BOMBARDIER SEA-DOO SPX 5838 1998 Shop Manual
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BOMBARDIER SEA-DOO SPX 5838 1998 Shop Manual

BOMBARDIER SEA-DOO SPX 5838 1998 Shop Manual

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  • Page 2 Bombardier Inc. © Bombardier Inc. 1998 Printed in Canada ® *Registered trademarks of Bombardier Inc. ® Loctite is a trademark of Loctite Corporation ® Snap-on is a trademark of Snap-on Tools Corporation ®...
  • Page 3 TABLE OF CONTENTS PAGE SECTION SUBSECTION SAFETY NOTICE ........................... WHAT’S NEW ............................INTRODUCTION ........................... SERVICE TOOLS 01 - Mandatory service tools............01-01-1 02 - Optional service tools..............01-02-1 AND PRODUCTS 03 - Service products ............... 01-03-1 MAINTENANCE 01 - Table of contents ..............02-01-1 02 - Periodic inspection chart ............
  • Page 4 TABLE OF CONTENTS STEERING SYSTEM 01 - Table of contents ..............10-01-1 02 - SPX model ................10-02-1 03 - GTS model ................10-03-1 04 - GS, GSX Limited, GTI and GTX Limited........10-04-1 05 - XP Limited ................10-05-1 06 - Alignment .................
  • Page 5 Always use common shop safety practice. This information relates to the preparation and use of Bombardier watercraft and has been utilized safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
  • Page 6 WHAT’S NEW WHAT’S NEW SERVICE TOOLS AND PRODUCTS 01 • Complete new section. MAGNETO SYSTEM 04-04 • New procedure to lock crankshaft on the 947 engine. REMOVAL AND INSTALLATION 04-03 • New service tool for engine alignment procedure. TOP END 04-05 •...
  • Page 7 INTRODUCTION INTRODUCTION This Shop Manual covers BOMBARDIER made All Models ® SEA-DOO watercraft models SPX 5838/5839, The Hull Identification Number is composed of 9 GS 5626/5844, GSX Limited 5629/5845, XP Limit- digits: ed 5665/5667, GTS 5819, GTI 5836/5841and GTX Limited 5837/5842.
  • Page 8 INTRODUCTION 787 Engine ARRANGEMENT OF THIS MANUAL The Engine Identification Number is located on the upper crankcase on PTO side. The manual is divided into 14 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL SYSTEM...
  • Page 9 INTRODUCTION TYPICAL PAGE Page heading indicates section and subsection detailed. Subsection title indicates beginning of the Section 03 ENGINE Subsection 04 (MAGNETO SYSTEM) subsection. MAGNETO SYSTEM 717 Engine Italic sub-title above exploded 5 N•m view indicate Drop represents (44 lbf•in) pertaining models.
  • Page 10 INTRODUTION TYPICAL PAGE Sub-title with part number(s) from exploded view followed by part name(s). Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS) Title indicates main procedure to be CARBURETOR REMOVAL DISASSEMBLY AND INSPECTION carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly, lows: spring screw, check valve housing, etc.).
  • Page 11 Technical Publications Bombardier Inc. reserves the right at any time to Bombardier Inc. discontinue or change specifications, designs, Valcourt (Quebec), Canada features, models or equipment without incurring obligation.
  • Page 12 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS) MANDATORY SERVICE TOOLS NOTE: The numbers outlined in black (example: ) are reference numbers to tools from other divi- sions (Ski-Doo Snowmobiles and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.
  • Page 13 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS) Piston pin puller Puller P/N 529 035 503 P/N 295 000 106 A00C1A4 Puller plate P/N 290 876 080 F00B0T4 APPLICATION All engines. MAG side PTO side F01D884 Sleeve set A00C1R4 A) P/N 529 035 542 1) Puller...
  • Page 14 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS) Alignment support plate kit MPEM programmer Engine leak tester kit P/N 529 035 506 P/N 529 035 502 P/N 295 500 352 1) Alignment plates A) P/N 529 035 507 B) P/N 529 035 508 2) Support P/N 529 035 511...
  • Page 15 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS) Puller plate P/N 529 035 533 F00B0S4 APPLICATION 947 engine. Polygonal key P/N 529 035 505 F00B0Y4 APPLICATION Exhaust system of the 947 engine. 01-01-4...
  • Page 16 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Hose pincher Pliers P/N 295 000 076 P/N 295 000 054 Caillau F01B1T4 APPLICATION A01B2I4 All models. APPLICATION NOTE: This tool is also used for the propulsion system. All models.
  • Page 17 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS) PROPULSION SYSTEM Impeller remover/installer Bearing/seal installer VTS tool P/N 295 000 001 P/N 295 000 107 P/N 295 000 133 F01J0T4 APPLICATION F01B2P4 All models. APPLICATION NOTE: This tool is also used for SPX, GSX Limited and XP Limited.
  • Page 18 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS) OPTIONAL SERVICE TOOLS NOTE: The numbers outlined in black (example: ) are reference numbers to tools from other divi- sions (Ski-Doo Snowmobiles and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.
  • Page 19 All models except SPX and GTS. A) Four-pin magneto harness P/N 295 000 131 Timing mark pointer B) Six-pin magneto harness P/N 295 000 130 Terminal remover P/N 295 000 136 Not sold by Bombardier Snap-on TT 600-4 F01B1J4 APPLICATION F01B284 All models. APPLICATION F01B2O4 A) 717 engine.
  • Page 20 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS) Slide hammer puller Crankshaft protector Engine lifting device Not sold by Bombardier P/N 420 876 552 Not sold by Bombardier Snap-on:Handle CJ93-1 Do it yourself Hammer CJ125-6 Refer to 04-03 then look for...
  • Page 21 Use with coupler hose (P/N 295 APPLICATION F01B0X4 500 258). XP Limited. APPLICATION All models. Suspension adjustment wrench Lighted adjustable mirror P/N 529 012 200 Not sold by Bombardier Snap-on 50101 F01B1I4 APPLICATION All models. A25A014 APPLICATION XP Limited. Hose pincher P/N 529 032 500...
  • Page 22 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS) PROPULSION SYSTEM Fitting Machinist’s square Impeller housing remover P/N 295 000 086 Not sold by Bombardier P/N 295 000 113 Snap-on PMF 122 F01B0Z4 F02B064 APPLICATION APPLICATION All models.
  • Page 23 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS) WATERCRAFT HANDLING Dolly (with wheels) Lift kit P/N 295 000 126 P/N 295 100 044 F01B014 Beach wheels (set of 2 wheels) F00B0Z4 P/N 295 000 005 APPLICATION All models. Tie-down 1.50 m (5 ft) long P/N 295 100 010...
  • Page 24 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS) SERVICE PRODUCTS NOTE: The numbers outlined in black (example: ) are reference to product numbers from other divi- sions (Ski-Doo Snowmobiles and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same product is being used, even if the part numbers are different.
  • Page 25 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS) Gasket stripper Primer for gasket eliminator Sikaflex primer 449 P/N 295 000 110 P/N 293 800 041 P/N 293 530 012 (500 mL) Loctite (475 mL) B O M B AR D I E R G A S K ET STR IP P E R EX TR EME...
  • Page 26 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS) Dielectric grease Super Lube grease Bombardier storage oil P/N 293 550 004 P/N 293 550 014 P/N 413 711 600 Dow Corning (12 x 350 g) (150 g) P ERMATE X...
  • Page 27 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS) BOMBARDIER-ROTAX BOMBARDIER-ROTAX Formula Adhesive activator injection oil XP-S P/N 293 530 036 synthetic injection oil P/N 413 802 900 (250 mL) P/N 413 711 000 (3 x 4 L) (12 x 1 L) P/N 413 710 700 (205 L) ®...
  • Page 28 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS) SMC spray paint Sea-Doo spray paint for gelcoat Gelcoat (liquid) A) Purple night metallic A) Super white (140 g) A) Super white (1 L) P/N 293 500 120 P/N 293 500 082 P/N 293 500 075 B) Norwegian sea metallic B) Viper red (140 g)

  • Page 29: Table Of Contents

    Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART.................... 02-02-1 FLUSHING AND LUBRICATION.................... 02-03-1 GENERAL ........................... 02-03-1 PROCEDURE ........................02-03-1 WATER-FLOODED ENGINE....................02-04-1 GENERAL ........................... 02-04-1 PROCEDURE ........................02-04-1 STORAGE..........................02-05-1 GTX RFI 02-01-1...

  • Page 30: Periodic Inspection Chart

    Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency. FREQUENCY Every DESCRIPTION Every Every Every 100 hours or 10 hours 25 hours 50 hours seasonally Lubrication/corrosion protection of metallic components Engine ignition timing Spark plug replacement...

  • Page 31: Flushing And Lubrication

    Do not touch any electrical parts or jet pump area when engine is running. Clean jet pump by spraying water in its inlet and outlet and then spray BOMBARDIER LUBE lubri- cant. WARNING Always remove safety lanyard cap from switch to prevent accidental engine starting before cleaning the jet pump area.
  • Page 32 Run the engine about 3 minutes at a fast idle around 3500 RPM. Spray BOMBARDIER LUBE lubricant through air intake silencer keeping engine at fast idle. F00E01A 1. Quick connect adapter...
  • Page 33 Serious engine damage can occur if hose 1. Air intake silencer pincher is not removed. 2. Pull plug 3. Spray BOMBARDIER LUBE here All Models Except SPX and GTS Models CAUTION Remove quick connect adapter after flush- ing operation (if used).
  • Page 34 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) F01H64A GTS MODEL F00H0AA 1. Spark plug cables on grounding device XP LIMITED 1. Grounding device F00H0DA SPX, GS AND GTI MODELS F06H1WA 1. Spark plug cables on grounding device GSX LIMITED 1.
  • Page 35 Reinstall plug on air intake silencer cover (SPX, GS, GTS and GTI models). NOTE: Engine fogging should be done with BOMBARDIER LUBE lubricant whenever the wa- tercraft is to be stored for a few days or a long period. CAUTION Never leave rags or tools in the engine com- partment or in the bilge.

  • Page 36: Water-Flooded Engine

    Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE GENERAL If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise en- gine will have to be overhauled. CAUTION A water-flooded engine must be properly lu- bricated, operated then lubricated again, otherwise parts will be seriously damaged.
  • Page 37 Be careful when cranking engine, water will side of the lower crankcase. spray out from spark plug holes. Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into spark plug holes. Crank engine again. Reinstall spark plugs and spark plug cables.
  • Page 38 Engine must be cooled using the flush kit. Check crankshaft if needed, it may be misaligned or deflected. Refer to BOTTOM END 04-06. After engine has started, spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running. 02-04-3...

  • Page 39: Storage

    Section 02 MAINTENANCE Subsection 05 (STORAGE) STORAGE Engine Draining Cooling System Flushing and Engine Internal Lubrication Check engine drain hose (lowest hose of engine). Make sure there is no sand or other particles in it Cooling system has to be flushed with fresh wa- and that it is not obstructed so that water can ter to prevent salt, sand or dirt accumulation leave the engine.
  • Page 40 Anticorrosion Treatment Wipe off any residual water in the engine com- partment. Spray BOMBARDIER LUBE lubricant over all me- tallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant. The seat should be partially left opened during storage (the engine cover for the XP model).
  • Page 41 Section 02 MAINTENANCE Subsection 05 (STORAGE) Additional Recommended Protection In cool regions (where freezing point may be en- countered), cooling system should be filled with water and antifreeze solution. CAUTION Always use ethylene-glycol antifreeze con- taining corrosion inhibitors specifically rec- ommended for aluminum engines.
  • Page 42 Section 02 MAINTENANCE Subsection 05 (STORAGE) Disconnect engine water return hose. F06E0FA 717 AND 787 ENGINES F06E0EA 1. Hose pincher installed on the engine water supply hose 717 AND 787 ENGINES 1. Disconnect engine water return hose Temporarily install a short piece of hose to engine water outlet at cylinder head.
  • Page 43 Section 03 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 have all causes for all problems. ENGINE WILL NOT START OTHER OBSERVATION POSSIBLE CAUSE REMEDY...
  • Page 44 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace • Faulty rev limiter or ignition module • Check, refer to subsection 08-02 •...
  • Page 45 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE CONTINUALLY BACKFIRES OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective spark plugs • Clean/replace • Malfunction of rev limiter • Clean/replace, refer to subsection 08-02 Ignition timing • Incorrect setting •...
  • Page 46 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE RUNS TOO FAST OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine RPM too high • Faulty rev limiter • Check, refer to subsection 08-02 • Improper impeller pitch (too low) • Check/replace, refer to subsection 09-02 Jet pump cavitation •...
  • Page 47 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST..........................04-02-1 GENERAL ........................... 04-02-1 PREPARATION ........................04-02-1 TESTING PROCEDURE ..................... 04-02-1 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............04-02-6 REMOVAL AND INSTALLATION..................04-03-1 GENERAL ........................... 04-03-1 ENGINE REMOVAL ......................04-03-1 CLEANING .........................
  • Page 48 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) EXHAUST SYSTEM ....................... 04-08-1 REMOVAL ........................... 04-08-4 TUNED PIPE REPAIR ......................04-08-8 INSTALLATION ........................04-08-8 04-01-2 GTX RFI...

  • Page 49: Leak Test

    Section 04 ENGINE Subsection 02 (LEAK TEST) LEAK TEST GENERAL PREPARATION NOTE: The leak test kit was not upgraded for the Verify fuel system for leaks. 947 engine at time of printing. A Service Bulletin will be issued. WARNING A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) If any fuel leak is found, do not start the en- is available to help diagnose engine problems gine.
  • Page 50 Section 04 ENGINE Subsection 02 (LEAK TEST) F01B2UB F01B2WA 717 ENGINE — REAR VIEW 787 ENGINE 1. Engine drain hose blocked with a hose pincher 1. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3.
  • Page 51 Section 04 ENGINE Subsection 02 (LEAK TEST) Bottom End and Top End Remove the carburetor(s) and gasket(s). Make sure the surface of the intake manifold (717 en- gine) or rotary valve cover (787 engine) are clean. Install the intake plate(s) no. 3 with fasteners from the kit and tighten adequately.
  • Page 52 Section 04 ENGINE Subsection 02 (LEAK TEST) Check also small oil injection pump lines and fit- tings; check for air bubbles or oil column going to- ward pump, which indicate a defective check valve. If the above mentioned components are not leak- ing, block both oil hoses of the rotary valve shaft using hose pinchers.
  • Page 53 Section 04 ENGINE Subsection 02 (LEAK TEST) F01B34A 787 ENGINE 1. Pump with reducer and nipple Activate pump and pressurize to 5 PSI (34 kPa). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal.

