Page 1 www.SeaDooManuals.net...
Page 2 2004 Shop Manual GTI, GTI LE, GTI RFI, GTI LE RFI, XP DI GTX 4-TEC /Supercharged /Limited Supercharged /Wakeboard Edition RXP 4-TEC Supercharged BOMBARDIER RECREATIONAL PRODUCTS INC. www.SeaDooManuals.net...
Page 3 Legal deposit: National Library of Quebec National Library of Canada 2004 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. Bombardier Recreational Products Inc. 2004 ©...
Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY NOTICE ................. . XII INTRODUCTION ..
Page 5 TABLE OF CONTENTS ANTICORROSION TREATMENT ..................48 CHECKLIST .
Page 6 TABLE OF CONTENTS 06 – ROTARY VALVE .................... . 153 GENERAL .
Page 7 TABLE OF CONTENTS OIL STRAINERS ....................241 ENGINE OIL PRESSURE REGULATOR.
Page 8 TABLE OF CONTENTS REGULATOR......................309 FUEL INJECTOR .
Page 9 TABLE OF CONTENTS FUEL SYSTEM..................... . 335 ELECTRICAL SYSTEM .
Page 10 TABLE OF CONTENTS 02 – COMPONENT INSPECTION AND ADJUSTMENT ............ . 403 GENERAL .
Page 11 TABLE OF CONTENTS COOLANT REPLACEMENT ..................491 COOLANT PUMP HOUSING .
Page 12 TABLE OF CONTENTS BATTERY ......................566 CABLE TERMINAL INSTALLATION .
Page 13 TABLE OF CONTENTS INSPECTION......................678 ASSEMBLY .
Page 14 02 – GTI RFI AND GTI LE RFI MODELS ......... ..
Page 15: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair all 2004 SEA-DOO watercraft. See model list below. This edition was primarily published to be used by watercraft mechanical technicians who are already fa- miliar with all service procedures relating to Bombardier made watercraft.
Page 16: Introduction
6136 (Sonora sand) GTI RFI (blue jay) 787 RFI 6137 GTI RFI International 787 RFI 6138 (blue jay) GTI RFI LE (Sonora sand) 787 RFI 6139 GTI RFI LE International 787 RFI 6140 (Sonora sand) GTX 4-TEC NA 1503 6147...
Page 17: Engine Identification Number (E.i.n.)
INTRODUCTION ENGINE IDENTIFICATION NUMBER (E.I.N.) 717 Engines The Engine Identification Number is located on the upper side of the magneto housing. 1. Engine Identification Number (E.I.N.) 947 DI Engines The Engine Identification Number is located on the upper crankcase on MAGNETO side. F01D01A TYPICAL 1.
Page 18: Arrangement Of This Manual
INTRODUCTION 1. Engine Identification Number (E.I.N.) ARRANGEMENT OF THIS MANUAL The manual is divided into many major sections as you can see in the main table of contents at the beginning of the manual. Several sections are divided in various subsec- tions.
Page 19 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 20 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 21: List Of Abbreviations Used In This Manual
INTRODUCTION LIST OF ABBREVIATIONS USED ABBREVI- DESCRIPTION IN THIS MANUAL ATION To Be Determined ABBREVI- DESCRIPTION Top Dead Center ATION Throttle Position Sensor Naturally-Aspirated Engine 4-TEC NA Volt Direct Current Analog to Digital Conversion Vehicle Communication Kit Alternate Current Volt Direct Current Air Pressure Sensor Variable Trim System Air Temperature Sensor...
Page 22: Illustrations And Procedures
INTRODUCTION ILLUSTRATIONS AND Dealers are not to modify the engine in any man- ner that would alter the horsepower or allow emis- PROCEDURES sion levels to exceed their predetermined factory The illustrations show the typical construction of specifications. the different assemblies and, in all cases, may not Exceptions include manufacturer's prescribed reproduce the full detail or exact shape of the parts changes, such as altitude adjustments for exam-...
Page 23: Self-Locking Fasteners Procedure
INTRODUCTION EPA INTERNET WEB SITE: – Apply a few drops of threadlocker at proposed tightened nut engagement area. http:/www.epa.gov/omswww – Position nut and tighten as required. SELF-LOCKING FASTENERS Blind Holes PROCEDURE The following describes the most common appli- cation procedures when working with self-locking fasteners.
Page 24: Stripped Thread Repair
INTRODUCTION Adjusting Screw – Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. – Put several drops of proper strength Loctite threadlocker on female threads and in hole. – Apply several drops of proper strength Loctite on stud threads.
Page 25: Gasket Compound
INTRODUCTION – if a plate is used to align bolt: – Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or a. Apply release agent on mating surfaces. 2 minutes. b. Put waxed paper or similar film on the surfaces. –...
Page 26: Case-In Components
INTRODUCTION Mounting in Tandem 1) Apply retaining compound on internal element bore. 2) Continue to assemble as shown above. CASE-IN COMPONENTS Metallic Gaskets A00A3VA 1. Proper strength Loctite – Clean inner housing diameter and outer gasket diameter. – Spray housing and gasket with Loctite Primer N (P/N 293 800 041).
Page 27: Tightening Torques
INTRODUCTION TIGHTENING TORQUES Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer to following table. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: lock- ing tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones, where specified.
Page 28: Service Tools And Products
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) MANDATORY SERVICE TOOLS NOTE: N–> indicates a new tool. ENGINE Degree wheel Sleeve set Carbon dam compressor (P/N 529 035 605) (P/N 529 035 716) a. (P/N 529 035 542) (20 mm sleeve) b.
Page 29 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) Piston pin puller Pusher Alignment shaft (P/N 529 035 503) (P/N 420 876 605) (P/N 295 000 141) Expansion sleeve (P/N 295 000 117) (787 RFI engines) APPLICATION All models.
Page 30 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) Flywheel extractor Handle Ring gear puller tool (P/N 295 000 156) (P/N 420 877 650) (P/N 420 976 235) (puller ass'y) (P/N 529 035 549) (puller bolt) APPLICATION Use with pushers (P/N 290 876 609) and (P/N 290 877 740).
Page 31 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) Ring gear blocking tool kit Camshaft looking tool Retaining key (P/N 529 035 839) (P/N 529 035 949) a) (P/N 529 035 846) APPLICATION 4-TEC engines. Drive shaft adaptor N–>...
Page 32: Cooling/Fuel/Oil Systems
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) COOLING/FUEL/OIL SYSTEMS Gear holder Fuel pressure gauge Oil pressure gauge (1 to 8 bars) (P/N 420 277 905) (P/N 529 035 591) (P/N 529 035 709) APPLICATION 717 engines. APPLICATION APPLICATION Pliers...
Page 33: Propulsion System
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) Coolant pump seal pusher (P/N 529 035 823) APPLICATION 4-TEC engines. PROPULSION SYSTEM N–> Impeller remover/installer Impeller shaft holder Inner seal installer (P/N 295 000 082) (P/N 529 035 609) a.
Page 34 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) Pliers Drive shaft holder Shaft pusher N–> (P/N 295 000 054) (P/N 529 035 819) a. (P/N 529 035 871) b. (P/N 529 035 987) APPLICATION All models. NOTE: This tool is also used for the fuel system.
Page 35: Steering System
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS ) STEERING SYSTEM O.P.A.S. cylinder nut wrench (P/N 529 035 840) APPLICATION Models equipped with O.P.A.S. system. smr2004-Complete Line Up www.SeaDooManuals.net...
Page 36: Optional Service Tools
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) OPTIONAL SERVICE TOOLS NOTE: N–> indicates a new tool. ENGINE Engine stand Coil centering tool N–> Spring installer/remover Not sold by Bombardier (P/N 420 876 922) (P/N 529 035 989) APPLICATION GTX 4-TEC models.
Page 37 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) Ring compressor Torque angle gauge Oil VAC Not sold by Bombardier Not sold by Bombardier (P/N 529 035 880) Snap-on RC980 Snap-on TA362 APPLICATION 4-TEC engines. APPLICATION Special pliers for valve stem seal 4-TEC engines.
Page 38 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) DESS adaptor Timing mark pointer Crimping tool N–> N–> (P/N 278 001 978) (P/N 295 000 130) Crimping tool alone (P/N 529 035 909) APPLICATION 787 RFI engines. APPLICATION 717 engines.
Page 39 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) Terminal (Packard) remover Slide hammer puller Exhaust outlet tool Not sold by Bombardier Not sold by Bombardier (P/N 295 000 132) Snap-on TT 600-4 Snap-on: Handle: CJ93-1 Hammer: CJ125-6 Claws: CJ93-4 APPLICATION All models.
Page 40 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) Rubber pad Digital multimeter 1) Puller ass'y (P/N 290 877 032) (P/N 529 035 868) (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 41: Cooling/Fuel/Oil Systems
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) COOLING/FUEL/OIL SYSTEMS Pump gauge tester Hose pincher Flushing adapter (P/N 295 000 114) (P/N 295 000 076) (P/N 295 500 473) APPLICATION 717 engines. APPLICATION APPLICATION Lighted adjustable mirror All models.
Page 42: Body
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS ) BODY Spring compressor Suspension adjustment wrench Suction cup (P/N 529 035 504) (P/N 529 012 200) (P/N 295 000 163) APPLICATION APPLICATION XP DI models. APPLICATION 4-TEC models. XP DI models.
Page 43: Service Products
Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS ) SERVICE PRODUCTS NOTE: N–> indicates a new product. 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 retaining Gasket eliminator...
Page 44 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS ) RTV silicone sealant Hylomar sealant Synthetic grease (P/N 293 800 066) (P/N 293 800 001) (P/N 293 550 010) Loctite 5900 (300 mL) PL-32 (100 g) (400 g) Super Lube grease Sealant Thread sealant (P/N 293 550 030)
Page 45 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS ) Grease Isoflex BOMBARDIER storage oil Premixed coolant (P/N 293 550 021) (P/N 413 711 600) (CDN) 50/50 -37°C (- 35°F) (50 g) (P/N 413 711 900) (U.S.) (P/N 293 600 038) (12 x 350 g) (16 x 1 L) Sea-Doo fuel stabilizer...
Page 46 Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS ) Sealant adhesive Jet pump bearing grease (P/N 293 800 086) (P/N 293 550 032) Loctite 5150 (29647) (110g) Instant gasket (P/N 293 800 088) (7 oz) Sea-Doo Cleaner (P/N 293 110 001) (400 g) (P/N 293 110 002) (4 L) Jet pump oil Pulley flange cleaner...
Page 47: Maintenance
Section 02 MAINTENANCE Subsection 01 (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 mainte- nance 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 48 Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) DESCRIPTION INTERVAL I: Inspect, verify, clean, adjust, lubricate. EVERY EVERY EVERY Replace if necessary FIRST 25 HOURS 50 HOURS 100 HOURS C: Clean L: Lubricate HOURS 3 MONTHS 6 MONTHS 1 YEAR R: Replace FUEL SYSTEM Throttle/choke cables (carburetor-equipped models)
Page 49 Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) DESCRIPTION INTERVAL I: Inspect, verify, clean, adjust, lubricate. EVERY EVERY EVERY Replace if necessary FIRST 25 HOURS 50 HOURS 100 HOURS C: Clean L: Lubricate HOURS 3 MONTHS 6 MONTHS 1 YEAR R: Replace PROPULSION SYSTEM Drive shaft boot and splines (if so equipped)
Page 50 Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) 4-TEC Models DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate. Replace if necessary EVERY EVERY EVER FIRST C: Clean 25 HOURS 50 HOURS 100 HOURS L: Lubricate HOURS R: Replace 3 MONTHS 6 MONTHS 1 YEAR GENERAL...
Page 51 Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate. Replace if necessary EVERY EVERY EVER FIRST C: Clean 25 HOURS 50 HOURS 100 HOURS L: Lubricate HOURS R: Replace 3 MONTHS 6 MONTHS 1 YEAR ELECTRICAL SYSTEM Electrical connections and fastening (ignition system,...
Page 52 Section 02 MAINTENANCE Subsection 01 (PERIODIC INSPECTION CHART) DESCRIPTION FREQUENCY I: Inspect, verify, clean, adjust, lubricate. Replace if necessary EVERY EVERY EVER FIRST C: Clean 25 HOURS 50 HOURS 100 HOURS L: Lubricate HOURS R: Replace 3 MONTHS 6 MONTHS 1 YEAR HULL/BODY Bailer pick-ups, check for obstructions...
Page 53: Flushing And Lubrication
Section 02 MAINTENANCE Subsection 02 (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 par- ticles in water jackets (engine, intercooler (if so equipped), exhaust manifold, tuned pipe) and/or hoses.
Page 54 Section 02 MAINTENANCE Subsection 02 (FLUSHING AND LUBRICATION) All Models except 4-TEC Models NOTE: No hose pincher is required to flush cooling system. To flush cooling system, start the engine then im- mediately open the water tap. WARNING Components inside engine compartment may be hot.
Page 55 Connect safety lanyard cap to the post. Crank the engine a few turns to distribute the oil onto cylinder wall. GTI RFI/GTI LE RFI Models Remove safety lanyard from its post. XP DI MODEL Depress the throttle lever at full throttle position 1.
Page 56 Section 02 MAINTENANCE Subsection 02 (FLUSHING AND LUBRICATION) 4-TEC Engines Closed Loop Cooling System The 4-TEC engines are equipped with a closed loop cooling system which does not need to be flushed even after salt water use. Open Loop Cooling System Flushing the exhaust cooling system including the 1.
Page 57 Section 02 MAINTENANCE Subsection 02 (FLUSHING AND LUBRICATION) 1. Coupler hose 2. Hose pincher Attach other end of coupler hose to a garden hose. Do not open water tap yet. All 4-TEC Models Flushing To flush the open loop cooling system , start the engine then immediately open the water tap.
Page 58: Anticorrosion Treatment
Section 02 MAINTENANCE Subsection 02 (FLUSHING AND LUBRICATION) Models without a Flushing Connector in Engine Compartment Disconnect the garden hose. CAUTION: Remove flushing adapter after oper- ation (if used). Models with a Flushing Connector in Engine Compartment Unlock and remove coupler hose. Reinstall dust cap over flushing connector.
Page 59: Water-Flooded Engine
Wait 2 seconds then, reinstall the safety lanyard cap. Press the start/stop button to crank the engine to allow water to escape from spark plug openings. GTI AND GTI LE MODELS 947 DI Models 1. Grounding device Remove the air pressure hose from the compres- sor.
Page 60 Section 02 MAINTENANCE Subsection 03 (WATER-FLOODED ENGINE) 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. 1. MAG side spark plug cable 787 RFI Engines Remove the filler plug of the counterbalance shaft 1.
Page 61 Section 02 MAINTENANCE Subsection 03 (WATER-FLOODED ENGINE) All Models except 947 DI and 4-TEC Models F07D07A 717 AND 787 RFI ENGINES 787 RFI ENGINES 1. Air intake silencer 1. Drain plug 2. Pull plug 3. Spray BOMBARDIER LUBE here Drain completely the crankcase oil of the coun- terbalance shaft.
Page 62 Section 02 MAINTENANCE Subsection 03 (WATER-FLOODED ENGINE) If it was submerged in salt water, spray bilge and Remove the water from oil/air separator breather all components with fresh water using a garden hose. hose to stop the salt corroding effect. Remove the exhaust pipe and drain it.
