Table Of Contents - SeaDoo 2007 4-TEC Series Shop Manual

Table of Contents

Table Of Contents3
Safety Notice10
General Information11
Hull Identification Number (Hin)11
Engine Identification Number (Ein)12
Arrangement Of This Manual, Illustrations And Procedures12
Engine Emissions Information16
Working On Watercraft16
Self-Locking Fasteners Procedure16
Loctite Application Procedure17
Threadlocker17
Stripped Thread Repair18
Standard Thread Repair18
Repair Of Small Holes/Fine Threads18
Permanent Stud Installation (Light Duty)18
Gasket Compound19
Mounting On Shaft19
Case-In Components19
Metallic Gaskets19
Tightening Torques21
Maintenance Chart22
Preseason Preparation24
Storage Procedures26
Engine Fogging27
Special Procedures30
Towing The Watercraft In Water30
Submerged Watercraft30
Water-Flooded Engine31
Oil Change Procedure (Water-Contaminated Oil)31
Boil Out Procedure32
Troubleshooting Chart34
Engine Will Not Start (Engine Does Not Turn Over)34
Engine Will Not Start (Engine Turns Slowly)35
Engine Will Not Start (Engine Turns Over)35
Engine Will Not Start (No Spark At Spark Plugs)36
Engine Hard To Start36
Engine Starts But Runs Only At Idle Speed37
Engine Misfires, Runs Irregularly37
Engine Continually Backfires38
Engine Detonation Or Pinging38
Engine Lacks Acceleration Or Power38
Engine Stops Running39
Engine Cannot Reach Maximum Rpm39
Engine Runs Too Fast (Vehicle Cannot Reach Its Top Speed)40
Engine Overheats (Coolant Level Too Low)40
Engine Overheats (Monitoring Beeper Sounds Continuously)41
Engine Smoke In The Exhaust41
Low Or No Engine Oil Pressure41
Engine Oil Contamination (Milky)42
Unusual Engine Noise And/Or Vibration42
Starter Does Not Turn43
Starter Engages But Does Not Crank The Engine43
Starter Turns But Starter Drive Does Not Mesh With Ring Gear43
Starter Keeps Running44
Electrical System Troubles44
Depth Gauge Operational Problem44
Inappropriate Speedometer Reading44
Steering System Troubles45
Abnormal Nose From Propulsion System45
Opas System Faults45
Engine Removal46
Engine Installation50
Engine Alignment50
Engine Leak Test53
Air Intake System56
Air Intake System Inspection58
Air Intake System Removal58
Air Intake System Installation59
Intake Manifold And Intercooler60
Intake Manifold Removal64
Intake Manifold Installation68
Intercooler Leak Test69
Intercooler Removal70
Intercooler Installation71
Supercharger72
Supercharger Inspection (Supercharger Installed)74
Supercharger Inlet Cleanliness74
Supercharger Clutch Slipping Moment74
Supercharger Removal76
Supercharger Disassembly77
Supercharger Parts Inspection79
Supercharger Clutch Components And Gear79
Spring Washer Check80
Supercharger Assembly80
Superharger Installation84
Exhaust System86
Exhaust System Cooling88
Exhaust System Overview90
Exhaust System Specifications91
Using Flushing Connector On Jet Pump Support91
Using Flushing Connector In Engine Compartment92
Exhaust Pipe Removal93
Exhaust Pipe Inspection94
Exhaust Pipe Installation94
Exhaust Manifold Removal96
Exhaust Manifold Inspection96
Exhaust Manifold Installation96
Resonator Removal97
Muffler Removal, Inspection And Installation97
Resonator Inspection And Installation98
Exhaust Outlet Removal, Inspection, Installation98
Pto Housing And Magento99
Pto Housing Removal101
Removing Oil In The Pto Housing Through The Timing Chain Area101
Pto Housing Inspection And Installation103
Pto Seal Inspection, Removal And Installation104
Coupling Removal104
Coupling Inspection And Installation105
Stator Removal105
Rotor And Trigger Wheel Removal And Inspection106
Stator Installation106
Rotor And Trigger Wheel Installation107
Ring Gear Removal, Inspection And Installation107
Starter Drive Removal, Inspection And Installation108
Oil Spray Nozzle Removal And Installation109
Lubrication System110
Lubrication System Maintenance113
Oil Level Verification113
Oil Change113
Oil Draining113
Oil Filter Removal114
Oil Filling114
Engine Oil Pressure Check115
Oil Filter Inspection And Installation115
Test At The Oil Pressure Switch Location115
Pto Oil Strainer Removal116
Test At The Cylinder Head Location116
Suction Pump Oil Strainer Removal117
