SeaDoo 3D Manual
  1. Manuals
  2. Brands
  3. SeaDoo Manuals
  4. Boat
  5. 3D
  6. Manual

SeaDoo 3D Manual

Hide thumbs
1
2
3
Table Of Contents
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
Table of Contents

Advertisement

Quick Links

Download this manual
www.SeaDooManuals.net

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 3D and is the answer not in the manual?

Questions and answers

Related Manuals for SeaDoo 3D

Summary of Contents for SeaDoo 3D

  • Page 1 www.SeaDooManuals.net...
  • Page 2 2005 Vehicle Shop Manual 2-Stroke Models www.SeaDooManuals.net...
  • Page 3 Legal deposit: National Library of Quebec National Library of Canada 2005 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) Bombardier Recreational Products Inc. (BRP) 2005 ©...

  • Page 4: Table Of Contents

    STEERING POLE IS HEAVIER THAN USUAL (3D SERIES) ....... . .
  • Page 5 3D SERIES ........... .
  • Page 6 TABLE OF CONTENTS GENERAL ..................... 110 OPERATING PRINCIPLE .
  • Page 7 TABLE OF CONTENTS GENERAL ..................... 154 ADJUSTMENT..
  • Page 8 3D SERIES ........... .
  • Page 9 02 – 3D SERIES ..........
  • Page 10 03 – 3D RFI MODEL ..........

  • Page 11: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2005 SEA-DOO watercraft as described in the model list of the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already fa- miliar with all service procedures relating to BRP made watercraft.

  • Page 12: Introduction

    2005 watercraft models. It should be used in conjunction with the 717/787 RFI ENGINE SHOP MANUAL. MODEL COLOR ENGINE TYPE MODEL NUMBER Yellow 787 RFI 195A, 195B 3D Premium 787 RFI 205E, 205F 3D Premium Yellow 787 RFI 205A, 205B Yellow 105A, 105B...

  • Page 13: Arrangement Of This Manual, Illustrations And Procedures

    Before undertaking any procedure, be sure that you have on hand all the tools required, or approved equivalents. TYPICAL — 3D SERIES 1. Hull Identification Number (H.I.N.) Engine Identification Number (E.I.N.) Refer to the 717/787 RFI ENGINE SHOP MANUAL.
  • Page 14 INTRODUCTION Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection. 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.
  • Page 15 INTRODUCTION Sub-title with part name(s) from exploded view. Section 06 FUEL SYSTEM Title indicates main procedure to be carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly, lows: spring screw, check valve housing, etc.). Sub-sub-title in Remove air vent tube support.

  • Page 16: List Of Abbreviations Used In This Manual

    INTRODUCTION LIST OF ABBREVIATIONS USED ABBREVIATION DESCRIPTION IN THIS MANUAL To Be Determined Top Dead Center ABBREVIATION DESCRIPTION Throttle Position Sensor Naturally-Aspirated Engine 4-TEC NA Volt Direct Current Analog to Digital Conversion Vehicle Communication Kit Alternate Current Volt Direct Current Air Pressure Sensor Variable Trim System Air Temperature Sensor...

  • Page 17: Self-Locking Fasteners Procedure

    INTRODUCTION The owner/operator is not to, and should not al- Use a metal brush or a screwtap to clean the hole low anyone to modify the engine in any manner properly then use a solvent, let act during 30 min- that would alter the horsepower or allow emis- utes and wipe off.
  • Page 18 INTRODUCTION Blind Holes – Install stud. – Install cover, etc. – Apply drops of proper strength Loctite on un- covered threads. – Tighten nuts as required. Pre-assembled Parts 1. On threads 2. On threads and at the bottom of hole –...
  • Page 19 INTRODUCTION Adjusting Screw b. Put waxed paper or similar film on the sur- faces. – Twist bolt when inserting it to improve thread conformation. NOTE: NOT intended for engine stud repairs. Repair of Small Holes/Fine Threads Option 1: Enlarge damaged hole, then follow Standard Thread Repair procedure.

  • Page 20: Tightening Torques

    INTRODUCTION Case-In Components – Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or Metallic Gaskets 2 minutes. – Apply GASKET ELIMINATOR 518 (P/N 293 800 038) on both sides of gasket, using a clean ap- plicator.
  • Page 21 INTRODUCTION In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following pro- cedure: – Manually screw all screws, bolts and/or nuts. – Apply the half of the recommended torque value. CAUTION: Be sure to use the proper tightening torque for the proper strength grade. NOTE: When possible, always apply torque on the nut.

  • Page 22: Maintenance

    NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte- nance operation to whatever time comes first. IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater frequency of inspection and maintenance. 3D SERIES A: ADJUST FIRST 10 HOURS C: CLEAN...
  • Page 23 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) 3D SERIES A: ADJUST FIRST 10 HOURS C: CLEAN EVERY 25 HOURS OR 3 MONTHS I: INSPECT EVERY 50 HOURS OR 6 MONTHS L: LUBRICATE R: REPLACE EVERY 100 HOURS OR 1 YEAR...
  • Page 24 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) GTI SERIES A: ADJUST FIRST 10 HOURS C: CLEAN EVERY 25 HOURS OR 3 MONTHS I: INSPECT EVERY 50 HOURS OR 6 MONTHS L: LUBRICATE R: REPLACE EVERY 100 HOURS OR 1 YEAR T: PROCEED WITH TASK PART/TASK LEGEND...
  • Page 25 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) GTI SERIES A: ADJUST FIRST 10 HOURS C: CLEAN EVERY 25 HOURS OR 3 MONTHS I: INSPECT EVERY 50 HOURS OR 6 MONTHS L: LUBRICATE R: REPLACE EVERY 100 HOURS OR 1 YEAR T: PROCEED WITH TASK PART/TASK LEGEND...

  • Page 26: Preseason Preparation

    Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION TO BE PERFORMED BY DEALER PRESEASON PREPARATION TO BE PERFORMED BY CUSTOMER MODELS TASK REFER TO GENERAL ✔ Lubrication/corrosion protection Storage All models ✔ Spark plugs replacement (1) Ignition System ENGINE ✔...
  • Page 27 Digitally Encoded Security System (DESS) and monitoring beeper DESS STEERING SYSTEM ✔ Steering system adjustment/inspection (2) All models ✔ Steering pole condition Steering System 3D Series ✔ Handlebar and adjuster condition O.P.A.S. SYSTEM ✔ Check O.P.A.S. system condition GTI Series O.P.A.S. O.T.A.S. SYSTEM ✔...

  • Page 28: Storage Procedures

    Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) STORAGE PROCEDURES SERVICE TOOLS Description Part Number Page flushing connector adapter ........... 295 500 473 ........... 10 large hose pincher ..............529 032 500 ....... 12, 14–15 small hose pincher..............295 000 076 ....... 12–13, 15 SERVICE PRODUCTS Description Part Number...

  • Page 29: Propulsion System

    Do not mix oil brands or types. PTO Flywheel All Models Except 3D RFI Remove PTO flywheel guard. Lubricate PTO flywheel at grease fitting with syn- 1. Grease seal carrier thetic grease (P/N 293 550 010).
  • Page 30 Subsection 03 (STORAGE PROCEDURES) Models with 787 RFI Engines Remove seat (GTI RFI and GTI RFI LE) or engine cover (3D Series). At the front of engine, disconnect the water sup- ply hose used to cool the magneto. It features a quick connect fitting.
  • Page 31 CAUTION: Always start the engine before 3. Garden hose opening the water tap. Open water tap im- NOTE: On 3D Series, the flushing connector is mediately after engine is started to prevent located on the right hand side on the jet pump overheating.
  • Page 32 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) CAUTION: Never run engine longer than 5 min- utes. Drive line seal has no cooling when wa- tercraft is out of water. Spray Bombardier Lube (P/N 293 600 016) through air intake silencer. NOTE: An increase of engine RPM may be no- ticed while spraying the lubricant in the air intake silencer.
  • Page 33 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) Wipe up any residual water from the engine. Reinstall plug on air intake silencer cover . CAUTION: Never leave rags or tools in the en- gine compartment or in the bilge. Antifreezing Protection In cool regions (where freezing point may be en- countered), cooling system should be filled pure antifreeze.
  • Page 34 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) 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.
  • Page 35 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) smr05-044-001_a 1. Engine water inlet hose Disconnect hose just above T-fitting as shown. 1. Engine drain hose Block the engine water outlet hose with a large hose pincher (P/N 529 032 500). TYPICAL 1.
  • Page 36 At preseason preparation, drain the remaining an- tifreeze from cooling system prior to using the wa- tercraft. Ensure no hose pincher was forgotten at storage. 3D Series Remove rear access panel and engine cover. Lock smr2005-044-002_A steering pole in upright position with the holder.
  • Page 37 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) smr2005-044-003_A 1. Water supply hose COOLING SYSTEM BLEED OUTLET 1. Recover water/antifreeze from this outlet Install a temporary hose on the engine fitting. To avoid hose bending, remove the storage tray and Place a container at rear of watercraft to recov- insert the hose by this opening.

  • Page 38: Electrical System

    The seat should be partially left opened during storage (the engine cover for the 3D Series). This will avoid engine compartment condensation and possible corrosion. If the watercraft is to be stored outside, cover it...

  • Page 39: Checklist

    Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) CHECKLIST ✔ OPERATION Check engine drain hose. Replace jet pump oil. Lubricate PTO flywheel or seal carrier (depending on model). Verify fuel system. Add fuel stabilizer. Flush the cooling system. Lubricate the engine. Remove, clean and store the battery.

  • Page 40: Special Procedures

    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE TOOLS Description Part Number Page large hose pincher ..............529 032 500 ........... 19 SERVICE PRODUCTS Description Part Number Page Bombardier Lube ..............293 600 016 ........21–22 Loctite 518................293 800 038 ........... 22 TOWING THE WATERCRAFT NOTE: A red tape on the water supply hose indi- IN WATER...

  • Page 41: Submerged Watercraft

    WARNING Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device. 3D SERIES 1. Water supply hose 2. Install hose pincher here on this side of the T-fitting 3. T-fitting smr2005-045...
  • Page 42 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Depress and hold the throttle lever at full throttle position. Wait 2 seconds then, reinstall the safety lanyard cap. Press the start/stop button to crank the engine during 10 seconds to allow water to escape from spark plug openings.

  • Page 43: Capsized Engine

    Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) 717 AND 787 RFI ENGINES F07D07A 1. Air intake silencer 2. Pull plug 787 RFI ENGINES 3. Spray BOMBARDIER LUBE here 1. Drain plug Drain completely the crankcase oil of the coun- CAPSIZED ENGINE terbalance shaft.
  • Page 44 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Remove spark plugs. Cover spark plug holes with a rag. Crank engine several times (while keeping throttle fully depressed on RFI models). Install new spark plugs. Reconnect cables. Start engine as explained above. smr2005-045 www.SeaDooManuals.net...

  • Page 45: Troubleshooting

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) TROUBLESHOOTING CHART The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to show all causes for all problems. NOTE: On RFI models, always check for fault codes. If a fault code is detected, service the fault code and recheck operating conditions.
  • Page 46 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Loose battery cable connections Check/clean/tighten Discharged/weak battery Check/charge/replace Restriction in jet pump Check/clean pump Partial seizure in jet pump Engine turns slowly Inspect, refer to PROPULSION SYSTEM Partial engine hydro-lock Check, refer to MAINTENANCE Partial engine seizure Check compression, refer to ENGINE...
  • Page 47 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Defective CPS (RFI models) Check operation of CPS and replace if necessary Water-contaminated fuel Check/siphon and refill Dirty fuel filter Clean/replace Fouled or defective spark plug Replace Water in engine Check, refer to MAINTENANCE Carburetion (carburetor models) Check, refer to FUEL SYSTEM...

  • Page 48: Engine Hard To Start

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE HARD TO START OTHER OBSERVATION POSSIBLE CAUSE REMEDY Wrong TPS zero setting (RFI models) Refer to ENGINE MANAGEMENT Throttle cable adjustment Refer to ENGINE MANAGEMENT (RFI models) Air lock in fuel rail Refer to ENGINE MANAGEMENT (RFI models) Water in fuel reservoir or contaminated...

  • Page 49: Engine Runs On Both Cylinders At Idle After Engine Is Warm-Up (Rfi Models)

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE RUNS ON BOTH CYLINDERS AT IDLE AFTER ENGINE IS WARM-UP (RFI MODELS) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Refer to COMPONENT ADJUSTMENT, – Water temperature sensor (WTS) and INSPECTION AND REPLACEMENT. its circuit –...
  • Page 50 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Low fuel level (carburetor models) Check/refill Carburetion dirty (carburetor models) Check/clean, refer to FUEL SYSTEM Low fuel pressure Check pump, regulator and injectors. (RFI models) Replace if necessary Check if filter is plugged.