Page 63 Section 02 MAINTENANCE Subsection 03 (WATER-FLOODED ENGINE) WARNING Make sure to safely secure the watercraft. – With the engine still running at 3500 RPM, in- stall a hose pincher to the coolant line going to the oil cooler. WARNING Certain components in the engine compart- ment may be very hot.
Page 64 Section 02 MAINTENANCE Subsection 03 (WATER-FLOODED ENGINE) Water in Supercharger CAUTION: Never run engine without supplying water to the exhaust cooling system when wa- Supercharged 4-TEC Engines tercraft is out of water. If there was water in the oil and presence of wa- –...
Page 65: Storage
Section 02 MAINTENANCE Subsection 04 (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 66: Propulsion System
Section 02 MAINTENANCE Subsection 04 (STORAGE) PROPULSION SYSTEM CAUTION: Water in heat exchanger system must be free to flow out. Should water freeze in engine, severe damage will occur. Jet Pump Reconnect hose when done. All Models except 4-TEC Models Lubricant in impeller shaft reservoir should be DI Models drained.
Page 67: Fuel System
Section 02 MAINTENANCE Subsection 04 (STORAGE) SEAL CARRIER CAUTION: Fuel stabilizer should be added prior to engine lubrication to ensure fuel sys- XP DI Models tem components protection against varnish Lubricate seal carrier of drive shaft support with deposits. synthetic grease. Stop lubricating when grease is just coming out of seal.
Page 68: Battery
Section 02 MAINTENANCE Subsection 04 (STORAGE) WATERCRAFT CLEANING Fogging of the engine is recommended at the end of the season and before any extended storage Clean the bilge with hot water and mild detergent period to provide additional corrosion protection. or with bilge cleaner.
Page 69 1. Engine drain hose NOTE: On RFI models, make sure the hose is properly connected to the magneto cover. GTI AND GTI LE MODELS — 717 ENGINES 1. Engine drain hose RFI MODELS — 787 ENGINES 1. Fitting properly connected smr2004-Complete Line Up www.SeaDooManuals.net...
Page 70 1. Disconnect engine water inlet hose 717 Engines Temporarily install a short piece of hose to engine GTI AND GTI LE MODELS — 717 ENGINES water inlet at cylinder head. 1. Hose pincher on injection hose going to tuned pipe...
Page 71 Section 02 MAINTENANCE Subsection 04 (STORAGE) Most of the antifreeze will drain out when remov- ing the hose pinchers. Use a container to recover it. DISPOSE ANTIFREEZE AS PER YOUR LOCAL LAWS AND REGULATIONS. NOTE: Although antifreeze will mainly drain out, the antifreeze has mixed with the water that was possibly trapped in the water jackets and thus pre- venting freezing problems.
Page 72 Section 02 MAINTENANCE Subsection 04 (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 create enough pressure so that it flows properly. XP DI MODELS 1.
Page 73 Section 02 MAINTENANCE Subsection 04 (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 74: Anticorrosion Treatment
Section 02 MAINTENANCE Subsection 04 (STORAGE) NOTE: Most of the antifreeze will drain out when Lubricate the throttle cable with BOMBARDIER removing the hose pinchers. Use a container to LUBE lubricant. recover it. DISPOSE ANTIFREEZE AS PER YOUR 4-TEC Models LOCAL LAWS AND REGULATIONS.
Page 75: Troubleshooting
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. If a fault code is detected, service the fault code and recheck operating conditions.
Page 76 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) 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 Inspect, refer to PROPULSION SYSTEM Partial engine hydro-lock Check, refer to MAINTENANCE Partial engine seizure Check compression, refer to ENGINE Engine turns slowly...
Page 77 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Defective CPS (fuel injection models) Check operation of CPS and replace if necessary Water-contaminated fuel Check/siphon and refill Dirty fuel filter Clean/replace Fouled or defective spark plug Replace Water in engine Check, refer to MAINTENANCE Carburetion (carburetor models)
Page 78: Engine Hard To Start
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 (fuel injection Refer to ENGINE MANAGEMENT models) Throttle cable adjustment Refer to ENGINE MANAGEMENT (fuel injection models) Temperature too low for available...
Page 79: Engine Misfires, Runs Irregularly
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 ECM or MPEM Check, refer to ENGINE MANAGEMENT (fuel injection models) Defective encoder wheel/CPS Check, refer to ENGINE MANAGEMENT (fuel injection models) Too much oil supplied to engine Adjust oil injection pump...
Page 80 Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Faulty direct injector(s) (DI models) Remove and replace direct injector(s), refer to ENGINE MANAGEMENT Defective sensor or ECM/MPEM Check faulty codes in ECM or MPEM (fuel injection models) (as applicable) memory, refer to ENGINE MANAGEMENT Rotary valve shaft seal leaking...
Page 81: Engine Continually Backfires
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 Refer to WIRING DIAGRAM Incorrect setting Check/reset, refer to ELECTRICAL SYSTEM Ignition timing Defective encoder wheel/CPS...
Page 82: Engine Lacks Acceleration Or Power
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/replace, refer to FUEL SYSTEM (carburetor models) Throttle does not open fully Check/readjust, refer to FUEL SYSTEM or ENGINE MANAGEMENT Low compression...
Page 83: Engine Stops Running
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 Engine dies during Improper ignition timing Check/reset operation (piston seizure/2–stroke Compression ratio is too high Install genuine parts engines) Poor injection oil quality...
Page 84: Engine Runs Too Fast (Vehicle Cannot Reach Its Top Speed)
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 Check, refer to ENGINE MANAGEMENT Improper impeller pitch (too low) Check/replace, refer to PROPULSION SYSTEM Engine RPM too high Incorrect throttle position sensor (TPS) Check and adjust TPS, refer to ENGINE...
Page 85: System Faults (Gtx 4-Tec Models)
Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) O.P.A.S. SYSTEM FAULTS (GTX 4-TEC MODELS) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Watercraft is more Side vanes do not go up while watercraft Refer to STEERING SYSTEM responsive than usual is at speed while turning Watercraft pulls on one One side vane does not go up while Refer to STEERING SYSTEM...
Page 86: Low Or No Engine Oil Pressure (4-Tec Series)
Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) LOW OR NO ENGINE OIL PRESSURE (4-TEC SERIES) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Oil level too low Refill. See TECHNICAL DATA for specifications Leaking gasket Replace Oil leaking out of weep hole (PTO housing) Replace oil seal on pump shaft Oil pressure sensor defective Check/replace Oil pump malfunctioning...
Page 87: Unusual Engine Noise And/Or Vibration (4-Tec Series)
Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART) UNUSUAL ENGINE NOISE AND/OR VIBRATION (4-TEC SERIES) OTHER OBSERVATION POSSIBLE CAUSE REMEDY Worn chain tensioner Replace Worn chain guide Replace Stretched chain and/or worn out sprockets Replace chain and sprockets Sprocket screws got loose Retorque Hydraulic element inside rocker arm(s) Replace faulty rocker arm(s) and/or lifters...
Page 88: Engine (2-Stroke)
Section 04 ENGINE (2-STROKE) Subsection 01 (LEAK TEST) LEAK TEST GENERAL PREPARATION A Sea-Doo Engine Leak Test Kit (P/N 295 500 Verify fuel system for leaks. 352) and Supplementary Engine Leak Test Kit WARNING (P/N 295 500 780) are available to help diagnose engine problems such as engine seizure, poor If any fuel leak is found, do not start the en- performance, oil leakage, etc.
Page 89 Section 04 ENGINE (2-STROKE) Subsection 01 (LEAK TEST) 717 ENGINES — REAR VIEW 787 RFI ENGINES — REAR VIEW 1. Engine drain hose blocked with a hose pincher 1. Loop hose and use clamps 2. Hose with clamps. Install pump to the end 3.
Page 90 Section 04 ENGINE (2-STROKE) Subsection 01 (LEAK TEST) Wait 3 minutes and check if pressure drops; if so, verify all testing components. – 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.
Page 91 Section 04 ENGINE (2-STROKE) Subsection 01 (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. Sim- ply 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 92 Section 04 ENGINE (2-STROKE) Subsection 01 (LEAK TEST) Check for leak through counterbalancing shaft seal toward air compressor (DI engines). Air bubbles in lowest fitting (oil return line) underneath compres- sor indicates a seal leakage. If the above mentioned components are not leak- ing, block both oil hoses of the rotary valve shaft (if so equipped) using hose pinchers.
Page 93 Section 04 ENGINE (2-STROKE) Subsection 01 (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 94: Engine Leakage Diagnostic Flow Chart
Section 04 ENGINE (2-STROKE) Subsection 01 (LEAK TEST) ENGINE LEAKAGE DIAGNOSTIC FLOW CHART 717 and 787 RFI Engines PRESSURIZE ENGINE COOLING SYSTEM IS SYSTEM LEAKING? CHECK TESTING KIT 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 95 Section 04 ENGINE (2-STROKE) Subsection 01 (LEAK TEST) 947 DI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 96: Removal And Installation
Section 04 ENGINE (2-STROKE) Subsection 02 (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 re- moval is necessary to repair BOTTOM END. ENGINE REMOVAL DI Models Use the VCK (Vehicle Communication Kit) (P/N 529...
Page 97 947 DI ENGINES 1. Disconnect hose here 1. Unplug connector Refer to ENGINE MANAGEMENT for location of GTI RFI Series sensors and connectors. Disconnect throttle position sensor (TPS), air Unplug air compressor lines (inlets and outlets): pressure sensor (APS) and air temperature sensor cooling, oil (outlet only) and air (inlet only on throt- (ATS).
Page 98 Turn fuel valve to OFF. Disconnect fuel supply and fuel return hoses. To remove carburetor(s), refer to CARBURETOR for proper procedure. GTI RFI Series Disconnect fuel supply hose from fuel rail. F02D08A 717 ENGINES 1. Remove screw of each engine support PRESS TABS AND PULL CONNECTOR 1.
Page 99 Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) TYPICAL — 787 RFI AND 947 DI ENGINES — REAR SUPPORT ENGINE LIFT TOOL 1. Remove screws Using a chain block, a hoist or other suitable equip- Lifting Engine ment, slightly lift engine to ease the remaining 717 Engines component removal.
Page 100 Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) Remove rear engine support. F01D3ZA TYPICAL — 717 ENGINES 1. Rotary valve oil supply line 2. Hose pincher installed TYPICAL 1. Rear support Removal of Remaining Components Lift up engine slowly until oil injection hoses can be reached.
Page 101: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) Disconnect RED positive cable from starter post. TYPICAL TYPICAL 1. Disconnect RED positive cable CLEANING Disconnect BLACK negative cable from engine crankcase. Wipe off any spillage in bilge. Clean with a bilge cleaner.
Page 102 Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) TORQUE TO 24 N•M (17 LBF•FT) AS PER SEQUENCE 1. Torque screws to 22 N•m (16 lbf•ft) NOTE: Remember to install sleeves and flat wash- 2. Torque nuts to 39 N•m (29 lbf•ft) ers.
Page 103 Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) NOTE: If the alignment is correct, the shaft will slide easily without any deflection in PTO fly- wheel. 1. Plate 2. Support F07D05A Alignment shaft (P/N 295 000 141). TYPICAL 1. Alignment shaft 2.
Page 104 Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) XP DI Models Carefully slide alignment shaft (P/N 295 000 141) through shaft support and seal carrier. Use: – plate (P/N 529 035 507) F05I08A TYPICAL 1. Alignment tool 2. Seal carrier 1.
Page 105 Section 04 ENGINE (2-STROKE) Subsection 02 (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. F00D0CA TYPICAL 1. Shim CAUTION: Whenever shims are used to cor- rect alignment, never install more than 1.3 mm (0.051 in) shim thickness.
Page 106 Section 04 ENGINE (2-STROKE) Subsection 02 (REMOVAL AND INSTALLATION) REAR ENGINE SUPPORT — 787 RFI AND 947 DI ENGINES 1. Torque to 25 N•m (18 lbf•ft) Final Inspection Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil injection pump as specified in OIL INJECTION PUMP and adjust throttle cable as specified in ENGINE MANAGEMENT (DI models).
Page 107: Magneto System
Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) MAGNETO SYSTEM 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 108 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 109 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) 947 DI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 110: Disassembly
Section 04 ENGINE (2-STROKE) Subsection 03 (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 111 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) Proceed as follows: – Before removing the armature plate, find a crankcase locating lug (the top one in this ex- ample). – Place a cold chisel at the end of chosen lug, then punch a mark on armature plate at this point.
Page 112 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) Generating Coil To replace generating coil no. 6: – Heat the armature plate to 93°C (200°F) around the screw holes to break the threadlocker bond. F00D09A 1. Heat the armature plate CAUTION: Protect harness from flame. –...
Page 113 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) SPECIAL TOOL (P/N 529 035 846) 787 RFI ENGINES 1. Disconnect water inlet hose 2. Heat exchanger cover Remove oil pump shaft from magneto rotor nut. 1. Special tool (P/N 529 035 846) Remove crankshaft position sensor no.
Page 114 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) 1. Ring gear blocking tool with retaining plate 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. Magneto Housing To remove magneto housing no.
Page 115 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) Unscrew bolts no. 20 and remove stator no. 9 from magneto cover. F06D23A TYPICAL 1. Remove oil pump shaft Rotor and Ring Gear 787 RFI ENGINES Lock ring gear using special tool (P/N 529 035 1.
Page 116 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) TYPICAL 1. Screw To remove the ring gear/rotor assembly, unscrew TYPICAL 1. Puller nut no. 13 counterclockwise when facing it. Tighten puller screw and at the same time, tap on screw head using a hammer to release magneto rotor from its taper.
Page 117: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 03 (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 crankshaft.
Page 118 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) NOTE: Do not spray Gun Kote into magneto fly- wheel threaded holes. 1) Clean thoroughly and degrease replacement part using a non oil base solvent. 2) Apply coating in light thin coats using a spray gun.
Page 119 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) Install gasket no. 24 between magneto housing 1. Stator screws 2. Bracket and engine crankcase. Magneto Housing Install magneto housing and torque screws no. 19 to 9 N•m(80 lbf•in). To install oil seal no. 28 of magneto housing no. 5, use pusher(P/N 290 877 740) and handle (P/N 420 Rotor and Ring Gear 877 650).
Page 120 Section 04 ENGINE (2-STROKE) Subsection 03 (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 121 Section 04 ENGINE (2-STROKE) Subsection 03 (MAGNETO SYSTEM) F06D24A 1. Loctite 243 (blue) on crankshaft taper 1. Align notch with the emboss Install flywheel and make sure to align keyway with the crankshaft Woodruff key. Apply Loctite 243 (blue) on nut no. 13. Install nut with lock washer and torque to 115 N•m (85 lbf•ft).
Page 122: Top End
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) TOP END 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 123 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 124 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 947 DI Engines 24 23 22 smr2004-Complete Line Up www.SeaDooManuals.net...
Page 125: General
Section 04 ENGINE (2-STROKE) Subsection 04 (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 126 Section 04 ENGINE (2-STROKE) Subsection 04 (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 127: Disassembly
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) MAINTENANCE There are no wear parts anywhere in the system and there are no adjustments to be periodical- ly checked. The only possible maintenance re- quired would be cleaning of carbon deposits from the guillotine slide.
Page 128 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Remove spring 787 RFI Engines 1. Remove screws Remove spring no. 30 retaining bellows no. 21 to Remove RAVE valve no. 15. valve piston no. 20. Remove the cover no. 18 of the valve by releasing the spring no.
