Sea-doo 2003 XP DI Shop Manual

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Page 1 www.SeaDooManuals.net...
Page 2 2003 Shop Manual GTI, GTI LE, GTI LE RFI, GTX DI, XP DI, RX DI, LRV DI, GTX 4-TEC SERIES www.SeaDooManuals.net...
Page 3 The following trademarks are the property of Bombardier Inc. or its subsidiaries: SEA-DOO ® BOMBARDIER-ROTAX ® ® BOMBARDIER LUBE BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil BOMBARDIER Formula XP-S DI Synthetic Injection Oil BOMBARDIER-ROTAX Injection Oil Sea-Doo Synthetic Grease Sea-Doo LK DESS Rotax ® O.P.A.S. TOPS www.SeaDooManuals.net...
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 PAGE SECTION SUBSECTION FUEL SYSTEM 01 - Table of contents ..............10-01-1 02 - Fuel circuit ................10-02-1 03 - Air intake (2-stroke)..............10-03-1 04 - Carburetor................. 10-04-1 LUBRICATION 01 - Table of contents ..............11-01-1 02 - Oil injection system ..............11-02-1 SYSTEM (2-stroke) 03 - Oil injection pump..............
Page 6: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair all 2003 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
HULL IDENTIFICATION NUMBER T h i s S h o p M a n u a l c o v e r s t h e f o l l o w i n g ® BOMBARDIER made SEA-DOO 2003 watercraft (H.I.N.) models.
Page 8 INTRODUCTION All Models The Hull Identification Number is composed of 12 digits: ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engines 1. Engine Identification Number (E.I.N.) The Engine Identification Number is located on the 947 DI Engines upper side of the magneto housing. The Engine Identification Number is located on the upper crankcase on MAGNETO side.
Page 9 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 10 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 11: 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 12: 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 watercrafts any task, you read and thoroughly understand the manufactured by Bombardier are certified to the...
Page 13 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 14 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 15 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 16: 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 17 INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft SMR2003_001_00_00A2.FM www.SeaDooManuals.net...
Page 18 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 SMR2003_001_00_00A2.FM www.SeaDooManuals.net...
Page 19 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 ..................01-02-5 PROPULSION SYSTEM..................... 01-02-7 STEERING SYSTEM ......................01-02-9 OPTIONAL SERVICE TOOLS ....................01-03-1 ENGINE ..........................01-03-1 COOLING/FUEL/OIL SYSTEMS ..................
Page 20: Mandatory Service Tools
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) MANDATORY SERVICE TOOLS ENGINE Degree wheel Sleeve set Carbon dam compressor P/N 529 035 607 P/N 529 035 716 A) P/N 529 035 542 (20 mm sleeve) B) P/N 529 035 543 (21 mm sleeve) F12B0N4 APPLICATION...
Page 21 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Starter drive bearing pusher Puller Puller ass’y P/N 420 876 502 P/N 529 035 547 P/N 290 876 488 1) Screw P/N 290 240 860 2) Hexagonal nut P/N 290 242 210 F06B054 A00C1A4 APPLICATION...
Page 22 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Adapter Flywheel extractor Supplementary engine leak test P/N 529 035 590 P/N 295 000 156 P/N 295 500 780 F00B124 APPLICATION XP DI models. 1a) 787 RFI Intake plate P/N 296 000 024 Alignment adaptor F00B044...
Page 23 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Polygonal wrench Camshaft looking tool Oil seal pusher P/N 529 035 505 P/N 529 035 839 P/N 290 877 740 F18B074 APPLICATION 4-TEC engines. F00B0Y4 Drive shaft adaptor F01B2C4 APPLICATION P/N 529 035 892 APPLICATION...
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 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) Engine oil pressure adapter P/N 529 035 652 V00B074 APPLICATION 4-TEC engines. Oil seal guide P/N 529 035 822 F18B094 APPLICATION 4-TEC engines. Coolant pump seal pusher P/N 529 035 823 F18B084 APPLICATION 4-TEC engines.
Page 26: Propulsion System
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) PROPULSION SYSTEM Impeller remover/installer Bearing/seal installer Pliers A) P/N 295 000 001 P/N 295 000 107 P/N 295 000 054 B) P/N 529 035 820 Caillau F01B1T4 APPLICATION F01J0T4 APPLICATION All models.
Page 27 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) PTO seal support Seal/bearing pusher P/N 529 035 842 P/N 529 035 818 F18B0D4 APPLICATION F18B0F4 GTX 4-TEC models. APPLICATION GTX 4-TEC models. Shaft pusher P/N 529 035 819 Drive shaft holder P/N 529 035 871 F18B0G4...
Page 28: Steering System
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (MANDATORY SERVICE TOOLS) STEERING SYSTEM O.P.A.S. cylinder nut wrench P/N 529 035 840 F18B0A4 APPLICATION Models equipped with the O.P.A.S. system 01-02-9 SMR2003-002_01_02A.FM www.SeaDooManuals.net...
Page 29: Optional Service Tools
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) OPTIONAL SERVICE TOOLS ENGINE Engine stand Lifting tool Distance gauge Not sold by Bombardier P/N 529 035 940 A) P/N 529 034 800, 14 mm (.551 in) B) P/N 529 034 900, 15.4 mm (.606 in) C) P/N 529 035 100, 11.5 mm (.453 in)
Page 30 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Valve spring compressor clamp Valve stem seal installer Oil VAC P/N 529 035 724 P/N 529 035 687 P/N 529 035 880 V00B044 V04B0H4 APPLICATION APPLICATION 4-TEC engines. F18B0B4 4-TEC engines.
Page 31 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Dial indicator (TDC gauge) Timing mark pointer P/N 295 000 143 P/N 295 000 135 Crimp pliers (P/N 529 035 730) A00B4E4 APPLICATION A00B6A4 All 2-stroke models. F01H544 APPLICATION APPLICATION Starter and battery cable terminals Digital/induction type...
Page 32 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Safety lanyard switch tool Gear/bearing puller Rubber pad P/N 529 034 600 P/N 290 877 665 P/N 295 000 101 F01B0J4 F01B244 APPLICATION APPLICATION 717 and 787 RFI engines. All models.
Page 33 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) Digital multimeter P/N 529 035 868 F01D885 V00B0H4 APPLICATION 1) Puller ass’y All models. P/N 420 877 635 2) Protective cap P/N 420 876 557 P/N 290 877 414 (947 DI engines) 3) Ring (both ends) P/N 420 977 490...
Page 34: Cooling/Fuel/Oil Systems
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) COOLING/FUEL/OIL SYSTEMS Pump gauge tester Flexible spout (oil) P/N 295 000 114 P/N 414 837 300 F04B044 F01B0X4 APPLICATION APPLICATION All models. 717 engines. Flushing adapter Lighted adjustable mirror P/N 295 500 473 Not sold by Bombardier Snap-on...
Page 35: 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 36: Body
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) BODY Spring compressor P/N 529 035 504 A01B4O4 APPLICATION XP DI models. Suspension adjustment wrench P/N 529 012 200 A25A014 APPLICATION XP DI models. Suction cup P/N 295 000 163 F00B1Y4 APPLICATION 4-TEC models.
Page 37: Watercraft Handling
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (OPTIONAL SERVICE TOOLS) WATERCRAFT HANDLING Dolly (with wheels) Lift kit P/N 295 000 126 A) P/N 295 100 206 B) P/N 295 100 205 C) P/N 295 100 204 F01B014 Beach wheels (set of 2 wheels) P/N 295 000 005 F00B1Z4 APPLICATION...
Page 38: 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 39 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 04 (SERVICE PRODUCTS) Chisel gasket remover Primer for gasket eliminator Dielectric grease P/N 413 708 500 P/N 293 800 041 P/N 293 550 004 (510 mL) Loctite 764 Dow Corning (150 g) A00B1X4 High temperature RTV sealant (P/N 293 800 090) Ultra Copper (80 mL)
Page 40 A00B554 Super Lube grease BOMBARDIER LUBE P/N 293 550 030 A00B634 P/N 293 600 016 (12 x 14 oz) Sea-Doo fuel stabilizer P/N 413 408 600 236 mL (8 oz) V00B0I4 Anti-seize lubricant P/N 293 800 070 Loctite 76764 454 g (16 oz)
Page 41 (16 x 1 L) A00B5S4 Instant gasket P/N 293 800 088 F18B0H4 (7 oz) Sea-Doo Cleaner P/N 293 110 001 (400 g) P/N 293 110 002 (4 L) A00B5X4 BOMBARDIER FORMULA XP-S II synthetic injection oil P/N 293 600 045...
Page 42 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 43: Periodic Inspection Chart
Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) PERIODIC INSPECTION CHART The schedule should be adjusted according to operating conditions and use. NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenance operation to whatever time comes first. IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater frequency of inspection and maintenance.
Page 44 Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace LUBRICATION SYSTEM Oil injection pump ➄ Oil filter and lines Oil filter Oil reservoir straps ELECTRICAL SYSTEM Electrical connections and fastening (ignition system, electrical box(es), starting system, fuel injectors (RFI and DI models), etc.)
Page 45 Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) 4-TEC Models DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace GENERAL Lubrication/corrosion protection ENGINE Engine oil and filter (including cover’s O-rings) Support and rubber mount Seals and fasteners Exhaust system fasteners ➄...
Page 46 Section 02 MAINTENANCE Subsection 02 (PERIODIC INSPECTION CHART) DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate, replace if necessary C: Clean L: Lubricate R: Replace PROPULSION SYSTEM I ➁ Drive shaft protection boot Grease splines in jet pump Shifter system/cable ➅...
Page 47: 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 48 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) All Models except 4-TEC 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 49 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) All Models except 4-TEC Apply anti-seize lubricant on spark plug threads then reinstall them. Reinstall plug on air intake silencer cover (if so equipped, on 717 and 787 RFI engines). NOTE: Engine fogging should be done with BOMBARDIER LUBE lubricant whenever the water- craft is to be stored for a few days or a long period.
Page 50 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) Models without a Flushing Connector in Models with a Flushing Connector in Engine Engine Compartment Compartment Connect a garden hose to connector located at the rear This flushing connector allows flushing while wa- of watercraft on jet pump support.
Page 51 Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION) Install a hose pincher (supplied inside tool kit in CAUTION: Never flush a hot engine. Always rear storage compartment) on water outlet hose. start the engine before opening the water tap. Open water tap immediately after engine is NOTE: This prevents water from directly exiting started to prevent overheating.
Page 52: 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 53 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) 947 DI Models 787 RFI Engines Remove the air pressure hose from the compres- Remove the filler plug of the counterbalance shaft sor. on the engine crankcase. CAUTION: Failure to remove the air pressure hose from the compressor will result in the bending of the compressor connecting rod, when cranking the engine.
Page 54 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) Carburetor-Equipped Models 947 DI Models Turn fuel valve to ON position. Spray, through hole of air intake silencer. Start engine. It may be necessary to use the NOTE: An increase of engine RPM may be noticed choke.
Page 55 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) Whenever the engine is stopped, all the valves hange Procedure close thus preventing water from being ingested (water-contaminated oil) in the engine. 1. Using the oil VAC (P/N529 035 880), siphon oil from reservoir through dipstick hole. Supercharged 4-TEC Engines CAUTION: Never crank or start engine when si- Inlet duct should be disconnected from super-...
Page 56 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) 10. Level the engine. 11. Remove the oil vac tool and the fitting. Apply Loctite 243 and reinstall the drain plug. NOTE: If spillage occurs, clean immediately with the Pulley flange cleaner (P/N 413 711 809) to pre- vent oil stains.
Page 57 Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE) 4. With the engine still running at 3000 RPM, in- Water in Supercharger stall a hose pincher to the coolant line going to Supercharged 4-TEC Engines the oil cooler. If there was water in Tthe oil and presence of wa- WARNING ter is suspected in the shaft and bearing area of the supercharger, it is recommended to take the...
Page 58: 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 59 Section 02 MAINTENANCE Subsection 05 (STORAGE) CAUTION: Water in heat exchanger system must be free to flow out. Should water freeze in engine, severe damage will occur. Reconnect hose when done. DI Models Disconnect the quick connect fitting. Press both tabs and pull fitting.
Page 60: Propulsion System
Verify fuel system. Check fuel hoses and carbure- tor(s), if so equipped, for leaks. Replace damaged hoses or clamps if necessary. Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv- alent should be added in fuel tank to prevent fuel deterioration and, if so equipped, carburetor(s) gumming.
Page 61: Engine Oil Change And Filter
Section 02 MAINTENANCE Subsection 05 (STORAGE) CAUTION: Fuel stabilizer should be added prior ENGINE LUBRICATION to engine lubrication to ensure fuel system com- 4-TEC Engines ponents protection against varnish deposits. Fogging of the engine is recommended at the end WARNING of the season and before any extended storage period to provide additional corrosion protection.
Page 62: Battery
Section 02 MAINTENANCE Subsection 05 (STORAGE) IMPORTANT: Never cut the locking ties of coil WATERCRAFT CLEANING connectors. This would allow mixing the wires be- Clean the bilge with hot water and mild detergent tween cylinders. or with bilge cleaner. Rinse thoroughly. Lift front –...
Page 63 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 64 Section 02 MAINTENANCE Subsection 05 (STORAGE) All 2-Stroke Models except DI Insert a funnel into hose and pour antifreeze mixed with water (40% water, 60% antifreeze) in engine until the colored solution appears at the cooling sys- tem bleed outlet. 717 AND 787 RFI ENGINES 1.
Page 65 Section 02 MAINTENANCE Subsection 05 (STORAGE) 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 them. Reconnect hose to T-fitting and remove hose pincher (if applicable).
Page 66 Section 02 MAINTENANCE Subsection 05 (STORAGE) RX DI, GTX DI AND LRV DI MODELS RX DI AND LRV DI MODELS 1. Engine cylinder drain hose 1. Crankcase cooling cover outlet hose Hose Disconnection Disconnect water INLET hose at engine between T-fitting and cylinder head fitting.
Page 67 Section 02 MAINTENANCE Subsection 05 (STORAGE) At this point, install a hose pincher on bleed outlet hose. GTX DI MODELS 1. Disconnect this side of the T-fitting RX DI MODELS Temporarily install a short piece of hose to replace 1. Bleed outlet hose the one removed.
Page 68 Section 02 MAINTENANCE Subsection 05 (STORAGE) Continue to pour until antifreeze flows in air com- All 2-Stroke Models except XP DI pressor water outlet hose. Most of the antifreeze will drain out when removing the hose pinchers. Use a container to recover it. DIS- POSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS.
Page 69 Section 02 MAINTENANCE Subsection 05 (STORAGE) Antifreeze Insert a funnel into the temporary hose. Ensure to hold the funnel approximately 1 m (3 ft) above the deck when pouring the antifreeze to cre- ate enough pressure so that it flows properly. XP DI MODELS 1.
Page 70 Section 02 MAINTENANCE Subsection 05 (STORAGE) 1. Engine drain hose (crankcase cooling outlet) Continue to pour until antifreeze flows in air com- pressor water outlet hose. XP DI MODELS 1. Bleed outlet hose Continue to pour until antifreeze appears at the en- gine drain hose (crankcase cooling outlet).
Page 71: Anticorrosion Treatment
Lubricate PTO flywheel or seal carrier. NOTE: Although antifreeze will mainly drain out, Verify fuel system. the antifreeze has mixed with the water that was Add Sea-Doo fuel stabilizer. possibly trapped in the water jackets and thus pre- venting freezing problems. Flush the cooling system At preseason preparation, drain the remaining an- (except 4-TEC engines).
Page 72: 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 show all causes for all problems. NOTE: On fuel injection models, always check for fault codes recorded in the MPEM (DI models) or EMS ECU (RFI and 4-TEC models) first using the VCK (vehicle communication kit (P/N 529 035 844).
Page 73 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE WILL NOT START (cont’d) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Loose battery cable connections • Check/clean/tighten • Discharged/weak battery • Check/charge/replace • Restriction in jet pump • Check/clean pump • Partial seizure in jet pump •...
Page 74 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE WILL NOT START (cont’d) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Flooded engine • Check, refer to FUEL SYSTEM – Carburetor needle valve stuck open (carburetor models) • Excessive rotary valve clearance • Check, refer to ENGINE (if so equipped) •...
Page 75 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE HARD TO START OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Defective idle bypass valve • Refer to ENGINE MANAGEMENT (4-TEC models) • Wrong TPS zero setting • Refer to ENGINE MANAGEMENT (4-TEC models) •...
Page 76 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Fouled, defective, worn spark plugs • Check/verify heat range/gap/replace • Faulty EMS ECU or MPEM • Check, refer to ENGINE (fuel injection models) MANAGEMENT •...
Page 77 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) (cont’d) ENGINE MISFIRES, RUNS IRREGULARLY OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Flame arrester dirty or restricted • Check/replace (if so equipped) • Partially closed choke • Check/adjust choke cable (carburetor models) • Carburetor adjustment •...
Page 78 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 79 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE LACKS ACCELERATION OR POWER OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weak spark • Check/replace, refer to ELECTRICAL SYSTEM • Carburetion, jetting too rich/lean • Check/adjust, refer to FUEL SYSTEM (carburetor models) • Throttle does not open fully •...
Page 80 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE STOPS RUNNING OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Spark plug heat range too high • Check/change to correct range • Improper ignition timing • Check/reset (2-stroke engines) Engine dies during regular operation (piston seizure) •...
Page 81 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE RUNS TOO FAST (vehicle cannot reach its top speed) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Faulty rev limiter in EMS ECU/MPEM • Check, refer to ENGINE MANAGEMENT • Improper impeller pitch (too low) •...
Page 82 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) O.P.A.S. SYSTEM FAULTS OTHER OBSERVATION POSSIBLE CAUSE REMEDY Watercraft is more • Side vanes do not go up while • Refer to STEERING SYSTEM watercraft is at speed responsive than usual while turning Watercraft pulls on one •...
Page 83 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ENGINE OIL CONTAMINATION (MILKY) (4-TEC SERIES) OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Oil seal and rotary seal on coolant • Replace both seals. Refer to PTO pump shaft leaking HOUSING. Change oil • Cylinder head gasket leaking •...
Page 84 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) ABNORMAL NOISE FROM PROPULSION SYSTEM OTHER OBSERVATION POSSIBLE CAUSE REMEDY • Weeds/debris caught in intake grate • Check/clean or impeller • Low oil level in jet pump • Check/troubleshoot source of leak/ (if so equipped) refill supply, refer to PROPULSION SYSTEM •...
Page 85 Section 04 ENGINE (2-STROKE) 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 86 Section 04 ENGINE (2-STROKE) Subsection 01 (TABLE OF CONTENTS) EXHAUST SYSTEM ....................... 04-08-1 REMOVAL ........................... 04-08-6 TUNED PIPE REPAIR ......................04-08-11 INSTALLATION ........................04-08-12 04-01-2 SMR2003-049_04_01ATOC.FM www.SeaDooManuals.net...
Page 87: 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 88 Section 04 ENGINE (2-STROKE) 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 ENGINES — REAR VIEW 1. Loop hose and use clamps 2.
Page 89 Section 04 ENGINE (2-STROKE) Subsection 02 (LEAK TEST) – If kit components are not leaking and pressure drops, verify all external jointed surfaces, tem- perature sensor and the O-ring between the spark plug area and the engine cylinder head cover. If none of these components are leaking, there is an internal leak and it can be detected with Bottom End and Top End testing.
Page 90 Section 04 ENGINE (2-STROKE) Subsection 02 (LEAK TEST) NOTE: Engines with the RAVE system, the boot (carburetor-equipped engines) and O-ring can be checked for leakage with the valve in place. Simply remove the cover to expose the parts. Make sure the spark plugs (and the air/fuel rail on DI engine) are installed and tightened.
Page 91 Section 04 ENGINE (2-STROKE) 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 92 Section 04 ENGINE (2-STROKE) Subsection 02 (LEAK TEST) 787 RFI ENGINES 1. Pump with reducer and nipple Activate pump and pressurize to 34 kPa (5 PSI). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal or crankcase is not sealed correctly.
Page 93: Engine Leakage Diagnostic Flow Chart
Section 04 ENGINE (2-STROKE) 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 94 Section 04 ENGINE (2-STROKE) Subsection 02 (LEAK TEST) 947 DI Engines 04-02-8 SMR2003-007_04_02A.FM www.SeaDooManuals.net...
Page 95: Removal And Installation
Section 04 ENGINE (2-STROKE) 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 96 Section 04 ENGINE (2-STROKE) 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 97 Section 04 ENGINE (2-STROKE) 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 98 Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) Hook engine lift tool (P/N 529 035 940) into lifting CAUTION: Take care not to damage cable or oil ring holes. injection hoses. Remove rear engine support. ENGINE LIFT TOOL Using a chain block, a hoist or other suitable equip- TYPICAL ment, slightly lift engine to ease the remaining 1.
Page 99 Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) Install a hose pincher to oil return hose of rotary Disconnect RED positive cable from starter post. valve shaft (except the 947 DI engines); then, dis- connect hose. TYPICAL 1. Disconnect RED positive cable Disconnect BLACK negative cable from engine F01D3ZA crankcase.
Page 100: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) Engine Support 717 Engines Torque front and rear engine supports as shown in the following illustration. TYPICAL CLEANING Wipe off any spillage in bilge. Clean with a bilge cleaner. 1. Torque screws to 22 N•m (16 lbf•ft) 2.
Page 101 Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) 947 DI Engines Support plate kit (P/N 529 035 506). Install and torque the engine support screws to NOTE: Use plate (P/N 529 035 508) for the 139.5 mm 24 N•m (17 lbf•ft) in the indicated order. Refer to (5-1/2 in) jet pump and plate (P/N 529 035 507) for the following illustration.
Page 102 Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) – Insert shaft end into PTO flywheel. XP DI Models NOTE: Ensure the protective hose and carbon Use: ring (or seal carrier) is removed to check engine – plate (P/N 529 035 507) alignment.
Page 103 Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) Carefully slide alignment shaft (P/N 295 000 141) through shaft support and seal carrier. F00D0CA TYPICAL 1. Shim F05I08A TYPICAL CAUTION: Whenever shims are used to correct 1. Alignment tool alignment, never install more than 1.3 mm (0.051 in) 2.
Page 104 Section 04 ENGINE (2-STROKE) Subsection 03 (REMOVAL AND INSTALLATION) Engine Support Screws All Models Apply Loctite 243 (blue) on screw threads. Torque engine support screws to 25 N•m (18 lbf•ft) when procedure is completed. REAR ENGINE SUPPORT — 787 RFI AND 947 DI ENGINES 1.
Page 105: Magneto System
Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engines 04-04-1 SMR2003-009_04_04A.FM www.SeaDooManuals.net...
Page 106 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) 787 RFI Engines 04-04-2 SMR2003-009_04_04A.FM www.SeaDooManuals.net...
Page 107 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) 947 DI Engines 04-04-3 SMR2003-009_04_04A.FM www.SeaDooManuals.net...
Page 108: Disassembly
Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) DISASSEMBLY Using a suitable socket, unscrew retaining nut no. 13 COUNTERCLOCKWISE when facing it. 717 Engines NOTE: If socket is found too large to be inserted in NOTE: The magneto system can be disassembled puller plate, machine or grind its outside diameter without removing the engine from the watercraft.
Page 109 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) Proceed as follows: – Before removing the armature plate, find a crank- case locating lug (the top one in this example). – Place a cold chisel at the end of chosen lug, then punch a mark on armature plate at this point.
Page 110 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) – Remove screws. – Uncrimp and unsolder YELLOW and YELLOW/ BLACK wires from coil. – Uncrimp and unsolder ground wire (BLACK) from coil core. F00D08A 1. Heat the armature plate CAUTION: Protect harness from flame. –...
Page 111 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) Remove oil pump shaft from magneto rotor nut. 1. Oil pump shaft 1. Special tool (P/N 529 035 846) Remove crankshaft position sensor no. 18 before Rotor and Ring Gear removing the ring gear. Remove starter.
Page 112 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) Magneto Housing To remove magneto housing no. 5, starter has to be removed. Refer to STARTING SYSTEM. Unscrew retaining screws no. 19, then withdraw housing. 1. Crankshaft position sensor Using a suitable socket, unscrew retaining nut no.
Page 113 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) 947 DI Engines Cover Loosen screws no. 11. Remove engine magneto cover no. 1. TYPICAL 1. Screw To remove the ring gear/rotor assembly, unscrew nut no. 13 counterclockwise when facing it. TYPICAL 1.
Page 114: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) CLEANING Clean all metal components in a solvent. CAUTION: Clean coils and magnets using only a clean cloth. Clean crankshaft taper and threads using acetone. Apply the acetone on a rag first then clean the crank- shaft.
