Sea-doo GTI California 6116 Shop Manual

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Summary of Contents for Sea-doo GTI California 6116

Page 1 www.SeaDooManuals.net...
Page 2 2002 Shop Manual Volume 1 GTI, GTI LE, GTX, GTX RFI, XP, RX, RX DI, LRV DI www.SeaDooManuals.net...
Page 3 Legal deposit: National Library of Quebec trimester 2002 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2002 Technical Publications Bombardier Inc.
Page 4 TABLE OF CONTENTS PAGE SECTION SUBSECTION SAFETY NOTICE ..........................INTRODUCTION ........................... SERVICE TOOLS 01 - Table of contents ..............01-01-1 02 - Mandatory service tools............01-02-1 AND PRODUCTS 03 - Optional service tools..............01-03-1 04 - Service products ............... 01-04-1 MAINTENANCE 01 - Table of contents ..............
Page 5: Table Of Contents
TABLE OF CONTENTS PROPULSION 01 - Table of contents ..............11-01-1 02 - Jet pump................... 11-02-1 SYSTEM 03 - Drive system................11-03-1 04 - Reverse system................ 11-04-1 05 - Variable trim system ..............11-05-1 STEERING SYSTEM 01 - Table of contents ..............12-01-1 02 - Steering system................
Page 6: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair all 2002 SEA-DOO watercraft. See model list below. This edition was primarily published to be used by watercraft mechanical technicians who are already familiar with all service procedures relating to Bombardier made watercraft.
Page 7: Hull Identification Number
INTRODUCTION INTRODUCTION HULL IDENTIFICATION NUMBER This Shop Manual covers the following BOMBAR- ® DIER made SEA-DOO 2002 watercraft models. (H.I.N.) MODEL ENGINE It is located on footboard at the rear of watercraft. MODELS TYPE NUMBER GTS, GTI and RX Series...
Page 8 INTRODUCTION All Models 787 RFI Engine The Hull Identification Number is composed of 12 The Engine Identification Number is located on the digits: upper crankcase on PTO side. ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engine The Engine Identification Number is located on the upper side of the magneto housing.
Page 9 INTRODUCTION ARRANGEMENT OF THIS MANUAL The manual is divided into 16 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 ENGINE MANAGEMENT (RFI) 06 ENGINE MANAGEMENT (DI) 07 COOLING SYSTEM 08 FUEL SYSTEM 09 LUBRICATION SYSTEM 10 ELECTRICAL SYSTEM 11 PROPULSION SYSTEM 12 STEERING SYSTEM...
Page 10 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 11 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 12: General Information
INTRODUCTION LIST OF ABBREVIATIONS USED GENERAL INFORMATION IN THIS MANUAL The use of RIGHT (starboard) and LEFT (port) indi- cations in the text, always refers to driving position DESCRIPTION (when sitting on watercraft). Analog to Digital Conversion Besides, in the marine industry, FRONT is called Alternate Current BOW and REAR is called STERN.
Page 13: Engine Emissions Information
As many of the procedures in this manual are in- EPA Emission Regulations terrelated, we suggest, that before undertaking All new 1999 and more recent Sea-Doo water- any task, you read and thoroughly understand the crafts manufactured by Bombardier are certified...
Page 14 INTRODUCTION LOCTITE APPLICATION Blind Holes PROCEDURE The following describes the most common appli- cation 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 15 INTRODUCTION 1. Clean threads (stud and hole) with solvent. Adjusting Screw 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Put several drops of proper strength Loctite threadlocker on female threads and in hole. 4.
Page 16 INTRODUCTION Standard Thread Repair NOTE: Avoid grinding. 1. Follow instructions on Loctite FORM-A-THREAD 2. Clean both mating surfaces with solvent. 81668 package. 3. Spray Loctite Primer N on both mating surfaces 2. If a plate is used to align bolt: and on both sides of gasket.
Page 17: Tightening Torques
INTRODUCTION TIGHTENING TORQUES Mounting in Tandem 1. Apply retaining compound on internal element Tighten fasteners to torque mentioned in explod- bore. ed views and text. When they are not specified 2. Continue to assemble as shown above. refer to following table.The table also gives the metric conversion.
Page 18 INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft SMR2002_015_00A2.FM www.SeaDooManuals.net...
Page 19 INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS Technical Publications Bombardier Inc. Valcourt (Quebec), Canada SMR2002_015_00A2.FM www.SeaDooManuals.net...
Page 20 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MANDATORY SERVICE TOOLS ................... 01-02-1 ENGINE ..........................01-02-1 COOLING/FUEL/OIL SYSTEMS ..................01-02-4 PROPULSION SYSTEM..................... 01-02-5 OPTIONAL SERVICE TOOLS ....................01-03-1 ENGINE ..........................01-03-1 COOLING/FUEL/OIL SYSTEMS ..................01-03-4 PROPULSION SYSTEM.....................
Page 21: Mandatory Service Tools
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) MANDATORY SERVICE TOOLS ENGINE Degree wheel Air compressor ring compressor PTO flywheel remover/installer P/N 529 035 607 P/N 529 035 713 P/N 295 000 001 F01J0T4 APPLICATION 717 engine. F12B0L4 NOTE: This tool is also used for APPLICATION...
Page 22 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Puller Puller ass’y Adapter P/N 529 035 547 P/N 290 876 488 P/N 529 035 590 1) Screw P/N 290 240 860 2) Hexagonal nut P/N 290 242 210 A00C1A4 F00B124 APPLICATION...
Page 23 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Engine leak tester kit Ring gear puller tool Ring gear blocking tool kit P/N 295 500 352 P/N 420 976 235 (puller ass’y) P/N 529 035 846 Pump only P/N 529 035 549 (puller bolt) P/N 529 021 800 F15B014...
Page 24: Cooling/Fuel/Oil Systems
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Gear holder Fuel pressure gauge 1. Fuel pressure gauge P/N 420 277 905 P/N 529 035 591 P/N 529 035 709 2. Fuel pressure gauge T-fitting P/N 529 035 710 3.
Page 25: Propulsion System
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) PROPULSION SYSTEM Impeller remover/installer Bearing/seal installer Pliers P/N 295 000 001 P/N 295 000 107 P/N 295 000 054 Caillau F01J0T4 APPLICATION F01B1T4 All models. APPLICATION NOTE: This tool is also used for All models.
Page 26 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) OPAS cylinder nut wrench P/N 529 035 840 F18B0A4 APPLICATION GTI LE. 01-02-6 SMR2002-016_01_02A.FM www.SeaDooManuals.net...
Page 27: Optional Service Tools
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) OPTIONAL SERVICE TOOLS ENGINE Coil centering tool Stroboscopic timing light Digital/induction type tachometer P/N 420 876 922 P/N 529 031 900 P/N 529 014 500 A01B1V4 APPLICATION 717 engine. A00B4F4 APPLICATION F01B1G4...
Page 28 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Crimping tool Safety lanyard switch tool Gear/bearing puller P/N 295 100 164 P/N 529 034 600 P/N 290 877 665 F01B244 APPLICATION F00B0E4 All models. APPLICATION Contacts of AMP plug connectors. F04B034 Slide hammer puller APPLICATION...
Page 29 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Feeler gauge 45° MPEM programmer Not sold by Bombardier P/N 529 035 878 Snap-on FB 300 A F01B1K4 A01B5B4 APPLICATION APPLICATION 717 and 787 engines. All models. Steering cable tool Piston ring compressor (2) P/N 295 000 145 A) P/N 290 876 965 (88 mm)
Page 30: Cooling/Fuel/Oil Systems
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Pump gauge tester Spring compressor Flushing adapter P/N 295 000 114 P/N 529 035 504 P/N 295 500 473 F01B0X4 APPLICATION All models except RFI and DI mod- F00B104 els.
Page 31: Propulsion System
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) PROPULSION SYSTEM Fitting P/N 295 000 086 F01B0Z4 APPLICATION All models. Slide hammer puller Not sold by Bombardier Snap-on: Handle: CJ93-1 Hammer: CJ125-6 Claws: CJ93-4 F01J0Z4 APPLICATION All models. NOTE: This tool is also used to re- move rotary valve shaft bearing.
Page 32: Watercraft Handling
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) WATERCRAFT HANDLING Dolly (with wheels) Tie-down with ratchet P/N 295 000 126 3.60 m (12 ft) long P/N 295 100 104 APPLICATION All models. Tie-down 1.50 m (5 ft) long P/N 295 100 103 F01B014 Beach wheels (set of 2 wheels)
Page 33: Service Products
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) SERVICE PRODUCTS ® Loctite is a trademark of Loctite™ Corporation. ® Permatex is a trademark of Loctite™ Corporation. Dow Corning ® is a trademark of Dow Corning Corporation. Medium strength threadlocker High temperature threadlocker Retaining compound P/N 293 800 060...
Page 34 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Flange sealant Thread sealant Primer for gasket eliminator P/N 293 800 081 P/N 293 800 050 P/N 293 800 041 Loctite 5910 Loctite 577 Loctite 764 (300 mL) (250 mL) F00B0W4 Solvent P/N 413 711 809...
Page 35 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Dielectric grease Grease P/N 293 550 004 P/N 293 550 005 Grease Isoflex Dow Corning (400 g) (150 g) (P/N 293 550 021) (50 g) A00B2L4 A00B1X4 Synthetic grease P/N 293 550 010 (400 g) High temperature RTV sealant (P/N 293 800 090)
Page 36 P/N 293 600 038 (16 x 1 L) A00B5S4 Instant gasket P/N 293 800 088 (7 oz) A00B634 Sea-Doo fuel stabilizer P/N 413 408 600 A00B5X4 236 mL (8 oz) BOMBARDIER FORMULA XP-S II synthetic injection oil P/N 293 600 245...
Page 37 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Sea-Doo Cleaner P/N 293 110 001 (400 g) P/N 293 110 002 (4 L) F01B2J4 Pulley flange cleaner P/N 413 711 809 A00B5V4 01-04-5 SMR2002-016_01_04A.FM www.SeaDooManuals.net...
Page 38 Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS PERIODIC INSPECTION CHART ................... 02-02-1 FLUSHING AND LUBRICATION ................... 02-03-1 GENERAL ........................... 02-03-1 PROCEDURE ........................02-03-1 WATER-FLOODED ENGINE ....................02-04-1 GENERAL ........................... 02-04-1 PROCEDURE ........................02-04-1 STORAGE..........................02-05-1 ENGINE DRAINING ......................02-05-1 PROPULSION SYSTEM.....................
Page 39: Periodic Inspection Chart
Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART FREQUENCY DESCRIPTION ➀ ✔ Lubrication/corrosion protection ✔ ✔ Support and rubber mount condition/tightness Exhaust system fasteners ➄ ✔ ✔ RAVE valve cleaning (if so equipped) ➄ ✔ ✔ Top end inspection (leak test, piston and ring clearance) ➈...
Page 40 Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) FREQUENCY DESCRIPTION Electrical connections condition and fastening (ignition system, electrical ✔ ✔ box(es), starting system, fuel injectors (RFI and DI models), etc.) ✔ MPEM mounting brackets/fasteners ✔ ✔ Digitally Encoded Security System ✔...
Page 41: Flushing And Lubrication
Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) FLUSHING AND LUBRICATION GENERAL Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and/or hoses.
Page 42 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) All Models Start the engine then immediately open the water tap. WARNING Do not touch any electrical parts or jet pump area when engine is running. CAUTION: Never flush a hot engine. Always start the engine before opening the water tap.
Page 43 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) All Carburetor-Equipped Models Connect safety lanyard cap to the switch. Fully depress the throttle lever then press the start/stop button to crank the engine a few turns to distribute the oil onto cylinder wall. GTX RFI Models On RFI models, fully depress throttle lever and connect the safety lanyard to the switch.
Page 44: Water-Flooded Engine
Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) WATER-FLOODED ENGINE GENERAL If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise en- gine will have to be overhauled. CAUTION: A water-flooded engine must be prop- erly lubricated, operated then lubricated again, otherwise parts will be seriously damaged.
Page 45 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) Remove spark plugs and dry them with a clean cloth. A contact cleaner spray can be used. It may be preferable to replace spark plugs. Do NOT in- stall spark plugs on engine yet. Cover spark plug holes with a rag.
Page 46 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) RFI and DI Models Spray BOMBARDIER LUBE lubricant or equiva- lent, through hole of air intake silencer keeping en- Start engine according to normal starting procedure. gine at fast idle during one minute. All Models CAUTION: To avoid starting motor overheat- ing, the cranking period should not exceed 5-...
Page 47: Storage
Section 02 MAINTENANCE Subsection 05 (STORAGE) STORAGE ENGINE DRAINING All Carburetor-Equipped Engines Check engine drain hose (lowest hose of engine). Make sure there is no sand or other particles in it and that it is not obstructed so that water can exit the engine.
Page 48: Propulsion System
Reservoir should be cleaned and refilled with SEA-DOO synthetic 75W90 GL5 polyolester oil. Refer to JET PUMP for proper procedure. CAUTION: Use only SEA-DOO jet pump oil or equivalent synthetic gear oil, otherwise com- ponent service life could be reduced. Do not mix oil brands or types.
Page 49: Fuel System
CHARGING SYSTEM. hoses or clamps if necessary. WATERCRAFT CLEANING Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv- alent should be added in fuel tank to prevent fuel Clean the bilge with hot water and mild detergent deterioration and, if so equipped, carburetor(s) or with bilge cleaner.
Page 50 Section 02 MAINTENANCE Subsection 05 (STORAGE) Hose Pinchers Installation NOTE: On RFI models, make sure the hose is properly connected to the magneto cover. Some hoses have to be plugged to prevent drain- ing, before filling cooling system jackets with the antifreeze.
Page 51 Section 02 MAINTENANCE Subsection 05 (STORAGE) NOTE: On XP models, open rear cover to have access to engine drain hose. 717 AND 787 RFI ENGINES 1. Engine water outlet hose XP MODELS — 947 ENGINE 1. Hose pincher installed on engine drain hose Install hose pincher on injection hose going to tuned pipe.
Page 52 Section 02 MAINTENANCE Subsection 05 (STORAGE) Hose Disconnection Some hoses have to be disconnected. Disconnect hoses at the following location. 947 Carburetor-Equipped Engines At this point, remove the hose pincher at tuned pipe bleed hose. If necessary, continue to pour anti- freeze mix until the colored solution appears at the 717 AND 787 RFI ENGINES other cooling system bleed outlet (stern eyelet).
Page 53 Section 02 MAINTENANCE Subsection 05 (STORAGE) 787 RFI and 947 Carburetor-Equipped Engines Install a hose pincher just below T-fitting. RX DI MODELS 1. Water outlet hose 1. Hose pincher below T-fitting Pour approximately 300 mL (10 oz) of antifreeze in the water regulator valve supply hose to allow an- tifreeze flowing through the valve and into muffler to protect it.
Page 54 Section 02 MAINTENANCE Subsection 05 (STORAGE) At this point, install a hose pincher on bleed outlet 1. Engine cylinder drain hose hose. Hose Disconnection Disconnect water INLET hose at engine between T- fitting and cylinder head fitting. 1. Disconnect this side of the T-fitting Temporarily install a short piece of hose to replace the one removed.
Page 55: Anticorrosion Treatment
Lubricate PTO flywheel or seal carrier 3. Engine cylinder drain hose. Verify fuel system 4. Water outlet hose. Add Sea-Doo fuel stabilizer Pour approximately 200 mL (7 oz) of antifreeze in the water regulator valve supply hose to allow an- Flush the cooling system tifreeze flowing through the valve and into muffler to protect it.
Page 56: Troubleshooting Chart
Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) TROUBLESHOOTING CHART The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems. NOTE: On RFI and DI models, always check for fault codes recorded in the MPEM first using the VCK (vehicle communication kit (P/N 529 035 844).
Page 57 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE WILL NOT START (cont’d) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Faulty component in the fuel injection • Check for fault codes with the VCK system (RFI and DI models) (vehicle communication kit). Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT •...
Page 58 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE HARD TO START OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Water in fuel reservoir or • Flush reservoir and refill with fresh gas contaminated fuel • Mechanical engine failure • Check cylinder compression •...
Page 59 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY (cont’d) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Low fuel level • Check/refill • Low fuel pressure • Check pump, regulator, injectors and (RFI and DI models) hose pinchers or if filter is plugged. Replace if necessary •...
Page 60 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY (cont’d) • Partially closed choke • Check/adjust choke cable (carburetor models) • Flame arrester dirty or restricted • Check/replace (if so equipped) • Carburetor adjustment • Check/adjust, refer to section FUEL (carburetor models) SYSTEM •...
Page 61 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE CONTINUALLY BACKFIRES OTHER OBSERVATION POSSIBLE CAUSE REMEDY Weak spark • Fouled, defective spark plugs • Clean/replace Spark plugs • Ignition coil leads or wiring reversed • Check with wiring diagram • Incorrect setting •...
Page 62 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weak spark • Check/replace, refer to section ELECTRICAL SYSTEM • Carburetion, jetting too rich/lean • Check/adjust, refer to section FUEL (carburetor models) SYSTEM •...
Page 63 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE CANNOT REACH MAXIMUM RPM OTHER OBSERVATION POSSIBLE CAUSE REMEDY • RAVE valve does not open • Check, refer to section ENGINE and COOLING SYSTEM • Faulty water regulator valve • Check, refer to COOLING SYSTEM •...
Page 64 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE OVERHEATS OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Check/replace. Refer to ENGINE • Temperature sensor defect MANAGEMENT • Worn water pump impeller • Check/replace • Damaged ride plate or hoses • Check. Refer to COOLING SYSTEM and HULL/BODY Monitoring beeper sounds continuously...
Page 65 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST..........................04-02-1 GENERAL ........................... 04-02-1 PREPARATION ........................04-02-1 TESTING PROCEDURE ..................... 04-02-1 ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............04-02-7 REMOVAL AND INSTALLATION..................04-03-1 GENERAL ........................... 04-03-1 ENGINE REMOVAL......................04-03-1 CLEANING .........................
Page 66 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) EXHAUST SYSTEM ....................... 04-08-1 REMOVAL ........................... 04-08-7 TUNED PIPE REPAIR ......................04-08-12 INSTALLATION ........................04-08-13 04-01-2 SMR2002-052_04_01ATOC.FM www.SeaDooManuals.net...
Page 67: Leak Test
NOTE: If a leak is found, it is important to continue testing as there is the possibility of having more A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) than one leak. Continue pumping to compensate and Supplementary Engine Leak Test Kit (P/N 295 for the air lost to find another leak.
Page 68 Section 04 ENGINE Subsection 02 (LEAK TEST) Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube(s) as necessary. 787 RFI ENGINE — REAR VIEW 1. Loop hose and use clamps 2.
Page 69 Section 04 ENGINE Subsection 02 (LEAK TEST) 947 CARBURETOR-EQUIPPED ENGINE — REAR VIEW 947 DI ENGINE — SIDE VIEW 1. Block engine drain hose with a hose pincher 1. Block engine drain hose with a hose pincher 2. Install pump to water inlet hose 2.
Page 70 Section 04 ENGINE Subsection 02 (LEAK TEST) Activate pump and pressurize engine cooling sys- NOTE: Engines with the RAVE system, the boot tem to 34 kPa (5 PSI). (carburetor-equipped engines) and O-ring can be checked for leakage with the valve in place. Wait 3 minutes and check if pressure drops;...
Page 71 Section 04 ENGINE Subsection 02 (LEAK TEST) Check also small oil injection pump lines and fit- tings; check for air bubbles or oil column going to- ward pump, which indicate a defective check valve. Check for leak through counterbalancing shaft seal toward air compressor (DI engines).
Page 72 Section 04 ENGINE Subsection 02 (LEAK TEST) 787 RFI ENGINE 787 RFI ENGINE 1. Oil return hose blocked with hose pincher 1. Pump with reducer and nipple Install pump with reducer and nipple to the oil sup- Activate pump and pressurize to 34 kPa (5 PSI). ply hose of the rotary valve shaft.
Page 73: Engine Leakage Diagnostic Flow Chart
Section 04 ENGINE Subsection 02 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 717 and 787 RFI Engines PRESSURIZE ENGINE COOLING SYSTEM CHECK TESTING KIT IS SYSTEM LEAKING? REPLACE O-RING OF CYLINDER HEAD PRESSURIZE ENGINE AND/OR CYLINDER BASE GASKET IS ENGINE LEAKING? RECHECK ENGINE SEALING CHECK TESTING KIT CHECK ALL JOINTED SURFACES,...
Page 74 Section 04 ENGINE Subsection 02 (LEAK TEST) 947 Engine 04-02-8 SMR2002-021_04_02A.FM www.SeaDooManuals.net...
Page 75: Removal And Installation
Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL On some models, it is not necessary to remove engine from watercraft to service TOP END, PTO FLYWHEEL or MAGNETO. However, engine remov- al is necessary to repair BOTTOM END. ENGINE REMOVAL DI Models Use the VCK (Vehicle Communication Kit) (P/N 529...