  • Page 54: Engine Leakage Diagnostic Flow Chart

    Section 04 ENGINE Subsection 02 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART PRESSURIZE ENGINE COOLING SYSTEM CHECK TESTING KIT IS SYSTEM LEAKING? REPLACE O-RING OF CYLINDER HEAD PRESSURIZE ENGINE AND/OR CYLINDER BASE GASKET IS ENGINE LEAKING? RECHECK ENGINE SEALING CHECK TESTING KIT CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS.

  • Page 55: Removal And Installation

    Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL All Models Disconnect temperature switch wire and spark It is not necessary to remove engine from water- plug cables. craft to service TOP END, PTO FLYWHEEL or Disconnect magneto wiring harness. MAGNETO.
  • Page 56 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) F02D08A F07D08A 947 ENGINE 717 ENGINE 1. Unplug connector 1. Remove screw of each engine support Cooling System Disconnect the engine water supply hose. Disconnect the engine water return hose. Tuned Pipe To remove tuned pipe, refer to EXHAUST SYS- TEM 04-08.
  • Page 57 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Lifting Engine 787 and 947 Engines Engine can be easily lifted by inserting a hook into 717 Engine exhaust manifold eyelet. Engine can be easily lifted using the following suggested tools: – Cut porcelain from 2 old spark plugs. –...

  • Page 58: Cleaning

    Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) All Engines Install a hose pincher to oil supply hoses of oil in- jection pump and rotary valve shaft (except the 947 engine); then, disconnect hoses. F01D7RA TYPICAL A01B2JB CLEANING TYPICAL Wipe off any spillage in bilge. Clean with a bilge 1.
  • Page 59 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Engine Support Positive Starter Cable Torque nut of positive starter cable to 6 N•m 717 Engine (53 lbf•in). Apply dielectric grease on nut. Torque front and rear engine supports as shown in the following illustration.
  • Page 60 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) XP Limited On this model, the PTO flywheel adapter (P/N 295 000 157) must be used in conjunction with the alignment shaft. F00B05A 1. Adapter (P/N 295 000 157) F07D05A NOTE: Ensure the mid bearing is removed to TYPICAL check engine alignment.
  • Page 61 REAR ENGINE SUPPORT — 787 AND 947 ENGINES 1. Torque to 25 N•m (18 lbf•ft) Loctite Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. F02D0KA After its installation, properly adjust and bleed oil 717 ENGINE injection pump as specified in OIL INJECTION 1.

  • Page 62: Magneto System

    Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engine 5 N•m (44 lbf•in) 9 N•m (80 lbf•in) Loctite Loctite 6 N•m (53 lbf•in) Loctite 6 N•m (53 lbf•in) 6 N•m (53 lbf•in) Loctite 242 GTS model Loctite only 4 N•m (35 lbf•in) Loctite...
  • Page 63 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 787 Engine Loctite 242 Lithium grease 10 N•m (88 lbf•in) Loctite 648 10 N•m (88 lbf•in) Loctite 648 Loctite 242 105 N•m (77 lbf•ft) 4.5 N•m (40 lbf•in) 10 N•m (88 lbf•in) 10 N•m (88 lbf•in) 9 N•m (80 lbf•in)
  • Page 64 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 947 Engine 9 N•m (80 lbf•in) Loctite 242 Anti-seize lubricant 13 N•m (115 lbf•in) Loctite 242 9 N•m (80 lbf•in) Loctite 242 Loctite 648 115 N•m (85 lbf•ft) 13 N•m (115 lbf•in) Loctite F06D0IS PARTS FLAT RATE...

  • Page 65: General

    Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) GENERAL The following procedures can be performed with- out removing engine from watercraft. DISASSEMBLY 717 Engine 1, Magneto Housing Cover Remove screws no. 2 and wire support no. 17, then withdraw cover. 4,5, Magneto Flywheel and Ring Gear Magneto flywheel is locked with puller plate (P/N F01D48A 290 876 080), sleeves (P/N 290 847 220) and ex-...
  • Page 66 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Magneto flywheel is easily freed from crankshaft 4,5, Magneto Flywheel and Ring Gear with puller (P/N 295 000 106). Lay magneto flywheel on a steel plate. Tap lightly on ring gear using a hammer to release it from magneto flywheel.
  • Page 67 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) – Remove screws. – Uncrimp and unsolder YELLOW and YELLOW/ BLACK wires from coil. – Uncrimp and unsolder ground wire (BLACK) from coil core. A25E0QA 1. Uncrimp and unsolder wire here 13, Battery Charging Coil To replace battery charging coil: –...
  • Page 68 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) – Find manufacturer’s mark on armature plate. In line with this mark, punch another mark on ad- jacent crankcase lug. F01D4DA 1. Crankcase locating lug 2. Mark armature plate at the end of lug F01D4FA –...
  • Page 69 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 787 Engine 1, Magneto Housing Cover Loosen screws no. 2. Remove engine magneto cover. Remove oil pump shaft from flywheel nut. 4,5, Rotor and Flywheel Remove starter. Refer to STARTING SYSTEM 08-04. NOTE: Crankshaft can also be locked by using the PTO flywheel.
  • Page 70 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 947 Engine 1, Cover Loosen screws no. 2. Remove engine magneto cover. F06D0LA 1. Screw To remove the flywheel/rotor assembly, unscrew nut no. 6 counterclockwise when facing it. F06D1RA 1. Cover 2. Screw Remove oil pump shaft from flywheel nut.

  • Page 71: Cleaning

    Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) CLEANING Clean all metal components in a solvent. CAUTION Clean coils and magnets using only a clean cloth. Clean crankshaft taper and threads. ASSEMBLY 717 Engine 11, Generating Coil Strip end of old wire then crimp and solder on F06D0PA new coil.
  • Page 72 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 13, Battery Charging Coil Whenever replacing either ring gear or magneto flywheel, Gun Kote must be applied to prevent Position new coil, crimp and solder all wires. possible corrosion. Prior to assembly, apply Loctite 242 (blue). CAUTION Use magneto coil centering tool (P/N 290 876 922) and install it so that it fits around armature...
  • Page 73 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) CAUTION Never use any type of impact wrench at mag- neto installation. Ignition Timing For ignition timing procedures of the 717 engine, refer to IGNITION SYSTEM 08-02. 1, Magneto Housing Cover Properly install O-ring no. 3 in magneto housing. Apply Loctite 767 anti-seize on screws no.
  • Page 74 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 105 N•m (77 lbf•ft). CAUTION Never use any type of impact wrench at mag- neto installation. 1, Cover Before installation, properly install O-ring no.
  • Page 75 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 4,5, Rotor and Flywheel Install flywheel and make sure to align keyway with the crankshaft Woodruff key. Apply Loctite 648 (green) on mating surface of the Apply Loctite 242 (blue) on nut no. 6. Install nut rotor no.

  • Page 76: Top End

    Section 04 ENGINE Subsection 05 (TOP END) TOP END 717 Engine 24 N•m Loctite 242 (17 lbf•ft) Synthetic grease Synthetic grease 24 N•m (17 lbf•ft) Loctite Loctite rollers Synthetic grease rollers Synthetic grease F00D0DT PARTS FLAT RATE 04-05-1...
  • Page 77 Section 04 ENGINE Subsection 05 (TOP END) 787 Engine Loctite 242 24 N•m (17 lbf•ft) Synthetic grease Synthetic grease Synthetic 40 N•m grease (30 lbf•ft) Loctite Loctite 24 23 34 rollers Synthetic grease Synthetic grease 34 rollers F01D7DU PARTS FLAT RATE 04-05-2...
  • Page 78 Section 04 ENGINE Subsection 05 (TOP END) 947 Engine 34 N•m Loctite (25 lbf•ft) Synthetic grease 34 N•m (25 lbf•ft) Synthetic grease Loctite 29 28 27 5 N•m (44 lbf•in) Loctite Loctite 9 N•m (80 lbf•in) rollers Synthetic grease F06D17T PARTS FLAT RATE 04-05-3...

  • Page 79: General

    BOMBARDIER-ROTAX has patented a remark- ably simple system to automatically change the exhaust port height based on pressure in the ex- haust system (and RPM for the 947 engine).
  • Page 80 Section 04 ENGINE Subsection 05 (TOP END) F01D7HA VALVE FULLY CLOSED 947 Engine On this engine, the RAVE valves are controlled by the Multi-Purpose Electronic Module (MPEM). The MPEM measures 2 factors to control the RAVE valves: engine speed (RPM) and its rate of acceleration.
  • Page 81 Section 04 ENGINE Subsection 05 (TOP END) F06D16S RAVE VALVE OPENED 1. Pulse from crankcase 2. Check valve 3. Positive pressure to solenoid 4. Solenoid activated 5. Positive crankcase pressure to RAVE valves 04-05-6...
  • Page 82 Section 04 ENGINE Subsection 05 (TOP END) F06D16T RAVE VALVE CLOSED 1. Pulse from crankcase 2. Check valve 3. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. RAVE valves are opened to atmosphere 04-05-7...

  • Page 83: Disassembly

    Section 04 ENGINE Subsection 05 (TOP END) 787 and 947 Engines MAINTENANCE There are no wear parts anywhere in the system The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so and there are no adjustments to be periodically equipped, it can make moving the peak horse- checked.
  • Page 84 Section 04 ENGINE Subsection 05 (TOP END) F01D8MA 1. Unscrew piston 2. Hold sliding valve F01D8HA 947 Engine 1. Spring Loosen Allen screws no. 26 and remove RAVE Loosen Allen screws no. 26 each side of RAVE valve. valve. F06D0QA F01D8IA 1.
  • Page 85 Section 04 ENGINE Subsection 05 (TOP END) Remove RAVE valve no. 15. Remove spring no. 30 retaining bellows no. 21 to valve piston no. 20. Remove the cover no. 18 of the valve by releasing the spring no. 16. WARNING Firmly hold cover to valve base.
  • Page 86 Section 04 ENGINE Subsection 05 (TOP END) Unscrew valve piston no. 20 from sliding valve Remove supporting ring no. 28. no. 22. NOTE: Hold the sliding valve to prevent it from turning. F06D27A 1. Remove supporting ring F06D0TB Remove O-ring no. 23. 1.
  • Page 87 Section 04 ENGINE Subsection 05 (TOP END) Remove sliding valve no. 22. If shells, sand, salt or any other particles are present in cylinder head, clean with a vacuum cleaner. Remove cylinder head no. 2. If shells, sand, salt water or any other particles are present in cylinder cooling jacket, clean with a vacuum cleaner.
  • Page 88 Section 04 ENGINE Subsection 05 (TOP END) Remove cylinder head no. 2. Remove cylinder head gasket no. 34. F06D2BA 1. Remove studs F06D0YA Remove cylinder block no. 9. 1. Remove gasket 9, Cylinder 787 Engine Remove air intake silencer and support, refer to AIR INTAKE 06-03.
  • Page 89 Section 04 ENGINE Subsection 05 (TOP END) All Engines To remove circlip no. 5, insert a pointed tool in pis- ton notch then pry it out and discard. WARNING Always wear safety glasses when removing piston circlips. F01B0JA 1. Rubber pad (P/N 295 000 101) If the other cylinder has been removed, complete- ly cover its opening with a clean rag.
  • Page 90 Section 04 ENGINE Subsection 05 (TOP END) – Fully thread on puller handle. – Insert extractor spindle into the piston pin. – Slide the sleeve and shoulder sleeve onto the spindle. – Screw in extracting nut with the movable ex- tracting ring towards spindle.

  • Page 91: Cleaning

    Section 04 ENGINE Subsection 05 (TOP END) The inspection of engine top end should include the following measurements. TOLERANCES ENGINE NEW PARTS WEAR MEASUREMENT (min.) (max.) LIMIT 0.05 mm 0.1 mm Cylinder Taper N.A. (.002 in) (.004 in) Cylinder Out 0.008 mm 0.08 mm N.A.
  • Page 92 Section 04 ENGINE Subsection 05 (TOP END) Piston/Cylinder Wall Clearance To determine the piston dimension, take the mea- surement on the piston dome. F00D0EA F01D8AA 1. Piston dome 1. Measuring perpendicularly (90 ° ) to piston pin axis 2. Piston measurement 2.
  • Page 93 Section 04 ENGINE Subsection 05 (TOP END) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the micrometer, otherwise the reading will be false.
  • Page 94 Section 04 ENGINE Subsection 05 (TOP END) 717 Engine GASKET IDENTIFICATION THICKNESS HOLES 0.3 mm (.012 in) 0.5 mm (.020 in) 0.6 mm (.024 in) 787 Engine F01D0OA IDENTIFICATION GASKET 1. Top of cylinder THICKNESS HOLES 2. Ring end gap 0.3 mm 10, Cylinder Base Gasket (.012 in)

  • Page 95: Assembly

    Section 04 ENGINE Subsection 05 (TOP END) 15, RAVE Valve Install a new gasket no. 24. It must be installed at the same time as the sliding valve no. 22. 787 and 947 Engines Position the valve housing no. 25 onto the cylin- Check RAVE valve bellow no.
  • Page 96 Section 04 ENGINE Subsection 05 (TOP END) NOTE: On the 787 and 947 engines, the exhaust ports are located on the same side as the intake. Carefully cover crankcase opening as for disas- sembly. 4,6, Piston Pin and Roller Bearing To install roller bearing and piston pin use, piston pin puller (P/N 529 035 503) with the appropriate set of sleeves as for disassembly.
  • Page 97 Section 04 ENGINE Subsection 05 (TOP END) – Insert extractor spindle into the piston pin, – Make sure thrust washers are present each screw on extracting nut. side of rollers. F01D0VA F00B0PA 1. Puller installed on the opposite side of the piston pin 1.
  • Page 98 Section 04 ENGINE Subsection 05 (TOP END) 717 and 787 Engines Secure circlip with its opening located at the bot- tom of the piston. CAUTION To minimize the stress on the circlips, it is important to install them as described. F01D0SA –...
  • Page 99 Section 04 ENGINE Subsection 05 (TOP END) All Engines To easily insert circlip into piston, use circlip in- staller. ENGINE TOOL P/N 717 and 787 290 877 016 290 877 518 F00B0RA CAUTION The hand retaining the piston should absorb the energy to protect the connecting rod.
  • Page 100 Section 04 ENGINE Subsection 05 (TOP END) 717 Engine The aligning tool (P/N 290 876 902) or the exhaust manifold can be used to align cylinders. F01D0ZA 1. Ring end gap aligned with piston locating pin Slide cylinder over piston. F01D44A 717 ENGINE 1.
  • Page 101 Section 04 ENGINE Subsection 05 (TOP END) 787 Engine The exhaust manifold is used to align cylinders. A01B1TA 1. Slide this edge NOTE: For each ring, make sure to align ring end gap with piston locating pin. Install cylinder block. Install O-rings no.
  • Page 102 Section 04 ENGINE Subsection 05 (TOP END) 787 Engine Apply Loctite 518 in O-ring groove of cylinder sleeves. Prior installation, apply synthetic grease below screw head and Loctite 518 on screw threads. Install cylinder head. Install M10 x 105 screws on exhaust side and the 947 Engine M10 x 73.5 on opposite side.