  • Page 51: Engine Continually Backfires

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Check spark plug condition, check Check, refer to ENGINE MANAGEMENT fault codes, check fuel pressure (RFI and FUEL SYSTEM. models). Starts, but runs poorly Bent or missing tooth on trigger wheel Check, refer to MAGNETO SYSTEM in (RFI models) the appropriate ENGINE SHOP MANUAL...

  • Page 52: Engine Lacks Acceleration Or Power

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Check/replace, refer to ELECTRICAL SYSTEM Carburetion, jetting too rich/lean Check/replace, refer to FUEL SYSTEM (carburetor models) Throttle does not open fully Check/readjust, refer to FUEL SYSTEM or ENGINE MANAGEMENT Low compression...

  • Page 53: Engine Stops Running

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE STOPS RUNNING OTHER OBSERVATION POSSIBLE CAUSE REMEDY Spark plug heat range too high Check/change to correct range Engine dies during Improper ignition timing Check/reset operation Compression ratio is too high Check combustion chamber volume (piston seizure) Poor injection oil quality Use proper XP–S™...

  • Page 54: Engine Overheats

    Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE OVERHEATS OTHER OBSERVATION POSSIBLE CAUSE REMEDY Temperature sensor defective (RFI Check/replace. Refer to ENGINE models) MANAGEMENT Monitoring beeper Cooling system restriction Check/flush, refer to MAINTENANCE sounds continuously Grounded temperature sensor or sensor Check/repair/replace wire (carburetor models) VEHICLE CANNOT REACH ITS TOP SPEED...

  • Page 55: Abnormal Noise From Propulsion System

    Adjust (carbureted models) Check fault codes (RFI models) Broken engine mounts Check/replace, refer to ENGINE STEERING POLE IS HEAVIER THAN USUAL (3D SERIES) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Steering pole return spring adjustment Set the adjuster to reduce the weight at the handlebar.

  • Page 56: Engine System

    Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ........... 41 Loctite 518................293 800 038 ........... 41 smr2005-047 www.SeaDooManuals.net...
  • Page 57 Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) 717 Engines smr2005-047 www.SeaDooManuals.net...
  • Page 58 Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) 787 RFI Engines smr2005-047 www.SeaDooManuals.net...

  • Page 59: General

    Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) GENERAL During assembly, use the torque values and ser- vice products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
  • Page 60 Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) CAUTION: Do not modify air intake system, otherwise calibration will be affected. Flame Arrester Base On 717 engines, apply Loctite 518 (P/N 293 800 038) on mating surfaces of flame arrester base no.

  • Page 61: Exhaust System

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ........... 48 Loctite 518................293 800 038 ........... 56 silicone sealant (clear)............293 800 086 ........... 56 smr2005-048 www.SeaDooManuals.net...

  • Page 62: Gti Series

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) GTI SERIES GTI Model (717 Engine) smr2005-048 www.SeaDooManuals.net...
  • Page 63 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) GTI RFI and GTI RFI LEmodels (787 RFI Engine) smr2005-048 www.SeaDooManuals.net...

  • Page 64: General

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) GENERAL Disconnect tuned pipe bleed hose. During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
  • Page 65 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) F06D14A 1. Loosen clamp TYPICAL Remove screws no. 7 and washers no. 9 at tuned 1. Loosen hose clamps pipe head flange. 2. Upper type resonator 3. Muffler holding strap Remove screw no. 6 and screw no. 20 retaining tuned pipe to supports.

  • Page 66: Repair

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Detach holding strap retaining resonator inside CAUTION: Always ensure water passages are not blocked partially or completely while weld- bilge. ing tuned pipe. Pull resonator out of bilge. NOTE: Prior to verify leaks, plug all holes and pres- Muffler surize tuned pipe while immerging it in water.
  • Page 67 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Push cone no. 5 until it touches tuned pipe, then tighten exhaust clamp no. 4 and torque to 4 N•m (35 lbf•in). CAUTION: There must be no gap between tuned pipe cone and tuned pipe head. NOTE: Exhaust clamp nuts should be tightened al- ternately to assure no leakage and to obtain spec- ified torque.
  • Page 68 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Press the pipe support on the engine before torquing the pipe support bolts. smr2005-048 www.SeaDooManuals.net...

  • Page 69: 3D Series

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) 3D SERIES smr2005-048-002 smr2005-048 www.SeaDooManuals.net...

  • Page 70: General

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) GENERAL Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking de- vices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified.
  • Page 71 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Exhaust Manifold Disconnect hose from exhaust manifold. smr2005-048-007_A 1. Tuned pipe retaining screws smr2005-048-010_A 1. Exhaust manifold – tuned pipe support screws 2. Cooling system indicator hose For removal procedure of the exhaust manifold, refer to the 717/787 RFI ENGINE SHOP MANUAL.
  • Page 72 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Unscrew hose adaptor clamp then disconnect hose from adaptor. smr2005-048-014_A 1. Clamps 2. Extension pipe 3. Muffler 4. Water trap Remove heat shield from extension pipe. Detach straps holding water trap against fuel tank. smr2005-048-015_A 1.

  • Page 73: Repair

    Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) smr2005-048-018_A smr2005-048-016_A 1. Lower resonator 1. Straight resonator hose clamp 2. Clamp on hull fitting 2. T-fitting Remove hose with resonator. REPAIR Upper Resonator Tuned Pipe Remove strap, loosen clamps then pull out res- onator.
  • Page 74 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Exhaust Outlet Ensure rubber bushings no. 17 and sleeve no. 18 are not damaged and are properly installed into Prior to installing exhaust outlet, apply silicone tuned pipe supports. sealant (clear) (P/N 293 800 086) as shown. CAUTION: Damage to bushings and/or sleeve will eventually cause stress to tuned pipe and may cause cracking.
  • Page 75 Section 03 ENGINE SYSTEM Subsection 02 (EXHAUST SYSTEM) Press the pipe support on the engine before torquing the pipe support bolts. TUNED PIPE TORQUING SEQUENCE smr2005-048 www.SeaDooManuals.net...

  • Page 76: Removal And Installation

    Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page alignment shaft..............295 000 141 ........66–67 engine lift tool............... 529 035 940 ........... 62 lifting rings ................529 035 830 ........... 62 plate..................
  • Page 77 Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) F06D0FA 787 RFI ENGINES 1. Unplug connector smr2005-049-001_a 787 RFI Engines GTI — 717 ENGINES Disconnect throttle position sensor (TPS), air 1. Water supply hose 2. Water return hose pressure sensor (APS) and air temperature sensor 3.
  • Page 78 The fuel hose may be under pressure. Cov- er the fuel line connection with an absorbent smr2005-049-003_a shop rag. Slowly disconnect the fuel hose 3D — 787 RFI ENGINES to release the pressure. Wipe off any fuel 1. Water supply hose 2. Water return hose spillage inside bilge.
  • Page 79 Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) LIFTING RING TYPICAL — 787 RFI ENGINES — FRONT SUPPORT 1. Remove screw ENGINE LIFT TOOL Remove spark plugs and replace by lifting ring. Hook engine lift tool into lifting ring holes. Using a chain block, a hoist or other suitable equip- smr2005-049-007_a ment, slightly lift engine to ease the remaining...
  • Page 80 Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) A01B2JB TYPICAL 1. Small hose pincher TYPICAL — GTI RFI SHOWN Install another small hose pincher (P/N 295 000 Using a chain block, a hoist or other suitable equip- 076) to oil return hose of rotary valve shaft; then, ment, slightly lift engine to ease the remaining disconnect hose.

  • Page 81: Cleaning

    Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) F04D10A TYPICAL — 787 RFI ENGINES 1. Rotary valve oil supply line 1. Positive starter cable 2. Hose pincher installed 2. Ground cable 3. Starter cable Carry on engine lifting then tilt engine so that it can Disconnect RED (+) cable from starter post.
  • Page 82 Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) Rubber Mount Check tightness and condition of rubber mounts. If they have been removed, apply Loctite 243 (blue) (P/N 293 800 060) on screw threads. Torque screws to 25 N•m (18 lbf•ft). CAUTION: Strict adherence to this torque is important to avoid damaging threads of alu- minum insert in bilge.

  • Page 83: Alignment Shaft

    Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) F07D05A TYPICAL 1. Plate 1. Alignment shaft 2. Support 2. PTO flywheel – alignment shaft (P/N 295 000 141) If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft end.

  • Page 84: Plate

    (.1968 in) (P/N 270 000 446) CAUTION: Whenever shims are used to cor- rect alignment, never install more than 5 mm (.1968 in) shim thickness. 3D Series Use: – plate (P/N 529 035 507) smr2005-049-005_a 787 RFI ENGINES — FRONT...

  • Page 85: Pto Flywheel Adapter

    Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) 1. Alignment shaft – PTO flywheel adapter (P/N 529 035 590). 1. Alignment shaft 2. Adapter Continue to slide the alignment shaft forward and install PTO adapter on shaft end. If the alignment is incorrect loosen engine support 1.
  • Page 86 Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) Engine Support Screws Apply Loctite 243 (blue) (P/N 293 800 060) on screw threads. Torque engine support screws to 25 N•m (18 lbf•ft) when procedure is completed. smr2005-049-006_a 787 RFI ENGINES — REAR CAUTION: Whenever shims are used to cor- rect alignment, never install more than 5 mm (.1968 in) shim thickness.
  • Page 87 Section 03 ENGINE SYSTEM Subsection 03 (REMOVAL AND INSTALLATION) REAR ENGINE SUPPORT — 787 RFI ENGINES 1. Torque to 25 N•m (18 lbf•ft) Final Inspection Check throttle cable condition and lubricate cable with Bombardier Lube (P/N 293 600 016). After its installation, properly adjust and bleed oil injection pump as specified in OIL INJECTION PUMP and adjust throttle cable as specified in CARBURETOR or ENGINE MANAGEMENT (RFI).

  • Page 88: Lubrication System

    Section 04 LUBRICATION SYSTEM Subsection 01 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM SERVICE TOOLS Description Part Number Page pump gauge tester ............... 295 000 114 ........... 75 small hose pincher..............295 000 076 ........... 74 SERVICE PRODUCTS Description Part Number Page Loctite 271 (red) ..............
  • Page 89 Section 04 LUBRICATION SYSTEM Subsection 01 (OIL INJECTION SYSTEM) GTI Series smr2005-050-001_aen smr2005-050 www.SeaDooManuals.net...
  • Page 90 Section 04 LUBRICATION SYSTEM Subsection 01 (OIL INJECTION SYSTEM) 3D Series smr2005-050-006_aen smr2005-050 www.SeaDooManuals.net...

  • Page 91: General

    Oil filter no. 4 should be replaced annually. When installing, point the arrow toward the engine. Oil Reservoir Pad 3D Series When the foam pad under oil reservoir is installed, apply Loctite 271 (red) (P/N 293 800 005) on screw threads.
  • Page 92 Section 04 LUBRICATION SYSTEM Subsection 01 (OIL INJECTION SYSTEM) smr2005-050-005_a 787 RFI ENGINES — LH SIDE OF ENGINE 1. Rotary valve shaft oil return hose Connect the pump gauge tester (P/N 295 000 114) to oil injection reservoir vent check valve. 295000114 smr2005-050-003_a 787 RFI ENGINES —...

  • Page 93: Oil Injection Pump

    Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) OIL INJECTION PUMP SERVICE TOOLS Description Part Number Page gear holder................420 277 905 ........... 80 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ........... 80 Loctite anti-seize lubricant ............ 293 800 070 ........... 81 smr2005-051 www.SeaDooManuals.net...
  • Page 94 Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) 717 Engines smr2005-051 www.SeaDooManuals.net...
  • Page 95 Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) 787 RFI Engines smr2005-051 www.SeaDooManuals.net...

  • Page 96: Oil Pump Identification

    Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) OIL PUMP IDENTIFICATION Disconnect oil injection pump cable from oil pump lever. Pump Lever Disconnect oil hoses from oil pump fittings. Different engines need different pumps. See Remove pump. identification on lever. 787 RFI Engines CAUTION: Always mount proper pump on en- Disconnect oil injection pump cable no.

  • Page 97: Adjustment

    Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) ADJUSTMENT CAUTION: As oil injection pump adjustment is dependent on throttle cable position, make sure to perform throttle cable adjustment first except if otherwise specified. Preliminary Synchronization NOTE: To check synchronization of pump as a routine maintenance, see FINAL SYNCHRONIZA- TION.
  • Page 98 Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) Start and bring engine to normal operating temper- ature. CAUTION: If watercraft is out of water, engine must be cooled using the flush kit. If air bub- bles are present in the oil injection system, bleed system before operating engine.

