K07A 1 1 Remove bolt and washer Steering Stem Arm and Support Loosen bolts no 17 retaining steering stem arm no 15 and support no 16 698 smr2004 Complete Line Up www Sea...

Page 699: ...ove the sup port no 16 and steering stem arm no 15 F08K0AA 1 1 Remove support and steering stem arm Steering Stem Disconnect wiring harnesses and throttle cable from engine Remove steering stem no 14 Steering Cable Remove glove box Disconnect steering cable no 11 at lever no 10 F08K05A 1 1 Disconnect steering cable Unscrew bolts from retaining block no 20 to re move steering cable from cable suppo...

Page 700: ...10 apply synthetic grease to pivot Steering Stem Apply synthetic grease to front and rear thrust bearing surface 1 F08K0MA 1 Apply synthetic grease Steering Stem Arm and Support Position steering stem arm no 15 and support no 16 onto steering stem no 14 WARNING Make sure integrated flat keys of steering stem arm and support are properly seated in steering stem keyways Handle Grip and Grip Insert W...

Page 701: ... CAUTION Ensure to install flat washer other wise screw will damage grip end Ball Joint Secure the steering cable ball joint no 21 to the nozzle as per following illustration CAUTION Ensure the ball joint is parallel 10 to the nozzle arm F06K01A 1 2 TYPICAL 1 Ball joint on top of steering arm 2 Torque nut to 7 N m 62 lbf in STEERING ALIGNMENT For steering alignment procedure refer to ALIGN MENT sm...

Page 702: ... 7 N m 15 lbf in 32 30 23 6 7 N m 62 lbf in 7 29 28 2 2 N m 19 lbf in 8 2 20 N m 15 lbf ft 3 4 5 1 7 6 7 N m 62 lbf in Hull 8 2 2 N m 19 lbf in 28 29 23 26 34 2 2 N m 19 lbf in 33 35 1 7 N m 15 lbf in 26 36 25 12 1 2 N m 10 lbf in 24 22 5 5 N m 49 lbf in 2 2 N m 19 lbf in 11 9 10 17 16 21 27 21 2 2 N m 19 lbf in GTX Series only GTX Series GTI Series and RXP 4 TEC 12 13 18 20 16 17 702 smr2004 Comp...

Page 703: ... Series When engine is running at approximately 75 or more RPM the side vanes are automatically raised to upper position since they are not required at that vehicle speed range Between 30 and 75 engine RPM side vanes are gradually raised from lower position to upper position F18K02A 1 1 Side vane in upper position When throttle is released and engine RPM drops the side vanes are automatically lowe...

Page 704: ...of tie rod stabilizing fitting no 21 from the cylinder support should be 45 1 mm 1 65 04 in A F18K0ZA A 45 1 mm 1 65 04 in Assembly Assembly is the reverse process of disassembly Torque tie rod retaining screw no 10 to 4 5 N m 40 lbf in Torque socket screw no 11 to 2 2 N m 19 lbf in CYLINDER SUPPORT Disassembly Removal procedure for RH and LH cylinder sup port assembly is same Remove side vane as ...

Page 705: ...hose 3 Cylinder support Assembly Assembly is the reverse process of disassembly make sure of the following when doing assembly GTX 4 TEC Series Always discard old threaded cover rod no 14 and replace with new one 1 F18K0YA 1 Replace threaded cover Check pivot rod no 13 for cracks or scratches Replace pivot rod if necessary Replace the cylinder seal ring whenever servic ing All Models Socket screws...

Page 706: ...sembly Removal procedure for RH and LH sealed tube no 27 is same Remove side van cylinder housing assembly and O P A S U lever as mentioned above Remove jet pump refer PROPULSION SYSTEM Remove Phillips screws no 28 and remove rod grommet no 29 2 F18K0SA 1 1 Phillips screws 2 Rod grommet Pull sealed tube out with tie rod from inside of bilge towards jet pump side 1 F18K0TA 2 TYPICAL 1 Sealed tube 2...

Page 707: ...no 34 from valve collar 1 F18K0WA TYPICAL 1 Phillips screws Remove valve downwards from pump tunnel Assembly Assembly is the reverse process of disassembly make sure of the following when doing assembly Check for cracks on formed hose no 32 change if necessary Make sure the valve is installed in the right po sition Torque Phillips screws no 34 to 2 2 N m 19 lbf in Tighten gear clamps no 31 manuall...

Page 708: ...late Remove resonator refer to EXHAUST SYSTEM All Models For RH and LH Cross Support Plates Remove side vane and cylinder support assembly as mentioned above Unscrew the screw no 24 1 F18K0XA 1 Remove screw Remove cross support plate no 36 from the in side of bilge Assembly Assembly is the reverse process of disassembly make sure of the following when doing assembly Check for cracks and deteriorat...

