Page 1 www.SeaDooManuals.net...
Page 2 2005 Vehicle Shop Manual 4-TEC Series www.SeaDooManuals.net...
Page 3 Legal deposit: National Library of Quebec National Library of Canada 2005 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) Bombardier Recreational Products Inc. (BRP) 2005 ©...
Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY NOTICE ................. .. VI INTRODUCTION ..
Page 5 TABLE OF CONTENTS ENGINE SYSTEM 01 – AIR INTAKE SYSTEM ..................27 INSPECTION.
Page 6 TABLE OF CONTENTS IDLE SPEED ......................111 IGNITION TIMING .
Page 7 TABLE OF CONTENTS STARTER SPECIFICATION ..................171 04 –...
Page 8 TABLE OF CONTENTS HULL/BODY 01 – ADJUSTMENT AND REPAIR ................251 GENERAL .
Page 9: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2005 SEA-DOO watercraft as describe in the model list in the INTRODUCTION. This edition was primarily published to be used by watercraft mechanical technicians who are already fa- miliar with all service procedures relating to BRP made watercraft.
Page 10: Introduction
INTRODUCTION INTRODUCTION GENERAL INFORMATION This VEHICLE SHOP MANUAL covers the following BRP made SEA-DOO ® 2005 watercraft models. It should be used in conjunction with the 1503 4-TEC ENGINE SHOP MANUAL. MODEL COLOR ENGINE MODEL NUMBER Twilight Blue Pearl 1503 Naturally Aspirated 145A, 145B GTX Limited Midnight Black Pearl...
Page 11: Arrangement Of This Manual
INTRODUCTION ARRANGEMENT OF THIS It is located on footboard at the rear of watercraft. MANUAL The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual. Several sections are divided in various subsec- tions.
Page 12: Illustrations And Procedures
INTRODUCTION ABBREVIATION DESCRIPTION RAVE Rotax Adjustable Variable Exhaust Rotax Fuel Injection Revolution Per Minute Supercharger Standard To Be Determined Top Dead Center Throttle Position Sensor Volt Direct Current Vehicle Communication Kit Volt Direct Current Variable Trim System Water Temperature Sensor ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction of...
Page 13 INTRODUCTION Page heading indicates section and subsection detailed. Subsection title indicates beginning of the subsection. Italic sub-title above exploded view indicate pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 243 to screw threads.
Page 14 INTRODUCTION Sub-title with part name(s) from exploded view. Section 06 FUEL SYSTEM Title indicates main procedure to be carried-out. To remove carburetors from engine, proceed as fol- Inspect parts for corrosion dammage (shaft, butterfly, lows: spring screw, check valve housing, etc.). Sub-sub-title in Remove air vent tube support.
Page 15: Engine Emissions Information
INTRODUCTION ENGINE EMISSIONS EPA Emission Regulations INFORMATION All new 1999 and more recent Sea-Doo water- crafts manufactured by BRP are certified to the Manufacturer's Responsibility EPA as conforming to the requirements of the regulations for the control of air pollution from Beginning with 1999 model year engines, PWC new watercraft engines.
Page 16: Loctite Application Procedure
INTRODUCTION LOCTITE APPLICATION Blind Holes PROCEDURE The following describes the most common ap- plication procedures when working with Loctite products. NOTE: Always use proper strength Loctite prod- uct as recommended in this SHOP MANUAL. Threadlocker Uncovered Holes (bolts and nuts) 1.
Page 17 INTRODUCTION – Install stud. Adjusting Screw – Install cover, etc. – Apply drops of proper strength Loctite on un- covered threads. – Tighten nuts as required. Preassembled Parts 1. Apply here 2. Plunger – Adjust screw to proper setting. – Apply drops of proper strength Loctite thread- locker on screw/body contact surfaces.
Page 18 INTRODUCTION b. Put waxed paper or similar film on the sur- – Apply GASKET ELIMINATOR 518 (P/N 293 800 faces. 038) on both sides of gasket, using a clean ap- plicator. – Twist bolt when inserting it to improve thread conformation.
Page 19: Tightening Torques
INTRODUCTION Case-in Components In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the Metallic Gaskets following procedure: – Manually screw all screws, bolts and/or nuts. – Apply the half of the recommended torque value. CAUTION: Be sure to use the proper tightening torque for the proper strength grade.
Page 20 INTRODUCTION FASTENER GRADE/TORQUE FASTENER SIZE Grade Grade Grade Grade 10.9 12.9 1.5 — 2 N•m 2.5 — 3 N•m 3.5 — 4 N•m 4 — 5 N•m (13 — 18 lbf•in) (22 — 27 lbf•in) (31 — 35 lbf•in) (35 — 44 lbf•in) 3 —...
Page 21: Maintenance
Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART The schedule should be adjusted according to operating conditions and use. NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte- nance operation to whatever time comes first. IMPORTANT: Watercraft rental operations or intensive use of watercraft, will require greater frequency of inspection and maintenance.
Page 22 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) 4-TEC MODELS A: ADJUST FIRST 10 HOURS C: CLEAN EVERY 25 HOURS OR 3 MONTHS I: INSPECT EVERY 50 HOURS OR 6 MONTHS L: LUBRICATE R: REPLACE EVERY 100 HOURS OR 1 YEAR T: PROCEED WITH TASK PART/TASK LEGEND...
Page 23: Preseason Preparation
Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) PRESEASON PREPARATION TO BE PERFORMED BY PRESEASON PREPARATION REFER TO CUSTOMER DEALER GENERAL ✔ Lubrication and corrosion protection Storage Procedure ✔ Spark plugs replacement (1) Ignition System ENGINE ✔ Exhaust system condition and fasteners Exhaust System SHOP Appropriate engine...
Page 24 Section 01 MAINTENANCE Subsection 02 (PRESEASON PREPARATION) TO BE PERFORMED BY PRESEASON PREPARATION REFER TO CUSTOMER DEALER PROPULSION SYSTEM ✔ Shifter system condition and cable adjustment Reverse System Variable Trim System (VTS) condition ✔ VTS System (if so equipped) ✔ Propulsion system inspection Jet Pump and Drive System HULL and BODY...
Page 25: Storage Procedures
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) STORAGE PROCEDURES SERVICE TOOLS Description Part Number Page flushing connector adaptor ........... 295 500 473 ..........6 small hose pincher..............295 000 076 ..........7 SERVICE PRODUCTS Description Part Number Page anticorrosion coating ............219 700 304 ..........9 Bombardier fuel stabilizer .............
Page 26 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) Cooling system flushing should be performed when the watercraft is not expected to be used further the same day or when the watercraft is stored for any extended time. CAUTION: Failure to flush open loop cooling system, when necessary, will severely dam- age engine intercooler and/or exhaust system.
Page 27 Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) Close the water tap, then stop the engine. Install a small hose pincher (P/N 295 000 076) (sup- plied inside vehicle tool kit) on water outlet hose. CAUTION: Always close the water tap before This prevent water from directly existing exhaust stopping the engine.
Page 28: Closed Loop Cooling System (Engine)
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) CAUTION: Never run engine without supplying – Spray liberally BOMBARDIER LUBE lubricant water to the exhaust cooling system when wa- (P/N 293 600 016) into the intake ports. tercraft is out of water. –...
Page 29: Battery
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) – Let the intercooler drain, then connect the bot- If the watercraft is to be stored outside, cover it tom hose. with an opaque tarpaulin to prevent sun rays and grime from affecting the plastic components, wa- –...
Page 30: Checklist
Section 01 MAINTENANCE Subsection 03 (STORAGE PROCEDURES) CHECKLIST ✔ OPERATION Verify jet pump grease. Verify fuel system. Add Bombardier fuel stabilizer. Fill up fuel tank. Change engine oil and filter. Check engine drain hose(s). Flush exhaust cooling system. Replace antifreeze. Check solution concentration in the cooling system (in cool regions).
Page 31: Special Procedures
Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE TOOLS Description Part Number Page large hose pincher ..............529 032 500 ........... 11 oil pump cover fitting............293 710 037 ........... 13 pump ..................529 035 880 ........... 13 SERVICE PRODUCTS Description Part Number...
Page 32: Submerged Watercraft
Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Throttle Body Throttle body should be lubricated to prevent corrosion if watercraft was submerged. Refer to STORAGE for procedure. WATER-FLOODED ENGINE If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise en- gine will have to be overhauled.
Page 33 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) Supercharger Supercharged 4-TEC Engines If there was water in the oil or in the intake mani- fold, it is recommended to take the supercharger apart, dry all the components, replace the slip clutch needle bearings and shaft ball bearings. Refer to 1503 4-TEC ENGINE SHOP MANUAL.
Page 34 Section 01 MAINTENANCE Subsection 04 (SPECIAL PROCEDURES) CAUTION: Never run engine without supplying WARNING water to the exhaust cooling system when wa- Make sure to safely secure the watercraft. tercraft is out of water. – Run the engine for 5 minutes at 3000 RPM. –...
Page 35: Troubleshooting
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) TROUBLESHOOTING CHART The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to show all causes for all problems. NOTE: On fuel injection models, always check for fault codes. If a fault code is detected, service the fault code and recheck operating conditions.
Page 36 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Loose battery cable connections Check/clean/tighten Discharged/weak battery Check/charge/replace Restriction in jet pump Check/clean pump Partial seizure in jet pump Inspect, refer to PROPULSION SYSTEM Partial engine hydro-lock Check, refer to MAINTENANCE Partial engine seizure 1503 Check compression, refer to the...
Page 37: Engine Hard To Start
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Engine turns over (cont'd) Defective encoder/trigger wheel Check, refer to ENGINE MANAGEMENT Incorrectly aligned flywheel and trigger Properly position flywheel and trigger 1503 4-TEC ENGINE wheel wheel, refer to the SHOP MANUAL Insufficient engine compression Replace defective part(s)
Page 38: Engine Starts But Runs Only At Idle Speed
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED OTHER OBSERVATION POSSIBLE CAUSE REMEDY The system is in limp home mode Refer to ENGINE MANAGEMENT and check the fault codes Broken or loose throttle cable Change/readjust ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION...
Page 39: Engine Continually Backfires
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Check spark plug condition, check fault Check, refer to IGNITION SYSTEM and codes, check fuel pressure. ENGINE MANAGEMENT. If some work has been performed on the unit, make sure injector wire connectors were not Starts, but runs poorly mixed.
Page 40: Engine Lacks Acceleration Or Power