  • Page 103: Adjustment

    Section 04 ENGINE Subsection 05 (TOP END) 947 Engine Turn the red plastic knob no. 17 until it is fully tightened. F01D46A TORQUING SEQUENCE F00D0WA 1. Knob fully tightened ADJUSTMENT This will ensure the correct preload on the return RAVE Valve spring no.
  • Page 104 Section 04 ENGINE Subsection 05 (TOP END) NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be lev- eled. 1. Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge.

  • Page 105: Bottom End

    Section 04 ENGINE Subsection 06 (BOTTOM END) BOTTOM END 717 Engine Loctite Lithium grease Anti-seize lubricant Loctite Anti-seize lubricant Anti-seize lubricant Loctite Loctite 24 N•m (17 lbf•ft) Lithium grease Synthetic Loctite grease Loctite Synthetic grease 24 N•m (17 lbf•ft) 10 N•m 40 N•m (88 lbf•in) (30 lbf•ft)
  • Page 106 Section 04 ENGINE Subsection 06 (BOTTOM END) 787 Engine 30 mL (1 oz) SAE 30 Loctite motor oil Anti-seize lubricant Lithium grease Lithium grease Anti-seize lubricant Loctite Anti-seize Anti-seize lubricant lubricant Lithium grease Loctite Loctite Loctite Synthetic grease Anti-seize Synthetic Loctite 24 N•m lubricant...
  • Page 107 Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engine 40 mL (1.35 oz) SAE 30 motor oil Synthetic Synthetic grease grease Loctite Loctite 242 Loctite Loctite Anti-seize lubricant Synthetic 9 N•m (80 lbf•in) 9 N•m grease Loctite Anti-seize (80 lbf•in) lubricant Loctite Loctite...

  • Page 108: Disassembly

    Section 04 ENGINE Subsection 06 (BOTTOM END) DISASSEMBLY Engine has to be removed from watercraft to open bottom end. Refer to REMOVAL AND INSTALLA- TION 04-03. NOTE: Before proceeding with the disassembly of the engine, it is possible to make a few verifica- tions.
  • Page 109 Section 04 ENGINE Subsection 06 (BOTTOM END) Using a suitable socket with a breaker bar, lock crankshaft. Loosen Allen screws no. 21 of coupler no. 20. F00B04A Install special tool. F06D37A 1. Loosen Allen screws 2. Breaker bar locking crankshaft Remove the coupler no.
  • Page 110 Section 04 ENGINE Subsection 06 (BOTTOM END) GSX Limited, XP Limited and GTX Limited NOTE: Puller plate can be used without the ex- tension handle. Install puller plate (P/N 529 035 533) and exten- sion handle (P/N 295 000 125) to PTO flywheel. 27, Starter Drive Assembly NOTE: Puller plate can be used without the ex- 947 Engine Only...
  • Page 111 Section 04 ENGINE Subsection 06 (BOTTOM END) 28, Reed Valve 947 Engine Place engine upright on crankcase magneto side. 947 Engine Only Loosen crankcase screws. Remove both carburetor flanges. F06D0JA 1. Carburetor flange Remove reed valves from crankcase. F07D09A 5, Seal All Engines If a crankshaft end seal has to be replaced, bot- Put engine back on a support.
  • Page 112 Section 04 ENGINE Subsection 06 (BOTTOM END) F01B09A 717 ENGINE F01D1LA 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) TYPICAL 3. Distance ring, MAG side only (P/N 290 876 569) 1. Separate halves by prying at provided lugs 4.
  • Page 113 Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engine To remove end bearings from crankshaft, use the following tools. F06B03A 947 ENGINE 1. Puller (P/N 420 877 635) F01D1PA 2. Protective cap (P/N 290 877 414) 3. Distance ring (P/N 290 876 569) 1.
  • Page 114 Section 04 ENGINE Subsection 06 (BOTTOM END) F00B0CA 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) 3. Ring (P/N 290 977 480) 4. Ring halves (P/N 290 876 330) 5. Screw M8 x 40 (P/N 290 840 681) F00D0IA 1.

  • Page 115: Cleaning

    Section 04 ENGINE Subsection 06 (BOTTOM END) Use a press to remove the gear no. 14 from the CLEANING counterbalance shaft. Discard all oil seals, gaskets, O-rings and sealing rings. Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent.
  • Page 116 – Remove flywheel nut (and magneto rotor for the 787 and 947 engines). Refer to MAGNETO SYSTEM 04-04 for procedures. – Install Bombardier degree wheel (P/N 295 000 007) on crankshaft end. Hand-tighten nut only. – Remove both spark plugs.
  • Page 117 Section 04 ENGINE Subsection 06 (BOTTOM END) Connecting Rod Straightness Align a steel ruler on edge of small end connect- ing rod bore. Check if ruler is perfectly aligned with edge of big end. F01D1TA 1. Measuring MAG side deflection in crankcase Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated.
  • Page 118 Section 04 ENGINE Subsection 06 (BOTTOM END) Connecting Rod Big End Axial Play 28, Reed Valve 947 Engine NEW PARTS WEAR MEASUREMENT LIMIT Check reed valve petals no. 29 for cracks or other (min.) (max.) defects. The reed petals must lie completely flat Connecting rod 0.390 mm 0.737 mm...

  • Page 119: Assembly

    Section 04 ENGINE Subsection 06 (BOTTOM END) NOTE: Distance should be the same on both sides. Bent stopper as required to obtain the proper dis- tance. ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures. However pay particular attention to the following.
  • Page 120 Section 04 ENGINE Subsection 06 (BOTTOM END) F00D0MA 1. Keyway 2. Long flange toward the crankshaft counterweight F06D1LA 1. Seal lip in crankcase recess 5, Seal 6, Drive Pin At seal assembly, apply a light coat of lithium grease on seal lips. Make sure drive pins of bearings are properly in- stalled in crankcase recesses at assembly.
  • Page 121 Section 04 ENGINE Subsection 06 (BOTTOM END) Proceed as follows to check if the gear no. 14 is 947 Engine properly positioned on the counterbalance shaft: Install bearing no. 31 and washer no. 32. – Temporarily install the counterbalance shaft in When installing seals no.
  • Page 122 Section 04 ENGINE Subsection 06 (BOTTOM END) F06D1MA F06D1OA 947 ENGINE 1. Seal in place 1. Marks must be aligned 2, Crankcase Turn by hand the crankshaft and counterbalance shaft. Make sure they do not interfere with the All Engines crankcase.
  • Page 123 Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engine 7,8,9, Crankcase Screw Make sure all locating dowels are in place. 717 Engine Apply Loctite 518 on screw threads and synthetic grease below head screws. Torque crankcase screws to 24 N•m (17 lbf•ft) as per following illustrated sequence.
  • Page 124 Section 04 ENGINE Subsection 06 (BOTTOM END) F01D81A As a final step, torque only M10 screws no. 8 of F07D09B crankcase to 40 N•m (30 lbf•ft) as per following As a final step, torque only the M10 x 73.5 bolts sequence.
  • Page 125 Section 04 ENGINE Subsection 06 (BOTTOM END) 11, Fitting 1, PTO Flywheel 717 and 787 Engines 787 Engine If inlet and outlet oil fittings of rotary valve shaft Install O-ring onto crankshaft. have been removed from crankcase, reinstall them with their ends pointing toward ignition housing.
  • Page 126 Section 04 ENGINE Subsection 06 (BOTTOM END) Final Assembly 717 and 787 Engines For rotary valve timing and assembly procedures, refer to ROTARY VALVE 04-07. 787 Engine When engine assembly is completed, add 30 mL (1oz) of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug.

  • Page 127: Rotary Valve

    Section 04 ENGINE Subsection 07 (ROTARY VALVE) ROTARY VALVE 717 and 787 Engines Lithium grease 787 Engine 20 N•m (15 lbf•ft) 717 Engine 20 N•m (15 lbf•ft) F01D7SS PARTS FLAT RATE 04-07-1...
  • Page 128 Section 04 ENGINE Subsection 07 (ROTARY VALVE) GENERAL The following verification procedures such as clear- ance of rotary valve cover or rotary valve shaft gear backlash can be performed without remov- ing engine from watercraft. However engine must be removed from water- craft to work on rotary valve shaft/components.
  • Page 129 Section 04 ENGINE Subsection 07 (ROTARY VALVE) F01D3PA TYPICAL 1. Solder If rotary valve cover clearance is out of specifica- F01D3OA tion, machine rotary valve cover seating surface SAME AMOUNT REMOVED FROM COVER SEATING SURFACE or replace the cover. AND O-RING GROOVE BASE 1.
  • Page 130 Section 04 ENGINE Subsection 07 (ROTARY VALVE) DISASSEMBLY 3, Rotary Valve Shaft To remove the rotary valve shaft assembly, first remove snap ring no. 4 from crankcase. F01D61A 1. Hold bolt F01D22A 1. Removing snap ring CAUTION Bottom end must be opened to remove rota- ry valve shaft.
  • Page 131 Section 04 ENGINE Subsection 07 (ROTARY VALVE) 8, Bearing Snap-on hammer puller including: Handle CJ93-1 To remove bearing use a bearing extractor such as Snap-on no CJ-950 as illustrated. Slide off dis- Hammer CJ125-6 tance sleeve, remove snap ring no. 7 and press Claws CJ93-4 shaft out.
  • Page 132 Section 04 ENGINE Subsection 07 (ROTARY VALVE) INSPECTION Deflection must not exceed 0.08 mm (.003 in). Replace shaft as necessary. 1, Rotary Valve Cover ASSEMBLY Inspect rotary valve cover for warpage. Small de- formation can be corrected by surfacing with fine Assembly is essentially the reverse of disassem- sand paper on a surface plate.
  • Page 133 Section 04 ENGINE Subsection 07 (ROTARY VALVE) F01D2DA 1. Shield side (toward gear) A13C0FB Push bearing until it stops on its seat. 1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950 Install shim no. 15, snap ring no. 7 and slide dis- tance sleeve no.
  • Page 134 Section 04 ENGINE Subsection 07 (ROTARY VALVE) 717 Engine Push shaft until it stops on bearing seat. To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 605). A00C0YA 1. Pusher Push shaft until its stops on bearing seat. F01D8OA 717 and 787 Engines 4, Snap Ring...
  • Page 135 Section 04 ENGINE Subsection 07 (ROTARY VALVE) F01D73V 1. 159º ROTARY VALVE TIMING CAUTION 295 000 007 Never use the ridge molded in crankcase as a timing mark. The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston.
  • Page 136 Section 04 ENGINE Subsection 07 (ROTARY VALVE) Rotary valve must be set so that timing occurs as follows: TIMING ENGINE OPENING CLOSING BTDC ATDC 147° 147° ± 5 65.5° ± 5 147° ± 5 63.5° ± 5 For the following instructions, let’s use these specifications as example: OPENING: 147°...
  • Page 137 NOTE: Rotary valve is asymmetrical. Therefore, try flipping it over then reinstall on splines to ob- tain best installation position. Apply BOMBARDIER-ROTAX injection oil on rota- ry valve before reassembling rotary valve cover. – Remove TDC gauge. 1, Rotary Valve Cover Install O-ring no.

  • Page 138: Exhaust System

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) EXHAUST SYSTEM SPX Model 25 N•m 25 N•m (18 lbf•ft) (18 lbf•ft) Loctite Loctite Loctite 518 Loctite Loctite 40 N•m (30 lbf•ft) sealant 40 N•m (30 lbf•ft) 10 N•m (88 lbf•in) Synthetic grease Loctite 242 4 N•m 40 N•m...
  • Page 139 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) GS, GTS and GTI Models 25 N•m Loctite 242 (18 lbf•ft) 25 N•m Loctite 242 (18 lbf•ft) Synthetic grease 25 N•m 24 N•m (18 lbf•ft) (17 lbf•ft) Loctite 10 N•m (88 lbf•in) 4 N•m (35 lbf•in) 4 N•m (35 lbf•in)
  • Page 140 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) GSX Limited, XP Limited and GTX Limited 23 N•m (17 lbf•ft) 2 N•m (18 lbf•in) 4 N•m sealant (35 lbf•in) 2 N•m (18 lbf•in) 4 N•m (35 lbf•in) 14 N•m sealant (10 lbf•ft) Loctite Loctite 242 Loctite 271...

  • Page 141: Removal

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) REMOVAL Remove tuned pipe retaining screw no. 6 from exhaust manifold side. Tuned Pipe Remove screws no. 7, nut no. 8 and flat washers no. 9 from tuned pipe flange. SPX, GS and GSX Limited NOTE: Slightly lift tuned pipe to release nut as Remove seat.
  • Page 142 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Remove retaining screw no. 20 of tuned pipe Remove exhaust hose no. 3 from tuned pipe head. cone no. 5. Move tuned pipe cone no. 5 in front of bilge be- tween body and fuel tank. F01D76A 1.
  • Page 143 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Disconnect at the tuned pipe head no. 10 the wa- Disconnect the water bleed hose. ter supply hose of the water flow regulator valve. F06E0BA F06E09A 1. Water bleed hose 1. Water supply hose for the regulator valve Loosen clamp no.
  • Page 144 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen and remove clamp no. 4 retaining tuned pipe head no. 10 to tuned pipe cone no. 5. F06D1TA 1. Tuned pipe flange F06D1SA Loosen bolt no. 20 of tuned pipe head above the 1.