Page 709: ...nce on each side of the straight edge If necessary steering alignment adjustment should be performed at steering cable support GTI and GTX 4 TEC Series Open storage compartment cover and remove basket if so equipped Remove access panel if so equipped RXP 4 TEC Models Remove seat All Models except XP DI Loosen 2 bolts retaining block at cable support Turn adjustment nut as required 1 3 F01K18A 2 AL...

Page 710: ... 1 Support 2 Adjustment nut 3 Loosen bolts All Models After adjustment torque retaining block bolts 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 or VTS ring if so equipped 710 smr2004 Complete Line Up www SeaDooManuals net ...

Page 711: ...ubsection 01 DIRECT ACTION SUSPENSION DIRECT ACTION SUSPENSION XP DI Models F08Q07S 34 N m 25 lbf ft 10 11 2 3 13 12 1 9 5 4 8 10 N m 89 lbf in 34 N m 25 lbf ft Loctite 243 6 smr2004 Complete Line Up 711 www SeaDooManuals net ...

Page 712: ...n pull outer boot downward F08L12A 1 1 Loosen gear clamp Remove rear access panel from body Loosen lower gear clamp no 4 then push inner boot no 5 upward F08I03B 1 1 Loosen gear clamp Remove bolt no 6 and lock nut no 7 from shock absorber lower support no 8 F08Q03A 2 1 1 Bolt 2 Lock nut Tilt seat upward Loosen upper gear clamp no 9 of inner boot no 5 712 smr2004 Complete Line Up www SeaDooManuals ...

Page 713: ...spring and remove cup no 13 Unload tool and remove spring from shock ab sorber INSPECTION Boot Inspect condition of boots If there are any signs of tear renew boot s Shock Absorber Inspect shock absorber for wear Extend and compress the piston several times over its entire stroke it should move smoothly and with uniform resistance Pay attention to the following conditions that will denote a defect...

Page 714: ...PENSION ASSEMBLY Assembly is essentially the reverse of disassem bly procedure Refer to the main illustration at the beginning of this subsection for torque specifica tions and service products to be used 714 smr2004 Complete Line Up www SeaDooManuals net ...

Page 715: ...T AND REPAIR ADJUSTMENT AND REPAIR GTI Series bow F17L14T Silicone sealant 5 N m 44 lbf in 3 N m 26 lbf in 8 N m 71 lbf in 7 N m 62 lbf in 8 N m 71 lbf in Silicone sealant 15 N m 133 lbf in Body smr2004 Complete Line Up 715 www SeaDooManuals net ...

Page 716: ...ion 16 HULL BODY Subsection 01 ADJUSTMENT AND REPAIR GTI Series stern 15 Silicone sealant Silicone sealant Loctite 243 F17L1AS Silicone sealant 4 4 5 5 12 716 smr2004 Complete Line Up www SeaDooManuals net ...

Page 717: ...over F17L16T Loctite 243 4 N m 35 lbf in 1 4 N m 35 lbf in 5 N m 44 lbf in Loctite 243 Loctite 454 15 N m 133 lbf in LE Models Loctite 243 Synthetic grease 4 N m 35 lbf in 3 N m 26 lbf in 8 N m 71 lbf in 4 N m 35 lbf in smr2004 Complete Line Up 717 www SeaDooManuals net ...

Page 718: ...Section 16 HULL BODY Subsection 01 ADJUSTMENT AND REPAIR GTI Series seats F07L2OS GTI seats Loctite 414 718 smr2004 Complete Line Up www SeaDooManuals net ...

Page 719: ...BODY Subsection 01 ADJUSTMENT AND REPAIR XP DI Models bow F08L1JT Loctite 243 Silicone sealant 10 6 Loctite 243 Silicone sealant Body 15 N m 11 lbf ft Loctite 271 8 7 smr2004 Complete Line Up 719 www SeaDooManuals net ...

Page 720: ... AND REPAIR XP DI Models stern 23 4 4 5 5 12 13 12 3 5 N m 44 lbf in Loctite 243 Front tray Body Loctite 243 4 N m 35 lbf in 4 N m 35 lbf in Loctite 243 Body 5 N m 44 lbf in Loctite 243 3 F12L0KS 720 smr2004 Complete Line Up www SeaDooManuals net ...

Page 721: ...AND REPAIR XP DI Models engine cover F08L1KT Loctite 243 4 N m 35 lbf in Loctite 243 8 N m 71 lbf in Loctite 243 4 N m 35 lbf in Loctite 243 4 N m 35 lbf in Loctite 648 8 N m 71 lbf in Loctite 243 smr2004 Complete Line Up 721 www SeaDooManuals net ...

Page 722: ...DY Subsection 01 ADJUSTMENT AND REPAIR XP DI Models front cover Engine cover Synthetic grease 3 N m 27 lbf in Loctite 271 2 N m 18 lbf in Loctite 243 Loctite 243 F12L0MS 722 smr2004 Complete Line Up www SeaDooManuals net ...