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark Check/replace, refer to IGNITION SYSTEM Throttle does not open fully Check/readjust, refer to ENGINE MANAGEMENT Low compression 1503 4-TEC Check/repair, refer to the ENGINE SHOP MANUAL Water in fuel Check/siphon/replace...
Page 41: Engine Cannot Reach Maximum Rpm
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE CANNOT REACH MAXIMUM RPM OTHER OBSERVATION POSSIBLE CAUSE REMEDY Low fuel pressure Check fuel pump pressure output Jet pump related problem Check propulsion components. Refer to JET PUMP Limp home mode activated Refer to ENGINE MANAGEMENT Exhaust system blockage/muffler Check and repair...
Page 42: Engine Overheats
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE OVERHEATS OTHER OBSERVATION POSSIBLE CAUSE REMEDY Coolant level low Refill/check for leaks Coolant leaking out of weep hole Replace seal (PTO housing) Hoses or clamps missing/defective Repair/replace Coolant level too low Cylinder head gasket leaks Replace cylinder head gasket (white exhaust gas) Thermostat failure...
Page 43: Low Or No Engine Oil Pressure
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) LOW OR NO ENGINE OIL PRESSURE OTHER OBSERVATION POSSIBLE CAUSE REMEDY Oil level too low Refill. See TECHNICAL DATA for specifications Leaking gasket Replace Oil leaking out of weep hole (PTO housing) Replace oil seal on pump shaft Oil pressure sensor defective Check/replace Oil pump malfunctioning...
Page 44: Unusual Engine Noise And/Or Vibration
Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) UNUSUAL ENGINE NOISE AND/OR VIBRATION OTHER OBSERVATION POSSIBLE CAUSE REMEDY Worn chain tensioner Replace Worn chain guide Replace Stretched chain and/or worn out sprockets Replace chain and sprockets Sprocket screws got loose Retorque Hydraulic element inside rocker arm(s) Replace faulty rocker arm(s) and/or lifters is worn out (valve adjustment) or lifter...
Page 45 Section 02 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) NOTE: Prior to replacing an ECM or MPEM, refer to the appropriate ECM/MPEM section or ECM/MPEM replacement in the ENGINE MANAGEMENT section and read carefully the tests to do before replacing an ECM/MPEM that could otherwise be good. smr2005-006 www.SeaDooManuals.net...
Page 46: Engine System
Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM SERVICE TOOLS Description Part Number Page hook tool................529 035 989 ........... 30 smr2005-029 www.SeaDooManuals.net...
Page 47 Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) 4-TEC Naturally Aspirated Engine smr2005-029 www.SeaDooManuals.net...
Page 48 Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) 4-TEC Supercharged and Supercharged Intercooled Engines smr2005-029 www.SeaDooManuals.net...
Page 49: Inspection
Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) INSPECTION Check for water in air silencer no. 1. If so, replace check valves no. 2. Check collar tightness. En- sure there is no water trapped in tube no. 3 (if so equipped).
Page 50: Installation
Section 03 ENGINE SYSTEM Subsection 01 (AIR INTAKE SYSTEM) 1. Lift lock tab 1. Vent tube support 2. Remove retaining screws 3. Pay attention to nuts underneath – coolant expansion tank – tube from air intake hose Pull tube out. Step 1: Push tab (each side) to release Step 2:...
Page 51: Lubrication System
Section 03 ENGINE SYSTEM Subsection 02 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page suction pump................ 529 035 880 ........... 35 SERVICE PRODUCTS Description Part Number Page pulley flange cleaner............. 413 711 809 ........... 35 GENERAL Prior to changing the oil, ensure vehicle is on a level surface.
Page 52: Oil Change
Section 03 ENGINE SYSTEM Subsection 02 (LUBRICATION SYSTEM) Check the oil level as follows: NOTE: It is of the utmost importance to follow this procedure in order to obtain an accurate reading of the engine oil level. – Watercraft must be level. Check oil level either with watercraft in water or out of water.
Page 53: Oil Type And System Capacity
Section 03 ENGINE SYSTEM Subsection 02 (LUBRICATION SYSTEM) OIL TYPE AND SYSTEM Run engine for 10 seconds at 4000 RPM and shut it off at this RPM. This will move oil from PTO CAPACITY housing to oil tank to allow maximum oil draining. Refer to TECHNICAL SPECIFICATIONS.
Page 54 Section 03 ENGINE SYSTEM Subsection 02 (LUBRICATION SYSTEM) Check and clean the oil filter inlet and outlet area for dirt and other contaminations. TYPICAL 1. Inlet bore from the oil pump to the oil filter 2. Outlet bore to the engine oil providing system Installation For installation, reverse the removal procedure.
Page 55: Cooling System
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page pliers Oetiker 1099 ............... 295 000 070 ........... 46 test cap................. 529 035 991 ........... 39 vacuum/pressure pump ............529 021 800 ........... 39 SERVICE PRODUCTS Description Part Number...
Page 56: Closed Loop Cooling System (Engine)
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) CLOSED LOOP COOLING SYSTEM (engine) smr2005-008 www.SeaDooManuals.net...
Page 57: Circuit
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) CIRCUIT COOLING SYSTEM LEAK TEST A closed loop cooling system is utilized on the WARNING 1503 4-TEC engines, which offers an efficient en- To avoid potential burns, do not remove the gine cooling while keeping dirt and salt water out expansion tank cap or loosen the ride plate of the cooling system.
Page 58: Inspection
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) CAUTION: To prevent rust formation or freez- ing condition in cold areas, always replenish the system with 50% antifreeze and 50% dem- ineralized water. Pure antifreeze will freeze at a higher temperature than the optimal water/ antifreeze mix.
Page 59 Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) Drain the cooling system. Clean thoroughly using the Valvoline Zerex Super Cleaner (or equivalent). Add the cleaning product in coolant expansion tank then fill cooling system with demineralized water. Reinstall cap on coolant expansion tank. Install watercraft in a water tank or ride on a water plane.
Page 60: Care
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) TECHNICAL SPECIFICATIONS 1. This becomes hot when thermostat opens Last, refill expansion tank and install pressure cap. TYPE Closed loop cooling system. When engine has completely cooled down, recheck coolant level in radiator and coolant tank COOLANT FLOW Flow from coolant pump.
Page 61: Opened Loop Cooling System (Exhaust System)
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) OPENED LOOP COOLING SYSTEM (exhaust system) GTX 4-TEC and WAKE smr2005-008-001_a GTX 4-TEC Supercharged smr2005-008-002_a smr2005-008 www.SeaDooManuals.net...
Page 62 Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) GTX 4-TEC Limited and RXT smr2005-008-003_a smr2005-008-004_a smr2005-008 www.SeaDooManuals.net...
Page 63: Circuit
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) CIRCUIT The water supply is provided by a pressurized area in the jet pump between the impeller and venturi. The water flow is controlled by a reducer located between the jet pump support and the jet pump on the inlet side.
Page 64: Care
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) 1. Cutting clamp 2. Securing clamp CARE For flushing and winterization procedures of the opened loop cooling system, refer to STORAGE. When servicing the hull, rotate watercraft either way (seen from the rear) maximum to 90°. TYPICAL 1.
Page 65: Technical Specifications
Section 03 ENGINE SYSTEM Subsection 03 (COOLING SYSTEM) TECHNICAL SPECIFICATIONS TYPE Total Loss Cooling System (TLCS). COOLANT FLOW Flow from jet pump (no water pump). TEMPERATURE Calibrated outlet fittings CONTROL (no thermostat). SYSTEM BLEEDING Self-bleed type (hose at uppermost point of circuit). SYSTEM DRAINING Self-drain type (hose at lowest point of circuit).
Page 66: Exhaust System
Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page exhaust outlet tool..............295 000 132 ........... 56 spring installer/remover ............529 035 989 ........... 51 SERVICE PRODUCTS Description Part Number Page high temperature RTV sealant ..........293 800 090 ........... 52 Loctite 518................
Page 67 Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) RXP models smr2005-009-001_aen smr2005-009 www.SeaDooManuals.net...
Page 68: Exhaust Pipe
Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) EXHAUST PIPE Removal WARNING Certain components in the engine compart- ment may be very hot. Direct contact may result in skin burn. Let exhaust system cool down prior to removing parts. All Models except RXP Remove seat and seat extension.
Page 69 Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) Move muffler no. 4 backward enough to allow the exhaust pipe to be pulled out. Inspection Inspect exhaust pipe condition paying attention for cracks or other damage. Check joints, coupling ar- eas, heat shield and hoses. Replace any defective part.
Page 70 Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) smr2005-009-002_a 1. Exhaust pipe step 1. Engine manifold 2. Muffler hose 2. Exhaust pipe flange 3. Muffler hose clamp 4 - 5 mm (5/32 - 3/16 in) apart 4. Bottom clamp CAUTION: Exhaust pipe alignment with the manifold is critical to the bellows life.
Page 71: Exhaust Manifold
Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) After installation, ensure there is no water or ex- haust gas leak when engine is running. Test run the engine while supplying water to the flushing connector. CAUTION: Never run engine without supplying water to the exhaust cooling system when wa- tercraft is out of water.
Page 72: Muffler
Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) TYPICAL Inspection After installation, ensure there is no coolant or ex- haust gas leak when the engine is running. Test Inspect exhaust manifold condition paying atten- run the engine while supplying water to the flush- tion for cracks or other damage.
Page 73: Resonator
Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) RESONATOR Inspection Inspect parts condition paying attention for defor- Removal mation, cracks or other damage. Check hoses. RXP Models Replace any defective part. Remove supercharger inlet hose. Installation Disconnect speed sensor connector. Installation is the reverse of the removal proce- Remove VTS.
Page 74 Section 03 ENGINE SYSTEM Subsection 04 (EXHAUST SYSTEM) Inspection Inspect parts condition paying attention for cracks or other damage. Check hose. Replace any de- fective part. Installation Installation is essentially the reverse of the re- moval procedures. However, pay particular atten- tion to the following.
Page 75: Removal And Installation
Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page Alignment shaft ..............295 000 141 ........... 64 engine alignment adapter ............ 529 035 719 ........... 64 Engine alignment adapter............. 529 035 719 ........... 64 plate..................
Page 76 Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) All Models 1. Remove connectors 2. Disconnect ECM 3. Remove ECM Unplug VTS connector. Cut locking ties retaining vehicle wiring harness to engine. 1. Battery ground 2. Engine grounds GTX 4-TEC Series and RXT 4-TEC Disconnect the throttle position sensor (TPS), manifold air pressure sensor (MAPS) and man- ifold air temperature sensor (MATS) (refer to...