  • Page 99: Checking Operation

    Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) CHECKING OPERATION On Watercraft NOTE: Oil line supply must be full of oil. See bleeding procedure above. Start engine and run at idle while holding the pump lever in fully open position. Oil must advance into small oil lines.
  • Page 100 Section 04 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION PUMP) TYPICAL 1. Supply oil line to an oil container 2. Hold lever in fully open position 3. Drill in reverse position 4. Oil must drip here For an accurate test, each port should be checked separately to ensure equal delivery on both ports.

  • Page 101: Fuel System

    Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) CARBURETOR SERVICE TOOLS Description Part Number Page digital inductive type tachometer ......... 529 014 500 ........... 94 pump gauge tester ............... 295 000 114 ....... 88–89, 91 SERVICE PRODUCTS Description Part Number Page Bombardier Lube ..............
  • Page 102 Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) Mikuni BN-40i smr2005-052-001_aen smr2005-052 www.SeaDooManuals.net...

  • Page 103: General

    Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) GENERAL The following illustration shows which part of the carburetor begins to function at different throttle plate openings. F06F0LA TYPICAL 1. Pulse line 2. Loosen gear clamp Disconnect fuel supply line from fuel pump. F01F13A Disconnect fuel return line.

  • Page 104: Inspection

    Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) CAUTION: Heavy duty carburetor cleaner may be harmful to the rubber parts, O-rings, etc. Therefore, it is recommended to remove these parts prior to cleaning. INSPECTION Inspect parts for corrosion damage (shaft, throttle plate, spring, screw, check valve housing, etc.).
  • Page 105 Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) Replace filter if damaged. F01F0YA TYPICAL 1. Pump gauge tester 1. Filter 2. Hose installed to inlet nipple 3. Outlet nipple obstructed Fuel Accelerator Pump Diaphragm no. 10 must stand pressure for 10 sec- Disconnect inlet and outlet hoses from accelerator onds.

  • Page 106: Assembly

    Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) NOTE: Injectors are also equipped with check valves. F04F0JB TYPICAL F01F0ZA 1. Install pump gauge tester to injector hose 2. Injector 1. Metering chamber floor 2. Lever end 3. Flush Pump tester. Injector check valve should open at 19.4 kPa ±...
  • Page 107 Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) Leak Test Needle valve no. 3 must stand a pressure of 69 kPa (10 PSI) for 30 seconds. Otherwise, hold carburetor upside down, pour oil over needle valve and apply pressure. Check for bubbles. If they come from seat or O-ring, bubbles will exit around seat.

  • Page 108: Installation

    Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) Fuel Accelerator Pump Lubricate pump plunger, roller and cam with syn- thetic grease (P/N 293 550 010) and roller shaft with Bombardier Lube (P/N 293 600 016). F06F06B F01F11A TYPICAL 1. Apply synthetic grease to plunger TYPICAL 2.

  • Page 109: Adjustments

    Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) For fuel system pressurization, refer to FUEL CIR- CUIT. ADJUSTMENTS Carburetor Adjustment There is no mixture adjustment to be performed by the dealer. IMPORTANT: Trying to bypass the anti-tamper screws could damage the carburetor. It could also change the engine emission level and lead the engine not to meet the emission control reg- ulations.
  • Page 110 Section 05 FUEL SYSTEM Subsection 01 (CARBURETOR) 1. Idle speed screw F02F1QA Connect the digital inductive type tachometer TYPICAL 1. Adjustment screw (P/N 529 014 500) on spark plug cable of magneto 2. Small gap side to measure engine speed. NOTE: Turning the adjustment screw clockwise NOTE: To adjust idle speed, ensure flame arrester will increase the gap.

  • Page 111: Fuel Tank And Fuel Pump

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page engine leak test kit ............... 295 500 352 ......... 106 fuel pressure gauge.............. 529 035 591 ......... 101 pliers Oetiker 1099 ...............
  • Page 112 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) GTI Models smr2005-053-001_aen smr2005-053 www.SeaDooManuals.net...
  • Page 113 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) GTI RFI and GTI RFI LE Models smr2005-053-002_aen smr2005-053 www.SeaDooManuals.net...
  • Page 114 Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) 3D Series smr2005-053-003_aen smr2005-053 www.SeaDooManuals.net...

  • Page 115: General

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) GENERAL Oetiker Clamps To secure or cut Oetiker clamps no. 1 on fuel lines, WARNING use pliers Oetiker 1099 (P/N 295 000 070). The fuel system of a fuel injection system holds much more pressure than on a car- bureted watercraft.

  • Page 116: Testing Procedures

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) WARNING Use of improper fuel lines could compromise fuel system integrity. To remove the darts from the front access panel (if so equipped), use the pliers Oetiker 1099 (P/N 295 000 070).
  • Page 117 It validates the pressure regulator, the fuel pump and leaks in the system. Open the front storage compartment cover (GTI RFI Series) or remove the engine cover (3D Se- ries). Remove storage basket. On GTI RFI Series, remove glove box to have ac- cess to fuel pump.

  • Page 118: Removal

    (when installing safety lanyard) GTI RFI Series and 386 - 414 kPa 3D Series (56 - 60 PSI) Disconnect the fuel pressure gauge and reconnect Crank or start engine and observe fuel pressure. The fuel pressure should be the same as above.
  • Page 119 (if necessary). Electric Fuel Pump RFI Models Open the front storage compartment cover (GTI F01F20A RFI Series) or remove the engine cover (3D Se- 1. Pick-up tube ries). 2. Fuel sensor 3. Baffle pick-up Remove the storage basket.
  • Page 120 Models). Refer to the above section. TYPICAL 1. Loosen nuts Detach all fuel tank straps no. 12. On 3D Series, to have access to the rear fuel tank holding strap, CAUTION: While pulling out the fuel pump, pay remove exhaust hoses with the resonator.

  • Page 121: Inspection

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) Fuel Filler Hose Unscrew clamp no. 13 then detach the fuel filler hose no. 14 from fuel tank. All Models Pull out fuel tank. Verify fuel filler hose no. 14 for damage. Always ensure that clamps no.
  • Page 122 Fuel Tank Pressure Test (supply and vent circuits) TYPICAL — 3D SERIES WARNING 1. Connect pump to air inlet fitting 2. Install hose pincher on the hose...

  • Page 123: Installation

    Section 05 FUEL SYSTEM Subsection 02 (FUEL TANK AND FUEL PUMP) Insert fuel tank in the vehicle and place straps in bottom clips. Use tape to hold straps on the top of fuel tank. Insert strap ends in hoops. Properly secure harnesses. Reinstall all other removed parts.

  • Page 124: Engine Management (Rfi)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) OVERVIEW ENGINE MANAGEMENT SYSTEM (EMS) - ATS: air temperature sensor - SP: spark plug - FT: fuel tank - APS: air pressure sensor - FI: fuel injector - FP: fuel pump - TPS: throttle position sensor - IC: ignition coil - FRe: fuel regulator - CPS: crankshaft position sensor...

  • Page 125: General

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) GENERAL The Rotax Fuel Injection (RFI) is composed of the following main components: The engine management system (EMS) is respon- sible of the fuel injection, ignition timing and RAVE Fuel Pump Module valves operation.
  • Page 126 Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) F07F0LA F07F0IA REGULATOR 1. End cap of fuel pump module removed 2. Internal fuel filter (not replaceable) External and Internal Fuel Filters This filter is not replaceable. If clogged, the fuel Fuel filters protect the components of the fuel in- pump module should be replaced.

  • Page 127: Electrical System

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) ELECTRICAL SYSTEM Digitally Encoded Security System (DESS) This antistart system allows starting the vehicle Engine Control Module (ECM) only with safety lanyard(s) that has been pro- The ECM is a VDO-Siemens module. grammed to operate a specific watercraft.
  • Page 128 Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) Remove spark plugs and dry them using a rag. Cover spark plug holes with a rag. While engine is stopped, depress and HOLD the throttle lever at full throttle position for cranking. Crank the engine several times.
  • Page 129 Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) smr2005-054-004_b TYPICAL 1. Fuse holders of the main fuse (VCM and charging fuse) 1. Fuse location and identification Gauges Current Supply FUSE FUSE CAPACITY AND When installing the safety lanyard it activates the IDENTIFICATION FUNCTION reading of gauges without the engine running.

  • Page 130: Engine Management

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) ECM and VCM Interaction with the Electrical System smr2005-054-001_aen ENGINE MANAGEMENT IGNITION TIMING The ECM is programmed with data for optimum ELECTRONIC FUEL INJECTION ignition timing under all operating conditions. Us- ing data provided by the sensors, the ECM con- The ECM receives the signals from 5 sensors trols the ignition timing for optimum engine oper- which indicate engine operating conditions at...

  • Page 131: Other Engine Management Functions

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) For mechanical inspection of the RAVE valves, re- These performance-reduced modes allow the rid- fer to TOP END in the 717/787 RFI ENGINE SHOP er to go back home which would not be possible MANUAL.

  • Page 132: Diagnostic Procedures

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES GENERAL TPS (Throttle Position Sensor) Faults Faults which are reported in B.U.D.S. fall into two Here is the basic order suggested to diagnose a groups: TPS faults and adaptation faults. These suspected engine management or fuel injection are displayed on the B.U.D.S.
  • Page 133 Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES) POSSIBLE CAUSES ACTION Sensor has been replaced • Reset Closed and TPS closed position Throttle. not reset. Throttle body has been • Reset Closed replaced and TPS closed Throttle. position not reset. ECM has been replaced •...
  • Page 134 Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES) EMS Fault Code Table COMMENT NORMAL OPERATION RESUMES WHEN... ENGINE SPEED LIMITATION DETECTED WHEN ENGINE RUNS DETECTED WHEN ENGINE STOPPED CHECK ENGINE LIGHT BEEPER CODE DESCRIPTION CODE The engine speed is limited Rave valve solenoid signal too When the fault is P0079...
  • Page 135 Starter relay open circuit removed When the fault is P-0617 Starter relay shorted to 12 V recovered Check engine circuit open When the fault is 3D Series and GTI LE RFI P-0650 recovered circuit or shorted to ground only smr2005-055 www.SeaDooManuals.net...
  • Page 136 Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES) COMMENT NORMAL OPERATION RESUMES WHEN... ENGINE SPEED LIMITATION DETECTED WHEN ENGINE RUNS DETECTED WHEN ENGINE STOPPED CHECK ENGINE LIGHT BEEPER CODE DESCRIPTION CODE Throttle position sensor When the fault is P-1102 adaptation failure recovered Throttle position sensor...

  • Page 137: Vck (Vehicle Communication Kit)

    035 981) is the primary tool to diagnose engine management and fuel injection related problems. smr2005-055-006_a 3D MODELS NOTE: The MPEM programmer does not work on RFI models with the VDO-Siemens ECM. NOTE: Ensure to use the latest B.U.D.S. version available on BossWeb.
  • Page 138 Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES) Ensure the status bar shows the kW2000 and the number 1 to the right. So that B.U.D.S. communi- cate with the ECM, number 1 must be displayed. If an “X” is shown instead of a 1, this means that no communication between MPI and ECM takes place.

  • Page 139: Component Adjustment, Inspection And Replacement

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT SERVICE TOOLS Description Part Number Page ECM adapter................. 420 277 010 ......... 127 Fluke 111 ................529 035 868 ......... 126 VCK (Vehicle Communication Kit) ......... 295 035 981 ......... 131 GENERAL When a repair is completed, ensure that hose from fuel rail going to fuel pump is properly se-...
  • Page 140 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) NOTE: Troubleshooting should be performed us- Before replacing a ECM, always check electri- ing the VCK. After a problem has been solved, en- cal connections. Make sure that they are very sure to clear the fault(s).
  • Page 141 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) ECM Connectors TEMPERATURE RESISTANCE (OHMS) °C °F NOMINAL HIGH - 30 - 22 12600 11800 13400 - 20 11400 11000 11800 - 10 9500 8000 11000 5900 4900 6900 3800 3100...
  • Page 142 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) TERMINAL IDENTIFICATION OF ECM CONNECTOR A (WIRING HARNESS SIDE) CAUTION: Do not disconnect the ECM connec- tors needlessly. They are not designed to be disconnected/reconnected repeatedly. NOTE: For more details on ECM connectors ser- vicing, refer to ELECTRICAL CONNECTORS AND WIRING DIAGRAMS section.

  • Page 143: Adjustment

    Ensure to reset the Closed TPS. See below. NOTE: Idle speed in water is 1550 ± 100 RPM. 3D RFI Series THROTTLE CABLE NOTE: For throttle cable replacement, refer to STEERING SYSTEM. GTI RFI Series Fully depress throttle lever.
  • Page 144 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) Right throttle cable adjustment is to be done at the Fully depress throttle lever and hold. Throttle adjuster on top of steering pole. However, first lever stopper should almost contact throttle body. ensure adjuster at throttle body is fully screwed To ensure there is free play, apply a light pres- sure on the throttle plate, a slight play should be...