Page 723: ...STMENT AND REPAIR XP DI Models seat F12L0LS Loctite 243 15 N m 11 lbf ft 17 5 N m 44 lbf in Loctite 271 13 N m 10 lbf ft 3 N m 27 lbf in 23 22 21 20 19 18 3 N m 27 lbf in 24 Synthetic grease smr2004 Complete Line Up 723 www SeaDooManuals net ...

Page 724: ...L BODY Subsection 01 ADJUSTMENT AND REPAIR GTX 4 TEC Models body front view F17L1BS Body 10 11 8 12 9 7 7 N m 62 lbf in Silicone sealant Silicone sealant Loctite 243 724 smr2004 Complete Line Up www SeaDooManuals net ...

Page 725: ...2 5 N m 22 lbf in 6 Some models Some models Silicone sealant Silicone sealant 1 2 3 1 4 15 2 2 N m 19 lbf in Some models Silicone sealant 15 N m 11 lbf in Silicone sealant 10 N m 89 lbf in Loctite 243 8 N m 70 lbf in Loctite 5900 21 23 25 20 26 24 smr2004 Complete Line Up 725 www SeaDooManuals net ...

Page 726: ...ADJUSTMENT AND REPAIR GTX 4 TEC Models front storage compartment F18L34T Body Some models Synthetic grease Loctite 243 5 N m 44 lbf in 3 N m 26 lbf in Loctite 271 Loctite 243 Loctite 243 726 smr2004 Complete Line Up www SeaDooManuals net ...

Page 727: ...Section 16 HULL BODY Subsection 01 ADJUSTMENT AND REPAIR GTX 4 TEC Models seats F18L1HS Loctite 414 Loctite 414 Loctite 414 Loctite 414 Loctite 414 smr2004 Complete Line Up 727 www SeaDooManuals net ...

Page 728: ...16 HULL BODY Subsection 01 ADJUSTMENT AND REPAIR RXP Models body rear view 1 F19L11S 6 3 2 Loctite 243 18 N m 159 lbf in 1 1 2 4 Loctite 243 18 N m 159 lbf in 728 smr2004 Complete Line Up www SeaDooManuals net ...

Page 729: ...Section 16 HULL BODY Subsection 01 ADJUSTMENT AND REPAIR RXP 4 TEC Models body rear view 2 F19L12S Loctite 243 Silicone sealant smr2004 Complete Line Up 729 www SeaDooManuals net ...

Page 730: ... 01 ADJUSTMENT AND REPAIR RXP 4 TEC Models hull rear rear view F19L13S 15 N m 133 lbf in Silicone sealant Silicone sealant Silicone sealant Silicone sealant 11 12 15 Silicone sealant 730 smr2004 Complete Line Up www SeaDooManuals net ...

Page 731: ...Y Subsection 01 ADJUSTMENT AND REPAIR RXP 4 TEC Models front storage compartment F19L14S Loctite 243 Loctite 243 Loctite 243 Loctite 243 Synthetic grease 11 N m 97 lbf in smr2004 Complete Line Up 731 www SeaDooManuals net ...

Page 732: ...Section 16 HULL BODY Subsection 01 ADJUSTMENT AND REPAIR RXP 4 TEC Models seats F19L15S Loctite 414 732 smr2004 Complete Line Up www SeaDooManuals net ...

Page 733: ...it does not come in contact with ABS plastic parts paint ed parts It could lead to plastic cracks or other damage GLOVE BOX Removal GTX 4 TEC Series Lift the glove box top cover Gently push on both rear tabs while lifting out rear of glove box compartment F18L3MA 1 1 Push tabs Pull the glove box out of body GTI Series Remove handle from shift lever 1 F16L07A 1 Unscrew Remove darts and then remove ...

Page 734: ...hole and press glove box lock tabs to release 1 F16L0AA 1 Insert your hand here to release the lock tabs From front storage compartment pull glove box out F16L0BA 1 1 Lock tabs RXP 4 TEC Models Place shift lever in forward position Remove seat Pull dart out See illustration F19L16A 1 1 Pull dart out Carefully pull the side molded part to release the glove box Pulling too much might lead to damag i...

Page 735: ...side the same way to fi nally pull glove box out Installation Reverse the removal procedure ENGINE COVER RXP 4 TEC Models Remove seat Detach coolant expansion tank and move away F19L1BA 1 1 Coolant expansion tank Remove Bombardier logo at rear F19L1AA 1 1 Logo Remove retaining screws 1 F19L1CA 1 Retaining screws smr2004 Complete Line Up 735 www SeaDooManuals net ...