Page 77 Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) O.P.A.S. To disconnect O.P.A.S., refer to STEERING sec- tion. Jet Pump Removal To withdraw jet pump, refer to PROPULSION sec- tion. Drive System To withdraw drive shaft, refer to PROPULSION section. Cooling System Drain cooling system, refer to COOLING SYSTEM section.
Page 78 Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) FRONT SUPPORT 1. Remove screw TYPICAL 1. Lifting brackets RXP 4-TEC Models Slightly move engine rearward to take advantage of the larger opening. The engine have to be hooked-up at an additional location.
Page 79: Cleaning
Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) 1. Lift steel rope/chain here to rotate engine 2. Usual lifting brackets All Models Removal of Remaining Components CLEANING Disconnect RED positive cable from starter post. Wipe off any spillage in bilge. Clean with the pul- ley flange cleaner (P/N 413 711 809).
Page 80 Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) Ensure contact surface is perfectly clean then re- connect grounds wires/cable to engine. Engine Support Do not apply threadlocker to engine support screws and do not torque yet. Engine/Jet Pump Alignment Alignment is necessary to eliminate possible vi- bration and/or damage to components.
Page 81 Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) TYPICAL 1. Engine alignment adapter 2. Alignment shaft If the alignment is incorrect loosen engine sup- port screws to enable to align engine alignment adapter with shaft end. NOTE: Use shim(s) (P/N 270 000 024) or (P/N 270 1.
Page 82 Section 03 ENGINE SYSTEM Subsection 05 (REMOVAL AND INSTALLATION) 1. Torque to 25 N•m(18 lbf•ft) Properly align exhaust pipe. Refer to EXHAUST SYSTEM in ENGINE section. Final Inspection Check throttle cable condition and lubricate it with BOMBARDIER LUBE (P/N 293 600 016) lubricant. After its installation, properly adjust throttle cable then perform the TPS reset as specified in EN- GINE MANAGEMENT.
Page 83: Engine Management (1503 4-Tec)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) OVERVIEW ECM Engine Control Module Multi-Purpose Electronic Module Knock Sensor Cranshaft Position Sensor Oil Pressure Sensor Oil Separator Pressure Sensor Coolant Temperature Sensor Camshaft Position Sensor Exhaust Gas Temperature Sensor Manifold Air Pressure Sensor Manifold Air Temperature Sensor Tip-Over Protection System Connector for Engine Wiring Harness...
Page 84: Operating Principle
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) OPERATING PRINCIPLE AIR INDUCTION Throttle Body It is a 52 mm throttle body mounted on intake manifold. Fitted on the throttle body, the TPS and the idle bypass valve allow the ECM to control the RPM while the throttle plate is closed.
Page 85 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) Intake Manifold The intake manifold is mounted on the RH side of the cylinder block. It provides support for the fuel injectors, the fuel rail, the ECM, the flame arrester and the throttle body. The intake manifold is a resonator between the throttle body and the cylinder head.
Page 86: Fuel System
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) Intercooler The intercooler is a tube which comprises smaller tubes. Water taken from the outside of the wa- tercraft is pumped through the smaller tubes and cools down the intake air. Therefore the air densi- ty is higher and you get more air into the engine.
Page 87 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) For communication link troubleshooting, refer to The fault codes can be seen from either the infor- INSTRUMENTS AND ACCESSORIES in ELECTRI- mation center or B.U.D.S. Refer to DIAGNOSTIC CAL section. PROCEDURES section. The communication link is also used to communi- cate informative messages, monitoring and diag- nostic codes to the information center and to the...
Page 88: Engine Management System (Ems)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) ENGINE MANAGEMENT SYSTEM (EMS) A highly advanced EMS has been used to ensure a high power output with cleanest combustion. The EMS calculates the proper air/fuel mixture and ignition timing for each cylinder separately. NOTE: The EMS includes an ECM (engine control module), MPEM (multi-purpose electronic mod- ule), sensors, injectors, electromagnetic valves...
Page 89 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) smr2005-011-003_a 1. MPEM IMPORTANT: Some components are continu- ously powered with the supply from the battery through MPEM. The ECM switches the ground to complete the electrical circuits it controls. Take this into account when troubleshooting the elec- trical system.
Page 90: Ems - Engine Management System Functions
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS As shown in the 1503 4-TEC CONTROL SYSTEM illustration, the ECM is the central point of the engine management system. It reads the inputs, makes computations, uses pre-determined parameters and sends the proper signals to the outputs for proper engine management.
Page 91 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) Electronic Fuel Injection This ignition system allows spark plugs to spark independently. The ECM reads the signals from different sensors which indicate engine operating conditions at milli- All three ignition coils are located on the cylinder second intervals.
Page 92 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) Engine Modes of Operation NOTE: The memory of the ECM is programmed to recognize the digital code of the safety lan- The ECM controls different operation modes of yard cap. This is achieved with the VCK (Vehicle the engine to allow proper operation for all possi- Communication Kit) (P/N 529 035 981).
Page 93 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 01 (OVERVIEW) Limp Home Modes Low-Oil Pressure Warning Device Besides the signals as seen above, the ECM may When the oil pressure falls under a certain level, automatically uses default parameters for the en- the ECM sends out signals to the beeper and to gine management to ensure the adequate opera- the information center gauge.
Page 94: Diagnostic Procedures
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES SERVICE TOOLS Description Part Number Page VCK (Vehicle Communication Kit) ......... 529 035 981 ......... 105 GENERAL Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem.
Page 95 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) – Refer to COMPONENT INSPECTION, RE- PLACEMENT AND ADJUSTMENT section for procedures. Terminology Some documents or softwares use technical terms that may be different from the one used in this manual. The following table will help to find the equivalence.
Page 96: Self-Diagnostic Mode
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) SELF-DIAGNOSTIC MODE Refer to the following chart. For other problems, refer to COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT section. CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (while Engine can be started. •...
Page 97: Engine Management System Fault Codes
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) CODED SIGNALS POSSIBLE CAUSE REMEDY 2 seconds beep every 1 Turn watercraft upright. If it does not • Watercraft is upside down. minute interval. work, check the TOPS switch. Refer to ENGINE MANAGEMENT section.
Page 98 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) TPS (Throttle Position Sensor) Faults Faults which are reported in B.U.D.S. fall into two groups: TPS faults and adaptation faults. These are displayed on the B.U.D.S. system as TPS OUT OF RANGE and TPS ADAPTATION FAILURE. TPS “OUT OF RANGE”...
Page 99 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) Supplemental Information for Some Specific Faults Communication link fault code 1681: Some- times the information center does not synchronize fast enough for the MPEM. That brings this fault code. Simply clear the fault and try again. ECM fault codes P0601, P0602, P0604 and P605: These codes may occur in the following situations: –...
Page 100: Ems Fault Code Table
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) EMS Fault Code Table FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING...
Page 101 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 102 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 103 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 104 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 105 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 106 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 107 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 108 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 109 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 110 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 111 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 112 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 113 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 114 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 115 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 116 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 117 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (INFO CTR) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 118 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) Beeper Code Explanation BEEPER BEEPER PATTERN NOTE CODE smr2005-012 www.SeaDooManuals.net...
Page 119 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) Fuse and Related Fault Code FAULT DETECTED FUSE RATING (A) FAULT CODE WHILE ENGINE NOT RUNNING P0344, P1200 TOPS Depth gauge (if so equipped) or spare fuse P1675 Cylinder #3 ignition coil and injection P0353, P0267 Information center P1680, P1681...
Page 120: Vck (Vehicle Communication Kit)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) VCK (VEHICLE COMMUNICATION For more information pertaining to the use of the software B.U.D.S., use its help which contains de- KIT) tailed information on its functions. The VCK (Vehicle Communication Kit) (P/N 529 WARNING 035 981) is the primary tool to diagnose engine management and fuel injection related problems.
Page 121 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURES) MPEM AND ECM ARE CONNECTED Number 1 means that 1 “ECU” is connected (ei- ther MPEM or ECM). Therefore, there is a prob- lem. Check fuses and connections. ONLY ONE “ECU” IS WORKING. THERE IS A PROBLEM If an “X”...
Page 122: Component Inspection, Replacement And Adjustment
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT SERVICE TOOLS Description Part Number Page ECM adapter................. 420 277 010 ......... 110 engine leak test pump ............529 021 800 ......... 130 Fluke 111 ................
Page 123: Electrical System
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) WARNING WARNING Fuel lines remain under pressure at all times. If any gasoline leak and/or odor are present, Always proceed with care and use appro- do not start the engine. Repair the leak. priate safety equipment when working on pressurized fuel system.