Page 115 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) To apply Gun Kote proceed as follows: 1. Clean thoroughly and degrease replacement part using a non oil base solvent. 2. Apply coating in light thin coats using a spray gun. NOTE: Do not spray Gun Kote into magneto fly- wheel threaded holes.
Page 116: Magneto Flywheel
Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) 787 RFI Engines Stator Install the stator no. 9 in magneto housing cover no. 1 and torque screws no. 20 to 9 N•m (80 lbf•in). Install wiring harness bracket no. 26 of stator and torque screws no.
Page 117 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) 947 DI Engines Stator and Trigger Coil/CPS (Crankshaft Position Sensor) Install the stator no. 9 and trigger no. 10 coil in engine magneto cover. Torque screws to 9 N•m (80 lbf•in). Reinstall wiring harness bracket no. 29 using tap- tite screws no.
Page 118 Section 04 ENGINE (2-STROKE) Subsection 04 (MAGNETO SYSTEM) Rotor and Ring Gear Install trigger wheel no. 30 on ring gear no. 3. F06D24A 1. Loctite 243 (blue) on crankshaft taper Install flywheel and make sure to align keyway with the crankshaft Woodruff key. Apply Loctite 243 (blue) on nut no.
Page 119: Top End
Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) TOP END 717 Engines 04-05-1 SMR2003-010_04_05A.FM www.SeaDooManuals.net...
Page 120 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 787 RFI Engines 04-05-2 SMR2003-010_04_05A.FM www.SeaDooManuals.net...
Page 121 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 947 DI Engines 24 23 22 04-05-3 SMR2003-010_04_05A.FM www.SeaDooManuals.net...
Page 122: General
Section 04 ENGINE (2-STROKE) 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 DI engines uses reed valves in the crankcase.
Page 123 Section 04 ENGINE (2-STROKE) 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 124: Disassembly
Section 04 ENGINE (2-STROKE) 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.
Page 125 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Remove RAVE valve no. 15. 787 RFI engines Remove the cover no. 18 of the valve by releasing Remove spring no. 30 retaining bellows no. 21 to the spring no. 16. valve piston no. 20. WARNING Firmly hold cover to valve base.
Page 126 Section 04 ENGINE (2-STROKE) 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 127 Section 04 ENGINE (2-STROKE) 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 128 Section 04 ENGINE (2-STROKE) 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 129 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Use Snap-On Torx socket E12 and unscrew cylin- 947 DI Engines der head screws no. 14 following the sequence Remove cylinders screws then cylinders no. 9. shown in the next illustration. Piston NOTE: All engines feature cageless piston pin bearings.
Page 130 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 947 DI 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) on crankcase. sleeves. Secure with screws.
Page 131 Section 04 ENGINE (2-STROKE) 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 132: Cleaning
Section 04 ENGINE (2-STROKE) 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 133: Used Piston Measurement
Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Cylinder Taper Using a cylinder bore gauge, measure cylinder diam- eter at 16 mm (5/8 in) from top of cylinder just below auxiliary transfer port, facing exhaust port and just be- low the auxiliary transfer port facing the exhaust port. Compare readings.
Page 134 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Using a micrometer, measure piston skirt perpen- Piston/Cylinder Wall Clearance dicularly (90°) to piston pin according to the follow- Used and New Pistons ing table. IMPORTANT: Make sure used piston is not worn more than specified.
Page 135: Ring End Gap
Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the micrometer, otherwise the reading will be false.
Page 136: Assembly
Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Using a feeler gauge, check ring end gap. If gap All Engines exceeds specified tolerance, rings should be re- GASKET IDENTIFICATION placed. THICKNESS HOLES 0.3 mm (.012 in) 0.4 mm (.016 in) 0.5 mm (.020 in) 0.6 mm (.024 in) 0.8 mm (.031 in)
Page 137 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Position the valve housing no. 25 onto the cylinder 947 DI Engines so that its opening is toward the bottom. Check the piston valve O-ring. Replace if neces- sary. 1. Piston valve O-ring Check the sliding valve O-ring.
Page 138 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Check the O-ring under valve housing. Replace if Piston necessary. At assembly, place the pistons no. 3 with the let- ters “AUS” (over an arrow on the piston dome) facing in direction of the exhaust port. 1.
Page 139 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) – Install the shoulder sleeve tool on the opposite Plastic Mounting Device Method side of the piston pin. This is an alternate method when no service tool is available. Replacement roller bearings are delivered in a con- venient plastic mounting device.
Page 140 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) – Insert piston pin into piston until it comes flush – As necessary, pull halves of inner sleeve with with inward edge of piston hub. long nose pliers. F01D0RA F01D0TA 1. Piston pin flush here 1.
Page 141 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 947 DI Engines – Position end of tool against piston pin opening. Secure circlip in piston groove with its bent end in – Firmly hold piston against tool and tap tool with piston notch as shown.
Page 142 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) NOTE: Ring compressor will not fit on oversize 717 Engines parts. The aligning tool (P/N 420 876 904) or the exhaust Make sure to align ring end gap with piston locat- manifold can be used to align cylinders. ing pin.
Page 143 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 787 RFI Engines To easily slide cylinder block over pistons, use ring compressor (P/N 290 876 965). The exhaust manifold is used to align cylinders. 1. Slide this edge NOTE: For each ring, make sure to align ring end gap with piston locating pin.
Page 144 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 787 RFI Engines All Engines Prior installation, apply Molykote 111 below screw Cylinder Head head and Loctite 243 (blue) on screw threads. Install cylinder head gasket. Install M10 x 105 screws on exhaust side and the 717 and 787 RFI Engines M10 x 73.5 on opposite side.
Page 145: Adjustment
Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) Cylinder Head Cover Combustion Chamber Volume Measurement 717 and 787 RFI Engines All Engines Install cylinder head cover no. 1. NOTE: This procedure is required to determine Apply Loctite 243 (blue) below head of screws no. 14. the thickness of the cylinder base gasket to be in- Apply also Molykote 111 on threads of screws no.
Page 146 Section 04 ENGINE (2-STROKE) Subsection 05 (TOP END) 947 DI Engines 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 147: Bottom End
Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) BOTTOM END 717 Engines 04-06-1 SMR2003-011_04_06A.FM www.SeaDooManuals.net...
Page 148 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 787 RFI Engines 04-06-2 SMR2003-011_04_06A.FM www.SeaDooManuals.net...
Page 149 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 947 DI Engines 15 17 XP DI only 04-06-3 SMR2003-011_04_06A.FM www.SeaDooManuals.net...
Page 150: Disassembly
Section 04 ENGINE (2-STROKE) 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 Engines To remove PTO flywheel no. 1, the crankshaft TYPICAL must be locked.
Page 151 Section 04 ENGINE (2-STROKE) 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 DI Models COUNTERCLOCKWISE when facing it.
Page 152 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 947 DI Engines Starter Drive Assembly Install puller plate (P/N 529 035 533) and extension 947 DI 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 153 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Crankcase 947 DI Engines Place engine upright on crankcase magneto side. Before opening the bottom end, remove the fol- Loosen crankcase screws. lowing parts: – engine supports (717 engines) – magneto flywheel, refer to MAGNETO SYSTEM –...
Page 154 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 717 Engines To remove end bearings no. 4 from crankshaft, use the following tools. 717 ENGINES 1. Puller (P/N 420 877 635) F01D1LA 2. Protective cap (P/N 420 876 557) 3. Distance ring, MAG side only (P/N 420 876 569) TYPICAL 4.
Page 155 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 947 DI Engines To remove end bearings from crankshaft, use the following tools. 947 DI ENGINES 1. Puller (P/N 420 877 635) F01D1PA 2. Protective cap (P/N 290 877 414) 3. Distance ring (P/N 420 876 569) 1.
Page 156 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Install the puller as per following illustration. 1. Puller (P/N 420 877 635) 2. Protective cap (P/N 420 876 557) 3. Ring (P/N 420 977 480) 4. Ring halves (P/N 420 876 330) 5.
Page 157: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Use a press to remove the gear no. 14 from the CLEANING counterbalance shaft. All Models Discard all oil seals, gaskets, O-rings and sealing rings. Clean oil passages and make sure they are not clogged.
Page 158: Inspection
Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 1. Main journal alignment here To accurately check if crankshaft is twisted on cen- ter main journal, proceed as follows: – Remove magneto housing cover. SECOND PASS – Remove flywheel nut (and magneto rotor for Finish the cleaning with acetone.
Page 159 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Such misalignment may make it difficult to manu- ally turne the crankshaft. Verification can be done by measuring deflection each end of crankshaft. If deflection is found greater than specified toler- ance, this indicates worn bearing(s), bent and/or disaligned crankshaft.
Page 160 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Crankshaft Deflection All Models MEASUREMENT MAG SIDE PTO SIDE Crankshaft 0.050 mm 0.030 mm deflection (max.) (.002 in) (.001 in) Crankshaft deflection is measured each end with a dial indicator. First, check deflection with crankshaft in crank- case.
Page 161 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clock- wise so that claws open and become firmly tight against bearing.
Page 162: Assembly
Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Check stopper distance from center of reed valve To properly position the outer bearing(s), a dis- block. tance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it.
Page 163 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) Crankshaft Gear 787 RFI Engines Position PTO seal against the retaining shim; the 787 RFI Engines 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 164 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) – The notch of the couterweight on the opposite end of the counterbalance shaft must also be aligned with the cranckcase. F00D0OA 1. Drive pins Counterbalance Shaft F00D0VA 787 RFI Engines 1. Counterweight notch aligned with the crankcase Press gear no.
Page 165 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) F00D0PA 1. Bearing 787 RFI ENGINES 2. Washer in crankcase groove 1. Marks must be aligned 3. Lubrication hole on top (if so equipped) Place seals no. 17 in their respective positions. 947 DI ENGINES F06D1OA 1.
Page 166 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 717 and 787 RFI Engines Rotary valve shaft must be installed in crankcase before closing halves. CAUTION: Before joining crankcase halves, make sure that crankshaft gear is well engaged with ro- tary valve shaft gear. 717 Engines Temporarily install armature plate to align crank- case halves with each other.
Page 167 Section 04 ENGINE (2-STROKE) Subsection 06 (BOTTOM END) 947 DI 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 Engines Install the bearing cover no. 19 with its hollow side toward the bearing.
Page 168 Section 04 ENGINE (2-STROKE) 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 947 DI Engines 717 and 787 RFI Engines Apply Molykote 111 below head of screws and If inlet and outlet oil fittings no.
Page 169 Install O-ring onto crankshaft. F07D06A 1. Remove plug and add SAE 30 motor oil 947 DI Engines Add 40 mL (1.35 oz) of Sea-Doo synthetic jet F01D84A pump oil (P/N 293 600 011) or standard gear oil 1. O-ring through crankcase ventilation nipple.
Page 170: Rotary Valve
Section 04 ENGINE (2-STROKE) Subsection 07 (ROTARY VALVE) ROTARY VALVE 717 and 787 RFI Engines 787 RFI engines 717 engines 04-07-1 SMR2003-012_04_07A.FM www.SeaDooManuals.net...
Page 171 Section 04 ENGINE (2-STROKE) 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 172 Section 04 ENGINE (2-STROKE) 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 173 Section 04 ENGINE (2-STROKE) 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 174 Section 04 ENGINE (2-STROKE) Subsection 07 (ROTARY VALVE) End bearing no. 9 can be easily removed from up- INSPECTION 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 175 Section 04 ENGINE (2-STROKE) 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 176: Rotary Valve
Section 04 ENGINE (2-STROKE) Subsection 07 (ROTARY VALVE) 717 Engines 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 177 Section 04 ENGINE (2-STROKE) 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 SMR2003-012_04_07A.FM www.SeaDooManuals.net...
Page 178: Rotary Valve Timing
Section 04 ENGINE (2-STROKE) 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 179 Section 04 ENGINE (2-STROKE) 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 180: Exhaust System
Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) EXHAUST SYSTEM 717 Engines (GTI and GTI LE Models) 04-08-1 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 181 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 787 RFI Engines (GTI LE RFI Models) 04-08-2 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 182 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 947 DI Engines (XP DI Models) 12-13 16 22 04-08-3 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 183 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 947 DI Engines (RX DI Models) 14 12-13 16 22 04-08-4 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 184 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 947 DI Engines (GTX DI Models) 16 22 12-13 04-08-5 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 185: Removal
Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) REMOVAL All Models except XP DI Remove seat(s). Remove rear vent hose support from body opening. Remove seat support (all models except RX DI and XP DI). TYPICAL 1. Bleed hose removed 2.
Page 186 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 787 RFI Engines 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.
Page 187 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 4. Disconnect the water bleed hose. 6. Loosen and remove clamp no. 4 retaining tuned pipe head no. 10 to tuned pipe cone no. 5. F06E0BA F06D1SA 1. Water bleed hose 1. Loosen and remove clamp 5.
Page 188 Section 04 ENGINE (2-STROKE) 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 189 Section 04 ENGINE (2-STROKE) 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.
Page 190: Tuned Pipe Repair
Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) Loosen clamps and disconnect hoses. Withdraw Detach holding strap retaining resonator inside resonator from watercraft. bilge. Pull resonator out of bilge. Muffler On DI models, disconnect the EGT (exhaust gas temperature) sensor. Disconnect hoses from muffler no.
Page 191: Installation
Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) Test 787 RFI Engines 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 192 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 947 DI Engines Tuned Pipe Apply Molykote 111 on threads of Allen screws 717 Engines no. 12. CAUTION: Torque wrench tightening specifica- Install and hand tighten Allen screws no. 12 as per tions must be strictly adhered to.
Page 193 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) Position clamp no. 4 as illustrated. Do not tighten 787 RFI Engines 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 194 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) Press the pipe support on the engine before torquing the pipe support bolt. 04-08-15 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 195 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 947 Engines 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 196 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) 04-08-17 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 197 Section 04 ENGINE (2-STROKE) Subsection 08 (EXHAUST SYSTEM) Install exhaust hose. F06D14A 1. Torque clamp to 4 N•m (35 lbf•in) 04-08-18 SMR2003-013_04_08A.FM www.SeaDooManuals.net...
Page 198 Section 05 ENGINE (4-TEC) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS LEAK TEST..........................05-02-1 LEAK TEST PROCEDURE ....................05-02-1 PREPARATION........................05-02-1 PROCEDURE ........................05-02-2 INSTALLATION........................05-02-3 INTAKE SYSTEM ........................05-03-1 INSPECTION ........................05-03-4 REMOVAL........................... 05-03-6 ASSEMBLY......................... 05-03-15 EXHAUST SYSTEM....................... 05-04-1 EXHAUST PIPE ........................
Page 199 Section 05 ENGINE (4-TEC) Subsection 01 (TABLE OF CONTENTS) LUBRICATION SYSTEM......................05-07-1 GENERAL..........................05-07-3 OIL LEVEL VERIFICATION ....................05-07-3 ENGINE OIL PRESSURE TEST ..................05-07-4 OIL FILTER .......................... 05-07-5 OIL STRAINERS........................05-07-6 ENGINE OIL PRESSURE REGULATOR ................05-07-9 OIL PRESSURE PUMP ....................... 05-07-10 OIL SUCTION PUMP ......................
Page 200: Leak Test
Section 05 ENGINE (4-TEC) Subsection 02 (LEAK TEST) LEAK TEST LEAK TEST PROCEDURE – unplug ignition coil and pull it out – spark plug from cylinder head. The procedure has to be done when engine operat- NOTE: Ignition coil may be used as an extractor. ing temperature of approx.
Page 201: Procedure
Section 05 ENGINE (4-TEC) Subsection 02 (LEAK TEST) PROCEDURE As the engine is turned over, observe the move- ment of intake rocker arm of the cylinder no. 3. The following procedure has to be performed for After it completes the cycle and the intake valve each cylinder separately, because of the 120°...
Page 202: Installation
Section 05 ENGINE (4-TEC) Subsection 02 (LEAK TEST) Note the amount of leaking or percentage (de- General Engine Leakage pending on tester). Spray soap/water solution at the indicated location and look and/or listen for air bubbles. LEAKAGE ENGINE PERCENTAGE CONDITION Paying attention to the following checkpoints: 0% to 7% Excellent condition.
Page 203: Intake System
Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) INTAKE SYSTEM 4-TEC Engines TYPICAL 05-03-1 SMR2003-015_05_03A.FM www.SeaDooManuals.net...
Page 204 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) 4-TEC Supercharged Engines 05-03-2 SMR2003-015_05_03A.FM www.SeaDooManuals.net...
Page 205 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) 4-TEC Supercharged Engines 05-03-3 SMR2003-015_05_03A.FM www.SeaDooManuals.net...
Page 206: Inspection
Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) INSPECTION NOTE: Rotate supercharger nut to align camshaft holes and to allow insertion of the locking tool. Slipping moment Inspection Remove seat, storage basket, vent tube and its support. Refer to REMOVAL below. Refer to EXHAUST SYSTEM section and remove the following components.
Page 207 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) LOCK WASHER THICKNESS mm (in) NEW MINIMUM 6.900 mm (.2717 in) NEW MAXIMUM 7.100 mm (.2795 in) SERVICE LIMIT 6.600 mm (.2598 in) Replace worn parts by new ones. If all parts are within specifications, replace spring washer pack- age on supercharger shaft.
Page 208: Removal
Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) REMOVAL Unlock coolant expansion tank, pull out then move away. All 4-TEC Engines Air Intake Manifold Remove seat and storage basket. Disconnect vent tube as follows. Lift lock tab and holding the tab, pull the tube to release it.
Page 209 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) WARNING Always disconnect battery cables exactly in the specified order, BLACK negative cable first then the RED positive battery cable last. Release the fuel pressure in the system, refer to ENGINE MANAGEMENT section. Disconnect fuel hose connector at fuel rail.
Page 210 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) 4-TEC Supercharged Engines 4-TEC NA Engines Unplug connectors from ignition coils, idle bypass NOTE: The TPS connector is hidden behind the valve, engine connector, CTS, CAPS, KS, CPS, mag- TOPS hose. Disconnect hose from TOPS valve neto, OPS and EGT.
Page 211 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) TYPICAL 1. Oil filter housing 1. CAPS connector 2. OPS Unplug the “B” connector from the Engine ECU. TYPICAL 1. EGT connector 1. Push this end to unlock NOTE: On Supercharged models, a long screw- driver may be used to unlock the connector from the sensor.
Page 212 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Pull wiring harness away from intake manifold. All 4-TEC Engines Remove manifold retaining screws and push the 4-TEC NA Engines oil dipstick tube out of the manifold slot. Slacken air intake silencer collar. Unlock throttle cable housing from throttle body.
Page 213 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Supercharger 4-TEC NA Engines Detach throttle cable end from throttle body. 4-TEC Supercharged Engines CAUTION: Be scrupulous when working on su- percharger parts. Supercharger rotation reach- es 40 000 rpm. Any modification, improper re- pair/assembly or damage on the parts, may result in damage of the supercharger.
Page 214 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Remove retaining screws and pull out the super- Mount supercharger ass’y on support plate (P/N charger ass’y. 529 035 947). 1. Retaining screws To remove the upper screw, use the Torx adapter 1.
Page 215 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) 1. Washer PLASTIC HAMMER 2. Supercharger impeller 3. O-ring NOTE: The cap nut on the supercharger shaft has 4. Step collar LH threads. Loosen nut on supercharger shaft engine side Loosen cap nut (turn clockwise) on supercharger while holding shaft with a retaining key (P/N 529 shaft impeller side while holding shaft with a re- 035 949).
Page 216 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) CAUTION: When removing the drive gear with CAUTION: Every time when removing the su- the needle pins, be careful not to lose one of percharger shaft, both ball bearings have to be the 40 pins.
Page 217: Assembly
Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Remove ball bearing from supercharger ground plate by using a press and a suitable bearing pusher. 1. Supercharger ground plate 2. Bearing pusher ASSEMBLY All 4-TEC Engines 1. Supercharger shaft 2. Ball bearing Assembly is essentially the reverse of removal 3.
Page 218 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Apply Loctite 243 on retaining disc and install it in Apply heat outside of the housing with a heat gun supercharger ground plate by using the 4-pin sock- to expand its diameter prior to inserting the shaft. et (P/N 529 035 948).
Page 219 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Install step collar, O-ring, supercharger impeller Complete installation on supercharger shaft en- and washer on supercharger shaft impeller side gine side. Install spring washers and L-Ring and and tighten with cap nut. Apply Loctite 243 on cap tighten with nut.
Page 220 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) Install supercharger housing on supercharger Ensure to install the tool perpendicularly (90°) to ground plate. Apply Loctite 243 on retaining torque wrench to apply the proper torque to the screws and torque to 10 N•m (88 lbf•in) according screw.
Page 221 Section 05 ENGINE (4-TEC) Subsection 03 (INTAKE SYSTEM) First, position intake manifold on front mounting bracket then push manifold toward engine to then proceed with rear mounting bracket. When installing the intake manifold, lift up the oil dipstick tube a little bit to fit in the slot of the man- ifold.
Page 222: Exhaust System
Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) EXHAUST SYSTEM 05-04-1 SMR2003-016_05_04A.FM www.SeaDooManuals.net...
Page 223: Exhaust Pipe
Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) EXHAUST PIPE All 4-TEC Engines Disconnect the 3 cooling hoses from exhaust pipe Removal no. 1. WARNING Certain components in the engine compartment may be very hot. Direct contact may result in skin burn.
Page 224 Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) Loosen both exhaust hose clamps no. 15 and re- Slowly unscrew exhaust clamp nut no. 4 and re- move the exhaust hose no. 16 between the muf- move it. fler (LH) and the muffler (RH). NOTE: Unscrewing the nut too fast generates heat that will make it harder to unscrew.
Page 225 Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) Inspection Inspect exhaust pipe condition paying attention for cracks or other damage. Check joints, coupling areas, heat shield and hoses. Replace any defective part. Installation Installation is essentially the reverse of the remov- al procedures.
Page 226: Exhaust Manifold
Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) EXHAUST MANIFOLD Reinstall the exhaust clamp no. 4 to the exhaust pipe flange and tighten enough to maintain the ex- Removal haust pipe in the proper position. Supercharged Models Remove plastic resonator. 1.
Page 227: Muffler (Lh)
Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) Unscrew the exhaust manifold no. 9 beginning Torque screws to 10 N•m (88 lbf•in) as per follow- with the bottom screws. This will help holding the ing illustrated sequence. Repeat the procedure, manifold while you remove the screws.
Page 228: Muffler (Rh)
Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) Detach the strap no. 11 from the muffler (LH) using All 4-TEC Engines the spring installer/remover (P/N 529 035 559). Loosen both exhaust hose clamps no. 15 and discon- nect the exhaust hoses no. 7 and no. 16 from the muffler (RH) no.
Page 229: Exhaust Outlet
Section 05 ENGINE (4-TEC) Subsection 04 (EXHAUST SYSTEM) Inspection Inspect parts condition paying attention for cracks or other damage. Check hoses. Replace any defec- tive part. Installation Installation is the reverse of the removal procedures. After installation, ensure there is no coolant or ex- haust gas leak when the engine is running.
Page 230: Removal And Installation