Page 76 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Disconnect connectors from fuel injectors and di- Tuned Pipe rect injectors. To remove tuned pipe, refer to EXHAUST SYSTEM. Disconnect connector from knock sensor. Air Intake Silencer Disconnect RAVE valve hose where shown. Inspect hose.
Page 77 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) All Models Engine Support NOTE: Be careful when removing engine sup- port(s) or rubber mount adapters, shims could have been installed underneath. Shims control engine/jet pump alignment. Always note position of shims for reinstallation, to avoid altering engine alignment.
Page 78 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) 787 RFI and 947 Engines Removal of Remaining Components Engine can be easily lifted by inserting a hook into Lift up engine slowly until oil injection hoses can be exhaust manifold eyelet. reached.
Page 79: Cleaning
Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) F04D10A TYPICAL — 787 RFI ENGINE 1. Rotary valve oil supply line 1. Positive starter cable 2. Hose pincher installed 2. Ground cable 3. Disconnect RED positive cable Carry on engine lifting then tilt engine so that it can Disconnect RED positive cable from starter post.
Page 80: Installation
Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) INSTALLATION Installation of engine in watercraft is essentially the reverse of removal procedures. However pay particular attention to the following. Rubber Mount, Shim and Screw Check tightness and condition of rubber mounts. If they have been removed, apply Loctite 243 (blue) on screw threads.
Page 81 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Oil Injection Hoses All Models except XP To verify alignment proceed as follows: 717 and 787 RFI Engines – Install the appropriate plate with the support to Make sure to reinstall hoses before completely low- hull with four nuts.
Page 82 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) NOTE: Use shim(s) (P/N 270 000 024 or P/N 270 – alignment shaft (P/N 295 000 141) 000 025) as necessary between engine supports and rubber mounts to correct alignment. 1. Alignment shaft –...
Page 83 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Place grease fitting on the top and torque seal car- NOTE: Use shim(s) (P/N 270 000 024 or P/N 270 rier nuts in a criss-cross sequence in two steps as 000 025) as necessary between engine supports per following illustration.
Page 84 Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION) Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil in- jection pump as specified in OIL INJECTION PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT (DI models).
Page 85: Magneto System
Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engine 04-04-1 SMR2002-023_04_04A.FM www.SeaDooManuals.net...
Page 86 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 787 RFI Engine 04-04-2 SMR2002-023_04_04A.FM www.SeaDooManuals.net...
Page 87 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 947 Carburetor-Equipped Engines 04-04-3 SMR2002-023_04_04A.FM www.SeaDooManuals.net...
Page 88 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 947 DI Engines 04-04-4 SMR2002-023_04_04A.FM www.SeaDooManuals.net...
Page 89: Disassembly
Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) DISASSEMBLY Using a suitable socket, unscrew retaining nut no. 13 COUNTERCLOCKWISE when facing it. 717 Engine NOTE: If socket is found too large to be inserted NOTE: On 717 engine, the magneto system can in puller plate, machine or grind its outside diame- be disassembled without removing the engine ter as necessary.
Page 90 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) The following procedure is to find a common ref- erence point on both crankcases (old and new) to position armature plate. Proceed as follows: – Before removing the armature plate, find a crankcase locating lug (the top one in this exam- ple).
Page 91 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Magneto Housing Battery Charging Coil To remove magneto housing no. 5, starter has to To replace battery charging coil no. 7: be removed. Refer to STARTING SYSTEM. – Heat the armature plate to 93°C (200°F) around the Unscrew retaining screws, then withdraw housing.
Page 92 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) 787 RFI Engine Rotor and Ring Gear Magneto Housing Cover Remove starter. Refer to STARTING SYSTEM. NOTE: Crankshaft can also be locked by using the Disconnect water hoses from heat exchanger cover. PTO flywheel extractor tool. For procedure, refer to Loosen screws no.
Page 93 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Remove special tool locking ring gear. Insert crankshaft protector to outer end of crank- shaft and fully thread puller in magneto rotor. 1. Ring gear blocking tool (P/N 295 000 134) 2. Retaining plate (P/N 295 000 154) TYPICAL 1.
Page 94 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Stator Assembly Remove oil pump shaft from magneto rotor nut. 787 RFI Engine Remove holding plate and withdraw plug from cover. Unscrew bolts no. 20 and remove stator no. 9 from magneto cover. F06D23A 1.
Page 95: Cleaning
Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) DI Models CAUTION: Be careful after ring gear removal not to bend the encoder wheel teeth. Also pay attention when putting away. If you suspect a bent tooth, refer to ENGINE MANAGEMENT for inspection procedure.
Page 96: Assembly
Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) ASSEMBLY Magneto Flywheel and Ring Gear Apply Loctite 648 (green) to magneto flywheel 717 Engine mating surface. Lay ring gear on a steel plate, then Generating Coil heat with a propane torch in order to install it on magneto flywheel.
Page 97: Magneto Flywheel
Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Armature Plate Magneto Flywheel Position the armature plate on the crankcase, Apply Loctite 243 (blue) on crankshaft taper. aligning the marks on both parts. Position Woodruff key and magneto flywheel. Ap- When reinstalling armature plate on a new crank- ply Loctite 243 (blue) on nut no.
Page 98 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Magneto Housing Crankshaft Position Sensor To install oil seal no. 28 of magneto housing no. 5, Install crankshaft position sensor no. 18 on mag- use pusher (P/N 290 877 740) and handle (P/N 420 neto housing.
Page 99 Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM) Cover Before installing cover, make sure oil pump shaft is properly positioned. Before installation, properly install O-ring no. 25 in engine magneto cover no. 1. Apply Loctite 767 anti-seize compound on screws no. 11. Torque screws in a criss-cross sequence to 9 N•m (80 lbf•in).
Page 100: Top End
Section 04 ENGINE Subsection 05 (TOP END) TOP END 717 Engine 04-05-1 SMR2002-024_04_05A.FM www.SeaDooManuals.net...
Page 101 Section 04 ENGINE Subsection 05 (TOP END) 787 RFI Engine 04-05-2 SMR2002-024_04_05A.FM www.SeaDooManuals.net...
Page 102 Section 04 ENGINE Subsection 05 (TOP END) 947 Carburetor-Equipped Engines 24 23 29 27 04-05-3 SMR2002-024_04_05A.FM www.SeaDooManuals.net...
Page 103 Section 04 ENGINE Subsection 05 (TOP END) 947 DI Engine 24 23 22 04-05-4 SMR2002-024_04_05A.FM www.SeaDooManuals.net...
Page 104: General
Section 04 ENGINE Subsection 05 (TOP END) GENERAL The 2-stroke ROTAX engine rotates counterclock- wise seen from the rear (PTO flywheel). The 717 and 787 RFI engines have a rotary valve to control opening and closing of the intake. The 947 engine uses reed valves in the crankcase.
Page 105 Section 04 ENGINE Subsection 05 (TOP END) RAVE VALVE CLOSED 1. Solenoid 1. Pulse from crankcase 2. Pressure from air compressor 2. Check valve 3. Pressure to RAVE valves 3. Positive pressure blocked by the solenoid 4. Vent to air intake silencer 4.
Page 106: Disassembly
Section 04 ENGINE Subsection 05 (TOP END) MAINTENANCE There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide. Cleaning intervals would depend upon the user’s riding style and the quality of the oil used.
Page 107 Section 04 ENGINE Subsection 05 (TOP END) Remove RAVE valve no. 15. NOTE: The following procedures relates the steps for the 787 RFI and 947 carburetor-equipped en- Remove the cover no. 18 of the valve by releasing gines. The DI engine is explained below. the spring no.
Page 108 Section 04 ENGINE Subsection 05 (TOP END) Unscrew valve piston no. 20 from sliding valve Remove supporting ring no. 28. no. 22. NOTE: Hold the sliding valve to prevent it from turning. 1. Remove supporting ring Remove O-ring no. 23. 1.
Page 109 Section 04 ENGINE Subsection 05 (TOP END) Remove sliding valve no. 22. 1. Remove sliding valve 1. Remove screws Remove bellows no. 21. Remove RAVE valve no. 15. Remove the cover no. 18 of the valve by releasing the spring no. 16. WARNING Firmly hold cover to valve base.
Page 110 Section 04 ENGINE Subsection 05 (TOP END) Remove the compression spring no. 19. Remove sliding valve from valve housing. 1. Valve piston 2. Valve housing 3. Sliding valve Cylinder Head Cover and Cylinder Head Disconnect temperature sensor wire and spark plug cables.
Page 111 Section 04 ENGINE Subsection 05 (TOP END) 947 Carburetor-Equipped Engines Remove cylinder head no. 2. NOTE: Due to the cylinder mounting studs, it is Remove cylinder head gasket no. 34. recommended to remove the engine from the hull to service the top end. However, one might unfas- ten the engine support to allow leaning the engine so that cylinder can be pulled out.
Page 112 Section 04 ENGINE Subsection 05 (TOP END) Remove cylinders no. 9, being careful that con- NOTE: To ease removal, a plastic tip hammer can necting rods do not hit crankcase edge. be used. Remove cylinder base gasket no. 10. WARNING 947 DI Engine If screws need to be heated for removal when engine is in watercraft, fuel system pressuriza-...
Page 113 Section 04 ENGINE Subsection 05 (TOP END) 947 Engines To extract piston pin no. 4, use piston pin puller (P/N 529 035 503) with the appropriate set of Install rubber pad (P/N 290 877 032) to crankcase. sleeves. Secure with screws. Lower piston to be removed until it sits on pad.
Page 114 Section 04 ENGINE Subsection 05 (TOP END) NOTE: The tool cutout must be positioned toward – Loosen the extracting nut and remove puller. the bottom of the piston. – Remove the shoulder sleeve from piston. 1. Tool cut-out toward bottom of piston 1.
Page 115: Cleaning
Section 04 ENGINE Subsection 05 (TOP END) CLEANING The inspection of engine top end should include the following measurements. Discard all gaskets and O-rings. TOLERANCES Clean all metal components in a solvent. ENGINE NEW PARTS WEAR MEASUREMENT Clean water passages and make sure they are not (min.) (max.) LIMIT clogged.
Page 116: Used Piston Measurement
Section 04 ENGINE Subsection 05 (TOP END) NOTE: Replacement cylinder sleeves are avail- able if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and over- size pistons of 0.5 mm (.020 in) are available for the 717 engine.
Page 117 Section 04 ENGINE Subsection 05 (TOP END) Using a micrometer, measure piston skirt perpen- dicularly (90°) to piston pin according to the follow- ing table. MAXIMUM A ENGINE TYPE mm (in) 29 (1.142) 787 RFI 28 (1.102) 28 (1.102) 947 DI 24 (0.945) 1.
Page 118: Ring End Gap
Section 04 ENGINE Subsection 05 (TOP END) F01D0XA 1. Feeler gauge 2. Rectangular ring (bottom) 1. Indicator set to zero 947 Engines Position the dial bore gauge at 16 mm (5/8 in) be- Due to the semi-trapez rings, it is not possible to low cylinder top edge.
Page 119: Assembly
Section 04 ENGINE Subsection 05 (TOP END) Cylinder Base Gasket RAVE Valve NOTE: The general procedure is to install a new 787 RFI Engine gasket of the same thickness. However, if you do Make sure to insert O-ring no. 23 onto rod of slid- not know the gasket thickness that was installed ing valve no.
Page 120 Section 04 ENGINE Subsection 05 (TOP END) Check the sliding valve O-ring. Replace if neces- sary. 1. Sliding valve O-ring 947 Carburetor-Equipped Engines Check the O-ring under valve housing. Replace if necessary. Install the supporting ring no. 28 with the bevel side facing the O-ring no.
Page 121 Section 04 ENGINE Subsection 05 (TOP END) – Replace the inner halves by the appropriate sleeve tool in the connecting rod bore. – Insert piston pin into piston until it comes flush with inward edge of piston hub. – Warm piston to approximately 50 - 60°C (122 - 140°F) and install it over connecting rod.
Page 122 Section 04 ENGINE Subsection 05 (TOP END) Plastic Mounting Device Method – Insert piston pin into piston until it comes flush with inward edge of piston hub. This is an alternate method when no service tool is available. Replacement roller bearings are delivered in a con- venient plastic mounting device.
Page 123 Section 04 ENGINE Subsection 05 (TOP END) 947 Engines Secure circlip in piston groove with its bent end in piston notch as shown. F01D0TA 1. Pulling inner sleeve half Circlip F07D0AB Always use new circlips. 1. Circlip end in piston notch All Engines WARNING To easily insert circlip into piston, use circlip installer.
Page 124 Section 04 ENGINE Subsection 05 (TOP END) – Position end of tool against piston pin opening. NOTE: Ring compressor will not fit on oversize parts. – Firmly hold piston against tool and tap tool with a hammer to insert circlip into its groove. Make sure to align ring end gap with piston locat- ing pin.
Page 125 Section 04 ENGINE Subsection 05 (TOP END) 717 Engine The aligning tool (P/N 420 876 904) or the exhaust manifold can be used to align cylinders. 787 RFI ENGINE 1. Aligning cylinders using exhaust manifold Cylinder Block 947 Carburetor-Equipped Engine 717 ENGINE 1.
Page 126 Section 04 ENGINE Subsection 05 (TOP END) To easily slide cylinder block over pistons, use ring Torque screws in a criss-cross sequence for each compressor (P/N 290 876 965). cylinder to 20 N•m (15 lbf•ft). Repeat the proce- dure, retightening all cylinder screws to 40 N•m (30 lbf•ft).
Page 127 Section 04 ENGINE Subsection 05 (TOP END) 717 and 787 RFI Engines 947 DI Engine Make sure to install O-rings no. 12 around spark Apply Loctite 243 (blue) below head of cylinder plug holes and O-ring no. 11 of cylinder head as head bolts no.
Page 128: Adjustment
Section 04 ENGINE Subsection 05 (TOP END) ADJUSTMENT Combustion Chamber Volume Measurement RAVE Valve All Engines 787 RFI Engine NOTE: This procedure is required to determine Turn the red plastic knob no. 17 until it is flush to the thickness of the cylinder base gasket to be in- the valve cover.
Page 129 Section 04 ENGINE Subsection 05 (TOP END) 947 DI Engine NOTE: The liquid level in cylinder must not drop for a few seconds after filling. If so, there is a leak 1. Remove both direct injectors and bring one pis- between piston and cylinder.
Page 130: Bottom End
Section 04 ENGINE Subsection 06 (BOTTOM END) BOTTOM END 717 Engine 04-06-1 SMR2002-025_04_06A.FM www.SeaDooManuals.net...
Page 131 Section 04 ENGINE Subsection 06 (BOTTOM END) 787 RFI Engine 04-06-2 SMR2002-025_04_06A.FM www.SeaDooManuals.net...
Page 132 Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Carburetor-Equipped Engines 15 17 only 04-06-3 SMR2002-025_04_06A.FM www.SeaDooManuals.net...
Page 133 Section 04 ENGINE Subsection 06 (BOTTOM END) 947 DI Engines 15 17 04-06-4 SMR2002-025_04_06A.FM www.SeaDooManuals.net...
Page 134: Disassembly
Section 04 ENGINE Subsection 06 (BOTTOM END) DISASSEMBLY Engine has to be removed from watercraft and top end has to be disassembled to open bottom end. Refer to REMOVAL AND INSTALLATION and TOP END. PTO Flywheel 717 Engine To remove PTO flywheel no. 1, the crankshaft TYPICAL must be locked.
Page 135 Section 04 ENGINE Subsection 06 (BOTTOM END) Install special tool. 1. Loosen Allen screws 2. Breaker bar locking crankshaft 1. PTO flywheel extractor Remove the coupler no. 20. Install the extension handle (P/N 295 000 125) on the PTO flywheel extractor. Loosen PTO flywheel XP Models COUNTERCLOCKWISE when facing it.
Page 136 Section 04 ENGINE Subsection 06 (BOTTOM END) All 947 Engines Starter Drive Assembly Install puller plate (P/N 529 035 533) and extension 947 Engines Only handle (P/N 295 000 125) to PTO flywheel. Loosen 2 Allen screws no. 24 retaining starter NOTE: Puller plate can be used without the exten- drive cover no.
Page 137 Section 04 ENGINE Subsection 06 (BOTTOM END) Reed Valve 717 and 787 RFI Engines Put engine on a stand. Loosen crankcase screws. 947 Engines Only Remove both carburetor flanges. 717 ENGINE 1. M10 x 73.5 flanged screws 2. M8 x 68.5 flanged screws 3.
Page 138 Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engines Place engine upright on crankcase magneto side. Loosen crankcase screws. F01D1LA TYPICAL 1. Separate halves by prying at provided lugs Remove crankshaft and counterbalance shaft (787 RFI and 947 engines). 947 DI Engines Open air compressor and disconnect the piston as described in ENGINE MANAGEMENT.
Page 139 Section 04 ENGINE Subsection 06 (BOTTOM END) 717 Engine 947 Engines To remove end bearings no. 4 from crankshaft, To remove end bearings from crankshaft, use the use the following tools. following tools. 947 ENGINES 717 ENGINE 1. Puller (P/N 420 877 635) 1.
Page 140 Section 04 ENGINE Subsection 06 (BOTTOM END) Or, use a bearing extractor such as Proto no. 4332 Install the puller as per following illustration. and a press to remove two bearings at a time (ex- cept on PTO side for the 787 RFI engine). 1.
Page 141 Section 04 ENGINE Subsection 06 (BOTTOM END) Counterbalance Shaft 787 RFI Engine Bearings no. 15 on counterbalance shaft no. 13 can be removed by using the following tools: F00D0SA 1. Index mark 1. Puller (P/N 420 877 635) 2. Protective cap (P/N 420 876 557) Use a press to remove the gear no.
Page 142: Cleaning
Section 04 ENGINE Subsection 06 (BOTTOM END) 947 Engines Use a press to remove counterweights no. 16 and bearings no. 15. CAUTION: There is no woodruff key to position the counterweights. An index mark must be traced to retain the proper position of the counterweight. F06D1HA 1.
Page 143: Inspection
Section 04 ENGINE Subsection 06 (BOTTOM END) Finish the cleaning with acetone. – Install Bombardier degree wheel (P/N 529 035 607) on crankshaft end. Hand-tighten nut only. CAUTION: Ensure to clean compressor lubrica- tion nipple. – Remove both spark plugs. CAUTION: Be careful not to spray cleaner on –...
Page 144 Section 04 ENGINE Subsection 06 (BOTTOM END) Crankshaft Alignment at Connecting Connecting Rod Straightness Rod Journal Align a steel ruler on edge of small end connecting rod bore. Check if ruler is perfectly aligned with Counterweights can also be twisted on connect- edge of big end.
Page 145 Section 04 ENGINE Subsection 06 (BOTTOM END) NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe. Connecting Rod Big End Axial Play CONNECTING ROD BIG END AXIAL PLAY NEW PARTS WEAR MODEL LIMIT (min.) (max.) 0.390 mm 0.737 mm 1.2 mm 947 engine...
Page 146 Section 04 ENGINE Subsection 06 (BOTTOM END) Starter Drive Bearing Reed Valve 947 Engines Only 947 Engines Only Check bearing no. 23 of starter drive assembly Check reed valve petals no. 29 for cracks or other no. 27 in crankcase. defects.
Page 147: Assembly
Section 04 ENGINE Subsection 06 (BOTTOM END) NOTE: Distance should be the same on both sides. Bent stopper as required to obtain the proper dis- tance. Air Compressor Refer to ENGINE MANAGEMENT for compo- nents inspection. However, if you find aluminum dust or debris in this area, they may have flowed F01B0HA toward the injection oil reservoir.
Page 148 Section 04 ENGINE Subsection 06 (BOTTOM END) Crankshaft Gear 787 RFI Engine Position PTO seal against the retaining shim; the 787 RFI Engine gap between the seal no. 5 and bearing no. 4 will Position the long flange of the gear no. 18 toward ensure proper lubrication of the bearing.
Page 149 Section 04 ENGINE Subsection 06 (BOTTOM END) Drive Pin Make sure drive pins no. 6 of bearings are proper- ly installed in crankcase recesses at assembly. F00D0UA 1. Gear notch aligned with the crankcase F00D0OA – The notch of the couterweight on the opposite 1.
Page 150 Section 04 ENGINE Subsection 06 (BOTTOM END) Reinstall counterweights no. 16 using a press and Turn by hand the crankshaft and counterbalance take care to align index marks previously traced. shaft. Make sure they do not interfere with the crankcase. Crankshaft and Counterbalance Shaft 947 Engines 787 RFI and 947 Engines...
Page 151 Temporarily install armature plate to align crank- case halves with each other. 947 DI Engines Add 40 mL (1.35 oz) of Sea-Doo synthetic jet pump oil (P/N 293 600 011) or standard gear oil in the counterbalance shaft gear cavity.
Page 152 Section 04 ENGINE Subsection 06 (BOTTOM END) All 947 Engines Make sure all locating dowels are in place. Torque 2 M10 crankcase screws to 40 N•m (30 lbf•ft). F06D1PA 1. Dowel Counterbalance Shaft Bearing Cover 787 RFI Engine Install the bearing cover no. 19 with its hollow side toward the bearing.
Page 153 Section 04 ENGINE Subsection 06 (BOTTOM END) As a final step, torque only M10 screws no. 8 of crankcase to 40 N•m (30 lbf•ft) as per following se- quence. F07D09C Oil Fittings All 947 Engines 717 and 787 RFI Engines Apply Molykote 111 below head of screws and If inlet and outlet oil fittings no.