Page 124 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Never use a battery charger to substitute Before replacing a MPEM or ECM, always check temporarily the battery, as it may cause the electrical connections. Make sure that they are MPEM/ECM to work erratically or not to work at very tight and they make good contact and that all.
Page 125 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) ECM Connectors TEMPERATURE RESISTANCE (OHMS) The most recommended and safest method to °C °F NOMINAL HIGH probe ECM connector terminals is to use the - 30 - 22 12600 11800 13400...
Page 126: Testing Procedures
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Wrap the tachometer's wire a few times around the protruding part of ignition coil. PROBE ONLY TOP OF TERMINAL Use this diagram to locate the terminal numbers on the ECM connector “A”...
Page 127: Ecm And Mpem
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Connect one test probe to the WHITE/GREY wire Disconnect both ECM connectors from ECM. and the other test probe to the switch top ter- minal. Measure resistance, it must be close to 0 ohm.
Page 128: Engine Wiring Harness
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) ENGINE WIRING HARNESS Finalizing ECM Replacement After performing the required resets, ensure to clear all faults from the newly replaced ECM. Start the engine and increase engine speed above 5000 RPM to be sure no fault appears.
Page 129 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) TYPICAL 1. Wiring harness ALL 4-TEC SUPERCHARGED ENGINES 1. ECM connector 2. CTS connector Remove complete wiring harness. 3. EGTS connector 4. CAPS connector Installation 5. Fuel injector connector (cylinder 1) 6.
Page 130: Fuel Injector
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Also connect now the MATS, TPS, idle bypass and TOPS valve to the wiring harness. Fix the wiring for the MATS with a locking tie to support the cables. 1.
Page 131 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) The leakage test is validated when performing the Resistance Test FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW Reconnect the injector and disconnect the ECM CHART elsewhere in this section. connector A.
Page 132: Throttle Body
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Fuel Injector Replacement Unscrew rail retaining screws. Gently pull rail up by hand, working each side Removal slightly at a time. Remove fuel rail cover from the engine. Pull rail out with fuel injectors.
Page 133: Throttle Body
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Replacement Removal To remove the throttle body from engine, proceed as follows: – Disconnect air intake silencer from throttle body. Move boot away. – Remove retaining screws of throttle body. TYPICAL 1.
Page 134 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Installation Throttle Cable Adjustment Installation of the new throttle body is the reverse Mechanically adjust the throttle cable. of the removal procedure. Lubricate cable with BOMBARDIER LUBE lubri- cant.
Page 135: Throttle Position Sensor (Tps)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Tighten jam nut and recheck adjustment. WARNING Make sure idle speed stopper contacts throt- tle cam when throttle lever is fully released at handlebar. Closed Throttle and Idle Actuator Reset Perform the CLOSED THROTTLE AND IDLE AC- TUATOR RESET as described in THROTTLE POSI- TION SENSOR (TPS) below.
Page 136 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) To see the connector pin-out, temporarily remove the connector shield joining the harness, to ex- pose the terminal numbers. Connect a voltmeter to the terminals of the wiring harness as per the following table.
Page 137: Idle Bypass Valve
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Ensure the throttle body plate stop lever rest If resistance test of valve windings is good, check against its stopper. Open throttle approximately continuity of circuits A-35, A-36, A-37, A-38. one quarter then quickly release.
Page 138: Camshaft Position Sensor (Caps)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) CAMSHAFT POSITION SENSOR NOTE: Take into account that a CPS fault can be triggered by a bent or missing trigger wheel tooth. (CAPS) First check fault codes then CPS as per follow- ing procedure;...
Page 139: Manifold Air Temperature Sensor (Mats)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) CAPS PIN-OUT 1. CAPS 2. Conductor If the voltage is not good, replace the CAPS. Replacement Unscrew the retaining screw and replace the CAPS. Ensure to reinstall O-ring. Apply Loctite 243 (blue) on thread and torque to 6 N•m (53 lbf•in).
Page 140: Coolant Temperature Sensor (Cts)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Resistance Test If resistance tests good, reconnect the CTS and disconnect the ECM connector A on the ECM. Disconnect the connector from the MATS and check the resistance of the sensor itself. Using a multimeter, recheck resistance value be- tween terminals 11 and 27.
Page 141: Exhaust Gas Temperature Sensor (Egts)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Replacement NOTE: This sensor is a dual function device. When engine is started and it runs at idle speed, Disconnect MAPS connector and remove the the sensor takes the atmospheric pressure and MAPS.
Page 142: Knock Sensor (Ks)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Replacement If resistance is good, disconnect the ECM connec- tor A from ECM. Disconnect EGTS connector and remove EGTS. Apply Loctite 518 on threads of the EGTS then install.
Page 143: Oil Pressure Sensor (Ops)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) CAUTION: Improper torque might prevent sen- When engine is running and the oil pressure reach- sor to work properly and lead engine to severe es 180 - 220 kPa (26 - 32 PSI), the resistance of the damage of internal components.
Page 144: Oil Separator Pressure Sensor (Osps)
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Dynamic Test Activate the TOPS valve by installing the safety lanyard on the DESS post. If you can hear the movement of the piston (knock- ing), the valve works fine, otherwise follow the procedure shown in the following chart.
Page 145: Tops Switch
Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) – Check if crankcase blow-by pressure stays be- When engine is stopped and the blow-by pressure low 40 kPa (6 PSI) as described in the DYNAMIC is released, the resistance of the OSPS is close to TEST below.
Page 146 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) smr2005-013-005_a MEASURE WHEN DESS KEY IS ON smr2005-013-003_a Measure resistance between pin A and C. In the If battery voltage is not read, check TOPS switch UP position, it should be approximately 35 . fuse condition.
Page 147 Section 04 ENGINE MANAGEMENT (1503 4-TEC) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Connect safety lanyard Repair or replace TOPS valve opens Check (short knocking noise) TOPS switch Fails Install engine leak test pump Fails Check gauge on oil dipstick tube wiring harness Lower than 8 V Check output voltage...
Page 148: Fuel System
Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page engine leak test kit ............... 295 500 352 ......... 139 fuel pressure gauge.............. 529 035 591 ......... 141 hook tool................
Page 149 Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) Naturally aspirated engines Other engines smr2005-014 www.SeaDooManuals.net...
Page 150: General
Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) GENERAL WARNING Ensure to verify fuel line connections for WARNING damage and that NO fuel line is disconnect- The fuel system of a fuel injection system ed prior to installing the safety lanyard on holds much more pressure than on a car- the DESS post.
Page 151: Removal
Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) REMOVAL Fuel Filter NOTE: The fuel filter does not require replace- ment under normal operating conditions. Replace only if permanently clogged or damaged. The fuel pump assembly has to be removed from the fuel tank to have access to the fuel filter.
Page 152: Inspection
Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) CAUTION: While pulling out the fuel pump, pay attention to fuel sensor float arm. Float arm can get stuck and bend which can reduce the fuel sensor capabilities. 1. Screws Pull fuel pump out from glove box opening.
Page 153 Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) Pressure Relief Valve NOTE: A fuel tank is comprised of 3 components: the tank, the fuel pick-up neck and the filler neck. This valve no. 17 will eliminate fuel spillage when The necks are injection molded and the tank is the watercraft is upside down.
Page 154: Installation
Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) NOTE: The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes. Never pressur- ize over 34 kPa (5 PSI). WARNING If any leak is found, do not start the engine and wipe off any fuel leakage.
Page 155: Testing Procedures
Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) TIGHTENING SEQUENCE CAUTION: Running pump a few minutes with 1. Fuel tank neck 2. Align reverse polarity can damage the pump. If pump does not run, replace the fuel pump mod- Perform a pressure test on fuel tank.
Page 156 Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) Install fuel pressure gauge (P/N 529 035 591) be- tween disconnected hose (inline installation). a. If battery voltage is read, check continuity of circuit B-29 going towards ECM. If it is good, try a new ECM.
Page 157 Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) Crank or start engine and observe fuel pressure. The fuel pressure should be the same as above. If pressure is good, fuel pump and pressure regu- lator are working adequately. A rapid pressure drop indicates leakage either from the fuel rail or from the fuel pump check valve.
Page 158 Section 05 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) Fuel Delivery Flow Chart 4-TEC Fuel pump does not run Connect safety lanyard Fuel pump runs for 2 sec. then stops Install fuel pressure gauge Check fuses. on fuel pressure line Check safety lanyard connection.
Page 159: Electrical System
Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page ECM adapter................. 420 277 010 ......... 148 SERVICE PRODUCTS Description Part Number Page silicone lubricant ..............293 600 041 ......... 149 smr2005-015 www.SeaDooManuals.net...
Page 160 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) smr05-015-100_aen smr2005-015 www.SeaDooManuals.net...
Page 161: General
Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) GENERAL NOTE: The EMS controls the ignition system. For more information, refer to ENGINE MANAGE- MENT. 1. Ignition coil smr05-015-005_a NOTE: The MPEM energizes the primary side of You should hear the spark occurring. In doubt, use each ignition coil individually while the ECM com- an inductive spark tester or a sealed tester - avail- pletes the circuit by switching it to the ground at...