  • Page 145: Tuned Pipe Repair

    Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen bolt no. 6 of tuned pipe cone beside the TUNED PIPE REPAIR engine water return hose. This procedure is given to repair tuned pipe cracks using T.I.G. welding process. Procedure – Sand the cracked area to obtain bare metal. –...
  • Page 146 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 717 Engine Torque exhaust manifold screws to 24 N•m (17 lbf•ft) as per following illustrated sequence. Apply synthetic grease on threads of screws Repeat the procedure, retightening screws to 40 no. 12. N•m (30 lbf•ft). Install exhaust manifold no.
  • Page 147 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Torque Allen screws to 24 N•m (17 lbf•ft) as per fol- All Models lowing illustrated sequence. Repeat the procedure, Ensure rubber bushings no. 19 and sleeve no. 18 retightening Allen screws to 40 N•m (30 lbf•ft). are not damaged and are properly installed into tune pipe support(s).
  • Page 148 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Push cone no. 5 until it touches tuned pipe, then Torque bolt of tuned pipe head above the engine tighten exhaust clamp no. 4 and torque to 10 N•m magneto to 25 N•m (18 lbf•ft). (88 lbf•in).
  • Page 149 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Torque clamp of tuned pipe head to 14 N•m Torque exhaust hose clamp no. 1 of tuned pipe (10 lbf•ft). cone to 4 N•m (35 lbf•in). F06D1SA F06D14A 1. Torque clamp to 14 N•m (10 lbf•ft) 1.
  • Page 150 Section 05 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT, COMPONENTS AND CARE................... 05-02-1 CIRCUIT ..........................05-02-5 COMPONENTS ........................05-02-9 CARE ..........................05-02-13 05-01-1 GTX RFI...

  • Page 151: Circuit, Components And Care

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE SPX Model Loctite 592 Bleed hose Loctite 592 Cooling System 1.2 N•m Indicator (CSI) (11 lbf•in) 1.2 N•m (11 lbf•in) Tuned pipe water inlet 2 N•m hose Engine (18 lbf•in)
  • Page 152 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GS and GTI Models Loctite 592 1.2 N•m (11 lbf•in) Loctite Bleed hose Water injection hose Tuned pipe water inlet hose Loctite Engine water supply hose 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) Engine...
  • Page 153 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GTS Model Loctite 1.2 N•m (11 lbf•in) Loctite Bleed hose Water injection Tuned pipe hose water inlet hose Loctite 1.2 N•m (11 lbf•in) Engine water supply hose Loctite Engine water return hose 1.2 N•m (11 lbf•in)
  • Page 154 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GSX Limited, XP Limited and GTX Limited Loctite 592 Engine water return hose 1.2 N•m Loctite (11 lbf•in) 1.2 N•m Loctite (11 lbf•in) Engine drain hose Loctite Bleed hose Cooling System Indicator Loctite (CSI) 1.2 N•m...

  • Page 155: Circuit

    All hoses and fittings of the cooling system have calibrated inside diameters to assure proper cooling of the engine. Always replace using appropriate Bombardier part number. 717 and 787 Engines A Serial Cooling System is utilized on the 717 and...
  • Page 156 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Draining of the cooling system is accomplished by As with other models, the water supply is provid- a drain hose located at the lowest point of the cir- ed by a pressurized area in the jet pump between cuit.
  • Page 157 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) After water has circulated in the cylinder-block Draining of the cooling system is accomplished by water jackets, it is directed in the 1 piece cylinder the drain hose connected to a fitting at the bottom head which features improved combustion cham- of the cylinder-block, on tuned pipe side.
  • Page 158 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Regulated water is injected in the tuned pipe by a calibrated fitting. F06E09A 1. Water supply of the water flow regulator valve F06E0AA The lower hose of the valve is the water supply 1.

  • Page 159: Components

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COMPONENTS CAUTION 1, Clamp The elbow fittings are calibrated and can not be interchanged with one of a different size To cut or secure non-reusable Oetiker clamps of as severe engine damage could result. cooling system hoses, use pliers (P/N 295 000 070).
  • Page 160 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The water flow regulator valve is mounted directly CAUTION onto the muffler. Do not change the calibration of the spring, otherwise serious engine damage can occur. At low speed, water pressure in the supply hose of the regulator valve is not sufficient to overcome the spring of the regulator valve;...
  • Page 161 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) F01E1RA 1. Spring 2. Cover Remove fitting no. 7 from valve housing. F01E2CA HIGH SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve (more restriction) 3. Water injected in the muffler Adjustment The water flow regulator valve has been calibrat- ed at the factory and should not be modified.
  • Page 162 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) F01E1TA F01E21A 1. Tapered needle Loosen clamp to separate valve from bellows. Remove the tapered needle from valve housing. F01E24A 1. Clamp Inspection F01E20A Inspect parts for damage. Verify especially bel- 1.

  • Page 163: Care

    Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CARE max. 90 ° For flushing purposes, the cooling system is equip- ped with either a fitting spigot or a hose adapter depending upon the model. For flushing operation, a coupler hose is available (unnecessary for models with the hose adapter) to connect to the fitting spigot.
  • Page 164 Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isn’t any exhaust pressure to carry the water out the exhaust outlet.
  • Page 165 Section 06 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................06-02-1 GENERAL ........................... 06-02-6 REMOVAL........................... 06-02-6 INSPECTION ........................06-02-10 ASSEMBLY......................... 06-02-11 FUEL SYSTEM PRESSURIZATION ................... 06-02-11 AIR INTAKE ..........................06-03-1 REMOVAL........................... 06-03-3 ASSEMBLY......................... 06-03-4 CARBURETOR ........................06-04-1 GENERAL ...........................

  • Page 166: Fuel Circuit

    Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT SPX Model 3 N•m (27 lbf•in) Body 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 1 N•m (9 lbf•in) 22 N•m (16 lbf•ft) 4 N•m (35 lbf•in) 4 3 N•m (27 lbf•in) 4 N•m (35 lbf•in) 4...
  • Page 167 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GS and GTI Models 3 N•m (27 lbf•in) Body 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 1.2 N•m 1.2 N•m (11 lbf•in) (11 lbf•in) 22 N•m (16 lbf•ft) 1.2 N•m 4 N•m 4 N•m (11 lbf•in) (35 lbf•in)
  • Page 168 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GSX Limited and GTX Limited 3 N•m (27 lbf•in) Body 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m 1.2 N•m (11 lbf•in) (11 lbf•in) 1.2 N•m (11 lbf•in) 22 N•m (16 lbf•ft)
  • Page 169 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) XP Limited 4 N•m (35 lbf•in) Engine 1.2 N•m (11 lbf•in) 3 N•m (27 lbf•in) 1.2 N•m 1.2 N•m (11 lbf•in) (11 lbf•in) 6 N•m (53 lbf•in) Synthetic grease 1.2 N•m 2 N•m (11 lbf•in) 1.2 N•m (18 lbf•in)
  • Page 170 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTS Model 3 N•m (27 lbf•in) 2 N•m (18 lbf•in) 6 N•m (53 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) 22 N•m (16 lbf•ft) 4 N•m Engine (35 lbf•in) 1.2 N•m (11 lbf•in) Dielectric grease...

  • Page 171: General

    1. Securing clamp in limited access When replacing fuel lines on SEA-DOO water- craft, be sure to use “B1” hoses as available from Bombardier parts department. This will ensure continued proper and safe operation. WARNING Use of improper fuel lines could compromise fuel system integrity.
  • Page 172 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Pull fuel filter no. 1 toward the bottom. F01F04A F02L1MA TYPICAL TYPICAL 8, Fuel Baffle Pick Up 1. Press on vent tube All Models NOTE: The baffle pick up has an integrated fuel sender for the fuel gauge.
  • Page 173 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Empty fuel tank. GTS Model Open storage compartment cover. WARNING Remove storage basket from watercraft. Fuel is flammable and explosive under cer- Siphon fuel tank. tain conditions. Always work in a well venti- Remove vent tube.
  • Page 174 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) F02F1PA 1. Front fuel tank strap 2. Middle fuel tank strap From the engine compartment, disconnect the F02F1NA strap retaining the oil injection reservoir and fuel 1. Remove fuel filter tank. Disconnect the fuel lines from baffle pick up and NOTE: It is not necessary to remove the oil injec- loosen lower clamp no.

  • Page 175: Inspection

    Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GS, GSX Limited, GTI and GTX Limited Disconnect fuel lines from baffle pick up and loos- en lower clamp no. 10. F01F02A 1. Gasket in bowl F02F1OA TYPICAL WARNING 1. Disconnect fuel hoses 2.

  • Page 176: Assembly

    Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) 9, Baffle Pick Up Filter GTS Model Only Insert vent tube in body and clip it in place. Inspect filter no. 9 of baffle pick up. Clean or re- place as necessary. WARNING 14, Fuel Tank Vent tube must be in place to provide proper...
  • Page 177 Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) F01F0KA TYPICAL 1. Disconnect air inlet hose 2. Install a hose pincher to vent hose – Connect pump gauge tester (P/N 295 021 800) to air inlet hose. NOTE: This pump is included in the ENGINE LEAK TESTER KIT (P/N 295 500 352).

  • Page 178: Air Intake

    Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) AIR INTAKE SPX, GS, GTS and GTI Models 10 N•m (89 lbf•in) 10 N•m (89 lbf•in) Loctite Loctite Loctite Loctite 242 10 N•m (89 lbf•in) GS/GTS/GTI Loctite 518 Loctite 518 F00F0DS PARTS FLAT RATE 06-03-1...
  • Page 179 Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) GSX Limited, XP Limited and GTX Limited Loctite 242 10 N•m (89 lbf•in) 24 N•m Loctite 242 (17 lbf•ft) 10 N•m (89 lbf•in) Loctite Super Lube grease F06F0DS PARTS FLAT RATE 06-03-2...

  • Page 180: Removal

    Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) REMOVAL 7, Flame Arrester Base Remove flame arrester no. 5. SPX, GS, GTS and GTI Models Remove screws no. 8 retaining support no. 6 of 1, Air Intake Silencer Cover flame arrester base to the cylinder head cover (717 engine) or to the exhaust manifold (787 en- Unlock the 6 retaining slides holding air intake si- gine).

  • Page 181: Assembly

    Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE) Push the air intake silencer out of the carburetor WARNING adapter no. 3. Pull the air intake silencer rearward to remove it Do not operate watercraft without flame ar- from the lower bracket no. 4 and remove it in a rester.

  • Page 182: Carburetor

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) CARBURETOR Mikuni BN-38I, BN-40I and BN-46I Loctite 20 N•m (15 lbf•ft) Loctite Loctite 242 Anti-seize lubricant Synthetic grease F06F0ES PARTS FLAT RATE 06-04-1...

  • Page 183: General

    Section 06 FUEL SYSTEM Subsection 04 (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 184: Cleaning

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) CLEANING The carburetor exterior surfaces should be cleaned with a general solvent and dried with compressed air before disassembly. CAUTION Be careful at carburetor cleaning not to remove paint. Paint removal will cause carburetor to rust very rapidly.
  • Page 185 Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Repeat the same procedure at the outlet nipple. This time the outlet valve should hold with pres- sure and release under vacuum. Inspect valves. The pumping area should be free of holes, tears or imperfections. Replace as needed. 5, Filter To verify filter condition proceed as follows: Remove pump cover no.

  • Page 186: Assembly

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Connect a clean plastic tubing to the valve inlet Pump tester. Injector check valve should open at nipple and alternately apply pressure and vacuum. 13 ± 3 PSI. The check valve should release with pressure and NOTE: If the obtained valve is too low, the check hold under vacuum.
  • Page 187 Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) To adjust, bend lever very slightly to change its height. CAUTION When adjusting lever, do not pry it so that it applies pressure on needle. This could dam- age valve seat/needle. F01F10A TYPICAL 1.
  • Page 188 (P/N 293 600 016) to prevent sticking. 20, 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). F01F11A TYPICAL 1. Pilot jet 2.

  • Page 189: Installation

    Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) INSTALLATION At installation, pay attention to the following: Install carburetor(s) with gasket(s) to intake mani- fold (rotary valve cover for the 787 engine). Apply Loctite 577 on screws no. 20. Then, install screws no. 20 with lock washers no. 21 and torque to 20 N•m (15 lbf•ft).
  • Page 190 Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) Throttle Cable Lubricate cable with BOMBARDIER LUBE lubri- cant. Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket. F01F32B 787 ENGINE F01K08A 1. Throttle lever stoppers (behind levers) 2.
  • Page 191 Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) 2, Low Speed Screw CAUTION Do not attempt to set engine idle speed with low-speed screw. Tighten low speed screw until a slight resistance is felt. Then, back it off to the specification as per following chart.
  • Page 192 Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) F06F0PB 947 ENGINE F06F0IA 1. High speed screw (PTO side shown) 717 ENGINE 15, Idle Speed Screw 1. High speed screw Turning screw clockwise increases engine idle speed and turning screw counterclockwise de- creases engine idle speed.
  • Page 193 Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR) CAUTION If watercraft is out of water, engine must be cooled using the flush kit. Turn screw so that engine idles at 1500 RPM in water or 3000 RPM out of water. 20, Fuel Accelerator Pump Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM in water.
  • Page 194 Section 07 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ...................... 07-02-1 GENERAL ........................... 07-02-7 OIL SYSTEM PRESSURIZATION ..................07-02-7 OIL INJECTION PUMP ......................07-03-1 REMOVAL........................... 07-03-4 DISASSEMBLY........................07-03-4 CLEANING ......................... 07-03-4 ASSEMBLY......................... 07-03-4 ADJUSTMENT ........................07-03-5 CHECKING OPERATION....................

