Cleaning; Assembly - Sea-doo 2003 XP DI Shop Manual

Section 04 ENGINE (2-STROKE)
Subsection 04 (MAGNETO SYSTEM)
TYPICAL
1. Puller
Tighten puller screw and at the same time, tap on
screw head using a hammer to release magneto
rotor from its taper.
CAUTION: Be careful after ring gear removal
not to bend the encoder wheel teeth. Also pay
attention when putting away. If you suspect a
bent tooth, refer to ENGINE MANAGEMENT for
inspection procedure.
Stator and Trigger Coil/CPS
(Crankshaft Position Sensor)
Loosen screws no. 20 and no. 21 to remove the
stator no. 9 and trigger coil no. 10 from the engine
magneto cover.
1. Remove screws
04-04-10

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.

ASSEMBLY

717 Engines
Generating Coil
Strip end of old wire then crimp and solder on new
coil.
Apply Loctite 243 (blue) to screws no. 22 and in-
stall the new coil on armature plate.
Use magneto coil centering tool (P/N 420 876 922)
and install so that it fits around armature plate be-
fore tightening screws.
F00D0AA
1. Magneto coil centering tool (P/N 420 876 922)
CAUTION: Before reinstalling the magneto, re-
move the loose epoxy from harness.
Battery Charging Coil
Position new coil, crimp and solder all wires.
Prior to assembly, apply Loctite 243 (blue).
Use magneto coil centering tool (P/N 420 876 922)
and install it so that it fits around armature plate
before tightening screws no. 23.
www.SeaDooManuals.net
1
SMR2003-009_04_04A.FM