Section 05 ENGINE (4-TEC) Subsection 05 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL Drive System To withdraw drive shaft, refer to PROPULSION Engine removal is necessary to repair BOTTOM section. END. Cooling System ENGINE REMOVAL To remove cooling system hoses, refer to COOL- Use the VCK (Vehicle Communication Kit) (P/N 529 ING SYSTEM section 035 844) and release the fuel pressure in the fuel sys-...
Page 231 Section 05 ENGINE (4-TEC) Subsection 05 (REMOVAL AND INSTALLATION) Removal of Remaining Components Disconnect RED positive cable from starter post. REAR SUPPORT 1. Remove screws Lifting Engine TYPICAL 1. Disconnect RED positive cable Using a chain block, a hoist or other suitable equip- ment, slightly lift engine to ease the remaining com- Carry on engine lifting to remove from the body ponent removal.
Page 232: Cleaning
Section 05 ENGINE (4-TEC) Subsection 05 (REMOVAL AND INSTALLATION) CLEANING Engine/Jet Pump Alignment Alignment is necessary to eliminate possible vi- Wipe off any spillage in bilge. Clean with a bilge bration and/or damage to components. Check cleaner. alignment of engine using the following alignment Clean external parts of engine.
Page 233 Section 05 ENGINE (4-TEC) Subsection 05 (REMOVAL AND INSTALLATION) To verify alignment proceed as follows: – Secure plate and support to hull with four nuts. TYPICAL TYPICAL – Install adapter (P/N 529 035 719) on drive shaft. 1. Engine alignment adapter 2.
Page 234 Section 05 ENGINE (4-TEC) Subsection 05 (REMOVAL AND INSTALLATION) Engine Support Screws Apply Loctite 243 (blue) (P/N 293 800 060) on screw threads. Torque engine support screws to 25 N•m (18 lbf•ft) when procedure is completed. 1. Torque to 25 N•m (18 lbf•ft) Properly align exhaust pipe.
Page 235: Pto Housing/Magneto
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) PTO HOUSING/MAGNETO 4-TEC Supercharged only 05-06-1 SMR2003-018_05-06A.FM www.SeaDooManuals.net...
Page 236: General
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) GENERAL Always perform the electric tests before removing or installing any components. Clean threads before using Loctite when installing the screws. PTO HOUSING Removal NOTE: When drive shaft will be removed, some oil will flow out.
Page 237 Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) Remove: NOTE: Carefully separate the PTO housing from the engine using two flat screwdrivers prying – jet pump equally at the same time. Proceed slowly so that (refer to JET PUMP in PROPULSION SYSTEM) starter gear disc springs no.
Page 238 Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) Position the disc springs no. 6 and washer no. 7 as per the following illustration. 1. Washer 2. Disc spring 3. Flange washer 4. Starter drive ass’y CAUTION: Ensure the starter drive gear shaft is well engaged in its bore.
Page 239: Pto Seal
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) PTO SEAL COUPLING Inspection Removal Check the PTO seal no. 22 and O-rings no. 10 on Lock crankshaft with locking tool (P/N 529 035 821). the PTO housing. If brittle, hard or damaged, or if Refer to CRANKSHAFT LOCKING in ENGINE BLOCK you see a sign of oil leakage, replace it.
Page 240: Stator
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) Installation For installation, reverse the removal procedure. However, pay attention to the following. Torque PTO coupling to 250 N•m (184 lbf•ft). Ap- ply Loctite anti-seize on threads. STATOR Removal Remove: – PTO housing (refer to PTO HOUSING REMOVAL elsewhere in this section) –...
Page 241: Rotor And Encoder Wheel
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) Place the rubber grommets on both cables in the proper notches at the PTO housing. TYPICAL 1. Hexagonal screws 2. Rotor 3. Encoder wheel TYPICAL Inspection 1. Grommet on CPS cable 2. Grommet on stator cable Check rotor, bent teeth and encoder wheel condi- Apply Loctite 243 on threads.Torque stator and tion.
Page 242: Ring Gear
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) TYPICAL 1. Hexagonal screws 2. Rotor 3. Encoder wheel 4. Ring gear WRONG INSTALLATION 1. Rotor Inspection 2. Balancing holes 3. Encoder wheel Check ring gear condition, especially teeth condi- 4. Large gap tion.
Page 243: Starter Drive Ass'y
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) STARTER DRIVE ASS’Y Inspection Check condition of the teeth, shaft, etc. and if the Removal sprag clutch operates well. If damaged, replace faulty part. Remove: – PTO housing and ring gear as described above Installation –...
Page 244: Oil Spray Nozzle
Section 05 ENGINE (4-TEC) Subsection 06 (PTO HOUSING/MAGNETO) 4-TEC Supercharged Models Installation For installation, reverse the removal procedure. OIL SPRAY NOZZLE However, pay attention to the following. Removal Apply Loctite 648 on oil spray nozzle fitting surface. Remove the PTO housing as described above: CAUTION: The oil spray nozzle must be in ex- act position to supply enough oil to the super- –...
Page 245: Lubrication System
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 4-TEC Supercharged only 25 26 05-07-1 SMR2003-019_05_07A.FM www.SeaDooManuals.net...
Page 246 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) in 11 05-07-2 SMR2003-019_05_07A.FM www.SeaDooManuals.net...
Page 247: General
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) GENERAL Check the oil level as follows: NOTE: Before checking the oil level on this en- Prior to changing the oil, ensure vehicle is on a gine, it is necessary to let it idle for 30 seconds level surface.
Page 248: Engine Oil Pressure Test
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) 7. Remove dipstick and read oil level. It should be between marks. 1. Oil filter housing 2. Pressure test plug 1. Full NOTE: Oil pressure switch works between 180 kPa 2. Add 3.
Page 249: Oil Filter
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) CAUTION: Failure to flush exhaust cooling sys- Pull siphon tube out of dipstick hole then crank tem, when engine is out of water, may severely engine (do not start) while in engine drown mode damage engine and/or exhaust system.
Page 250: Oil Strainers
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Place rags in filler area to prevent spillage. If spillage occurs, clean immediately with the pulley flange cleaner (P/N 413 711 809) to prevent stains. WARNING Wear safety glasses and work in a well venti- lated area when working with strong chemical products.
Page 251 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Cleaning and Inspection Suction Pump — Oil Strainer Clean oil strainer with a part cleaner then use an air Removal gun to dry it. – Remove TOPS ventilation hose no. 7. WARNING Always wear eye protector.
Page 252 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) – Remove suction pump cover with oil separator. If rubber rings are brittle, cracked or hard, replace them. – Remove oil strainer no. 12. Clean both contact surfaces of oil strainer cover. Check and clean the oil inlet and outlet area for dirt and other contaminations.
Page 253: Engine Oil Pressure Regulator
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Torque suction pump cover screws to 10 N•m WARNING (88 lbf•in) as per sequence illustrated below. Ap- Oil pressure regulator plug on oil pump housing ply Loctite 243 on threads. is spring loaded. ENGINE OIL PRESSURE REGULATOR 1.
Page 254: Oil Pressure Pump
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) OIL PRESSURE PUMP – extract the coolant/oil pump shaft no. 24 from outside PTO housing with a pusher The oil pressure pump is located in the PTO hous- – remove rotary seal no. 25 with a screwdriver ing and is driven by the balance shaft.
Page 255 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Using a vernier depth gauge, measure side wear as shown. 1. Pittings on the teeth Using a feeler gauge, measure the clearance be- tween inner and outer rotors. 1. PTO housing surface 2.
Page 256 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Installation Install the coolant/oil pump shaft using the rotary seal pusher (P/N 529 035 823) on the opposite For installation, reverse the removal procedure. Pay side to support the rotary seal. Use the oil seal attention to the following details.
Page 257: Oil Suction Pump
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) OIL SUCTION PUMP – Remove oil suction pump housing with oil sep- arator. The oil suction pump is located on the front side – Remove oil pump screws no. 27 and cover no. 28. of the engine at the bottom of the oil separator.
Page 258 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Inspection If clearance between inner and outer rotors ex- ceeds the tolerance, replace oil pump shaft as- Inspect oil pump shaft assembly, housing and cov- sembly. Ensure to also check oil pump housing er for marks or other damages.
Page 259: Oil Cooler
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) OIL COOLER Installation For installation, reverse the removal procedure. Pay The oil cooler is located below the air intake man- attention to the following details. ifold. TYPICAL 1. Oil cooler 1. Screws M6 x 85 Removal 2.
Page 260: Oil Separator
Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) – O-rings no. 38. 1. O-rings Inspection TYPICAL If O-rings are brittle, cracked or hard, replace them. 1. TOPS ventilation hose Clean both contact surfaces of oil cooler. – Disconnect wiring harness from TOPS valve no.
Page 261 Section 05 ENGINE (4-TEC) Subsection 07 (LUBRICATION SYSTEM) Inspection If O-rings and rubber rings are brittle, cracked or hard, replace them. Clean all contact surfaces of oil separator. Check and clean the oil and blow-by channels for dirt and other contaminations. Installation For installation, reverse the removal procedure.
Page 262: Cylinder Head And Valves
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) CYLINDER HEAD AND VALVES NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle. 05-08-1 SMR2003-020_05_08A.FM www.SeaDooManuals.net...
Page 263: General
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) GENERAL Unscrew spark plug no. 2 then use the single- spark ignition coil to take spark plug out of spark NOTE: When diagnosing an engine problem, al- plug hole. ways perform a cylinder leak test. This will help pin-point a problem.
Page 264: Rocker Arm
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) CAUTION: Never assemble the cover on a gas- ket having this tab. The tab must be cut out. 1. Cut this tab NOTE: Install the valve cover screws according to following sequence.
Page 265 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Remove: – spark plug – valve cover – spark plug tube no. 7 1. Rocker arm shaft 2. Rocker arms (exhaust side) 3. Rocker arm (intake side) 1. Spark plug tube –...
Page 266 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Rocker Arm Press the hydraulic lifter with your thumb. If the hydraulic lifter groove disappears inside rocker Inspect each rocker arm for cracks and scored fric- arm casting, replace rocker arm assembly. Lifter tion surfaces.
Page 267 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Apply engine oil on rocker arm shaft. IMPORTANT: The rocker arm shaft can only be installed in one specific position. Therefore crank- shaft as well as camshaft has to be positioned with their locking pins when the piston of cylinder no.
Page 268: Camshaft Timing Gear
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Using the camshaft locking tool (P/N 529 035 839), lock camshaft on TDC position. 1. Rocker arm shaft screw 2.
Page 269: Timing Chain
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) CYLINDER HEAD Install timing chain. Refer to ENGINE BLOCK sec- tion. Removal Ensure chain guides are in place. Loosely install screws. Lock crankshaft with crankshaft locking tool (P/N 529 035 821), refer to CRANKSHAFT LOCK- Install chain tensioner.
Page 270 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Ensure dowel pins are in place. Install new cylinder head gasket. CAUTION: Each installation of the cylinder head requires a new cylinder head gasket.
Page 271: Camshaft
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) CAMSHAFT CAMSHAFT LOBE - EXHAUST VALVE Removal NEW MINIMUM 31.699 mm (1.248 in) Remove: NEW MAXIMUM 31.809 mm (1.252 in) – valve cover SERVICE LIMIT 31.670 mm (1.247 in) – rocker arms CAMSHAFT LOBE - INTAKE VALVE –...
Page 272: Valve Spring
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Grease the camshaft bearing journals well by us- ing the grease Klueber Isoflex (P/N 293 550 021) or a similar product.
Page 273: Valve
Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Withdraw valve spring compressor, valve spring Installation retainer no. 25 and valve springs. For installation, reverse the removal procedure. Pay attention to the following details. Colored area of the valve spring must be placed on top.
Page 274 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Remove valve stem seal no. 28 with special pliers Change valve if valve stem is out of specification such as Snap-on YA 8230. or has other damages such as wear or friction sur- face.
Page 275 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Replace valve guide if it is out of specification or has other damages such as wear or friction sur- face. Refer to valve guide replacement below. VALVE GUIDE DIAMETER mm (in) NEW MINIMUM Exhaust 5.994 mm (.2359 in)
Page 276 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Check valve guide bore for abreased material. NOTE: If valve guide has caused scoring during extraction, replace the cylinder head. The inlet and exhaust valve guides have the same length and are interchangeable. Grease the bore in cylinder head and the leading end of valve guide with Molykote G-N slide paste.
Page 277 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) Valve Face and Seat If valve seat contact width is too wide or has dark spots, replace the cylinder head. 1. Valve seat A. Valve face contact width 2. Exhaust valve contaminated area B.
Page 278 Section 05 ENGINE (4-TEC) Subsection 08 (CYLINDER HEAD AND VALVES) A. Valve Seat Outer Diameter INTAKE VALVE SEAT OUTER DIAMETER mm (in) 1. Valve stem seal Intake 37.35 mm (1.4705 in) Apply engine oil on valve stem and install it. Exhaust 30.3 mm (1.1929 in) CAUTION: Be careful when valve stem is passed...
Page 279: Engine Block
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) ENGINE BLOCK 05-09-1 SMR2003-021_05_09A.FM www.SeaDooManuals.net...
Page 280 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) 05-09-2 SMR2003-021_05_09A.FM www.SeaDooManuals.net...
Page 281: General
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) GENERAL When disassembling parts that are duplicated in the engine, (e.g.: pistons, connecting rods etc.), it is strongly recommended to note their position (cylinder 1, 2 or 3) and to keep them as a “group”. If you find a defective component, it would be much easier to find the cause of the failure within the group of parts (e.g.: you found a worn valve...
Page 282 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) – oil tank plug screws no. 1 with O-ring no. 2 NOTE: Before removing the connecting rod bear- ing caps, mark them to remember the right posi- tion when reassembling. ENGINE UPSIDE DOWN 1.
Page 283 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) – crankshaft no. 5. Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between butting face of connecting rod and crankshaft counterweight. If the distance exceeds specified tolerance, replace the worn part. 1.
Page 284 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Installation CRANKSHAFT JOURNAL DIAMETER mm (in) For installation, reverse the removal procedure. Pay attention to following details. NEW MINIMUM 49.91 mm (1.9650 in) NOTE: Before installing the crankshaft, make sure NEW MAXIMUM 50.01 mm (1.9689 in) that the timing chain is on the crankshaft and the SERVICE LIMIT...
Page 285 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Insert thrust washers as soon as crankshaft is in Install the crankshaft cover before mounting the place as per following illustration. engine bracket. Apply oil on O-ring and press cover in. Crankshaft cover has to be flush with engine block surface.
Page 286: Timing Chain
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) TIMING CHAIN CHAIN TENSIONER Inspection Removal Check timing chain on camshaft gear for excessive NOTE: Removal of the air intake manifold allows radial play. easier access to the chain tensioner, but is not necessary.
Page 287: Balancer Shaft
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) BALANCER SHAFT – engine block screws no. 3 Removal Remove: – engine oil (refer to OIL CHANGE in LUBRICATION section) – engine from vehicle (refer to REMOVAL AND INSTALLATION) – cylinder head (refer to CYLINDER HEAD REMOV- AL in CYLINDER HEAD AND VALVES section) –...
Page 288 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Inspection Installation Check balancer shaft and replace if damaged. For installation, reverse the removal procedure. Pay attention to following detail. If the gear on the balancer shaft is damaged, re- place balancer shaft. CAUTION: Balancer shaft and crankshaft marks have to be aligned.
Page 289: Engine Block
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) CAUTION: Thrust washers have to be flush CAUTION: Install crankshaft locking tool (P/N with the engine block sealing surface. 529 035 821) right away to position crankshaft at TDC before installing the camshaft and rockers (refer to CYLINDER HEAD AND VALVES).
Page 290 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Bushings – Snap-on hammer puller including: When bushings need to be removed from the en- – handle CJ93-1 gine block, mark them to identify the correct posi- – hammer CJ125-6 tion at installation. See the following illustration for –...
Page 291 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Measure the inside diameter of the bushings with CYLINDER TAPER IN DIAMETER a bore gauge. mm (in) NEW MAXIMUM 0.038 mm (.001 in) SERVICE LIMIT 0.090 mm (.004 in) Distance between measurements should not ex- ceed the service limit mentioned above.
Page 292 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Oil Spray Nozzles Correctly install bushings. Top crankshaft bushing halves have a bore which has to be placed in the Remove oil spray nozzle no. 16 and banjo screw upper engine block. no.
Page 293 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Engine block mating surfaces are best cleaned us- ing a combination of the chisel gasket remover (P/N 413 708 500) and a brass brush.
Page 294 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Before continuing the installation process, the ax- Install the crankshaft cover before mounting the ial clearance of balancer shaft and crankshaft has engine bracket. Apply oil on O-ring and press cover to be checked. in.
Page 295: Piston/Connecting Rod
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) PISTON/CONNECTING ROD NOTE: The removal of both piston circlips is not necessary to remove piston pin. Removal Push piston pin no. 9 out of piston. Disassemble engine block as per ENGINE BLOCK REMOVAL above.
Page 296 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) To measure the connecting rod big end diameter, use the OLD screws no. 11. Install the OLD bushings no. 12 as they were mounted initially. Do the torque procedure as described below. A.
Page 297 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Piston With the micrometer set to the dimension, adjust a cylinder bore gauge to the micrometer dimen- Inspect piston for scoring, cracking or other dam- sion and set the indicator to 0 (zero). ages.
Page 298 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) If clearance exceeds specified tolerance, rehone Replace connecting rod if diameter of connecting cylinder sleeve and replace piston ass’y by an rod small end is out of specifications. Refer to oversize one. CRANKSHAFT AND BALANCER SHAFT for removal procedure of connecting rod.
Page 299 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) Using a piston ring compressor plier, such Snap- Correctly install bushings and carefully clean split ON RC-980, slide piston into cylinder. surface on both sides (cracked area). CAUTION: Install piston with punched arrow toward exhaust side.
Page 300: Piston Rings
Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) PISTON RINGS Ring End Gap RING END GAP Removal mm (in) Remove piston ass’y as described above. NEW MINIMUM Remove rings. RECTANGULAR 0.15 mm (.006 in) Inspection TAPER-FACE 0.15 mm (.006 in) Ring/Piston Groove Clearance OIL SCRAPER RING 0.15 mm (.006 in)
Page 301 Section 05 ENGINE (4-TEC) Subsection 09 (ENGINE BLOCK) CAUTION: Ensure that top and second rings are not interchanged. NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. Check that rings rotate smoothly after installation. Space the piston ring end gaps 120°...
Page 302 Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................06-02-1 AIR INDUCTION......................... 06-02-2 FUEL DELIVERY......................... 06-02-2 FUEL PUMP ........................06-02-2 FUEL PRESSURE REGULATOR ..................06-02-2 FUEL FILTERS ........................06-02-3 FUEL PUMP MODULE....................... 06-02-3 FUEL INJECTORS ......................06-02-3 ELECTRONIC MANAGEMENT..................
Page 303 Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (TABLE OF CONTENTS) TROUBLESHOOTING SUMMARY ..................06-05-1 ENGINE DOES NOT START ....................06-05-1 FLOODED ENGINE FEATURE.................... 06-05-1 SPARK PLUG INSPECTION ....................06-05-1 ECU FAULT CODES ......................06-05-1 ENGINE STARTS BUT RUNS POORLY ................06-05-1 ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS .....
Page 304: Overview
Section 06 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 305: Air Induction
Section 06 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 306: Fuel Filters
Section 06 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 307: Electronic Management
Section 06 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 308 Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (OVERVIEW) PARAMETERS SENSORS FUEL DELIVERY SIGNAL MANAGEMENT 06-02-5 SMR2003-022_06_02A.FM www.SeaDooManuals.net...
Page 309: Diagnostic Procedures
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES IMPORTANT: When using the software B.U.D.S., ensure that the protocol matching the connection (Vehicle Communication Kit) used is properly selected in “MPI“ under “Choose protocol” as per the following chart. The VCK (Vehicle Communication Kit) (P/N 529 035 844) is the primary tool to diagnose fuel injec- TYPE OF...
Page 310 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (DIAGNOSTIC PROCEDURES) By selecting the VEHICLE INFO you will access a NOTE: Line no. 1 BOSCH INFO will display the iden- 9-line sub-menu. Select BOSCH SYSTEM from tification of the watercraft and the MPEM/ECU. the sub-menu and press ENTER.
Page 311: Fault Code Tables
Section 06 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 312: Output Signal Faults
Section 06 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 313: Component Inspection
Section 06 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 314 Section 06 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 315: Air Induction System
Section 06 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 316: Fuel Injector
Section 06 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 317: Leak Test (Supply And Ventilation Circuits)
Section 06 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 #4 on the MPEM. Check for fuel leakage from the injector nozzle.
Page 318: Electronic Management
Section 06 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 319 Section 06 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 320 Section 06 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 321 Section 06 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 322 Section 06 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 323 Section 06 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 324: 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 325: Throttle Position Sensor (Tps)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 06 (ADJUSTMENT) ADJUSTMENT THROTTLE CABLE Choose CLOSE TPS in the ADJUSTMENT menu. ADJUSTMENT The screen will display the actual adjustment of the TPS in degrees and it will also offer to adjust it. Fully depress throttle lever. Lever must touch han- CAUTION: Do not select “YES”...
Page 326: Crankshaft Position Sensor (Cps)
Section 06 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 327 Section 06 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 328 Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................07-02-1 OPERATING PRINCIPLE ....................07-02-2 AIR INDUCTION......................... 07-02-2 AIR COMPRESSOR SYSTEM.................... 07-02-2 FUEL DELIVERY SYSTEM....................07-02-2 BASIC OPERATION ......................07-02-2 AIR/FUEL RAIL ASSEMBLY ....................07-02-2 FUEL PUMP MODULE....................... 07-02-3 ELECTRONIC MANAGEMENT..................
Page 329 Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (TABLE OF CONTENTS) TDC SETTING ........................07-03-34 SPARK PLUGS........................07-03-38 CRANKING SYSTEM......................07-03-39 DI SYSTEM TEST SUMMARY................... 07-03-39 DIAGNOSTIC PROCEDURES....................07-04-1 GENERAL..........................07-04-1 FAULT DETECTION AND COMPENSATORY ACTIONS ..........07-04-2 COMPONENT FAILURE WARNING SYSTEM ..............07-04-2 VCK (Vehicle Communication Kit) ...................
Page 330: Overview
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) OVERVIEW 07-02-1 SMR2003-023_07-02A.FM www.SeaDooManuals.net...
Page 331: Operating Principle
Section 07 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 332: Fuel Pump Module
Section 07 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 333: Electronic Management
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) ELECTRONIC MANAGEMENT – distributing information – start/stop function MPEM – DESS (Digitally Encoded Security System) (Multi-Purpose Electronic Module) – ignition timing maps The electronic fuel injection is equipped with a – injection maps (fuel injector and direct injector) MPEM.
Page 334 The MPEM also offers a special safety lanyard — the Sea-Doo LK™ (learning key) — which can be pro- Engine RPM Limiter grammed so that the vehicle can be run only at a The MPEM will limit the maximum engine speed.
Page 335 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (OVERVIEW) MPEM — Engine Management Functions 07-02-6 SMR2003-023_07-02A.FM www.SeaDooManuals.net...
Page 336 In this case, removing and ble conditions: Cranking, start up, idle, warm up, reinstalling the safety lanyard on its post may al- normal operation, Sea-Doo LK™ (learning key) low retrieving normal operation. (limited vehicle speed), engine speed limiter, flooded engine and limp home (see below).