Page 129 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Bellows removed from piston 1. Remove spring 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.
Page 130 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Remove O-ring 1. Remove bellows Remove sliding valve no. 22. 947 DI Engines Loosen Allen screws no. 26 each side of RAVE valve. 1. Remove sliding valve Remove bellows no. 21. 1.
Page 131 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Spring Remove the compression spring no. 19. 1. Unscrew piston 2. Hold sliding valve Remove sliding valve from valve housing. 1. Valve piston 2. Valve housing 3. Sliding valve 1. Remove spring Cylinder Head Cover and Cylinder Head Unscrew valve piston no.
Page 132 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) Remove cylinder head no. 2. 947 DI Engines If shells, sand, salt water or any other particles Remove cylinders screws then cylinders no. 9. are present in cylinder cooling jacket, clean with Piston a vacuum cleaner.
Page 133 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) F06B06B 1. Rubber pad (P/N 290 877 032) 1. Puller All Engines 2. Shoulder sleeve 3. Sleeve To remove circlip no. 5, insert a pointed tool in piston notch then pry it out and discard. –...
Page 134: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Tool cut-out toward bottom of piston 1. Remove shoulder sleeve – Firmly hold puller and rotate handle to pull pis- – Carefully remove the piston no. 3. ton pin no. 4. –...
Page 135: Inspection
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) INSPECTION TOLERANCES ENGINE Visually inspect all parts for corrosion damage. NEW PARTS WEAR MEASUREMENT (min.) (max.) LIMIT Inspect piston for damage. Light scratches can be sanded with a fine sand paper. 0.05 mm 0.1 mm Cylinder taper N.A.
Page 136: Used Piston Measurement
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) F01D8AA 1. Measuring perpendicularly (90°) to piston pin axis 2. Auxiliary transfer port F01D8BA A. 16 mm (5/8 in) 1. Measuring in piston pin axis 2. Measuring perpendicularly (90°) to piston pin axis Cylinder Out of Round A.
Page 137 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 787 RFI 28 (1.102) 947 DI 24 (0.945) 1. Piston dome 2. Piston measurement F01D0NA Adjust and lock a micrometer to the specified val- ue on the piston dome. 1. Measuring perpendicularly (90°) to piston pin axis A.
Page 138 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) F01D0KA 1. Use the micrometer to set the cylinder bore gauge 1. Measuring perpendicularly (90°) to piston pin axis 2. Dial bore gauge A. 16 mm (5/8 in) Read the measurement on the cylinder bore gauge.
Page 139: Assembly
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 947 DI Engines Due to the semi-trapez rings, it is not possible to accurately measure ring/piston groove clearance. Ring End Gap Position ring halfway between exhaust port and top of cylinder. NOTE: In order to correctly position ring in cylin- der, use piston as a pusher.
Page 140 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Sliding valve 2. O-ring 3. TOP Install a new gasket no. 24. It must be installed at the same time as the sliding valve no. 22. Position the valve housing no. 25 onto the cylinder 947 DI Engines so that its opening is toward the bottom.
Page 141 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 1. Sliding valve O-ring Check the O-ring under valve housing. Replace if necessary. 1. Sliding valve ridge toward housing groove Piston 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.
Page 142 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) – Replace the inner halves by the appropriate Plastic Mounting Device Method sleeve tool in the connecting rod bore. This is an alternate method when no service tool – Insert piston pin into piston until it comes flush is available.
Page 143 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) F01D0RA F01D0TA 1. Piston pin flush here 1. Pulling inner sleeve half 2. Thrust washers Circlip – Place piston over connecting rod and align Always use new circlips. bores, then gently tap piston pin with a fiber hammer to push out inner plastic ring on oppo- WARNING site side.
Page 144 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) 947 DI Engines Secure circlip in piston groove with its bent end in piston notch as shown. TYPICAL 1. Circlip near end of tool – Position end of tool against piston pin opening. –...
Page 145 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) Cylinder 717 and 787 RFI Engines To easily slide cylinder no. 9 over piston, use pis- ton ring compressor (P/N 290 876 979). 1. Slide this edge F01D10A NOTE: Ring compressor will not fit on oversize When reassembling cylinders to crankcase, it is parts.
Page 146 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) F01D45A 1. Dowels 717 ENGINES 1. Aligning cylinders using exhaust manifold To easily slide cylinder block over pistons, use ring compressor (P/N 290 876 965). 787 RFI Engines The exhaust manifold is used to align cylinders. 1.
Page 147 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) Install and torque screws to 40 N•m (30 lbf•ft) in the indicated order. Refer to the following illustra- tion. 787 RFI Engines Prior installation, apply Molykote 111 below screw All Engines head and Loctite 243 (blue) on screw threads. Cylinder Head Install M10 x 105 screws on exhaust side and the M10 x 73.5 on opposite side.
Page 148: Adjustment
Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) ADJUSTMENT Apply Molykote 111 on threads of cylinder head bolts no. 14. RAVE Valve Torque bolts to 20 N•m (15 lbf•ft) as per following 787 RFI Engines sequence in the next illustration. Repeat the torquing sequence by retightening to 40 N•m Turn the red plastic knob no.
Page 149 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) All Engines except 947 DI – Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge. 1. Graduated burette (0 - 50 cc) – Open burette valve to fill its tip. Add liquid in F01D2IA burette until level reaches 0 cc.
Page 150 Section 04 ENGINE (2-STROKE) Subsection 04 (TOP END) Compare the obtained value with the table below. The volume should be within the allowable range. If the volume of the combustion chamber is not within specifications, change cylinder base gasket thickness as follow. A higher volume dictates a thinner gasket.
Page 151: Bottom End
Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) BOTTOM END 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 152 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 153 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 947 DI Engines 15 17 XP DI only smr2004-Complete Line Up www.SeaDooManuals.net...
Page 154: Disassembly
Section 04 ENGINE (2-STROKE) Subsection 05 (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 155 Section 04 ENGINE (2-STROKE) Subsection 05 (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 XP DI Models the PTO flywheel extractor.
Page 156 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) Loosen bolt no. 22 retaining the PTO flywheel to the crankshaft using a suitable socket and breaker bar. 1. Cover 2. Allen screw F06D38A Remove starter drive cover no. 25 and spring 1.
Page 157 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) – magneto flywheel, refer to MAGNETO SYS- 947 DI Engines Place engine upright on crankcase magneto side. – magneto housing (except 947 DI engines) Loosen crankcase screws. – starter – rotary valve cover and valve (except 947 DI en- gines) –...
Page 158 Section 04 ENGINE (2-STROKE) Subsection 05 (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 159 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 947 DI ENGINES 1. Puller (P/N 420 877 635) 2. Protective cap (P/N 290 877 414) 3. Distance ring (P/N 420 876 56) 4. Ring (P/N 420 977 480) 5. Ring halves (P/N 420 876 330) 6.
Page 160 Section 04 ENGINE (2-STROKE) Subsection 05 (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 161: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) Clean all metal components in a solvent. Crankcase mating surfaces are best cleaned us- ing a combination of the chisel gasket remover (P/N 413 708 500) and a brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch).
Page 162: Inspection
Section 04 ENGINE (2-STROKE) Subsection 05 (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 the 787 RFI and 947 DI engines).
Page 163 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 1. Connecting rod journal alignment here Such misalignment may make it difficult to manu- ally turn 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 F01D4IA disaligned crankshaft.
Page 164 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 1. Ruler must be aligned with edge of connecting rod here 1. Measuring MAG side deflection in crankcase 2. Align ruler here Crankshaft Deflection Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated. All Models MEASUREMENT MAG SIDE...
Page 165 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe. Connecting Rod Big End Axial Play CONNECTING ROD BIG END AXIAL PLAY NEW PARTS WEAR MODEL (min.) (max.) LIMIT 0.311 mm 0.677 mm 1.2 mm engines...
Page 166: Assembly
Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) Air Compressor Refer to ENGINE MANAGEMENT for components inspection. However, if you find aluminum dust or debris in this area, they may have flowed to- ward the injection oil reservoir. In this case, the oil reservoir and lines must be flushed and the fil- ter replaced.
Page 167 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) F01D1YA F00D0MA TYPICAL 1. Keyway 1. Distance gauge 2. Long flange toward the crankshaft counterweight 2. Outer bearing Crankshaft Seal Distance Ring All Models When installing the distance ring no. 12, make When installing seal assembly no.
Page 168 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 947 DI Engines Proceed as follows to check if the gear no. 14 is properly positioned on the counterbalance shaft: Seals are positioned with the outer lip in the – Temporarily install the counterbalance shaft in crankcase recess.
Page 169 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) When installing seals no. 17, apply a light coat of Molykote 111 on seal lips. Prior to installation, place bearings no. 15 into a container filled with oil, previously heated to 75°C (167°F).
Page 170 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) NOTE: It is recommended to apply this specific sealant as described here to get an uniform appli- cation without lumps. If you do not use the roller method, you may use your finger to uniformly dis- tribute the sealant (unlike the Drei Bond sealing compound, using a finger will not affect the adhe- sion).
Page 171 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) F00D0QA Do not apply in excess as it will spread out inside 1. Hollow side facing bearing crankcase. Crankcase Screws CAUTION: If sealant spreads out inside air com- pressor area, it could plug the compressor lu- 717 Engines brication nipple and serious compressor dam- Apply Loctite 518 on screw threads and Molykote...
Page 172 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 787 RFI Engines Apply Loctite 518 on screw threads and Molykote 111 below head screws. Torque crankcase screws to 12 N•m (106 lbf•in) as per following sequence. Repeat procedure, retightening all screws to 24 N•m (17 lbf•ft). As a final step, torque only the M10 x 73.5 bolts to 40 N•m (30 lbf•ft) as per following sequence.
Page 173 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) Stud 717 and 787 Engines 717 Engines Apply Loctite anti-seize lubricant (P/N 293 800 070) to crankshaft threads. At assembly in crankcase, apply Loctite 518 on threads of studs no. 10. Torque to 10 N•m Using the same tools as for disassembly proce- (89 lbf•in).
Page 174 Section 04 ENGINE (2-STROKE) Subsection 05 (BOTTOM END) 947 DI Engines Add 40 mL (1.35 oz) of Sea-Doo synthetic jet pump oil (P/N 293 600 011) or standard gear oil through crankcase ventilation nipple. 1. Crankcase ventilation nipple Add approximately 10 mL (.3 oz) of injection oil in bottom of crankcase for each cylinder.
Page 175: Rotary Valve
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) ROTARY VALVE 717 and 787 RFI Engines 787 RFI engines 717 engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 176: General
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) GENERAL The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from watercraft. However engine must be removed from water- craft to work on rotary valve shaft/components.
Page 177: Disassembly
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) Rotary Valve Shaft Gear Backlash Reinstall cover in place WITHOUT its O-ring and torque screws to 20 N•m (15 lbf•ft). Remove PTO flywheel guard. Remove cover then clean and measure com- Remove spark plugs, rotary valve cover and valve. pressed soldering wire thickness, it must be Manually feel backlash at one position, then turn within the specified tolerance 0.30 ±...
Page 178 Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) F01D23B PULLER (P/N 290 876 488) Place puller over rotary valve shaft end and screw 1. Compress seat on puller bolt into shaft. While retaining bolt with 2. Remove circlips a wrench, turn puller nut CLOCKWISE until shaft Shaft Bearing comes out.
Page 179: Cleaning
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) CLEANING Discard all seals and O-rings. Clean all metal components in a solvent. Clean oil passages and make sure they are not clogged. Clean rotary valve shaft and inside of distance sleeve no. 14. INSPECTION Rotary Valve Cover 1.
Page 180: Assembly
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) 1. Shield side (toward gear) Push bearing until it stops on its seat. 1. Rotary valve shaft 2. End bearing in place Deflection must not exceed 0.08 mm (.003 in). Replace shaft as necessary. ASSEMBLY Assembly is essentially the reverse of disassem- bly procedures.
Page 181 Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) A00C0YA 1. Pusher Push shaft until its stops on bearing seat. 1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950 Install washer no. 15, snap ring no. 7 and slide distance sleeve no. 14 on shaft. 1.
Page 182 Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) F01D8OA 717 and 787 RFI Engines Snap Ring Position snap ring no. 4 so that its sharp edge faces outwards. Rotary Valve The rotary valve no. 13 controls the opening and closing of the inlet ports. Therefore its efficiency will depend on the precision of its installation.
Page 183 Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 184: Rotary Valve Timing
Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) ROTARY VALVE TIMING CAUTION: Never use the ridge molded in crank 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 185 Section 04 ENGINE (2-STROKE) Subsection 06 (ROTARY VALVE) 65° F01D3EB CLOSING MARK Step 1: Top of MAG inlet port. Align 360 ° line of degree wheel Step 2: Find 65 ° on outer scale of degree wheel and mark here –...
Page 186: Exhaust System
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) EXHAUST SYSTEM 717 Engines (GTI and GTI LE models) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 187 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 787 RFI Engines (GTI RFI, GTI LE RFI models) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 188 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 947 DI Engines (XP DI models) 12-13 16 22 smr2004-Complete Line Up www.SeaDooManuals.net...
Page 189: Removal
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) REMOVAL All Models except XP DI Remove seat(s). Remove rear vent hose support from body open- ing. Remove seat support (all models except XP DI). TYPICAL 1. Bleed hose removed 2. Injection hose removed 3.
Page 190 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) F06D14A 1. Loosen clamp 1. Water return hose Remove screws no. 7 and washers no. 9 at tuned 2. Disconnect small hose from water outlet fitting pipe head flange. at the tuned pipe head no. 10. Remove screw no.
Page 191 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 3. Disconnect the water injection hose at tuned pipe head no. 10. F06D14A TYPICAL 1. Loosen clamp F06E0AA 6. Loosen and remove clamp no. 4 retaining 1. Water injection hose tuned pipe head no. 10 to tuned pipe cone no. 5. 4.
Page 192 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) F06D1UA 1. Loosen Allen screw 1. Remove bolt 8. Remove external seal. 11. Remove tuned pipe head no. 10. 9. Loosen Allen screws no. 7 and nut no. 8 at 12. Loosen bolt no. 6 of tuned pipe cone beside tuned pipe flange.
Page 193 (P/N 529 035 505). Remove 8 Allen screws no. 12 and lock washers no. 13 then withdraw exhaust manifold. Resonators GTI and GTI LE Models Remove vent tube support. Upper Type Resonators Detach resonator from body. Loosen clamps and disconnect hoses. Withdraw resonator from watercraft.
Page 194 2. Upper type resonator 3. Muffler holding strap Footwell Type Resonators NOTE: Some models are equipped with both types of resonators (GTI RFI, GTI LE RFI). TYPICAL 1. Water supply hose 2. To injection fitting on tuned pipe Disconnect retaining strap no. 2 of muffler.
Page 195: Tuned Pipe Repair
Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) Tip seat forward. Unfasten fuel tank straps. Move fuel tank forward as much as possible. Push muffler forward, rotate and pull out rear- ward. All Models Pull muffler no. 11 out of bilge. TUNED PIPE REPAIR This procedure is given to repair tuned pipe cracks using T.I.G.
Page 196 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 947 DI Engines Apply Molykote 111 on threads of Allen screws no. 12. Muffler Install and hand tighten Allen screws no. 12 as per XP DI Models following picture. At muffler reinstallation, ensure to properly posi- tion fuel tank paddings so that fuel tank is centered relatively to drive shaft.