Page 162 Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) COMPONENT CIRCUIT NUMBER Cylinder 1 Cylinder 2 Cylinder 3 If wiring harness is defective, repair the connector or replace the wiring harness between ECM con- nector and the ignition coil. If wiring harness is good, try a new ECM. IGNITION COIL Resistance Test smr05-015-001_a...
Page 163: Spark Plugs
Section 06 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Disconnect the wiring harness from the ignition RESISTANCE CIRCUIT TERMINAL coil. @ 20°C (68°F) Remove the ignition coil. 1 and spark Secondary 9.5 - 13.5 k plug terminal First unscrew the spark plug one turn. Clean the spark plug and cylinder head with pres- If any resistance is not good, replace ignition coil.
Page 164: Charging System
Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page 3-pin magneto harness adapter ..........529 036 016 ......... 155–156 multimeter Fluke 111 ............529 035 868 ......... 153 smr2005-016 www.SeaDooManuals.net...
Page 165 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) smr2005-016-200_aen smr2005-016 www.SeaDooManuals.net...
Page 166: General
Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) GENERAL Battery The battery is the DC source for the electric The purpose of the charging system is to keep the starter, the MPEM, ECM and all accessories. battery at a full state of charge. Fuse Magneto If the battery is regularly discharged, check charg-...
Page 167: Rectifier/Regulator
Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) RECTIFIER/REGULATOR Continuity Test Due to internal circuitry, there is no static test avail- – If current is below specification, check magneto able to check continuity. (stator) output prior to concluding that rectifier is faulty.
Page 168: Stator
Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) NOTE: If it is continually necessary to add distilled RESISTANCE @ TERMINAL water to the battery, this indicates an over voltage 20°C (69°F) situation, requiring replacement of the rectifier/ 1 and 2 regulator.
Page 169 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) IMPORTANT: Leave wiring harness side discon- nected. smr05-016-007 – Disconnect the magneto wiring harness con- nector. 1. Do not plug these connectors – Set multimeter to – Connect multimeter between YELLOW wires. RESISTANCE @ TERMINAL 20°C (69°F)
Page 170: Battery
Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) BATTERY Troubleshooting SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE REMEDY Battery posts and/or Clean and coat with cable terminal oxidized. dielectric grease. Loose or bad Check wiring and connections. connector cleanliness, damaged or short circuit. Faulty battery (sulfated, Replace.
Page 171 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Cleaning With a multimeter, voltage readings appear in- stantly to show the state of charge. Always Clean the battery casing, caps, cables and battery respect polarity. A fully charge battery will have a posts using a solution of baking soda and water.
Page 172 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CAUTION: Battery electrolyte temperature must not exceed 50°C (122°F). The casing EXAMPLE NO. 1 EXAMPLE NO. 2 should not feel hot. TEMPERATURE ABOVE 21°C (70°F): TEMPERATURE ABOVE 21°C (70°F): Clean battery terminals and cable connections us- Hydrometer reading: 1.250 Hydrometer reading: 1.235 Electrolyte temperature: - 1°C (30°F)
Page 173 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) A17E0RB 1. Battery electrolyte 2. Upper level line A17E0FB 1. Sealing tube removed – Connect a 2 A battery charger for 3 to 5 hours. 2. Battery electrolyte 3. Upper level line –...
Page 174 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Charging a Used Battery WARNING Never charge battery while installed in water- craft. For best results, battery should be charged when the electrolyte and the plates are at room tempera- ture. A battery that is cold may not accept current for several hours after charging begun.
Page 175 Section 06 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Unless this procedure is properly followed, a good – Secure vent line to the battery and support. En- battery may be needlessly replaced. sure vent line is not kinked or obstructed. – Measure the voltage at the battery posts with WARNING an accurate voltmeter.
Page 176: Starting System
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE PRODUCTS Description Part Number Page dielectric grease ..............293 550 004 ......... 170 Isoflex Topas NB52............... 293 550 021 ......... 170 Loctite 243 ................290 897 651 ......... 170 smr2005-017 www.SeaDooManuals.net...
Page 177 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) smr05-017-001_aen smr2005-017 www.SeaDooManuals.net...
Page 178 Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) smr05-017-002_aen smr2005-017 www.SeaDooManuals.net...
Page 179: Starting System Troubleshooting
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY STARTER DOES NOT Burnt fuse. Check wiring condition and replace TURN. fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten.
Page 180: General
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) GENERAL Engine Start/Stop Switch A quick operation test can be done using the ve- Causes of troubles are not necessarily related to hicle communication kit (VCK) with the B.U.D.S. starter but may be due to a burnt fuse, faulty software, using the Monitoring tab.
Page 181: Starter Removal
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Disconnect RED cable connection from battery. NOTE: To facilitate starter removal on RXP mod- els, remove engine cover.
Page 182: Starter Cleaning
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) F06H1JA TYPICAL 1. Pull armature shaft Remove brushes from brush holder by loosening retaining screws. 1. Through bolts Remove end cover. Remove thrust washer from armature shaft. 1. Brushes 2. Retaining screw 3.
Page 183: Starter Inspection
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Brush WARNING Measure brush length. If less than 8.5 mm Always wear safety glasses when using com- (.335 in), replace them. pressed air. NOTE: New brush length is 12 mm (.472 in). Remove dirt, oil or grease from commutator using a clean cloth soaked in suitable solvent.
Page 184: Starter Specification
Section 06 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Ensure to slide protector over nut to hide metallic parts. 1. Grease on O-rings. 2. Torque nut to 7 N•m (62 lbf• in ) and apply dielectric grease and install protection cover 3.
Page 185: Instruments And Accessories
Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES SERVICE TOOLS Description Part Number Page multimeter FLUKE 111 ............529 035 868 ......... 178–179 GENERAL Install safety lanyard to activate MPEM to perform testing procedures that requires the device to be supplied with electricity.
Page 186 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) FUEL LEVEL INDICATOR Exterior Temperature: Displays the exterior air temperature (E TEMP) in degrees Celsius (°C) or Bar gauge continuously indicates the amount of Fahrenheit (°F). fuel in the fuel tank while riding. A low-fuel con- dition is also indicated in the information center Trip Hour Meter: (TRIPMTR) Allows to measure when only one bar is displayed.
Page 187 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Display Selection Repeatedly pressing the MODE button scrolls the following displays: Compass, tachometer, speedometer, average speed, distance, hourme- ter, water temperature, exterior temperature, depth gauge (GTX 4-TEC Limited models), and trip hour meter. smr05-018-003_A 1.
Page 188 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 1. Press and hold for 2 seconds 1. Press to end English/Metric System Allows to display the units in the metric system or in the SAE English system. NOTE: This function is not available when infor- mation center displays the compass, hourmeter or trip hour meter.
Page 189: Procedures
Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) – Check communication link wires (WHITE/RED and WHITE/BLACK): • To quickly check if the communication link is working, temporarily disconnect a sensor on the engine to create a fault code. Start the engine.
Page 190 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) To check the oil sensor, unplug its connector and FLOAT HEIGHT RESISTANCE pull sensor out of oil tank. (bottom of float with bottom of pump module) (mm) Using the multimeter FLUKE 111 (P/N 529 035 868), check the continuity between the BLUE and 4.8 ±...
Page 191 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) VTS Control Module – Push sensor in seal. – Plug connector. RXP Models NOTE: This sensor turns the LED to ON if the It receives its current from the battery. It is pro- connector has been forgotten unconnected even tected by its own fuse located on the MPEM mod- when there is enough oil in tank.
Page 192 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Exterior Temperature Sensor The temperature sensor is located in the storage cover. B.U.D.S. can be used to check the operation. Look in the Monitoring tab. Remove the back panel of the storage cover to access the temperature sensor.
Page 193 Section 06 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) To check if the speed sensor is operational, dis- connect the speed sensor connector housing from inside bilge. Using an appropriate terminal remover (Snap-on TT600-4), remove the PURPLE/YELLOW and BLACK/ORANGE wires from the tab housing of the speed sensor.
Page 194: Propulsion
Section 07 PROPULSION Subsection 01 (JET PUMP) JET PUMP SERVICE TOOLS Description Part Number Page impeller remover/installer ............. 529 035 820 ......... 191, 198 impeller remover/installer ............. 529 035 956 ......... 191, 198 impeller shaft pusher............529 035 955 ......192, 196, 198 lift kit..................
Page 195 Section 07 PROPULSION Subsection 01 (JET PUMP) GTX 4-TEC and Wake Models 6 N•m (53 lbf•in) 25 7.5 N•m (66 lbf•in) 2.5 N•m 2.5 N•m (22 lbf•in) (22 lbf•in) 6 2.5 N•m (22 lbf•in) smr2005-019 www.SeaDooManuals.net...
Page 196 Section 07 PROPULSION Subsection 01 (JET PUMP) GTX 4-TEC Limited, GTX 4-TEC Supercharged, RXP and RXT Models RXP 4-TEC 2.5 N•m (22 lbf•in) 2.5 N•m (22 lbf•in) smr2005-019 www.SeaDooManuals.net...
Page 197: General
Section 07 PROPULSION Subsection 01 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive GTX 4-TEC Stainless 267 000 115 pitch and Wake steel 10° - 21° Progressive GTX 4-TEC Stainless 267 000 119 pitch Supercharged steel 10° - 21° Progressive GTX 4-TEC Stainless...
Page 198: Removal
Section 07 PROPULSION Subsection 01 (JET PUMP) Disconnect steering and reverse cables. Disconnect O.P.A.S. hose from top of pump (if ap- plicable). RXP Models Disconnect VTS link rod. TYPICAL 1. Inspect impeller and boot Impeller/Wear Ring Clearance This clearance is critical for jet pump performance. To check clearance, remove jet pump.