Pto Oil Strainer Cleaning, Inspection And Installation117
Suction Pump Oil Strainer Cleaning And Inspection118
Suction Pump Oil Strainer Installation118
Engine Oil Pressure Regulator Removal And Installation119
Oil Pressure Pump Removal119
Oil Pressure Pump Inspection120
Oil Pressure Pump Installation121
Oil Suction Pump Removal123
Oil Suction Pump Inspection124
Oil Suction Pump Installation124
Oil Separator Cover Removal125
Oil Separator Cover Inspection126
Oil Separator Cover Installation126
Tops Valve Removal, Inspection And Installation127
Oil Cooler Removal, Inspection And Installation128
Cooling System129
Cooling System Circuit132
Cooling System Specifications132
Pressure Cap Check132
Cooling System Leak Test132
Coolant Replacement133
Recommended Coolant133
Draining The System133
Cleaning The Cooling System134
Refilling The Cooling System134
Clamps Replacement135
Water Pump Housing Removal And Installation136
Water Pump Impeller Removal And Installation137
Thermostat Removal137
Thermostat Leak Test137
Thermostat Dynamic Test137
Rotary Seal Inspection138
Thermostat Installation138
Rotary Seal Removal138
Rotary Seal Installation139
Cylinder Head141
Exhaut Manifold Removal And Installation143
Valve Cover Removal And Installation143
Rocker Arm Removal144
Spark Plug Tube Inspection145
Rocker Arm Inspection145
Rocker Arm Shaft Inspection146
Rocker Arm Installation146
Camshaft Timing Gear Removal, Inspection And Installation147
Cylinder Head Removal148
Cylinder Head Inspection149
Cylinder Head Installation149
Camshaft Removal150
Camshaft Inspection150
Valve Spring Removal151
Camshaft Installation151
Valve Spring Inspection152
Valve Spring Installation152
Valve Removal153
Valve Inspection153
Valve Stem Seal Check153
Valve Stem And Valve Guide Clearance Check153
Valve Guide Replacement154
Valve Face And Seat156
Valve Seat Grinding156
Valve Installation157
Cylinder Block158
Timing Chain Inspection161
Timing Chain Removal161
Timing Chain Installation161
Chaing Tensioner Removal And Installation161
Piston/Connecting Rod Removal162
Connecting Rod Big End Axial Play Check162
Connecting Rod/Piston Pin Clearance Check162
Connecting Rod Big End Radial Play Check163
Piston Check163
Piston Pin Inspection165
Piston Pin/Connecting Rod Bearing Clearance Check165
Piston/Connecting Rod Installation165
Piston Rings Removal166
Piston Rings Inspection167
Ring/Piston Groove Clearance Check167
Piston Rings Installation167
Crankshaft Locking168
Crankshaft Removal168
Crankshaft Inspection170
Crankshaft Radial Play Check170
Crankshaft Pin Check170
Crankshaft Axial Clearance Check170
Crankshaft Installation171
Balancer Shaft Removal172
Balancer Shaft Inspection173
Balancer Shaft Bearing Seat Play Check173
Balancer Shaft Installation173
Cylinder Block Disassembly175
Cilinder Block Bearings175
Starter Drive Bearing175
Cylinder Block Inspection176
Cylinder Taper Check176
Cylinder Out Or Round Check176
Bearings Check176
Cylinder Block Assembly177
Oil Spray Nozzles Check177
Engine Management System180
Air Induction181
Throttle Body181
Intake Manifold181
Fuel System182
Flame Arrester182
Intercooler182
Fuel Rail182
Electrical System183
Fuel Injector183
Fuel Pump Module183
Multi-Purpose Electronic Module (Mpem)183
Ecm (Engine Control Module)184
Fuel Pump Current Supply184
Addition Of Electrical Accessories184
Low-Fuel Level Warning Device184
Ecm And Mpem Interaction With The Electrical System185
Electronic Fuel Injection186
Ignition Timing/Coils186
Engine Modes Of Operation186
Engine Starting186
Limp Home Modes187
Low-Oil Pressure Warning Device187
High Coolant Temperature And Egtc Warning Device187
Engine Management System Diagram188
Ems Diagnostic And Communication Tools189
Monitoring System190
Fault Codes191
Tps (Throttle Position Sensor) Faultes191
Tps "Out Of Range" Fault191
Supplemental Information For Some Specific Faults192
Communication Tools193
Mpi (Multi-Purpose Interface)193
Mpi Supply193
Mpi-2 (Multi-Purpose Interface)195
Buds Software196
Mpi-2 Supply196
Changes In Ecm197
Adjustment And Repair Procedures198
Fuel System Adjustment And Repair198
Electrical System Adjustment And Repair199