Page 154 Section 04 ENGINE Subsection 06 (BOTTOM END) PTO Flywheel 787 RFI Engine When engine assembly is completed, add 30 mL 787 RFI Engine (1 oz) of motor oil SAE 30 to the counterbalance Install O-ring onto crankshaft. shaft gear through the crankcase filler plug. F01D84A F07D06A 1.
Page 155: Rotary Valve
Section 04 ENGINE Subsection 07 (ROTARY VALVE) ROTARY VALVE 717 and 787 RFI Engines 787 RFI engine 717 engine 04-07-1 SMR2002-026_04_07A.FM www.SeaDooManuals.net...
Page 156 Section 04 ENGINE Subsection 07 (ROTARY VALVE) GENERAL The following verification procedures such as clear- ance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing en- gine from watercraft. However engine must be removed from water- craft to work on rotary valve shaft/components.
Page 157 Section 04 ENGINE Subsection 07 (ROTARY VALVE) Remove cover then clean and measure compressed Manually feel backlash at one position, then turn soldering wire thickness, it must be within the spec- crankshaft about 1/8 turn and recheck. Continue ified tolerance 0.30 ± 0.05 mm (.012 ± .002 in). this way to complete one revolution.
Page 158 Section 04 ENGINE Subsection 07 (ROTARY VALVE) Place puller over rotary valve shaft end and screw Shaft Bearing on puller bolt into shaft. While retaining bolt with To remove bearing no. 8 use a bearing extractor a wrench, turn puller nut CLOCKWISE until shaft such as Snap-on no.
Page 159 Section 04 ENGINE Subsection 07 (ROTARY VALVE) INSPECTION End bearing no. 9 can be easily removed from up- per crankcase half using the following suggested tool (or equivalent): Rotary Valve Cover – Snap-on hammer puller including: Inspect rotary valve cover no. 1 for warpage. Small –...
Page 160 Section 04 ENGINE Subsection 07 (ROTARY VALVE) ASSEMBLY Seal Apply Molykote 111 on seal lips. Position seal no. 11 Assembly is essentially the reverse of disassem- with shielded portion against shaft splines. bly procedures. However pay particular attention to the following. Bearing Bearing Install ball bearing as illustrated.
Page 161 Section 04 ENGINE Subsection 07 (ROTARY VALVE) 717 Engine Push shaft until it stops on bearing seat. To install rotary valve shaft in crankcase, use a pusher (P/N 420 876 605). A00C0YA 1. Pusher Push shaft until its stops on bearing seat. F01D8OA 717 and 787 RFI Engines Snap Ring...
Page 162 Section 04 ENGINE Subsection 07 (ROTARY VALVE) There is no identification code on the valve. To find out the duration, place an angle finder on the valve and measure the valve cut-out angle or use the following template. 04-07-8 SMR2002-026_04_07A.FM www.SeaDooManuals.net...
Page 163: Rotary Valve Timing
Section 04 ENGINE Subsection 07 (ROTARY VALVE) ROTARY VALVE TIMING Proceed as follows: – Turning crankshaft, bring MAG side piston to CAUTION: Never use the ridge molded in crank- Top Dead Center using a TDC gauge. case as a timing mark. The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston.
Page 164 Section 04 ENGINE Subsection 07 (ROTARY VALVE) – For closing mark, first align 360° line of degree wheel with TOP of MAG side inlet port. Then, find 65° line on outer scale of degree wheel and mark crankcase at this point. 65°...
Page 165: Exhaust System
Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) EXHAUST SYSTEM 717 Engine Model GTI and GTI LE 6-19 04-08-1 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 166 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 787 RFI Engine 04-08-2 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 167 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Carburetor-Equipped Engines (XP Model) 14 12-13 16 22 04-08-3 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 168 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Carburetor-Equipped Engines (GTX Model) in 4 7 9 10 12-13 21 22 04-08-4 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 169 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Carburetor-Equipped Engines (RX Model) 12-13 16 22 04-08-5 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 170 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 DI Engines 16 22 12-13 04-08-6 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 171: Removal
Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) REMOVAL XP Model Open engine compartment cover. All Models except XP Remove storage basket. Remove seat(s). Remove rear vent hose support from body opening. Tuned Pipe 717 Engine Disconnect water supply hose and water injection hose.
Page 172 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 787 RFI Engine Remove air intake silencer. Disconnect water supply hose and water injection hose at tuned pipe. Loosen hose clamp no. 1 retaining exhaust hose no. 3 to tuned pipe cone. 1. Water return hose 2.
Page 173 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 6. Loosen and remove clamp no. 4 retaining tuned pipe head no. 10 to tuned pipe cone no. 5. F06E0AA 1. Water injection hose F06D1SA 4. Disconnect the water bleed hose. 1. Loosen and remove clamp 7.
Page 174 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 9. Loosen Allen screws no. 7 and nut no. 8 at tuned 11. Remove tuned pipe head no. 10. pipe flange. 12. Loosen bolt no. 6 of tuned pipe cone beside NOTE: To loosen nut, use polygonal wrench (P/N the engine water return hose.
Page 175 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Loosen Allen screw retaining carburetor bracket to tuned pipe head. F06D1UA 1. Remove bolt F06D2DA Remove tuned pipe assembly. 1. Loosen Allen screw Block exhaust opening in the manifold to keep de- Loosen Allen screws no. 7 and nut no. 8 at tuned bris from entering cylinder during threads cleaning pipe flange.
Page 176: Tuned Pipe Repair
Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Detach holding strap retaining resonator inside bilge. Pull resonator out of bilge. Muffler On DI models, disconnect the EGT (exhaust gas temperature) sensor. Disconnect hoses from muffler no. 11. Disconnect hoses of the water flow regulator valve (except 717 engine).
Page 177: Installation
Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Test 787 RFI Engine Apply Loctite 518 on 2 screws no. 12. On the oth- – Use compressed air at 124 kPa (18 PSI) to pres- er screws no. 12, apply Molykote 111 on threads. surize tuned pipe.
Page 178 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Engine Tuned Pipe Apply Molykote 111 on threads of Allen screws 717 Engine no. 12. CAUTION: Torque wrench tightening specifica- Install and hand tighten Allen screws no. 12 as per tions must be strictly adhered to. Locking de- following picture.
Page 179 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Position clamp no. 4 as illustrated. Do not tighten 787 RFI clamp yet. CAUTION: Torque wrench tightening specifica- tions must be strictly adhered to. Locking de- vices (ex.: locking tabs, elastic stop nuts, self- locking fasteners, etc.) must be installed or re- placed with new ones where specified.
Page 180 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Press the pipe support on the engine before torquing the pipe support bolt. 04-08-16 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 181 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 947 Engine Apply a thin layer of Loctite 30542 heat resistant sealant (P/N 293 800 090) all around sealing ring CAUTION: Torque wrench tightening specifica- no. 15. tions must be strictly adhered to. Locking de- vices (ex.: locking tabs, elastic stop nuts, self- CAUTION: Damage to bushings and/or sleeve locking fasteners, etc.) must be installed or re-...
Page 182 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) 04-08-18 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 183 Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM) Install exhaust hose. F06D14A 1. Torque clamp to 4 N•m (35 lbf•in) 04-08-19 SMR2002-027_04_08A.FM www.SeaDooManuals.net...
Page 184 Section 05 ENGINE MANAGEMENT (RFI) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................05-02-1 AIR INDUCTION......................... 05-02-2 FUEL DELIVERY......................... 05-02-2 FUEL PUMP ........................05-02-2 FUEL PRESSURE REGULATOR ..................05-02-2 FUEL FILTERS ........................05-02-3 FUEL PUMP MODULE....................... 05-02-3 FUEL INJECTORS ......................05-02-3 ELECTRONIC MANAGEMENT..................
Page 185 Section 05 ENGINE MANAGEMENT (RFI) Subsection 01 (TABLE OF CONTENTS) TROUBLESHOOTING SUMMARY ..................05-05-1 ENGINE DOES NOT START ....................05-05-1 FLOODED ENGINE FEATURE.................... 05-05-1 SPARK PLUG INSPECTION ....................05-05-1 ECU FAULT CODES ......................05-05-1 ENGINE STARTS BUT RUNS POORLY ................05-05-1 ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS .....
Page 186: Overview
Section 05 ENGINE MANAGEMENT (RFI) Subsection 02 (OVERVIEW) OVERVIEW DESCRIPTION OF THE FUEL INJECTION SYSTEM 1. Fuel tank 9. Throttle plate 2. Fuel filter 10. Throttle Position Sensor (TPS) 3. Fuel pump 11. Air Pressure Sensor (APS) 4. Regulator 12. Air Temperature Sensor (ATS) 5.
Page 187: Air Induction
Section 05 ENGINE MANAGEMENT (RFI) Subsection 02 (OVERVIEW) FUEL DELIVERY The Rotax Fuel Injection (RFI) is a semi-direct elec- tronic fuel injection system. FUEL PUMP Fuel is injected into each cylinder through the rear transfer port. With this design, the injector is not An electric fuel pump provides fuel pressure and exposed to high combustion pressure, tempera- flow rate to the system.
Page 188: Fuel Filters
Section 05 ENGINE MANAGEMENT (RFI) Subsection 02 (OVERVIEW) FUEL FILTERS FUEL PUMP MODULE A dual piece fuel filter protects the fuel pump, reg- All these components are comprised in a single ulator and injectors. module mounted in the fuel tank. The fuel gauge sender is also mounted on this module.
Page 189: Electronic Management
Section 05 ENGINE MANAGEMENT (RFI) Subsection 02 (OVERVIEW) ELECTRONIC MANAGEMENT Fail-Safe Function In the event of a sensor malfunction, the ECU will ELECTRONIC CONTROL UNIT use a default operating mode to ensure driveability to shore. A message may be displayed on the Info (ECU) Center to inform the operator.
Page 190 Section 05 ENGINE MANAGEMENT (RFI) Subsection 02 (OVERVIEW) PARAMETERS SENSORS FUEL DELIVERY SIGNAL MANAGEMENT 05-02-5 SMR2002-028_05_02A.FM www.SeaDooManuals.net...
Page 191: Diagnostic Procedures
Section 05 ENGINE MANAGEMENT (RFI) Subsection 03 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES The MPEM programmer is the primary tool to di- By selecting DIAGNOSIS the following message agnose fuel injection related problems. “INITIALIZING IN PROCESS” will be displayed a few seconds, then a new menu will appear on the The latest software designed for the RFI model screen.
Page 192: Fault Code Tables
Section 05 ENGINE MANAGEMENT (RFI) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT CODE TABLES ECU FAULTS FAULT CODE FAULT DETECTION TYPE OF FAULT MPEM B.U.D.S. programmer No fault detected FF FF 88 N.A. • No defect FF FF 00 P 0604 • Internal defect Electronic Control Unit Internal memory FF FF 1B...
Page 193: Output Signal Faults
Section 05 ENGINE MANAGEMENT (RFI) Subsection 03 (DIAGNOSTIC PROCEDURES) OUTPUT SIGNAL FAULTS FAULT CODE FAULT DETECTION TYPE OF FAULT MPEM B.U.D.S. programmer 04 E1 1C P 0262 • Short circuit to battery Injector 1 04 E1 1D P 0261 • Short circuit to ground 04 E1 1E P 1200 •...
Page 194: Component Inspection
Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) COMPONENT INSPECTION GENERAL CAUTION: Never use injector cleaning products. They may contain additive that could damage in- jector components. A copper wire brush may be WARNING used to clean the tip of the direct injectors if nec- The fuel system of a fuel injection system holds essary.
Page 195 Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) Pay particular attention to ensure that pins are not Resistance Measurement out of their connectors or out of shape. The trou- When measuring the resistance with an ohmmeter, bleshooting procedures cover problems not re- all values are given for a temperature of 20°C sulting from one of these causes.
Page 196: Air Induction System
Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) REGULATOR Also remember this validates the operation of the sensor at ambient temperature. It does not vali- The regulator is mounted on top of the fuel pump date the over temperature functionality. To test it, assembly.
Page 197: Fuel Injector
Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) FUEL INJECTOR Install a fuel pressure gauge (P/N 529 035 591) to the quick connect fitting of the fuel hose. FUEL PRESSURE GAUGE (P/N 529 035 591) Install the safety lanyard cap on the switch to ac- F07F0CA tivate the fuel pump.
Page 198: Leak Test (Supply And Ventilation Circuits)
Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) Check the resistance of the fuel injector circuits. Install the safety lanyard cap on the switch to ac- tivate the fuel pump. Disconnect the AMP plug connector no. 4 on the MPEM.
Page 199: Electronic Management
Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) ELECTRONIC MANAGEMENT Press on both tabs and pull quick connect fitting to disconnect the fuel hose from fuel rail. THROTTLE POSITION SENSOR (TPS) Check the resistance value of the throttle position sensor.
Page 200 Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) The resistance should be between 710 Ω and CRANKSHAFT POSITION 1380 Ω. SENSOR (CPS) Check the resistance of the crankshaft position sensor. If resistance is below specifications, replace the F07H0CA throttle position sensor (TPS). 1.
Page 201 Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) AIR TEMPERATURE SENSOR If resistance is below specifications, replace air temperature sensor (ATS). (ATS) If resistance is above specifications, disconnect NOTE: When testing the resistance of the air tem- the connector of the air temperature sensor and perature sensor (ATS), it is important to check the check resistance of wiring harness and terminals ambient temperature.
Page 202 Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) The resistance should be between 2.280 kΩ and If there is not 5 V, check the wiring harness and 2.736 kΩ at temperature of 19°C to 21°C (66°F to pin #12 on the #4 AMP plug connector. 70°F).
Page 203 Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) RAVE SOLENOID Using a multimeter, check the resistance between terminal 9 (WHITE/BLUE wire) and terminal 2 (BLACK/BLUE wire) on the plug connector. The resistance should be between 3.4 kΩ and RAVE SOLENOID 8.2 kΩ.
Page 204 Section 05 ENGINE MANAGEMENT (RFI) Subsection 04 (COMPONENT INSPECTION) RFI SENSORS RESISTANCE VALUES TERMINAL RESISTANCE COMPONENT WIRE COLOR VOLTS NUMBER VALUE 1 and 2 PU/BL and BK/BL 2.4 k - 8.2 k ohms 5 Vdc between Air pressure sensor PU/BL and BK/BL 9 and 2 WH/BL and BK/BL 3.4 k - 8.2 k ohms...
Page 205: Spark Plug Inspection
Check battery voltage. When voltage is too low, Reversed high tension cables will not allow the RFI the MPEM limits the engine revolutions. to run. Unlike other Sea-Doo models, the spark plugs Recharge or replace battery. spark independently on each piston stroke. Re- The RAVE system is not functioning properly.
Page 206: Throttle Position Sensor (Tps)
Section 05 ENGINE MANAGEMENT (RFI) Subsection 06 (ADJUSTMENT) ADJUSTMENT THROTTLE CABLE CAUTION: Do not select “YES” until the idle speed screw is loosened to allow the throttle ADJUSTMENT plate to close. Fully depress throttle lever. Lever must touch han- Loosen the lock nut of the idle speed screw. dlebar grip.
Page 207: Crankshaft Position Sensor (Cps)
Section 05 ENGINE MANAGEMENT (RFI) Subsection 07 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION MPEM CRANKSHAFT POSITION SENSOR (CPS) IMPORTANT: When MPEM is replaced, the safe- ty lanyard(s), the TPS closed position and the TDC Disconnect the connector of the CPS. setting must be reprogrammed/reset.
Page 208 Section 05 ENGINE MANAGEMENT (RFI) Subsection 07 (REMOVAL AND INSTALLATION) Remove fuel pump assembly from fuel tank. REGULATOR The regulator is not serviceable. Replace the fuel pump assembly if the regulator is defective. FUEL FILTER The fuel filter is not serviceable. Replace the fuel pump assembly if the fuel filter must be replaced.
Page 209 Section 06 ENGINE MANAGEMENT (DI) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................06-02-1 OPERATING PRINCIPLE ....................06-02-2 AIR INDUCTION......................... 06-02-2 AIR COMPRESSOR SYSTEM.................... 06-02-2 FUEL DELIVERY SYSTEM....................06-02-2 BASIC OPERATION ......................06-02-2 AIR/FUEL RAIL ASSEMBLY ....................06-02-2 FUEL PUMP MODULE....................... 06-02-3 ELECTRONIC MANAGEMENT..................
Page 210 Section 06 ENGINE MANAGEMENT (DI) Subsection 01 (TABLE OF CONTENTS) SPARK PLUGS........................06-03-35 CRANKING SYSTEM......................06-03-36 DI SYSTEM TEST SUMMARY................... 06-03-36 DIAGNOSTIC PROCEDURES....................06-04-1 GENERAL..........................06-04-1 DESS SYSTEM ........................06-04-2 FAULT DETECTION AND COMPENSATORY ACTIONS ..........06-04-4 COMPONENT FAILURE WARNING SYSTEM ..............06-04-4 VCK (VEHICLE COMMUNICATION KIT) ................
Page 211: Overview
Section 06 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) OVERVIEW 06-02-1 SMR2002-029_06_02A.FM www.SeaDooManuals.net...
Page 212: Operating Principle
Section 06 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) OPERATING PRINCIPLE The Orbital Combustion Process (OCP) provides a stratified combustion process resulting from the direct injection of a finely atomized fuel spray (less than 10 microns). This is achieved by using a pneu- matically assisted direct injection system, a unique combustion chamber geometry and a pre- cise control of the combustion process by the...
Page 213: Fuel Pump Module
Section 06 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) FUEL PUMP MODULE The air/fuel rail assembly is mounted on top of the cylinder head. It provides support for the air/fuel injectors and both air and fuel regulators. It also contains passages for the air and the fuel. The rail is a small reservoir for the injectors that keeps enough fluid at the proper pressure to supply the injectors demand.
Page 214: Electronic Management
Section 06 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) ELECTRONIC MANAGEMENT The MPEM is directly powered by the battery. It is responsible for the following engine management/ MPEM electrical functions: (multi-purpose electronic module) – interpreting information – distributing information The electronic fuel injection is equipped with a MPEM.
Page 215 The MPEM also offers a special safety lanyard — the the MPEM may send out 1 long beep when press- Sea-Doo LK™ (learning key) — which can be pro- ing the start/stop switch. The current supply to grammed so that the vehicle can be run only at a gauges will be stopped as explained in the ANTI- limited speed —...
Page 216 Section 06 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) Low-Fuel and Low-Oil Level Warning Device Power Distribution When the fuel level in the reservoir is low, the fuel The MPEM distributes power from battery to all level sensor transmits a signal to the MPEM. The accessories.
Page 217 In this case, removing and ble conditions: Cranking, flare, idle, warm up, nor- reinstalling the safety lanyard on its post may al- mal operation, Sea-Doo LK™ (learning key) (limit- low retrieving normal operation. ed vehicle speed), engine speed limiter, drowned engine and limp home (see below).
Page 218: Ignition System
Section 06 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) These performance-reduced modes allow the rid- Ignition Coil er to go back home which would not be possible Ignition coil induces voltage to a high level in the without this advanced system. Refer to the DIAG- secondary windings to produce a spark at the NOSTIC PROCEDURES for a complete chart.
Page 219: Component Inspection And Adjustment
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT GENERAL WARNING Engine problems are not necessarily related to the Fuel lines remain under pressure at all times. Al- electronic fuel injection system. ways proceed with care and use appropriate safety equipment when working on pressurized It is important to ensure that the mechanical integ- fuel system.
Page 220: Electrical System
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: Never use injector cleaning products. Pay particular attention to ensure that pins are not They may contain additive that could damage in- out of their connectors or out of shape. The trou- jector components.
Page 221: Amp Connector Pin-Out
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Measurement Also remember this validates the operation of the sensor at ambient temperature. It does not vali- When measuring the resistance with an ohmmeter, date the over temperature functionality. To test it, all values are given for a temperature of 20°C the sensor could be removed from the engine/ (69°F).
Page 222: Quick Fuel Pressure Test
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) QUICK FUEL PRESSURE TEST WARNING Read PRESSURE TEST under AIR/FUEL RAIL farther in this section for precautions and setup to take care of, before performing this test. The procedure here is a quick summary. Disconnect outlet hose (the one with the fuel fil- ter) from fuel pump using tool (P/N 529 035 714).
Page 223: Air Induction System