Page 199 Section 07 PROPULSION Subsection 01 (JET PUMP) Connecting Rod Remove: – reverse gate – pivot bolt no. 10. Withdraw connecting rod no. 11. Pivot Triangle Remove: – reverse gate – connecting rod – pivot triangle bolts no. 12. Withdraw pivot triangle no. 13. Pivot Arm Remove reverse gate and connecting rod.
Page 200 Section 07 PROPULSION Subsection 01 (JET PUMP) Remove O.P.A.S. “U” lever screws and pull out – nozzle no. 18 lever. – pivot arm no. 16. Unplug O.P.A.S. hose from plastic elbow. Remove retaining screws no. 23 and withdraw venturi no. 24. It's possible to remove the venturi without remov- ing the reverse gate and the nozzle, see the fol- lowing instructions.
Page 201: Disassembly
Section 07 PROPULSION Subsection 01 (JET PUMP) Jet Pump Housing Remove pump as an assembly or remove the fol- lowing: – nozzle no. 18 – venturi no. 24. Remove 4 hexagonal nuts/screws from jet pump housing. Remove jet pump with a wiggle movement. CAUTION: When removing pump unit, a shim could have been installed between hull and pump housing.
Page 202 Section 07 PROPULSION Subsection 01 (JET PUMP) Impeller Install jet pump housing no. 27 over this tool. Remove impeller ring no. 3 and impeller boot no. 2. RXP Models Unscrew impeller boot no. 2 CLOCKWISE. Using a 12 mm Allen key, unscrew the impeller. NOTE: It may be needed to heat the impeller to release the threads.
Page 203 Section 07 PROPULSION Subsection 01 (JET PUMP) Use the impeller shaft pusher (P/N 529 035 955) to RXP Models press out impeller shaft no. 36 of pump housing. Use steel blocks against inner race of bearing to Bearing no. 28, will come out with the impeller push bearing out.
Page 204: Cleaning
Section 07 PROPULSION Subsection 01 (JET PUMP) PARTS INSPECTION Remove large O-ring no. 37 from pump housing. Wear Ring Impeller Inspect wear ring before removing it. See PARTS Visually inspect impeller splines. Check for wear INSPECTION further. or deformation. Renew parts if damaged. Remove the screws no.
Page 205: Assembly
Section 07 PROPULSION Subsection 01 (JET PUMP) The radial play should be 0 (zero). 1. Check for cavitation, deep scratches or other damage TYPICAL — MEASURING IMPELLER SHAFT RADIAL PLAY Wear Ring 1. Dial gauge 2. Measure close to threads at shaft end Check wear ring no.
Page 206 Section 07 PROPULSION Subsection 01 (JET PUMP) Manually engage ring in housing making sure it is equally inserted all around. Place wood piece over ring. Using a hammer, strike on wood to push ring. Strike one side then rotate wood piece about 90°...
Page 207 Section 07 PROPULSION Subsection 01 (JET PUMP) 1. Seal/bearing pusher TYPICAL From the outlet side of pump, press impeller shaft Bearing assembly into housing using the impeller shaft pusher (P/N 529 035 955). Using the seal/bearing pusher (P/N 529 035 819) press the bearing no.
Page 208 Section 07 PROPULSION Subsection 01 (JET PUMP) 1. Lips facing up 1. O-ring at bottom 2. Sleeve Apply 4 cc of jet pump bearing grease (P/N 293 550 032) on bearing. Use a new tube of grease each time a jet pump is rebuilt (1 tube = 1 pump). 1.
Page 209 Section 07 PROPULSION Subsection 01 (JET PUMP) Apply BOMBARDIER LUBE (P/N 293 600 016) on the wear ring surface. Start screwing the impeller on its shaft. If impeller is too tight, use the im- peller shaft pusher (P/N 529 035 955) to turn im- peller to machine wear ring before installing on ve- hicle.
Page 210: Pump Pressurization
Section 07 PROPULSION Subsection 01 (JET PUMP) NOTE: If there is a pressure drop spray soapy wa- ter around cover. If there are no bubbles, impeller shaft, impeller shaft seal, or jet pump housing is leaking through porosity and has to be replaced. Jet pump unit has to be disassembled.
Page 211 Section 07 PROPULSION Subsection 01 (JET PUMP) Generously apply synthetic grease (P/N 293 550 010) on drive shaft splines. Install jet pump. If necessary, wiggle jet pump to engage drive shaft splines in impeller. CAUTION: Some watercraft require a shim between hull and pump;...
Page 212 Section 07 PROPULSION Subsection 01 (JET PUMP) NOTE: When installing the reverse gate no. 5, pay attention to position its lever behind the reverse gate support stopper. 1. Stopper Steering Cable Refer to STEERING SYSTEM. Reverse Cable Refer to REVERSE SYSTEM. Jet Pump Support and Riding Plate Refer to HULL AND BODY.
Page 213: Drive System
Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) DRIVE SYSTEM SERVICE TOOLS Description Part Number Page Drive shaft holder ..............529 035 986 ......... 205, 212 Drive shaft/floating ring tool ..........529 035 841 ......... 206, 212 Drive shaft/floating ring tool ..........529 035 987 ......... 206, 212 PTO seal support tool ............
Page 214 Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) smr2005-020 www.SeaDooManuals.net...
Page 215: General
Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) GENERAL All Models NOTE: Use this sequence to minimize the amount Jet pump must be removed to replace any com- of movement the drive shaft will slide back into ponents of the drive system. Refer to JET PUMP PTO seal assembly.
Page 216 Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) TYPICAL 1. Drive shaft holder TYPICAL — DRIVE SHAFT/FLOATING RING TOOL 1. Small opening 2. Large opening Install tool as shown. Due to configuration of some models, it may be TYPICAL necessary to disconnect EGTS sensor to make 1.
Page 217 Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) Turn screw clockwise so that the tool pushes the floating ring no. 1 rearwards to expose the circlip no. 2. Do not remove circlip at this time. NOTE: This step is done to ensure floating ring is free and not stuck on the drive shaft no.
Page 218: Inspection
Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) NOTE: It will be necessary to push the shaft in to TYPICAL 1. Largest opening here install the drive shaft holder tool. 2. Floating ring 3. PTO seal support tool Reinstall drive shaft/floating ring tool as shown. 4.
Page 219: Installation
Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) TYPICAL 1. Surface condition 2. Groove condition 3. Splines condition Excessive deflection could cause vibration and damage to drive shaft splines, impeller, flywheel 1. O-rings or floating ring. 2. Floating ring contact surface Place drive shaft on V-blocks and set-up a dial gauge in center of shaft.
Page 220 Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) Drive Shaft NOTE: Ensure to install floating ring no. 1 before inserting the drive shaft no. 3 in PTO seal assem- bly. Before installing drive shaft, inspect PTO seal as- sembly. The inner sleeve must be flush with outer circumference of the assembly.
Page 221 Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) CAUTION: Note that drive shaft features a tell- tale groove. If exposed after installation, the installation is wrong and PTO seal assembly will be pressed into crankshaft splines which could rub a hole in seal thus creating an oil leak. 1.
Page 222 Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) Refer to the following table to use the appropriate tool according to the model. MODEL TOOL GTX 4-TEC Limited, Drive shaft/floating ring RXP and RXT tool (P/N 529 035 987) GTX 4-TEC, Wake Drive shaft/floating ring and GTX 4-TEC tool (P/N 529 035 841)
Page 223: Lubrication
Section 07 PROPULSION Subsection 02 (DRIVE SYSTEM) Now ensure everything is properly positioned: Cover carbon seal ring and floating ring with a rag Telltale is not exposed, inner sleeve is flush with or plastic wrap to prevent the protectant to reach outer circumference of PTO seal assembly and the carbon ring.
Page 224: Reverse System
Section 07 PROPULSION Subsection 03 (REVERSE SYSTEM) REVERSE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......... 219 synthetic grease ..............293 550 010 ......... 219 smr2005-021 www.SeaDooManuals.net...
Page 225 Section 07 PROPULSION Subsection 03 (REVERSE SYSTEM) smr2005-021 www.SeaDooManuals.net...
Page 226: Disassembly
Section 07 PROPULSION Subsection 03 (REVERSE SYSTEM) DISASSEMBLY Reverse Gate To remove reverse gate, refer to JET PUMP sec- tion. Reverse Cable Unscrew bolt no. 1, washers and the elastic stop nut retaining reverse cable no. 2 on pivot arm. 1.
Page 227: Shift Lever
Section 07 PROPULSION Subsection 03 (REVERSE SYSTEM) Interior Lever Detach the reverse cable from interior lever no. 3. Unscrew the shift lever retaining bolt no. 4, wash- er and nut, then remove interior lever. TYPICAL 1. Engine vent tube 2. Vent tube locking tab 3.
Page 228: Inspection
Section 07 PROPULSION Subsection 03 (REVERSE SYSTEM) – bracket no. 6 TYPICAL 1. Interior lever cursor TYPICAL 2. Reverse cable support slider 1. Bracket 2. Reverse cable Interior Lever – bolts no. 7. Apply synthetic grease (P/N 293 550 010) on the Withdraw reverse cable support no.
Page 229: Variable Trim System
Section 07 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM SERVICE TOOLS Description Part Number Page VTS socket tool..............295 000 133 ......... 223, 225 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......... 225 Loctite Primer N ..............
Page 230 Section 07 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) smr2005-028 www.SeaDooManuals.net...
Page 231: General
Section 07 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) GENERAL DISASSEMBLY To test VTS control module, motor or switch, refer Cover to INSTRUMENTS AND ACCESSORIES. Remove VTS cover no. 7 by pressing on tabs. REMOVAL Remove seat and engine cover to have access to VTS module.
Page 232: Inspection
Section 07 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) INSPECTION Rubber Boot Make sure rubber boot no. 3 is in good condition. If it is cracked or torn, replace boot. Worm Inspect threads and splines of worm no. 9 for wear. If worm replacement is necessary, renew also sliding shaft.
Page 233: Adjustment
Section 07 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) Apply Loctite 243 (blue) (P/N 293 800 060) to nut no. 4. Install nut with sealing washer and torque to 7 N•m (62 lbf•in) using the VTS socket tool (P/N 295 000 133). Apply synthetic grease (P/N 293 550 010) to slid- ing shaft.
Page 234: Steering System
Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page safety lanyard switch tool............. 529 035 943 ......... 230 steering cable tool ..............295 000 145 ......... 234 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............
Page 235 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) models GTX series RXT series GTX Supercharged LTD only smr05-022-001_aen smr2005-022 www.SeaDooManuals.net...
Page 236: Disassembly
Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) DISASSEMBLY Adjustment Handle GTX Supercharged Limited Models Only Set handlebar to its lowest position by turning ad- justment handle no. 1 counterclockwise. While holding adjustment handle, turn support bushing no. 2 clockwise. 1.
Page 237 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Steering cover 1. Tapping screw 2. Screws 2. Multifunction switch housing On GTX Supercharged Limited models, un- Remove covers no. 14 and no. 15 then the throttle screw the adjustment handle no. 1. handle housing no.