Page 197 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) Push cone no. 5 until it touches tuned pipe, then tighten exhaust clamp no. 4 and torque to 4 N•m (35 lbf•in). CAUTION: There must be no gap between tuned pipe cone and tuned pipe head. NOTE: Exhaust clamp nuts should be tightened al- ternately to assure no leakage and to obtain spec- ified torque.
Page 198 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) Press the pipe support on the engine before torquing the pipe support bolt. smr2004-Complete Line Up www.SeaDooManuals.net...
Page 199 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) 947 Engines NOTE: Apply Loctite 243 (P/N 293 800 060) on stud nut before tightening to 2.5 N•m (22 lbf•in). CAUTION: Torque wrench tightening specifi- Use special tool (P/N 529 035 505). cations must be strictly adhered to.
Page 200 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 201 Section 04 ENGINE (2-STROKE) Subsection 07 (EXHAUST SYSTEM) Install exhaust hose. F06D14A 1. Torque clamp to 4 N•m (35 lbf• in ) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 202: Engine (4-Tec)
Section 05 ENGINE (4-TEC) Subsection 01 (LEAK TEST) LEAK TEST LEAK TEST PROCEDURE The procedure has to be done when engine op- erating temperature of approx. 70°C (158°F) is reached. WARNING Prevent burning yourself due to handling on the hot engine. PREPARATION Remove: –...
Page 203: Procedure
Section 05 ENGINE (4-TEC) Subsection 01 (LEAK TEST) 1. Valve cover 1. Intake rocker arms 2. Valve cover screw As the engine is turned over, observe the move- PROCEDURE ment of intake rocker arm of the cylinder to be checked. After it completes the cycle and the in- The following procedure has to be performed for take valve closes, observe the piston.
Page 204: Installation
Section 05 ENGINE (4-TEC) Subsection 01 (LEAK TEST) INSTALLATION NOTE: For installation use the torque values and Loctite products from the exploded views (refer to proper engine subsection). For installation, reverse the preparation proce- dure. NOTE: Prior to inserting the ignition coil in its lo- cation, apply some Molykote 111 (P/N 413 707 000) around the seal area that touches the spark plug hole.
Page 205: Leak Test Procedure For Intercooler
Section 05 ENGINE (4-TEC) Subsection 01 (LEAK TEST) 1. Weep hole – coolant escaping from coolant pump housing means damaged gasket(s) and/or loosened screws (refer to COOLING SYSTEM). NOTE: For all the checkpoints mentioned above see the appropriate engine section to diagnose and repair the engine.
Page 206: Intake System
Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) INTAKE SYSTEM 4-TEC Engines TYPICAL smr2004-Complete Line Up www.SeaDooManuals.net...
Page 207 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 4-TEC Supercharged Engines — Supercharger smr2004-Complete Line Up www.SeaDooManuals.net...
Page 208 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 4-TEC Supercharged Engines — Intake Manifold and Throttle Body smr2004-Complete Line Up www.SeaDooManuals.net...
Page 209 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 4-TEC Supercharged Intercooled Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 210: Inspection
Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) INSPECTION Otherwise, remove intercooler from manifold to spray soapy water on it. If air bubbles are present, Intercooler Leak Test replace the intercooler. Refer to procedures far- ther in this section. 4-TEC Supercharged Intercooled Engines Properly reinstall removed parts.
Page 211 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) Remove air intake hose from supercharger ass'y. 1. Torque wrench Supercharger should start to turn at a torque be- tween 7 to 12 N•m (62 to 106 lbf•in). 1. Supercharger ass'y 2. Air intake hose If the torque is less, remove supercharger ass'y from engine (refer to SUPERCHARGER RE- Remove valve cover and install camshaft locking...
Page 212: Removal
Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) Check the wear limit on drive gear, lock wash- Put spring washer package together as it is as- er and driven plate on supercharger shaft. Check sembled on the supercharger shaft. Measure the drive gear for cracks.
Page 213 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Lift lock tab Step 1: Push tab (each side) to release Step 2: Pull tank out Then proceed with the tab under the tube. Refer to the following illustration to see it. Remove vent tube support.
Page 214 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) WARNING Always disconnect battery cables exactly in the specified order, BLACK negative cable first then the RED positive battery cable last. Disconnect fuel hose connector at fuel rail. 4-TEC SUPERCHARGED ENGINES 1. Cut locking ties to release harness coming from vehicle 4-TEC NA (Naturally Aspirated) Engines Unplug connectors from ignition coils, TOPS valve, OSPS, TPS, idle bypass valve, engine con-...
Page 215 Section 05 ENGINE (4-TEC) Subsection 02 (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, TOPS hose. Disconnect hose from TOPS valve magneto, OPS and EGTS.
Page 216 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) TYPICAL 1. CAPS connector 1. Oil filter housing 2. OPS Unplug the “B” connector from the ECM. TYPICAL 1. EGTS connector NOTE: On Supercharged models, a long screw- 1. Push this end to unlock driver may be used to unlock the connector from the sensor.
Page 217 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) Pull the connectors for KS, CPS and magne- 4-TEC Supercharged Intercooled Engines to out of the ECM support. Refer to WIRING Remove the hoses connected to the intercooler. DIAGRAMS section. Disconnect KS and CPS connectors.
Page 218 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) TYPICAL 1. Mounting brackets NOTE: The flame arrester and the intercooler (if so 4-TEC NA Engines equipped) in the intake manifold are maintenance Detach throttle cable end from throttle body. free. Supercharger 4-TEC Supercharged Engines CAUTION: Be scrupulous when working on supercharger parts.
Page 219: Disassembly
Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Upper retaining screws DISASSEMBLY 1. Inlet hose 2. Outlet hose Air Intake Manifold Remove retaining screws and pull out the super- 4-TEC Supercharged Intercooled Engines charger ass'y. Intercooler Remove collar from intercooler. 1.
Page 220 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Intercooler 2. O-Ring 3. Collar PLASTIC HAMMER Supercharger 4-TEC Supercharged Engines NOTE: The cap nut on the supercharger shaft has LH threads. Take apart supercharger housing. Loosen cap nut (turn clockwise) on supercharger shaft turbine side while holding shaft with a retain- ing key (P/N 529 035 949).
Page 221 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Nut 2. L-ring 1. Washer 3. Spring washers 2. Turhine 4. Lock washer 3. O-ring 5. Ceramic washers 4. Step collar 6. Drive gear 7. Needle bearings Loosen nut on supercharger shaft engine side while holding shaft with a retaining key (P/N 529 Carefully push out supercharger shaft towards en- 035 949).
Page 222: Assembly
Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Supercharger housing half (engine side) 2. Bearing pusher ASSEMBLY All 4-TEC Engines 1. Supercharger shaft Assembly is essentially the reverse of removal 2. Ball bearing 3. Retaining key procedures. However pay particular attention to the following.
Page 223 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Outlet hose distance A. 3 - 7 mm (0.12 - 0.27 in) 1. Intake manifold flange Supercharger 2. Nipple parallel with manifold flange 4-TEC Supercharged Engines NOTE: If intercooler is hard to push in, a clamp can CAUTION: Every time when supercharger shaft be used to press intercooler in.
Page 224 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) 1. Retaining disc 2. 4-pin socket To press supercharger shaft in housing half (en- 1. Supercharger shaft gine side), properly support bearing, using support 2. Ball bearing plate (P/N 529 035 947) and bearing support/push- 3.
Page 225 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) Apply engine oil on supercharger shaft. Press shaft with distance sleeve together in supercharg- er housing half. 1. Step collar 2. O-ring 3. Supercharger impeller 4. Washer 5. Cap nut Complete installation of supercharger shaft, en- 1.
Page 226: Installation
Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) NOTE: On the RXP 4-TEC supercharged inter- Hold the lock washer of the supercharger shaft cooled engine, the ceramic washers differ in their (engine side) using the retaining key (P/N 529 035 inner diameter.
Page 227 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) Ensure to properly route and resecure wiring har- ness with locking ties. INTAKE MANIFOLD WARNING 1. Gaskets Always check O-ring for damage such as First, position intake manifold on front mounting deformation at reinstallation. Replace the bracket then push manifold toward engine to then O-ring if it is damaged.
Page 228 Section 05 ENGINE (4-TEC) Subsection 02 (INTAKE SYSTEM) Ensure to install the tool perpendicularly (90°) to torque wrench to apply the proper torque to the screw. 4-TEC SUPERCHARGED ENGINES 1. Cable position in bracket 2. Cable barrel position in cam 1.
Page 229: Exhaust System
Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM smr2004-Complete Line Up www.SeaDooManuals.net...
Page 230: Exhaust Pipe
Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) EXHAUST PIPE Removal WARNING Certain components in the engine compart- ment may be very hot. Direct contact may result in skin burn. Let exhaust system cool down prior to removing parts. GTX 4-TEC Series Remove seat and seat extension.
Page 231 Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) Move muffler no. 4 backward enough to allow the exhaust pipe to be pulled out. Inspection Inspect exhaust pipe condition paying attention for cracks or other damage. Check joints, coupling ar- eas, heat shield and hoses. Replace any defective part.
Page 232 Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) 1. Exhaust pipe step 2. Exhaust hose 1. Engine manifold 3. Exhaust hose clamp 4 - 5 mm (5/32 - 3/16 in) apart 2. Exhaust pipe flange Finalize alignment by rotating (axially) and mov- CAUTION: Exhaust pipe alignment with the ing (longitudinally) the muffler so that the exhaust manifold is critical to the bellows life.
Page 233: Exhaust Manifold
Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) Remove the exhaust clamp no. 4 and detach the muffler from its support. Move the muffler no. 6 rearwards to separate the exhaust pipe from the manifold. See above in EXHAUST PIPE. Disconnect the cooling system supply hose no.
Page 234: Muffler
Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) Inspect plane surfaces for warpage. Small defor- Disconnect the temperature sensor connector. mation can be corrected by grinding surface with Disconnect the outlet hose no. 5. a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper.
Page 235: Exhaust Outlet
Section 05 ENGINE (4-TEC) Subsection 03 (EXHAUST SYSTEM) TYPICAL Inspection Inspect parts condition paying attention for defor- mation, cracks or other damage. Check hoses. Replace any defective part. Installation Installation is the reverse of the removal proce- dures. TYPICAL 1. Exhaust outlet nut For resonator installation, remove hose no.
Page 236: Removal And Installation
Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION GENERAL All Models Engine removal is necessary to repair BOTTOM END. ENGINE REMOVAL Use the VCK (Vehicle Communication Kit) (P/N 529 035 981) and release the fuel pressure in the fuel system.
Page 237 Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) O.P.A.S. To disconnect O.P.A.S., refer to STEERING sec- tion. Jet Pump Removal To withdraw jet pump, refer to PROPULSION sec- tion. Drive System To withdraw drive shaft, refer to PROPULSION section. Cooling System Drain cooling system, refer to COOLING SYSTEM section.
Page 238 Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) FRONT SUPPORT 1. Remove screw 1. Detach hose 2. Disconnect cable Disconnect fuel rail supply line. Disconnect water inlet hose coming from jet pump connected to the intercooler. REAR SUPPORT 1. Remove screws Lifting Engine Using a chain block, a hoist or other suitable equip- ment, slightly lift engine to ease the remaining...
Page 239 Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) TYPICAL 1. Lifting brackets 1. Lift steel rope/chain here to rotate engine 2. Usual lifting brackets RXP 4-TEC Models Slightly move engine rearward to take advantage All Models of the larger opening. Removal of Remaining Components The engine have to be hooked-up at an additional location.
Page 240: Cleaning
Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) Ensure contact surface is perfectly clean then re- connect grounds wires/cable to engine. Engine Support Do not apply threadlocker to engine support screws and do not torque yet. Engine/Jet Pump Alignment Alignment is necessary to eliminate possible vi- bration and/or damage to components.
Page 241 Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) To verify alignment proceed as follows: – Secure plate and support to hull with four nuts. TYPICAL 1. Engine alignment adapter 2. Alignment shaft – Install adapter (P/N 529 035 719 ) in engine PTO If the alignment is incorrect loosen engine sup- housing.
Page 242 Section 05 ENGINE (4-TEC) Subsection 04 (REMOVAL AND INSTALLATION) 1. Torque to 25 N•m(18 lbf•ft) Properly align exhaust pipe. Refer to EXHAUST SYSTEM in ENGINE section. Final Inspection Check throttle cable condition and lubricate it with BOMBARDIER LUBE lubricant. 1. Torque to 25 N•m (18 lbf•ft) 2.
Page 243: Pto Housing/Magneto
Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) PTO HOUSING/MAGNETO 4-TEC Supercharged only smr2004-Complete Line Up www.SeaDooManuals.net...
Page 244: General
Section 05 ENGINE (4-TEC) Subsection 05 (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 245 Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) – slightly lift rear part of engine and safely block CAUTION: Ensure to use prying lugs to sepa- rate PTO housing to prevent damaging contact in this position. Remove rear LH side engine surface.
Page 246 Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) TYPICAL 1. Washer 2. Disc spring 3. Flange washer 4. Starter drive ass'y NOTE: When installing a new starter drive ass’y, oil the shaft and threads of the gear with engine oil. CAUTION: Ensure the starter drive gear shaft is TYPICAL well engaged in its bore.
Page 247: Pto Seal
Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) PTO SEAL Installation Reinstall removed parts in the reverse order. Inspection CAUTION: When installing PTO seal on su- Check the PTO seal no. 22 and O-rings no. 10 on percharged models make sure to position the the PTO housing.
Page 248: Stator
Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) TYPICAL Inspection TYPICAL 1. CPS screws Check if seal no. 13 is brittle, cracked or hard. 2. Holding plate 3. CPS Check coupling for worn splines. If damaged, replace faulty part. – screws no. 16 –...
Page 249: Rotor And Encoder Wheel
Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) ROTOR AND ENCODER WHEEL Installation For installation, reverse the removal procedure. Removal However, pay attention to the following. Lock crankshaft with locking tool (P/N 529 035 NOTE: There is only one position for the stator 821).
Page 250: Starter Drive Ass'y
Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) Remove: Apply Loctite 243 on threads. Torque rotor screws to 24 N•m (17 lbf•ft). – PTO housing cover – hexagonal screws no. 18. STARTER DRIVE ASS'Y Withdraw rotor no. 19, encoder wheel no. 20 and starter ring no.
Page 251: Oil Spray Nozzle
Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) Inspection CAUTION: Be sure not to forget the distance washer, disc springs and washer on the starter Check condition of the teeth, shaft, etc. and if the drive shaft when assembling. sprag clutch operates well. If damaged, replace faulty part.
Page 252 Section 05 ENGINE (4-TEC) Subsection 05 (PTO HOUSING/MAGNETO) Only use supercharger spray nozzle installer to push in the nozzle no. 23. Use retaining screw hole to ensure the exact position. 1. Spray nozzle installer 2. Screw hole for positioning smr2004-Complete Line Up www.SeaDooManuals.net...
Page 253: Lubrication System
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) LUBRICATION SYSTEM 4-TEC Supercharged only 25 26 smr2004-Complete Line Up www.SeaDooManuals.net...
Page 254 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 255: General
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) GENERAL NOTE: It is of the utmost importance to follow this procedure in order to obtain an accurate reading of Prior to changing the oil, ensure vehicle is on a the engine oil level. level surface.
Page 256: Engine Oil Pressure Test
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) To prevent the EMS to go in limp home mode (at 2500 RPM) or to generate a fault code, start en- gine, THEN ground OPS connector to engine. You may find easier on supercharged engines to remove the plug from the end of engine head.