  • Page 145: Throttle Position Sensor (Tps)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) Click Reset button to reset the TPS value to pro- vide the zero scale value to ECM. NOTE: There will be an “EMS Tracking” message that will say “Remove key from vehicle”. When this occurs, remove the safety lanyard from its post and wait until the message disappears (it lasts approximately 15 seconds after lanyard re-...

  • Page 146: Fuel Injector

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) FUEL INJECTOR smr2005-056-001_en smr2005-056 www.SeaDooManuals.net...
  • Page 147 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) Electrical Test NOTE: Because B.U.D.S. sends pulsating voltage to the injector, you will not read full 12 V. Short Voltage Test readings of approximately 9 V indicate a working Safety lanyard must be on DESS post.
  • Page 148 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) CONNECTOR CONNECTOR INJECTOR 5-31 A-15 1 (MAG) 5-15 A-33 2 (PTO) smr2005-056-013_a – Repair wire/connector if defective. If wires test good and there was a fault code, try a new ECM.

  • Page 149: Throttle Position Sensor (Tps)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) THROTTLE POSITION SENSOR Leakage Test (TPS) To perform a leakage test, the injectors and fu- el rail have to be removed from engine. See RE- MOVAL in this subsection for the procedure. NOTE: Do not detach injectors from fuel rail.

  • Page 150: Throttle Body

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) THROTTLE WIDE OPEN ECM CONNECTOR IDLE THROTTLE POSITION POSITION RESISTANCE @ 20°C (68°F) A-24 A-25 2600 - 2700 710 - 1300 A-25 A-39 1600 - 2400 1600 - 2400 A-24 A-39 710 - 1300...

  • Page 151: Air Temperature Sensor (Ats)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) ECM CONNECTOR MEASUREMENT ECM CONNECTOR MEASUREMENT RESISTANCE RESISTANCE @ 20°C (68°F) @ 20°C (68°F) A-19 774 - 946 A-21 2280 - 2736 smr2005-056-015_a smr2005-056-015_a If not within specification, check wiring harness. If not within specification, check wiring harness.

  • Page 152: Air Pressure Sensor (Aps)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) ECM CONNECTOR MEASUREMENT ECM CONNECTOR MEASUREMENT RESISTANCE RESISTANCE @ 20°C (68°F) @ 20°C (68°F) A-11 A-27 2280 - 2736 3400 - 8200 A-18 2400 - 8200 smr2005-056-015_a If not within specification, check wiring harness. smr2005-056-015_a If wiring is faulty, repair/replace.

  • Page 153: Rave Solenoid

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) If voltage test is not good, try a new ECM. If voltage test is good, everything is in order. RAVE SOLENOID smr2005-056-018_a If resistance is incorrect, replace RAVE solenoid. If resistance is correct, proceed with the VOLT- AGE TEST below.

  • Page 154: Parts Replacement

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) IMPORTANT: When the ECM is replaced, the Closed TPS and ignition timing must be reset. Refer to ADJUSTMENT in this section for the TPS and to IGNITION SYSTEM section for the ignition timing.

  • Page 155: Throttle Position Sensor (Tps)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) VCM Replacement Disconnect battery cables. WARNING Battery BLACK negative cable must always be disconnected first and connected last. Disconnect connectors from VCM. Remove re- taining nuts on top. smr2005-056-005 TYPICAL 1.

  • Page 156: Air Temperature Sensor (Ats)

    Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) Remove the air temperature sensor to ease re- moval of the TPS. Disconnect the TPS connector. Loosen 2 Allen screws retaining the TPS. Remove TPS. NOTE: Resetting should be done using VCK each time the TPS is loosened, removed or changed.
  • Page 157 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT ADJUSTMENT, INSPECTION AND REPLACEMENT) F07F0SA 1. Loosen screws retaining the fuel rail Remove the fuel rail with both fuel injectors. To remove the fuel injector from the fuel rail, pry off the retaining clip. 1.

  • Page 158: Electrical System

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page 4-pin magneto harness adapter ..........295 000 131 ......... 150 787 RFI Timing tool............... 529 036 017 ......... 158 ECM adapter................. 420 277 010 ......... 161 Fluke 111 ................

  • Page 159: Adjustment

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Scribing a Timing Mark (Static Test) The unregulated AC current from the magneto generator coil supplies the Multi-Purpose Elec- – Disconnect MAG side spark plug wire and tronic Module (MPEM) for its ignition functions. connect wire to grounding device then remove spark plug.
  • Page 160 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION TIMING ENGINE (BTDC) 2.59 mm (.102 in) – Scribe a thin mark on PTO flywheel in the mid- dle of tool slot. F01H5TA TYPICAL 1. TDC gauge on MAG side – Rotate PTO flywheel counterclockwise (when F01H5SB facing it) until piston is at top dead center.
  • Page 161 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) F00H0GA F00H0IA 1. Tachometer pick-up 1. Timing light straight in line with tool slot CAUTION: If engine is to be run more than a – Connect timing light pick-up to MAG side spark few seconds, engine must be cooled using the plug wire.
  • Page 162 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) TYPICAL F01H5UA 1. To retard 2. To advance 1. Too advanced timing To adjust, loosen 3 armature plate retaining In this case, turn armature plate clockwise when screws and slightly rotate armature plate in prop- facing it.

  • Page 163: Testing Procedures

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Repeat armature plate positioning procedure if Check resistance with a multimeter. Refer to the timing mark position is not adequate. following table for values and wire colors. TESTING PROCEDURES ADAPTER PART NAME RESISTANCE WIRE When dealing with ignition problems, the follow-...

  • Page 164: Multi-Purpose Electronic Module (Mpem)

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) NOTE: If the generating coil tests good, discon- Primary Winding 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, either the MPEM or wiring harness is defective.
  • Page 165 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) CAUTION: Do NOT use coil tester on metal work bench. Follow manufacturer instruc- tions. – With ignition coil removed from craft, discon- nect spark plug caps from high tension cables. – Hook high tension leads from tester to ignition coil high tension cables.

  • Page 166: 787 Rfi Engine

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) 787 RFI ENGINE smr2005-057-003_aen IGNITION SYSTEM ELECTRICAL DIAGRAM smr2005-057 www.SeaDooManuals.net...

  • Page 167: General

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) GENERAL Prior to troubleshooting any ignition problems, ver- ify for any fault codes from the engine manage- ment system. Refer to ENGINE MANAGEMENT for more details. Magneto The magneto is the primary source of electrical energy.

  • Page 168: Adjustment

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) ADJUSTMENT Vehicle Control Module (VCM) The VCM energizes the primary side of each igni- IGNITION TIMING tion coil individually (positive voltage). Before checking ignition timing with a stroboscop- ic timing light (dynamic test), it is mandatory to scribe a timing mark on the PTO flywheel (static test) corresponding to the specific engine.
  • Page 169 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) F06H05A 1. Timing mark pointer tool – Install and adjust a TDC gauge (P/N 295 000 F01H4LA 143) in MAG side spark plug hole. TYPICAL 1. Adjust gauge dial at zero – From this point, rotate flywheel clockwise to reach proper specification according to engine.
  • Page 170 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) F06H06A 1. Tachometer pick-up smr2005-057-013_a – Connect timing light pick-up to MAG side spark 1. Tool end 2. Flywheel mark plug wire. NOTE: This mark becomes the reference when verifying the ignition timing (dynamic test). –...
  • Page 171 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) F07F0HA smr2005-057-001 AIR INTAKE SILENCER REMOVED FOR CLARITY PURPOSE ONLY 1. Air pressure sensor (APS) – Disconnect WTS (water temperature sensor). smr2005-057-002_a 1. WTS connector F07F0GA 2. Timing tool 1. Water temperature sensor (WTS) –...

  • Page 172: Testing Procedures

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) CAUTION: If engine is to be run 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.

  • Page 173: Vehicle Control Module (Vcm)

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) smr2005-057-018 PRIMARY CIRCUIT smr2005-057-015 RESISTANCE CIRCUIT TERMINAL You should hear the spark occurring. In doubt, use @ 20°C (68°F) an inductive spark tester or a sealed tester — avail- 1 and 2 able from tool suppliers —...

  • Page 174: Engine Control Module (Ecm)

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) ENGINE CONTROL MODULE (ECM) Verify the ECM ignition ground circuit as follows: Resistance Test NOTE: For this test, use the ECM adapter (P/N 420 277 010) to probe ECM connector. Refer to ENGINE MANAGEMENT for more infor- mation.
  • Page 175 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Fouling The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug oper- Fouling of the spark plug is indicated by irregular ating temperature will be and inversely, the short- running of the engine, decreased engine speed er the heat path, the colder the operating temper- due to misfiring, reduced performance, and in-...
  • Page 176 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) 1. Proper socket 2. Improper socket Spark Plug Chart SPARK ENGINE TORQUE PLUG 717 and 24 N•m 0.4 - 0.5 mm 787 RFI BR8ES (17 lbf•ft) (.016 - .020 po) engines NOTE: Refer to next page for NGK SPARK PLUG SYMBOL EXPLANATION.
  • Page 177 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) NGK Spark Plug Symbol Explanation WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040") B R 8 E S 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Firing end Thread...

  • Page 178: Charging System

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page 4-pin magneto harness adapter ..........295 000 131 ....167–168, 172–174 multimeter Fluke 111 ............529 035 868 ......... 171 SERVICE PRODUCTS Description Part Number Page dielectric grease ..............
  • Page 179 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) TYPICAL TYPICAL 1. Vent tubes removed 1. MPEM 2. Electrical box FUSE IDENTIFICATION — 5 A: MPEM AND 15 A: BATTERY smr2005-059-006_a TYPICAL 1. Fuse Step 1: Pull tab Step 2: Pull fuse housing smr2005-058 www.SeaDooManuals.net...

  • Page 180: Testing Procedures

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) TESTING PROCEDURES Using an appropriate terminal remover (Snap-on TT600-4), remove the RED and BLACK wires from NOTE: First, ensure that battery is in good condi- the tab housing of the rectifier/regulator. tion prior to performing the following tests. Reconnect the connector housing.
  • Page 181 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) F02H0KA 1. Multimeter 2. Magneto harness adapter TYPICAL 3. YELLOW and BLACK/YELLOW wires 1. Multimeter 2. Magneto harness adapter Insulation 3. Positive (+) probe to YELLOW wire 4. Negative (-) probe to ground –...

  • Page 182: 787 Rfi Engine

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) 787 RFI ENGINE Ignition System Electrical Diagram smr2005-058-001_aen smr2005-058 www.SeaDooManuals.net...

  • Page 183: General

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) GENERAL Rectifier/Regulator Magneto smr2005-057-011_a MAGNETO OUTPUT ENGINE TYPE WATT 787 RFI 270 @ 6000 RPM The purpose of the charging system is to keep the battery at a full state of charge. smr2005-058-002_a The magneto is the primary source of electrical 1.

  • Page 184: Testing Procedures

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Dynamic Test DC Current Test Proceed as follows: Remove charging system fuse. smr2005-058-003_a 1. Charging system fuse The rectifier/regulator could be the culprit of a blown fuse. To check, simply disconnect the rectifier/regulator from the circuit.

  • Page 185: Stator

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) – Read voltage. – Install the 4-pin magneto harness adapter (P/N 295 000 131) between unplugged connec- tors. TEST ENGINE SPEED VOLTAGE 5500 RPM max. 15 Vdc TYPICAL TYPICAL – If voltage is above specification, replace rectifi- er/regulator.
  • Page 186 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) smr2005-058-007_a – If any result is out of specification, replace sta- tor. smr2005-058-008_a – Replug connectors properly. 1. Do not plug these connectors Insulation – Set multimeter to – Disconnect the magneto wiring harness con- –...
  • Page 187 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) smr2005-058-007_b – Set multimeter to Vac scale. – Start engine. smr2005-058-009_a – Connect multimeter between YELLOW wires. 1. Voltage regulator/rectifier 2. Unplug connectors TEST ENGINE TERMINAL VOLTAGE – Disconnect the magneto wiring harness con- SPEED nector.

  • Page 188: Battery

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) BATTERY Cleaning Clean the battery casing, caps, cables and battery Troubleshooting posts using a solution of baking soda and water. CAUTION: Do not allow cleaning solution to en- SYMPTOM: DISCHARGED OR WEAK BATTERY ter battery.
  • Page 189 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Most hydrometers give a true reading at 21°C SPECIFIC GRAVITY READING USING (70°F). A HYDROMETER ELECTROLYTE TEMPERATURE STATE OF CHARGE 27°C (80°F) 4°C (40°F) 100% 1.26/1.27 1.27/1.28 1.21/1.22 1.22/1.23 1.16/1.17 1.17/1.18 1.12/1.13 1.13/1.14 1.10 or less 1.11 or less...
  • Page 190 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Clean battery casing and caps using a solution of baking soda and water. CAUTION: Do not allow cleaning solution to en- ter battery. Rinse battery with clear water and dry well using a clean cloth.
  • Page 191 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Step 1: Unplug battery charger Step 2: Disconnect - lead A17E0RB Step 3: Disconnect + lead 1. Battery electrolyte 2. Upper level line – Test battery state of charge. Use a hydrometer. –...
  • Page 192 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protection WARNING feature which prevents charging unless the charg- Always charge battery in a well ventilated er leads are connected to the correct battery ter- area. minals.