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) AIR INDUCTION SYSTEM Remove TPS, throttle lever, spring and guide from the old throttle body. THROTTLE BODY Installation Mechanical Inspection Reinstall removed parts on the new throttle body. For TPS replacement procedures, refer to THROTTLE Check that the throttle plates moves freely and POSITION SENSOR (TPS) in ELECTRONIC MAN-...
Page 224 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: In the following illustrations, the lower link plate has been removed for clarity purposes only. It does not have to be removed to perform the adjustment. Loosen lock nut of idle set screw. Unscrew idle set screw so that master throttle plate completely closes in the throttle body.
Page 225 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Ensure spring is still well positioned on stoppers. Properly reinstall the plastic cap to the synchroni- zation screw. Apply Loctite 5900 (P/N 293 800 066) flange seal- ant on idle set screw head. 1.
Page 226: Air Compressor
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Throttle Cable Adjustment Injection Oil Pump Cable Adjustment Mechanically adjust the throttle cable using the ad- As oil injection cable is throttle dependent, always justing device underneath body, below steering. proceed with the oil injection pump cable adjust- Slacken lock nut to allow adjuster rotation.
Page 227: Repair
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If pressure is below limits, ensure inlet hose is not obstructed, bent or kinked. Otherwise, repair the air compressor. Remove pressure gauge and reinstall air compres- sor hose. REPAIR Top End Remove retaining screws.
Page 228 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Remove engine support and slightly lift engine to allow access. Block engine in this position. Remove top end as explained above. Remove access plug of air compressor connect- ing rod. Remove connecting rod retaining screw.
Page 229 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The inspection of top end should include the fol- Install the oil ring with the “TOP” marking on top. lowing measurements. Identify the correct position by looking at beveled edge of oil ring and while installation, make sure TOLERANCES that the beveled edge should be towards the top...
Page 230: Fuel Delivery
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) When attaching connecting rod to “crankpin”, strict- ly follow this procedure: 1. Block counterbalance shaft to prevent any rota- tion. 2. Install the “crankpin” (bushing) with the previ- ously marked end outside. If the mark is not present anymore, place a straight edge against bushing end to find the tapered end (concave).
Page 231 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Install safety lanyard and observe fuel pressure. Do not crank engine. FUEL REGULATOR PRESSURE (when installing safety lanyard) 185 ± 14 kPa (27 ± 2 PSI) If pressure is within limits, fuel pressure regulator is working adequately.
Page 232: Fuel Injector
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Test Safety lanyard must be on DESS post. Using the vehicle communication kit (VCK) with the B.U.D.S. software, energize the fuel injector from the Activation section. If the injector does not work, disconnect the plug connector from the injector.
Page 233: Air/Fuel Rail
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Installation Air/Fuel Rail Replacement For the installation, reverse the removal proce- Removal dure. Paying attention to the following details. Release the fuel pressure in the system. If the same injector is reinstalled, it is recommend- Disconnect air compressor supply hose from rail.
Page 234: Direct Injector
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Gently pull rail up by hand, working each side slight- Leakage Test ly at a time. If direct injector leaks through its large top O-ring, Pull rail out. there will be an air/fuel leak between the injector and the air/fuel rail.
Page 235: Fuel Pump
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Disconnect direct injector connector then pull in- Carbon Dam Replacement jector out of cylinder head. Remove direct injector. See procedure above. NOTE: When replacing a carbon dam, it is recom- mended to replace it on both injectors.
Page 236 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Pressure gauge (P/N 529 035 709) 1. Fuel pump outlet hose (fuel filter side) 2. T-adapter (P/N 529 035 710) 2. Fuel pump return line 3. Pressure relief valve (P/N 529 035 711) 3.
Page 237 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Install a temporary connector to the fuel pump with wires long enough to make the connection outside the bilge and apply voltage (12 V) to this test harness. If pump does not run, replace the fuel pump. Otherwise, check the continuity of the fuel pump circuit.
Page 238 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART NOTE: The tolerance for the pressure is ± 14 kPa (2 PSI). Fuel pump runs Fuel pump does not run Connect safety lanyard for 2 sec.
Page 239: Electronic Management
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRONIC MANAGEMENT Select the Activation tab. Point the mouse cursor over the PTO TPS. Check MPEM REPLACEMENT the ADC reading. It must be between 23 and 45. General Prior to replacing a suspected MPEM, ensure that Activation all the recommendations in the general introduc- tion of this section have been followed.
Page 240: Throttle Position Sensor (Tps)
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) THROTTLE POSITION SENSOR NOTE: In this particular case, by comparing the signals from both sensors, the MPEM will gener- (TPS) ate a fault code when the TPS is malfunctioning due to specific “spots”.
Page 241 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Check the resistance between terminal 5 and ter- minal 14 with the throttle plate in idle position. The resistance should be 2500 Ω. Check the resistance between terminal 5 and ter- minal 10 with the throttle plate in idle position.
Page 242: Crankshaft Position Sensor (Cps)
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Use the vehicle communication kit (VCK) with the Otherwise, validate the information center is B.U.D.S. software to perform this adjustment. working by activating the tachometer using the software B.U.D.S. under Activation (first ensure Ensure the throttle body plate stop lever rest against information center is in tachometer mode).
Page 243 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Install a pointed wire on one of the threaded hole Voltage Test of crankcase with the screw as shown in the fol- Unplug magneto connector. lowing illustration. Check connector pins for corrosion or damage. Remove and reinstall the safety lanyard to activate the MPEM.
Page 244: Manifold Air Temperature Sensor (Mats)
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Using a multimeter, recheck resistance value be- tween terminals 16 and 19. If resistance value is correct, try a new MPEM. Re- fer to MPEM REPLACEMENT procedures else- where in this section. If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connec- tor and the MATS.
Page 245: Manifold Air Pressure Sensor (Maps)
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If resistance value is correct, try a new MPEM. Re- Ensure sensor is correctly installed elbow adaptor. fer to MPEM REPLACEMENT procedures else- Otherwise, the MAPS could generate a fault code where in this section.
Page 246: Exhaust Gas Temperature Sensor (Egt)
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) EXHAUST GAS TEMPERATURE KNOCK SENSOR (KS) SENSOR (EGT) 1. Knock sensor (KS) Dynamic Test 1. Muffler 2. Exhaust gas temperature sensor (EGT) Using the vehicle communication kit (VCK) with the B.U.D.S.
Page 247: Rave Solenoid
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Replacement Install leak test pump (P/N 529 021 800) on hose end and pressurize air line to 69 - 103 kPa (10 - 15 PSI). Unscrew and remove knock sensor. Wait some time to see if pressure drops.
Page 248: Ignition Coil
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) IGNITION COIL Pressure Relief Circuit When RAVE valve is released, the pressure es- NOTE: The MPEM energizes the primary side of cape from this vented hose. If the RAVE valves each ignition coil individually.
Page 249 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Using a multimeter, recheck resistance value be- WARNING tween terminals 21 and 22 for MAG side and ter- Do NOT use coil tester on metal work bench. minals 20 and 23 for PTO side. Follow manufacturer instructions.
Page 250: Tdc Setting
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Normally TDC setting should not be required. It has been set at factory and it should remain cor- rectly set since every part is fixed and not adjust- able. The only time the TDC setting might have to be changed would be when replacing the crank- shaft, the magneto rotor, the CPS, the encoder wheel or the MPEM.
Page 251 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 4. Install and adjust a TDC gauge (P/N 295 000 143) NOTE: This specification is of the type “indirect in MAG side spark plug hole. measurement” relative to the piston movement since we are measuring at a 45°...
Page 252 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) IMPORTANT: To check the TDC setting, the spark CAUTION: If the TDC setting is adjusted too ad- advance curve must be locked first. This allows to vanced, this will cause serious damage to the perform TDC setting at any RPM by keeping the engine.
Page 253: Spark Plugs
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: This will write the new value immediately Safety Lanyard Removed to the MPEM. There is no need to write the doc- Connect test probes to switch BLACK and BLACK/ ument to the MPEM for the TDC setting unless YELLOW wires.
Page 254: Cranking System
Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Proper socket 1. Cold 2. Improper socket 2. Hot CAUTION: Severe engine damage might occur SPARK ENGINE TORQUE if a wrong heat range plug is used. PLUG mm (in) A too “hot”...
Page 255 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Tests TERMINAL COMPONENT CONNECTOR WIRE COLOR VALUE NUMBER 26 and pin B PU/PK Fuel pump AMP no. 4 0 ohm (continuity) 24 and pin D BK/PK Fuel injector MAG 7 and 13 BL/PU and BL/BK AMP no.
Page 256 Section 06 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TERMINAL COMPONENT CONNECTOR WIRE COLOR VALUE NUMBER Exhaust gas AMP no. 4 10 and 12 TA/GY and BK/TA 2280 - 2740 ohms temperature (EGT) Knock sensor (KS) AMP no. 4 2 and 17 BK/BL and YL/BL 5 M ohms...
Page 257: Diagnostic Procedures
Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES GENERAL Here is the basic order suggested to diagnose a suspected fuel injection related problem: – Check the chart in TROUBLESHOOTING sec- tion to have an overview of problems and sug- gested solutions.
Page 258: Dess System
Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DESS SYSTEM Basic Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart. SIGNAL CAUSE REMEDY...
Page 259 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft post. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.
Page 260: Fault Detection And Compensatory Actions
Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) FAULT DETECTION AND COMPENSATORY ACTIONS For a basic overview of the monitoring system and the limp home modes, see OVERVIEW section. COMPONENT FAILURE WARNING SYSTEM Sensor Failures Refers to open or short circuit failures on sensors, drivers, injectors or ignition. BUZZER LIMP HOME MODE PROBLEM...
Page 261 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) System Failures Refers to operating conditions outside normal and/or safe ranges such as demand system failures, ex- treme voltages, over temperature conditions or low fuel/oil levels. BUZZER LIMP HOME MODE PROBLEM INFO CENTER RED LED BUZZER...
Page 262: Vck (Vehicle Communication Kit)
Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) Buzzer Code BUZZER BUZZER PATTERN NOTE CODE WARNING (vehicle communication kit) If the computer you are using is connected to the 110 Vac power outlet, there is a potential The VCK (Vehicle Communication Kit) (P/N 529 risk of electrocution when working in contact 035 844) is the primary tool to diagnose fuel injec- with water.
Page 263: Di System Fault Codes
Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DI SYSTEM FAULT CODES – Electrical noise might also lead engine to occa- sional cutout without generating a fault code when engine is restarted. When looking at the General fault code, pay attention to the “count” value in The faults registered in the MPEM are kept when the software B.U.D.S.
Page 264 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) TPS “OUT OF RANGE” Fault It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range.
Page 265 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) DI System Fault Code Chart SERVICE ACTION POSSIBLE CAUSES Service action: Check for 1 - 1.6 ohm resistance between system circuits 4-15 Direct Open or and 4-5. Check for + 12 volts on pin A of injector connector (color). Return to P1100 injector...
Page 266 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Service action: Check for 5 volts on pin 1 and 0-0.5 volts on pin 3 and 0 volts on pin 2. Check system circuits 4-1, 4-2, 4-18. Check with throttle closed the resistance between 1 and 2 is 2000 ohms and between 2 and 3 is 1000 ohms and between 1 and 3 2500 ohms.
Page 267 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Service action: Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5 volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2. Check Sensor housing is correctly inserted into manifold.
Page 268 Section 06 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Battery Full reset. Battery Possible causes: P1500 BV_HI_RED voltage Key off and voltage Battery failure, rectifier failure, battery terminal connection. very high Service action: Check fuse. Check system circuits 3-25 to battery + terminal, 2-26 to regulator Battery As soon as Battery...
Page 269 Section 07 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT, COMPONENTS AND CARE................... 07-02-1 CIRCUIT ..........................07-02-10 COMPONENTS ........................07-02-14 CARE ..........................07-02-17 07-01-1 SMR2002-052_07_01ATOC.FM www.SeaDooManuals.net...
Page 270: Circuit, Components And Care
Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE GTI and GTI LE Models (717 engine) 07-02-1 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 271 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GTX RFI Models (787 RFI engine) 07-02-2 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 272 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) GTX Models (947 carburetor-equipped engine) 07-02-3 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 273 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) XP and RX Models (947 carburetor-equipped engine) 07-02-4 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 274 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) RX DI and LRV DI (947 DI engines) 07-02-5 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 275 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 717 Engines 07-02-6 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 276 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines 07-02-7 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 277 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 Engine — Carburetor-Equipped Models 07-02-8 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 278 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 DI Engines 07-02-9 SMR2002-032_07_02A.FM www.SeaDooManuals.net...
Page 279: Circuit
Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT CAUTION: All hoses and fittings of the cooling system have calibrated inside diameters to as- sure proper cooling of the engine. Always replace using appropriate Bombardier part number. 717 Engines A Serial Cooling System is utilized on the 717 en- gines, which offers an efficient cooling of the combustion chamber to prevent the possibilities...
Page 280 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines Water is directed to the water inlet fitting at cylin- der head. The 787 RFI engines features a heat exchanger sys- tem. This system allows water coming out of the cylinder head to circulate through a magneto heat exchanger and the crankcase heat exchanger.
Page 281 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water enters cylinder block water jackets and is DI Models directed to the water jackets of the exhaust man- Water flows out of tuned pipe water jacket from ifold and tuned pipe head through passages locat- upper fitting of tuned pipe and is directed to the ed above and below exhaust ports.
Page 282 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The water supply of the water flow regulator is pro- vided by the water supply hose coming from the pump. F06E0AA 1. Injection fitting All Models 1. Water flow going to CSI CAUTION: Never modify cooling system arrange- ment, otherwise serious engine damage could The lower hose of the valve is the water supply...
Page 283: Components
Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COMPONENTS The elbow fitting can be identified by using the number stamped onto the fitting or by measuring its inside diameter. Refer to the following illustra- Clamp tion and chart. To cut or secure non-reusable Oetiker clamps of cooling system hoses, use pliers (P/N 295 000 070).
Page 284 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The water flow regulator valve no. 2 is mounted directly onto the muffler. F01E1FA TYPICAL 1. Water supply hose of regulator valve 2. Regulated water to injection fitting 3. Water injected into the muffler LOW SPEED OPERATION 1.
Page 285 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. The valve cap on the DI models is sealed and it is not adjustable.
Page 286: Care
Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Pull the valve slightly. Using pliers, release the clamp For winterization of cooling system, refer to STOR- which retains the bellows no. 8. AGE. Remove valve no. 7 and bellows no. 8. GTI and GTI LE Models When servicing the hull, always rotate watercraft counterclockwise (seen from the rear).
Page 287 Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Towing the Watercraft in Water Special precautions should be taken when towing a Sea-Doo watercraft in water. Maximum recommended towing speed is 24 km/h (15 MPH). When towing your watercraft in water, pinch the water supply hose from the jet pump housing to the engine with a large Hose Pincher (P/N 529 032 500).
Page 288 Section 07 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) TYPICAL — RX SERIES AND LRV DI MODELS 1. Hose pincher on water supply hose on this side of the T-fitting CAUTION: When finished towing the watercraft, the hose pincher must be removed before oper- ating it.
Page 289 Section 08 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................08-02-1 GENERAL ........................... 08-02-7 REMOVAL........................... 08-02-7 INSPECTION ........................08-02-9 ASSEMBLY......................... 08-02-10 FUEL SYSTEM PRESSURIZATION ................... 08-02-11 AIR INTAKE ..........................08-03-1 REMOVAL........................... 08-03-5 ASSEMBLY......................... 08-03-6 CARBURETOR ........................08-04-1 GENERAL ...........................
Page 290: Fuel Circuit
Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT GTI and GTI LE Models GTI/GTI LE 08-02-1 SMR2002-033_08_02A.FM www.SeaDooManuals.net...
Page 291 Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTX Models 08-02-2 SMR2002-033_08_02A.FM www.SeaDooManuals.net...
Page 292 Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) XP Models 08-02-3 SMR2002-033_08_02A.FM www.SeaDooManuals.net...
Page 293 Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTX RFI Models 08-02-4 SMR2002-033_08_02A.FM www.SeaDooManuals.net...
Page 294 Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) RX (carburetor-equipped models) 08-02-5 SMR2002-033_08_02A.FM www.SeaDooManuals.net...
Page 295 Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) DI Models 08-02-6 SMR2002-033_08_02A.FM www.SeaDooManuals.net...
Page 296: General
Always wipe off any fuel spillage from the watercraft. 1. Securing clamp in limited access When replacing fuel lines on SEA-DOO water- To secure or cut Oetiker clamps on fuel lines, use craft, be sure to use “B1” hoses as available from pliers (P/N 295 000 070).
Page 297 Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTI, GTI LE Models GTX RFI Models Remove seat. The fuel pump assembly has to be removed from the fuel tank to have access to the fuel filter. Refer Carburetor-Equipped Models to ENGINE MANAGEMENT (RFI). Turn the fuel valve to OFF position.
Page 298: Inspection
Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Remove rear panel of storage compartment (if so Fuel tank equipped). All Models Siphon fuel tank. NOTE: On all models (except GTX, GTX RFI and Remove steering assembly. Refer to STEERING LRV DI), it is necessary to remove the engine. Re- SYSTEM for procedure.
Page 299: Assembly
Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Fuel Tank WARNING All Models Ensure that there is no leakage from the fuel filter. Visually inspect the inside and outside of the fuel tank necks for crack(s). If crack(s) are existing, re- place fuel tank no.