Page 238 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) TYPICAL 1. Screws 1. Rubber pad 2. Steering padding 2. Stopper Remove steering padding no. 23. Cable Support Handlebar RXP Models Remove steering cover and steering padding as mentioned above. Remove front vent tube. Remove 4 elastic stop nuts M8 no.
Page 239 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) F07K04A 1. Boot 1. Steering support 2. Locking tie 2. Bolt Disconnect the throttle cable from throttle body. Disconnect the wiring harnesses leading out of steering stem and cut locking tie. 1. Steering support 2.
Page 240 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Steering stem arm 2. Bolts 1. Steering stem arm 2. Steering cable Pull steering stem no. 38 out of steering support. Remove bolts no. 31 retaining cable support Handlebar Support no. 30 to steering support no. 32. Remove bolts no.
Page 241: Assembly
Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Steering Cable Disconnect steering cable no. 43 from steering stem arm no. 33. Remove retaining block no. 29. Disconnect ball joint no. 44 from jet pump nozzle. Remove ball joint and jam nut no. 45 from cable. Loosen nut no.
Page 242 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Apply Loctite antiseize lubricant (P/N 293 800 070) on pivot bolt no. 39. CAUTION: Make sure antiseize lubricant does not come in contact with threads of bolt. Apply Loctite 271 (red) (P/N 293 800 005) on threads of jam nut no.
Page 243: Alignment
Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) TYPICAL 1. Ball joint below steering arm 2. Torque nut to 7 N•m (62 lbf• in ) 1. Pad must not exceed stopper ALIGNMENT All Models Position handlebar no. 9. Install steering clamp Position handlebar in straight ahead position by no.
Page 244 Section 08 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) TYPICAL 1. Measure the distance on each side of the straight edge If necessary, steering alignment adjustment should be performed at steering cable support. GTX Series, Wake and RXT Models ALL MODELS 1.
Page 245: Off-Power Assisted Steering System (O.p.a.s.)
Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.) SERVICE TOOLS Description Part Number Page O.P.A.S. cylinder nut wrench ..........529 035 840 ......244, 246–247 SERVICE PRODUCTS Description Part Number Page silicone sealant (clear)............293 800 086 ......... 247 smr2005-039 www.SeaDooManuals.net...
Page 246 Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) GTX Series, Wake and RXT Models smr2005-039-001_aen smr2005-039 www.SeaDooManuals.net...
Page 247 Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) RXP Models smr2005-039-002_aen smr2005-039 www.SeaDooManuals.net...
Page 248: General
Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) GENERAL The Off-Power Assisted Steering (O.P.A.S.) sys- tem uses a dual side vanes design that assists the watercraft steering in deceleration, to redirect wa- tercraft path when steering is turned after throttle has been released or engine stopped.
Page 249: Cylinder Support
Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) 1. Socket screw A. 45 ± 1 mm (1.65 ± .04 in) To adjust the tie-rod fitting no. 5, remove tie-rod Remove the tie-rod screw no. 3. screw no. 3 and turn tie-rod fitting. Place tie-rod screw in its place and measure again.
Page 250 Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) 529035840 1. Socket screws GTX Series, Wake and RXT Models Remove Oetiker clamp no. 9 to remove water hose no. 10 from the cylinder support no. 6. 1. Cylinder cap 2.
Page 251 Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) To do this: – Remove the spring no. 13. – Remove the spring pin no. 14 from piston and pivot rod no. 4. smr05-039-005 – Repeat the same procedure for the lower split ring no.
Page 252: Tie Rod
Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) Remove side vane no. 1 and cylinder support no. 6 as mentioned above. Remove O.P.A.S. “U” lever screw no. 17, flat washer no. 18, bushing no. 19 and venturi bush- ing no.
Page 253: Filter
Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) O.P.A.S. filter is part of plastic elbow no. 28. Check for cleanness. Replace or clean it as nec- essary. VALVE GTX Series, Wake and RXT Models Removal Remove O.P.A.S. “U” lever screw no. 17, flat washer no.
Page 254: Water Hose
Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) Installation Installation is the reverse process of removal, make sure of the following when doing installa- tion: – Check for cracks on formed hose no. 29, change if necessary. –...
Page 255 Section 08 STEERING SYSTEM Subsection 02 (OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)) NOTE: Use the same procedure for the RH or the LH cross support plate no. 36. Remove side vane no. 1 and cylinder support no. 6 as mentioned above. Unscrew the screw no.
Page 256: Hull/Body
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR SERVICE TOOLS Description Part Number Page suction cup ................295 000 163 ......... 271 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............293 800 060 ......263, 270, 278 Loctite 271 (red) ..............
Page 257 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX Models (Body Front View) smr2005-024-001_aen smr2005-024 www.SeaDooManuals.net...
Page 258 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) smr2005-024-002_aen smr2005-024 www.SeaDooManuals.net...
Page 259 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX Models (Body Rear View) smr2005-024-003_aen smr2005-024 www.SeaDooManuals.net...
Page 260 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX Models (Front Storage Compartment) smr2005-024-004_aen smr2005-024 www.SeaDooManuals.net...
Page 261 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX Models (Seats) smr2005-024-005_aen smr2005-024 www.SeaDooManuals.net...
Page 262 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models (Body Rear View #1) smr2005-024 www.SeaDooManuals.net...
Page 263 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models (Body Rear View #2) smr2005-024-006_aen smr2005-024 www.SeaDooManuals.net...
Page 264 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models (Hull Rear View) smr2005-024-007_aen smr2005-024 www.SeaDooManuals.net...
Page 265 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models (Front Storage Compartment) smr2005-024 www.SeaDooManuals.net...
Page 266 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models (Seats) smr2005-024 www.SeaDooManuals.net...
Page 267: General
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GENERAL Verify hinges condition and latching mechanisms condition and operation. Replace any damaged components. When applying threadlocker Loctite products (anaerobic products), pay attention so that it does not come in contact with ABS plastic parts (paint- ed parts).
Page 268: Engine Cover
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Installation Reverse the removal procedure. ENGINE COVER RXP Models Remove seat. Detach coolant expansion tank and move away. 1. Retaining screws NOTE: Pay attention not to drop retaining blocks under cover when removing screws. Pull out engine cover.
Page 269: Storage Compartment Inner Shell
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXT Models TYPICAL — FRONT SEAT 1. Lock pin 2. Adjustment nut (Loctite 243). Torque to 8 N•m (71 lbf• in ) 1. Lock pin A. 33 ± 1 mm (1-35/64 ± 3/64 in) 2.
Page 270 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. One long retaining screw (front) 2. Short retaining screw (one on each side to the back) – Remove storage cover. 1. Access panel 2. Multifunction connector – Remove seven inner skin short screws (flanged screws).
Page 271 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. Storage cover 2. Inner skin 3. Rubber hammer – Remove connector harness from the inner skin by cutting tie raps. 1. Inner skin 2. Temperature sensor 3. Compass 1. Inner skin 2.
Page 272 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Install new inner skin in the reverse process. For installation, proceed as follows: – Install the compass and secure it with the two darts. – Install the temperature sensor in grommet. – Install the tie raps around wire harnesses. –...
Page 273 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. Align cover tab with inner shell slot 1. Retaining screws Install front screws. This will properly move inner Slide inner shell out as shown. shell forward and lock it into cover tabs. Install top retaining screws (those located un- der the top tubes).
Page 274: Storage Cover Shock
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Reinstall inner shell. STORAGE COVER SHOCK To remove storage cover shock proceed as fol- lows: – Unlock shock rod from circlip and remove wash- 1. Shock rod 2. Circlip 3. Washer Install a 2 x 4 piece of wood between storage cov- er and body.
Page 275: Storage Compartment Cover Adjustment
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. Bottom support bracket FIXED TYPE LOCK PIN 2. Shock bottom locking device 1. Lock pin (apply Loctite 243 on threads) 2. Adjustment nut. Torque to 5 N•m (44 lbf• in ) A.
Page 276: Cluster
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) – Remove two hexagonal screws and flat wash- ers. – Remove defective mirror with a spatula. 1. Mirror 2. Spatula 1. Suction cup installed on one side of Info Center NOTE: A pry bar or a screwdriver may also be used –...
Page 277: Side Molding
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Remove screw and side molding. After installing side molding, install a plug (P/N 291 000 279) in the side molding screw hole. 1. Inner skin 2. Deflector retaining clips 1. Plug GTX Supercharged Limited Removal procedure for RH and LH side moldings RELEASE DEFLECTOR with deflector/grill is the same.
Page 278: Riding Plate
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) When installing inlet grate, apply Loctite 271 (red) (P/N 293 800 005) on threads of M6 bolts. Follow this sequence referring to the illustration: Hand tighten screws from 1 to 4. Torque screw from 1 to 3 to11 N•m (97 lbf•in). Torque screw 4 to 26 N•m (19 lbf•ft).
Page 279: Jet Pump Support
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models F05K02A TYPICAL 1. Unscrew nut Remove ball joint, boot, nut, half rings and O-rings from reverse cable. smr2005-024-009_a Remove boot and nut from VTS sliding shaft (RXP Properly seal and reinstall hose fittings to ride models).
Page 280: Drain Plug Installation
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Installation All Models except RXP Ensure to position the longest threaded portion of studs towards the jet pump. Apply Loctite 518 (P/N 293 800 038) against contact surface of studs with jet pump support. All Models Apply Loctite 5900 (P/N 293 800 066) as indicated by the shaded areas in the next illustrations.
Page 281: Seat Cover Replacement
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Remove screws to remove side bumper rail. Mark hole positions on body straight and bow sec- tions. TYPICAL 1. Drain plug 1. Front bumper 2. Silicone sealant around the middle hole and in the screw holes 2.