Page 337: Ignition System
Section 07 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 338: Component Inspection And Adjustment
Section 07 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 integrity fuel system.
Page 339: Electrical System
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: Never use injector cleaning products. To perform verifications, a good quality multimeter They may contain additive that could damage in- such as Fluke 111 (P/N 529 035 868) should be jector components.
Page 340: Amp Connector Pin-Out
Section 07 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 341: Quick Fuel Pressure Test
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) QUICK FUEL PRESSURE TEST WARNING Read PRESSURE TEST under AIR/FUEL RAIL further 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 342: Air Induction System
Section 07 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 THROT- Check that the throttle plates moves freely and TLE POSITION SENSOR (TPS) in ELECTRONIC smoothly when depressing throttle lever.
Page 343 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: In the following illustrations, the lower link Turn idle set screw clockwise until ohmmeter reading reaches the computed value above ± 20 Ω. plate has been removed for clarity purposes only. It does not have to be removed to perform the adjustment.
Page 344 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Ensure spring is still well positioned on stoppers. Properly reinstall the plastic cap on the synchroni- zation screw. Apply Loctite 5900 (P/N 293 800 066) RTV silicone sealant on idle set screw head. 1.
Page 345 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Throttle Cable Adjustment Mechanically adjust the throttle cable using the ad- justing device as shown. Slacken lock nut to allow adjuster rotation. Free-play on lever should be be- tween 2 and 3.5 mm (1/16 and 1/8 in). When done, tighten lock nut.
Page 346: Air Compressor
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Closed TPS Adjustment Connect adapters and pressure relief valve to pres- sure gauge as shown. Perform the CLOSED TPS ADJUSTMENT as de- scribed in THROTTLE POSITION SENSOR (TPS) in ELECTRONIC MANAGEMENT below. Injection Oil Pump Cable Adjustment As oil injection cable is throttle dependent, always proceed with the oil injection pump cable adjust-...
Page 347: Repair
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If pressure is within limits, air compressor is work- Ensure to position O-ring, around top of cylinder ing adequately. sleeve. If pressure is below limits, ensure inlet hose is not obstructed, bent or kinked.
Page 348 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Bottom End CAUTION: Failure to properly clean the oil sys- tem will result in serious engine damage. To gain access to piston, rings and connecting rod, The inspection of top end should include the fol- engine PTO flywheel must be removed.
Page 349 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Assembly Use ring compressor (P/N 529 035 713) and insert piston in cylinder. Apply injection oil in cylinder and on rings prior to installing. NOTE: Cylinder may be removed from crankcase to install piston more easily from the bottom.
Page 350: Fuel Delivery
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY Install pressure gauge between disconnected ends (inline installation). FUEL PRESSURE REGULATOR Pressure Test The pressure test will show the available pressure at the air/fuel rail. It validates the pressure regula- tor and leaks in the system.
Page 351: Fuel Injector
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Remove pressure gauge and reinstall fuel hose. At Gently pull rail up by hand, working each side slight- installation apply engine oil on O-ring. ly at a time. Pull rail out. WARNING Unscrew retaining plate screws.
Page 352: Air/Fuel Rail
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Test Installation For the installation, reverse the removal proce- Safety lanyard must be on DESS post. dure. Paying attention to the following details. Using the vehicle communication kit (VCK) with If the same injector is reinstalled, carefully inspect the B.U.D.S.
Page 353 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Air/Fuel Rail Replacement Removal Release the fuel pressure in the system. Disconnect air compressor supply hose from rail. Disconnect fuel hoses (supply and return) at their inline connectors. Temporarily connect these hose ends together to prevent rail draining.
Page 354: Direct Injector
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: When lifting/removing air/fuel rail, we rec- Using a multimeter, check resistance value be- ommend replacing carbon dams on direct injec- tween terminals as follows. tors that have been running for 50 hours or more. COMPONENT TERMINAL LOCATION Remove fuel injectors, fuel pressure regulator and...
Page 355: Fuel Pump
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP NOTE: A thin film of injection oil may be applied to carbon dam if necessary to ease insertion in cyl- inder head. Pressure Test Reconnect electrical connector. The pressure test will show the available pressure from the fuel pump.
Page 356 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Install pressure gauge between disconnected Electrical Test hoses on fuel pump side (closed-loop installation When connecting the safety lanyard to the DESS on fuel pump). Make sure the pressure-relief valve post, the fuel pump should run for 2 seconds to is installed on the fuel pump return line side.
Page 357 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) RX DI Models All Models except XP DI Remove tube Y-connector. From glove box opening, remove fuel pump retain- ing nuts. Remove tube bracket by unscrewing nuts from bilge (front storage area). 1.
Page 358 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) RX DI Models All Models Compress springs of pump module to reduce its Installation height to allow pulling pump out. For installation, reverse the removal process but pay attention to the following. All Models except XP DI Install fuel pump on fuel tank and torque nuts to Pull fuel pump toward front of vehicle.
Page 359 Section 07 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 360: Electronic Management
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRONIC MANAGEMENT If the previous MPEM was NOT read with B.U.D.S. MPEM REPLACEMENT – Enter the vehicle and engine serial numbers in the Vehicle tab. General – Enter the old MPEM serial number in the Part Prior to replacing a suspected MPEM, ensure that Replacement under History tab.
Page 361: Throttle Position Sensor (Tps)
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Start the engine and increase engine speed above Slowly and regularly depress the throttle. Observe 5000 RPM to be sure no fault appears. the needle movement. It must change gradually and regularly as you move the throttle.
Page 362 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If voltage test is good, replace the TPS. Replacement If voltage test is not good, check the resistance of Remove the air intake silencer. the TPS circuit. Remove the air duct. Disconnect the TPS connector.
Page 363: Crankshaft Position Sensor (Cps)
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: An improperly adjusted TPS may Check for RPM display at the information center lead to poor engine performance and emission while cranking engine (first ensure information compliance could possibly be affected. center is in tachometer mode).
Page 364 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The encoder wheel can also be inspected for bent The maximum allowed difference between teeth teeth by the following alternative method. is 0.15 mm (.006 in). Otherwise, straighten the tooth or replace the encoder wheel.
Page 365: Manifold Air Temperature Sensor (Mats)
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Remove CPS. If resistance tests good, reconnect the MATS and disconnect the AMP connector number 4 on the MPEM. Using a multimeter, recheck resistance value be- tween terminals 16 and 19. If resistance value is correct, try a new MPEM.
Page 366: Manifold Air Pressure Sensor (Maps)
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Using a multimeter, recheck resistance value be- Ensure sensor is correctly installed in elbow adap- tween terminals 9 and 11. tor. Otherwise, the MAPS could generate a fault code for an unexpected sensor range at idle when If resistance value is correct, try a new MPEM.
Page 367: Exhaust Gas Temperature Sensor (Egt)
Section 07 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 368: Rave Solenoid
Section 07 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 369: Ignition Coil
Section 07 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 do each ignition coil individually.
Page 370 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The resistance should be between .45 - .55 Ω at Dynamic Test 20°C (68°F). Use an ignition coil tester, available from after-market Otherwise, replace the ignition coil. tool/equipment suppliers. If resistance tests good, reconnect the ignition WARNING coil connector and disconnect the AMP connector...
Page 371: Tdc Setting
Section 07 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 372 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 4. Install and adjust a TDC gauge (P/N 295 000 143) 6. From this point, rotate magneto flywheel back 1/4 in MAG side spark plug hole. turn then rotate it clockwise to reach 7.87 mm (.310 in).
Page 373 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 10. Connect timing light pick-up to MAG side spark CAUTION: If engine is to be run more than a few plug wire. seconds, engine must be cooled using the flush kit.
Page 374 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Choose the Setting tab and look under IGNI- If wiring harness tests good, it could be the MPEM. TION OFFSET. Try a new MPEM referring to MPEM REPLACE- MENT procedures elsewhere in this section.
Page 375: Spark Plugs
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) With safety lanyard INSTALLED on its switch: The “hot” type plug has a longer insulator nose Measure resistance. There should be continuity. and transfers heat more slowly away from its firing Otherwise replace DESS switch.
Page 376: Cranking System
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 3. Hand screw spark plug into cylinder head. Then, tighten the spark plug clockwise an additional 1/4 turn with a proper socket. 1. Proper socket 2. Improper socket SPARK ENGINE TORQUE PLUG...
Page 377 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Tests TERMINAL COMPONENT CONNECTOR WIRE COLOR VALUE NUMBER 26 and terminal B PU/PK Fuel pump AMP no. 4 0 ohm (continuity) 24 and terminal D BK/PK Fuel injector MAG 7 and 13 BL/PU and BL/BK AMP no.
Page 378 Section 07 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 379: Diagnostic Procedures
Section 07 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 section to have an overview of problems and suggested solutions. –...
Page 380: Fault Detection And Compensatory Actions
Section 07 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 381 Section 07 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 382: Vck (Vehicle Communication Kit)
Section 07 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 383: Di System Fault Codes
Section 07 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) Electrical Connections IMPORTANT: After a problem has been solved, ensure to clear the fault(s) in the MPEM using the DI Models Through the 6-Pin Connector VCK. This will properly reset the appropriate counter(s).
Page 384 Section 07 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 385 Section 07 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 386 Section 07 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 387 Section 07 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 388 Section 07 ENGINE MANAGEMENT (DI) Subsection 04 (DIAGNOSTIC PROCEDURES) SERVICE ACTION POSSIBLE CAUSES Battery As soon as Battery Possible causes: P0563 BV_HI_WARN voltage fault is not voltage Battery failure, rectifier failure, battery terminal connection. high present Battery Full reset. Battery Possible causes: P1500 BV_HI_RED...
Page 389 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OVERVIEW..........................08-02-1 COMPLETE ELECTRICAL SYSTEM OVERVIEW .............. 08-02-1 MAGNETO SYSTEM AND POWER SUPPLY ..............08-02-3 OPERATING PRINCIPLE OF ENGINE MANAGEMENT ........... 08-02-3 AIR INDUCTION......................... 08-02-3 FUEL DELIVERY SYSTEM....................08-02-4 BASIC OPERATION ......................
Page 390 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (TABLE OF CONTENTS) OIL SEPARATOR PRESSURE SENSOR (OSPS) ............... 08-03-27 TOPS VALVE (blow-by) ...................... 08-03-29 IGNITION COILS......................... 08-03-31 TDC SETTING (TOP DEAD CENTER)................. 08-03-32 ENGINE START/STOP SWITCH VERIFICATION ............... 08-03-32 SAFETY LANYARD SWITCH VERIFICATION..............08-03-33 SPARK PLUGS........................
Page 391: Overview
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) OVERVIEW COMPLETE ELECTRICAL SYSTEM OVERVIEW INFORMATION CENTER EMS ECU MPEM 08-02-1 SMR2003-026_08-02A.FM www.SeaDooManuals.net...
Page 392 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) Engine Management System Electronic Control Unit Multi-Purpose Electronic Module Knock Sensor Cranshaft Position Sensor Oil Pressure Sensor Oil Separator Pressure Sensor Coolant Temperature Sensor Camshaft Position Sensor Exhaust Gas Temperature Manifold Air Pressure Sensor Manifold Air Temperature Sensor Tip-Over Protection System Connector for Engine Wiring Harness...
Page 393: Magneto System And Power Supply
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) MAGNETO SYSTEM AND AIR INDUCTION POWER SUPPLY 4-TEC Normally-Aspirated Models The magneto is the primary source of electrical Air for combustion is drawn directly at the front of energy. It transforms magnetic field into electric the engine through one 52 mm throttle body.
Page 394: Fuel Delivery System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) INTAKE MANIFOLD 4-TEC Supercharged Models Air for combustion is drawn at the back of the en- gine by a mechanical driven supercharger. The compressed air flows through one 52 mm throttle body and is controlled by a throttle plate and an idle bypass valve.
Page 395: Fuel Pump Module
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) The intake manifold is mounted on the R.H. side of The fuel pump module is located inside the fuel the engine block. It provides support for the fuel tank. The module includes fuel pump, fuel pres- injectors, the fuel rail, the EMS ECU, the flame ar- sure regulator and fuel level sensor.
Page 396: Ems - General Functions
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) – engine RPM limiter – etc. The EMS ECU features a permanent memory that will keep the programmed safety lanyard(s) active, fault codes and other engine information, even when the battery is removed from the watercraft. EMS —...
Page 397 The EMS ECU also offers a special safety lanyard If start/stop button is held after engine has started, — the Sea-Doo LK™ (learning key) — which can the EMS ECU automatically stops the starter be programmed so that the vehicle can be run only when the engine speed reaches 1600 RPM.
Page 398: Ems - Engine Management Functions
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) EMS — ENGINE MANAGEMENT FUNCTIONS 08-02-8 SMR2003-026_08-02A.FM www.SeaDooManuals.net...
Page 399 The ignition coils receive input from the EMS ECU. sible conditions: Cranking, start-up, idle, warm up, Each coil provides high voltage to its correspond- part load, full load, Sea-Doo LK™ (learning key, lim- ing spark plug. ited vehicle speed), engine speed limiter, drowned This ignition system allows spark plugs to spark engine and limp home (see below).
Page 400 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) Flooded Engine (drowned mode) When minor fault occurs, the fault and message/ beeper will disappear automatically, if the condi- If engine is fuel-flooded and does not start, this tion does not exist anymore. special mode can be activated to prevent fuel in- Releasing throttle and letting the engine returning jection and ignition while cranking.
Page 401: Mpem - Multi-Purpose Electronic Module
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (OVERVIEW) MPEM — MULTI-PURPOSE ELECTRONIC MODULE Power Distribution The MPEM distributes power from battery to all accessories and the EMS ECU. Accessories are protected by fuses integrated in the MPEM. Fuse ratings is identified besides their holder. 7.5A 7.5A Monitoring System...
Page 402: Component Inspection And Adjustment
Section 08 ENGINE MANAGEMENT (4-TEC) 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. electronic fuel injection system. Always proceed with care and use appropriate safety equipment when working on pressurized It is important to ensure that the mechanical integ- fuel system.
Page 403: Electrical System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) To check fuel rail for leaks, first pressurize the sys- Never use a battery charger to substitute tempo- tem then spray soapy water on all hose connec- rarily the battery, as it may cause the MPEM/EMS tions, regulators and injectors.
Page 404: Engine Connector Pin-Out
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: For diagnostics purposes, use Vehicle Also remember this validates the operation of the Communication Kit (VCK). See DIAGNOSTIC sensor at ambient temperature. It does not vali- PROCEDURES subsection. date the over temperature functionality.
Page 405: Connectors On Engine
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) EMS ECU Connector Use this diagram to locate the terminal numbers on the EMS ECU connector A of the wiring har- ness when performing tests. EMS ECU CONNECTOR PIN-OUT (WIRING HARNESS SIDE) 1.
Page 406: Air Induction System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) AIR INDUCTION SYSTEM THROTTLE BODY IMPORTANT: Never mix up throttle bodies of nor- mally-aspirated and supercharged 4-TEC engines. Doing so will automatically lead to a misfunction of the EMS and will cause a bad engine calibration. 1.
Page 407 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) – EMS ECU has been replaced and the Closed Throttle and Idle Actuator reset has not been performed. Electrical Inspection Refer to THROTTLE POSITION SENSOR (TPS) and IDLE BYPASS VALVE in ELECTRONIC MANAGE- MENT below.
Page 408 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: It is not allowed to perform any Ensure throttle body is fully open at full throttle po- change on the idle stop screw. sition. At this position, throttle lever stopper is al- most in contact with throttle body.
Page 409: Fuel Delivery
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY 4-TEC Fuel pump does not run Connect safety lanyard Fuel pump runs for 2 sec. then stops Install fuel pressure gauge Check fuses. on fuel pressure line Check safety lanyard connection.
Page 410: Fuel Pump
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP Before proceeding to the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts. Release the fuel pressure in the system using B.U.D.S.
Page 411 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Test From glove box opening, remove fuel pump retain- ing nuts. When connecting the safety lanyard to the DESS post, the fuel pump should run for 2 seconds to build up the pressure in the system.
Page 412: Fuel Rail
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL RAIL Wrap a rag around the hose end to prevent rail drain- ing. Pressure at fuel rail is supplied and controlled by Cut tie raps and remove the wiring harness from the fuel pump module.
Page 413 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Properly reinstall removed parts. Resistance Test The leakage test is validated when performing the Reconnect the injector and disconnect the EMS FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW ECU connector A. CHART elsewhere in this section.
Page 414: Electronic Management
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 4-TEC Models Apply Loctite 243 on rail retaining screws then torque to 10 N•m (89 lbf•in). The resistance should be between 11.4 and 12.6 Ω. If resistance value is correct, try a new EMS ECU. WARNING Refer to EMS ECU REPLACEMENT procedures Perform a fuel pressure test and ensure that...
Page 415 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Disconnect both EMS ECU connectors from EMS Finalizing EMS ECU Replacement ECU. After performing the required resets, ensure to clear all faults from the newly replaced EMS ECU. Start the engine and increase engine speed above 5000 RPM to be sure no fault appears.
Page 416: Engine Wiring Harness
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ENGINE WIRING HARNESS 4-TEC ENGINES 1.EMS ECU connector 4-TEC SUPERCHARGED ENGINES 2.CTS connector 1.EMS ECU connector 3.EGT connector 2.CTS connector 4.CAPS connector 3.EGT connector 5.Fuel injector connector (cylinder 1) 4.CAPS connector 6.Ignition coil connector (cylinder 1) 5.Fuel injector connector (cylinder 1)
Page 417 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Removal Lead the cable bundle with the injector and igni- tion coil connectors to the fuel rail and fix it also by Remove fuel rail cover. using 4 locking ties. Disconnect the wiring harness from all sensors/ actuators.
Page 418: Throttle Position Sensor (Tps)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Connect the CPS, KS, OPS, and the MAPS to the wiring harness. Also connect now the MATS, TPS, OSPS, idle by- pass and TOPS valve to the wiring harness. Fix the wiring for the MATS with a locking tie to support the cables.
Page 419 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test Resistance Test Check the EMS ECU voltage output from to the throt- Reconnect the TPS. tle position sensor. Disconnect the EMS ECU connector A on the EMS ECU.
Page 420 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If resistance values are incorrect, repair connector NOTE: Reset must be done each time the throttle or replace the wiring harness between EMS ECU position sensor (TPS) or the idle bypass valve is connector and the TPS.
Page 421: Idle Bypass Valve
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) IDLE BYPASS VALVE CRANKSHAFT POSITION SENSOR (CPS) An idle bypass valve with good resistance mea- surement can still be faulty. It is also possible that a mechanical failure occurs which is not detect- able without measuring the air flow.
Page 422 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If resistance tests good, reconnect the CPS and Encoder Wheel Inspection disconnect the EMS ECU connector A on the EMS To check the encoder wheel for bent teeth, pro- ECU.
Page 423: Camshaft Position Sensor (Caps)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAMSHAFT POSITION SENSOR b. If 12 V is not read, check continuity of circuit 2-19 from MPEM to the CAPS. If it tests good, try a (CAPS) new MPEM. Otherwise, repair wiring harness. Remove the CAPS from the cylinder head.
Page 424: Manifold Air Temperature Sensor (Mats)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Test Disconnect the connector from the MATS and check the resistance of the sensor itself. The resistance should be between 2280 Ω and 2740 Ω at 20°C (68°F). Otherwise, replace the MATS.
Page 425: Coolant Temperature Sensor (Cts)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) COOLANT TEMPERATURE Replacement SENSOR (CTS) Unlock expansion tank and temporarily move away to gain access. Remove the fuel rail cover. Disconnect CTS connector and remove CTS. Install the new CTS and torque to 18 N•m (159 lbf•in).
Page 426: Exhaust Gas Temperature Sensor (Egt)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) EXHAUST GAS TEMPERATURE Voltage Test SENSOR (EGT) Check the voltage output from EMS ECU to the man- ifold air pressure sensor (MAPS). Disconnect connector from MAPS and connect a voltmeter to the terminals of the wiring harness as per the following table.
Page 427: Knock Sensor (Ks)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) KNOCK SENSOR (KS) Static Resistance Test Using a multimeter, check the resistance between both terminals on the knock sensor harness side. Ω. The resistance should be approximately If resistance is not good, replace knock sensor. If resistance is good, reconnect the knock sensor connector and disconnect the EMS ECU connec- tor A from the EMS ECU.
Page 428: Oil Pressure Sensor (Ops)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) OIL PRESSURE SENSOR (OPS) If resistance values are incorrect, replace OPS. If the values are correct, check the continuity of the wiring harness. Disconnect the EMS ECU connector A from the EMS ECU and check continuity of circuit 6.
Page 429 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TOPS Pressure Test Resistance Test Disconnect the connector from the OSPS and use WARNING a multimeter to check the resistance between The TOPS system might be pressurized. OSPS terminal and engine ground while engine is When the TOPS valve is disconnected from stopped (without blow-by pressure) and while en- the wiring harness, never open the oil filler...
Page 430: Tops Valve (Blow-By)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TOPS VALVE (blow-by) Connect safety lanyard Repair or replace TOPS valve opens Check (short knocking noise) TOPS switch Fails Install engine leak test pump Fails Check gauge on oil dipstick tube wiring harness Lower than 8 V Check output voltage...
Page 431 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The valve is turned on as soon as safety lanyard is NOTE: Take into account that you could hear the installed on its post. The valve opening allows ven- piston movement and the valve might not be tilation of crankcase.
Page 432: Ignition Coils
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Position switch as it is located in vehicle. Resistance An ignition coil with good resistance measure- should be close to 0 Ω. ment can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an Rotate switch as it would do in vehicle.
Page 433: Tdc Setting (Top Dead Center)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If 12 V is read, disconnect the EMS ECU connector If the resistance of one of both windings is not A from the EMS ECU and check the continuity of good, replace the defective ignition coil.
Page 434: Safety Lanyard Switch Verification
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If the switch tests good, temporarily disconnect If it still does not work, disconnect the DESS aux- the inline DESS auxiliary module (if so equipped) iliary module and connect the regular 6-pin DESS (see safety lanyard switch verification below for harness.