  • Page 195: Oil Injection System

    Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM SPX and GTS Models To electrical box Dielectric grease 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) 3.5 N•m (31 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) 1.2 N•m (11 lbf•in) F02G07S...
  • Page 196 Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GS Model Loctite 518 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) 3.5 N•m (31 lbf•in) 1.2 N•m Dielectric (11 lbf•in) grease 1.2 N•m (11 lbf•in) F06G03S PARTS FLAT RATE 07-02-2...
  • Page 197 Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GSX Limited Loctite 518 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) Dielectric grease F06G04S PARTS FLAT RATE 07-02-3...
  • Page 198 Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) XP Limited Dielectric grease To oil injection pump F08G01S PARTS FLAT RATE 07-02-4...
  • Page 199 Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GTI Model To engine crankcase 27 N•m (return) To oil (20 lbf•ft) injection pump 3.5 N•m (31 lbf•in) To engine crankcase (supply) 1.2 N•m 1.2 N•m (11 lbf•in) (11 lbf•in) 3.5 N•m (31 lbf•in) 1.2 N•m (11 lbf•in)
  • Page 200 Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GTX Limited 27 N•m (20 lbf•ft) 3.5 N•m (31 lbf•in) Dielectric grease 3.5 N•m (31 lbf•in) F07G03S PARTS FLAT RATE 07-02-6...

  • Page 201: General

    Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GENERAL – Install a hose pincher to oil injection pump sup- ply hose. Whenever repairing the oil injection system, al- – Connect pump gauge tester (P/N 529 021 800) ways verify for water infiltration in reservoir. to check valve of oil injection reservoir vent.

  • Page 202: Oil Injection Pump

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL INJECTION PUMP 717 Engine Loctite 518 10 N•m (89 lbf•in) Loctite 242 6 N•m (53 lbf•in) Loctite 242 8 N•m (71 lbf•in) 4.5 N•m Loctite 242 5 N•m (40 lbf•in) (44 lbf•in) F00G02S PARTS...
  • Page 203 Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 787 Engine 6 N•m (53 lbf•in) 3 N•m (27 lbf•in) 4.5 N•m 4.5 N•m (40 lbf•in) (40 lbf•in) Loctite 4.5 N•m (40 lbf•in) F01G0TT PARTS FLAT RATE 07-03-2...
  • Page 204 Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 947 Engine Loctite 242 4.5 N•m (40 lbf•in) 4.5 N•m (40 lbf•in) 4.5 N•m (40 lbf•in) F06G05S PARTS FLAT RATE 07-03-3...

  • Page 205: Removal

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) REMOVAL DISASSEMBLY NOTE: Some oil pump parts are not available in 1, Oil Injection Pump single parts. A gasket set is available for the pump. 717 Engine If the pump is found defective, it should be re- Remove air intake silencer (refer to AIR INTAKE placed by a new one.

  • Page 206: Adjustment

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 2, Intake Manifold Turn idle speed screw until it contacts stopper. Turn idle speed screw 2 turns. Install intake manifold to rotary valve cover and torque screws no. 5 to 10 N•m (89 lbf•in). Turn cable adjustment nut to align marks on pump.
  • Page 207 Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 787 Engine Adjust idle speed to specification. Refer to CAR- BURETOR 06-04. NOTE: The adjustment nut and jam nut for the oil injection pump cable are located at the cable sup- Stop engine.

  • Page 208: Checking Operation

    Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) If not, remove pump assembly and check the pump gear (717 engine) or shaft (787 and 947 en- gines) for defects, replace as necessary. Test pump as describes below: NOTE: Through normal use, oil level must not drop in small tubes.
  • Page 209 Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Compare the results with the chart below. If oil pump is out of specification, replace it. OIL PUMP FLOW RATE AT ENGINE 1500 RPM (30 SECONDS) 1.24 - 1.51 mL (each port) 0.71 - 0.87 mL (each port) 0.83 - 1.01 mL (each port) NOTE: Test can also be done at 3000 RPM.
  • Page 210 Section 08 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM........................ 08-02-1 GENERAL ........................... 08-02-1 IGNITION TIMING ......................08-02-5 IGNITION SYSTEM TESTING PROCEDURE ..............08-02-12 SPARK PLUGS ........................08-02-16 CHARGING SYSTEM......................08-03-1 GENERAL ........................... 08-03-1 TESTING PROCEDURE ..................... 08-03-1 BATTERY ..........................

  • Page 211: Ignition System

    Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION SYSTEM GENERAL Ignition Coil 717 Engine The digital Capacitor Discharge Ignition (CDI) sys- tem includes the following components: Magneto It is the primary source of electrical energy. It transforms magnetic field into electric current. The flywheel contains 4 permanent magnets and spins around the generating coil.
  • Page 212 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Multi-Purpose Electronic Module (MPEM) The MPEM is directly powered by the battery. It has a micro-processor inside of its sealed case. The MPEM is responsible of the following electri- cal functions: – interpreting information –...
  • Page 213 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) F06E06A GSX LIMITED F00H0AB 1. Electrical box XP LIMITED 1. Electrical box SPX Model The other components are located in the conven- tional electrical box. GSX Limited, XP Limited and GTX Limited The other components are integrated to the Multi- Purpose Electronic Module (MPEM).
  • Page 214 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Trigger Coil Multi-Purpose Electronic Module (MPEM) The trigger coil is mounted outside the rotor (in- side the magneto housing of the engine) and is The MPEM is directly powered by the battery. It not adjustable.

  • Page 215: Ignition Timing

    Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 787 and 947 Engines Normally ignition timing adjustment should not be required. It has been set at factory and it should remain correctly adjusted since every part is fixed and not adjustable. The only time the ignition tim- ing might have to be changed would be when re- placing the crankshaft, the magneto rotor, the trigger coil and the MPEM.
  • Page 216 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 787 and 947 Engines 6. Rotate PTO flywheel counterclockwise (when facing it) until piston is at Top Dead Center. 4. Remove middle screw securing the engine to the rear engine mount. Reinstall screw with timing mark pointer tool.
  • Page 217 1. Tachometer pick-up 10. Reinstall spark plug and connect wire. 2. Connect timing light pick-up to MAG side spark plug wire. Dynamic Test To check ignition timing, use Bombardier timing light (P/N 529 031 900). F00H0HA 1. Timing light pick-up A00B4FA...
  • Page 218 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 3. Start engine and point timing light straight in 787 and 947 Engines line with timing tool slot. Bring engine to 6000 1. Connect an induction-type tachometer (P/N RPM. 295 000 100) to spark plug wire. F00H0IA F06H06A 1.
  • Page 219 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) A25E0RA F06H07A 1. Timing light straight in line with tool slot TYPICAL 1. To retard 2. To advance CAUTION To adjust, loosen 3 armature plate retaining screws If engine is to be run more than a few sec- and slightly rotate armature plate in proper direc- onds, engine must be cooled using the flush tion.
  • Page 220 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Example 1 Reinstall removed parts. Refer to MAGNETO SYS- TEM 04-04. When PTO flywheel mark is on right side of timing tool slot, it indicates advanced timing. Recheck ignition timing (make sure engine is cold). Repeat armature plate positioning procedure if timing mark position is not adequate.
  • Page 221 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Examples: – You recheck the timing with the timing light and if the mark is aligned, the ignition timing a. You found the flywheel mark advanced. You is properly set. must retard the ignition timing. Proceed as Follows to Adjust the Ignition –...

  • Page 222: Ignition System Testing Procedure

    Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION SYSTEM TESTING Connect one test probe to the BLACK wire and the other test probe to the switch ring. Measure PROCEDURE resistance, it must be close to 0 ohm. When dealing with ignition problems, the follow- Safety Lanyard on Switch ing items should be verified in this order: Connect test probes to switch BLACK and BLACK/...
  • Page 223 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Generating Coil Verification METER (+) LEAD METER (-) VALUE 717 Engine < 1Ω (ring terminal) (female terminal) STATIC TEST RED/PURPLE Disconnect magneto wiring harness connector. < 1Ω (ring terminal) (female terminal) Install the 4-pin magneto harness adapter (P/N 295 000 131).
  • Page 224 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) DYNAMIC TEST 1. Connect spark plug cables to grounding device. 2. Disconnect magneto wiring harness connector. 3. Install the 4-pin magneto harness adapter (P/N 295 000 131). 4. Connect positive test probe of the multimeter to the RED/BLACK wire of the 4-pin magneto harness adapter.
  • Page 225 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Primary Winding DYNAMIC TEST GTS Model All Models Except GTS Due to the integrated CDI module, it is not possi- Use an ignition coil tester, available from after- ble to take any resistance measurement. market tool/equipment suppliers.

  • Page 226: Spark Plugs

    Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) SPARK PLUGS CAUTION Disassembly Severe engine damage might occur if a First unscrew the spark plug one turn. wrong heat range plug is used. Clean the spark plug and cylinder head with pres- A too “hot”...
  • Page 227 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Spark Plug Installation Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to the following chart.
  • Page 228 Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) NGK Spark Plug Symbol Explanation WIDE GAP SUFFIX PREFIX 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 8 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...

  • Page 229: Charging System

    Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL XP Limited Two 15 A fuses protect the charging system. The Magneto first one is mounted on the MPEM and the other one is located in the front electrical box. The purpose of the charging system is to keep the battery at a full state of charge.
  • Page 230 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Voltage Test Battery Charging Coil Proceed as follows: 717 Engine – Start engine. STATIC TEST: CONTINUITY – Connect a multimeter to battery posts. Set mul- 1. Disconnect the magneto wiring harness con- timeter to Vdc scale.
  • Page 231 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Stator 787 and 947 Engines STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness con- nector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Check resistance between two of the YELLOW wires.

  • Page 232: Battery

    Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) BATTERY CAUTION Troubleshooting Should any electrolyte spillage occur, imme- diately wash off with a solution of baking SYMPTOM: DISCHARGED OR WEAK BATTERY soda and water. CAUSE REMEDY Cleaning 1. Battery posts and/or Clean and coat with cable terminal dielectric grease.
  • Page 233 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Unload Test This chart will be useful to find the correct read- ing. Check charge condition using either a hydrometer or multimeter. ELECTROLYTE With a multimeter, voltage readings appear in- OPERATION TO TEMPERATURE stantly to show the state of charge.
  • Page 234 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Clean battery terminals and cable connections using WARNING a wire brush. Apply a light coat of dielectric grease on terminals. Failure to remove the sealing tube could re- Clean battery casing and caps using a solution of sult in an explosion.
  • Page 235 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 4. Readjust the electrolyte level to the UPPER 6. Disconnect battery charger. LEVEL line. A17E0IB A17E0RB Step : Unplug battery charger 1. Battery electrolyte Step : Disconnect - lead 2. Upper level line Step : Disconnect + lead 5.
  • Page 236 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Do not charge a frozen battery. If the battery – Measure the voltage at the battery posts with charge is very low, the battery may freeze. If it is an accurate voltmeter. If it is below 10 volts, the suspected to be frozen, keep it in a heated area battery will accept current at very low rate, in term of milliamperes, because electrolyte is...
  • Page 237 Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: On the SPX model, secure the negative battery cable on top of the small ground wire with- out using a washer. A17E0PA TYPICAL 1. Two batteries = 4 A F01H63A WARNING SPX MODEL 1.

  • Page 238: Starting System

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM 717 Engine 22 N•m (16 lbf•ft) Loctite 242 5 N•m (44 lbf•in) Dielectric grease 22 N•m (16 lbf•ft) Loctite 271 Ground cable 22 N•m (16 lbf•ft) Loctite 242 F00H0BT PARTS FLAT RATE 08-04-1...
  • Page 239 Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 787 Engine 22 N•m (16 lbf•ft) Loctite 242 25 N•m (18 lbf•ft) Dielectric 5 N•m grease Loctite 242 (44 lbf•in) 22 N•m (16 lbf•ft ) 14 Loctite 242 16 22 N•m Loctite 271 (16 lbf•ft) Ground cable Loctite 242...
  • Page 240 Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 Engine Dielectric grease Loctite 242 Synthetic grease 10 N•m (89 lbf•in) Ground cable Synthetic grease Loctite 271 10 N•m (89 lbf•in) Loctite 10 N•m (89 lbf•in) F06H1XS PARTS FLAT RATE 08-04-3...

  • Page 241: General

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) GENERAL Safety Lanyard Switch The following continuity tests can be performed Causes of troubles are not necessarily related to using an ohmmeter: starter but may be due to a burnt fuse, faulty bat- tery, start/stop switch, safety lanyard switch, Disconnect switch wires.

  • Page 242: Starting System Troubleshooting

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY Burnt 5 A fuse. Check wiring condition and replace Starter does not turn. fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten.

  • Page 243: Starter Removal

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER REMOVAL STARTER DISASSEMBLY Disconnect BLACK cable ground connection from 717 and 787 Engines battery. Before disassembling, trace index marks on yoke no. 1 and clutch housing no. 10 to ease further WARNING assembly.
  • Page 244 Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Turn clutch assembly no. 9 clockwise to remove it from armature assembly no. 11. Pull housing from armature. 947 Engine Locate index marks on yoke no. 1 and end covers no. 3 and no. 6. F06H1HA 1.

  • Page 245: Cleaning

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Release brush wires of yoke from brush holder To remove bearing and seal in end cover, release no. 2. tabs of retainer. Remove brush holder no. 2. F06H1MA 1. Retainer F06H1KA 1. Remove brush holder CLEANING To remove brushes from yoke no.

  • Page 246: Parts Inspection

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) PARTS INSPECTION 2, Brush Holder Check brush holder for insulation using an ohm- 11, Armature meter. Place one test probe on insulated brush holder and the other test probe on brush holder NOTE: An ohmmeter may be used for the follow- plate.
  • Page 247 Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Slide stop collar no. 7 over circlip no. 6 and se- Open brushes no. 4 and slide over commutator. cure in place by punching it at 2 or 3 places. Align end frame locating notch with yoke locating protrusion and properly sit brush holder no.

  • Page 248: Starter Installation

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Install the 3 washers no. 8 and no. 9 onto arma- ture shaft, with the thicker one in the middle. F06H1NA 1. Thick washer in the middle F01H0UA When installing end covers no. 3 and no. 6 to Step : Retaining brush holder with a screwdriver yoke, align index marks.
  • Page 249 Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 14,15, Screw and Teeth Washer 787 Engine Apply Loctite 271 (red) to screw. 18, Locking Collar Connect BLACK negative cable to starter using Install the locking collar of the fuel hose. Apply flat washer, teeth washer and screw.
  • Page 250 Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 12, Screw Apply Loctite 271 (red) to Allen screw. Connect BLACK negative starter cable using flat washer, teeth washer and screw. Torque to screw 10 N•m (89 lbf•in). Apply dielectric grease. F06H1EA 947 ENGINE 1.

  • Page 251: Starter Specification

    Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER SPECIFICATION 717 and 787 Engines Nominal output 0.6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight Approx. 2 kg (4.4 lb) Performance specification at 20°C (68°F) No load 11.5 V 20 A max.