Page 257 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) Run engine for 10 seconds at 4000 RPM and shut OIL PRESSURE it off at this RPM. This will move oil from PTO MEASURED AT CYLINDER housing to oil tank to allow maximum oil draining. HEAD LOCATION Remove oil filler cap and dipstick.
Page 258: Oil Filter
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) Oil Filling Inspection Refill engine with oil meeting the specific require- Check oil filter cover O-ring no. 4 and oil filter ments of the engine. Refer to TECHNICAL DATA. screw O-ring, change if necessary. Reinstall oil filler cap and dipstick.
Page 259: Oil Strainers
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) OIL STRAINERS The oil strainers do not need to be cleaned at every oil change. Clean them during other inspections, especially when the engine is disassembled. PTO — Oil Strainer Removal Remove: –...
Page 260 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) TYPICAL — GTX 4-TEC ENGINES RXP 4-TEC ENGINES 1. Oil strainer 1. TOPS ventilation hose – Disconnect wiring harness from TOPS valve no. 8 and OSPS no. 9. – Detach air silencer from throttle body. –...
Page 261 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) TYPICAL TYPICAL — GTX 4-TEC ENGINES 1. Oil inlet to the oil pump 1. O-ring 2. Rubber ring gasket Installation For installation, reverse the removal procedure. Position screws according to their length as shown.
Page 262: Engine Oil Pressure Regulator
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) ENGINE OIL PRESSURE REGULATOR The oil pressure regulator is located on the bottom of the PTO housing. TYPICAL — RXP 4-TEC ENGINES 1. Oil pressure regulator NOTE: The oil pressure regulator system opens when the oil pressure exceeds 400 kPa (58 PSI).
Page 263: Oil Pressure Pump
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) COMPRESSION SPRING FREE LENGTH NEW NOMINAL 60 mm (2.362 in) SERVICE LIMIT 50.3 mm (1.980 in) Replace parts if important wear or damage are present. Clean bore and threads in the PTO housing from metal shavings and other contaminations.
Page 264 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) TYPICAL CAUTION: Be careful not to damage the surface of the rotary seal bore in PTO housing cover. 1. Screws 2. Oil pump cover – oil seal no. 26. – outer oil pump rotor no. 23 1.
Page 265 Section 05 ENGINE (4-TEC) Subsection 06 (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 266: Oil Suction Pump
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) NOTE: Never use oil in the press fit area of the rotary seal. Push coolant/oil pump shaft seal in place by using thumb. 1. Oil seal guide 2. Coolant/oil pump shaft 1. Oil seal Install the new rotary seal by using the rotary seal pusher (P/N 529 035 823).
Page 267 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) WARNING Wear safety glasses and work in a well venti- lated area when working with strong chem- ical products. Also wear suitable non-ab- sorbent gloves to protect your hands. – Remove oil suction pump housing with oil sep- arator.
Page 268 Section 05 ENGINE (4-TEC) Subsection 06 (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 269: Oil Cooler
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) Check the inside of oil pump housing and its cover for scoring or other damages and replace if dam- aged. Installation For installation, reverse the removal procedure. Pay attention to the following details. TYPICAL 1.
Page 270: Oil Separator
Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) 1. O-rings Inspection If O-rings are brittle, cracked or hard, replace TYPICAL — GTX 4-TEC ENGINES them. 1. TOPS ventilation hose Clean both contact surfaces of oil cooler. Check and clean the oil inlet and outlet area for dirt and other contaminations.
Page 271 Section 05 ENGINE (4-TEC) Subsection 06 (LUBRICATION SYSTEM) WARNING Wear safety glasses and work in a well venti- lated area when working with strong chem- ical products. Also wear suitable non-ab- sorbent gloves to protect your hands. – Remove suction pump cover with oil separator ass'y.
Page 272: Cylinder Head And Valves
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) CYLINDER HEAD AND VALVES NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle. smr2004-Complete Line Up www.SeaDooManuals.net...
Page 273: General
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) GENERAL NOTE: When diagnosing an engine problem, al- ways perform a cylinder leak test. This will help pin-point a problem. Refer to the instructions in- cluded with your leak tester and LEAK TEST for procedures.
Page 274: Rocker Arm
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) 1. Valve cover screws – valve cover no. 5 and profile sealing ring no. 6. Torque screws to 10 N•m (89 lbf•in). ROCKER ARM Removal Lock crankshaft with crankshaft locking tool (P/N 529 035 821) , refer to CRANKSHAFT LOCK- ING in ENGINE BLOCK section.
Page 275 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Inspection Spark Plug Tube Check seals on spark plug tube. If seals are brittle, cracked or hard, replace spark plug tube. 1. Rocker arm shaft screws – rocker arm shaft no. 9 with rocker arm assem- 1.
Page 276 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Measure rocker arm shaft diameter. ROCKER ARM BORE DIAMETER NEW MINIMUM 19.980 mm (.7866 in) NEW MAXIMUM 19.993 mm (.7871 in) SERVICE LIMIT 19.965 mm (.7860 in) 1. Rocker arm (exhaust side) 2.
Page 277: Camshaft Timing Gear
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Then, the camshaft sprocket lines should be lined up as shown in the following illustration. – Torque screws to 20 N•m (177 lbf•in). – Finish tightening screws turning an additional 90°...
Page 278 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) – chain guide no. 12 – Allen screws no. 13 – camshaft timing gear no. 14. NOTE: Secure timing chain no. 15 with a retaining wire. Inspection Check camshaft timing gear for wear or deteriora- tion.
Page 279: Timing Chain
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) 1. Position lines TYPICAL CAUTION: Ensure to remove locking tools 1. Coolant hose when finished. 2. TOPS ventilation hose TIMING CHAIN – chain tensioner (refer to CHAIN TENSIONER REMOVAL in ENGINE BLOCK section) Refer to ENGINE BLOCK section.
Page 280: Camshaft
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) CYLINDER SCREW M11 SERVICE LIMIT 148.5 mm (5.846 in) Torque screws according to following sequence. First torque to 40 N•m (30 lbf•in). Then tighten screws turning an additional 120° ro- tation with a torque angle gauge and finish tight- ening with a 90°...
Page 281 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) CAMSHAFT LOBE - EXHAUST VALVE NEW MINIMUM 31.699 mm (1.248 in) NEW MAXIMUM 31.809 mm (1.252 in) SERVICE LIMIT 31.670 mm (1.247 in) CAMSHAFT LOBE - INTAKE VALVE NEW MINIMUM 31.480 mm (1.239 in) NEW MAXIMUM 31.590 mm (1.244 in)
Page 282: Valve Spring
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) 1. Camshaft lock position For other parts, refer to proper installation proce- dure. VALVE SPRING 1. Valve spring compressor clamp 2. Valve spring compressor cup Removal Remove: – rocker arms –...
Page 283: Valve
Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Installation For installation, reverse the removal procedure. Pay attention to the following details. Colored area of the valve spring must be placed on top. NOTE: Valve cotters must be properly engaged in valve stem grooves.
Page 284 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Remove valve stem seal no. 28 with special pliers such as Snap-on YA 8230. A. Valve stem diameter VALVE STEM DIAMETER NEW MINIMUM Exhaust 5.946 mm (.2341 in) Inspection Intake 5.961 mm (.2347 in) Valve Stem Seal NEW MAXIMUM...
Page 285 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Chase valve guide out of the cylinder head to- VALVE GUIDE DIAMETER wards combustion chamber by using a suitable NEW MINIMUM punch. Exhaust 5.994 mm (.2359 in) Intake NEW MAXIMUM Exhaust 6.018 mm (.2369 in) Intake...
Page 286 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) VALVE GUIDE PROTRUSION MINIMUM 12.4 mm (.4882 in) MAXIMUM 12.8 mm (.5039 in) NOTE: For lubrication of the reamer use only cut- ting oil. Turn the reamer only forward, in cutting direction, never backward.
Page 287 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) VALVE SEAT CONTACT WIDTH 1.25 to 1.55 mm Exhaust (.049 to.061 in) 1.10 to 1.30 mm Intake (.043 to.051 in) SERVICE LIMIT Exhaust 2 mm (.078 in) Intake 1.8 mm (.07 in) If valve seat contact width is too wide or has dark spots, replace the cylinder head.
Page 288 Section 05 ENGINE (4-TEC) Subsection 07 (CYLINDER HEAD AND VALVES) Installation After spring is installed, ensure it is properly locked by tapping on valve stem end with a soft For installation, reverse the removal procedure. hammer so that valve opens and closes a few Pay attention to the following details.
Page 289: Engine Block
Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) ENGINE BLOCK smr2004-Complete Line Up www.SeaDooManuals.net...
Page 290 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 291: General
Section 05 ENGINE (4-TEC) Subsection 08 (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 292 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) NOTE: Before removing the connecting rod bear- ing caps, mark them to remember the right posi- tion when reassembling. ENGINE UPSIDE DOWN 1. Oil tank plug screw with O-ring – engine block screws no. 3 and no. 7 1.
Page 293 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) 1. Crankshaft 1. Crankshaft 2. Feeler gauge Inspection Replace crankshaft if the gears are worn or other- CONNECTING ROD BIG END mm (in) wise damaged. NEW MINIMUM 0.150 (.06) NEW MAXIMUM 0.302 (.01) SERVICE LIMIT 0.5 (.02) Crankshaft Radial Play...
Page 294 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) NOTE: Before installing the crankshaft, make CRANKSHAFT JOURNAL DIAMETER mm (in) sure that the timing chain is on the crankshaft and NEW MINIMUM 49.91 (1.9650) the chain guide has been installed first. Those parts cannot be installed when the crankshaft is NEW MAXIMUM 50.01 (1.9689)
Page 295: Timing Chain
Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) THRUST WASHER INSERT DIRECTION 1. Thrust washer CAUTION: Thrust washers have to be flush 1. O-ring 2. Crankshaft cover with the engine block sealing surface. CAUTION: Install crankshaft locking tool (P/N 529 035 821) right away to position crank- shaft at TDC before installing the camshaft and rockers (refer to CYLINDER HEAD AND VALVES).
Page 296: Chain Tensioner
Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) – chain tensioner no. 20. 1. Timing chain If chain is excessively worn or damaged, replace it as a set (camshaft timing gear and timing chain). Removal Remove: – engine oil (refer to OIL CHANGE in LUBRICA- TION section) –...
Page 297 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) – oil suction pump with oil separator ass'y (re- fer to SUCTION PUMP REMOVAL in LUBRICA- TION section) – engine mounting brackets – oil reservoir plug screws no. 1 with O-ring no. 2 1.
Page 298 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) BALANCER SHAFT SEAT DIAMETER mm (in) NEW MINIMUM 31.984 (1.2592) NEW MAXIMUM 32.000 (1.2598) SERVICE LIMIT 31.960 (1.2583) BALANCER SHAFT SEAT RADIAL CLEARANCE mm (in) SERVICE LIMIT 0.07 (.0028) Installation For installation, reverse the removal procedure. Pay attention to following detail.
Page 299: Engine Block
Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) – cylinder head (refer to CYLINDER HEAD RE- MOVAL in CYLINDER HEAD AND VALVES sec- tion) – PTO housing (refer to PTO HOUSING RE- MOVAL in PTO HOUSING/MAGNETO section) – starter gear (refer to STARTER GEAR RE- MOVAL in PTO HOUSING/MAGNETO section) –...
Page 300 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) Cylinder Taper Measure cylinder bore and if it is out of specifi- cations, rehone cylinder sleeve and replace piston ass'y with first oversize. NOTE: It is not necessary to have all cylinders rehoned if they are not all out of specification.
Page 301 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) CRANKSHAFT BUSHING INSIDE DIAMETER mm (in) SERVICE LIMIT 50.1 (1.9724) A. Perpendicular to crankshaft axis B. Parallel to crankshaft axis CYLINDER OUT OF ROUND mm (in) NEW MAXIMUM 0.008 (.0003) SERVICE LIMIT 0.015 (.0006) ENGINE UPSIDE DOWN 1.
Page 302 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) Check if ball inside moves freely in the banjo Bushings have to be flush with the engine block screw. Clean Nozzle and banjo screw from dirt split surface and their protrusions have to fit in the and debris.
Page 303 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) NOTE: It is recommended to apply this specific sealant as described here to get an uniform appli- cation without lumps. If you do not use the roller method, you may use your finger to uniformly dis- tribute the sealant (unlike the Drei Bond sealing compound, using a finger will not affect the adhe- sion).
Page 304: Piston/Connecting Rod
Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) CRANKSHAFT AXIAL CLEARANCE mm (in) NEW MINIMUM 0.08 (.003) NEW MAXIMUM 0.22 (.009) SERVICE LIMIT 0.35 (.014) 1. O-ring 2. Crankshaft cover CAUTION: Install crankshaft locking tool (P/N 529 035 821) right away to position crank- shaft at TDC before installing the camshaft and rockers (refer to CYLINDER HEAD AND VALVE).
Page 305 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) 1. Piston 1. Connecting rod screws 2. Piston pin 3. Circlip NOTE: Before removing the connecting rod bear- ing caps, mark them to remember the right posi- Detach piston no. 10 from connecting rod. tion when reassembling.
Page 306 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) A. Piston pin diameter in the area of the bushing CONNECTING ROD SMALL END DIAMETER mm (in) NEW MINIMUM 23.01 (.9059) NEW MAXIMUM 23.02 (.9063) SERVICE LIMIT 23.07 (.908) A. Connecting rod big end bushing PISTON PIN DIAMETER mm (in) CONNECTING ROD BIG END DIAMETER mm (in) NEW MINIMUM...
Page 307 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) 1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge 1. Measuring perpendicularly (90°) to piston pin axis A. 18 mm (.709 in) The measured dimension should be as described in the subsequent table.
Page 308 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) If clearance exceeds specified tolerance, rehone Replace connecting rod if diameter of connect- cylinder sleeve and replace piston ass'y by an ing rod small end is out of specifications. Refer oversize one. to CRANKSHAFT AND BALANCER SHAFT for re- moval procedure of connecting rod.
Page 309 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) CAUTION: Install piston with punched arrow toward exhaust side. 1. Half bushing of connecting rod big end 2. Split surface of the connecting rod 3. Protrusion of bushing in line with connecting rod groove Torque NEW connecting rod screws no.
Page 310: Piston Rings
Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) PISTON RINGS RING/PISTON GROOVE CLEARANCE mm (in) Removal NEW MINIMUM Remove piston ass'y as described above. RECTANGULAR 0.025 (.001) Remove rings. TAPER-FACE 0.015 (.0006) Inspection OIL SCRAPER RING 0.020 (.0008) Ring/Piston Groove Clearance NEW MAXIMUM Using a feeler gauge measure each ring/piston RECTANGULAR...
Page 311 Section 05 ENGINE (4-TEC) Subsection 08 (ENGINE BLOCK) Ring End Gap NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. RING END GAP mm (in) Check that rings rotate smoothly after installation. NEW MINIMUM Space the piston ring end gaps 120°...
Page 312: Engine Management (Rfi)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (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 313: Air Induction
Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (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 314: Fuel Pump Module
Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) F07F0KA 1. Fuel pump assembly 2. External fuel filter F07F09A FUEL PUMP ASSEMBLY FUEL INJECTORS The injectors inject a metered quantity of fuel from the fuel rail into the cylinder rear transfer port in ac- cordance with the signal from the Electronic Con- trol Unit (ECU).