Page 300: Fuel System Pressurization
Section 08 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL SYSTEM PRESSURIZATION – Turn fuel valve to OFF position (except GTX RFI and DI). WARNING – Pressurize fuel system to 34 kPa (5 PSI). – If no leaks are found, turn fuel valve to ON po- Whenever doing any type of repair on water- sition and pressurize once more.
Page 301: Air Intake
Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) AIR INTAKE 717 Engines 08-03-1 SMR2002-034_08_03A.FM www.SeaDooManuals.net...
Page 302 Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) 787 RFI Engine 08-03-2 SMR2002-034_08_03A.FM www.SeaDooManuals.net...
Page 303 Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) 947 Carburetor-Equipped Engines 08-03-3 SMR2002-034_08_03A.FM www.SeaDooManuals.net...
Page 304 Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) 947 DI Engines 11 12 08-03-4 SMR2002-034_08_03A.FM www.SeaDooManuals.net...
Page 305: Removal
Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) REMOVAL Flame Arrester Base Remove flame arrester no. 5. 717 and 787 RFI Engines Remove screws no. 8 retaining support no. 6 of Air Intake Silencer Cover flame arrester base to the cylinder head cover (717 engine) or to the exhaust manifold (787 engine).
Page 306: Assembly
Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) Unlock the clip no. 2 on top of air intake silencer. XP Model Remove bolts retaining both air ducts to engine (both Pull the air silencer forward to remove it from the sides).
Page 307 Section 08 FUEL SYSTEM Subsection 03 (AIR INTAKE) Gasket All 947 Engines NOTE: Make sure the air intake silencer is retained Inspect condition of gasket no. 9. Make sure to by the lower bracket no. 4. properly install gasket. Place protector pads on duct supports. Use slot in All 947 Engines rubber to insert pad on bracket eyelet.
Page 308: Carburetor
Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) CARBURETOR For fuel system on RFI and DI models, refer to appropriate ENGINE MANAGEMENT section. Mikuni BN-40i and BN-46i PTO/MAG 08-04-1 SMR2002-035_08_04A.FM www.SeaDooManuals.net...
Page 309: General
Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) GENERAL The following illustration shows which part of the carburetor begins to function at different throttle plate openings. F06F0LA TYPICAL 1. Pulse line 2. Loosen gear clamp Disconnect fuel supply line from fuel pump. F01F13A Disconnect fuel return line.
Page 310: Cleaning
Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) CLEANING The carburetor exterior surfaces should be cleaned with a general solvent and dried with compressed air before disassembly. CAUTION: Be careful at carburetor cleaning not to remove paint. Paint removal will cause carbu- retor to rust very rapidly.
Page 311 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) Internal Fuel Filter – Obstruct outlet nipple with a finger and hold while pumping. To verify condition of filter no. 5, proceed as follows: – Pump tester until it reaches 28 kPa (4 PSI). Remove pump cover no.
Page 312: Assembly
Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) To check the injector, install pump gauge tester to Needle Valve Lever the injector hose. Rounded end of needle valve lever no. 8 must be NOTE: Injectors are also equipped with check flush with surrounding metering chamber floor valves.
Page 313 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) CAUTION: Do not stretch or cut spring. LEAK TEST Needle valve must stand a pressure of 69 kPa (10 PSI) for 30 seconds. Otherwise, hold carbure- tor upside down, pour oil over needle valve and apply pressure.
Page 314: Installation
Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) INSTALLATION Check Valve Assembly The check valve is needed if a back pressure oc- Carburetors curs into carburetor. It will prevent fuel from flow- ing back into carburetor lower portion. At installation, pay attention to the following: Inspect check valve no.
Page 315 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) TYPICAL TYPICAL 1. Stopper 1. Throttle lever PTO side 2. Idle speed screw 2. Marks Loosen jam nuts on carburetor linkage and adjust CAUTION: Throttle plates must open simulta- linkage with adjustment nut. neously, otherwise this will cause engine to vi- brate and/or misfire.
Page 316 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) 717 ENGINE 1. Adjustment nut 2. Jam nut 3. Throttle lever stopper Tighten jam nut and recheck adjustment. WARNING Make sure idle speed screw contacts stopper when throttle lever is fully released at handle- bar.
Page 317 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) Ensure throttle plates are completely closed on both carburetors. Loosen jam nut and turn adjustment nut to elimi- nate all the slack in the throttle cable between sen- sor and carburetor. Tighten jam nut. 1.
Page 318 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) CAUTION: Do not attempt to adjust high speed screw by removing plastic cap. 947 ENGINE 1. Low speed screw (PTO side shown) CAUTION: Do not attempt to set engine idle speed with low-speed screw. 717 ENGINE Tighten low speed screw until a slight resistance 1.
Page 319 Section 08 FUEL SYSTEM Subsection 04 (CARBURETOR) Fuel Accelerator Pump All Engines Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM for the 717 engines and 1400 RPM for the 947 engines in water. With the engine not running, loosen adjustment screw lock nut.
Page 320 Section 09 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ...................... 09-02-1 GENERAL ........................... 09-02-6 OIL SYSTEM PRESSURIZATION ..................09-02-6 OIL INJECTION PUMP ......................09-03-1 OIL PUMP IDENTIFICATION ..................... 09-03-5 REMOVAL........................... 09-03-5 DISASSEMBLY ........................09-03-5 CLEANING .........................
Page 321: Oil Injection System
Section 09 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM GTI and GTI LE Models 09-02-1 SMR2002-036_09_02A.FM www.SeaDooManuals.net...
Page 322 Section 09 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) XP Models 09-02-2 SMR2002-036_09_02A.FM www.SeaDooManuals.net...
Page 323 Section 09 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GTX Models 09-02-3 SMR2002-036_09_02A.FM www.SeaDooManuals.net...
Page 324 Section 09 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GTX RFI Models 09-02-4 SMR2002-036_09_02A.FM www.SeaDooManuals.net...
Page 325 Section 09 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) DI Models 09-02-5 SMR2002-036_09_02A.FM www.SeaDooManuals.net...
Page 326: General
Section 09 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM) GENERAL Carburetor-Equipped Models – Connect pump gauge tester (P/N 529 021 800) Whenever repairing the oil injection system, al- to check valve of oil injection reservoir vent. ways verify for water infiltration in reservoir. DI Models Perform also a pressure test of the oil injection system.
Page 327: Oil Injection Pump
Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL INJECTION PUMP 717 Engine 09-03-1 SMR2002-037_09_03A.FM www.SeaDooManuals.net...
Page 328 Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 787 RFI Engine 09-03-2 SMR2002-037_09_03A.FM www.SeaDooManuals.net...
Page 329 Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 947 Carburetor-Equipped Engines 09-03-3 SMR2002-037_09_03A.FM www.SeaDooManuals.net...
Page 330 Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) DI Models 09-03-4 SMR2002-037_09_03A.FM www.SeaDooManuals.net...
Page 331: Oil Pump Identification
Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) OIL PUMP IDENTIFICATION Remove 2 Allen screws no. 6 with flat washers retaining oil injection pump to intake manifold no. 2. Pump Lever Remove pump. Different engines need different pumps. See iden- tification on lever.
Page 332: Assembly
Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) ASSEMBLY 787 and 947 Engines Oil Injection Pump and Shaft 717 Engine Make sure shaft no. 8 is installed in crankshaft Oil Injection Pump and Intake Manifold end. Install oil injection pump no. 1 to intake manifold Install pump.
Page 333: Adjustment
Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) 717 Engine F01D4RE TYPICAL 1. Cable end completely inserted 2. Cable end NOT seated on the steps 1. Jam nut 2. Adjustment nut CAUTION: Ensure cable end is completely en- 3. Aligned marks tered in its housing.
Page 334 Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Loosen jam nut and turn cable adjustment nut to The adjustment is located under the throttle body obtain proper pump setting. bracket. The adjustment nut and jam nut for the oil injection pump cable are located at the cable support on the throttle body.
Page 335 Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) All Engines Start and bring engine to normal operating temper- ature. CAUTION: If watercraft is out of water, engine must be cooled using the flush kit. If air bubbles are present in the oil injection system, bleed system before operating engine.
Page 336: Checking Operation
Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Check small oil lines of pump. They must be full NOTE: The engine should have a rich mixture, of oil. idling irregularly and emitting smoke at exhaust outlet. If not, remove pump assembly and check the pump gear (717 engine) or shaft (787 RFI and 947 engines) for defects, replace as necessary.
Page 337 Section 09 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP) Compare the results with the chart below. If oil pump is out of specification, replace it. OIL PUMP FLOW RATE AT ENGINE 1500 RPM (5 minutes) 9.9 - 12.1 mL (each port) 787 RFI 5.7 - 6.9 mL (each port) 8.3 - 10.1 mL (each port)
Page 338 Section 10 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM........................ 10-02-1 GENERAL ........................... 10-02-1 MULTI-PURPOSE ELECTRONIC MODULE (MPEM)............10-02-3 THROTTLE CABLE ......................10-02-6 IGNITION TIMING ......................10-02-7 IGNITION SYSTEM TESTING PROCEDURE ..............10-02-14 SPARK PLUGS ........................10-02-18 CHARGING SYSTEM......................
Page 339: Ignition System
Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION SYSTEM GENERAL 717 Engines The flywheel contains 4 permanent magnets and NOTE: For DI models, refer to ENGINE MANAGE- spins around the generating coil. This electric cur- MENT section. rent flows to the Multi-Purpose Electronic Module The ignition system consist of different sub-systems (GTI and GTI LE models).
Page 340 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) An AC voltage is generated by the sensor and is sent to the ECU to calculate the crankshaft posi- tion and the engine speed. 1. Coil 2. Magnet 3. Rotor protrusion 4. Magnetic field outside of coil 5.
Page 341: Multi-Purpose Electronic Module (Mpem)
Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Both coils are located inside the electrical box. Dynamic Ignition Advance Curve 947 Carburator-Equipped Models The throttle cable features a Hall Effect Switch that flattens the advance curve until it reaches 80% throttle.
Page 342 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Antistart Feature Engine RPM Limiter When connecting a safety lanyard cap on the switch The MPEM will limit the maximum engine speed. the DESS system inside the MPEM is activated Engine Stopping and will emit audible signals: There are two ways to stop the engine.
Page 343 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) GTI and GTI LE Models On these models, the MPEM is used as a electrical box. TYPICAL 1. MPEM Compared to the magneto system, the DC-CDI TYPICAL system offers a more powerful and stable ignition at low RPM.
Page 344: Throttle Cable
Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) XP MODELS 1. Electric box THROTTLE CABLE GTX RFI MODELS GTX, XP and RX Models 1. Electrical box 2. Rectifier/regulator The throttle cable can be checked for proper oper- ation with a timing light. Mark the PTO flywheel, like when the ignition tim- ing is checked.
Page 345: Ignition Timing
Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) IGNITION TIMING 947 Engines Only With this DC-CDI system, the ignition timing can Before checking ignition timing with a stroboscop- be checked with either the engine hot or cold. Al- ic timing light (dynamic test), it is mandatory to so, the ignition timing is to be checked at 3500 scribe a timing mark on the PTO flywheel (static RPM with the timing light.
Page 346 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 787 RFI Engines All Engines 4. Remove middle screw securing the engine to 6. Install and adjust a TDC gauge (P/N 295 000 143) the rear engine mount. Reinstall screw with tim- in MAG side spark plug hole.
Page 347 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 8. From this point, rotate flywheel clockwise to reach proper specification according to engine. Refer to the following chart. IGNITION TIMING ENGINE (BTDC) 2.59 mm (.102 in) 787 RFI 1.02 mm (.040 in) 2.99 mm (.118 in) Scribe a thin mark on PTO flywheel in the middle of tool slot (717 engine) or aligned with timing...
Page 348 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) F06H06A 1. Timing light pick-up 1. Tachometer pick-up 3. Start engine and point timing light straight in line 2. Connect timing light pick-up to MAG side spark with timing tool slot. Bring engine to 6000 RPM. plug wire.
Page 349 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) To adjust, loosen 3 armature plate retaining screws and slightly rotate armature plate in proper direction. NOTE: As a guideline, turn the armature plate the same amount needed to align mark on PTO flywheel. F06H07A 1.
Page 350 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Fixed Timing Function 1. Connect the communication cable to the MPEM programmer and the other end to the safety lan- yard switch on the craft. 2. Press the ON/C button on programmer and enter your password.
Page 351 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Access the BOSCH SYSTEM in the MPEM pro- Knowing that, you select with the programmer the grammer, then select ADJUSTMENT in the sub- higher or lower number to advance or retard the menu.
Page 352: Ignition System Testing Procedure
Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) – You recheck the timing with the timing light 10. Press 8 to choose Save + Quit (even if item and found that the flywheel mark is still too no. 8 is not visible on the display, it is active advanced.
Page 353 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) CAUTION: Whenever replacing a component Rev Limiter Verification in ignition system, check ignition timing. To check engine rev limiter, connect an induction NOTE: To perform verification, a good quality mul- tachometer (P/N 529 014 500), start engine and timeter such as Fluke 73 (P/N 529 022 000) should check its maximum speed.
Page 354 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 3. Connect one of the multimeter probes to the WHITE wire of the 6-pin magneto harness adapt- 4. Connect the other multimeter probe to the BLACK/YELLOW wire of the 6-pin magneto har- ness adapter.
Page 355 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Ignition Coil Verification NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter. STATIC TEST NOTE: An ignition coil with good resistance mea- 787 RFI Engines surement can still be faulty. Voltage leak can occur Primary Winding at high voltage level which is not detectable with an ohmmeter.
Page 356: Spark Plugs
Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) 947 Engines 1. With ignition coil removed from craft, discon- nect spark plug caps from high tension cables. Primary Winding 2. Hook high tension leads from tester to ignition coil high tension cables. 3.
Page 357 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Such a plug is used in heavy duty or continuous Fouling high speed operation to avoid overheating. Fouling of the spark plug is indicated by irregular The “hot” type plug has a longer insulator nose running of the engine, decreased engine speed and transfers heat more slowly away from its firing due to misfiring, reduced performance, and in-...
Page 358 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) Spark Plug Installation Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to the following chart.
Page 359 Section 10 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM) NGK Spark Plug Symbol Explanation WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040") B R 8 E S 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 360: Charging System
Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL Fuse If the battery is regularly discharged, check fuse Magneto condition. The purpose of the charging system is to keep the The rectifier/regulator could be the culprit of a blown battery at a full state of charge.
Page 361 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Current reading should be approximately 4 am- peres for the 717 engine and 5 amperes for the 947 carburetor-equipped and 947 DI engines. If not, check magneto output prior to concluding that rec- tifier is faulty.
Page 362 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: If it is continually necessary to add distilled ADAPTER RESISTANCE PART NAME water to the battery, this indicates an over voltage WIRE COLOR (Ω) situation, requiring replacement of the rectifier/ regulator. If, on the other hand, the battery will not YELLOW with Battery 0.05 - 0.6...
Page 363 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Stator 947 Engines STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness connec- tor. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Check resistance between two of the YELLOW wires.
Page 364: Battery
Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 3. Check resistance between the BLACK/YELLOW BATTERY and the BLACK wires of the 4-pin magneto har- ness adapter. The resistance should be between Troubleshooting 0.1 to 1.0 ohm. SYMPTOM: DISCHARGED OR WEAK BATTERY 4.
Page 365 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) All Models except GTI, GTI LE and GTX RFI CAUTION: Should any electrolyte spillage oc- Models cur, immediately wash off with a solution of baking soda and water. Proceed as follows: 1. Disconnect the BLACK negative cable first. Cleaning 2.
Page 366: Battery Storage
Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) A hydrometer measures the charge of a battery in SPECIFIC GRAVITY READING terms of specific gravity of the electrolyte. A fully USING A HYDROMETER charge battery will have a specific gravity between 1.265 to 1.280.
Page 367 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric grease on terminals. Clean battery casing and caps using a solution of baking soda and water. CAUTION: Do not allow cleaning solution to en- ter battery.
Page 368 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 5. Connect a 2 A battery charger for 3 to 5 hours. 7. Test battery state of charge. Use a hydrometer. Step : Connect + lead to battery + post Step : Connect - lead to battery - post Step : Plug battery charger 1.
Page 369 Section 10 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) – State of charge: Because the electrolyte is near- – Since the battery chargers vary in the amount ly pure water in a completely discharged battery, of voltage and current they provide, the time it cannot accept current as well as electrolyte.
Page 370: Starting System
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM 717 Engine 10-04-1 SMR2002-040_10_04A.FM www.SeaDooManuals.net...
Page 371 Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 787 RFI Engine 10-04-2 SMR2002-040_10_04A.FM www.SeaDooManuals.net...
Page 372 Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 Engine 10-04-3 SMR2002-040_10_04A.FM www.SeaDooManuals.net...
Page 373: General
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) GENERAL MPEM If 2 short beeps are not heard when installing the Causes of troubles are not necessarily related to safety lanyard, refer to DIGITALLY ENCODED SE- starter but may be due to a burnt fuse, faulty bat- CURITY SYSTEM or ENGINE MANAGEMENT.
Page 374: Starting System Troubleshooting
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY STARTER DOES NOT TURN. Burnt 5 A fuse on MPEM. Check wiring condition and replace fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten.
Page 375: Starter Removal
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER REMOVAL STARTER DISASSEMBLY Disconnect BLACK cable ground connection from 717 and 787 RFI Engines battery. Before disassembling, trace index marks on yoke no. 1 and clutch housing no. 10 to ease further WARNING assembly.
Page 376 Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 Engine Locate index marks on yoke no. 1 and end covers no. 3 and no. 10. 1. Thrust washers Remove the other end cover no. 10 and gasket. 1. Index marks Remove the three washers no.
Page 377: Cleaning
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Release brush wires of yoke from brush holder no. 2. Remove brushes. Remove brush holder no. 2. To remove bearing and seal in end cover, release tabs of retainer. F06H1KA 1. Retainer 1.
Page 378: Parts Inspection
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) PARTS INSPECTION Brush Measure brush length. If less than 8.5 mm (.335 in), Armature replace them. NOTE: An ohmmeter may be used for the follow- NOTE: New brush length is 12 mm (.472 in). ing testing procedures, except for the one con- cerning shorted windings in armature.