Sensor Resistance Measurement200
Ecm Connectors201
Engine Wiring Harness202
Idle Speed Adjustment204
Throttle Cable Adjustment204
Closed Throttle And Idle Actuator Reset205
Ignition Timing205
Engine Control Module (Ecm) Repair205
Ecm Replacement205
Multi-Purpose Electronic Module (Mpem) Replacement206
Fuel Injector Repair Adjustment And Repair207
Fuel Injector Leakage Test207
Fuel Injector Electrical Test207
Fuel Injector Replacement208
Throttle Body Mechanical Inspection209
Throttle Position Sensor (Tps) Repair210
Throttle Body Replacement210
Throttle Position Sensor (Tps) Wear Test211
Throttle Position Sensor (Tps) Voltage Test211
Throttle Position Sensor (Tps) Resistance Test211
Throttle Position Sensor (Tps) Replacement211
Idle Bypass Valve Resistance Test212
Crankshaft Position Sensor (Cps) Resistance Test212
Camshaft Position Sensor (Caps) Voltage Test213
Idle Bypass Valve Replacement213
Manifold Air Temperature Sensor (Mats) Resistance Test214
Coolant Temperature Sensor (Cts) Resistance Test215
Coolant Temperature Sensor (Cts) Replacement215
Manifold Air Pressure Sensor (Maps)215
Exhaust Gas Temperature Sensor (Egtc) Resistance Test216
Manifold Air Pressure Sensor (Maps) Voltage Test216
Manifold Air Pressure Sensor (Maps) Resistance Test216
Manifold Air Pressure Sensor (Maps) Replacement216
Knock Sensor (Ks) Dynamic Test217
Oil Pressure Sensor (Ops)217
Knock Sensor Static Resistance Test217
Knock Sensor Replacement217
Tops Switch218
Oil Pressure Sensor (Ops) Oil Pressure Test218
Oil Pressure Sensor (Ops) Resistance Test218
Oil Pressure Sensor (Ops) Dynamic Test218
Fuel Tank And Fuel Pump220
Fuel System Leak Test222
Check Valve And Pressure Relief Valve223
Fuel Pump Pressure Test224
Fuel Hoses And Oetiker Clamps Inspection And Replacement225
Fuel Filter Removal226
Fuel Tank Inspection226
Fuel Tank Removal227
Fuel Tank Installation227
Fuel Pump Test228
Fuel Pump Removal228
Fuel Pump Installation229
Fuel Pump Diagnostic Flow Chart230
Ignition System231
Ignition System Wiring Diagram232
Ignition Coil Quick Test With Buds233
Ignition Coil Voltage Test233
Ignition Coil Resistance Test234
Spark Plugs Disassembly235
Spark Plug Installation235
Charging System236
Charging System Testing238
Magneto238
Rectifier/Regulator238
Fuse238
Rectifier/Regulator Tests239
Stator Continuity Test239
Stator Insulation Test240
Stator Voltage Test241
Battery Troubleshooting241
Battery Removal242
Battery Inspection242
Electrolyte Level242
Battery Testing243
Electrolyte Reading243
Battery Storage244
Activation Of A New Battery244
Charging A Used Battery246
Charging A Very Flat Or Completely Discharged Battery246
Battery Installation247
Starting System248
Starting System Wiring Diagram250
Fuse Test251
Engine Control Module (Ecm) Test251
Engine Start/Stop Switch Test251
Solenoid Continuity Test252
Solenoid Dynamic Test252
Starter Removal And Installation253
Starter Gear Removal And Installation254
Digitally Encoded Security System (Dess)255
Key Reminder255
Key Programming256
Dess Key Troubleshooting257
Dess Post257
Dess Key Removed From Post257
Dess Key On Post258
Gauge, Sensors And Fuses259
Checking For Shorts Between 2 Wires259
Fuses Info260
Mpem Fuses Identification260
Main Fuses Identification261
Mpem Fuse Replacement261
Information Center Overview262
Information Display262
Indicator Lights263
Water Depth Display263
Message Display263
Information Center Troubleshooting264
Water Temperature Display264
Information Center Removal264
Vts Position Indicator264
Information Center Installation265
New Information Center Settings265
Fuel Baffle Pick-Up Sender266
Water Temperature Sensor266
Compass266
Speed Sensor267
Depth Gauge Removal, Inspection And Installation267
Propulsion268
Jet Pump268
Plastic Housing Diagram269
Aluminium Housing Diagram270
Impeller Condition Inspection271
Jet Pump Main Components View271
Impeller/Wear Ring Clearance Inspection271
Jet Pump Leak Test271
Sacrificial Anode Removal And Installation272
Venturi Removal272
Jet Pump Housing Removal273
Venturi Installation273
Jet Pump Housing Installation274
Impeller Cover Removal275
Impeller Removal276