  • Page 193: Starting System

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 193 Loctite 271................293 800 005 ......... 193 smr2005-059 www.SeaDooManuals.net...

  • Page 194: Electric Starter Exploded View

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) ELECTRIC STARTER EXPLODED VIEW 717 Engine smr2005-059 www.SeaDooManuals.net...
  • Page 195 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 787 RFI Engine smr2005-059 www.SeaDooManuals.net...

  • Page 196: Starting System Electrical Diagram

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM ELECTRICAL DIAGRAM RFI Models smr2005-059-001_aen smr2005-059 www.SeaDooManuals.net...

  • Page 197: Starting System Troubleshooting Chart

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING CHART SYMPTOM CAUSE REMEDY STARTER DOES NOT 2 short beeps are not heard when Refer to GENERAL in this section. TURN. installing safety lanyard Burnt fuse (see text above). Check wiring condition and replace fuse.

  • Page 198: General

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) GENERAL TESTING PROCEDURES Causes of troubles are not necessarily related to Fuse starter but may be due to a burnt fuse, faulty bat- Make sure the following fuse(s) is (are) in good tery, bad grounds, start/stop switch, DESS switch, condition.
  • Page 199 Engine Start/Stop Switch smr2005-058-003_b 1. Main fuse Disconnect start/stop switch connector. Measure resistance between switch wires as per table. Fuse F4: 10A, Ignition coil and starter solenoid NOTE: On 3D models, check both switches one at a time. SWITCH SWITCH RESISTANCE CONNECTOR POSITION @ 20°C (68°F)
  • Page 200 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) SWITCH CONNECTOR RESISTANCE @ 20°C (68°F) WIRE WHITE/GRAY switch terminal close to 0 smr2005-057-007_b smr2005-059-002_a SWITCH CONNECTOR 1. Solenoid RESISTANCE @ 20°C (68°F) WIRE 787 RFI Engine Solenoid is located above ECM/VCM. BLACK switch ring close to 0...
  • Page 201 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) SOLENOID CONNECTOR MEASUREMENT RESISTANCE @ 20°C (68°F) approximately 5 1. Grounding device Depress start/stop button and while engine is cranking, measure the voltage drop as follows with a multimeter. SOLENOID CONNECTOR MEASUREMENT smr2005-059-004_a TYPICAL VOLTAGE...

  • Page 202: Removal

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) REMOVAL Starter Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. 1. Pinion stop collar Disconnect RED cable connection from battery. Turn clutch assembly no. 9 clockwise to remove Remove the following parts: it from armature assembly no.

  • Page 203: Assembly

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, enough to resurface only. Check commutator for mica depth. If depth is less than 0.20 mm (.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed.
  • Page 204 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 1. Locating protrusion is the higher one 1. Armature shaft 2. Circlip 3. Pinion stop collar 4. Punch Yoke Assembly and Clutch Housing Align previously traced indexing marks. F01H0TA 1. Brush holder locating notch To ease end frame installation, retain brush hold- er with a small screwdriver while installing end frame.

  • Page 205: Installation

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) BLACK Negative Cable Retaining Screw and Teeth Washer Apply Loctite 271 (P/N 293 800 005) to screw. Connect BLACK negative cable to starter using flat washer, teeth washer no. 15 and screw no.

  • Page 206: Starter Specification

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTER SPECIFICATION Nominal output 0.6 kW Voltage 12 V Rated time 30 seconds Counterclockwise (viewed Rotation from pinion side) Weight Approx. 2 kg (4.4 lb) Performance 11.5 V, 20 A max. 5500 RPM specification load at 20°C...

  • Page 207: Instruments And Accessories

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES SERVICE TOOLS Description Part Number Page Fluke 111 ................529 035 868 ......... 195 GENERAL Multi-Purpose Electronic Module (MPEM) Install safety lanyard to activate MPEM or VCM/ECM to perform testing procedures that requires the device to be supplied with electricity.

  • Page 208: Multi-Purpose Electronic Module (Mpem)

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) FUSE IDENTIFICATION — 5 A: MPEM AND 15 A: BATTERY Electrical Box smr2005-059-006_a TYPICAL 1. Fuse holder Step 1: Pull tab Step 2: Pull fuse housing RFI Models Refer to ENGINE MANAGEMENT. MULTI-PURPOSE ELECTRONIC MODULE (MPEM) NOTE: For models with a 787 RFI Engine, refer to...
  • Page 209 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Digitally Encoded Security – ignition system System (DESS) – Digitally Encoded Security System – monitoring system When connecting a safety lanyard cap on the switch, the DESS system inside the MPEM is –...

  • Page 210: Information Center

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Diagnostic Mode In order to facilitate the use of the watercraft, a system controls the digitally encoded security sys- tem (DESS) and sends, through a beeper, some audible signals informing the operator of a specif- ic situation.
  • Page 211 Language Option • compass error (COMPAS) While in the compass mode (while “SeaDoo” is • maintenance (MAINT) displayed on models without compass): • engine overheating (H-TEMP) • low fuel (FUEL-LO) •...

  • Page 212: Testing Procedures

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 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: 1. Press to end English/Metric System Allows to display the units in the metric system or in the SAE English system.

  • Page 213: Information Center

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Fuel Level If there is no current supply to the electrical com- ponents while the DESS switch and the cut-off re- Fuel Level Sender lay test good, check the wiring harness. If it tests Test fuel level sender.
  • Page 214 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Adjust potentiometer to the resistance values as VCM CONNECTOR MEASUREMENT per following chart to test the accuracy of the In- RESISTANCE formation Center. 20°C (68°F) DISPLAYED LOW FUEL Closed circuit RESISTANCE 5–5 5-21 SEGMENT ON...
  • Page 215 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) smr2005-060-003_a smr2005-060-003_b SENSOR CONNECTOR MAIN HARNESS CONNECTOR If resistance is out of specification, replace the RESISTANCE ( ) TEMPERATURE (°C) speed sensor. Otherwise, perform the following 25407 5 ± 2 procedure. 19911 10 ±...
  • Page 216 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) smr2005-060-004_a Select the exterior temperature mode in the Infor- smr2005-060-005_b mation Center. 1. Sensor test wires Use a heat gun and warm up the sensor. The tem- Remove test wires. perature should raise rapidly on the gauge. If resistance is out of specification, replace sensor.
  • Page 217 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Open top storage compartment cover. smr2005-060-007_a Remove the compass from the support. Change the direction of the compass and keep it horizontal (± 10°). There should be a change of direction on the Information Center. smr2005-060-006_a NOTE: To check the accuracy of the compass, you can use a portable compass and point it in...

  • Page 218: Indicator Light Cluster

    INDICATOR LIGHT CLUSTER Models with Fuel Level Lights When safety lanyard is installed and fuel tank is 3D Series full, all fuel level lights are continuously turned on. As fuel level goes down, the fuel level lights will turn off one at a time to indicate remaining fuel.

  • Page 219: Fuel Gauge/Low Oil Warning Light

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) The low oil warning light is part of the gauge. It CLUSTER MEASUREMENT will light when injection oil level is low. The oil CONNECTOR LIGHT sensor monitors the oil level. VOLTAGE Vdc Check engine Full (fuel level) Half...
  • Page 220 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) The resistance measured between PINK/BLACK Disconnect fuel pump connector. and PINK wires of the sender must be in accor- Measure resistance as per table. dance with fuel level (measured from under the flange) as specified in the following chart.

  • Page 221: Oil Sensor

    Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 3D RFI Series When the oil level goes at critical LOW level inside the oil tank (and therefore in sensor reservoir), the sensor detects the absence of liquid and the light...

  • Page 222: Speedometer

    Slowly rotate paddle wheel within 5.5 - 8.5 ELECTRIC BILGE PUMP 3D Series When safety lanyard cap is installed on its post, the bilge pump is automatically turned on. It will remain on until all water is evacuated (if so), then it will shut down automatically.
  • Page 223 Section 07 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) smr2005-060-012_a Using a voltmeter, measure voltage as shown. Battery voltage should be read. smr2005-060-011_a If so, replace bilge pump. Otherwise, check wiring/connectors. If they test good, try a new VCM. smr2005-060 www.SeaDooManuals.net...

  • Page 224: Digitally Encoded Security System (Dess)

    Section 07 ELECTRICAL SYSTEM Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS)) DIGITALLY ENCODED SECURITY SYSTEM (DESS) SERVICE TOOLS Description Part Number Page DESS adapter ............... 529 035 684 ......... 215 MPEM programmer.............. 529 035 878 ......... 215 Vehicle Communication Kit (VCK) ......... 529 035 981 ......... 215 GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unauthorized use of the watercraft.

  • Page 225: Self-Diagnostic Mode

    Section 07 ELECTRICAL SYSTEM Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS)) SELF-DIAGNOSTIC MODE It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme- diate monitoring. Refer to the following chart. 717 Engines CODED SIGNAL POSSIBLE CAUSE REMEDY...

  • Page 226: Dess Key Programming

    Section 07 ELECTRICAL SYSTEM Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS)) CODED SIGNAL POSSIBLE CAUSE REMEDY A 2 seconds beep every 15 minutes • Water temperature sensor or • Refer to COOLING SYSTEM. intervals. circuit malfunction. • Starter solenoid circuit •...
  • Page 227 Section 07 ELECTRICAL SYSTEM Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS)) smr2005-072-001_en Install key on MPI DESS post. smr2005-055-006_a 3D MODELS smr2005-072-002 Click on ADD KEY button on bottom of screen. smr2005-055-005_a GTI RFI MODELS Unplug communication connector and plug VCK connector.
  • Page 228 Section 07 ELECTRICAL SYSTEM Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS)) Ensure the status bar shows the kW2000 and the number 1 to the right. So that B.U.D.S. communi- cate with the ECM, number 1 must be displayed. smr2005-072-003_Aen 1. Click on this tab A new key is now saved in the computer.
  • Page 229 Section 07 ELECTRICAL SYSTEM Subsection 05 (DIGITALLY ENCODED SECURITY SYSTEM (DESS)) Programming Keys with the MPEM Programmer 717 Engines Only Connect the communication cable of the MPEM programmer to the vehicle DESS post. The following chart lays out the complete procedure to program a new key. Scroll to select PROGRAM KEY item.

  • Page 230: Cooling System

    Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) COMPONENTS AND CIRCUIT SERVICE TOOLS Description Part Number Page pliers Oetiker 1099 ............... 295 000 070 ......... 228 smr2005-061 www.SeaDooManuals.net...
  • Page 231 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) 717 Engines smr2005-061 www.SeaDooManuals.net...
  • Page 232 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) smr2005-061 www.SeaDooManuals.net...
  • Page 233 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) 787 RFI Engines (GTI RFI and GTI RFI LE Models) smr2005-061 www.SeaDooManuals.net...
  • Page 234 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) smr2005-061 www.SeaDooManuals.net...
  • Page 235 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) 787 RFI Engines (3D Series) smr2005-061-001_aen smr2005-061 www.SeaDooManuals.net...
  • Page 236 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) CAUTION: smr2005-061-002_aen smr2005-061 www.SeaDooManuals.net...

  • Page 237: Circuit

    Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) CIRCUIT CAUTION: All hoses and fittings of the cooling system have calibrated inside diameters to as- sure proper cooling of the engine. Always re- place using appropriate BRP part number. 717 Engines A serial cooling system is utilized on the 717 engines, which offers an efficient cooling of the combustion chamber to prevent the possibilities...
  • Page 238 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) Storage Procedure 787 RFI Engines The 787 RFI engines features a heat exchanger Refer to STORAGE for winterization procedure of system. This system allows water coming out of cooling system. the cylinder head to circulate through a magneto Hull Servicing heat exchanger and the crankcase heat exchang- 717 Engines...

  • Page 239: Components

    Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) smr2005-061-003_A 1. Temperature sensor To test the sensor, unplug and remove it from en- gine. Put in water and heat water. The temperature sensor should operate when wa- TYPICAL ter temperature reaches 90° C ± 4° C (194° F ± 39° Technical Data F).
  • Page 240 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) Elbow Fitting The water flow regulator valve no. 2 is mounted directly onto the muffler. Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe. The elbow fitting no. 1 has a calibrated inside diameter to optimize water flow in tuned pipe.
  • Page 241 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. If the maximum engine speed cannot be attained or if the engine has poor performance, the water flow regulator valve should be considered in the troubleshooting of the problem.
  • Page 242 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) F01E20A 1. Fitting 1. Remove tapered needle Unscrew the tapered needle no. 6. Pull the valve slightly. Using pliers, release the clamp which retains the bellows no. 8. NOTE: Hold the valve to prevent it from turning. Remove valve no.
  • Page 243 Section 08 COOLING SYSTEM Subsection 01 (COMPONENTS AND CIRCUIT) Inspection Inspect parts for damage. Verify especially bel- lows for cracks. Assembly Assembly is essentially the reverse of disassem- bly procedures. smr2005-061 www.SeaDooManuals.net...