  • Page 252: Instruments And Accessories

    Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL Lake Temperature Sensor GSX Limited and GTX Limited It is possible to activate the instruments when the engine is not running. The lake temperature sensor is integrated with the speed sensor located on the ride plate.
  • Page 253 1000 Connect the positive probe of a multimeter to speed sensor PURPLE/YELLOW wire and the negative probe to speed sensor BLACK/ORANGE Bombardier wire. With the safety lanyard removed, depress the start/ stop button to activate the MPEM timer. Slowly rotate the paddle wheel. Every 1/8 turn,...
  • Page 254 SCROLLING FUNCTIONS Press the MODE button until the desired function is displayed on the Info Center. Bombardier RESET A FUNCTION To reset a function such as the chronometer, peak speed, trip meter, etc., select the desired function using the MODE button then press and hold the SET button for 2 seconds.
  • Page 255 Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Press the MODE button to adjust the hours and LOW FUEL RESISTANCE FUEL LEVEL the SET button to adjust the minutes. LEVEL RED (Ω) LCD GRAPHIC Press again on both the MODE and SET buttons LIGHT to exit the setting mode (or the gauge will auto- 0 + 2.2...
  • Page 256 Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) LAKE TEMPERATURE NOTE: The gauge must be activated to obtain a reading. Disconnect the 2-circuit connector housing of the Info Center which contains a BLACK/ORANGE RESISTANCE DISPLAY and TAN/ORANGE wires. (Ω) TEMPERATURE (°C) Connect potentiometer test probes to the BLACK/ 25590.1...
  • Page 257 Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Bombardier Bombardier F01H4RA F01G07A SPX, GTS AND XP LIMITED TYPICAL 1. Low oil warning light 1. Bow up 2. Bow down Accuracy of gauge can be checked with a potenti- ometer.
  • Page 258 Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Fuel Baffle Pick Up Sender FUEL LEVEL AND RESISTANCE (GTS) The baffle pick-up has an integrated fuel sender. To verify fuel sender, a resistance test should be FUEL LEVEL RESISTANCE performed with a multimeter allowing the float to (mm) (Ω) move up through a sequence.
  • Page 259 Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) When the oil level goes at critical LOW level in- FUEL LEVEL AND RESISTANCE side the oil tank (and therefore in sensor reser- (XP Limited) voir), the sensor detects the absence of liquid and the light TURNS ON.
  • Page 260 Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) VTS Switch VTS Control Module SPX, GSX Limited and XP Limited SPX, GSX Limited and XP Limited Always confirm first that the fuse is in good con- It receives its current from the battery. It is pro- dition.

  • Page 261: Digitally Encoded Security System

    Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) DIGITALLY ENCODED SECURITY SYSTEM GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unautho- rized use of the watercraft. The following components are specially designed for this system: Multi-Purpose Electronic Module (MPEM), safety lanyard cap and safety lanyard switch.
  • Page 262 Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Basic Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme- diate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
  • Page 263 Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft switch. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.
  • Page 264 Section 09 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ..........................09-02-1 GENERAL ........................... 09-02-2 JET PUMP INSPECTION ON WATERCRAFT ..............09-02-2 REMOVAL........................... 09-02-5 DISASSEMBLY........................09-02-6 CLEANING ......................... 09-02-9 PARTS INSPECTION ......................09-02-9 ASSEMBLY......................... 09-02-12 PUMP PRESSURIZATION ....................09-02-18 INSTALLATION ........................

  • Page 265: Jet Pump

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) JET PUMP All models except GS, GTS and GTI SPX/GTS Loctite Right Stuff SPX/ Synthetic GSX Limited/ grease XP Limited/ GTX Limited Right Stuff Loctite Loctite Loctite GS/GTS/GTI 20 N•m (15 lbf•ft) Loctite Loctite Loctite...

  • Page 266: General

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL The jet pump housing and venturi are made of plastic. Progressive Stainless 271 000 828 pitch steel On the GS, GTS and GTI models, the jet pump hous- 16°-23°...
  • Page 267 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller Condition Condition of impeller no. 20, boot no. 15 and ring no. 16 can be quickly checked from underneath of the watercraft. Remove grate and look through water inlet opening. F01J0EA TYPICAL —...
  • Page 268 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models Oil Replacement Remove 4 screws retaining venturi to jet pump Remove venturi as described in Oil Inspection. housing. Remove 3 screws retaining cover. GTI and GTX Limited Remove reverse gate and support. All Models Pull nozzle and venturi from jet pump housing.

  • Page 269: Removal

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) REMOVAL 11, Venturi Remove nozzle no. 5 prior removing venturi. 5, Nozzle Remove 4 retaining screws and withdraw venturi. Disconnect steering cable from jet pump nozzle. GS, GTS, GTI and GTX Limited Remove 2 retaining screws no.

  • Page 270: Disassembly

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) GTS, GTI and GTX Limited DISASSEMBLY Detach ball joint of reverse cable and springs (GTS NOTE: Whenever removing a part, visually check model) from reverse gate. for damage such as: corrosion, crack, split, break, porosity, cavitation, deformation, distortion, heat- All Models except GTS ing discoloration, wear pattern, missing plating,...
  • Page 271 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models 18, Cover With pump assembly in horizontal position, remove 3 retaining screws no. 19. Place container under cover to catch oil. Using a fiber hammer, gently tap cover to release it from jet pump housing.
  • Page 272 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Rotate impeller remover tool counterclockwise and unscrew completely impeller. CAUTION Never use any impact wrench to loosen im- peller. To remove impeller, apply a rotating movement and pull at same time. Slide impeller out of hous- ing.

  • Page 273: Cleaning

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Brush and clean impeller shaft threads, impeller and drive shaft splines with Loctite Safety solvent 755 (P/N 293 800 019) or equivalent. Free threads and splines from any residue. CAUTION Be careful not to damage impeller shaft diam- eter.
  • Page 274 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) F02J0UA F01J18A 1. Check for cavitation, deep scratches or other damage TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 21, Wear Ring 2. Measure close to threads at shaft end To check both bearings, proceed the same way Check wear ring for deep scratches, irregular sur- with other shaft end.
  • Page 275 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) 18,24, Cover and Impeller Shaft END PLAY End play of impeller shaft is checked with shaft in housing, without impeller and with cover installed. Retain housing in a soft jaw vise making sure not to damage housing lug.

  • Page 276: Assembly

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Refer to the following illustration to determine the ASSEMBLY wear limit of the pusher. 21, Wear Ring The wear ring features a lip on one edge; position lip outwards of housing. NOTE: To ease insertion into housing, apply BOM- BARDIER LUBE lubricant (P/N 293 600 016) onto outside circumference of wear ring.
  • Page 277 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) F01J1HA 1. Stamped end this side F01J5EA CAUTION 1. Piece of wood 2. Seal lip facing upward 3. Wear ring Never hammer the bearing into its housing. 22,23, Seal and Needle Bearing Bearings and seal will be properly installed in housing using bearing/seal installer tool (P/N 295 000 107).
  • Page 278 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Bearing on impeller side must be 1.5 to 2.5 mm CAUTION (.060 - .100 in) inside reservoir measured from seal seat. Bearing on venturi side must be 2 to Prevent sealant from contacting any needles 3 mm (.080 - .120 in) inside reservoir measured of bearing.
  • Page 279 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) 25, Thrust Washer 24, Impeller Shaft Position jet pump housing no. 9 with the stator To prevent seal lip damage when inserting impel- vanes on top. ler shaft, use impeller shaft guide (P/N 295 000 002).
  • Page 280 Insert a new boot no. 15 and ring no. 16 to impel- ler. F00J0HA 1. Impeller shaft holder secured in a vice To ease impeller installation, apply BOMBARDIER LUBE lubricant on wear ring. Insert impeller into wear ring. Manually rotate im- peller and push so that it slides on impeller shaft threads.
  • Page 281 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) 18, Cover Place housing horizontally as in its operating posi- tion so that filler plug is located on top. Remove Install O-ring no. 27 to cover. Apply Loctite 518 on filler plug from cover. Pour SEA-DOO JET PUMP O-ring.

  • Page 282: Pump Pressurization

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) Apply Loctite 518 (Gasket Eliminator) on mating Proceed as follows: surface. – Remove drain plug from cover. Position venturi with bailer passages on top. – Apply Loctite PST 592 on threads of fitting tool Apply Loctite 242 (blue) on threads of screws (P/N 295 000 086) then secure on cover.

  • Page 283: Installation

    Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) INSTALLATION GTS Model Apply Loctite Right Stuff around bailer and water 28, Neoprene Seal supply fittings as well as around wear ring lip. SPX, GSX Limited, XP Limited and GTX Limited If neoprene seal is damaged, replace it with a new one.
  • Page 284 Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP) SPX and GTS Models WARNING Secure water supply hose and both bailer tubes to jet pump housing using tie raps. Whenever removing screw always renew locking disks. Screw must be torqued as spec- ified.

  • Page 285: Drive System

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) DRIVE SYSTEM SPX Model 2 N•m (18 lbf•in) 2 N•m (18 lbf•in) Synthetic grease Synthetic grease F01I0KS PARTS FLAT RATE 09-03-1...
  • Page 286 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GS, GTS and GTI Models Loctite 2 N•m (18 lbf•in) Synthetic 2 N•m grease (18 lbf•in) Synthetic grease F02I05S PARTS FLAT RATE 09-03-2...
  • Page 287 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GSX Limited and GTX Limited Synthetic grease Loctite 518 2 N•m (18 lbf•in) Loctite Synthetic 2 N•m Synthetic grease (18 lbf•in) grease Loctite Synthetic grease F06I05S PARTS FLAT RATE 09-03-3...
  • Page 288 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP Limited 22 N•m (16 lbf•ft) Synthetic grease 22 N•m (16 lbf•ft) 22 N•m Synthetic (16 lbf•ft) grease Loctite Loctite Synthetic grease Loctite Loctite 271 Loctite 10 N•m 17 15 (88 lbf•in) Loctite 518 2 N•m (18 lbf•in)

  • Page 289: General

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GENERAL – Insert pointed tips of pliers in closing hooks. Jet pump must be removed to replace any com- ponents of the drive system. Refer to JET PUMP 09-02 for removal procedure. REMOVAL 1, PTO Flywheel Guard SPX, GS and GSX Limited...
  • Page 290 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) All Models Except the XP Limited 12, Drive Shaft Simply pull out drive shaft. NOTE: If the drive shaft is jammed into PTO fly- wheel, make the following tool and use it in con- junction with the jet pump housing remover (P/N 295 000 113) to withdraw drive shaft.
  • Page 291 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) F01I06A TYPICAL F08I04A 1. Jet pump housing remover 2. Drive shaft puller 1. Pull drive shaft to disengage coupler from splines 3. Screws Remove rear drive shaft. CAUTION Remove coupler no. 19. Be careful not to damage hull rear section or 20, Front Drive Shaft engine rubber mounts.
  • Page 292 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) F08Q01A F08L12A 1. Remove bolts and lock nuts 1. Loosen gear clamp Loosen 4 screws and remove bottom cover of Tilt seat. seat. Remove front drive shaft. 14, Seal Carrier of Mid Bearing To remove the seal carrier from support, loosen the 6 nuts no.

  • Page 293: Disassembly

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GSX Limited, XP Limited and GTX Limited 10, Boot Loosen gear clamp no. 11 holding boot, then pull boot with seal carrier. 14, Seal Carrier of Thru Hull Fitting Loosen gear clamp no. 9 and remove seal carrier from boot no.
  • Page 294 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) SPX, GS, GTS and GTI Models 6,7, Floating Ring and O-ring Inspect condition of O-rings and floating ring con- tact surface. F06I06A 1. Push floating ring 2. Remove circlip Slide floating ring far enough forward in order to release it from carbon ring.

  • Page 295: Assembly

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) ASSEMBLY Install double-lip seal no. 15 with protector to- ward jet pump. GSX Limited, XP Limited and GTX Limited On both seals no. 15, raised edge of lip must be located outwards of seal carrier. 14, Seal Carrier Properly support seal carrier housing no.

  • Page 296: Installation

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) INSTALLATION – PTO flywheel adapter (P/N 295 000 157). Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. XP Limited 14, Seal Carrier of Mid Bearing Properly index flanges no.
  • Page 297 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) 3, Drive Shaft Install drive shaft and jet pump at the same time. SPX, GS, GTS and GTI Models Insert drive shaft through carbon ring no. 8 and floating ring no. 6. NOTE: Make sure to install floating ring before in- serting the drive shaft in the PTO flywheel.
  • Page 298 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) F06I06A 1. Push floating ring 2. Insert circlip in the groove F01J2BA Slide the floating ring onto the circlip. TYPICAL 1. Closing hooks All Models Except the XP Limited – Squeeze pliers. When both large and small win- dows are directly over the 2 locking hooks, 2, Large Clamp press those windows down to engage hooks in...

  • Page 299: Lubrication

    Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) LUBRICATION PTO Flywheel All Models Except the XP Limited Using a grease gun, carefully lubricate PTO fly- wheel with synthetic grease (P/N 293 550 010), until boot is just beginning to expand. At this point, immediately stop greasing.
  • Page 300 Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP Limited Using a grease gun, lubricate seal carrier of mid bearing with synthetic grease (P/N 293 550 010). F05I09A TYPICAL 1. Grease fitting 09-03-16...

  • Page 301: Reverse System

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) REVERSE SYSTEM GTS Model Synthetic grease 2.5 N•m (22 lbf•in) 8 N•m (71 lbf•in) 7 N•m (62 lbf•in) 10 N•m 6 N•m 3 N•m (88 lbf•in) (53 lbf•in) (27 lbf•in) 8 N•m (71 lbf•in) 7 N•m (62 lbf•in)

  • Page 302: General

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GENERAL It is not necessary to remove reverse system from watercraft for servicing. However reverse system removal is necessary to replace reverse support. DISASSEMBLY Remove storage tray from watercraft. Press on vent tube upper part to enable to with- draw tube from body.

  • Page 303: Assembly

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) 7, Reverse Gate Unhook reverse gate springs and remove ball joint fasteners to release reverse cable from reverse gate. F02J06A TYPICAL 1. Reverse support 2. Reverse cable 3. Triangular lever F02J08A 6, Reverse Support 1.
  • Page 304 Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Torque triangular lever screw to 8 N•m (71 lbf•in). CAUTION Install sliding block to lever and torque nut to 8 N•m (71 lbf•in). Always hook reverse gate springs in order to ease reverse gate operation. 1,5, Locking Lever and Sliding Block Insert locking lever end in support hole then align lever and sliding block holes.