Page 736: ...he lock pin is removed then reinstalled The threads on new lock pin are coated with a self locking prod uct do not apply Loctite 243 on threads F07L08A A 2 1 TYPICAL GTX 4 TEC SERIES FRONT SEAT 1 Lock pin 2 Adjustment nut Loctite 243 Torque to 5 N m 44 lbf in A 33 1 mm 1 35 64 3 64 in F06L03A A 1 2 TYPICAL GTX 4 TEC SERIES REAR SEAT 1 Lock pin 2 Adjustment nut apply Loctite 243 Torque to 5 N m 44 ...

Page 737: ... rear end and pull apart towards the small end front See illustration 1 F16L05A 2 1 Gently pull starting this end 2 Finish with this end For installation proceed as follows Sand both inner and outer shells in area to be glued except GTI models Clean to remove any dust with isopropylic alco hol Let dry Apply a 2 mm 3 32 in bead of Loctite 454 Reinstall inner shell with its retaining screws Tighten ...

Page 738: ... 1 1 One long retaining screw front 2 Short retaining screw one on each side to the back Remove storage cover Remove seven inner skin short screws flanged screws Remove two long inner skin screws hex screws 1 F18L1PA 2 3 3 4 3 3 1 Storage cover 2 Inner skin 3 Inner skin short screws x 7 4 Inner skin long screws x 2 Use a rubber hammer to remove the inner skin from the cover If the inner skin is to...

Page 739: ...ner skin by cutting tie raps 2 1 F18L1RA 3 3 1 Inner skin 2 Storage cover 3 Connector harness Remove compass by removing dart 2 Remove temperature sensor from grommet 3 1 F18L1SA 2 1 Inner skin 2 Temperature sensor 3 Compass 1 F18L1TA 1 2 1 Dart x 2 2 Compass 1 F18L1UA 2 1 Temperature sensor 2 Grommet smr2004 Complete Line Up 739 www SeaDooManuals net ...

Page 740: ...skin back locking bracket F18L1PB 2 1 1 1 Inner skin lateral locking hook 2 Inner skin back locking bracket 1 F18L1VA 2 1 Storage cover lateral locking bracket 2 Inner skin lateral locking hook 1 F18L1WA 2 1 Storage cover back locking hook 2 Inner skin back locking bracket Secure the inner skin in the storage cover by using the rubber hammer Fasten the seven inner skin short screws and the two inn...

Page 741: ...rage compartment remove retain ing screws of grill For the front screws holes have to be drilled in inner shell to reach the screws Follow this pro cedure From inside of storage compartment drill 2 ac cess holes as shown F19L1GA A B C A 44 mm 1 73 in B 23 mm 91 in C 2 x 25 mm 1 in dia holes From top of storage compartment drill 2 access holes as shown F19L1HA A B C A 44 mm 1 73 in B 48 mm 1 9 in C...

Page 742: ...ont grill F19L1NA 1 2 Step 1 Pull out the bottom edges by slightly twisting to hook up Step 2 Push the top corner to snap in Snap the other tabs of front grill To reinstall the front screws place some sticky product in a socket and put screw in the socket Install screws to retain front grill Plug holes with cap plug P N 291 000 279 on the lower face of the inner shell Ensure to apply sili cone sea...

Page 743: ...F19L1RA 1 1 Align cover tab with inner shell slot Install front screws This will properly move inner shell forward and lock it into cover tabs Install top retaining screws those located un der the top tubes Torque screws to 11 N m 97 lbf in Install remaining retaining screws of inner shell Front Grill Remove inner shell Remove retaining screws of grill Carefully release the locking tabs CAUTION Pr...

Page 744: ...front grill Install screws to retain front grill Reinstall inner shell STORAGE COVER SHOCK All Models except XP DI To remove storage cover shock proceed as fol lows 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 from circlip and remove wash er F18L1NA 1 3 2 1 Shock rod 2 Circlip 3 Washer Release th...

Page 745: ...ly Loctite 243 on threads All Models Adjust lock pin no 3 as per following specifica tions F06L04A A 2 1 FIXED TYPE LOCK PIN 1 Lock pin apply Loctite 243 2 Adjustment nut Torque to 5 N m 44 lbf in A 34 1 mm 1 11 32 3 64 in 2 F16L0UA 1 3 A FLOATING TYPE 1 Lock pin apply Loctite 243 2 Rubber washer 3 Lock nut Torque to 5 N m 44 lbf in A 39 2 1 mm 1 35 64 3 64 in NOTE Some models have a floating type...

Page 746: ...Torque to 22 N m 16 lbf ft A 20 1 mm 25 32 3 64 in MIRROR GTI LE and GTI LE RFI Place the mirror frame in hot water to soften the material to allow mirror installation in its frame GTX 4 TEC Series and RXP 4 TEC Models To remove mirror proceed as follows Remove storage compartment inner shell from storage cover as described earlier in this sec tion Remove two hexagonal screws and flat wash ers Rem...