  • Page 244: Propulsion

    Section 09 PROPULSION Subsection 01 (JET PUMP) JET PUMP SERVICE TOOLS Description Part Number Page bearing/seal installer tool ............295 000 107 ......... 243 bearing/seal remover tool ............. 295 000 144 ......... 239 fitting tool ................295 000 086 ......... 249 impeller remover/installer tool ..........
  • Page 245 Section 09 PROPULSION Subsection 01 (JET PUMP) smr2005-062-001_aen smr2005-062 www.SeaDooManuals.net...

  • Page 246: General

    Section 09 PROPULSION Subsection 01 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive Stainless 267 000 201 pitch steel 11° - 20° Progressive Stainless 271 001 297 pitch steel 10° - 20° Progressive GTI RFI, Stainless 271 001 496 pitch GTI RFI LE steel...
  • Page 247 Section 09 PROPULSION Subsection 01 (JET PUMP) Using a feeler gauge, measure clearance between If oil level is low, check impeller shaft housing for impeller blade tip and wear ring. Measure each leaks. A pressure test must be performed. See blade at its center.

  • Page 248: Removal

    Section 09 PROPULSION Subsection 01 (JET PUMP) Place housing horizontally with a tilt angle of 15° with the filler plug located on top. Remove filler plug no. 5 from cover. Pour jet pump synthetic oil (P/N 293 600 011) in reservoir until oil comes level with bottom of hole.
  • Page 249 Section 09 PROPULSION Subsection 01 (JET PUMP) Cover Impeller no. 1 is loosened using the impeller re- mover/installer tool (P/N 295 000 001). With pump assembly in horizontal position, re- move 3 retaining screws no. 9. Place container under cover no. 6 to catch oil. Using a fiber hammer, gently tap cover to release it from jet pump housing.

  • Page 250: Cleaning

    Section 09 PROPULSION Subsection 01 (JET PUMP) 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. TYPICAL TYPICAL 1. Snap-on HS3 F00J0MA 1.

  • Page 251: Parts Inspection

    Section 09 PROPULSION Subsection 01 (JET PUMP) F02J0VB F01J13A TYPICAL 1. Replaced if blunted round or damaged 1. Water passages 2. Oil passages Check impeller for cavitation damage, deep scratches or any other damage. Brush and clean impeller shaft threads, impeller and drive shaft splines with pulley flange cleaner (P/N 413 711 809) or equivalent.
  • Page 252 Section 09 PROPULSION Subsection 01 (JET PUMP) Install bearings, 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, without impeller.

  • Page 253: Assembly

    Section 09 PROPULSION Subsection 01 (JET PUMP) Thrust Washer and Thrust Bearing Seal Visually inspect thrust washer no. 14, thrust bear- Carefully inspect seal lips. Make sure that lips are ing no. 15 and their contact surface. Check for not worn, distorted, cracked or show signs of any scoring, pitting, flaking, discoloration or other evi- other damage.
  • Page 254 Section 09 PROPULSION Subsection 01 (JET PUMP) Seal and Needle Bearing Impeller Side Bearing no. 16 and seal no. 7 on impeller side will be properly installed in housing using the bear- ing/seal installer tool (P/N 295 000 107). BEARING/SEAL INSTALLER TOOL 1.
  • Page 255 Section 09 PROPULSION Subsection 01 (JET PUMP) NOTE: Apply synthetic grease (P/N 293 550 010) on tool to ease seal insertion. Install seal with the spring toward the outside. 1. Spring of seal facing tool CAUTION: Prevent sealant from contacting any 1.
  • Page 256 Section 09 PROPULSION Subsection 01 (JET PUMP) 1. Loctite 518 all around and behind 2. Spring of seal lip this side Venturi Side For the bearing no. 17 on venturi side use the inner 1. Press on tool until it stops bearing installer tool (P/N 529 035 609).
  • Page 257 Section 09 PROPULSION Subsection 01 (JET PUMP) F01J1OA Insert tool onto shaft end then carefully install shaft in jet pump housing. F00J0DA 1. Thrust washer properly installed in stator seat Thrust Bearing Apply jet pump synthetic oil (P/N 293 600 011) on both sides of thrust bearing.
  • Page 258 Section 09 PROPULSION Subsection 01 (JET PUMP) F00J08A 1. Impeller remover/installer tool F00J0GA CAUTION: Make sure thrust washer and bear- 1. Apply antiseize on threads ing are not wedged in shaft groove. To check, manually pull and push jet pump housing, Using 2 screws previously removed from venturi, some axial play must be felt.

  • Page 259: Pump Pressurization

    Section 09 PROPULSION Subsection 01 (JET PUMP) 1. Spring 2. Slider Insert slider and spring into cover no. 6. NOTE: Align the longer slider tab with hole. Install O-ring no. 8 to cover. Apply jet pump bear- ing grease (P/N 293 550 032) on mating surface of cover.

  • Page 260: Installation

    Section 09 PROPULSION Subsection 01 (JET PUMP) – Apply Loctite 567 (pipe sealant) (P/N 293 800 013) on threads of fitting tool (P/N 295 000 086) then secure on cover. – Connect pressure/vacuum pump (P/N 529 021 800) to fitting. –...
  • Page 261 Section 09 PROPULSION Subsection 01 (JET PUMP) 1. Torque screws to 21 N•m (16 lbf•ft) Steering Cable Refer to STEERING SYSTEM. Reverse Gate and Cable Refer to REVERSE SYSTEM. smr2005-062 www.SeaDooManuals.net...

  • Page 262: Drive System

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) DRIVE SYSTEM SERVICE TOOLS Description Part Number Page alignment shaft..............295 000 141 ......... 264 bearing/seal installer tool ............295 000 107 ......... 262–263 bearing/seal remover tool ............. 295 000 144 ......... 260 Caillau pliers................

  • Page 263: Gti Series

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) GTI SERIES smr2005-063-001_aen smr2005-063 www.SeaDooManuals.net...

  • Page 264: General

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) GENERAL Jet pump must be removed to replace any com- ponents of the drive system. Refer to JET PUMP for removal procedure. Large Clamp Unfasten large clamp no. 1 of PTO flywheel boot no. 2 as follows: –...
  • Page 265 Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) F01B1TA – To open clamp, place flat side of pliers on clamp embossment, squeeze and twist pliers. TYPICAL 1. Closing hooks – Squeeze pliers. When both large and small windows are directly over the 2 locking hooks, press those windows down to engage hooks in windows.

  • Page 266: Removal

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) REMOVAL INSPECTION PTO Flywheel Guard Drive Shaft Remove seats. Inspect condition of drive shaft and PTO flywheel splines. Remove seat support. Inspect condition of groove. Remove plastic wing nuts no. 4 retaining PTO fly- wheel guard no.
  • Page 267 Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) Damper Visually inspect shape of dampers no. 13 for de- formation or other damage. Floating Ring and O-Ring Inspect condition of O-rings no. 14 and contact surface of floating ring no. 6. 1. Boot A.

  • Page 268: Installation

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) F06I06A 1. Spacer 1. Push floating ring 2. Insert circlip in the groove NOTE: Drive shaft must be removed to install Slide the floating ring onto the circlip. spacer. LUBRICATION INSTALLATION PTO Flywheel Installation is essentially the reverse of removal procedure.

  • Page 269: 3D Series

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) 3D SERIES smr2005-063-002_aen smr2005-063 www.SeaDooManuals.net...

  • Page 270: General

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) GENERAL Jet pump must be removed to replace any com- ponents of the drive system. Refer to JET PUMP for removal procedure. REMOVAL PTO Flywheel Guard Lift and lock steering pole, remove engine cover and storage tray.

  • Page 271: Inspection

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) F05I05A F06I06A TYPICAL TYPICAL 1. Push floating ring 1. Nut (6) 2. Remove circlip Bearing no. 17 and seals no. 18 can be easily removed using the bearing/seal remover tool Rear Drive Shaft (P/N 295 000 144).
  • Page 272 Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) Damper With your finger nail, feel machined surface of drive shaft. If any irregular surface is found, re- Visually inspect shape of damper no. 24 for defor- new drive shaft. mation or other damage. Floating Ring and O-Ring Inspect condition of O-rings no.

  • Page 273: Assembly

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) 1. Boot 1. Spacer A. Measure here NOTE: Drive shaft must be removed to install Push floating ring no. 6 to compress boot no. 7; spacer. then, remove circlip no. 8 out of drive shaft groove.
  • Page 274 Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) F01J51A 1. Press bearing in its housing TYPICAL 1. Double-lip seal toward engine NOTE: Bearing can also be installed with the same 2. Double-lip seal with protector toward jet pump driver used at disassembly. Center bearing in lon- 3.

  • Page 275: Installation

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) INSTALLATION Install the large washer no. 26 and nuts no. 16. Slightly tighten nuts but keep loose so that the as- Installation is essentially the reverse of removal sembly still can move and self adjust when insert- procedure.
  • Page 276 Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) F05I08A TYPICAL 1. Alignment tool 2. Seal carrier TYPICAL 1. Shaft support If alignment tool does not slide easily through seal 2. Loosen screws on both sides carrier, perform the alignment as follows. When done, ensure to apply Loctite 243 (blue) For vertical alignment, loosen damping support (P/N 293 800 060) on screw threads then torque...

  • Page 277: Lubrication

    Section 09 PROPULSION Subsection 02 (DRIVE SYSTEM) Front Drive Shaft Circlip Install front drive shaft no. 13. Push the floating ring no. 6 to compress the boot no. 7. Insert the circlip no. 8 in the drive shaft Rear Drive Shaft groove.

  • Page 278: Reverse System

    Section 09 PROPULSION Subsection 03 (REVERSE SYSTEM) REVERSE SYSTEM SERVICE PRODUCTS Description Part Number Page synthetic grease ..............293 550 010 ......... 271 smr2005-064 www.SeaDooManuals.net...
  • Page 279 Section 09 PROPULSION Subsection 03 (REVERSE SYSTEM) GTI Series smr2005-064-001_en smr2005-064 www.SeaDooManuals.net...

  • Page 280: Disassembly

    Section 09 PROPULSION Subsection 03 (REVERSE SYSTEM) DISASSEMBLY Reverse Gate To remove reverse gate no. 1, put shift lever in reverse position. Unscrew pivot bolt no. 2, located on the top of reverse gate. 1. Pivot bolt 2. Pivot support 3.
  • Page 281 Section 09 PROPULSION Subsection 03 (REVERSE SYSTEM) On the interior lever no. 21, unscrew the elastic stop nut no. 22 and remove the washer no. 23 retaining the reverse cable. Remove the retaining bracket no. 24. NOTE: Before removing reverse cable no. 11 from hull, note cable routing for reinstallation.

  • Page 282: Inspection

    Section 09 PROPULSION Subsection 03 (REVERSE SYSTEM) Shift Lever Handle Housing Unscrew the shift lever retaining bolt no. 25, Remove: washer and nut. – shift lever no. 26 Disengage the shift lever slots from interior lever – interior lever no. 21 tabs, then remove the shift lever no.

  • Page 283: Adjustment

    Section 09 PROPULSION Subsection 03 (REVERSE SYSTEM) 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. Pivot Triangle When installing pivot triangle, install head of bolts toward inside.

  • Page 284: Variable Trim System

    Section 09 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......... 276 smr2005-065 www.SeaDooManuals.net...
  • Page 285 Section 09 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) 3D PREMIUM smr2005-065 www.SeaDooManuals.net...

  • Page 286: Removal

    Section 09 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) REMOVAL Trim Ring Remove nut no. 1, bolt no. 2, flat washers no. 3, and bushing no. 4 from pivot no. 5. smr2005-065-003 Adjustment System Remove nut no. 1, bolt no. 2, flat washers no. 3, and bushing no.

  • Page 287: Assembly

    Section 09 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) ASSEMBLY Adjustment Screw Assembly is essentially the reverse of disassem- bly procedures. Refer to the main illustration at the beginning of this subsection as a guideline and for torque specification. INSTALLATION The installation is the reverse of the removal pro- cedure.

  • Page 288: Steering System

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page steering cable tool ..............295 000 145 ......... 282, 292 SERVICE PRODUCTS Description Part Number Page synthetic grease ..............293 550 010 ......... 300 smr2005-066 www.SeaDooManuals.net...