Page 315: Mpem (Multi-Purpose Electronic Module)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) Diagnostic Mode The ECU is able to detect malfunctions in the sen- sor network. The malfunction is recorded in the memory of the ECU. The memory of the ECU can be checked using VCK (Vehicle Communication Kit) (P/N 529 035 981) or MPEM programmer tool.
Page 316 Section 06 ENGINE MANAGEMENT (RFI) Subsection 01 (OVERVIEW) PARAMETERS SENSORS FUEL DELIVERY SIGNAL MANAGEMENT smr2004-Complete Line Up www.SeaDooManuals.net...
Page 317: Diagnostic Procedures
Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES ) DIAGNOSTIC PROCEDURES INTRODUCTION The ECU is able to detect malfunctions in the sen- sor network. The malfunction is recorded in the memory of the ECU as fault codes. SELF-DIAGNOSTIC MODE When installing the safety lanyard cap on the DESS post, an audible signal should be heard.
Page 318 Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES ) Diagnostic Option Example Using The programmer will offer PRESS ANY KEY. If MPEM Programmer there is more than 1 fault in the ECU memory, the next fault code will be displayed. Turn on the programmer and enter your password.
Page 319: Fault Code Tables
Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES ) FAULT CODE TABLES ECU Faults FAULT CODE FAULT DETECTION TYPE OF FAULT MPEM programmer B.U.D.S. No fault detected FF FF 88 N.A. • No defect Electronic Control Unit FF FF 00 P 0604 •...
Page 320: Output Signal Faults
Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES ) Output Signal Faults FAULT CODE FAULT DETECTION TYPE OF FAULT MPEM programmer B.U.D.S. Injector 1 04 E1 1C P 0262 • Short circuit to battery 04 E1 1D P 0261 •...
Page 321: Component Inspection
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) COMPONENT INSPECTION GENERAL WARNING Ensure to verify fuel line connections for WARNING damage and that NO fuel line is disconnected The fuel system of a fuel injection system prior to installing the safety lanyard on the holds much more pressure than on a car- DESS post.
Page 322 Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) Resistance Measurement WARNING When measuring the resistance with an ohmme- All electrical actuators (injectors, fuel pump, ter, all values are given for a temperature of 20°C RAVE solenoid, ignition coil and starter sole- (69°F).
Page 323: Air Induction System
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) Also remember this validates the operation of the sensor at ambient temperature. It does not val- idate the over temperature functionality. To test it, the sensor could be removed from the engine/ muffler and heated with a heat gun while it is still connected to the harness to see if the MPEM will detect the high temperature condition and gener-...
Page 324: Fuel Injector
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) Install a fuel pressure gauge (P/N 529 035 591) to the quick connect fitting of the fuel hose. F07F0CA FUEL PRESSURE GAUGE (P/N 529 035 591) 1. Inlet side 2. Filter Install the safety lanyard cap on the switch to ac- 3.
Page 325: Leak Test (Supply And Ventilation Circuits)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) 1. Fuel injectors 2. Fuel rail 3. Injector nozzles The resistance should be between 2.3 and 2.5 at temperature of 20°C (68°F). If not within specification, replace the fuel injec- tor(s).
Page 326: Electronic Management
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) ELECTRONIC MANAGEMENT THROTTLE POSITION SENSOR (TPS) Check the resistance value of the throttle position sensor. 1. Quick connect fitting 2. Fuel rail Install fuel pressure gauge (P/N 529 035 591) be- tween fuel rail and fuel hose from fuel tank.
Page 327: Crankshaft Position Sensor (Cps)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) CRANKSHAFT POSITION SENSOR (CPS) Check the resistance of the crankshaft position sensor. If resistance is below specifications, replace the throttle position sensor (TPS). F07H0CA If resistance is above specifications, disconnect 1.
Page 328: Air Temperature Sensor (Ats)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (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 329: Air Pressure Sensor (Aps)
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) Remove the TAN/ORANGE wire from the #12 po- sition on the AMP plug connector, install a test connector (a female connector with about 25 mm (1 in) of wire) then reconnect the AMP plug con- nector.
Page 330: Rave Solenoid
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) RAVE SOLENOID The resistance should be between 3.4 k 8.2 k . Check also the resistance between terminal 2 RAVE SOLENOID (BLACK/BLUE wire) and terminal 1 (PURPLE/ BLUE wire) of the plug connector. Disconnect the AMP plug connector #4 from the MPEM module.
Page 331: Rfi Sensors Resistance Values
Section 06 ENGINE MANAGEMENT (RFI) Subsection 03 (COMPONENT INSPECTION ) RFI SENSORS RESISTANCE VALUES TERMINAL RESISTANCE COMPONENT WIRE COLOR VOLTS NUMBER VALUE 5 Vdc between 1 and 2 PU/BL and BK/BL 2.4 k - 8.2 k ohms PU/BL and BK/BL Air pressure sensor 9 and 2 WH/BL and BK/BL...
Page 332: Troubleshooting Summary
Section 06 ENGINE MANAGEMENT (RFI) Subsection 04 (TROUBLESHOOTING SUMMARY) TROUBLESHOOTING SUMMARY ENGINE DOES NOT START ECU FAULT CODES If the engine does not start, the following items Fault codes in the ECU memory will identify poten- should be verified in this order: tial problems with the RFI system.
Page 333: Engine Cannot Reach Maximum Revolutions
Section 06 ENGINE MANAGEMENT (RFI) Subsection 04 (TROUBLESHOOTING SUMMARY) ENGINE CANNOT REACH MAXIMUM REVOLUTIONS Check battery voltage. When voltage is too low, the MPEM limits the engine revolutions. Recharge or replace battery. The RAVE system is not functioning properly. The sliding valves do not open.
Page 334: Adjustment
Section 06 ENGINE MANAGEMENT (RFI) Subsection 05 (ADJUSTMENT) ADJUSTMENT THROTTLE CABLE Using VCK ADJUSTMENT Use the VCK (Vehicle Communication Kit) (P/N 295 035 981) with B.U.D.S. software. Look under the Fully depress throttle lever. Lever must touch SETTING section to perform the Closed TPS re- handlebar grip without causing strain to cable or setting.
Page 335: Removal And Installation
Section 06 ENGINE MANAGEMENT (RFI) Subsection 06 (REMOVAL AND INSTALLATION ) REMOVAL AND INSTALLATION MPEM/ECU At installation, apply Loctite 518 on threads of the WTS. NOTE: When MPEM or ECU are replaced, the safety lanyard(s), the TPS closed position and the CRANKSHAFT POSITION ignition timing setting must be reprogrammed/re- SENSOR (CPS)
Page 336: Regulator
Section 06 ENGINE MANAGEMENT (RFI) Subsection 06 (REMOVAL AND INSTALLATION ) 1. Loosen nuts CAUTION: While pulling out the fuel pump, pay attention to fuel sensor float arm. Float arm 1. Fuel filter 2. Inner plastic ring can get stuck and bend which can reduce the fuel sensor capabilities.
Page 337 Section 06 ENGINE MANAGEMENT (RFI) Subsection 06 (REMOVAL AND INSTALLATION ) F07F0SA 1. Loosen screws retaining the fuel rail Remove the fuel rail with both fuel injectors. To remove the fuel injector from the fuel rail, pry off the retaining clip. 1.
Page 338: Engine Management (Di)
Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) 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 pneumatically assisted direct injection system, a unique combustion chamber geometry and a precise control of the combustion process by the...
Page 339: Air/Fuel Rail Assembly
Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) AIR/FUEL RAIL ASSEMBLY Direct Injector Also called air injector, two direct injectors (one per cylinder) are used to inject air/fuel mixture into the combustion chamber. Air Pressure Regulator An air pressure regulator regulates the pressure of air delivered by the air compressor.
Page 340: Electronic Management
Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) ELECTRONIC MANAGEMENT The MPEM is directly powered by the battery. It is responsible for the following engine manage- ment/ electrical functions: MPEM (MULTI-PURPOSE – interpreting information ELECTRONIC MODULE) – distributing information The electronic fuel injection is equipped with a –...
Page 341 Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) The safety lanyard cap contains a magnet and a When ordering a new MPEM from the regular ROM chip. The magnet actually closes the reed parts channel, the DESS circuitry will be activat- switch inside the post which is the equivalent of a mechanical ON/OFF switch.
Page 342 Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) The MPEM distributes power from battery to all accessories (except bilge pump which is connect- ed to battery power). Accessories are protected by fuses integrated in the MPEM, in fuse holder(s) close to MPEM or in the electrical box. Fuses are identified besides their holder.
Page 343: Mpem - Engine Management Functions
Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) MPEM — ENGINE MANAGEMENT FUNCTIONS smr2004-Complete Line Up www.SeaDooManuals.net...
Page 344 Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) This engine management system controls both Flooded Engine (drowned mode) the fuel injection and the ignition timing. If the engine does not start and it is flooded, pro- As shown in the DI CONTROL SYSTEM illustra- ceed as follows: tion, the MPEM is the central point of the fuel in- Remove spark plug cables and connect them on...
Page 345: Ignition System
Section 07 ENGINE MANAGEMENT (DI) Subsection 01 (OVERVIEW) These performance-reduced modes allow the rid- er to go back home which would not be possible without this advanced system. Refer to the DIAG- NOSTIC PROCEDURES for a complete chart. If a fault occurs and involves a limp home mode operation, the DI system will reduce engine RPM gradually to the proper level.
Page 346: Component Inspection And Adjustment
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT GENERAL WARNING Fuel lines remain under pressure at all times. Engine problems are not necessarily related to the Always proceed with care and use appro- electronic fuel injection system.
Page 347: Electrical System
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: Never use injector cleaning prod- To perform verifications, a good quality multimeter ucts. They may contain additive that could such as Fluke 111 (P/N 529 035 868) should be damage injector components.
Page 348: Amp Connector Pin-Out
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Measurement Also remember this validates the operation of the sensor at ambient temperature. It does not val- When measuring the resistance with an ohmme- idate the over temperature functionality. To test ter, all values are given for a temperature of 20°C it, the sensor could be removed from the engine/ (69°F).
Page 349 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Disconnect outlet hose (the one with the fuel fil- ter) from fuel pump using tool (P/N 529 035 714). Connect adapter to pressure gauge as shown. NOTE: Remove seat and rubber plug underneath to gain access to fuel pump and hoses.
Page 350: Air Induction System
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Remove pressure gauge and reinstall fuel hose. If only one throttle body replacement is required, At installation apply engine oil on O-ring. detach them and remove the sealant on idle set screw head.
Page 351 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Remove synchronizing screw and spring between levers. NOTE: The 175 resistance mentioned below is used to open the throttle plates the same amount on each throttle body to obtain the proper synchro- nization.
Page 352 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Slave TPS Install a new synchronizing screw. Screw in and ensure screw end clears the lever stopper. En- sure also to keep slave throttle plate completely closed in the throttle body. WARNING Ensure to use a new screw which is coated with the proper threadlocker to avoid further...
Page 353: Air Compressor
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Closed TPS Adjustment WARNING Perform the CLOSED TPS ADJUSTMENT as de- Ensure no Loctite product protrudes screw scribed in THROTTLE POSITION SENSOR (TPS) head. in ELECTRONIC MANAGEMENT further in this section.
Page 354: Repair
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) If pressure is below limits, ensure inlet hose is not obstructed, bent or kinked. Otherwise, repair the air compressor. Remove pressure gauge and reinstall air compres- sor hose. REPAIR Top End Remove retaining screws.
Page 355 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Bottom End To gain access to piston, rings and connecting rod, engine PTO flywheel must be removed. Refer to ENGINE section. Remove engine support and slightly lift engine to allow access.
Page 356 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: Failure to properly clean the oil sys- Assembly tem will result in serious engine damage. Apply injection oil in cylinder and on rings prior to The inspection of top end should include the fol- installing.
Page 357: Fuel Delivery
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) When attaching connecting rod to “crankpin”, IMPORTANT: Before checking air/fuel rail pres- strictly follow this procedure: sure, make sure the fuel pressure from the fuel pump and the air pressure from the air compres- –...
Page 358 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) WARNING Wipe off any fuel spillage in the bilge. Fu- el is flammable and explosive under certain conditions. Always work in a well ventilated area. Fuel Pressure Regulator Replacement Removal Release the fuel pressure in the system.
Page 359: Fuel Injector
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Test Gently pull rail up by hand, working each side slightly at a time. Safety lanyard must be on DESS post. Pull rail out. Using the vehicle communication kit (VCK) with Unscrew retaining plate screws.
Page 360: Air/Fuel Rail
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Air/Fuel Rail Replacement If the same injector is reinstalled, carefully inspect O-ring condition before reinstalling fuel injector. Removal Replace O-ring with a new one if damaged. Release the fuel pressure in the system. Insert the fuel injector in place with your hand.
Page 361: Direct Injector
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: When lifting/removing air/fuel rail, we rec- ommend replacing carbon dams on direct injec- tors that have been running for 50 hours or more. Remove fuel injectors, fuel pressure regulator and air pressure regulator.
Page 362 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Otherwise, check the resistance of the direct in- Compress the carbon dam using tool (P/N 529 035 jector circuit. 716). Reconnect the injector and disconnect the AMP Carefully install direct injector in cylinder head connector number 4 on the MPEM.
Page 363: Fuel Pump
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP Install pressure gauge between disconnected hoses on fuel pump side (closed-loop installation Pressure Test on fuel pump). Make sure the pressure-relief valve is installed on the fuel pump return line side. The pressure test will show the available pressure from the fuel pump.
Page 364 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Electrical Test 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. If the pump does not work, disconnect the con- nector from the fuel pump.
Page 365: Fuel Filters
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) WARNING Always wipe off any fuel spillage from the wa- tercraft. While dealing with fuel or fuel sys- tem always work in well ventilated area. TORQUE AS PER SEQUENCE FUEL FILTERS Installation Fuel Pump Filter...
Page 366 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TYPICAL 1. Fuel pump 2. Fuel filter Using low compressed air, check if the fuel filter 1. Fuel filter is clogged. 2. Inner plastic ring NOTE: Respect the fuel filter flow (check the ar- Inspection row).
Page 367 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (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 368: Electronic Management
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (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 Replacement under History tab.
Page 369: Throttle Position Sensor (Tps)
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) After performing the required resets, ensure to Using the vehicle communication kit (VCK) with clear all faults from the newly replaced MPEM. the B.U.D.S. software, use the Throttle Opening Now, all faults must be inactive (except the Diag- display under Monitoring.
Page 370 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: Resistance values are different at idle on each TPS. MAG Side Disconnect the AMP connector number 3 on the MPEM. Using a multimeter, check resistance value be- tween terminals 10 and 14. The resistance should be 1600 - 2400 .
Page 371: Crankshaft Position Sensor (Cps)
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Ensure the throttle body plate stop lever rests Otherwise, validate the information center is against its stopper. Open throttle approximately working by activating the tachometer using the one quarter then quickly release. Repeat 2 - 3 software B.U.D.S.
Page 372 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (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 373: Manifold Air Temperature Sensor (Mats)
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 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 374: Manifold Air Pressure Sensor (Maps)
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) If resistance tests good, reconnect the WTS and Ensure sensor is correctly installed in elbow adap- disconnect the AMP connector number 4 on the tor. Otherwise, the MAPS could generate a fault MPEM.