  • Page 305: Adjustment

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) 2, Spring ADJUSTMENT Insert spring in lever stem hole and then install 7, Reverse Gate curved end in sliding block groove. Position handlebar in a straight ahead position, nozzle should be parallel to rear of watercraft. Using a square, set it to 129 ±...
  • Page 306 Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Tighten adjustment nuts and recheck gate posi- tion. Reinstall vent tube. WARNING Vent tube must be in place to provide proper bilge ventilation. F02J0FA 1. REVERSE position If reverse gate needs to be readjusted, it can be done at support with adjustment nuts.
  • Page 307 Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTI and GTX Limited 3 N•m (27 lbf•in) Loctite 242 Synthetic Loctite grease 3.5 N•m (31 lbf•in) 2.5 N•m (22 lbf•in) Sealant 4 N•m 6 N•m 3 N•m (35 lbf•in) (53 lbf•in) (27 lbf•in) Loctite 7 N•m...

  • Page 308: Disassembly

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) DISASSEMBLY 1, Reverse Gate Put shift lever in reverse position. Disconnect reverse cable by loosing bolt no. 2 and lock nut no. 3 from cable lever. Loosen 2 Allen screws no. 4 and remove reverse gate.

  • Page 309: Assembly

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) ASSEMBLY Make sure the shift lever action is smooth and precise. Forward, neutral and reverse positions Assembly is essentially the reverse of disassem- should be easy to select with a detent position be- bly procedures.

  • Page 310: Adjustment

    Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) 21, Reverse Cable Install reverse cable to cable lever as per following illustration. F07J09A 1. Reverse cable support 2. Loosen bolts 3. Adjustment nut F07J08A When adjustment is completed, there should be gap of 2 to 3 mm (5/64 to 7/64 in) between handle 1.

  • Page 311: Variable Trim System

    Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM SPX Model Loctite Synthetic grease Loctite 242 5 N•m Synthetic (44 lbf•in) grease sealant 10 N•m (89 lbf•in) 2.5 N•m (23 lbf•in) 13 N•m (10 lbf•ft) Loctite 7 N•m Loctite 242 (62 lbf•in) 13 N•m...
  • Page 312 Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) GSX Limited and XP Limited Loctite Synthetic grease Loctite 242 5 N•m (44 lbf•in) Synthetic grease 10 N•m (89 lbf•in) 7 N•m (62 lbf•in) 2.5 N•m 13 N•m (23 lbf•in) (10 lbf•ft) Loctite Loctite 242 13 N•m...

  • Page 313: General

    Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) GENERAL 8, Motor Disconnect wires of motor. To test VTS control module, motor or switch, refer to INSTRUMENTS AND ACCESSORIES 08-05. Remove retaining nuts no. 11. REMOVAL Disconnect ball joint no. 1. Remove clamps no.

  • Page 314: Assembly

    Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) F01J25A F01J2GA 1. Inspect threads and splines Apply Loctite 242 (blue) to nuts no. 11 and tighten to 7 N•m (62 Ibf•in). ASSEMBLY Connect wires of motor. Assembly is essentially the reverse of disassem- bly procedures.

  • Page 315: Adjustment

    Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) Apply Primer N to threads of VTS housing and Loctite 242 (blue) to nut no. 4. Install nut with sealing washer and torque to 6 N•m (53 lbf•in) using the VTS socket tool. 1, Ball Joint SPX Model Install ball joint on RIGHT side of sliding shaft...
  • Page 316 Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) If an adjustment is necessary, loosen jam nut no. 16 of link rod ball joint no. 1. Turn adjustment nut of ball joint to obtain the desired gap between trim ring and venturi. F06J01A GSX LIMITED SHOWN 1.
  • Page 317 Section 10 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SPX MODEL........................... 10-02-1 REMOVAL AND INSTALLATION ..................10-02-2 GTS MODEL........................... 10-03-1 REMOVAL AND INSTALLATION ..................10-03-2 GS, GSX LIMITED, GTI AND GTX LIMITED................. 10-04-1 DISASSEMBLY........................10-04-2 ASSEMBLY......................... 10-04-4 XP LIMITED..........................

  • Page 318: Spx Model

    Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL) SPX MODEL 1 N•m (8.5 lbf•in) 14 N•m 14 N•m 1 N•m (10 lbf•ft) (10 lbf•ft) (8.5 lbf•in) 0.5 N•m 26 N•m (4 lbf•in) (19 lbf•ft) 8 N•m (72 lbf•in) 15 N•m (11 lbf•ft) Synthetic 15 N•m...

  • Page 319: Removal And Installation

    Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL) REMOVAL AND INSTALLATION When installing the grip insert in the handlebar no. 12, ensure that its notch is properly inserted 1, Cover in the hole beneath the handlebar. To replace the cover, loosen set screws no. 19 of Install grip no.
  • Page 320 Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL) F01K1FA FRONT SUPPORT F01K17A 1. Apply synthetic grease 2. Thrust ring 1. Bolts 2. Steering stem arm NOTE: Make sure thrust rings are properly in- stalled. Remove support no. 11 and steering stem arm no.
  • Page 321 Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL) From bilge, route throttle cable and wiring har- Position steering stem arm no. 10 and support nesses into support no. 11 and steering stem arm no. 11 onto steering stem. no. 10, and finally in front steering support no.
  • Page 322 Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL) 18, Steering Cable Remove battery. For procedure, refer to CHARG- ING SYSTEM 08-03. Disconnect steering cable from steering stem Loosen nut no. 20 of steering cable. arm no. 10. Pull cable from rear of watercraft and remove half rings no.

  • Page 323: Gts Model

    Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL) GTS MODEL 3.5 N•m (30 lbf•in) Loctite 26 N•m (19 lbf•ft) 13 N•m (10 lbf•ft) Anti-seize lubricant 3.5 N•m (30 lbf•in) 15 N•m (11 lbf•ft) Loctite 15 N•m (11 lbf•ft) Loctite 15 N•m (11 lbf•ft) Loctite Loctite...

  • Page 324: Removal And Installation

    Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL) REMOVAL AND INSTALLATION Install grip no. 4 on handlebar no. 29 matching it to the hex form on the grip insert. 1, Cover Install flat washer no. 7 and screw no. 6. To replace the cover, loosen set screws no.
  • Page 325 Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL) Insert grommet no. 14 in dashboard hole and pull it from inside bilge. NOTE: To ease installation, apply water on grom- met. Insert wires of monitoring beeper and start/stop button. Insert spring washer no. 15 and the shim no. 16 onto steering stem no.
  • Page 326 Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL) Disconnect rear ball joint no. 22 of steering cable at jet pump nozzle; then, remove ball joint. From bilge, unscrew nut no. 24 retaining steering cable to hull. Remove half rings no. 25, rubber washer no. 26 and retaining ring no.

  • Page 327: Gs, Gsx Limited, Gti And Gtx Limited

    Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED) GS, GSX LIMITED, GTI AND GTX LIMITED 14 N•m (10 lbf•ft) 26 N•m (19 lbf•ft) Loctite 242 10 N•m (89 lbf•in) 4 N•m (35 lbf•in) 14 N•m (10 lbf•ft) Loctite 242 6 N•m...

  • Page 328: Disassembly

    Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED) DISASSEMBLY Remove cover. 1,21, Grip and Grip Insert 8, Cable Support To remove grip, pull out cap no. 2 and remove Loosen bolts no. 9 and remove retaining block screw no.
  • Page 329 Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED) F07K03A 1. Steering support 2. Bolts F06K03A Remove support. GS AND GSX LIMITED 1. Tie rap 2. Connectors 12, Steering Support GTI and GTX Limited Cut tie rap securing wiring harness boot. F07K05A GTI AND GTX LIMITED 1.

  • Page 330: Assembly

    Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED) 15,16, Steering Stem Arm and Support Loosen bolts no. 17 retaining steering stem arm to support. F07K06A 1. Steering stem arm 2. Steering cable Loosen bolts no. 11 retaining cable support no. 8 F07K08A to steering support no.
  • Page 331 Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED) 1,21, Grip and Grip Insert When installing the grip insert no. 21 in the han- dlebar no. 22, ensure that its notch is properly in- serted in the hole beneath the handlebar. Install grip no.
  • Page 332 Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED) GS and GTI Models F00J01A TYPICAL 1. Bolt 2. Flat washers 3. Lock nut. Torque to 2 N•m (18 lbf•in) STEERING ALIGNMENT For steering alignment procedure, refer to ALIGN- MENT 10-06.

  • Page 333: Xp Limited

    Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED) XP LIMITED Loctite 242 10 N•m (89 lbf•in) 2 N•m (17 lbf•in) 4 N•m (35 lbf•in) 13 N•m (10 lbf•ft) 13 N•m (10 lbf•ft) Synthetic grease 26 N•m (19 lbf•ft) 7 N•m (62 lbf•in) Loctite 242 Loctite 242...

  • Page 334: Disassembly

    Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED) DISASSEMBLY Remove 2 screws no. 9 and flat washers each side of cover. 1, Grip 10, Lever To remove grip, pull out cap no. 2 from grip end Open engine cover. and remove screw no. 3 and washer no. 4. Remove the top section of the engine cover by Pull out grip.
  • Page 335 Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED) Remove link rod no. 12. 15,16, Steering Stem Arm and Support Loosen bolts no. 17 retaining steering stem arm no. 15 and support no. 16. F08K08A 1. Loosen bolts Loosen nuts and bolts of steering support no. 18. F08K06A 1.

  • Page 336: Assembly

    Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED) Lift steering support no. 18 and slightly pullback Loosen cable support no. 19. steering stem no. 14 in order to remove the sup- port no. 16 and steering stem arm no. 15. F08k0AA 1.
  • Page 337 Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED) 14, Steering Stem CAUTION Apply synthetic grease to front and rear thrust bearing surface. Ensure to install flat washer otherwise screw will damage grip end. 15,16, Steering Stem Arm and Support Position steering stem arm and support onto 21, Ball Joint steering stem no.

  • Page 338: Alignment

    Section 10 STEERING SYSTEM Subsection 06 (ALIGNMENT) ALIGNMENT Position handlebar in straight ahead position by All Models Except the XP Limited measuring each side the distance from handlebar Open storage compartment cover and remove grip end to floorboard. basket. XP Limited Remove glove box.
  • Page 339 Section 10 STEERING SYSTEM Subsection 06 (ALIGNMENT) F08K0BA XP LIMITED F03K03A 1. Support 2. Adjustment nut GTS MODEL 3. Bolts 1. Retaining block 2. Adjustment nut 3. Bolts After adjustment, torque retaining block bolts to 6 N•m (53 Ibf•in). CAUTION Verify when the handlebar is turned com- pletely to the left or right side, that there is no interference with venturi.
  • Page 340 Section 11 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION.................... 11-02-1 REMOVAL .......................... 11-02-2 INSPECTION ........................11-02-3 ASSEMBLY......................... 11-02-3 11-01-1...

  • Page 341: Direct Action Suspension

    Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION XP Limited 5 N•m (44 lbf•in) 34 N•m (25 lbf•ft) 34 N•m (25 lbf•ft) 10 N•m (89 lbf•in) Loctite 10 N•m (89 lbf•in) Loctite F08Q02S PARTS FLAT RATE 11-02-1...

  • Page 342: Removal

    Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) REMOVAL Loosen lower gear clamp no. 4, then push inner boot no. 5 upward. 1, Shock Absorber Loosen 4 screws and remove bottom cover of seat. F08I03B 1. Loosen gear clamp Remove bolt no. 6 and lock nut no. 7 from shock F08L11A absorber lower support no.

  • Page 343: Inspection

    Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) F08L13A 1. Loosen gear clamp F05L0NA Remove bolt no. 10 and lock nut no. 11 from shock absorber upper support. Compress spring and remove cup no. 13. Unload tool and remove spring from shock ab- sorber.
  • Page 344 Section 12 HULL/BODY Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR ....................12-02-1 SEAT ADJUSTMENT......................12-02-17 STORAGE COMPARTMENT COVER ADJUSTMENT ............12-02-19 ACCESS PANEL ADJUSTMENT ..................12-02-20 INLET GRATE REMOVAL....................12-02-20 RIDING PLATE........................12-02-20 JET PUMP SUPPORT ......................12-02-21 DEFLECTOR ........................