  • Page 289: Gti Series

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) GTI SERIES Carburetor- equipped engines smr2005-066-001_aen smr2005-066 www.SeaDooManuals.net...

  • Page 290: Disassembly

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) DISASSEMBLY 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 no. 4 from handlebar no.
  • Page 291 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Retaining block 1. Screws 2. Steering padding Loosen bolts no. 21 each side of steering support no. 22. Handlebar Remove steering cover no. 12 and steering padding no. 15. Remove 4 nuts no. 16 to remove handle bar no. 5 from steering stem no.
  • Page 292 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Tie rap RIGHT SIDE 2. Connectors 1. Steering support 2. Bolts Disconnect the steering cable from the steering Remove cable support no. 23. stem arm no. 24. Steering Support Cut locking tie securing wiring harness boot. F07K04A 1.

  • Page 293: Assembly

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Remove ball joint no. 30 and jam nut no. 31 from cable. Loosen nut no. 32, then remove half rings no. 33 and O-ring no. 34. NOTE: To loosen nut, use the steering cable tool (P/N 295 000 145).
  • Page 294 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Keyways 2. Integrated flat key Replace lock nuts no. 35 by new ones. Torque bolts no. 19 of steering stem arm to 6 N•m 1. Grip insert (53 lbf•in). Install grip no. 1 on handlebar no. 5 matching it to Handlebar the notch in the handlebar.

  • Page 295: Steering Alignment

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Check jet pump nozzle position by placing a straight edge on nozzle outer end. Measure the distance on each side of the straight edge. It must be equalled. TYPICAL 1. Ball joint below steering arm 2.
  • Page 296 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) After adjustment, torque retaining block bolts no. 19 to 6 N•m (53 lbf•in). CAUTION: Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi. smr2005-066 www.SeaDooManuals.net...

  • Page 297: 3D Series

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 3D SERIES 11 20 smr2005-066-002_aen smr2005-066 www.SeaDooManuals.net...
  • Page 298 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) smr2005-066-003_aen smr2005-066 www.SeaDooManuals.net...

  • Page 299: Inspection

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) INSPECTION NOTE: A mechanism that is hard to move might only need to be disassembled, cleaned, lubricated then reinstalled. If there is excessive play in the following inspec- tions, replace worn bushings or any other worn component.
  • Page 300 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Steering Cover Pull up steering padding no. 10. Loosen set screws no. 11 of handlebar housings no. 12 and no. 13. Pull out throttle housing no. 12. Remove cover no. 14. LH Cover Pull out start/stop switch housing no.
  • Page 301 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Retaining screws Remove screws no. 19 of adjuster blocks no. 20. Handlebar and Adjuster Lift cover of steering padding support no. 16. Remove spring no. 21, steering padding support no. 16 then latch lever no. 22. Remove screws no.
  • Page 302 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Inspect notches of adjuster blocks no. 20 and the pin no. 23 for wear or other damage. Steering Stem and Support Remove top cover no. 24. Raise steering pole. Unbend lock tab no. 25 then unscrew steering stem screw no.
  • Page 303 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Screws removed Remove retaining block no. 30. Remove ball joint no. 31 and adjustment knob no. 32 from cable. Disconnect ball joint no. 33 from jet pump nozzle then from cable. Use the steering cable tool (P/N 295 000 145) and remove nut no.
  • Page 304 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Return spring 2. Adjustment 3. To increase preload 4. To reduce preload Lower steering pole. Remove front cover in the following step order. CAUTION: Work carefully when releasing lock- ing tabs from cover to avoid damaging cover. Remove side screws.
  • Page 305 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Side opening Push cover forward then lift front part to unlock cover. smr2005-066 www.SeaDooManuals.net...
  • Page 306 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) For the center rear locks, push plastic tabs rearward to release. smr2005-066 www.SeaDooManuals.net...

  • Page 307: Assembly

    Disconnect steering cable from jet pump nozzle. Maintain steering pole vertically while inserting Remove nozzle bolts retaining nozzle to venturi or steering cable in pole. bolts retaining nozzle to trim ring (3D Premium Models only). Insert return spring end into bridge mount hole. smr2005-066...
  • Page 308 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Lubricate moving parts and bushings no. 3. Position washers no. 43 against top nuts no. 44. Install steering pole retainer no. 45 on bottom screws. Secure pole to bridge mount. Torque nuts no. 40 in a criss-cross sequence.
  • Page 309 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Using a new tab lock no. 25 position its small tab into hole of washer no. 48. WARNING Ensure to use a new tab lock. 1. Rounded edge on backside 2. Small tab into hole of washer Torque screw no.
  • Page 310 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Wiring harness routing Handlebar and Adjuster When installing blocks no. 20 on handlebar, en- sure to position block pin into handlebar hole. NOTE: Block must be centered on handlebar. If not, it is in reverse position. 1.
  • Page 311 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) TORQUE SEQUENCE Install handlebar on steering support then upper clamps no. 18. Position pin no. 23 into slots of Lubricate friction areas and bushings no. 50 with blocks no. 20. synthetic grease (P/N 293 550 010) then slide bushings against blocks no.
  • Page 312 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Install cap no. 7. TYPICAL 1. Grip insert 2. Grip 3. Flat washer 4. Screw. Torque to 7 N•m (62 lbf• in ) 5. Cap CAUTION: Ensure to install flat washer other- wise screw will damage grip end.

  • Page 313: Steering Alignment

    Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Ensure moto seat works and locks adequately (if Check jet pump nozzle position by placing a so equipped). straight edge on nozzle outer end. Measure the distance on each side of the straight edge. It Perform steering alignment.
  • Page 314 Section 10 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Support 2. Adjustment nut 3. Loosen bolts After adjustment, torque retaining block bolts to 5 N•m (44 lbf•in). CAUTION: Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi or VTS ring.

  • Page 315: Off-Power Assisted Steering (Opas)

    Section 10 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING (O.P.A.S.)) OFF-POWER ASSISTED STEERING (O.P.A.S.) SERVICE TOOLS Description Part Number Page O.P.A.S. cylinder nut wrench ..........529 035 840 ......... 308 SERVICE PRODUCTS Description Part Number Page silicone sealant (clear)............293 800 086 ......... 309–310 smr2005-067 www.SeaDooManuals.net...
  • Page 316 Section 10 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING (O.P.A.S.)) GTI Models 14 15 smr2005-039-002_Ben smr2005-067 www.SeaDooManuals.net...

  • Page 317: General

    Section 10 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING (O.P.A.S.)) GENERAL Remove the tie-rod screw no. 3. The Off-Power Assisted Steering (O.P.A.S.) sys- tem uses a dual side vanes design that assists the watercraft steering in deceleration, to redirect wa- tercraft path when steering is turned after throttle has been released or engine stopped.
  • Page 318 Section 10 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING (O.P.A.S.)) To adjust the tie-rod, remove tie-rod screw no. 3 and turn tie-rod fitting no. 5. Place tie-rod screw in its place and measure again. Repeat the proce- dure until the distance is reached. When the adjustment is done, torque the tie-rod screw to 4.5 N•m (40 lbf•in).
  • Page 319 Section 10 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING (O.P.A.S.)) Perform the tie-rod adjustment. See above. Remove side vane no. 1, cylinder housing no. 6 and O.P.A.S. “U” lever no. 16 as mentioned Tie Rod above. Remove jet pump (refer to JET PUMP). Removal Remove Phillips screws no.
  • Page 320 Section 10 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING (O.P.A.S.)) Torque Phillips screws no. 19 to 2.2 N•m (19 lbf•in). Cross Support Plate For LH Side Cross Support Plate Remove inlet hose, exhaust pipe and muffler (re- fer to EXHAUST SYSTEM). For RH Side Cross Support Plate Remove resonator (refer to EXHAUST SYSTEM).

  • Page 321: Off-Throttle Assisted Steering (O.t.a.s.)

    Section 10 STEERING SYSTEM Subsection 03 (OFF-THROTTLE ASSISTED STEERING (O.T.A.S.)) OFF-THROTTLE ASSISTED STEERING (O.T.A.S.) SERVICE TOOLS Description Part Number Page digital tachometer..............529 014 500 ......... 311 multimeter FLUKE 111 ............529 035 868 ......... 312 Vehicle Communication Kit (VCK) ......... 529 035 981 ......... 313 GENERAL –...

  • Page 322: Adjustment

    Section 10 STEERING SYSTEM Subsection 03 (OFF-THROTTLE ASSISTED STEERING (O.T.A.S.)) Apply 12 V to the jumper wires. Solenoid should Disconnect the switch 4-pin connector. pull on the throttle cable and hold it. Also try to push on solenoid rod to make sure it is fully col- lapsed.
  • Page 323 Section 10 STEERING SYSTEM Subsection 03 (OFF-THROTTLE ASSISTED STEERING (O.T.A.S.)) The procedure consists of manually pushing the solenoid rod (which pulls the throttle cable and activates the throttle plate) while reading the TPS opening or resistance value depending on the tool used.
  • Page 324 Section 10 STEERING SYSTEM Subsection 03 (OFF-THROTTLE ASSISTED STEERING (O.T.A.S.)) 1. O.T.A.S. solenoid 2. Adjust here smr2005-068 www.SeaDooManuals.net...

  • Page 325: Gti Series

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) GTI SERIES SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......321, 323, 327 Loctite 271 (red) ..............293 800 005 ......... 324 Loctite 518................293 800 038 ......... 325 Loctite 5900................
  • Page 326 Section 11 HULL/BODY Subsection 01 (GTI SERIES) smr2005-069-001_aen smr2005-069 www.SeaDooManuals.net...
  • Page 327 Section 11 HULL/BODY Subsection 01 (GTI SERIES) Body smr2005-069-002_aen smr2005-069 www.SeaDooManuals.net...
  • Page 328 Section 11 HULL/BODY Subsection 01 (GTI SERIES) Cover LE models smr2005-069-003_aen smr2005-069 www.SeaDooManuals.net...
  • Page 329 Section 11 HULL/BODY Subsection 01 (GTI SERIES) Seats GTI (seats) smr2005-069 www.SeaDooManuals.net...

  • Page 330: General

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) GENERAL Verify hinges condition and latching mechanisms condition and operation. Replace any damaged components. When applying threadlocker products, pay atten- tion so that it does not come in contact with ABS plastic parts (painted parts). It could lead to plas- tic cracks or other damage.

  • Page 331: Seat

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) FRONT SEAT 1. Insert your hand here to release the lock tabs 1. Lock pin 2. Adjustment nut (apply Loctite 243). Torque to 8 N•m (71 lbf• in ) A. 34 ± 1 mm (1-11/32 ± 3/64 in) From front storage compartment, pull glove box out.

  • Page 332: Storage Cover Shock

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) 1. Gently pull starting this end 2. Finish with this end 1. Shock rod Installation 2. Circlip 3. Washer For installation, proceed as follows: • Reinstall inner shell with its retaining screws. – Release the shock from top linkage bracket •...

  • Page 333: Storage Compartment Cover

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) MIRROR Removal and Installation To remove mirror proceed as follows: – Remove storage compartment inner shell no. 6 from storage cover no. 1 as described earlier in this section. – Remove two hexagonal screws no. 15 and flat washers.

  • Page 334: Inlet Grate

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) INLET GRATE Remove the speed sensor from the riding plate (if applicable). Removal and Installation Loosen riding plate screws. Loosen screws and remove inlet grate. NOTE: An impact screwdriver should be used to NOTE: An impact screwdriver should be used to loosen tight screws.

  • Page 335: Jet Pump Support

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) Remove ball joint, boot, nut, half rings and O-rings from reverse cable. Disconnect water supply hose, water return hose and bailer hoses. Remove nuts, lock washers and flat washers re- taining jet pump support. F07L0AA TYPICAL Install all removed parts.

  • Page 336: Drain Plug

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) SEAT COVER Torque nuts to 31 N•m (23 lbf•ft) as per the fol- lowing sequence. Replacement Remove the old seat cover. Check the foam and replace it if necessary. Install staples with an electric tacker such as Ar- row tacker no.

  • Page 337: Sponson

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) smr2005-024-014_A 1. Sponson TYPICAL 2. Bolts 1. Front bumper 2. Corner bumper Clean any residues of silicone sealant on hull and 3. Straight section 4. Bow section sponson. – Slide bumper rail no. 18 under front bumper Installation no.

  • Page 338: Thru-Hull Fitting

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) THRU-HULL FITTING For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw. smr2005-045-001_A 1. Elbow fitting holes Remove check valves and shake them. If the in- ner parts move freely, the check valve is in good condition.

  • Page 339: Decals Replacement

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) NOTE: Align aluminum insert as much as possible Clean surface with a good solvent such as with PTO flywheel. ACRYLICLEAN DX 330 from PPG or equiva- lent (refer to manufacturer instructions). Using a pencil and the decal as a template, mark the area where decal will be located.