Page 435: Cranking System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 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 436: Diagnostic Procedures
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 04 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES GENERAL Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem: – Check the chart in TROUBLESHOOTING sec- tion to have an overview of problems and sug- gested solutions.
Page 437 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 04 (DIAGNOSTIC PROCEDURES) Terminology Some documents or softwares use technical terms that may be different from the one used in this man- ual. The following table will help to find the equiva- lence. TERMS USED TERMS USED IN OTHER IN THIS MANUAL DOCUMENTS/...
Page 438: Self-Diagnostic Mode
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 04 (DIAGNOSTIC PROCEDURES) SELF-DIAGNOSTIC MODE Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUSTMENT section. CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps • Confirms safety lanyard signal operation. Engine can be started.
Page 439: Vck (Vehicle Communication Kit)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 04 (DIAGNOSTIC PROCEDURES) IMPORTANT: When using the software B.U.D.S., with the 4-TEC engines, ensure that the protocol (Vehicle Communication Kit) “KW2000” is properly selected in “MPI” under “Choose protocol”. The VCK (Vehicle Communication Kit) (P/N 529 035 844) is the primary tool to diagnose engine When B.U.D.S.
Page 440: 4-Tec System Fault Codes
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 04 (DIAGNOSTIC PROCEDURES) 4-TEC SYSTEM FAULT CODES General – Electrical noise might also lead engine to occa- sional cutout without generating a fault code The faults registered in the MPEM/EMS ECU are when engine is restarted. When looking at the kept when the battery is disconnected.
Page 441 Section 08 ENGINE MANAGEMENT (4-TEC) 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 442 Section 09 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS CIRCUIT, COMPONENTS AND CARE................... 09-02-1 CIRCUIT ..........................09-02-11 COMPONENTS ........................09-02-15 CARE ..........................09-02-18 CIRCUIT ..........................09-02-20 COOLING SYSTEM LEAK TEST..................09-02-21 INSPECTION ........................09-02-22 DRAINING THE SYSTEM ....................09-02-23 COOLANT REPLACEMENT ....................
Page 443: Circuit, Components And Care
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE 717 Engines 09-02-1 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 444 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines 09-02-2 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 445 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 DI Engines TYPICAL 09-02-3 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 446 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Engines — Closed Loop System 09-02-4 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 447 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Engines — Open Loop System 09-02-5 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 448 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 717 Engines 09-02-6 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 449 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines 09-02-7 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 450 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 DI Engines — All Models except XP DI 09-02-8 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 451 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 947 DI Engines — XP DI 09-02-9 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 452 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Engines 09-02-10 SMR2003-029_09_02A.FM www.SeaDooManuals.net...
Page 453: Circuit
Section 09 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 454 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines The water is entering the engine by the water inlet fitting at the cylinder 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 455 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water enters cylinder block water jackets and is Water continues to flow in the crankcase water directed to the water jackets of the exhaust man- jacket to cool the crankcase area to then be ex- ifold and tuned pipe head through passages locat- pulsed to the transom area.
Page 456 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The water supply to the water flow regulator is Regulated water is injected in the tuned pipe by a provided by the water supply hose coming from calibrated fitting. the pump. F06E0AA 1.
Page 457: Components
Section 09 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 458 Section 09 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 459 Section 09 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 460: Care
Section 09 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. 717 Engines When servicing the hull, always rotate watercraft counterclockwise (seen from the rear).
Page 461 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 462: Circuit
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) The coolant flow comes from the coolant pump impeller into the engine block. It goes around the cylinders and straight up to the cylinder head. A smaller quantity of engine coolant enters the en- gine block on the exhaust side for a better cooling.
Page 463: Cooling System Leak Test
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COOLING SYSTEM LEAK TEST Water is directed to the exhaust manifold fitting located at front of manifold. WARNING To prevent burning yourself, do not remove the expansion tank cap or loosen the ride- plate drain plug if the engine is hot.
Page 464: Inspection
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Water enters exhaust pipe and flows in the water Clamp jacket of pipe. To cut or secure non-reusable Oetiker clamps of cooling system hoses, use pliers (P/N 295 000 070). 1.
Page 465: Draining The System
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) DRAINING THE SYSTEM Coolant Replacement Procedure WARNING WARNING To prevent burning yourself do not remove Never drain or refill cooling system when en- the expansion tank cap or loosen the ride gine is hot.
Page 466: Coolant Pump Housing
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COOLANT PUMP HOUSING Continue to pour and fill expansion tank between marks. 1. Coolant pump housing Removal Remove air compressor inlet and outlet hoses to make room. 1. Level between marks when engine is cold Do not install pressure cap at this time.
Page 467: Thermostat
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) Inspection CAUTION: To prevent leaking, take care that the gaskets are exactly in groove when you re- Check if gasket no. 7 is brittle, hard or damaged install the coolant pump housing. and replace as necessary.
Page 468: Coolant Pump Impeller
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) COOLANT PUMP IMPELLER Leak Test Plug the connections of the oil cooler return hose, Removal coolant tank hose, ride plate return hose and cyl- Remove: inder head return hose with a rag. –...
Page 469: Rotary Seal
Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) ROTARY SEAL Inspection Check weep hole for oil or coolant leak. 1. Retaining screws 2. Oil pump cover – remove oil pump cover no. 12 – remove outer oil pump rotor no. 13 1.
Page 470 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) – extract the coolant/oil pump shaft no. 9 from Installation outside PTO housing cover with a pusher The installation is the opposite of the removal pro- cedure. Pay attention to the following details. NOTE: Never use oil in the press fit area of the oil seal and rotary seal.
Page 471: Care
(seen from the rear) maximum to 90°. 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...
Page 472 Section 09 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE) TECHNICAL DATA TYPE: Closed and open loop cooling system. COOLANT FLOW: Pressure build-up at coolant pump. TEMPERATURE CONTROL: Thermostat. SYSTEM BLEEDING: Self-bleed type through expansion tank (hose at uppermost point of circuit). SYSTEM DRAINING: Self-drain type on the exhaust cooling system (hose at lowest point of circuit).
Page 473 Section 10 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS FUEL CIRCUIT........................10-02-1 GENERAL ........................... 10-02-6 REMOVAL........................... 10-02-6 INSPECTION ........................10-02-9 ASSEMBLY......................... 10-02-10 FUEL SYSTEM PRESSURIZATION ................... 10-02-10 AIR INTAKE (2-STROKE) ....................... 10-03-1 REMOVAL........................... 10-03-4 ASSEMBLY......................... 10-03-6 CARBURETOR ........................10-04-1 GENERAL ...........................
Page 474: Fuel Circuit
Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) FUEL CIRCUIT GTI and GTI LE Models 10-02-1 SMR2003-030_10_02A.FM www.SeaDooManuals.net...
Page 475 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) XP DI Models 10-02-2 SMR2003-030_10_02A.FM www.SeaDooManuals.net...
Page 476 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) GTI LE RFI Models 10-02-3 SMR2003-030_10_02A.FM www.SeaDooManuals.net...
Page 477 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) All DI Models except XP DI 10-02-4 SMR2003-030_10_02A.FM www.SeaDooManuals.net...
Page 478 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) 4-TEC Engines 10-02-5 SMR2003-030_10_02A.FM www.SeaDooManuals.net...
Page 479: General
Always wipe off any fuel spillage from the watercraft. 1. Securing clamp in limited access When replacing the vent hose on all SEA-DOO To secure or cut Oetiker clamps on fuel lines, use models be sure to use “B1” hoses when replac- pliers (P/N 295 000 070).
Page 480 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Carburetor-Equipped Models RFI Models Turn the fuel valve to OFF position. The fuel pump assembly has to be removed from the fuel tank to have access to the fuel filter. Refer WARNING to ENGINE MANAGEMENT (RFI).
Page 481 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Disconnect BLACK negative cable, then RED pos- Electric Fuel Pump itive cable of battery. RFI, 4-TEC and DI Models WARNING Refer to appropriate ENGINE MANAGEMENT section. Always disconnect battery cables exactly in the specified order, BLACK negative cable first.
Page 482: Inspection
Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Remove TOPS switch from electrical harness or Fuel Filter Bowl MPEM bracket. Check filter bowl for water contamination. Remove air box. (Refer to AIR INTAKE SYSTEM sub section. Gasket From storage compartment disconnect fuel pump Inspect gasket condition.
Page 483: Assembly
Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Pressure Relief Valve NOTE: A fuel tank is comprised of 3 components: the tank, the fuel pick up neck and the filler neck. This valve will eliminate fuel spillage when the wa- The necks are injection molded and the tank is tercraft is upside down.
Page 484 Section 10 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT) Pressure Test (supply and vent circuits) NOTE: The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes. Never pressurize All Models over 34 kPa (5 PSI). Proceed as follows: Reconnect air inlet hose of fuel tank to body.
Page 485: Air Intake (2-Stroke)
Section 10 FUEL SYSTEM Subsection 03 (AIR INTAKE (2-STROKE)) AIR INTAKE (2-STROKE) 717 Engines 10-03-1 SMR2003-031_10_03A.FM www.SeaDooManuals.net...
Page 486 Section 10 FUEL SYSTEM Subsection 03 (AIR INTAKE (2-STROKE)) 787 RFI Engines 10-03-2 SMR2003-031_10_03A.FM www.SeaDooManuals.net...
Page 487 Section 10 FUEL SYSTEM Subsection 03 (AIR INTAKE (2-STROKE)) 947 DI Engines XP DI only 10-03-3 SMR2003-031_10_03A.FM www.SeaDooManuals.net...
Page 488: Removal
Section 10 FUEL SYSTEM Subsection 03 (AIR INTAKE (2-STROKE)) 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 engines) or to the exhaust manifold (787 engines).
Page 489 Section 10 FUEL SYSTEM Subsection 03 (AIR INTAKE (2-STROKE)) Unlock the clip no. 2 on top of air intake silencer. XP DI Models Remove bolts retaining both air ducts to engine (both Detach 2 straps from the oil reservoir using spring sides).
Page 490: Assembly
Section 10 FUEL SYSTEM Subsection 03 (AIR INTAKE (2-STROKE)) ASSEMBLY WARNING Assembly is essentially the reverse of removal pro- While doing so, ensure that the clip snaps cedures. However pay particular attention to the fol- firmly, securing the air intake silencer in a lowing.
Page 491: Carburetor
Section 10 FUEL SYSTEM Subsection 04 (CARBURETOR) CARBURETOR For fuel system on RFI, DI and 4-TEC models, refer to appropriate ENGINE MANAGEMENT section. Mikuni BN-40i 10-04-1 SMR2003-032_10_04A.FM www.SeaDooManuals.net...
Page 492: General
Section 10 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 493: Cleaning
Section 10 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 494 Section 10 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 495: Assembly
Section 10 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 496 Section 10 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 497: Installation
Section 10 FUEL SYSTEM Subsection 04 (CARBURETOR) Check Valve Assembly INSTALLATION The check valve is needed if a back pressure oc- Carburetor 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 498 Section 10 FUEL SYSTEM Subsection 04 (CARBURETOR) CAUTION: Improper oil injection pump synchro- nization with carburetor can cause serious en- gine damage. All Models except California Models Low Speed Screw Adjustment F01K08A 1. Must touch handlebar grip Ensure carburetor throttle plate(s) is (are) fully open at full throttle position.
Page 499 Section 10 FUEL SYSTEM Subsection 04 (CARBURETOR) Fuel Accelerator Pump All Engines Ensure throttle cable and idle speed are properly adjusted. With the engine not running, loosen adjustment screw lock nut. Use a feeler gauge between lever tab and pump plunger. Turn adjustment screw to achieve approximately 0.05 - 0.15 mm (.002 - .005 in) gap.
Page 500 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS OIL INJECTION SYSTEM ...................... 11-02-1 GENERAL ........................... 11-02-4 OIL SYSTEM PRESSURIZATION ..................11-02-4 OIL INJECTION PUMP ......................11-03-1 OIL PUMP IDENTIFICATION ..................... 11-03-4 REMOVAL........................... 11-03-4 DISASSEMBLY ........................11-03-4 CLEANING .........................
Page 501: Oil Injection System
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM GTI Series 11-02-1 SMR2003-033_11_02A.FM www.SeaDooManuals.net...
Page 502 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION SYSTEM) XP DI Models 11-02-2 SMR2003-033_11_02A.FM www.SeaDooManuals.net...
Page 503 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION SYSTEM) RX DI and GTX DI Models 11-02-3 SMR2003-033_11_02A.FM www.SeaDooManuals.net...
Page 504: General
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION SYSTEM) GENERAL Carburetor-Equipped Models Connect pump gauge tester (P/N 529 021 800) to Whenever repairing the oil injection system, al- oil injection reservoir vent check valve. ways verify for water infiltration in reservoir. DI Models Also pressure test the oil injection system.
Page 505: Oil Injection Pump
Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) OIL INJECTION PUMP 717 Engines 11-03-1 SMR2003-034_11_03A.FM www.SeaDooManuals.net...
Page 506 Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) 787 RFI Engines 11-03-2 SMR2003-034_11_03A.FM www.SeaDooManuals.net...
Page 507 Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) 947 DI Engines 11-03-3 SMR2003-034_11_03A.FM www.SeaDooManuals.net...
Page 508: Oil Pump Identification
Section 11 LUBRICATION SYSTEM (2 STROKE) 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 509: Assembly
Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) ASSEMBLY 787 and 947 DI Engines Oil Injection Pump and Shaft 717 Engines Make sure shaft no. 8 is installed in crankshaft Oil Injection Pump and Intake Manifold end. Install oil injection pump no.
Page 510: Adjustment
Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) 717 Engines 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.
Page 511 Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) Loosen jam nut and turn cable adjustment nut to obtain proper pump setting. The adjustment nut and jam nut for the oil injection pump cable are located at the cable support on the throttle body.
Page 512 Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) CAUTION: Proper oil injection pump adjustment is very important. Any delay in the opening of pump can result in serious engine damage. Bleeding CAUTION: Oil injection system must be bled and adjustment checked before operating engine.
Page 513: Checking Operation
Section 11 LUBRICATION SYSTEM (2 STROKE) Subsection 03 (OIL INJECTION PUMP) All Engines except 947 DI Run engine at idle speed while manually holding pump lever in fully open position. Do not activate throttle lever. 947 DI Engines – Use the VCK (Vehicle Communication Kit) (P/N 529 035 676).
Page 514 Section 12 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION SYSTEM (CARBURETED ENGINES)..............12-02-1 GENERAL ........................... 12-02-1 MULTI-PURPOSE ELECTRONIC MODULE (MPEM)............12-02-2 IGNITION TIMING ......................12-02-2 IGNITION SYSTEM TESTING PROCEDURE ..............12-02-9 SPARK PLUGS ........................12-02-12 CHARGING SYSTEM......................12-03-1 GENERAL ...........................
Page 515: Ignition System (Carbureted Engines)
Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) IGNITION SYSTEM (CARBURETED ENGINES) GENERAL Magneto System The magneto is the primary source of electrical NOTE: For DI and 4-TEC models, refer to ENGINE energy. It transforms magnetic field into electric MANAGEMENT section.
Page 516: Multi-Purpose Electronic Module (Mpem)
Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) MULTI-PURPOSE ELECTRONIC 787 RFI Engines MODULE (MPEM) Crankshaft Position Sensor (CPS) The CPS is an inductive speed sensor located on 717 and 787 RFI Engines the magneto housing and is working in conjunc- The MPEM is responsible of the following electri- tion with a 60 teeth ring gear which has 2 teeth cal functions related to the ignition system:...
Page 517 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 787 RFI Engines 787 RFI Engines Normally ignition timing adjustment should not be 4. Remove middle screw securing the engine to required. It has been set at factory and it should the rear engine mount.
Page 518 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 6. Rotate PTO flywheel counterclockwise (when facing it) until piston is at Top Dead Center. F01H5SB TYPICAL 1. Tool slot 2. Flywheel mark NOTE: This mark becomes the reference when using the stroboscopic timing light.
Page 519 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 717 Engines 3. Start engine and point timing light straight in line with timing tool slot. Bring engine to 6000 RPM. NOTE: To perform this procedure, make sure to use a stroboscopic timing light rated up to 6000 RPM.
Page 520 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 2. Connect timing light pick-up to MAG side spark NOTE: If mark on PTO flywheel is perfectly align- plug wire. ed with timing mark pointer, no adjustment is re- quired. If mark does not align with pointer, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen or moved.
Page 521 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) Example 1 Recheck ignition timing (make sure engine is cold). When PTO flywheel mark is on right side of timing Repeat armature plate positioning procedure if tool slot, it indicates advanced timing. timing mark position is not adequate.
Page 522 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) IMPORTANT: When using the software B.U.D.S., Press 2 to choose Start Vehicle, the program- ensure that the protocol matching the connection mer will then ask Modify Max RPM, press menu used is properly selected in “MPI“...
Page 523: Ignition System Testing Procedure
Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) Access the BOSCH SYSTEM in the MPEM pro- NOTE: To perform verification, a good quality mul- grammer, then select ADJUSTMENT in the sub- timeter such as Fluke 111 (P/N 529 035 868) menu.
Page 524 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) Multi-Purpose Electronic Module (MPEM) Verification It is not possible to accurately check the MPEM condition without specialized tools. Therefore, re- place MPEM with a good known unit to conduct testing. NOTE: Before replacing the MPEM, make sure all connectors are properly secured and there is no water in connectors.
Page 525 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 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 526: Spark Plugs
Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 1. With ignition coil removed from craft, discon- A “cold” type plug has a relatively short insulator nect spark plug caps from high tension cables. nose and transfers heat very rapidly into the cylin- der head.
Page 527 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) Fouling Spark Plug Installation Fouling of the spark plug is indicated by irregular Prior to installation make sure that contact surfac- running of the engine, decreased engine speed es of the cylinder head and spark plug are free of due to misfiring, reduced performance, and in- grime.
Page 528 Section 12 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES)) 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...
Page 529: Charging System
Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL Battery The battery is the DC source for the electric start- Magneto er, the Multi-Purpose Electronic Module and all ac- cessories. The purpose of the charging system is to keep the battery at a full state of charge.
Page 530: Testing Procedure
Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) TESTING PROCEDURE – Note the reading. This is the current supplied by the regulator. NOTE: First, ensure that battery is in good condi- – Reinstall fuse. tion prior to performing the following tests. –...
Page 531 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Voltage Test Battery Charging Coil All Models 717 Engines Proceed as follows: STATIC TEST: CONTINUITY – Start engine. 1. Disconnect the magneto wiring harness connec- tor. – Connect a multimeter to battery posts. Set mul- timeter to Vdc scale.
Page 532 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) STATIC TEST: INSULATION 5. If the battery charging coil is out of specifica- tion, replace it. 1. Disconnect the magneto wiring harness connec- tor. Stator 2. Install the 4-pin magneto harness adapter (P/N 295 000 131) to the magneto wiring harness.
Page 533 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) STATIC TEST: INSULATION DYNAMIC TEST 1. Disconnect the magneto wiring harness connec- 1. Disconnect the magneto wiring harness connec- tor. tor. 2. Install the 6-pin magneto harness adapter (P/N 295 2. Install the 6-pin magneto harness adapter (P/N 295 000 136) to the magneto wiring harness.
Page 534: Battery
Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) STATIC TEST: INSULATION BATTERY 1. Disconnect the magneto wiring harness connec- Troubleshooting tor. 2. Install the 4-pin magneto harness adapter (P/N 295 SYMPTOM: DISCHARGED OR WEAK BATTERY 000 131) to the magneto wiring harness. Leave wiring harness side disconnected.
Page 535 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) RX DI Models Disconnect battery cables and vent tube from bat- tery. Remove LH side bilge vent tube at rear. Remove battery straps. Release battery from support and move it toward the front of the watercraft. Pull battery from under resonator and remove bat- tery from watercraft.
Page 536 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 4-TEC Models Most hydrometers give a true reading at 21°C (70°F). NOTE: Hand tighten caps then tighten a additional 1/4 turn using a 20 mm (3/4 in) socket. Using other tool could damage the plastic battery caps. WARNING Battery electrolyte is caustic.
Page 537 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) Clean battery casing and caps using a solution of SPECIFIC GRAVITY READING baking soda and water. USING A HYDROMETER CAUTION: Do not allow cleaning solution to en- ter battery. ELECTROLYTE STATE OF TEMPERATURE Rinse battery with clear water and dry well using CHARGE...
Page 538 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: This battery may fill slower than others 5. Connect a 2 A battery charger for 3 to 5 hours. due to the anti-spill check ball design. Step : Connect + lead to battery + post Step : Connect - lead to battery - post Step...
Page 539 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) 7. Test battery state of charge. Use a hydrometer. The time required to charge a battery will vary de- pending on some factors such as: – Battery temperature: The charging time is in- creased as the temperature goes down.
Page 540: Cable Terminal Installation
Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: Some chargers have a polarity protection RX Models feature which prevents charging unless the charg- Reinstall bilge vent tube. er leads are connected to the correct battery ter- minals. A completely discharged battery may not GTI, GTI LE and LRV DI Models have enough voltage to activate this circuitry, even Reinstall seat support.
Page 541 Section 12 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM) NOTE: Different wires require different crimp plier settings, so make sure to follow the instruction sup- plied with the tool. PROPERLY CRIMPED WIRE To verify, if the wire is properly crimped, apply some pulling force on wire and the terminal at the same time from both directions.
Page 542: Starting System
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM 717 Engines 12-04-1 SMR2003-037_12_04A.FM www.SeaDooManuals.net...
Page 543 Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 787 RFI Engines 12-04-2 SMR2003-037_12_04A.FM www.SeaDooManuals.net...
Page 544 Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) 947 DI Engines 12-04-3 SMR2003-037_12_04A.FM www.SeaDooManuals.net...
Page 545: General
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) GENERAL MPEM (or EMS ECU on 4-TEC engines) 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 546: Starting System Troubleshooting
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY STARTER DOES NOT TURN. Burnt fuse (see text above). 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 547: Starter Removal
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER REMOVAL 4 -TEC Engines Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Disconnect RED cable connection from battery. 717 and 787 RFI Engines Remove the following parts: –...