  • Page 345: Adjustment And Repair

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR SPX Model Loctite Loctite Loctite 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) Loctite 8 N•m Sealant (71 lbf•in) 5 N•m (44 lbf•in) Sealant Loctite Loctite 271 Sealant 732 15 N•m (11 lbf•ft) Body...
  • Page 346 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite 6 N•m (53 lbf•in) 15 N•m (11 lbf•ft) Sealant Loctite Loctite Sealant Sealant 732 1.5 N•m (13 lbf•in) F01L6IS PARTS FLAT RATE 12-02-2...
  • Page 347 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTS Model Loctite Loctite 271 Loctite 5 N•m 8 N•m (44 lbf•in) (71 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite Sealant 9 10 5 N•m (44 lbf•in) Sealant 15 N•m (11 lbf•ft) Loctite F02L26S PARTS...
  • Page 348 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) 7 N•m (62 lbf•in) Loctite 242 15 N•m (11 lbf•ft) Loctite Sealant 732 1.5 N•m (13 lbf•in) Sealant F02L27S PARTS FLAT RATE 12-02-4...
  • Page 349 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GS and GSX Limited 5 N•m (44 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite 5 N•m (44 lbf•in) Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) 5 N•m Loctite (44 lbf•in) Loctite 5 N•m (44 lbf•in)
  • Page 350 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite Loctite 8 N•m (71 lbf•in) 15 N•m (11 lbf•ft) Sealant Loctite Sealant 2.5 N•m (22 lbf•in) Sealant F06L02S PARTS FLAT RATE 12-02-6...
  • Page 351 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI and GTX Limited Loctite Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) Loctite 8 N•m (71 lbf•in) Loctite Loctite 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite Loctite Sealant 5 N•m (44 lbf•in) Body...
  • Page 352 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite Loctite 8 N•m (71 lbf•in) 15 N•m (11 lbf•ft) Loctite Loctite 8 N•m Sealant (71 lbf•in) Sealant 1.5 N•m (13 lbf•ft) Sealant F07L04S PARTS FLAT RATE 12-02-8...
  • Page 353 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) 8 N•m (71 lbf•in) 1.4 N•m (12 lbf•in) 0.8 N•m (7 lbf•in) Loctite Loctite 5 N•m (44 lbf•in) 5 N•m (44 lbf•in) 8 N•m (71 lbf•in) Loctite 3 N•m (26 lbf•in) Loctite 242 5 N•m (44 lbf•in) F07L05S...
  • Page 354 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite 242 4 N•m (35 lbf•in) 5 N•m (44 lbf•in) Loctite 242 Loctite 242 4 N•m (35 lbf•in) Loctite 242 5 N•m (44 lbf•in) Loctite 242 5 N•m (44 lbf•in) F07L06S PARTS FLAT RATE 12-02-10...
  • Page 355 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Limited Loctite 242 732 sealant 5 N•m (44 lbf•in) 732 sealant Loctite 15 N•m (11 lbf•ft) Body F08L14S PARTS FLAT RATE 12-02-11...
  • Page 356 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite Body Loctite 5 N•m (44 lbf•in) Body 5 N•m (44 lbf•in) 15 N•m (11 lbf•ft) Body Loctite 732 sealant 1.5 N•m (13 lbf•in) 732 sealant F08L15S PARTS FLAT RATE 12-02-12...
  • Page 357 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite 242 4 N•m (35 lbf•in) 15 N•m Loctite 242 (11 lbf•ft) 13 N•m (10 lbf•ft) 5 N•m Synthetic (44 lbf•in) grease Loctite 271 3 N•m (27 lbf•in) 3 N•m (27 lbf•in) F08L16S PARTS FLAT RATE...
  • Page 358 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite 242 4 N•m (35 lbf•in) 4 N•m (35 lbf•in) Loctite Loctite 8 N•m (71 lbf•in) 3 N•m (27 lbf•in) Loctite Loctite 648 Loctite 242 4 N•m 8 N•m (35 lbf•in) (71 lbf•in) F08L17S PARTS FLAT RATE...
  • Page 359 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite 3 N•m (27 lbf•in) Engine cover 2 N•m (18 lbf•in) F08L18S PARTS FLAT RATE 12-02-15...
  • Page 360 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loctite Loctite 22 N•m (16 lbf•ft) 4 N•m (35 lbf•in) Loctite 242 4 N•m (35 lbf•in) F08L19S PARTS FLAT RATE 12-02-16...

  • Page 361: Seat Adjustment

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT ADJUSTMENT All Models Except the XP Limited Adjust seat retainer no. 1 as per following specifi- cations: F02L24A GTS MODEL 1. Front hook 2. Adjustment nut (Loctite 271) 3. Nut (Loctite 242). Torque to 8 N•m (71 lbf•in) A.
  • Page 362 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) F06L03A F07L08A GS AND GSX LIMITED GTI AND GTX LIMITED — FRONT SEAT 1. Lock pin 1. Lock pin 2. Adjustment nut (apply Loctite 271) 2. Adjustment nut (Loctite 271) A. 33.5 ± 1 mm (1-5/16 ± 3/64 in) A.

  • Page 363: Storage Compartment Cover Adjustment

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) STORAGE COMPARTMENT COVER ADJUSTMENT Adjust lock pin no. 3 as per following specifica- tions: F07L09A GTI AND GTX LIMITED 1. Lock pin (apply Loctite 242) 2. Rubber washer 3. Flat washers A. 39.2 ± 1 mm (1-35/64 ± 3/64 in) F02L25C NOTE: The GTI and GTX Limited have a floating type lock pin.

  • Page 364: Access Panel Adjustment

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ACCESS PANEL ADJUSTMENT Remove jet pump. Refer to JET PUMP 09-02. Remove the speed sensor from the riding plate (if XP Limited applicable). Adjust lock pin no. 3 of access panel as per fol- Loosen riding plate screws.

  • Page 365: Jet Pump Support

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) F05K02A TYPICAL F07L0DA 1. Unscrew nut GS, GSX LIMITED, GTI AND GTX LIMITED Remove ball joint, boot, nut, half rings and O-rings from reverse cable (GTI and GTX Limited). Remove boot and nut from VTS sliding shaft (GSX Limited and XP Limited).

  • Page 366: Deflector

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) NOTE: Shims may have been installed between Installation support and body. Do not remove these shims, Apply Loctite 598 Ultra Black as indicated by the otherwise jet pump alignment will be altered. shaded area in the following illustration.

  • Page 367: Seat Removal

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT REMOVAL XP Limited Loosen 4 screws and remove bottom cover no. 17 of seat. F08L13A 1. Gear clamp Remove bolt and lock nut from shock absorber upper support. F08L11A 1. Remove cover Loosen gear clamp of outer boot;...

  • Page 368: Seat Cover Replacement

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Remove protective caps no. 18 and loosen screws SEAT COVER REPLACEMENT no. 19 to remove eyelet no. 20 on each side of Install staples with an electric tacker such as Ar- seat. row tacker no.

  • Page 369: Sponson Replacement

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) From bilge, unscrew sponsons no. 6 using a 10 mm deep socket with an extension. Remove sponsons no. 6. Clean any residues of sealant adhesive on hull. Install gaskets no. 7 on new sponsons no. 6. Apply 732 sealant (P/N 293 800 006) or sealant ad- hesive (P/N 293 800 033) around sponson studs.

  • Page 370: Engine Cover Removal

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ENGINE COVER REMOVAL Remove half of the decal back protective film and align decal with marks. Start sticking it from cen- XP Limited ter and remove the other half of the film to stick it completely.

  • Page 371: Hull And Body Repair

    FILLING THE CAVITY The prepared surface must be cleaned with ace- General tone on a cloth. Use the Bombardier gelcoat repair kit (P/N 295 500 100). Follow the mixing instruc- Gelcoat is the smooth and durable cosmetic finish tions in the kit when preparing the gelcoat putty.
  • Page 372 Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) In case of fractures which have not penetrated SANDING past the gelcoat layer, the repair concerns the Wash the polyvinyl alcohol off with water. De- gelcoat 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 373: Tools And Materials List

    For a small crack use an epoxy filler in the same – air mask way you would use Bombardier’s gelcoat repair – white cloths putty. When laying up a larger area you will use –...

  • Page 374: Hull Insert Repair

    Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) HULL INSERT REPAIR For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw. F01L2VA 1. Knurled surface 2. Inner bore Install aluminum insert into plastic hull insert. F01L2UA NOTE: Align aluminum insert as much as possi- ble with PTO flywheel.
  • Page 375 Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL) SPX MODEL ENGINE SPX (5838/5839) Engine type BOMBARDIER-ROTAX 787 Induction type Rotary valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Exhaust system Water injection fitting (cone)
  • Page 376 Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL) ELECTRICAL SPX (5838/5839) 180 W @ 6000 RPM Magneto generator output or 5.0 A @ 6000 RPM Ignition system type Digital DC-CDI Make and type NGK BR8ES Spark plug 0.5 - 0.6 mm (.020 - .024 in) mm (in) 3.38 (.133) Ignition timing...
  • Page 377 Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL) PROPULSION SPX (5838/5839) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC...
  • Page 378 Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL) MATERIALS SPX (5838/5839) Hull Composite Inlet grate Plastic Impeller housing/stator/venturi/nozzle Plastic/brass/plastic/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic with polyethylene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat...
  • Page 379 Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL) TIGHTENING TORQUES SPX (5838/5839) Exhaust manifold screw 40 N•m (30 lbf•ft) (3) (4) Magneto flywheel nut 105 N•m (77 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) 24 N•m (17 lbf•ft) (3) (4) Crankcase screws 40 N•m (30 lbf•ft)
  • Page 380 Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED) GS AND GSX LIMITED ENGINE GS (5626/5844) GSX Limited (5629/5845) Engine type BOMBARDIER-ROTAX 717 BOMBARDIER-ROTAX 947 Induction type Rotary valve Reed valve Water cooled, water injected Type Water cooled, water injected...
  • Page 381 Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED) ELECTRICAL GS (5626/5844) GSX Limited (5629/5845) 160 W @ 6000 RPM 180 W @ 6000 RPM Magneto generator output or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM Ignition system type Digital CDI Digital DC-CDI...
  • Page 382 Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED) PROPULSION GS (5626/5844) GSX Limited (5629/5845) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines...
  • Page 383 Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED) MATERIALS GS (5626/5844) GSX Limited (5629/5845) Hull Composite Inlet grate Aluminum Plastic/plastic/ Plastic/brass/aluminum/ Impeller housing/stator/venturi/nozzle plastic/plastic aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Tubular wire screen Exhaust muffler Aluminum Resonator Not applicable...
  • Page 384 Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED) TIGHTENING TORQUES GS (5626/5844) GSX Limited (5629/5845) Exhaust manifold screw 24 N•m (17 lbf•ft) (4) 40 N•m (30lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) (1) 115 N•m (85 lbf•ft) Flywheel (PTO side) •ft ) (5) 115 N•m (85 lbf•ft)
  • Page 385 Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED) XP LIMITED ENGINE XP Limited (5665/5667) Engine type BOMBARDIER-ROTAX 947 Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Exhaust system Water injection fitting (cone)
  • Page 386 Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED) ELECTRICAL XP Limited (5665/5667) 180 W @ 6000 RPM Magneto generator output or 5.0 A @ 6000 RPM Ignition system type Digital DC-CDI Make and type NGK BR8ES Spark plug 0.5 - 0.6 mm (.020 - .024 in) mm (in) 3.60 (.142) Ignition timing...
  • Page 387 Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED) PROPULSION XP Limited (5665/5667) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Split FR and RR SEA-DOO JET PUMP SYNTHETIC...
  • Page 388 Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED) MATERIALS XP Limited (5665/5667) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/brass/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Exhaust muffler Aluminum Resonator Plastic Steering padding Thermoplastic with polyethylene foam Fuel tank Polyethylene Oil injection reservoir...
  • Page 389 Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED) TIGHTENING TORQUES XP Limited (5665/5667) Exhaust manifold screw 40 N•m (30 lbf•ft) Magneto flywheel nut 115 N•m (85 lbf•ft) Flywheel (PTO side) 115 N•m (85 lbf•ft) 27 N•m (20 lbf•ft) (3) (4) Crankcase screws 40 N•m (30 lbf•ft)
  • Page 390 Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL) GTS MODEL ENGINE GTS (5819) Engine type BOMBARDIER-ROTAX 717 Induction type Rotary valve Type Water cooled, water injected Water injection fitting 3.5 mm (.139 in) Exhaust system (head) Water injection fitting 3.5 mm (.139 in)
  • Page 391 Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL) ELECTRICAL GTS (5819) Magneto generator output 160 W @ 6000 RPM or 4.0 A @ 2000 RPM Ignition system type Digital CDI Make and type NGK BR8ES Spark plug 0.5 - 0.6 mm (.020 - .024 in) mm (in) 2.59 (.102) Ignition timing...
  • Page 392 Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL) PROPULSION GTS (5819) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC...
  • Page 393 Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL) MATERIALS GTS (5819) Hull Composite Inlet grate Plastic Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/plastic Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Exhaust muffler Aluminum Steering padding Thermoplastic elastomer with polystyrene foam Fuel tank Polyethylene Oil injection reservoir Polyethylene...
  • Page 394 Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL) TIGHTENING TORQUES GTS (5819) Exhaust manifold screws 24 N•m (17 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) 24 N•m (17 lbf•ft) (3) (4) Crankcase screws 40 N•m (30 lbf•ft) (3) (4)
  • Page 395 Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED) GTI AND GTX LIMITED ENGINE GTI (5836/5841) GTX Limited (5837/5842) Engine type BOMBARDIER-ROTAX 717 BOMBARDIER-ROTAX 947 Induction type Rotary valve Reed valve Water cooled, water injected Type Water cooled, water injected...
  • Page 396 Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED) ELECTRICAL GTI (5836/5841) GTX Limited (5837/5842) 160 W @ 6000 RPM 180 W @ 6000 RPM Magneto generator output or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM Ignition system type Digital CDI Digital DC-CDI...
  • Page 397 Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED) PROPULSION GTI (5836/5841) GTX Limited (5837/5842) Propulsion system Bombardier Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines...
  • Page 398 Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED) MATERIALS GTI (5836/5841) GTX Limited (5837/5842) Hull Composite Inlet grate Aluminum Plastic/brass/plastic/ Plastic/brass/aluminum/ Impeller housing/stator/venturi/nozzle plastic aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Tubular wire screen Exhaust muffler Aluminum Resonator Not applicable...
  • Page 399 Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED) TIGHTENING TORQUES GTI (5836/5841) GTX Limited (5837/5842) Exhaust manifold screw 24 N•m (17 lbf•ft) (4) 40 N•m (30 lbf•ft) Magneto flywheel nut 145 N•m (107 lbf•ft) (1) 115 N•m (85 lbf•ft) Flywheel (PTO side) 110 N•m (81 lbf•ft) (5) 115 N•m (85 lbf•ft)
  • Page 400 Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WIRE COLOR CODES AMP PLUG CONNECTOR First color of a wire is the main color. Second color All Models Except SPX and GTS is the tracer. These connectors are found on the MPEM. Example: YELLOW/BLACK is a YELLOW wire When servicing electrical system, special care with a BLACK tracer.
  • Page 401 Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Removal Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header To remove the plug connector from the header as- on the MPEM. sembly, press both tabs and pull plug. F00H0NA Step : Press tabs (both sides)
  • Page 402 Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) F00H0QA F00H0OA 1. Screwdriver between wedge lock and connector 1. Rotate wire back and forth 2. Locking tab 2. Pull wire Repeat the same steps for the other locking tab POWER WIRE CONTACT retaining the wedge lock.
  • Page 403 Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) F00B0EA CRIMPING TOOL (P/N 295 100 164) All circuits are sealed by a diaphragm in the rubber wire seal. When installing wire contacts in plug connector, the diaphragm is pierced as the con- tact passes through it.
  • Page 404 Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CAUTION Do not pierce the diaphragm with a sharp point for electrical troubleshooting. The re- sulting pinholes in the insulation will allow moisture to penetrate the system and possi- bly result in system failure. Contact Installation For insertion of signal contact, make sure the wedge lock is in the open position.

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