Page 747: ...ull out Info Center from dashboard As far as possible pry out both sides of Info Center at the same time Take care not to crack or break plastic parts Refer to ELECTRICAL section to unplug gauges from harnesses Install new Info center Refer to ELECTRICAL section to plug gauges on the harnesses DEFLECTOR AND OR UPPER GRID Removal and Installation GTX 4 TEC Supercharged Limited To remove the deflect...

Page 748: ...deflector with grid and LH finition deflector with grid the is same Finition plate is mounted on deflector Remove three darts holding deflector and grid INLET GRATE Removal and Installation Loosen screws and remove inlet grate NOTE An impact screwdriver should be used to loosen tight screws GTI Series and RXP Models When reinstalling inlet grate apply Loctite 271 on threads Follow this sequence re...

Page 749: ...te 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 off all excess of sealant from riding plate and hull Clean hull surface with acetone based solvent to eliminate grease dust and any residue of sealant Clean fitting thre...

Page 750: ...install hoses to ride plate and refill cooling sys tem Refer to COOLING SYSTEM JET PUMP SUPPORT Removal Remove jet pump Refer to JET PUMP Remove inlet grate and riding plate Remove ball joint boot nut half rings and O rings from steering cable F05K02A 1 TYPICAL 1 Unscrew nut Remove ball joint boot nut half rings and O rings from reverse cable Remove boot and nut from VTS sliding shaft XP DI and RX...

Page 751: ...inst contact surface of studs with jet pump support All Models Apply Loctite 5900 P N 293 800 066 as indicated by the shaded areas in the next illustrations Fol low also the torquing sequence as shown in the same illustrations Torque to 31 N m 23 lbf ft 4 2 1 F08L1OA 3 GTI SERIES AND XP DI MODELS F18L28A 4 3 1 2 GTX 4 TEC SERIES F19J0AA 1 2 3 4 RXP 4 TEC MODELS DRAIN PLUG INSTALLATION Refer to the...

Page 752: ...uter boot then pull outer boot downward F08L12A 1 1 Loosen gear clamp Loosen gear clamp of inner boot then pull boot downward F08L13A 1 1 Gear clamp Remove bolt and lock nut from shock absorber upper support F08Q04A 2 1 1 Bolt 2 Lock nut Remove protective caps no 18 and loosen screws no 19 to remove eyelet no 20 on each side of seat 752 smr2004 Complete Line Up www SeaDooManuals net ...

Page 753: ...EAT COVER REPLACEMENT 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 completely pushed in place F01L3YA 2 1 TYPICAL 1 Piece of...

Page 754: ...other side GTX 4 TEC Series and RXP 4 TEC Models Remove trim no 1 from side bumper rail no 2 Remove screws no 4 to remove side bumper rail no 2 Mark hole positions on body straight and bow sec tions 4 F18L01A 3 2 1 TYPICAL 1 Front bumper 2 Corner bumper 3 Straight section 4 Bow section Slide bumper rail no 2 under front bumper no 6 Using a 4 80 mm 3 16 in drill bit drill first hole through bumper ...

Page 755: ...rify the physical condition of cylinder groove and adjustment holes 2 F18L3BA 1 2 1 Groove 2 Adjustment holes Align groove with stopper screw while inserting the cylinder into housing Tighten the stopper screw Installation Before Installation make sure inside cylinder slides up and down freely with out obstruction from grab handle safety lock pin operates properly stopper screw stops cylinder at i...

Page 756: ...plus Remove seat access cover for the XP DI models Remove seat support GTI Series Remove muffler Remove battery From inside bilge remove lock nuts no 10 using a 10 mm deep socket with an extension Remove sponsons no 6 Clean any residues of sealant adhesive on hull Install gaskets no 7 on new sponsons no 6 Apply silicone sealant P N 293 800 086 around sponson studs Apply Loctite 243 blue on sponson...

Page 757: ...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 plastic INSTALLATION O...

Page 758: ...f 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 759: ...ust 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 t...

Page 760: ...r If the size of the opening is too large for the pieces to maintain the proper shape you will have to use a backing support It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side It is held in place by tape or a support Inside Wipe down the area with acetone on a cloth Ap ply the same procedure as for outside repair when laminating the...

Page 761: ...r instructions Apply epoxy glue on aluminum insert P N 292 000 075 knurled surface and on plastic insert inner bore CAUTION If you notice any clearance between plastic insert and aluminum insert fill gap with epoxy glue to obtain good adhesion of aluminum insert F01L2VA 1 2 1 Knurled surface 2 Inner bore Install aluminum insert into plastic hull insert NOTE Align aluminum insert as much as possibl...

Page 762: ...rpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular New 0 25 0 40 mm 010 016 in Ring end gap Wear limit 1 00 mm 039 in New 0 025 0 070 mm 001 003 in Ring piston groove clearance Wear limit 0 2 mm 008 in New minimum 0 10 mm 0039 in Piston cylinder wall clearance Wear limit 0 20 mm 008 in Cylinder taper maximum 0 10 mm 004 in Cylinder out of round maximum 0 080 mm ...