Page 548: Starter Disassembly
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) STARTER DISASSEMBLY 947 DI Engines Locate index marks on yoke no. 1 and end covers 717 and 787 RFI Engines no. 3 and no. 10. Before disassembling, trace index marks on yoke no.
Page 549 Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Remove thrust washers no. 19 from armature shaft. Release brush wires of yoke from brush holder no. 2. Remove brush holder no. 2. 1. Thrust washers Remove the other end cover no. 10 and gasket. F06H1KA Remove the three washers no.
Page 550 Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Remove brushes. Locate index marks on yoke and end covers. To remove bearing and seal in end cover, release tabs of retainer. 1. Index marks Loosen through bolts. 1. Retainer 4-TEC Engines Remove bendix retaining circlip no.
Page 551: Cleaning
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Remove thrust washer from armature shaft. Remove brushes from brush holder by loosening retaining screws. TYPICAL 1. Thrust washers Remove the other end cover with brushes and brush holder assembly. Remove armature. 1.
Page 552: Parts Inspection
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) PARTS INSPECTION 4-TEC Engines Check commutator condition with an indicator. If Armature out of specification, replace the starter. NOTE: An ohmmeter may be used for the follow- ing testing procedures, except for the one con- cerning shorted windings in armature.
Page 553: Starter Assembly
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Overrunning Clutch Yoke Assembly and Clutch Housing Align previously traced indexing marks. 2-Stroke Engines Pinion of overrunning clutch should turn smoothly in clockwise direction, and should not slip in a counterclockwise direction. If defective, replace. Check pinion teeth for wear and damage.
Page 554: Starter Installation
Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) To ease end frame installation, retain brush holder Install the three washers no. 8 onto armature shaft. with a small screwdriver while installing end frame. When installing end covers no. 3 and no. 10 to yoke, align index marks.
Page 555 Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Screw and Teeth Washer Apply Loctite 271 (red) to screw. Connect BLACK negative cable to starter using flat washer, teeth washer no. 15 and screw no. 14. Torque screw to 22 N•m (16 lbf•ft). Apply dielectric grease on terminal and screw.
Page 556 Section 12 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM) Connect the RED positive cable to the starter and torque nut to 7 N•m (62 lbf•in). Apply dielectric grease on terminal and nut. Ensure to slide protector over nut to hide metallic parts.
Page 557: Starter Specification
Section 12 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 558: Instruments And Accessories
Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) INSTRUMENTS AND ACCESSORIES GENERAL Keeping the test probes on the same wires, con- nect a jumper wire between the BLACK/PURPLE Install safety lanyard to activate MPEM to perform wire from the cut-off relay to the battery ground. testing procedures that requires the device to be Measure voltage.
Page 559 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) IMPORTANT: Leaving the safety lanyard on its Engine Stopping post when engine is not running will slowly dis- There are two ways to stop the engine. charge the battery. Press start/stop switch or remove the safety lan- Antistart Feature yard cap from the switch.
Page 560: Information Center
Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Information Center 2-Stroke Models with the Information Center This is a LCD multifunction gauge. Different dis- plays and functions can be activated using 2 but- tons — MODE and SET — following specific se- quences as described below.
Page 561 If another func- rized SEA-DOO dealer when other messages occur. tion was set, the compass will be displayed. On models without the compass function, the word The warning light will blink at the same time.
Page 562: Other Functions
Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Other Functions Chronometer While in the chronometer mode: The following describes how to select other avail- able functions. Language Option While in the compass mode (while “SeaDoo” is displayed on models without compass): 1.
Page 563 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Components Description 1. Fuel level indicator 2. Numerical section 3. Units and messages section 1. Analog speedometer Fuel Level Display 2. Analog tachometer 3. Display area Bar gauge continuously indicates the amount of fuel in the fuel tank while riding.
Page 564 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Compass: Displays the cardinal points to indicate Resetting a Function the orientation of the watercraft. To reset a function (such as the trip hour meter, dis- tance, etc.) press and hold the SET button for 2 sec- WARNING onds while in the appropriate mode.
Page 565 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Other Functions The following describes how to select other avail- able functions. Language Option While in the compass mode: 1. Press to end English/Metric System Allows to display the units in the metric system or in the SAE English system.
Page 566 Except for low liquid levels, which can be corrected by refilling, it is recommended to see an authorized Sea-Doo dealer when other messages occur. NOTE: If a fault occurs, this system generates num- bered fault codes (P-XXXX) that can be displayed 1.
Page 567: Inspection
Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) INSPECTION RX DI, GTX DI and XP DI Models DISPLAYED Information Center LOW FUEL RESISTANCE SEGMENT ON LEVEL RED Some 2-Stroke Models (Ω) FUEL LEVEL LIGHT The PURPLE wire is the 12 Vdc power source of the Information Center.
Page 568 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Water Temperature (L temp) Adjust potentiometer to the resistance values as per following chart to test the accuracy of the In- Some Models formation Center. The water temperature sensor is integrated with RESISTANCE DISPLAY the speed sensor located on the ride plate or tran-...
Page 569 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Fuel/Oil Gauge/Low Oil Warning Light FUEL LEVEL AND RESISTANCE (GTI AND GTI LE) Some Models FUEL LEVEL RESISTANCE The fuel gauge has a pointer which indicates fuel (mm) (Ω) level in the tank. From 248.9 ±...
Page 570 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) GTI LE RFI Models All Models Oil Sensor FLOAT HEIGHT RESISTANCE (bottom of float with bottom The sensor sends the signal to the low-oil level (Ω) of pump module) (mm) light in the fuel gauge or the LED in the Information 4.8 + 2.2 228 ±...
Page 571 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Soak sensor in oil so that its reservoir fills up. Max- VTS Motor imum resistance should be approximately 2 Ω Some Models (closed circuit). Always confirm first that the fuse is in good con- TEST CONDITION READING (Ω) dition.
Page 572 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Read the resistance on the ohmmeter, it should indicate a resistance of 167 ohms ± 1%. RESISTANCE (Ω) NOZZLE POSITION 167 ± 1% 24 ± 1% DOWN NOTE: If the VTS control module passes this resis- tance test, it doesn’t mean it is in perfect condition.
Page 573 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Remove the compass from the support. Speed Sensor Change the direction of the compass and keep it Some Models horizontal (± 10°). There should be a change of The speedometer gives a reading through a speed direction on the Information Center.
Page 574 Section 12 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES) Depth Gauge 4-TEC Models TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Nothing is displayed in the The depth gauge is not activated in the Activate the depth gauge in Options information center MPEM. under Setting tab in B.U.D.S.
Page 575: Dess (Carbureted And Rfi Engines)
Section 12 ELECTRICAL SYSTEM Subsection 06 (DESS (CARBURETED AND RFI ENGINES)) DESS (CARBURETED AND RFI ENGINES) NOTE: For DI and 4-TEC models, refer to ENGINE NOTE: Actually, it is the memory of the MPEM MANAGEMENT section. which is programmed to recognize the digital code of the safety lanyard cap.
Page 576: Vck (Vehicle Communication Kit)
Section 12 ELECTRICAL SYSTEM Subsection 06 (DESS (CARBURETED AND RFI ENGINES)) RFI Models Through the 4-Pin Connector (Vehicle Communication Kit) NOTE: For 787 RFI models refer to ENGINE MAN- AGEMENT section. The VCK (Vehicle Communication Kit) (P/N 529 035 844) is the primary tool to gain access to the MPEM.
Page 577 Section 13 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS JET PUMP ..........................13-02-1 GENERAL ........................... 13-02-3 JET PUMP INSPECTION ON WATERCRAFT..............13-02-3 REMOVAL........................... 13-02-6 DISASSEMBLY........................13-02-8 CLEANING ......................... 13-02-10 PARTS INSPECTION ......................13-02-11 ASSEMBLY......................... 13-02-13 PUMP PRESSURIZATION ....................13-02-20 INSTALLATION ........................
Page 578 Section 13 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS) VARIABLE TRIM SYSTEM ..................... 13-05-1 GENERAL..........................13-05-3 REMOVAL ........................... 13-05-3 DISASSEMBLY ........................13-05-4 INSPECTION ........................13-05-4 ASSEMBLY ......................... 13-05-4 INSTALLATION ........................13-05-5 ADJUSTMENT........................13-05-6 13-01-2 SMR2003-049_13_01ATOC.FM www.SeaDooManuals.net...
Page 579: Jet Pump
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) JET PUMP LRV DI 13-02-1 SMR2003-040_13_02A.FM www.SeaDooManuals.net...
Page 580 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) All Models except LRV DI and GTX 4-TEC Series 13-02-2 SMR2003-040_13_02A.FM www.SeaDooManuals.net...
Page 581: General
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive Stainless XP DI 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...
Page 582 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller Condition Condition of impeller no. 1, boot no. 2 and ring no. 3 can be quickly checked from underneath of the watercraft. Remove grate and look through water inlet opening. F01J0EA TYPICAL —...
Page 583 Pour oil through hole until oil reaches the bottom To check oil condition, insert a wire through oil lev- of hole threads. Use SEA-DOO JET PUMP SYN- el hole then withdraw. A whitish oil indicates wa- THETIC OIL (P/N 293 600 011) only. Oil will drain ter contamination.
Page 584: Removal
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) REMOVAL Reverse Gate (if so equipped) All Models except LRV DI 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 585 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Connecting Rod Nozzle Remove: All Models except LRV DI and XP DI – reverse gate Disconnect steering cable from jet pump nozzle no. 20. – pivot bolt no. 14. Remove: Withdraw connecting rod. –...
Page 586: Disassembly
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) XP DI Models Disconnect steering cable from jet pump nozzle. Disconnect ball joint of VTS link rod. Loosen 2 screws each side of trim ring. 1. Remove screws Jet Pump Housing Remove: 1.
Page 587 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Cover Impeller is loosened using impeller remover tool (P/N 295 000 001). 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.
Page 588: Cleaning
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Insert bearing remover then press tool using a ar- bor press until seal and bearings are out. However, care should be taken not to damage bearing jour- nals. TYPICAL F00J0MA 1. Bearing/seal remover tool NOTE: It is always recommended to renew both bearings, even if only one bearing needs to be re- placed.
Page 589: Parts Inspection
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Carefully check water passages and oil passages. Blow low pressure compressed air through them and make sure they are clear. F02J0VB 1. Replaced if blunted round or damaged Check impeller for cavitation damage, deep scratch- F01J13A es or any other damage.
Page 590 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Needle Bearing and Impeller Shaft WEAR Inspect needle bearings no. 30 and their contact surface. Check for scoring, pitting, chipping or oth- er evidence of wear. With your finger nail, feel contact surface of seal. If any irregular surface is found, renew impeller shaft no.
Page 591: Assembly
Section 13 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 592 Section 13 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 LRV DI 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 593 Section 13 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 594 Section 13 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 595 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 596 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) NOTE: If jet pump housing rest against a table, Insert impeller into wear ring. Manually rotate im- raise it slightly to allow complete shaft insertion peller and push so that it slides on impeller shaft with the shaft guide.
Page 597 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 598: Pump Pressurization
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) CAUTION: This is a synthetic oil. Do not mix Apply Loctite 243 (blue) on threads of screws with mineral based oil. Do not mix oil brands. no. 39. NOTE: When filling reservoir, oil must be poured Install screws no.
Page 599: Installation
Insert bushings no. 42 in nozzle no. 20, position- no. 22 may be leaking; Add a small quantity of ing their flanges from inside of nozzle. SEA-DOO JET PUMP SYNTHETIC OIL to wet the oil seal. Let soak and recheck. Insert sleeves no. 22 in bushings no. 42.
Page 600 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) XP DI 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 601 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) GTX 4-TEC Series Models 32 33 GTX 4-TEC Supercharged models only 13-02-23 SMR2003-040_13_02A.FM www.SeaDooManuals.net...
Page 602: General
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive Stainless GTX 4-TEC 271 001 386 pitch steel 13° - 23° JET PUMP INSPECTION ON WATERCRAFT To work on watercraft, securely install it on a stand.
Page 603: Removal
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Impeller/Wear Ring Clearance This clearance is critical for jet pump performance. Clearance can be checked from water inlet open- ing or from venturi side. However, the last method requires more work. To check clearance from water inlet side, remove inlet grate.
Page 604 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Supercharged Models Only Pivot Support Remove the 2 bracket retaining bolts to remove Remove reverse gate. braket no. 47. Unscrew pivot support bolts no. 13. 1. Bolts to be removed 1. Pivot bolt All Models 2.
Page 605 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) – pivot arm bolts no. 18. Take note of bushing Venturi size for reinstallation. Remove: Withdraw pivot arm no. 19. – reverse gate – nozzle – bracket no. 47 – pivot arm. Unplug OPAS hose from plastic elbow.
Page 606: Disassembly
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Remove 4 retaining screws no. 39 and withdraw Cover venturi no. 24. With pump housing in vertical position, remove 3 retaining screws no. 26. TYPICAL 1. Remove screws Using a fiber hammer, gently tap cover to release Jet Pump Housing it from jet pump housing.
Page 607 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Remove both O-rings no. 37 and circlip. Install pump over this tool. Using a 12 mm Allen key, unscrew the impeller. NOTE: It may be needed to heat the impeller to break Loctite bond. Impeller Remove ring no.
Page 608: Cleaning
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Use the impeller shaft pusher (P/N 529 035 818) to press out impeller shaft no. 28 of pump hous- ing. Bearing no. 33, shaft sleeve no. 30, O-ring no. 46 and spacer no. 32 will come out with the impeller shaft.
Page 609: Parts Inspection
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) CAUTION: DO NOT use Loctite Stripper on wear ring since it will cause irreparable dam- age to it. Wipe Loctite Stripper with a clean cloth. Make sure surface is cleaned and dried of Loctite Stripper.
Page 610: Assembly
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Ball Bearing and Impeller Shaft Seal Carefully inspect seal lips. Make sure that lips are WEAR not worn, distorted, cracked or show signs of any IMPORTANT: Make sure to reassemble ball cage, other damage.
Page 611 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Wear Ring This model is equipped with large pump. It is im- portant that the screws retaining wear ring to housing are installed on this model. F01J5DA 1. Seal lip 2. Press wear ring If a press is not readily available, a piece of wood such as a 2 x 4 in x 12 in long, can be used.
Page 612 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Bearing Using the seal/bearing pusher (P/N 529 035 819) press the bearing no. 33 by its inner race on the impeller shaft no. 28. Be careful when removing the plastic retainer from the bearing no. 33 to avoid the inner races from falling apart.
Page 613 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Before installing any other parts. pump can be pressurized to insure proper seal installation. See PUMP PRESSURIZATION below. On the impeller side, install spacer no. 48 and seal no. 34. While installing make sure seal lips are fac- ing up.
Page 614: Pump Pressurization
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) TYPICAL Install impeller cover with new self-locking screws. Torque to 7 N•m (62 lbf•in). 1. Torque screws to 21 N•m (16 lbf•ft) Venturi O-Rings If needed, install new O-rings no. 38 around bailer passages.
Page 615: Installation
Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) CAUTION: Repair any leak, failure to correct a Apply Loctite 243 (blue) on stud threads of jet leak will lead to premature wear of pump com- pump housing. ponents. Install flat washers no. 40, lock washers no. 41 NOTE: If there is a pressure drop spray soapy wa- and nuts no.
Page 616 Section 13 PROPULSION SYSTEM Subsection 02 (JET PUMP) Nozzle Pivot Triangle Insert bushing no. 42 in nozzle no. 20. Install head bolts toward inside. Insert bushing no. 43 in nozzle no. 20 with its off- NOTE: Make sure the pivot triangle turn freely. set pointing rearward.
Page 617: Drive System
Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) DRIVE SYSTEM All Models except XP DI and 4-TEC Models 13-03-1 SMR2003-041_13_03A.FM www.SeaDooManuals.net...
Page 618 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP DI Models 13-03-2 SMR2003-041_13_03A.FM www.SeaDooManuals.net...
Page 619 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) GTX 4-TEC Models 13-03-3 SMR2003-041_13_03A.FM www.SeaDooManuals.net...
Page 620: General
Section 13 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 DI and 4-TEC Models Remove seat(s).
Page 621 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) – Use pliers (P/N 295 000 054). 4-TEC Models NOTE: When drive shaft will be removed, some oil will flow out. To prevent it, start engine, run at 4000 RPM for 10 seconds and stop engine at this RPM.
Page 622 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) 1. Drive shaft holder 1. PTO seal support tool Disconnect EGT sensor to make room. For the following operations, use the drive shaft/floating ring tool (P/N 529 035 841). NOTE: Note that there is a large opening and a small opening on the tool.
Page 623 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Install tool as shown. 1. Largest opening on through-hull fitting side 1. Largest opening on PTO seal side 1. Largest opening here 2. Floating ring Turn screw clockwise so that the tool pushes the floating ring rearwards to expose the c-clip.
Page 624 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Turn screw clockwise so that the tool pushes the PTO seal forward and the drive shaft to the rear to expose the O-rings contact area. Continue to pull drive shaft out until there is a distance of 18 mm (.71 in) between the tell tale groove and the tool edge.
Page 625 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP DI Models Rear Drive Shaft Remove rear access panel. Remove protective plate no. 18. 1. Use ball end mill for radius. This section of the slot should be 38 mm (1-15/32 in) deep 2.
Page 626 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Front Drive Shaft Loosen 4 screws and remove bottom cover of seat. Remove PTO flywheel guard no. 1. Remove bolts, lock nuts and sleeves from support. 1. Remove cover F08I04B Loosen gear clamp retaining the outer boot of the 1.
Page 627: Inspection
Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Seal Carrier of Mid Bearing All Models To remove the seal carrier from support, loosen Boot the 6 nuts no. 21. Loosen gear clamp no. 11 holding boot, then care- fully pull boot and carbon ring no. 8 from hull in- sert.
Page 628 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Maximum permissible deflection is 0.5 mm (.020 in). PTO Seal 4-TEC Models Discard both O-rings no. 26 and install new ones. All Models Boot Inspect the condition of boot. If there is any dam- age or evidence of wear, replace it.
Page 629: Assembly
Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) XP DI Models Seal Carrier of Mid Bearing Inspect seal carrier needle bearing no. 16. Check parts for scoring, pitting, chipping or other evi- dence of wear. Inspect seals no. 15 for deterioration or excessive wear.
Page 630: Installation
Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) NOTE: Bearing can also be installed with the same driver used at disassembly. Center bearing in longi- tudinal axis of housing. F01J1YA TYPICAL 1. Push bearing centered in its housing Pack seals and bearing with synthetic grease (P/N Install double-lip seal no.
Page 631 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Insert seal carrier housing no. 17 in remaining – alignment shaft (P/N 295 000 141). alignment washer. 1. Alignment shaft Install support plate at rear of watercraft. Carefully slide shaft through seal carrier and shaft support.
Page 632 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) For vertical alignment, loosen damping support NOTE: Ensure the alignment washers are still nuts no. 30 and move the support no. 29 up and loose. down as necessary. Check engine alignment. Refer to ENGINE sec- tion.
Page 633 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Refer to following illustration for tightening se- All Models except 4-TEC Models quence. Torque 1 to 6 at 3 N•m (27 lbf•in) and Circlip then 7 to 12 at 10 N•m (89 lbf•in). Push the floating ring to compress the boot.
Page 634 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) – Insert pointed tips of pliers first in closing hooks. 1. Squeeze plier 4-TEC Models TYPICAL NOTE: Ensure to install floating ring before insert- 1. Closing hooks ing the drive shaft in PTO seal assembly. –...
Page 635 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) WRONG INSTALLATION 1. Inner sleeve not flush with outer circumference 1. Tell tale groove Apply a thin coat of synthetic grease (P/N 293 550 Install PTO seal assembly. 010) on the O-rings of floating ring. Do not get grease on it’s sealing surface.
Page 636 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Continue pushing drive shaft towards engine care- fully guiding it in the PTO seal then in crankshaft splines. Then, push drive shaft until it bottoms against the engine. While someone is pushing drive shaft, slide float- ing ring rearward and guide drive shaft in PTO seal assembly.
Page 637: Lubrication
Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Remove drive shaft/floating ring tool, drive shaft holder then PTO seal support. NOTE: Pushing boot no. 10 rearwards will ease removal of PTO seal support tool. Now ensure everything is properly positioned: Tell tale is not exposed, inner sleeve is flush with outer circumference of PTO seal assembly and C-clip is not exposed.
Page 638 Section 13 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM) Seal Carrier of Mid Bearing Place a plastic sheet underneath hull to recover the excess of sprayed corrosion protectant. XP DI Models From underneath hull, spray the corrosion pro- Using a grease gun, lubricate seal carrier of mid tectant through the intake grate all over the visible bearing with synthetic grease (P/N 293 550 010).
Page 639: Reverse System
Section 13 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) REVERSE SYSTEM LRV DI Models 13-04-1 SMR2003-042_13_04A.FM www.SeaDooManuals.net...
Page 640: Disassembly
Section 13 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 641: Inspection
Section 13 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 642: Adjustment
Section 13 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) Make sure the shift lever action is smooth and pre- Reverse Cable cise. Forward, neutral and reverse positions should be Install reverse cable to cable lever as per following easy to select with a detent position between each. illustration.
Page 643 Section 13 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 644 Section 13 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTI Series, RX DI and GTX Series 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) Loctite 4 N•m 2 N•m...
Page 645: Disassembly
Section 13 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) DISASSEMBLY DO NOT REMOVE the vent tube completely. GTI Series, RX DI and GTX Series 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 646: Inspection
Section 13 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) GTI Series, RX DI and GTX Series Reverse Cable Support On the interior lever no. 3, unscrew the elastic stop Remove: nut and the washer retaining the reverse cable. – shift lever Remove the bracket no.
Page 647: Adjustment
Section 13 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM) 1. Interior lever cursor 2. Reverse cable support slider Interior Lever Apply synthetic grease on the interior lever pivot and in the reverse cable support hole. Install the interior lever in a rotating movement. Engage properly the interior lever tabs in the shift lever slots.
Page 648: Variable Trim System
Section 13 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM RX DI Models 13-05-1 SMR2003-043_13_05A.FM www.SeaDooManuals.net...
Page 649 Section 13 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) XP DI Models 13-05-2 SMR2003-043_13_05A.FM www.SeaDooManuals.net...
Page 650: General
Section 13 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 on RX DI models and remove rear access cover on XP DI).
Page 651: Disassembly