Page 379 Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) F01H0TA 1. Armature shaft 1. Brush holder locating notch 2. Circlip To ease end frame installation, retain brush holder 3. Pinion stop collar 4. Punch with a small screwdriver while installing end frame. Yoke Assembly and Clutch Housing Align previously traced indexing marks.
Page 380: Starter Installation
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 Engine Screw and Teeth Washer Install new O-rings and gaskets. Apply Loctite 271 (red) to screw. Insert thrust washers no. 19 onto armature shaft. Connect BLACK negative cable to starter using flat washer, teeth washer no.
Page 381 Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Connect the RED positive cable to the starter and torque nut no. 17 to 6 N•m (53 lbf•in). Apply di- electric grease on terminal and nut. GTX MODEL 1. Torque nut to 6 N•m (53 lbf•in), apply dielectric grease and install protection cover 2.
Page 382: Starter Specification
Section 10 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER SPECIFICATION 717 and 787 RFI Engines Nominal output 0.6 kW Voltage 12 V Rated time 30 seconds Rotation Counterclockwise (viewed from pinion side) Weight Approx. 2 kg (4.4 lb) No load 11.5 V 20 A max.
Page 383: Instruments And Accessories
Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL It is possible to activate the instruments when the engine is not running. Make sure the safety lanyard is removed, then de- press the start/stop button. The timer of the MPEM will maintain the gauge(s) activated during a period of approximately 33 sec- onds.
Page 384 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) When you are satisfied with your choice, stop press- The warning light will blink at the same time. ing the button. Warning Light Clock: Indicates the actual time in hours and min- utes (hh:mm).
Page 385: Other Functions
Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) As a self test, all LCD segments and the LED will English/Metric System turn on for 3 seconds each time the information Allows to display the units in the metric system or center is activated.
Page 386: Inspection
Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) NOTE: If maintenance message (MAINT) contin- ues to blink, it indicates a fault with the fuel injec- tion system on Di models. Refer to DIAGNOSTIC PROCEDURES section. INSPECTION Air Temperature Sensor GTX, GTX RFI and LRV DI Models 1.
Page 387 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Compass The BLACK wire is the ground. The GRAY wire is the pulse signal from the multi- GTX, GTX RFI and LRV DI Models purpose electronic module (MPEM). The compass is located in the storage cover. Speed Sensor Remove the back panel of the storage cover to ac- cess the compass.
Page 388 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Speedometer Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge. All Models except GTI NOTE: The gauge must be activated to obtain a reading.
Page 389 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Water Temperature (L temp) (if so equipped) NOTE: The gauge must be activated to obtain a read- ing. Disconnect the 2-circuit connector housing of the Info Center which contains a BLACK/ORANGE RESISTANCE DISPLAY and TAN/ORANGE wires.
Page 390 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Variable Trim Gauge XP Models + 45° The trim gauge shows the riding angle of the wa- tercraft. 0° Bombardier – 45° F01H0EA If gauge is not within the specifications, replace it. Fuel Baffle Pick Up Sender All Models except RFI and DI Models The baffle pick-up has an integrated fuel sender.
Page 391 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) The resistance measured between PINK/BLACK RFI and DI Models and PINK wires must be in accordance with fuel The fuel pick up system is part of the fuel pump level (measured from under the flange) as speci- module mounted inside the fuel reservoir.
Page 392 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) The bottom of the sensor has a small reservoir To Reinstall Sensor: with two small holes underneath to let the oil en- – Remove rubber seal from sensor. ter inside and one at the top to let the air enter –...
Page 393 Section 10 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) VTS Control Module (if so equipped) It receives its current from the battery. It is protect- ed by its own 7.5 A fuse, located on the MPEM module. Resistance Test Disconnect BROWN/BLACK wire and BROWN/ WHITE wire of VTS control module.
Page 394: Digitally Encoded Security System
Section 10 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) DIGITALLY ENCODED SECURITY SYSTEM Carburetor-Equipped Models NOTE: For RFI and DI models, refer to ENGINE MANAGEMENT section. GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unautho- rized use of the watercraft.
Page 395 Section 10 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Basic Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme- diate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
Page 396 Section 10 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM) Advanced Self-Diagnostic Mode It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft switch. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3.
Page 397 Section 11 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ..........................11-02-1 GENERAL ........................... 11-02-3 JET PUMP INSPECTION ON WATERCRAFT..............11-02-3 REMOVAL........................... 11-02-6 DISASSEMBLY........................11-02-8 CLEANING ......................... 11-02-11 PARTS INSPECTION ......................11-02-11 ASSEMBLY......................... 11-02-13 PUMP PRESSURIZATION ....................11-02-21 INSTALLATION ........................
Page 398: Jet Pump
Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) JET PUMP GTX RFI Models 11-02-1 SMR2002-043_11_02A.FM www.SeaDooManuals.net...
Page 399 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models except GTX RFI 11-02-2 SMR2002-043_11_02A.FM www.SeaDooManuals.net...
Page 400: General
Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive Stainless 271 000 920 pitch steel 15° - 21° Progressive Stainless 271 001 297 pitch steel 9° - 20° Progressive Stainless GTI LE 271 001 297 pitch steel 9°...
Page 401 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Using a feeler gauge with 30 cm (12 in) blades, measure clearance between impeller blade tip and wear ring. Measure each blade at its center. Clear- ance should not exceed 1.0 mm (.040 in). If clear- ance is greater, disassemble jet pump and inspect impeller and wear ring.
Page 402 To check oil condition, insert a wire through oil lev- Pour oil through hole until oil reaches the bottom el hole then withdraw. A whitish oil indicates wa- of hole threads. Use SEA-DOO JET PUMP SYN- ter contamination. THETIC OIL (P/N 293 600 011) only. Oil will drain...
Page 403: Removal
Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) REMOVAL Reverse Gate (if so equipped) All Models except GTX RFI To remove reverse gate no. 4, put shift lever in reverse position. Unscrew pivot bolt no. 5 retaining connecting rod no. 6 and pivot support no. 7. 1.
Page 404 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Connecting Rod Nozzle Remove: All Models except GTX RFI and XP – reverse gate Disconnect steering cable from jet pump nozzle no. 20. – pivot bolt no. 14. Remove: Withdraw connecting rod. –...
Page 405: Disassembly
Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) XP Models Disconnect steering cable from jet pump nozzle. Disconnect ball joint of VTS link rod. Loosen 2 screws each side of trim ring. F02J0TA 1. Remove screws Jet Pump Housing 1. Remove screws Remove: Remove nozzle.
Page 406 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Cover With pump assembly in horizontal position, remove 3 retaining screws no. 26. Place container under cover no. 27 to catch oil. Using a fiber hammer, gently tap cover to release it from jet pump housing. Impeller Insert impeller shaft holder (P/N 295 000 082) on impeller shaft flat end.
Page 407 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Rotate impeller remover tool counterclockwise After cutting ring, insert a screwdriver blade be- and unscrew completely impeller. tween jet pump housing and ring outside diameter. CAUTION: Never use any impact wrench to loos- Push ring so that it can collapse internally.
Page 408: Cleaning
Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) CLEANING PARTS INSPECTION All Models Impeller Thoroughly clean jet pump housing by applying Loc- Visually inspect impeller splines. Check for wear or tite Stripper (P/N 293 110 004). Allow it some time deformation.
Page 409 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Wear Ring To check both bearings, proceed the same way with other shaft end. Position gauge tip on diam- Check wear ring no. 31 for deep scratches, irreg- eter, close to flats on shaft. ular surface or any apparent damage.
Page 410: Assembly
Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Thrust Washer and Thrust Bearing Seal Visually inspect thrust washer no. 32, thrust bear- Carefully inspect seal lips. Make sure that lips are ing no. 33 and their contact surface. Check for not worn, distorted, cracked or show signs of any scoring, pitting, flaking, discoloration or other evi- other damage.
Page 411 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Manually engage ring in housing making sure it is Seal and Needle Bearing equally inserted all around. Press ring until it seats GTX RFI Models into bottom of housing. Bearings no. 30 and seal no. 29 will be properly installed in housing using bearing/seal installer tool (P/N 295 000 107).
Page 412 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller Side CAUTION: These tools have been designed to properly position bearings and seal, thus pro- All Models viding space for lubrication purposes. The tool Stamped end of bearings (showing identification flanges allow this. If a different pusher type is markings) must be located toward outside of hous- being used, components must be properly po- ing.
Page 413 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) CAUTION: Prevent sealant from contacting any Properly insert bearing on tool. Using an arbor needles of bearing. press only, push tool until tool flange contacts housing. Push on tool end with a press until tool flange con- tacts housing.
Page 414 F00J0DA 1. Thrust washer properly installed in stator seat Thrust Bearing Apply SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011) on both sides of thrust bearing. Position thrust bearing no. 33 on thrust washer no. 32.
Page 415 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) NOTE: If jet pump housing rest against a table, raise it slightly to allow complete shaft insertion with the shaft guide. Remove shaft guide. Impeller Apply Loctite primer N (P/N 293 600 012) on threads of impeller shaft no.
Page 416 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) Apply synthetic grease (P/N 293 550 010) on im- peller splines. Insert a new boot no. 2 and ring no. 3 to impeller. Apply synthetic grease in the center hole of the cover.
Page 417 Place housing horizontally as in its operating posi- tion so that filler plug is located on top. Remove filler plug from cover. Pour SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011) in reservoir un- til oil comes level with bottom of hole. Let oil drain into housing and after a few minutes add more oil until it is level with bottom of filler hole.
Page 418: Pump Pressurization
23 then torque to 20 N•m (15 lbf•ft). no. 22 may be leaking; Add a small quantity of SEA-DOO JET PUMP SYNTHETIC OIL to wet the oil seal. Let soak and recheck. 11-02-21 SMR2002-043_11_02A.FM...
Page 419 Section 11 PROPULSION SYSTEM Subsection 02 (JET PUMP) XP Models Install nozzle/trim ring assembly. Torque screws to 20 N•m (15 lbf•ft). NOTE: Trim ring has a tight fit; to install, insert both sides at the same time, taking care not to break plastic bushings.
Page 420: Drive System
Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) DRIVE SYSTEM All Models except XP 11-03-1 SMR2002-044_11_03A.FM www.SeaDooManuals.net...
Page 421 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP Models 11-03-2 SMR2002-044_11_03A.FM www.SeaDooManuals.net...
Page 422: General
Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GENERAL Jet pump must be removed to replace any com- ponents of the drive system. Refer to JET PUMP for removal procedure. REMOVAL PTO Flywheel Guard All Models except XP Remove seat(s). Remove vent tube support or seat support.
Page 423 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) – Use pliers (P/N 295 000 054). All Models except XP Drive Shaft Simply pull out drive shaft. NOTE: If the drive shaft is jammed into PTO fly- wheel, make the following tool and use it in con- junction with the jet pump housing remover (P/N 295 000 113) to withdraw drive shaft.
Page 424 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Mount on drive shaft puller the jet pump housing Pull rear drive shaft until coupler no. 19 is disen- remover; then, install assembly on drive shaft us- gage from splines. ing screws. TYPICAL F08I04A 1.
Page 425 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Loosen bolts and lock nuts retaining the lower sup- Loosen gear clamp retaining the outer boot of the port of the shock absorber. shock absorber. F08Q01A F08L12A TYPICAL 1. Loosen gear clamp 1.
Page 426: Inspection
Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Bearing no. 16 and seals no. 15 can be easily re- Excessive deflection could cause vibration and moved using the bearing/seal remover tool (P/N damage to drive shaft splines, impeller, flywheel 295 000 144). or floating ring (seal carrier depending upon the model).
Page 427: Assembly
Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Boot Slide floating ring far enough forward in order to release it from carbon ring. Inspect the condition of boot. If there is any dam- Measure boot free length. age or evidence of wear, replace it. Subtract the installed length measurement from To verify the preload of the boot no.
Page 428 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Install bearing no. 16 with the bearing/seal install- er tool (P/N 295 000 107). 1. Double-lip seal toward engine F01J51A 2. Double-lip seal with protector toward jet pump 3. Raised edge of lip outwards 1.
Page 429: Installation
Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) INSTALLATION Carefully slide shaft through support plate and seal carrier. Insert adapter end into PTO flywheel. Installation is essentially the reverse of removal NOTE: Ensure the mid bearing is loosened. procedure. However, pay particular attention to the following.
Page 430 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Front Drive Shaft Coupler and Damper NOTE: Make sure to install floating ring before in- serting the drive shaft in the PTO flywheel. Make sure to install dampers into drive shaft cou- While holding jet pump, guide and engage drive pler at both ends.
Page 431: Lubrication
Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) – Insert pointed tips of pliers first in closing hooks. Small Clamp To secure small clamp no. 4, place notch side of plier on clamp embossment and squeeze plier. TYPICAL 1. Closing hooks 1.
Page 432 Section 11 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Seal Carrier of Mid Bearing XP Models Using a grease gun, lubricate seal carrier of mid bearing with synthetic grease (P/N 293 550 010). F05I09A TYPICAL 1. Grease fitting 11-03-13 SMR2002-044_11_03A.FM www.SeaDooManuals.net...
Page 433: Reverse System
Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) REVERSE SYSTEM GTX RFI and LRV DI Models 11-04-1 SMR2002-045_11_04A.FM www.SeaDooManuals.net...
Page 434: Disassembly
Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) DISASSEMBLY Reverse Gate Support Unscrew 4 bolts which retain reverse gate support Reverse Gate no. 10 to venturi. Put shift lever in reverse position. Remove reverse gate support from venturi. Disconnect reverse cable from reverse gate no. 1. Remove lock nut no.
Page 435: Inspection
Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) ASSEMBLY Remove bolt no. 12 and lock nut no. 13 retaining reverse cable end to interior lever no. 11. Assembly is essentially the reverse of disassem- bly procedures. However, pay particular attention to the following.
Page 436: Adjustment
Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Spring and Pawl Lock Reverse Cable Make sure spring no. 8 is properly installed. One Install reverse cable to cable lever as per following end of the spring is hooked in the pawl lock no. 7 illustration.
Page 437 Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) If not, adjust reverse cable. Loosen 2 bolts no. 18 at reverse cable support no. 16. Turn adjustment nut no. 23 as required. F07J09A 1. Reverse cable support 2. Loosen bolts 3. Adjustment nut When adjustment is completed, there should be gap of 0 to 5 mm (0 to 3/16 in) between handle and left cover.
Page 438 Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTI, GT I LE, RX and RX DI Models Synthetic grease Loctite 2 N•m (18 lbf•in) 2.5 N•m (22 lbf•in) Silicone sealant 2.5 N•m (22 lbf•in) Loctite 2 N•m (18 lbf•in) 3.3 N•m (29 lbf•in) 4 N•m Loctite...
Page 439 Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTX Models 11-04-7 SMR2002-045_11_04A.FM www.SeaDooManuals.net...
Page 440: Disassembly
Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) DISASSEMBLY GTX, GTI, GTI LE, RX and RX DI Models Reverse Gate To remove reverse gate, refer to JET PUMP section. Reverse Cable Unscrew bolt no. 1, washers and the elastic stop nut retaining reverse cable no.
Page 441: Inspection
Section 11 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Handle Housing Remove: – shift lever – interior lever – reverse cable support – bolts no. 9. Then, remove handle housing no. 10. INSPECTION Visually inspect parts for wear or cracks. Replace all defective parts.
Page 442: Variable Trim System
Section 11 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM RX and RX DI Models 11-05-1 SMR2002-046_11_05A.FM www.SeaDooManuals.net...
Page 443 Section 11 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) XP Models 11-05-2 SMR2002-046_11_05A.FM www.SeaDooManuals.net...
Page 444: General
Section 11 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) GENERAL To test VTS control module, motor or switch, refer to INSTRUMENTS AND ACCESSORIES. To have access to VTS module, remove seat (ex- cept XP). NOTE: On XP models, open rear access cover. REMOVAL All Models Remove nut no.
Page 445: Disassembly
Section 11 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) DISASSEMBLY INSPECTION Cover Boot Remove VTS cover no. 7 by pressing on tabs. Make sure boot no. 3 is in good condition. If it is cracked or teared, replace boot. Worm Inspect threads and splines of worm no.
Page 446: Installation
Section 11 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) Install motor no. 8, worm and sliding shaft in VTS Apply Loctite Primer N (P/N 293 800 041) to threads housing. of VTS housing, and to nut no. 4. Apply Loctite 243 (blue) to nut no. 4. Install nut with sealing washer and torque to 7 N•m (62 lbf•in) using the VTS socket tool.
Page 447: Adjustment
Section 11 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) ADJUSTMENT RX and RX DI Models On these models, no adjustment is required. XP Models Push on VTS button up position until motor stops. When the nozzle is up (8°), nozzle edge must not interfere with venturi (there should be a gap of 1 mm (.039 in)).
Page 448 Section 12 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................12-02-1 DISASSEMBLY........................12-02-2 ASSEMBLY......................... 12-02-4 DISASSEMBLY ........................12-02-7 ASSEMBLY......................... 12-02-10 OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)..........12-02-12 GENERAL ............................12-02-13 SIDE VANE ......................... 12-02-13 CYLINDER SUPPORT ASSEMBLY ................... 12-02-14 TIE ROD ..........................
Page 449: Steering System
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) STEERING SYSTEM All Models except XP Carburetor-equipped engines 12-02-1 SMR2002-047_12_02A.FM www.SeaDooManuals.net...
Page 450: Disassembly
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) DISASSEMBLY Remove 2 screws no. 20 and flat washers no. 21 each side of cover. Handle Grip and Grip Insert To remove handle grip no. 1, pull out cap no. 2 and remove screw no.
Page 451 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Loosen bolts no. 11 each side of steering support Steering Support no. 12. All Models except XP Cut locking tie securing wiring harness boot. 1. Steering support F07K04A 2. Bolt 1. Boot 2.
Page 452: Assembly
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Disconnect the steering cable from the steering Steering Stem Arm and Support stem arm no. 15. Loosen bolts no. 17 retaining steering stem arm no. 15 to support no. 16. 1. Steering stem arm 2.
Page 453 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Handle Grip and Grip Insert When installing the grip insert no. 21 in the han- dlebar no. 22, ensure that it is properly inserted in the slot at the end of the handlebar tubing. 1.