Impeller Cover Inspection And Installation276
Impeller Inspection277
Wear Ring Inspection, Removal And Installation278
Impeller Cleaning278
Impeller Installation278
Impeller Shaft And Bearing Inspection279
Impeller Shaft And Bearing Removal280
Impeller Shaft And Bearing Installation281
Drive System284
Drive System - Corrosion Protection286
Drive Shaft Removal286
Drive Shaft Inspection And Lubrication289
Floating Ring Inspection And Lubrication290
Drive Shaft Installation290
Boot Inspection, Removal And Installation293
Carbon Ring Removal And Installation293
Reverse System294
Reverse Cable Removal296
Reverse Cable Installation And Adjustment297
Reverse Cable Lever Removal297
Shift Lever Removal, Inspection And Installation298
Reverse Cable Lever Installation298
Reverse Cable Support Removal And Installation299
Shift Lever Housing Removal And Installation299
Reverse Gate Removal And Installation300
Pivot Support Removal And Installation300
Link Rod Removal And Installation300
Pivot Triangle Removal And Installation301
Pivot Arm Removal And Installation301
Variable Trim System302
Variable Trim System Tests304
Control Module And Motor Removal304
Control Module And Motor Disassembly305
Control Module And Motor Inspection305
Control Module And Motor Assembly306
Control Module And Motor Installation306
Steering System307
Steering Alignment309
Nozzle Removal And Installation310
Handlebar Grip Removal And Installation310
Steering Cover Removal And Installation311
Steering Padding Removal And Installation312
Handlebar Removal And Installation313
Steering Cable Support Removal And Installation314
Steering Support Removal And Installation315
Steering Stem Removal And Installation316
Handlebar Support Removal And Installation316
Steering Cable Removal And Installation317
Off-Power Assisted Steering (Opas)319
Filter Removal And Installation322
Valve Disassembly And Assembly323
Water Hose Removal And Installation324
Side Vane Removal324
Side Vane Adjustment324
Cylinder Support Removal325
Cylinder Support Disassembly And Assembly325
Tie Rod Removal And Installation327
Sealed Tube Removal And Installation328
Cross Support Plate Removal And Inspection328
Hull/Body Adjustment And Repair330
Hull/Body Diagrams331
Decals Removal And Installation347
Glove Box Removal And Installation347
Seat Removal And Installation349
Removable Seat Cowling Removal And Installation350
Seat Cover Replacement350
Seat Latch Adjustment351
Engine Cover352
Storage Compartment Cover Removal352
Storage Compartment Cover Hinge Removal And Installation354
Storage Compartment Cover Shock Removal And Installation354
Storage Compartment Cover Latch Adjustment355
Storage Compartment Cover Inner Shell Removal355
Storage Compartment Cover Inner Shell Installation357
Frong Grill Of Compartment Cover Removal And Installation358
Access Cover Removal And Installation359
Console Removal And Installation359
Mirror Removal And Installation361
Deflector And/Or Upper Grid Removal And Installation361
Slide Molding Removal And Installation362
Inlet Grate Removal And Installation362
Riding Plate Removal And Installation363
Jet Pump Support Removal And Installation364
Thru-Hull Fitting Replacement365
Bumper Replacement366
Wake Pylon Removal And Installation366
Sponson Removal And Installation367
Sponson Adaptor Removal And Installation368
Drain Plug Inspection368
Carpet Removal And Installation369
Seat Cleaning369
Vinyl Cleaning Recommendations For Special Stains370
Hull And Body Repair370
Preparation Of Surface371
Filling The Cavity371
Buffing And Waxing371
Filling The Repair Area371
Numerous Fractures Over Large Surface372
Patching The Repair Area372
Tools And Materials List For Repair Of The Hull And Body373
Technical Specifications374
Electrical Connectors394
Deutsch Connectors394
Connector Disassembly395
Packard Connector396
Amp Connector396
Terminal Removal397
Power Wire Terminal398
Terminal Crimping399
Terminal Installation399
Terminal Identification400
Amp Connectors Of Mpem400
Amp Connectors Of Wiring Harness400
Terminal Crimping (Kostal)402
Battery And Starter Cable Terminals403
Wiring Diagram405