Section 13 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 torn, replace boot. Worm Inspect threads and splines of worm no.
Page 652: Installation
Section 13 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 (P/N 295 000 133).
Page 653: Adjustment
Section 13 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM) ADJUSTMENT If an adjustment is necessary, loosen jam nut no. 16 of VTS rod no. 1. Turn adjustment nut of VTS rod RX DI Models to obtain the desired gap between trim ring and venturi.
Page 654 Section 14 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................14-02-1 DISASSEMBLY........................14-02-3 ASSEMBLY......................... 14-02-8 DISASSEMBLY ........................14-02-13 ASSEMBLY......................... 14-02-16 OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)..........14-02-18 GENERAL ............................14-02-19 SIDE VANE ......................... 14-02-19 CYLINDER SUPPORT ASSEMBLY ................... 14-02-20 TIE ROD ..........................
Page 655: Steering System
Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) STEERING SYSTEM All Models except XP DI, GTX DI and GTX 4-TEC Series Carburetor-equipped engines 14-02-1 SMR2003-044_14_02A.FM www.SeaDooManuals.net...
Page 656 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) GTX DI Models and GTX 4-TEC Series GTX 4-TEC Supercharged LTD only 14-02-2 SMR2003-044_14_02A.FM www.SeaDooManuals.net...
Page 657: Disassembly
Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) DISASSEMBLY All Models Handle Grip and Grip Insert GTX 4-TEC Supercharged Limited Models Only To remove handle grip no. 1, pull out cap no. 2 and Adjustment Handle remove screw no. 3. Set handlebar to its lowest position by turning ad- Pull out grip and remove grip insert from handlebar justment handle no.
Page 658 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) All Model except GTX DI and GTX 4-TEC Series GTX DI Models and GTX 4-TEC Series Only Remove 2 tapping screws no. 42. 1. Set screw Remove 4 screws no. 7. 1. Tapping screw 2.
Page 659 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Remove lower steering cover no. 4. 1. Steering cover 1. Screws 2. Screws 2. Steering padding Unscrew DESS switch nut using safety lanyard Handlebar switch tool (P/N 529 034 600). GTX 4-TEC Supercharged Limited Models Only Remove upper steering cover no.
Page 660 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Detach steering clamp no. 44 and remove handle- All Models bar no. 22. Withdraw rubber pad no. 32 and stop- Cable Support per no. 33. Loosen bolts no. 9 and remove retaining block no.
Page 661 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Disconnect the wiring harnesses leading out of steering stem and cut locking tie. 1. Steering support 2. Bolts Remove cable support no. 8. ALL OTHER MODELS EXCEPT XP DI 1. Tie rap 2.
Page 662: Assembly
Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Remove bolts no. 13 and lock nuts no. 14 from Remove adjuster screw from block and detach steer- steering retaining strip studs. ing support from steering stem. Unscrew threaded pivots to remove threaded block from steering stem no.
Page 663 Section 14 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 664 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Install steering support no. 48 to steering stem no. 49 and secure with pivot bolt no. 47. Install nut and torque to 26 N•m (19 lbf•ft). 1. Pad must not exceed stopper Position handlebar no.
Page 665 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) All Models except XP DI TYPICAL 1. Ball joint on top of steering arm 2. Torque nut to 7 N•m (62 lbf•in) STEERING ALIGNMENT For steering alignment procedure, refer to ALIGN- MENT. 14-02-11 SMR2003-044_14_02A.FM www.SeaDooManuals.net...
Page 666 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) XP DI Models 14-02-12 SMR2003-044_14_02A.FM www.SeaDooManuals.net...
Page 667: Disassembly
Section 14 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 668 Section 14 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 669 Section 14 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 670: Assembly
Section 14 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 671 Section 14 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 672: Off-Power Assisted Steering System (O.p.a.s.)
Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.) 14-02-18 SMR2003-044_14_02A.FM www.SeaDooManuals.net...
Page 673: General
Section 14 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 674: Cylinder Support Assembly
Section 14 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 675: Tie Rod
Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) Unscrew 4 socket screws no. 22. – Check pivot rod no. 13 for cracks or scratches. Replace pivot rod, if necessary. – Socket screws no. 22 should be turned 2-3 turns by hand before tightening with tool. –...
Page 676: Sealed Tube
Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) SEALED TUBE Assembly Assembly is the reverse process of disassembly. Disassembly Apply silicone grease on the screws before install- Removal procedure for RH and LH sealed tube ing. no. 27 is same. Torque Phillips screws no.
Page 677: Water Hose
Section 14 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 678 Section 14 STEERING SYSTEM Subsection 02 (STEERING SYSTEM) 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 679: Alignment
Section 14 STEERING SYSTEM Subsection 03 (ALIGNMENT) ALIGNMENT Position handlebar in straight ahead position by measuring each side the distance from handlebar grip end to floorboard. F01K07A TYPICAL ALL MODELS EXCEPT XP DI 1. Measuring handlebar grip end/floorboard distance 1. Retaining block Check jet pump nozzle position by placing a straight 2.
Page 680 Section 14 STEERING SYSTEM Subsection 03 (ALIGNMENT) TYPICAL — XP DI 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 681 Section 15 SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DIRECT ACTION SUSPENSION.................... 15-02-1 REMOVAL .......................... 15-02-2 INSPECTION ........................15-02-3 ASSEMBLY......................... 15-02-3 15-01-1 SMR2003-049_15_01ATOC.FM www.SeaDooManuals.net...
Page 682: Direct Action Suspension
Section 15 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION XP DI Models 15-02-1 SMR2003-045_15_02A.FM www.SeaDooManuals.net...
Page 683 Section 15 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 684 Section 15 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. 1. Loosen gear clamp Remove bolt no. 10 and lock nut no. 11 from shock Compress spring and remove cup no.
Page 685 Section 16 HULL/BODY Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ADJUSTMENT AND REPAIR ....................16-02-1 GLOVE BOX ........................16-02-22 SEAT ADJUSTMENT......................16-02-23 STORAGE COMPARTMENT INNER SHELL ..............16-02-24 STORAGE COVER SHOCK ....................16-02-27 STORAGE COMPARTMENT COVER ADJUSTMENT ............16-02-28 ACCESS PANEL ADJUSTMENT ..................
Page 686: Adjustment And Repair
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR GTI, GTI LE RFI and GTI LE Models (bow) 16-02-1 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 687 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTI LE RFI and GTI LE Models (stern) 16-02-2 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 688 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTI LE RFI and GTI LE Models (cover) GTI LE 16-02-3 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 689 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTI, GTI LE RFI and GTI LE Models (seats) GTI (seats) 16-02-4 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 690 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX DI (bow) 16-02-5 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 691 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX DI (stern) 16-02-6 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 692 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX DI (cover) 16-02-7 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 693 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) RX DI (seat) 16-02-8 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 694 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) LRV DI (bow) 16-02-9 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 695 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) LRV DI (stern) 16-02-10 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 696 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) LRV DI (cover) 16-02-11 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 697 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) LRV DI (seat) 16-02-12 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 698 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP DI Models (bow) 16-02-13 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 699 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP DI Models (stern and rear) 16-02-14 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 700 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP DI Models (seat) 16-02-15 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 701 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP DI Models (suspension and engine cover) 16-02-16 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 702 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) XP DI Models (front cover) 16-02-17 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 703 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX DI and GTX 4-TEC Models (seats) 16-02-18 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 704 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX DI and GTX 4-TEC Models (front storage compartment) 4-TEC Limited and Wakeboard Edition only 16-02-19 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 705 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX 4-TEC Models and GTX DI Models (body-front view) GTX 4-TEC only GTX DI only 16-02-20 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 706 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX 4-TEC Models and GTX DI Models (body-rear view) GTX 4-TEC Wakeboard Edition only GTX 4-TEC Limited only GTX 4-TEC GTX DI 16-02-21 SMR2003-046_16_02A.FM www.SeaDooManuals.net...
Page 707: Glove Box
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GLOVE BOX GTI, GTI LE and RX DI Models Open front storage cover and remove the access LRV DI panel. Open the glove box cover then unscrew the four Detach the latch retaining vent tube to bracket. screws.
Page 708: Seat Adjustment
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) From front storage compartment, pull glove box out. TYPICAL — GTX DI, GTX 4-TEC SERIES, AND LRV DI — REAR SEAT 1. Lock tabs 1. Lock pin 2. Adjustment nut (apply Loctite 243). Torque to 5 N•m (44 lbf•in) Installation A.
Page 709: Storage Compartment Inner Shell
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) 1. Gently pull starting this end 2. Finish with this end For installation, proceed as follows: • Sand both inner and outer shells in area to be glued (except GTI). GTI AND GTI LE MODELS — REAR SEAT •...
Page 710 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) – Unlock shock rod from circlip and remove washer. 1. Storage cover 2. Inner skin 1. Shock rod 3. Inner skin short screws (x 7) 2. Circlip 4. Inner skin long screws (x 2) 3.
Page 711 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) – Remove compass by removing dart (2). Install new inner skin in the reverse process. – Remove temperature sensor from grommet. For installation, proceed as follows: – Install the compass and secure it with the two darts.
Page 712: Storage Cover Shock
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) – Release the shock from top linkage bracket and bottom support bracket by inserting a flat screwdriver in the shock top and bottom locking devices. 1. Storage cover back locking hook 2. Inner skin back locking bracket 1.
Page 713: Storage Compartment Cover Adjustment
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) FLOATING TYPE 1. Lock pin (apply Loctite 243) 2. Rubber washer 3. Lock nut. Torque to 5 N•m (44 lbf•in) A. 39.2 ± 1 mm (1-35/64 ± 3/64 in) 1. Shock absorber NOTE: Some models have a floating type lock pin.
Page 714: Access Panel Adjustment
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ACCESS PANEL ADJUSTMENT GTX 4-TEC Series and GTX DI Removal and Installation XP DI Models To remove mirror proceed as follows: Adjust lock pin no. 3 of access panel as per follow- ing specifications: –...
Page 715: Deflector And/Or Upper Grid
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) NOTE: Clean the Info Center before installing the – Remove the defective deflector and/or the up- suction cup (P/N 295 000 163) clean and dry sur- per grid from plastic retaining clip. Use two face helps the tool to hold and easily remove the screwdrivers to release the deflector or the Info Center.
Page 716: Inlet Grate
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Make a hole into the luggage compartment as INLET GRATE shown in the illustration below to gain access to the finition plate screw. Removal and Installation Loosen screws and remove inlet grate. NOTE: An impact screwdriver should be used to loosen tight screws.
Page 717: Riding Plate
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Torque screw number to 26 N•m (19 lbf•ft). Cleaning Scrape off all excess of sealant from riding plate and hull. Clean hull surface with acetone based solvent to eliminate grease, dust and any residue of sealant. Installation All Models except GTX DI and GTX 4-TEC Models...
Page 718: Jet Pump Support
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) GTX DI and GTX 4-TEC Models JET PUMP SUPPORT Apply Loctite RTV silicone sealant (P/N 293 800 Removal 066) as indicated by the shaded areas in the next illustrations. Follow also the torquing sequence as Remove jet pump.
Page 719: Deflector
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Using a heat gun, heat jet pump support until it is possible to pull it. NOTE: Shims may have been installed between support and body. Do not remove these shims, otherwise jet pump alignment will be altered. Installation Apply Loctite The Right Stuff Gasket (RTV silicone sealant (P/N 293 800 066) for GTX DI and GTX 4-...
Page 720: Drain Plug Installation
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT REMOVAL XP DI Models Loosen 4 screws and remove bottom cover no. 17 of seat. GTI LE RFI MODELS DRAIN PLUG INSTALLATION Refer to the following illustration to install drain plug no.
Page 721 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Loosen gear clamp of inner boot; then, pull boot Remove protective caps no. 18 and loosen screws downward. no. 19 to remove eyelet no. 20 on each side of seat. F08L1EA 1. Gear clamp 1.
Page 722: Seat Cover Replacement
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) SEAT COVER REPLACEMENT 3. Mark hole positions on body straight and bow sections. 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 723: Wake Pylon
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) WAKE PYLON Disassembly Loosen the stopper screw. GTX 4-TEC Wakeboard Edition only Removal Remove the rear seat and storage basket under it. Remove nuts no. 24 and 26. 1. Stopper screw Pull the safety lock pin to unlock and pull out the cylinder.
Page 724: Sponson Replacement
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Assembly Using a 4.80 mm (3/16 in) drill bit, drill first hole through bumper rail no. 2 at front of bow section. Before assembly verify the physical condition of cylinder groove and adjustment holes. CAUTION: When drilling, be careful not to damage bumper rail and/or hull.
Page 725 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Slide sponson cover towards front to about Other Models 15 mm and pull it out from sponson. Remove seat (access cover for the XP DI mod- Unscrew nut no. 10 and remove sponson no. 8. els).
Page 726: Engine Compartment Cover Removal
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) ENGINE COMPARTMENT COVER Remove half of the decal back protective film and align decal with marks. Start sticking it from center REMOVAL and remove the other half of the film to stick it completely.
Page 727: Hull And Body Repair
Curing time may depend on tempera- ture, amount of putty and percentage of catalyst. The body and hull of the Sea-Doo are constructed After 2 hours, press lightly on the surface with fin- of chopped fiberglass, saturated with resin. It is gers to test the hardness.
Page 728 Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) Minor Gelcoat Fractures Apply a coat of polyvinyl alcohol (PVA) to seal off the air and protect the gelcoat surface from dust. Possible causes: PVA speeds up the curing process because – Flexing of fiberglass laminate. gelcoat will not cure properly when exposed to air.
Page 729: Tools And Materials List
– stirring stick fiberglass resin and catalyst. Use a clean container – cover sheets (for Sea-Doo) to mix the resin, mix only what you will need. Fol- low the recommended catalyst ratio.
Page 730: Thru-Hull Fitting Installation
Section 16 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR) THRU-HULL FITTING Install aluminum insert into plastic hull insert. INSTALLATION NOTE: Align aluminum insert as much as possible with PTO flywheel. All Models except GTX 4-TEC Series Models For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw.
Page 731: Gti And Gti Le Models
Section 17 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 732 Section 17 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 733 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned 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 734 Section 17 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 735: Gti Le Rfi Models
Section 17 TECHNICAL DATA Subsection 02 (GTI LE RFI MODELS) GTI LE RFI MODELS ENGINE GTI LE 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...
Page 736 Section 17 TECHNICAL DATA Subsection 02 (GTI LE RFI MODELS) ELECTRICAL SYSTEM GTI LE RFI Magneto generator output 270 W @ 6000 RPM Ignition system type Digital, inductive Make and type NGK BR8ES Spark plug 0.4 - 0.5 mm (.016 - .020 in) mm (in) 1.02 (.040) Ignition timing (BTDC)
Page 737 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned 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 738 Section 17 TECHNICAL DATA Subsection 02 (GTI LE RFI MODELS) MATERIALS GTI LE 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...
Page 739 Section 17 TECHNICAL DATA Subsection 03 (GTX DI, RX DI, XP DI MODELS) GTX DI, RX DI, XP DI MODELS ENGINE GTX DI RX DI XP DI Engine type BOMBARDIER-ROTAX 947 DI, 2-stroke Induction type Reed valve Type Water cooled, water injected with regulator Water injection fitting (head) 3.5 mm (.139 in) Exhaust system...
Page 740 Section 17 TECHNICAL DATA Subsection 03 (GTX DI, RX DI, XP DI MODELS) ELECTRICAL GTX DI RX DI XP DI Magneto generator output 270 W @ 6000 RPM Ignition system type Digital Inductive Make and type NGK ZFR4F Spark plug 1.1 mm (.04 in) 5.39 ±...
Page 741 Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned 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 742 Section 17 TECHNICAL DATA Subsection 03 (GTX DI, RX DI, XP DI MODELS) MATERIALS GTX DI RX DI XP 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...
Page 743: Lrv Di Models
Section 17 TECHNICAL DATA Subsection 04 (LRV DI MODELS) LRV DI MODELS 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 744 Section 17 TECHNICAL DATA Subsection 04 (LRV DI MODELS) 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 745 Section 17 TECHNICAL DATA Subsection 04 (LRV DI MODELS) 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 746 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 747 Section 17 TECHNICAL DATA Subsection 04 (LRV DI MODELS) 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 748: Gtx 4-Tec Models
Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC MODELS GTX 4-TEC GTX 4-TEC/ SUPERCHARGED/ GTX 4-TEC VANS ENGINE GTX 4-TEC TRIPLE CROWN SUPERCHARGED EDITION LIMITED BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke, Engine type Single Over Head Camshaft (SOHC), liquid cooled Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment)
Page 749 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC GTX 4-TEC/ SUPERCHARGED/ GTX 4-TEC VANS ENGINE GTX 4-TEC TRIPLE CROWN SUPERCHARGED EDITION LIMITED Cylinder head screw Service limit 148.5 mm (5.846 in) Upper compression ring Piston ring type and quantity Lower compression ring Oil scraper ring Rectangular...
Page 750 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC GTX 4-TEC/ SUPERCHARGED/ GTX 4-TEC VANS ENGINE GTX 4-TEC TRIPLE CROWN SUPERCHARGED EDITION LIMITED Connecting rod big end diameter Service limit 45.080 mm (1.7740 in) Connecting rod big end clearance Service limit 0.09 mm (.0035 in) Minimum (new)
Page 751 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC GTX 4-TEC/ SUPERCHARGED/ GTX 4-TEC VANS ELECTRICAL GTX 4-TEC TRIPLE CROWN SUPERCHARGED EDITION LIMITED Magneto generator output 380 W @ 6000 RPM Ignition system type DI (Digital Induction) Ignition timing Not adjustable Make and type NGK DCPR8E...
Page 752 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC GTX 4-TEC/ SUPERCHARGED/ GTX 4-TEC VANS FUEL SYSTEM GTX 4-TEC TRIPLE CROWN SUPERCHARGED EDITION LIMITED Rotax EMS (engine management system) Fuel injection type Multipoint Fuel Injection. Single throttle body (52 mm (2.05 in)) Fuel pressure 42 PSI - 45 PSI Idle speed (in water/out of water)
Page 753 Transmission Direct drive Coupling type Crown splines Reverse system O.P.A.S. system Sea-Doo grease (P/N 293 550 032), Grease type 10 mL front bearing, 50 mL rear of bearing, 50 mL in pump cap Steering nozzle pivoting angle 20° Minimum required water level...
Page 754 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC GTX 4-TEC/ SUPERCHARGED/ GTX 4-TEC VANS MATERIALS GTX 4-TEC TRIPLE CROWN SUPERCHARGED EDITION LIMITED Hull Composite Inlet grate Aluminum Steering cover Thermoplastic Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum Air intake silencer N.A. Flame arrester Tubular wire screen Steering padding...
Page 755: Wiring Diagrams
Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WIRE COLOR CODES DEUTSCH CONNECTORS First color of a wire is the main color. Second color All Models is the tracer. Deutsch connectors are used to connect wiring Example: YELLOW/BLACK (YL-BK) is a YELLOW harness to the magneto the electrical box (some wire with a BLACK tracer.
Page 756 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 1. Engine connector bracket 1. Release button 2. Deutsch connectors 2. Deutsch connectors 3. Flat screwdriver To disconnect the two Deutsch connectors, slide a flat screwdriver between each other to disen- gage, press the release button and disconnect them.
Page 757 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Connector Disassembly All Models 1. Male connector 2. Female connector 3. Secondary lock 4. Sealing cap MALE CONNECTOR 1. Male lock CAUTION: Do not apply dielectric grease on ter- minal inside connector. NOTE: Before extraction, push wire forward to re- lieve pressure on retaining tab.
Page 758 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) – Pull back on the terminal wire to be sure the To remove terminal from Packard connector, use retention fingers are holding the terminal. Snap-on TT600-4 tool. – After all required terminals have been inserted, the lock must be installed.
Page 759 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Removal Each male connector is mechanically keyed to mate only with identical mechanical keyed con- To remove the male connector from the MPEM, nector on the MPEM. press both tabs and pull connector. F00H0NA Step : Press tabs (both sides)
Page 760 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Terminal 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 terminal is removed. Insert a screwdriver blade between the connector and the wedge lock tab.
Page 761 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Before extraction, push wire forward to relieve pres- CAUTION: If terminals are not crimped using sure on retaining tab. the proper crimping tool, the wire seal may be damaged. Insert a 4.8 mm (.189 in) wide screwdriver blade inside the front of the terminal cavity.
Page 762 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Terminal Installation AMP Connectors of Wiring Harness For insertion of signal terminal, make sure the wedge lock is in the open position. NOTE: For insertion of power terminal, the wedge lock may or may not be on the open position. Insert terminal into appropriate circuit cavity and push as far as it will go.
Page 763 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CAUTION: Probe on top of terminal only. Do not Cut both tie raps that secure the harness to the try to probe inside terminal or to use a paper connector. clip to probe inside terminal, it can damage the square-shaped terminal.
Page 764 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CAUTION: Using a tool tip larger than 0.76 mm IMPORTANT: Use genuine wires only. Otherwise (.030 in) may damage the terminal. wires will not fit properly. Insert the tool tip into the terminal cavity as When re-inserting the terminal, the locking tab shown, and locate its wire in the back of the con- must be installed facing the smaller cutout of the...
Page 765 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) MAIN FUSE HOLDER JOINT Install the new terminal in the crimping tool swiv- el. Close the swivel in place. Place the wire on CONNECTOR terminal barrel and crimp the wire firmly. DI Models The fuse holder is located in the rear electrical box.
Page 766 Section 18 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 1. While holding tool pressure, pull wire until terminal releases 2. Joint connector For installation, simply push the wire in the con- nector. You should hear a locking “click”. Try to pull the wire out to ensure terminal is properly locked.
Page 767 NOTE www.SeaDooManuals.net...
Page 768 NOTE www.SeaDooManuals.net...
Page 769 2003 GTI MODEL WARNING : F00Z0D www.SeaDooManuals.net...
Page 770 2003 GTI LE MODEL WARNING : F00Z0C www.SeaDooManuals.net...
Page 771 2003 GTI LE RFI MODEL WARNING : F00Z0E www.SeaDooManuals.net...
Page 772 2003 RX DI MODEL WARNING : F00Z0J www.SeaDooManuals.net...
Page 773 2003 GTX DI MODEL WARNING : F00Z0I www.SeaDooManuals.net...
Page 774 2003 XP DI MODEL WARNING : F00Z0K www.SeaDooManuals.net...
Page 775 2003 GTX 4-TEC MODEL WARNING : F00Z0F www.SeaDooManuals.net...
Page 776 2003 GTX 4-TEC MODEL WITH AUXILIARY DESS MODULE WARNING : F00Z0G www.SeaDooManuals.net...
Page 777 2003 GTX 4-TEC AND GTX 4-TEC SUPERCHARGED MODELS WARNING : F00Z0B www.SeaDooManuals.net...
Page 778 2003 LRV DI MODELS RE-PU WARNING : F11Z03 www.SeaDooManuals.net...
Page 779 www.SeaDooManuals.net...