Page 375: Exhaust Gas Temperature Sensor (Egts)
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) EXHAUST GAS TEMPERATURE KNOCK SENSOR (KS) SENSOR (EGTS) 1. Knock sensor (KS) Dynamic Test 1. Muffler 2. Exhaust gas temperature sensor (EGTS) Using the vehicle communication kit (VCK) with the B.U.D.S.
Page 376: Rave Solenoid
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Otherwise, repair the wiring harness/connectors between AMP connector and knock sensor. Replacement Unscrew and remove knock sensor. Clean contact surface, apply Loctite 243 in thread- ed hole then install the new knock sensor. Torque screw to 20 N•m (15 lbf•ft).
Page 377: Ignition Coil
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. RAVE solenoid 1. RAVE solenoid 2. Supply hose from air compressor 2. Pressure relief hose 3. Check valve 3. Install hose pincher here 4. Outlet hose to RAVE valves Resistance Test Install leak test pump on hose end and apply pres- Reconnect the solenoid and disconnect the AMP...
Page 378 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Secondary Winding WARNING Never make a spark test with spark plug re- Static Test moved. Flammable vapors may be present NOTE: An ignition coil with good resistance mea- in the bilge and ignited which could cause an surement can still be faulty.
Page 379: Ignition Timing
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TYPICAL 1. Lead to high tension cable 1. MAG side ignition coil at bottom 2. Leads to primary winding 2. Mag side ignition coil wire on edge of electrical box 3.
Page 380 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) With this ignition system, the ignition timing set- ting can be checked with either the engine hot or cold. Also, the ignition timing setting is to be checked at any RPM with the timing light. The ig- nition timing setting is best checked at idle speed as it is more accurate and easier than at higher speed, also it will keep the engine temperature...
Page 381 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: This specification is of the type “indirect CAUTION: If the spark advance curve is not locked using B.U.D.S. then a wrong ignition measurement” relative to the piston movement timing will be seen as the ignition curve does since we are measuring at a 45°...
Page 382 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Adjustment NOTE: This will write the new value immediately in the MPEM. There is no need to press the “Write In this operation, the ignition timing light and data” button to transfer the data to the MPEM un- B.U.D.S.
Page 383: Spark Plugs
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Safety Lanyard Removed Connect test probes to the small RED wire on the starter solenoid and on the RED/PURPLE wire Connect test probes to switch BLACK and from the cut-off relay. Reading should be 0 V. Oth- BLACK/YELLOW wires.
Page 384: Cranking System
Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Proper socket 1. Cold 2. Improper socket 2. Hot SPARK CAUTION: Severe engine damage might occur ENGINE TORQUE PLUG mm (in) if a wrong heat range plug is used. A too “hot”...
Page 385 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (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 386 Section 07 ENGINE MANAGEMENT (DI) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TERMINAL COMPONENT CONNECTOR WIRE COLOR VALUE NUMBER Manifold air temperature sensor AMP no. 4 16 and 19 WH/GY and BK/WH 2280 - 2740 ohms (MATS) Water temperature AMP no. 4 9 and 11 TA/OR and BK/OR 2280 - 2740 ohms...
Page 387: Diagnostic Procedures
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (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 so- lutions.
Page 388 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) SIGNAL CAUSE REMEDY A 2 seconds beep • Exhaust system overheat. • Refer to COOLING SYSTEM. every 2 seconds intervals. A 2 seconds beep • Fuel tank level is low. • Refill as soon as possible. every minutes •...
Page 389: Fault Detection And Compensatory Actions
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (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. LIMP HOME PROBLEM INFO CENTER...
Page 390 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (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 PROBLEM INFO CENTER RED LED BUZZER MODE ➀...
Page 391: Vck (Vehicle Communication Kit)
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) Buzzer Code BUZZER BUZZER PATTERN NOTE CODE WARNING (VEHICLE COMMUNICATION If the computer you are using is connected KIT) to the 110 Vac power outlet, there is a poten- tial risk of electrocution when working in con- The VCK (Vehicle Communication Kit) (P/N 529 tact with water.
Page 392: Di System Fault Codes
Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) Electrical Connections Be aware that a red light blinking with the MAINT message may not be for a fault code. It may be a DI Models Through the 6-Pin Connector maintenance inspection reminder. Press and hold the SET button of the information center for 2 sec- onds.
Page 393 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) TPS (Throttle Position Sensor) Faults Faults which are reported in B.U.D.S. fall into two groups TPS faults and adaption faults. These are dis- played on the B.U.D.S. system as TPS OUT OF RANGE and TPS ADAPTION FAILURE. TPS “OUT OF RANGE”...
Page 394 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) DI System Fault Code Chart NORMAL FAULT FAULT DIAGNOSED OPERATION FAULT FAULT DETECTED DETECTED COMPONENT/ INTERNAL RESUMES IF CODE DETECTED WHILE ENGINE WHILE ENGINE SENSOR/CIRCUIT NAME FAULT REMOVED RUNNING NOT RUNNING AND...
Page 395 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) NORMAL FAULT FAULT DIAGNOSED OPERATION FAULT FAULT DETECTED DETECTED COMPONENT/ INTERNAL RESUMES IF CODE DETECTED WHILE ENGINE WHILE ENGINE SENSOR/CIRCUIT NAME FAULT REMOVED RUNNING NOT RUNNING AND... Wrong pattern P0335 Encoder (CPS) Encoder Return to idle sensed...
Page 396 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) NORMAL FAULT FAULT DIAGNOSED OPERATION FAULT FAULT DETECTED DETECTED COMPONENT/ INTERNAL RESUMES IF CODE DETECTED WHILE ENGINE WHILE ENGINE SENSOR/CIRCUIT NAME FAULT REMOVED RUNNING NOT RUNNING AND... Sensor out of P0116 COOL _SENS Return to idle range...
Page 397 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) NORMAL FAULT FAULT DIAGNOSED OPERATION FAULT FAULT DETECTED DETECTED COMPONENT/ INTERNAL RESUMES IF CODE DETECTED WHILE ENGINE WHILE ENGINE SENSOR/CIRCUIT NAME FAULT REMOVED RUNNING NOT RUNNING AND... Overheat As soon as fault is P1401 EGTS EXH_RED...
Page 398 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) NORMAL FAULT FAULT DIAGNOSED OPERATION FAULT FAULT DETECTED DETECTED COMPONENT/ INTERNAL RESUMES IF CODE DETECTED WHILE ENGINE WHILE ENGINE SENSOR/CIRCUIT NAME FAULT REMOVED RUNNING NOT RUNNING AND... Battery voltage As soon as fault is P0562 Battery voltage BV_LO_WARN...
Page 399 Section 07 ENGINE MANAGEMENT (DI) Subsection 03 (DIAGNOSTIC PROCEDURES) NORMAL FAULT FAULT DIAGNOSED OPERATION FAULT FAULT DETECTED DETECTED COMPONENT/ INTERNAL RESUMES IF CODE DETECTED WHILE ENGINE WHILE ENGINE SENSOR/CIRCUIT NAME FAULT REMOVED RUNNING NOT RUNNING AND... Knock sensor P0325 Knock sensor KNOCK_SENS Yes, over 4500 Return to idle...
Page 400: Engine Management (4-Tec)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) OVERVIEW COMPLETE ELECTRICAL SYSTEM OVERVIEW INFORMATION CENTER MPEM smr2004-Complete Line Up www.SeaDooManuals.net...
Page 401 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) ECM Engine Control Module 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 Sensor Manifold Air Pressure Sensor Manifold Air Temperature Sensor Tip-Over Protection System Connector for Engine Wiring Harness...
Page 402: Magneto System And Power Supply
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) MAGNETO SYSTEM AND AIR INDUCTION POWER SUPPLY 4-TEC Naturally-Aspirated Engine The magneto is the primary source of electrical Air for combustion is drawn directly at the front energy. It transforms magnetic field into electric of the engine through one 52 mm throttle body.
Page 403: Fuel Delivery System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) FUEL DELIVERY SYSTEM BASIC OPERATION When the intake valve reaches the correct posi- tion, the ECM (Engine Control Module) opens the fuel injector and fuel is discharged into the intake port at the air intake manifold by the high fuel pres- sure inside the fuel rail.
Page 404 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) The intake manifold is mounted on the RH side of the engine block. It provides support for the fuel injectors, the fuel rail, the ECM, the flame arrester and the throttle body. The air intake manifold is a resonator between the throttle body and the cylin- der head.
Page 405: Fuel Pump Module
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) FUEL PUMP MODULE ELECTRONIC MANAGEMENT EMS (ENGINE MANAGEMENT SYSTEM) The EMS is controlled by its ECM (Engine Control Module). The fuel pump module is located inside the fuel tank. The module includes fuel pump, fuel pres- TYPICAL 1.
Page 406: Ems - General Functions
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) IMPORTANT: Leaving the safety lanyard on its EMS FUNCTIONS post when engine is not running will slowly dis- charge the battery. Antistart Feature This system allows starting the vehicle only with safety lanyard(s) that has been programmed to op- erate a specific watercraft.
Page 407 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) NOTE: If desired, a safety lanyard can be used on other watercraft equipped with the DESS. It only needs to be programmed for thet watercraft. When connecting a safety lanyard cap on the post, the DESS is activated and will emit audible signals: –...
Page 408: Ems - Engine Management Functions
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) EMS — ENGINE MANAGEMENT FUNCTIONS 1503 4-TEC CONTROL SYSTEM INPUTS OUTPUTS Electronic Fuel Injection This engine management system controls both the fuel injection and the ignition timing. The ECM reads the signals from different sensors As shown in the 1503 4-TEC CONTROL SYSTEM which indicate engine operating conditions at milli- illustration, the ECM is the central point of the fuel...
Page 409 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) Knock Sensor NOTE: The EGTS, CTS and OPS sensors do not provide control inputs to the ECM. Their sole pur- A knock sensor is mounted on the engine block pose is to protect the engine components by emit- behind the air intake manifold.
Page 410 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) Limp Home Modes Besides the signals as seen above, the ECM may automatically uses default parameters for the en- gine management to ensure the adequate opera- tion of the watercraft if a component of the fuel injection system is not operating properly.
Page 411: Mpem - Multi-Purpose Electronic Module
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) MPEM — MULTI-PURPOSE ELECTRONIC MODULE 7.5A 7.5A 7.5A Power Distribution Monitoring System The MPEM distributes power from battery to all The ECM monitors the electronic components accessories and the ECM. Accessories are pro- of the fuel injection system and also the engine tected by fuses integrated in the MPEM.
Page 412: Component Inspection And Adjustment
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT GENERAL WARNING Fuel lines remain under pressure at all times. Engine problems are not necessarily related to the Always proceed with care and use appro- electronic fuel injection system.
Page 413: Electrical System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) To check fuel rail for leaks, first pressurize the sys- WARNING tem then spray soapy water on all hose connec- All electrical actuators (idle bypass valve, tions, regulators and injectors. Air bubbles will TOPS valve, injectors, fuel pump, ignition show the leaking area.
Page 414: Engine Connector Pin-Out
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Measurement Also remember this validates the operation of the sensor at ambient temperature. It does not When measuring the resistance with an ohmme- validate the over temperature functionality. To ter , all values are given for a temperature of 20°C test it, the sensor could be removed from the (69°F).
Page 415: Connectors On Engine
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CONNECTORS ON ENGINE CAUTION: Probe on top of terminal only. Do not try to probe inside terminal or to use a pa- per clip to probe inside terminal, it can damage Removal the square-shaped terminal and this could lead To remove connectors from engine connector...
Page 416: Air Induction System
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) To disconnect two connectors slide a flat screw- driver between each other to disengage, press the release button and disconnect them. 1. Connectors 2. Release button AIR INDUCTION SYSTEM 1.
Page 417 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Mechanical Inspection Check that the throttle plate moves freely and smoothly when depressing throttle lever. Take this opportunity to lubricate the throttle cable. IMPORTANT: The throttle body is designed to be tamper proof.
Page 418 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Adjustment ALL 4-TEC SUPERCHARGED MODELS 1. Throttle body THROTTLE BODY 2. Screws 1. Idle stop screw (do not tamper adjustment) – Slightly pull throttle body out. CAUTION: It is not allowed to perform any change on the idle stop screw.
Page 419 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Besides, throttle lever must reach handlebar grip Closed Throttle and Idle Actuator Reset without causing strain to cable or brackets. En- Perform the CLOSED THROTTLE AND IDLE AC- sure throttle lever fully closes on it's stopper. TUATOR RESET as described in THROTTLE POSI- TION SENSOR (TPS) in ELECTRONIC MANAGE- MENT below.
Page 420: Fuel Delivery
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY 4-TEC Fuel pump does not run Fuel pump runs Connect safety lanyard for 2 sec. then stops Install fuel pressure gauge Check fuses. on fuel pressure line Check safety lanyard connection.
Page 421: Fuel Pump
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (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 422 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Disconnect electrical connector. WARNING Disconnect vent tube from fuel pump. Wipe off any fuel spillage in the bilge. Fu- el is flammable and explosive under certain Release the fuel pressure in the system using conditions.
Page 423: Fuel Filter
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TIGHTENING SEQUENCE 1. Fuel tank neck 2. Align 1. Fuel filter 2. Inner plastic ring Perform a pressure test on fuel tank. Refer to FU- Inspection EL SYSTEM section. Check if particles are present in fuel filter.
Page 424: Fuel Injector
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) A thin film of injection oil should be applied to O-rings of fuel injectors to ease installation in in- take manifold. Apply Loctite 243 on rail retaining screws then torque to 10 N•m (89 lbf•in).
Page 425 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) If the injector does not work, disconnect the con- nector from the injector. Install a temporary connector on the injector with wires long enough to make the connection out- side the bilge and apply voltage (12 V) to this test harness.
Page 426: Electronic Management
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRONIC MANAGEMENT If resistance value is incorrect, repair the wiring harness/connectors or replace the wiring harness between ECM connector and fuel injector. ECM AND MPEM REPLACEMENT Fuel Injector Replacement General Removal Prior to replacing a suspected ECM or MPEM, en-...
Page 427 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Start the engine and increase engine speed above 5000 RPM to be sure no fault appears. MPEM Replacement Disconnect battery cables. WARNING Battery BLACK negative cable must always be disconnected first and connected last.
Page 428: Engine Wiring Harness
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) ENGINE WIRING HARNESS 4-TEC ENGINES 1. ECM connector 2. CTS connector ALL 4-TEC SUPERCHARGED ENGINES 3. EGTS connector 1. ECM connector 4. CAPS connector 2. CTS connector 5. Fuel injector connector (cylinder 1) 3.
Page 429 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Locking ties Connect the fuel injectors, ignition coils, CAPS, TYPICAL 1. Wiring harness CTS and EGTS to the wiring harness. Remove complete wiring harness. WARNING Pay attention not to mix injectors or ignition Installation coils wires between cylinders.
Page 430: Throttle Position Sensor (Tps)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 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. ALL 4-TEC SUPERCHARGED ENGINES 1.
Page 431 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: On the Supercharged Models , a mirror Check the resistance between terminal A-24 and is useful to see under throttle body. terminal A-39 with the throttle plate in wide open position.
Page 432: Idle Bypass Valve
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Apply Loctite 243 on screw threads, install the Start engine and make sure it operates normally new TPS. through its full engine RPM range. If fault codes appear, refer to SYSTEM FAULT CODES in DIAG- Reinstall remaining removed parts.
Page 433: Crankshaft Position Sensor (Cps)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CRANKSHAFT POSITION SENSOR (CPS) If resistance value is correct, try a new ECM. Refer to ECM REPLACEMENT procedures elsewhere in this section. If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM connector and the CPS.