Page 282 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. Stopper screw 1. Screws to be removed Pull the safety lock pin to unlock and pull out the cylinder. 1. U-clamp Remove finition U-clamp, and screws then pull out wake post. Disassembly Loosen the stopper screw.
Page 283: Sponson Replacement
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Apply Loctite 243 (blue) (P/N 293 800 060) on sponson bolt threads. Install sponson and torque sponson bolts to 7 N•m (62 lbf•in). SPONSON ADAPTOR NOTE: Removal and installation procedure for RH 1.
Page 284: Decals Replacement
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Remove check valves and shake them. If the in- Pull decal slowly and when necessary apply more ner parts move freely, the check valve is in good heat to ease removal on the area that has to be condition.
Page 285: Hull And Body Repair
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Air Bubbles INSTALLATION ON PLASTIC (storage cover) Clean surface with isopropyl alcohol and dry thor- Possible cause: oughly. – Air pocket trapped between layers of laminate and gelcoat. Using a pencil and the decal as a template, mark the area where decal will be located.
Page 286 Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) A blister is a visible bump on the watercraft sur- Test spray the gelcoat mixture on paper to verify face that may not necessarily come right through its consistency and pattern. You may have to ap- the gelcoat layer.
Page 287: Tools And Materials List
Section 09 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Outside Inside Remove the damaged gelcoat and fiberglass with Wipe down the area with acetone on a cloth. Ap- a 24-grit disk using a power sander. Grind out- ply the same procedure as for outside repair when ward at least 2 inches from the fracture to allow laminating the alternating pieces of fiberglass ma- the patch to bond to strong material.
Page 288: Technical Specifications
Section 10 TECHNICAL SPECIFICATIONS Subsection 01 (GTX, WAKE AND GTX SC MODELS) GTX, WAKE AND GTX SC MODELS ENGINE WAKE GTX SC BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC), liquid cooled Engine type Naturally aspirated Supercharged Type Dry sump (2 oil pumps). Replaceable oil filter. Water-cooled oil cooler. XP-S 10W-40 4–Stroke Lubrication 10W40 4-stroke oil...
Page 289 Section 10 TECHNICAL SPECIFICATIONS Subsection 01 (GTX, WAKE AND GTX SC MODELS) FUEL SYSTEM WAKE GTX SC Rotax EMS (engine management system) Multipoint Fuel Injection. Fuel injection type Single throttle body (52 mm (2.05 in)) 379 - 414 kPa Fuel pressure 290 - 310 kPa (42 - 45 PSI) (55 - 60PSI) Idle speed (in water/out of water)
Page 290 Section 10 TECHNICAL SPECIFICATIONS Subsection 01 (GTX, WAKE AND GTX SC MODELS) PROPULSION WAKE GTX SC Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage. Greased bearings Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines Reverse system O.P.A.S.
Page 291 Section 10 TECHNICAL SPECIFICATIONS Subsection 01 (GTX, WAKE AND GTX SC MODELS) PERFORMANCE WAKE GTX SC Estimated pump power 53 kW (71 HP) 62 kW (83 HP) Maximum fuel consumption at wide open 43.1 L/h (11.4 U.S. gal/h) 59 L/h (15.6 U.S. gal/h) throttle Fuel tank without 63 minutes...
Page 292: Gtx Limited And Rxt Models
Section 10 TECHNICAL SPECIFICATIONS Subsection 02 (GTX LIMITED AND RXT MODELS) GTX LIMITED AND RXT MODELS ENGINE GTX LIMITED BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC), liquid cooled Engine type Supercharged intercooled Dry sump (2 oil pumps). Replaceable oil filter. Type Water-cooled oil cooler.
Page 293 Section 10 TECHNICAL SPECIFICATIONS Subsection 02 (GTX LIMITED AND RXT MODELS) FUEL SYSTEM GTX LIMITED Rotax EMS (engine management system) Multipoint Fuel Fuel injection type Injection. Single throttle body (52 mm (2.05 in)) Fuel pressure 379 - 414 kPa (55 - 60PSI) Idle speed (in water/out of water) 1800 ±...
Page 294 Section 10 TECHNICAL SPECIFICATIONS Subsection 02 (GTX LIMITED AND RXT MODELS) PROPULSION GTX LIMITED Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage. Greased bearings Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines Reverse system O.P.A.S.
Page 295 Section 10 TECHNICAL SPECIFICATIONS Subsection 02 (GTX LIMITED AND RXT MODELS) PERFORMANCE GTX LIMITED Estimated pump power 76.3 kW (102 HP) Maximum fuel consumption at wide open throttle 69 L/h (18 U.S. gal/h) Fuel tank without reserve 40 minutes Cruising time at full throttle Fuel tank reserve (from 13 minutes low level signal) ADDITIONAL INFORMATION:...
Page 296: Rxp Models
Section 10 TECHNICAL SPECIFICATIONS Subsection 03 (RXP MODELS) RXP MODELS ENGINE BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC), liquid cooled Engine type Supercharged intercooled Dry sump (2 oil pumps). Replaceable oil filter. Type Water-cooled oil cooler Lubrication Oil type XP-S 10W-40 4-stroke oil or an equivalent approved by BRP Water cooled/water injected.
Page 297 Section 10 TECHNICAL SPECIFICATIONS Subsection 03 (RXP MODELS) FUEL SYSTEM Rotax EMS (engine management system) Multipoint Fuel Fuel injection type Injection. Single throttle body (52 mm (2.05 in)) Fuel pressure 386 - 414 kPa (55 - 60 PS) Idle speed (in water/out of water) 1800 ±...
Page 298 Section 10 TECHNICAL SPECIFICATIONS Subsection 03 (RXP MODELS) PROPULSION Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage. Greased bearings Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines Reverse system O.P.A.S. system Grease type Jet pump bearing grease Steering nozzle pivoting angle...
Page 299 Section 10 TECHNICAL SPECIFICATIONS Subsection 03 (RXP MODELS) PERFORMANCE Estimated pump power 78 kW (105 HP) Maximum fuel consumption at wide open throttle 69 L/h (18.2 U.S. gal/h) Fuel tank without reserve 40 minutes Cruising time at full throttle Fuel tank reserve (from 13 minutes low level signal) ADDITIONAL INFORMATION:...
Page 300: Electrical Connectors And Wiring Diagrams
Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) ELECTRICAL CONNECTORS SERVICE TOOLS Description Part Number Page crimper die................529 035 906 ......... 304 crimper die................529 035 908 ......... 300 crimping pliers ..............529 035 730 ......... 305 crimping tool.................
Page 301 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) To disconnect the two Deutsch connectors, slide a flat screwdriver between each other to disengage, press the release button and disconnect them. 1. Deutsch connectors 2. Press release button Connector Disassembly 1.
Page 302 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) FEMALE CONNECTOR 1. Retaining tab FEMALE CONNECTOR To install: 1. Female lock – For insertion of a terminal, make sure the lock is removed. – Insert terminal into appropriate cavity and push as far as it will go.
Page 303: Packard Connector
Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) PACKARD CONNECTOR Description Packard connectors are used to connect electrical harnesses and gauges. F00H0WB F04H45A AMP CONNECTOR VIEW OF A 3-PIN PACKARD CONNECTOR 1. Male connector 1. Identification letters 2.
Page 304 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Each male connector is mechanically keyed to mate only with identical mechanical keyed con- nector on the MPEM. F00H0OA 1. Screwdriver between wedge lock and connector 2. Locking tab Repeat the same steps for the other locking tab retaining the wedge lock.
Page 305 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Step 1: Rotate wire back and forth Step 2: Pull wire POWER WIRE TERMINAL NOTE: The wedge lock must be removed to ex- tract power terminal. Open the wedge lock. Pull both locking tabs and remove wedge lock from connector.
Page 306 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) 529035909 1. Seal plug 2. Wire seal CAUTION: Do not pierce the diaphragm with a sharp point when performing electrical trou- 529035908 bleshooting. The resulting pinholes in the in- CAUTION: If terminals are not crimped using sulation will allow moisture to penetrate the the proper crimping tool, the wire seal may be...
Page 307: Ecm Connectors
Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) Terminal Identification AMP Connectors of MPEM 1. ECM 2. A connector (engine harness) 3. B connector (watercraft harness) For probing techniques and tool, refer to ENGINE MANAGEMENT. CAUTION: Do not disconnect the ECM connec- F04H6RA tors needlessly.
Page 308 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) A terminal remover such as Snap-On TT600-1 tool (or a 0.76 mm (.030 in) oxyacetylene torch tip cleaner or a #68 drill bit) must be inserted into the 1. Cover terminal cavity to release the locking tab from the Cut both tie raps that secure the harness to the connector.
Page 309 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) If the wire is in good condition but the terminal is rusted or corroded, remove defective terminal 529035909 and crimp a new one. If wire and terminal are de- fective, replace with a new genuine wire and new terminal and crimp them together as explained be- low.
Page 310: Battery And Starter Cable Terminals
Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) BATTERY AND STARTER CABLE TERMINALS Crimping Carefully strip the wire approximately to 10 mm (3/8 in) in length, using a wire stripping tool or sharp blade/knife. Insert terminal with wire in crimping pliers and po- A.
Page 311 Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 01 (ELECTRICAL CONNECTORS) CAUTION: Never weld the wire to the terminal. Welding can change the property of the wire and it can become brittle and break. Install the protective heat shrink rubber tube on the terminal.
Page 312: Wiring Diagrams
Section 11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS Subsection 02 (WIRING DIAGRAMS) WIRING DIAGRAMS NOTE: For wiring diagrams, refer to the end of the manual. WIRE COLOR CODES YL - BK smr05-026-002_a 1. Wire main color 2. Tracer (thin colored line) General Wire Color Use COLOR Battery power (12 Vdc directly...
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2005 4-tec series 2005 gtx 2005 rxp 2005 rxt 2005 wake 145a ... Show all

Sea-doo 2005 4-Tec models Shop Manual

Safety Notice

Introduction

Maintenance

Maintenance Chart

Preseason Preparation

Storage Procedures

Special Procedures

Troubleshooting

Troubleshooting Chart

Engine System

Air Intake System

Lubrication System

Cooling System

Exhaust System

Removal and Installation

Engine Management (1503 4-Tec)

Overview

Diagnostic Procedures

Component Inspection, Replacement and Adjustment

Fuel System

Fuel Tank and Fuel Pump

Electrical System

Ignition System

Charging System

Starting System

Instruments and Accessories

Propulsion

Jet Pump

Drive System

Reverse System

Variable Trim System

Steering System

1 Steeringsystem

Off-Power Assisted Steering System (O.p.a.s.)

Hull/Body

Adjustment and Repair

Technical Specifications

Gtx, Wake and Gtx Sc Models

Gtx Limited and Rxt Models

Rxp Models

Electrical Connectors and Wiring Diagrams

Electrical Connectors

Wiring Diagrams

Quick Links

Troubleshooting

Related Manuals for Sea-doo 2005 4-Tec models

Summary of Contents for Sea-doo 2005 4-Tec models