Page 763: ...AL INFORMATION 1 Engine cold 6000 RPM CARBURETION GTI GTI LE Type Mikuni BN 40i diaphragm fuel accelerator pump Carburetor Quantity 1 Main jet 167 5 Pilot jet 75 Spring 130 g 4 6 oz 115 g 4 1 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 ...

Page 764: ...idth 120 cm 47 in Overall height 104 cm 41 in Dry weight 282 kg 623 lb 291 kg 643 lb Load limit passenger and 10 kg 22 luggage 243 kg 536 lb ADDITIONAL INFORMATION CAPACITIES GTI GTI LE 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 765: ...on ratio 6 0 1 Cylinder head volume 47 7 0 4 cc Cylinder head warpage maximum 0 05 mm 002 in Piston ring type and quantity 1 semi trapez 1 rectangular New 0 40 0 55 mm 016 022 in Ring end gap Wear limit 1 00 mm 039 in New 0 025 0 070 mm 001 003 in Ring piston groove Wear limit 0 24 mm 009 in New minimum 0 13 mm 005 in Piston cylinder wall clearance Wear limit 0 22 mm 009 in Cylinder taper maximum ...

Page 766: ...L INFORMATION FUEL SYSTEM GTI RFI GTI LE RFI 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 2 280 k 2 74 k Water Temperature Sensor WTS 2 280 k 2 74 k Air Pressure Sensor APS 3 4 k and 8 2 k...

Page 767: ...verall height 104 cm 41 in Dry weight 315 kg 695 lb Load limit passenger and 10 kg 22 lb luggage 317 kg 700 lb 243 kg 536 lb ADDITIONAL INFORMATION CAPACITIES GTI RFI GTI LE RFI 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 Oil level height ...

Page 768: ...2 semi trapez chrome coated steel rings New 0 55 0 7 mm 022 028 in Ring end gap Wear limit 1 1 mm 043 in New 0 044 0 089 mm 002 003 in Ring piston groove clearance Wear limit 0 2 mm 0079 in New minimum 0 12 mm 0047 in Piston cylinder wall clearance Wear limit 0 22 mm 0087 in Cylinder taper maximum 0 10 mm 004 in Cylinder out of round maximum 0 08 mm 003 in New 0 390 0 737 mm 015 029 in Connecting ...

Page 769: ...7 5 A ADDITIONAL INFORMATION FUEL SYSTEM XP DI Fuel injection type Orbital Direct Fuel Injection twin throttle body 46 mm 1 81 in Fuel pressure 105 2 PSI 108 PSI Idle speed in water out of water 1450 50 RPM Throttle Position Sensor TPS 1 6 k 2 4 k Crankshaft Position Sensor CPS 5 volts Manifold Air Temperature Sensor MATS 2 28 k 2 74 k Water Temperature Sensor WTS 2 28 k 2 74 k Exhaust Gas Tempera...

Page 770: ...fferent brands or oil types DIMENSIONS XP DI Number of passenger driver incl 2 Overall length 272 cm 107 in Overall width 112 cm 44 in Overall height 104 cm 41 in Dry weight 274 kg 605 lb Load limit passenger and luggage 10 kg 22 lb 181 kg 400 lb ADDITIONAL INFORMATION CAPACITIES XP DI Fuel tank including reserve 51 L 13 5 U S gal Fuel tank reserve from low level signal 9 8 L 2 6 U S gal Oil injec...

Page 771: ...mp power 53 7 kW 72 HP Maximum fuel consumption at wide open throttle 47 L h 12 4 U S gal h Fuel tank without reserve 60 minutes Cruising time at full throttle Fuel tank reserve from low level signal 12 minutes ADDITIONAL INFORMATION 774 smr2004 Complete Line Up www SeaDooManuals net ...

Page 772: ... Minimum new 5 961 mm 2347 in Maximum new 5 975 mm 2352 in Intake Wear limit 5 930 mm 2330 in Minimum new 5 946 mm 2341 in Maximum new 5 960 mm 2346 in Valve stem diameter Exhaust Wear limit 5 930 mm 2330 in Minimum new 5 99 mm 2358 in Maximum new 6 01 mm 2366 in Valve guide diameter Wear limit 6 060 mm 2386 in Nominal new 41 02 mm 1 615 in Inner Wear limit 38 8 mm 1 499 in Nominal new 45 45 mm 1 ...

Page 773: ... center Wear limit 39 88 mm 1 5701 in Minimum new 25 000 mm 9842 in Maximum new 25 01 mm 9846 in Front Wear limit 25 02 mm 9850 in Minimum new 40 000 mm 1 5748 in Maximum new 40 01 mm 1 5752 in Camshaft bore PTO and center Wear limit 25 02 mm 9850 in Minimum new 31 654 mm 1 2462 in Maximum new 31 854 mm 1 2541 in Intake Wear limit 31 604 mm 1 2442 in Minimum new 31 435 mm 1 2376 in Maximum new 31 ...