Page 454 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) XP Models 12-02-6 SMR2002-047_12_02A.FM www.SeaDooManuals.net...
Page 455: Disassembly
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) DISASSEMBLY Remove 2 screws no. 9 and flat washers each side of cover. Handle Grip and Grip Insert To remove handle grip no. 1, pull out cap no. 2 from grip end and remove screw no. 3 and washer no.
Page 456 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Lever Remove link rod no. 12. Open engine compartment cover. Remove the top section of the engine cover by loosening the 10 Allen screws located inside the cover. F08K06A 1. Remove link rod Remove bolt no.
Page 457 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Steering Stem Arm and Support Loosen bolts no. 17 retaining steering stem arm no. 15 and support no. 16. 1. Remove support and steering stem arm F08K08A 1. Loosen bolts Steering Stem Loosen nuts and bolts retaining steering support Disconnect wiring harnesses, choke and throttle no.
Page 458: Assembly
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Unscrew bolts from retaining block no. 20 to re- move steering cable from cable support no. 19. 1. Apply synthetic grease Steering Stem Arm and Support F08K0KA Position steering stem arm no. 15 and support 1.
Page 459 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Install flat washer no. 4 and screw no. 3. Torque screw to 7 N•m (62 lbf•in). WARNING Correct torque must be strictly followed. 1. Grip insert 2. Grip 3. Flat washer 4. Torque screw to 7 N•m (62 lbf•in) 5.
Page 460: Off-Power Assisted Steering System (O.p.a.s.)
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.) 12-02-12 SMR2002-047_12_02A.FM www.SeaDooManuals.net...
Page 461: General
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) GENERAL When throttle is released and engine RPM drops, the side vanes are automatically lowered thus as- The Off-Power Assisted Steering (O.P.A.S.) system sisting steering control. uses a dual side vanes design that assists the water- craft steering in deceleration, to redirect watercraft path when steering is turned after throttle has been released or engine stopped.
Page 462: Cylinder Support Assembly
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) CYLINDER SUPPORT ASSEMBLY Disassembly Removal procedure for RH and LH cylinder sup- port assembly is same. Remove side vane as mentioned above. Unscrew bottom nut using O.P.A.S. cylinder nut wrench (P/N 529 035 840). 1.
Page 463: Tie Rod
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) – Socket screws no. 22 should be turned 2-3 turns by hand before tightening with tool. – Replace the cylinder seal ring whenever servic- ing. Torque socket screw no. 22 to 5.5 N•m (49 lbf•in). TIE ROD Disassembly Removal procedure for RH and LH tie rod is same.
Page 464: Sealed Tube
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) SEALED TUBE Assembly Assembly is the reverse process of disassembly. Disassembly Apply silicone grease on the screws before installing. Removal procedure for RH and LH sealed tube Torque Phillips screws no. 28 to 2.2 N•m (19 lbf•in). no.
Page 465: Water Hose
Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) WATER HOSE Unscrew bottom nut of valve no. 33 using O.P.A.S. cylinder nut wrench (P/N 529 035 840). Disassembly Removal procedure for RH and LH water hose is same. Remove side vane and cylinder support assembly as mentioned above.
Page 466 Section 12 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Remove cross support plate no. 36 from the in- side of bilge. Assembly Assembly is the reverse process of disassembly, make sure of the following when doing assembly: – Check for cracks and deterioration of screw threads on cross support plate, change if nec- essary.
Page 467: Alignment
Section 12 STEERING SYSTEM Subsection 03 (ALIGNMENT) ALIGNMENT Position handlebar in straight ahead position by Loosen 2 bolts retaining block at cable support. measuring each side the distance from handlebar Turn adjustment nut as required. grip end to floorboard. F01K07A TYPICAL 1.
Page 468 Section 12 STEERING SYSTEM Subsection 03 (ALIGNMENT) TYPICAL — XP MODELS 1. Support 2. Adjustment nut 3. Loosen bolts All Models After adjustment, torque retaining block bolts to 6 N•m (53 Ibf•in). CAUTION: Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi or VTS ring.
Page 469 Section 13 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION.................... 13-02-1 REMOVAL .......................... 13-02-2 INSPECTION ........................13-02-3 ASSEMBLY......................... 13-02-3 13-01-1 SMR2002-052_13_01ATOC.FM www.SeaDooManuals.net...
Page 470: Direct Action Suspension
Section 13 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION XP Model 13-02-1 SMR2002-048_13_02A.FM www.SeaDooManuals.net...
Page 471 Section 13 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) REMOVAL Remove rear access panel from body. Loosen lower gear clamp no. 4, then push inner Shock Absorber boot no. 5 upward. Loosen 4 screws and remove bottom cover of seat. F08I03B 1.
Page 472 Section 13 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) Tilt seat upward. Install shock absorber/coil spring assembly in spring compressor tool. Loosen upper gear clamp no. 9 of inner boot no. 5. F08L13A 1. Loosen gear clamp F05L0NA Remove bolt no. 10 and lock nut no. 11 from shock Compress spring and remove cup no.
Page 473 Section 14 HULL/BODY Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR ....................14-02-1 GLOVE BOX ........................14-02-19 SEAT ADJUSTMENT......................14-02-20 STORAGE COMPARTMENT INNER SHELL ..............14-02-21 STORAGE COMPARTMENT COVER ADJUSTMENT ............14-02-21 ACCESS PANEL ADJUSTMENT ..................14-02-22 MIRROR..........................
Page 474: Adjustment And Repair
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR GTI and GTI LE Models (bow) 14-02-1 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 475 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI and GTI LE Models (stern) 14-02-2 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 476 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI and GTI LE Models (cover) GTI LE 14-02-3 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 477 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI and GTI LE Models (seats) 14-02-4 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 478 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX Series (bow) 14-02-5 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 479 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX Series (stern) 14-02-6 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 480 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX Series (cover) 14-02-7 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 481 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX Series (seat) 14-02-8 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 482 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX, GTX RFI and LRV DI (bow) 14-02-9 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 483 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX, GTX RFI and LRV DI (stern) 14-02-10 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 484 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX, GTX RFI and LRV DI (cover) 14-02-11 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 485 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX, GTX RFI and LRV DI (seat) 14-02-12 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 486 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Models (bow) 14-02-13 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 487 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Models (stern) 14-02-14 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 488 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Models (seat) 14-02-15 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 489 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Models (suspension and engine cover) 14-02-16 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 490 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Models (front cover) 14-02-17 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 491 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP Models (rear cover) 14-02-18 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 492: Glove Box
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GLOVE BOX GTI, GTI LE and RX Series Open front storage cover and remove the access GTX, GTX RFI and LRV DI panel. Open the glove box cover then unscrew the four Detach the latch retaining vent tube to bracket.
Page 493: Seat Adjustment
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) From front storage compartment, pull glove box out. GTX, GTX RFI AND LRV DI — REAR SEAT 1. Lock pin 1. Lock tabs 2. Adjustment nut (apply Loctite 243). Torque to 5 N•m (44 lbf•in) A.
Page 494: Storage Compartment Inner Shell
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Gently pull on large end (rear end) and pull apart towards the small end (front). See illustration. 1. Gently pull starting this end 2. Finish with this end For installation, proceed as follows: GTI AND GTI LE MODELS —...
Page 495: Access Panel Adjustment
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) All Models NOTE: Some models have a floating type lock pin. It is normal to have a front and aft play of the lock Adjust lock pin no. 3 as per following specifica- pin.
Page 496: Mirror
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Adjust bolts no. 16 of access panel arms as per following specifications: 1. Lock nut. Torque to 22 N•m (16 lbf•ft) A. 20 ± 1 mm (25/32 ± 3/64 in) MIRROR GTI LE and RX Series Place the mirror frame in hot water to “soften”...
Page 497 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) TYPICAL 1. Hydraulic bottle jack 2. Steel plates Cleaning Scrape off all excess of sealant from riding plate and hull. Clean hull surface with acetone based solvent to GTI, GTI LE, LRV DI RX AND RX DI MODELS eliminate grease, dust and any residue of sealant.
Page 498: Jet Pump Support
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) NOTE: Apply Loctite The Right Stuff Gasket as in- dicated by the shaded area. F05K02A TYPICAL 1. Unscrew nut Remove ball joint, boot, nut, half rings and O-rings from reverse cable (GTI, GTI LE, RX series, GTX, GTX RFI and LRV DI).
Page 499: Deflector
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Installation Apply Loctite The Right Stuff Gasket as indicated by the shaded areas in the next illustrations. Fol- low also the torquing sequence as shown in the same illustrations. 4 N•m (35 lbf•in) LRV DI MODELS DEFLECTOR GTX, GTX RFI and LRV DI...
Page 500: Seat Removal
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT REMOVAL XP Models Loosen 4 screws and remove bottom cover no. 17 of seat. GTX RFI MODELS DRAIN PLUG INSTALLATION Refer to the following illustration to install drain plug F08L11A no. 15. 1.
Page 501 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loosen gear clamp of inner boot; then, pull boot downward. F08L1EA 1. Loosen screws of eyelet F08L13A Remove cup no. 21 on each side of seat. 1. Gear clamp Loosen nut no. 23 on each side of seat. Remove bolt and lock nut from shock absorber up- per support.
Page 502: Seat Cover Replacement
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT COVER REPLACEMENT Install staples with an electric tacker such as Ar- row tacker no. ETN-50 or with a manual tacker such as Arrow tacker no. T-50. NOTE: For an easier installation, it’s highly recom- mended to use an electric tacker.
Page 503: Engine Compartment Cover Removal
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Other Models Disconnect the gas assist cylinder. Remove seat (access cover for the XP models). Remove engine compartment cover. Remove seat support (GTI, GTI LE, GTX, GTX RFI Engine cover installation is essentially the reverse and LRV DI).
Page 504: Hull And Body Repair
Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) INSTALLATION ON GELCOAT The body and hull of the Sea-Doo are constructed of chopped fiberglass, saturated with resin. It is Clean surface with a good solvent such as ACRYLI- sprayed on the layer of gelcoat along with pieces...
Page 505 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Carefully mix the required amount while making PREPARING THE SURFACES sure there are no air bubbles in the mixture. With Small Fractures a putty knife, fill the repair area and cover with Open the cracks up with a sharp triangular can plastic film.
Page 506 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) BUFFING AND WAXING PATCHING THE REPAIR AREA Buff the surface using a heavy duty polisher with Outside a buffing pad. Make sure the pad is free of dirt or The outside should be done first. Wipe clean the you may damage the gelcoat.
Page 507: Tools And Materials List
Cut plastic hull insert flush with hull using a saw. – air mask – white cloths – sanding block – putty knife – plastic film – stirring stick – cover sheets (for Sea-Doo) – scissors – buffing pad – heavy-duty polisher – power sander – paint brush 1. Hull –...
Page 508 Section 14 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Install aluminum insert into plastic hull insert. NOTE: Align aluminum insert as much as possible with PTO flywheel. F01L2WA 1. Aluminum insert NOTE: The epoxy glue curing time is 30 minutes. 14-02-35 SMR2002-049_14_02A.FM www.SeaDooManuals.net...
Page 509: Gti And Gti Le Models
Section 15 TECHNICAL DATA Subsection 01 (GTI AND GTI LE MODELS) GTI AND GTI LE MODELS ENGINE GTI LE Engine type BOMBARDIER-ROTAX 717 Induction type Rotary valve Type Water cooled, water injected Water injection fitting 3.5 mm (.139 in) Exhaust system (head) Water injection fitting 3.5 mm (.139 in)
Page 510 Section 15 TECHNICAL DATA Subsection 01 (GTI AND GTI LE MODELS) ELECTRICAL GTI LE Magneto generator output 160 W @ 6000 RPM Ignition system type Digital CDI Make and type NGK BR8ES Spark plug 0.4 - 0.5 mm (.016 - .020 in) mm (in) 2.59 (.102) Ignition timing (BTDC)
Page 511 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
Page 512 Section 15 TECHNICAL DATA Subsection 01 (GTI AND GTI LE MODELS) MATERIALS GTI LE Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam...
Page 513: Gtx Rfi Model
Section 15 TECHNICAL DATA Subsection 02 (GTX RFI MODEL) GTX RFI MODEL ENGINE GTX RFI Engine type BOMBARDIER-ROTAX 787 Induction type Rotary valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Exhaust system Water injection fitting (cone) Not applicable Water injection fitting...
Page 514 Section 15 TECHNICAL DATA Subsection 02 (GTX RFI MODEL) ELECTRICAL SYSTEM GTX RFI Magneto generator output 270 W @ 6000 RPM Ignition system type Digital, inductive type Make and type NGK BR8ES Spark plug 0.4 - 0.5 mm (.016 - .020 in) mm (in) 1.02 (.040) Ignition timing (BTDC)
Page 515 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
Page 516 Section 15 TECHNICAL DATA Subsection 02 (GTX RFI MODEL) MATERIALS GTX RFI Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/aluminum Air intake silencer Thermoplastic Flame arrester Multi-layer wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION: PERFORMANCE...
Page 517: Xp Model
Section 15 TECHNICAL DATA Subsection 03 (XP MODEL) XP MODEL ENGINE Engine type BOMBARDIER-ROTAX 947 Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting 3.5 mm (.139 in) (head) Exhaust system Water injection fitting Not applicable (cone) Water injection fitting 3.5 mm (.139 in)
Page 518 Section 15 TECHNICAL DATA Subsection 03 (XP MODEL) ELECTRICAL Magneto generator output 180 W @ 6000 RPM Ignition system type Digital DC-CDI Make and type NGK BR8ES Spark plug 0.4 - 0.5 mm (.016 - .020 in) mm (in) 2.99 (.118) Ignition timing (BTDC) Degrees 20°...
Page 519 Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Split FR and RR rubber coupling SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
Page 520 Section 15 TECHNICAL DATA Subsection 03 (XP MODEL) MATERIALS Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION: PERFORMANCE Estimated pump output 53.1 kW (71.1 HP)
Page 521: Rx Di Model
Section 15 TECHNICAL DATA Subsection 04 (RX DI MODEL) RX DI MODEL RX DI RX DI ENGINE (5591/5592) (5583/5584/5585/5586) Engine type Bombardier-Rotax 947 DI Bombardier-Rotax 947 DI LE Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting 3.5 mm (.139 in) (head) Exhaust system...
Page 522 Section 15 TECHNICAL DATA Subsection 04 (RX DI MODEL) RX DI RX DI ENGINE (5591/5592) (5583/5584/5585/5586) Connecting rod/ 0.017 - 0.034 mm (.0006 - .0013 in) crankshaft pin radial Wear limit 0.050 mm (.002 in) clearance 0.001 - 0.014 mm (.000039 - .00055 in) Connecting rod/piston pin radial clearance Wear limit...
Page 523 Section 15 TECHNICAL DATA Subsection 04 (RX DI MODEL) RX DI RX DI FUEL SYSTEM (5591/5592) (5583/5580/5581/5582) Fuel injection type Orbital Direct Fuel Injection, twin throttle body (46 mm) Idle speed (in water) 1450 ± 50 RPM 1.6 kΩ - 2.4 kΩ (terminals 3-4) Throttle Position Sensor (TPS) 710 Ω...
Page 524 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
Page 525 Section 15 TECHNICAL DATA Subsection 04 (RX DI MODEL) RX DI RX DI MATERIALS (5591/5592) (5583/5580/5581/5582) Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam...
Page 526 Section 15 TECHNICAL DATA Subsection 05 (LRV DI MODEL) LRV DI MODEL ENGINE LRV DI Engine type BOMBARDIER-ROTAX 947 DI LE Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Exhaust system Water injection fitting (cone) Not applicable...
Page 527 Section 15 TECHNICAL DATA Subsection 05 (LRV DI MODEL) ENGINE LRV DI Connecting rod/ 0.017 - 0.034 mm (.0006 - .0013 in) crankshaft pin radial Wear limit 0.050 mm (.002 in) clearance Connecting rod/ 0.001 - 0.014 mm (.000039 - .00055 in) piston pin radial Wear limit 0.017 mm (.00067 in)
Page 528 Section 15 TECHNICAL DATA Subsection 05 (LRV DI MODEL) FUEL SYSTEM LRV DI Orbital Direct Fuel Injection, twin throttle body Fuel injection type (46 mm (1.81 in)) Idle speed (in water) 1450 ± 50 RPM 1.6 kΩ - 2.4 kΩ (terminals 3-4) Throttle Position Sensor (TPS) 710 Ω...
Page 529 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
Page 530 Section 15 TECHNICAL DATA Subsection 05 (LRV DI MODEL) MATERIALS LRV DI Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION: PERFORMANCE...
Page 531: Gtx And Rx Models
Section 15 TECHNICAL DATA Subsection 06 (GTX AND RX MODELS) GTX AND RX MODELS ENGINE Engine type BOMBARDIER-ROTAX 947 Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting 3.5 mm (.139 in) 3 mm (.118 in) (head) Exhaust system Water injection fitting...
Page 532 Section 15 TECHNICAL DATA Subsection 06 (GTX AND RX MODELS) ELECTRICAL Magneto generator output 180 W @ 6000 RPM Ignition system type Digital DC-CDI Make and type NGK BR8ES Spark plug 0.4 - 0.5 mm (.016 - .020 in) mm (in) 2.99 (.118) Ignition timing (BTDC) Degrees...
Page 533 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOLESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20° Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in)
Page 534 Section 15 TECHNICAL DATA Subsection 06 (GTX AND RX MODELS) MATERIALS Hull Composite Inlet grate Aluminum Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer Thermoplastic Flame arrester Tubular wire screen Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam ADDITIONAL INFORMATION: PERFORMANCE Estimated pump output...
Page 535: Wiring Diagrams
Section 16 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WIRE COLOR CODES CAUTION: Do not apply dielectric grease on con- tacts inside plug connector. First color of a wire is the main color. Second color To remove wire contacts from housing, proceed is the tracer.
Page 536 Section 16 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) PACKARD CONNECTOR NOTE: Before extraction, push wire forward to re- lieve pressure on retaining tab. Packard connectors are used to connect electrical – Insert a 4.8 mm (.189 in) wide screwdriver harnesses and gauges. blade inside the front of the contact cavity.
Page 537 Section 16 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Description 1. Apply a thin coat of DEOXIT contact lubricant CAUTION: Do not apply lubricant excessively. Care must be taken so that the lubricant will not F00H0WB come in contact with the mating seal; the seal AMP PLUG CONNECTOR may loose its sealing capacities.
Page 538 Section 16 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Contact Removal While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire SIGNAL WIRE until the contact is removed. Insert a screwdriver blade between the connector and the wedge lock tab.
Page 539 Section 16 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Before extraction, push wire forward to relieve pres- sure on retaining tab. Insert a 4.8 mm (.189 in) wide screwdriver blade inside the front of the contact cavity. CRIMPING TOOL (P/N 295 100 164) All circuits are sealed by a diaphragm in the rubber wire seal.
Page 540 Section 16 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Contact Installation For insertion of signal contact, make sure the wedge lock is in the open position. NOTE: For insertion of power contact, the wedge lock may or may not be on the open position. Insert contact into appropriate circuit cavity and push as far as it will go.
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Table of Contents