  • Page 340: Hull And Body Repair

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) HULL AND BODY REPAIR FILLING THE CAVITY The prepared surface must be cleaned with ace- General tone on a cloth. Use a gelcoat repair kit. Follow Gelcoat is the smooth and durable cosmetic fin- the mixing instructions in the kit when preparing ish which coats the fiberglass hull and body of a the gelcoat putty.
  • Page 341 Section 11 HULL/BODY Subsection 01 (GTI SERIES) In case of fractures which have not penetrated SANDING past the gelcoat layer, the repair concerns the gel- Wash the polyvinyl alcohol off with water. De- coat only. If flex cracking or impact are evident, pending on the size of the area repaired, you can then additional reinforcement may be necessary.

  • Page 342: Tools And Materials List

    Section 11 HULL/BODY Subsection 01 (GTI SERIES) Inside SANDING For the interior repair, you can grind more. This Outside will allow for more fiberglass material which will This surface will have to be prepared for applica- strengthen the area. If the fracture opening is too tion of gelcoat.

  • Page 343: 3D Series

    Section 11 HULL/BODY Subsection 02 (3D SERIES) 3D SERIES SERVICE TOOLS Description Part Number Page DESS switch tool..............529 034 600 ......... 340 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......... 345 Loctite 271 (red) ..............293 800 005 ......... 342 Loctite 518................
  • Page 344 Section 11 HULL/BODY Subsection 02 (3D SERIES) Hull smr2005-069-011_aen smr2005-069 www.SeaDooManuals.net...
  • Page 345 Section 11 HULL/BODY Subsection 02 (3D SERIES) Body smr2005-069-012_aen smr2005-069 www.SeaDooManuals.net...
  • Page 346 Section 11 HULL/BODY Subsection 02 (3D SERIES) Engine Cover smr2005-069-013_aen smr2005-069 www.SeaDooManuals.net...
  • Page 347 Section 11 HULL/BODY Subsection 02 (3D SERIES) Moto Seat smr2005-069-014_aen smr2005-069 www.SeaDooManuals.net...
  • Page 348 Section 11 HULL/BODY Subsection 02 (3D SERIES) Kart Seat smr2005-069-015_aen smr2005-069 www.SeaDooManuals.net...

  • Page 349: General

    Section 11 HULL/BODY Subsection 02 (3D SERIES) GENERAL Install the seat post in its receiver and ensure it latches properly. Inspect latch mechanism for Verify hinges condition and latching mechanisms wear. Try pulling out the post without releasing condition and operation. Replace any damaged the latch.
  • Page 350 Section 11 HULL/BODY Subsection 02 (3D SERIES) 1. Lower cover Position seat post in the receiver. 2. Remove screws Using a plastic hammer, push moto seat axle no. 3 Unscrew DESS switch nut using the DESS switch out while holding seat.

  • Page 351: Kart Seat (If So Equipped)

    Section 11 HULL/BODY Subsection 02 (3D SERIES) To clean the carpets, use 3M™ Citrus Base Clean- er (24 oz spay can) or the equivalent. KART SEAT (if so equipped) Check seat tab and anchor plate for wear or dam- age. Check latch mechanism for tightness, wear, cracks or other damage.

  • Page 352: Rear Access Cover

    Section 11 HULL/BODY Subsection 02 (3D SERIES) smr2005-069-016_a 1. Vent tubes in optimal position smr2005-069-023_a 2. Engine 3. Hull Step 1: Install screws, sequence 1 to 4 Step 2: Install rivets, sequence 5 to 26 REAR ACCESS COVER INLET GRATE When reinstalling cover no.

  • Page 353: Riding Plate

    Section 11 HULL/BODY Subsection 02 (3D SERIES) Clean hull surface with solvent to eliminate grease, dust and any residue of sealant. Clean fitting threads. Installation Apply Loctite 5900 (P/N 293 800 066) as indicated by the shaded areas in the next illustration. Follow also the torquing sequence as shown in the same illustration.

  • Page 354: Drain Plug

    Section 11 HULL/BODY Subsection 02 (3D SERIES) Apply Loctite 5900 (P/N 293 800 066) as indicated by the shaded areas in the next illustrations. smr2005-069-019 Torque nuts to 31 N•m (23 lbf•ft) as per the fol- F05K02A lowing sequence. TYPICAL 1.

  • Page 355: Bumper

    Section 11 HULL/BODY Subsection 02 (3D SERIES) CAUTION: When drilling, be careful not to damage bumper rail and/or hull. – Position bumper rail no. 10 properly onto body and cut excess length if necessary. – Slide bumper rail no. 10 in corner bumper no.

  • Page 356: Bailer Pick-Ups

    Section 11 HULL/BODY Subsection 02 (3D SERIES) Clean any residues of silicone sealant on hull and sponson. Installation Apply silicone sealant (clear) (P/N 293 800 086) around sponson bolts. Install sponson and torque sponson nuts to 5 N•m (44 lbf•in).

  • Page 357: Decals Replacement

    Section 11 HULL/BODY Subsection 02 (3D SERIES) Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off. If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few sec- onds to let it cool, then peel it off.

  • Page 358: Hull And Body Repair

    Section 11 HULL/BODY Subsection 02 (3D SERIES) Remove front protective film once decal has ad- WARNING hered to hull. Protect skin, wear gloves when in contact INSTALLATION ON PLASTIC (storage cover) with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose Clean surface with isopropyl alcohol and dry thor- area to open flame or lit cigarette.
  • Page 359 Section 11 HULL/BODY Subsection 02 (3D SERIES) BUFFING AND WAXING Numerous Fractures Over Large Surface: Buff the surface using a heavy duty polisher with Prepare the area for spray application of liquid gel- a buffing pad. Make sure the pad is free of dirt coat.
  • Page 360 Section 11 HULL/BODY Subsection 02 (3D SERIES) Compound fractures are those that have gone Using a clean paintbrush, brush the mixed resin on past the gelcoated surface and in through the lay- the surface. Place the smallest piece of mat over ers of fiberglass laminate.

  • Page 361: Tools And Materials List

    Section 11 HULL/BODY Subsection 02 (3D SERIES) TOOLS AND MATERIALS LIST Tools – safety glasses – putty knife – air mask – plastic film – white cloths – stirring stick – sanding block – buffing pad – scissors – heavy-duty polisher –...

  • Page 362: Technical Specifications

    Section 12 TECHNICAL SPECIFICATIONS Subsection 01 (GTI MODELS) GTI MODELS ELECTRICAL SYSTEM Magneto generator output 160 W @ 6000 RPM Make and type NGK BR8ES Spark plug 0.4 - 0.5 mm (.016 - .020 in) mm (in) 2.59 ± 0.38 (.102 ± .015) Ignition timing (BTDC) Degrees 20°...
  • Page 363 Section 12 TECHNICAL SPECIFICATIONS Subsection 01 (GTI MODELS) PROPULSION Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned splines Oil type XP-S™ synthetic jet pump oil or SAE 75W90 GL5 Steering nozzle pivoting angle 20°...

  • Page 364: Gti Rfi And Gti Rfi Le Models

    Section 12 TECHNICAL SPECIFICATIONS Subsection 02 (GTI RFI AND GTI RFI LE MODELS) GTI RFI AND GTI RFI LE MODELS ELECTRICAL SYSTEM GTI RFI GTI RFI LE Wattage 270 W @ 6000 RPM Magneto generator output Amperage 7 A @ 6000 RPM / 13.5 volts Ignition system type Digital, inductive Make and type...
  • Page 365 Section 12 TECHNICAL SPECIFICATIONS Subsection 02 (GTI RFI AND GTI RFI LE MODELS) PROPULSION GTI RFI GTI RFI LE Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned splines Oil type...

  • Page 366: 3D Rfi Model

    Section 12 TECHNICAL SPECIFICATIONS Subsection 03 (3D RFI MODEL) 3D RFI MODEL ELECTRICAL SYSTEM 3D RFI 3D RFI PREMIUM Wattage 270 W @ 6000 RPM Magneto generator output Amperage 7 A @ 6000 RPM/13.5 volts Ignition system type Digital Inductive...
  • Page 367 Section 12 TECHNICAL SPECIFICATIONS Subsection 03 (3D RFI MODEL) PROPULSION 3D RFI 3D RFI PREMIUM Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Rubber coupling, split FR & RR Oil type XP-S™...
  • Page 368 Section 12 TECHNICAL SPECIFICATIONS Subsection 03 (3D RFI MODEL) PERFORMANCE 3D RFI 3D RFI PREMIUM Estimated pump power 42.6 kW (57 HP) Maximum fuel consumption at wide open throttle 38 L/h (10 U.S. gal/h) Fuel tank without reserve 47 minutes...

  • Page 369: Electrical Connectors And Wiring Diagrams

    Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) ELECTRICAL CONNECTORS SERVICE TOOLS Description Part Number Page crimper die................529 035 906 ......... 369 crimper die................529 035 908 ......... 365 crimping pliers ..............529 035 730 ......... 372 crimping tool.................

  • Page 370: Packard Connector

    Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) – Pull back on the terminal wire to be sure the retention fingers are holding the terminal. – After all required terminals have been inserted, the lock must be installed. MALE CONNECTOR 1.

  • Page 371: Amp Connector

    Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) WARNING Ensure all terminals are properly crimped on wires and connector are properly fastened. AMP CONNECTOR GTI Series with 717 Engine These connectors are found on the MPEM. When servicing electrical system, special care must be taken when working with AMP connec- tors in order to prevent any malfunction of the system.
  • Page 372 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Terminal Removal SIGNAL WIRE Insert a screwdriver blade between the connector and 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.
  • Page 373 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) CRIMPING TOOL All circuits are sealed by a diaphragm in the rubber wire seal. When installing a terminal in connector, the diaphragm is pierced as the terminal passes through it. If the diaphragm is pierced and the cavity is not used, install a seal plug, large end first, into circuit cavity as far as it will go.

  • Page 374: Ecm Connectors

    Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Terminal Installation AMP Connectors of Wiring Harness 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.
  • Page 375 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) 1. Push in tab Lift the cover by pushing it forward. smr2005-056-004_a ECM CONNECTORS IDENTIFICATION CAUTION: Do not disconnect the ECM connec- tors needlessly. They are not designed to be disconnected/reconnected frequently.
  • Page 376 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Insert the tool tip into the terminal cavity as shown, and locate its wire in the back of the con- nector. You may have to pry the tool tip against the locking tab to release it, then remove the terminal from the connector.
  • Page 377 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) When re-inserting the terminal, the locking tab To properly crimp the wires, strictly follow this pro- must be installed facing the smaller cutout of the cedure. terminal cavity. Strip the wire to a maximum of 3 mm (1/8 in). TYPICAL A.

  • Page 378: Vcm Connectors

    Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) NOTE: A small screw driver may be used to re- lease locking tab while pulling connector out. 1. Top of terminal tabs 2. Align tabs with pliers edge smr2005-073-001_a Crimp terminal.
  • Page 379 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Open housing by lifting 4 tabs. TYPICAL 1. Tabs (2 on each side) TYPICAL 1. VCM (vehicle control module) 2. Firmly push down this tab and hold while pulling out connector Lift the top plastic lock of the female terminal to be removed and hold in position.

  • Page 380: Battery And Starter Cable Connectors

    Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) BATTERY AND STARTER CABLE CONNECTORS Crimping Carefully strip the wire approximately to 10 mm (3/8 in) in length, using a wire stripping tool or sharp blade/knife. POSITIONING THE CRIMPING PLIERS Step 1: Press Step 2:...
  • Page 381 Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) CAUTION: Never weld the wire to the terminal. Welding can change the property of the wire and it can become brittle and break. Install the protective heat shrink rubber tube on the terminal.

  • Page 382: Wiring Diagrams

    The letter (g) indicates a common circuit with an- wire with a BLACK tracer. other wire(s) bearing the same letter (g) in the cir- cuit. GTI RFI, GTI RFI LE and 3D Series On the ECM, circuits are identified by a letter fol- smr2005-071-001_aen lowed by a number.
  • Page 383 NOTES www.SeaDooManuals.net...
  • Page 384 NOTES www.SeaDooManuals.net...
  • Page 385 NOTES www.SeaDooManuals.net...
  • Page 386 NOTES www.SeaDooManuals.net...
  • Page 387 2005 3 D MODEL smr2005-071-100_aen www.SeaDooManuals.net...
  • Page 388 2005 GTI MODEL smr2005-071-101_aen www.SeaDooManuals.net...
  • Page 389 2005 GTI RFI MODEL smr2005-071-102_aen www.SeaDooManuals.net...
  • Page 390 2005 GTI LE RFI MODEL smr2005-071-103_aen www.SeaDooManuals.net...
  • Page 391 www.SeaDooManuals.net...

This manual is also suitable for:

3d premiumGtiGti rfiGti rfi le195a195b ... Show all

Table of Contents

Save PDF