Page 774: ...0 25 mm 0098 in Minimum new 9 960 mm 3921 in Maximum new 10 0 mm 3937 in Supercharger shaft driven plate journal depth Wear limit 9 700 mm 3819 in Minimum new 11 0 mm 4331 in Maximum new 11 050 mm 4350 in Supercharger drive gear thickness Wear limit 10 500 mm 4134 in Minimum new 6 900 mm 2717 in Maximum new 7 100 mm 2795 in Supercharger lock washer thickness Wear limit 6 600 mm 2598 in ADDITIONAL ...

Page 775: ...olts Camshaft Position Sensor CAPS 1 2 k Manifold Air Temperature Sensor MATS 2 28 k 2 74 k Coolant Temperature Sensor CTS 2 28 k 2 74 k Exhaust Gas Temperature Sensor EGT 2 28 k 2 74 k Manifold Air Pressure Sensor MAPS 6040 terminals 2 1 5554 terminals 3 2 5822 terminals 3 1 Knock Sensor KS 5 M Oil Pressure Switch OPS 0 if oil pressure is greater than 26 32 PSI Oil Separator Pressure Switch OSPS ...

Page 776: ...ngle 20 Minimum required water level 90 cm 35 in Drive shaft deflection maximum 0 5 mm 020 in Impeller outside diameter 159 0 0 06 mm 6 260 0024 in New 0 07 0 23 mm 003 009 in Impeller wear ring clearance Wear limit 0 35 mm 0138 in Impeller shaft end play new 0 Impeller shaft side play 0 Impeller material Stainless steel ADDITIONAL INFORMATION Do not mix different brands or oil types DIMENSIONS RX...

Page 777: ...oler Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION PERFORMANCE RXP 4 TEC Estimated pump power 77 5 kW 103 93 HP Maximum fuel consumption at wide open throttle 43 1 L h 11 4 U S gal h 62 L h 16 4 U S gal h Fuel tank without reserve 60 minutes Cruising time at full throttle Fuel tank reserve from low level sig...

Page 778: ... closing 45 ABDC Exhaust valve opening 50 BBDC Exhaust valve closing 5 ATDC 0 ATDC Starting system Electric start Minimum new 5 961 mm 2347 in Maximum new 5 975 mm 2352 in Intake Wear limit 5 930 mm 2330 in Minimum new 5 946 mm 2341 in Maximum new 5 960 mm 2346 in Valve stem diameter Exhaust Wear limit 5 930 mm 2330 in Minimum new 5 99 mm 2358 in Maximum new 6 01 mm 2366 in Valve guide diameter We...

Page 779: ...m 9815 in Minimum new 39 89 mm 1 5705 in Maximum new 39 9 mm 1 5709 in Camshaft bearing journal PTO and center Wear limit 39 88 mm 1 5701 in Minimum new 25 000 mm 9842 in Maximum new 25 01 mm 9846 in Front Wear limit 25 02 mm 9850 in Minimum new 40 000 mm 1 5748 in Maximum new 40 01 mm 1 5752 in Camshaft bore PTO and center Wear limit 25 02 mm 9850 in Minimum new 31 48 mm 1 2394 in 31 69 mm 1 2476...

Page 780: ...Maximum new 0 25 mm 0098 in Minimum new Not applicable 9 960 mm 3921 in Maximum new Not applicable 10 0 mm 3937 in Supercharger shaft driven plate journal depth Wear limit Not applicable 9 700 mm 3819 in Minimum new Not applicable 11 0 mm 4331 in Maximum new Not applicable 11 050 mm 4350 in Supercharger drive gear thickness Wear limit Not applicable 10 500 mm 4134 in Minimum new Not applicable 6 9...

Page 781: ...m Multipoint Fuel Injection Single throttle body 52 mm 2 05 in Fuel pressure 42 PSI 45 PSI Idle speed in water out of water 1800 50 RPM Throttle Position Sensor TPS 1 6 k 2 4 k Crankshaft Position Sensor CPS 190 290 Camshaft Position Sensor CAPS 12 volts Camshaft Position Sensor CAPS 1 2 k Manifold Air Temperature Sensor MATS 2 28 k 2 74 k Coolant Temperature Sensor CTS 2 28 k 2 74 k Exhaust Gas T...

Page 782: ...inhibitors for internal combustion aluminum engines Thermostat 87 C 188 F Monitoring beeper setting 100 C 212 F ADDITIONAL INFORMATION PROPULSION GTX 4 TEC GTX 4 TEC SUPERCHARGED Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage Greased bearings Impeller rotation seen from rear Counterclockwise Transmission Direct drive Coupling type Crown splines Reverse system Yes O...

