Engine Oil Change And Filter; Cooling System Flushing And Engine Internal Lubrication; Engine Lubrication - Sea-doo 2003 XP DI Shop Manual

Section 02 MAINTENANCE
Subsection 05 (STORAGE)
CAUTION: Fuel stabilizer should be added prior
to engine lubrication to ensure fuel system com-
ponents protection against varnish deposits.
WARNING
Fuel is inflammable and explosive under cer-
tain conditions. Always work in a well ventilat-
ed area. Do not smoke or allow open flames or
sparks in the vicinity. Fuel tank may be pres-
surized, slowly turn cap when opening. Never
use an open flame to check fuel level. When
fueling, keep watercraft level. Do not overfill or
top off the fuel tank and leave watercraft in the
sun. As temperature increases, fuel expands
and might overflow. Always wipe off any fuel
spillage from the watercraft. Periodically in-
spect fuel system. Always turn the fuel tank
valve (if so equipped) to OFF position when
storing the watercraft.
Carburetor-Equipped Models
Always turn the fuel valve to OFF position when
storing the watercraft.

ENGINE OIL CHANGE AND FILTER

4-TEC Engines
Change engine oil and filter. Refer to LUBRICA-
TION in ENGINE section.
All Models
COOLING SYSTEM FLUSHING
AND ENGINE INTERNAL
LUBRICATION
Cooling system (exhaust cooling system on 4-TEC
models) has to be flushed with fresh water to
prevent salt, sand or dirt accumulation which will
clog water passages.
Engine must be lubricated to prevent corrosion on
internal parts.
For proper procedure, refer to FLUSHING AND
LUBRICATION.
02-05-4

ENGINE LUBRICATION

4-TEC Engines
Fogging of the engine is recommended at the end
of the season and before any extended storage
period to provide additional corrosion protection.
This will lubricate the engine intake valves, the cyl-
inders and the exhaust valves.
To fog the engine intake valves, proceed as fol-
lows:
– Remove the two bolts that hold the fuel rail on.
– Remove the rail along with the three fuel injec-
tors.
– Spray BOMBARDIER LUBE lubricant into the
intake ports.
– Crank engine at wide open throttle to put it in
the drown engine mode. This will prevent fuel
injection and ignition.
– Carefully inspect O-rings condition before rein-
stalling fuel injectors. Replace O-rings with new
ones if damaged. Lubricate O-rings with injec-
tion oil prior to installing.
– Reinstall the injectors.
– Apply Loctite 243 and torque the two bolts to
10 N•m (89 lbf•in) that hold the fuel rail on.
– Make sure there is no leak at injectors when
cranking the engine in the upcoming steps.
If a leak is present, immediately stop the en-
gine. Do not start engine until the leak is re-
paired.
At preseason preparation, ensure to perform a
fuel pressure test and ensure there is no leak.
Also run engine and check for leaks. Refer to
ENGINE MANAGEMENT section.
– Pull engine cover upward to remove it.
– Disconnect ignition coil connectors.
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first.
Never check for engine ignition spark from an
open coil and/or spark plug in the engine
compartment as spark may cause fuel vapor
to ignite.
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WARNING
WARNING
WARNING
SMR2003-005_02_05A.FM