Table of Contents

Mandatory Service Tools

Optional Service Tools

Service Products

Table of Contents

Periodic Inspection Chart

Flushing and Lubrication

Water-Flooded Engine

Storage

Troubleshooting Chart

Table of Contents

Leak Test

Removal and Installation

Magneto System

Top End

Bottom End

Rotary Valve

Exhaust System

Table of Contents

Overview

Air Induction

Fuel Delivery

Electronic Management

Diagnostic Procedures

Fault Code Tables

Component Inspection

General

Fuel Delivery

Air Induction System

Electronic Management

Engine Cannot Reach Maximum Revolutions

Flooded Engine Feature

Spark Plug Inspection

Engine Starts but Runs Poorly

Ecu Fault Codes

Troubleshooting Summary

Engine Does Not Start

Fuel Pump Assembly

Table of Contents

Overview

Operating Principle

Air Compressor System

Air Induction

Fuel Delivery System

Electronic Management

Component Inspection and Adjustment

General

Quick Fuel Pressure Test

Air Induction System

Air Compressor

Fuel Delivery

Electronic Management

Diagnostic Procedures

General

Dess System

Fault Detection and Compensatory Actions

Vck (Vehicle Communication Kit)

DI System Fault Codes

Circuit, Components and Care/Circuit, Components and Care

Table of Contents

Fuel Circuit

Air Intake

Carburetor

Table of Contents

Oil Injection System

Oil Injection Pump

Table of Contents

Ignition System

Charging System

Starting System

Instruments and Accessories

Digitally Encoded Security System

Table of Contents

Jet Pump

Drive System

Reverse System

Variable Trim System

Table of Contents