Page 783: ... INFORMATION MATERIALS GTX 4 TEC GTX 4 TEC SUPERCHARGED HULL COMPOSITE Inlet grate Aluminum Steering cover Thermoplastic Impeller housing stator venturi nozzle Plastic plastic aluminum aluminum Aluminum aluminum aluminum aluminum Air intake silencer N A Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane fo...

Page 784: ...r wire s bearing the same letter g in the cir cuit ECM GTX 4 TEC Models On the ECM circuits are identified by a letter fol lowed by a number The letter indicates in which connector the wire is plugged in The number indicates the position of the wire in the connector The connector A is connected to the engine wiring harness The connector B is connected to the watercraft wiring harness DEUTSCH CONNE...

Page 785: ...onnect the two Deutsch connectors slide a flat screwdriver between each other to disengage press the release button and disconnect them 1 F18Z0LA 2 1 Flat screwdriver 2 Deutsch connectors 2 F18Z0MA 2 1 1 Release button 2 Deutsch connectors F18Z0NA 1 2 1 Deutsch connectors 2 Press release button 788 smr2004 Complete Line Up www SeaDooManuals net ...

Page 786: ...FEMALE CONNECTOR 1 Female lock V01G0PA 1 MALE CONNECTOR 1 Male lock NOTE Before extraction push wire forward to relieve pressure on retaining tab Insert a 4 8 mm 189 in wide screwdriver blade inside the front of the terminal cavity Pry back the retaining tab while gently pulling wire back until terminal is removed V01G0QA 1 1 FEMALE CONNECTOR 1 Retaining tab To install For insertion of a terminal ...

Page 787: ...ctor use Snap on TT600 4 tool F01B1JA WARNING Ensure all terminals are properly crimped on wires and connector are properly fastened AMP PLUG CONNECTOR These connectors are found on the MPEM When servicing electrical system special care must be taken when working with AMP plug connectors in order to prevent any malfunction of the system Description F00H0WB 2 3 4 5 6 7 8 9 9 1 AMP PLUG CONNECTOR 1 ...

Page 788: ...the wedge lock tab Release the locking tab and at the same time pry the wedge lock to the open position CAUTION The wedge lock should never be re moved from the connector for insertion or re moval of the signal wire terminals F00H0OA 1 2 1 Screwdriver between wedge lock and connector 2 Locking tab Repeat the same steps for the other locking tab retaining the wedge lock The wedge lock is now in the...

Page 789: ...ng The size of the wires must be 20 to 16 AWG with a wire insulation diameter having a minimum di mension of 1 7 mm 067 in and a maximum di mension of 2 78 mm 106 in The wire strip length must be 5 1 mm 13 64 in NOTE When stripping wires ensure conductor is not nicked scrapped or cut Wire stripping tool jaws may leave marks on the surface of the wire insulation If these marks occur at the location...

Page 790: ...ming electrical trou bleshooting The resulting pinholes in the in sulation will allow moisture to penetrate the system and possibly result in system failure Terminal Installation For insertion of signal terminal make sure the wedge lock is in the open position NOTE For insertion of power terminal the wedge lock may or may not be on the open position Insert terminal into appropriate circuit cavity ...

Page 791: ...ine harness 3 B connector watercraft system harness CAUTION Do not disconnect the ECM connec tors needlessly They are not designed to be disconnected reconnected frequently CAUTION Probe on top of terminal only Do not try to probe inside terminal or to use a pa per clip to probe inside terminal it can damage the square shaped terminal Terminal Removal Unlock the connector cover by pushing in the t...

Page 792: ... 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 but the terminal is ruste...

Page 793: ...nector terminal use the con nector crimping tool P N 529 035 909 and the crimper die P N 529 035 906 F00B0EA CRIMPING TOOL 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 Insert terminal with...

Page 794: ...ame procedure is to be used each side of the joint Insert the Deutsch joint connector tool no 114010 on the wire and push tool toward the joint to release it While holding the joint insulator push the tool until it bottoms It is now unlocked Maintaining the pressure with the tool pull the wire out F12H10A DEUTSCH JOINT CONNECTOR TOOL NO 114010 F12H11A 1 2 Step 1 Hold the insulator Step 2 Push the ...

Page 795: ...F17Z03 www SeaDooManuals net ...

Page 796: ...F17Z05 www SeaDooManuals net ...

Page 797: ...F17Z04 www SeaDooManuals net ...

Page 798: ...F17Z06 www SeaDooManuals net ...

Page 799: ...F08Z03 www SeaDooManuals net ...

Page 800: ...F18Z1A www SeaDooManuals net ...

Page 801: ...Smr 2004 ang FH8 Thu Jun 03 14 42 10 2004 Page 1 www SeaDooManuals net ...

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