This manual is also suitable for:

2003 rx di 2003 gtx 4-tex 2003 gti 2003 gtx di 2003 lrv di

Sea-doo 2003 XP DI Shop Manual

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

Leak Test

Leak Test Procedure

Intake System

Exhaust System

Removal and Installation

Pto Housing/Magneto

Lubrication System

Cylinder Head and Valves

Engine Block

Table of Contents

Overview

Fuel Delivery

Air Induction

Electronic Management

Diagnostic Procedures

VCK (Vehicle Communication Kit)

Fault Code Tables

General

Component Inspection

Air Induction System

Fuel Delivery

Electronic Management

Flooded Engine Feature

Spark Plug Inspection

Engine Cannot Reach Maximum Revolutions

Engine Starts but Runs Poorly

Engine Does Not Start

Ecu Fault Codes

Troubleshooting Summary

Throttle Cable Adjustment

Fuel Pump Assembly

Table of Contents

Overview

Fuel Delivery System

Air Induction

Air Compressor System

Operating Principle

Electronic Management

General

Component Inspection and Adjustment

Quick Fuel Pressure Test

Air Induction System

Air Compressor

Fuel Delivery

Electronic Management

Diagnostic Procedures

General

Fault Detection and Compensatory Actions

VCK (Vehicle Communication Kit)

DI System Fault Codes

Table of Contents

Complete Electrical System Overview

Overview

Air Induction

Operating Principle of Engine Management

Magneto System and Power Supply

Fuel Delivery System

Electronic Management

Component Inspection and Adjustment