Page 434: Camshaft Position Sensor (Caps)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test (harness) Remove PTO cover. Refer to PTO HOUS- ING/MAGNETO in ENGINE section. Disconnect the connector from the wiring har- Install a dial indicator on crankcase casting. Po- ness.
Page 435: Manifold Air Temperature Sensor (Mats)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) CAPS PIN-OUT 1. CAPS 2. Conductor If the voltage is not good, replace the CAPS. Replacement Unscrew the retaining screw and replace the CAPS. Ensure to reinstall O-ring. Apply Loctite 243 (blue) on thread and torque to 6 N•m (53 lbf•in).
Page 436: Coolant Temperature Sensor (Cts)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) COOLANT TEMPERATURE Resistance Test SENSOR (CTS) Disconnect the connector from the MATS and check the resistance of the sensor itself. The resistance should be between 2280 2740 at 20°C (68°F). Otherwise, replace the MATS.
Page 437: Manifold Air Pressure Sensor (Maps)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Replacement Voltage Test Unlock expansion tank and temporarily move Check the voltage output from ECM to the mani- away to gain access. fold air pressure sensor ( MAPS). Remove the fuel rail cover. Disconnect connector from MAPS and connect a voltmeter to the terminals of the wiring harness Disconnect CTS connector and remove CTS.
Page 438: Exhaust Gas Temperature Sensor (Egts)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) EXHAUST GAS TEMPERATURE KNOCK SENSOR (KS) SENSOR (EGTS) 1. Knock sensor (KS) TYPICAL Dynamic Test 1. Muffler 2. Exhaust gas temperature sensor (EGTS) Using the vehicle communication kit (VCK) with the B.U.D.S.
Page 439 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Knock sensor adaptor Replace sensor adaptor if resistors are not within values. If sensor adaptor is good, try a new ECM. Refer to ECM REPLACEMENT procedures elsewhere in this section.
Page 440: Oil Pressure Sensor (Ops)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) OIL PRESSURE SENSOR (OPS) If the values are correct, check the continuity of the wiring harness. Disconnect the ECM connector A from the ECM and check continuity of circuit 6. If wiring harness is good, try a new ECM.
Page 441 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) TOPS Pressure Test If the values are correct, check the continuity of the wiring harness. WARNING Disconnect the ECM connector A from the ECM The TOPS system might be pressurized. and check continuity of circuit 31.
Page 442: Tops Valve (Blow-By)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (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 443 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) The valve is turned on as soon as safety lanyard is installed on its post. The valve opening allows ventilation of crankcase. The OSPS monitors the pressure to detect a mal- function of this valve.
Page 444 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Solenoid valve TYPICAL 2. Spring 1. Tops switch 3. Valve disc 4. Retaining washer Using and ohmmeter, measure resistance be- WARNING tween terminals. The spring on the TOPS valve is tensioned Position switch as it is located in vehicle.
Page 445: Ignition Coils
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) IGNITION COILS Voltage Test WARNING 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.
Page 446: Ignition Timing
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) IGNITION TIMING If wiring harness is defective, repair the connector or replace the wiring harness between ECM con- The ECM is able to determine the exact position nector and the ignition coil. of camshaft and crankshaft.
Page 447: Spark Plugs
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT) Connect one test probe to the WHITE/GREY wire and the other test probe to the switch top termi- nal. Measure resistance, it must be close to 0 ohm. Connect one test probe to the BLACK wire and the other test probe to the switch ring.
Page 448: Diagnostic Procedures
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (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 449 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) Terminology Some documents or softwares use technical terms that may be different from the one used in this manual. The following table will help to find the equivalence. TERMS USED IN TERMS USED IN OTHER DOCUMENTS THIS MANUAL...
Page 450: Self-Diagnostic Mode
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) SELF-DIAGNOSTIC MODE Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUST- MENT section. CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (while installing • Confirms safety lanyard signal Engine can be started.
Page 451 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) CODED SIGNALS POSSIBLE CAUSE REMEDY 2 seconds beep every 1 minute • Watercraft is upside down. Turn watercraft upright. If it does not interval. work, check the TOPS switch. Refer to ENGINE MANAGEMENT section. •...
Page 452: Vck (Vehicle Communication Kit)
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) BEEPER BEEPER PATTERN NOTE CODE VCK (VEHICLE For more information pertaining to the use of the COMMUNICATION KIT) software B.U.D.S., use its help which contains de- tailed information on its functions. The VCK (Vehicle Communication Kit) (P/N 529 WARNING 035 981) is the primary tool to diagnose engine...
Page 453: 4-Tec System Fault Codes
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) Electrical Connections 4-TEC Models Through the 6-Pin Connector ONLY ONE “ECU” IS WORKING. THERE IS A PROBLEM If an “X” is shown, the safety lanyard is not in- stalled on its post or there is a problem with both “ECUs”.
Page 454 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) When using the service action suggested in the Fault section of B.U.D.S., the system circuits are referred as 4-23 for instance. It means Amp con- nector no. 4 and the circuit wire no. 23 as found in the wiring diagram.
Page 455 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (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 456: 4-Tec System Fault Codes Chart
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) 4-TEC SYSTEM FAULT CODES CHART FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING...
Page 457 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 458 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 459 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 460 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 461 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 462 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 463 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 464 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 465 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 466 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 467 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 468 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 469 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 470 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 471 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 472 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 473 Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) FAULT FAULT NORMAL RESPONSIBLE MODULE MESSAGE LIMP FAULT BEEPER WARNING DETECTED DETECTED OPERATION DISPLAYED HOME CODE INFORMATION CODE LIGHT WHILE ENGINE WHILE ENGINE RESUME MPEM (info ctr) MODE CENTER NOT RUNNING RUNNING WHEN...
Page 474: Burnt Fuse And Related Fault Code
Section 08 ENGINE MANAGEMENT (4-TEC) Subsection 03 (DIAGNOSTIC PROCEDURES) BURNT FUSE AND RELATED FAULT CODE FAULT DETECTED FUSE RATING (A) FAULT CODE WHILE ENGINE NOT RUNNING TOPS P0344, P1200 Depth gauge (if so equipped) or spare fuse P1675 P0353, P0267 Cylinder #3 ignition coil and injection Information center P1680, P1681...
Page 475: Cooling System
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT, COMPONENTS AND CARE 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 476 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 477 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 478 www.SeaDooManuals.net...
Page 479 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 947 DI Engines TYPICAL smr2004-Complete Line Up www.SeaDooManuals.net...
Page 480 www.SeaDooManuals.net...
Page 481: Circuit
Section 09 COOLING SYSTEM Subsection 01 (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 re- place using appropriate Bombardier part num- ber.
Page 482 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 787 RFI Engines The 787 RFI engines features a heat exchanger system. This system allows water coming out of the cylinder head to circulate through a magneto heat exchanger and the crankcase heat exchang- 1.
Page 483 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) F06E0IA 1. Water passages 1. Drain hose Water exits tuned pipe water jackets through an Bleeding of the cooling system is accomplished by outlet fitting. the bleed hose located at the uppermost point of the circuit at the tuned pipe.
Page 484: Components
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) F06E0AA 1. Water flow going to CSI 1. Injection fitting The lower hose of the valve is the water supply All 2-Stroke Engines and the upper hose is the regulated injection water for the tuned pipe.
Page 485 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 1. Stamped number A. Outlet diameter = 4.6 mm (.181 in) B. Inlet diameter = 5.5 mm (.219 in) 1. Cutting clamp 2. Securing clamp STAMPED NUMBER FITTING INLET OUTLET Elbow Fitting DIAMETER DIAMETER...
Page 486 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) F01E1FA TYPICAL 1. Water supply hose of regulator valve 2. Regulated water to injection fitting 3. Water injected into the muffler NOTE: The water injected into the muffler is not LOW SPEED OPERATION regulated by the tapered needle of the valve.
Page 487 Section 09 COOLING SYSTEM Subsection 01 (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 ad- justable.
Page 488: Care
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) Inspection Inspect parts for damage. Verify especially bel- lows for cracks. Assembly Assembly is essentially the reverse of disassem- bly procedures. CARE For flushing purposes, the cooling system is equipped with either a fitting spigot or a hose adapter depending upon the model.
Page 489 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CAUTION: Failure to do this may result in dam- age to the engine. If you must tow a strand- ed watercraft in water and do not have a hose pincher be sure to stay well below the maxi- mum towing speed of 24 km/h (15 MPH).
Page 490 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 947 DI ENGINES — XP DI MODELS 787 RFI ENGINE 1. Hose pincher on water supply hose 1. Follow this hose towards rear 2. Hose coming from engine CAUTION: When finished towing the wa- 3.
Page 491 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Engines — Engine Components smr2004-Complete Line Up www.SeaDooManuals.net...
Page 492 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Engines — Partial System smr2004-Complete Line Up www.SeaDooManuals.net...
Page 493 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Naturally-Aspirated Engines — Vehicle Connections smr2004-Complete Line Up www.SeaDooManuals.net...
Page 494 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Supercharged Engines — Vehicle Connections LTD Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 495 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) 4-TEC Supercharged Intercooled Engines — Vehicle Connections smr2004-Complete Line Up www.SeaDooManuals.net...
Page 496: Circuit
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CIRCUIT CAUTION: Never modify cooling system ar- rangement, otherwise serious engine damage could occur. Closed Loop System A closed loop cooling system is utilized on the Pressure Cap 1503 4-TEC engines, which offers an efficient en- Check if cap pressurize the system.
Page 497 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) The water flow is controlled by a reducer located between the jet pump support and the jet pump on the inlet side. The reducer is color coded ac- cording to watercraft model. Refer to JET PUMP. 4-TEC Supercharged Intercooled Engines Water is directed first through the intercooler.
Page 498: Inspection
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) Remove expansion tank cap. To drain cooling system, unscrew cooling system drain plug at the rear of ride plate. NOTE: Raising the front of the vehicle will con- tribute to drain the cooling system. 1.
Page 499: Coolant Replacement
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) Refill cooling system as described below. Ask someone to pour antifreeze in expansion tank while watching antifreeze and air bubble flowing COOLANT REPLACEMENT out through drain hole. When no air bubbles escape, reinstall drain plug.
Page 500: Coolant Pump Housing
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) When engine has completely cooled down, recheck coolant level in radiator and coolant tank and top up if necessary. Test the density of the coolant using an antifreeze hydrometer. NOTE: Follow hydrometer manufacturer instruc- tions for proper use.
Page 501: Thermostat
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) Installation The installation is the opposite of the removal pro- cedure. Install screws as per the following illus- tration. 1. Supercharger 2. Inlet hose 3. Outlet hose All 4-TEC Models Drain cooling system and engine oil, refer to LU- 1.
Page 502: Coolant Pump Impeller
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) Removal Installation Remove the coolant pump housing from the PTO For installation, reverse the removal procedure, cover. Refer to COOLANT PUMP HOUSING RE- paying attention to the following details. MOVAL elsewhere in this section. Refer to COOLANT PUMP HOUSING REPLACE- NOTE: The thermostat is located inside the MENT in this section.
Page 503 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) – remove outer oil pump rotor no. 13 1. Weep hole Coolant leaking out of the hole indicates a defec- 1. Outer oil pump rotor tive rotary seal. Leaking oil indicates a faulty oil seal.
Page 504: Care
Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CAUTION: Be careful not to damage the surface Install the coolant/oil pump shaft using the rotary of the rotary seal bore in magneto housing cov- seal installer (P/N 529 035 823) on the opposite side to the rotary seal and the oil seal protector (P/N 529 035 822) with a press.
Page 505 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) CAUTION: Failure to do this may result in dam- age to the engine. If you must tow a strand- ed watercraft in water and do not have a hose pincher be sure to stay well below the maxi- mum towing speed of 24 km/h (15 MPH).
Page 506 Section 09 COOLING SYSTEM Subsection 01 (CIRCUIT, COMPONENTS AND CARE) TECHNICAL DATA TYPE Closed and open loop cooling system. COOLANT FLOW Flow from coolant pump. TEMPERATURE Thermostat. CONTROL SYSTEM BLEEDING Self-bleed type through expansion tank (hose at uppermost point of circuit). SYSTEM DRAINING Self-drain type on the exhaust cooling system...
Page 507: Fuel System
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) FUEL CIRCUIT GTI and GTI LE (carburetor-equipped) Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 508 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) XP DI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 509 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) GTI RFI and GTI LE RFI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 510 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) GTX 4-TEC and GTX 4-TEC Wakeboard Edition smr2004-Complete Line Up www.SeaDooManuals.net...
Page 511 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) GTX 4-TEC Supercharged and GTX 4-TEC Limited Supercharged in 16 smr2004-Complete Line Up www.SeaDooManuals.net...
Page 512 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) RXP 4-TEC Supercharged IC in 16 smr2004-Complete Line Up www.SeaDooManuals.net...
Page 513: General
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) GENERAL WARNING The fuel system of a fuel injection system hold much more pressure than on a carbu- reted watercraft. Prior to disconnecting a hose or to removing a component from the fuel system, follow the recommendations described in ENGINE MANAGEMENT under FUEL SYSTEM.
Page 514: Removal
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) TYPICAL 1. Loosen counterclockwise 2. Pull Pull fuel filter no. 4 toward the bottom. 1. Dart REMOVAL Fuel Filter Carburetor-Equipped Models Turn the fuel valve OFF then remove the seat. WARNING The engine must not be running and fuel valve must be set to OFF position.
Page 515 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) Fuel Baffle Pick-Up Carburetor-Equipped Models NOTE: The baffle pick-up no. 8 has an integrated fuel sender for the fuel gauge. TYPICAL 1. Disconnect fuel hoses 2. Loosen lower clamp Disconnect wiring harness of fuel sender. Remove baffle from fuel tank.
Page 516: Inspection
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) Gasket From storage compartment disconnect fuel pump connections. Inspect gasket condition. Make sure gasket Remove fuel pump no. 5 from fuel tank no. 6. no. 14 is well positioned into the filter bowl. Refer to ENGINE MANAGEMENT section.
Page 517: Assembly
Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) ASSEMBLY NOTE: It is a one-way valve with an arrow to indi- cate the air flow. Assembly is essentially the reverse of disassem- bly procedures. However pay particular attention Check Valve to the following. Check if the check valve no.
Page 518 Section 10 FUEL SYSTEM Subsection 01 (FUEL CIRCUIT) Pressure Test (supply and vent circuits) NOTE: Before removing the hose pincher, block with your finger the outlet fitting to feel if air is All Models coming out when removing hose pincher. This Proceed as follows: will indicate that pressure relief valve and the out- –...
Page 519: Air Intake (2-Stroke)
Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) AIR INTAKE (2-STROKE) 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 520 Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 521: General
Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) GENERAL During assembly, use the torque values and ser- vice products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
Page 522: Assembly
Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) ASSEMBLY Assembly is essentially the reverse of removal procedures. However pay particular attention to the following. CAUTION: Do not modify air intake system, otherwise calibration will be affected. Flame Arrester Base On 717 engines, apply Loctite 518 on mating sur- faces of flame arrester base no.
Page 523 Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) 947 DI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 524: Removal
Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) REMOVAL Air Intake Silencer Pull hair pin out to allow removal of clip no. 1. 1. Air duct NOTE: Do not disconnect oil lines. Push the air intake silencer out of the throttle body. 1.
Page 525: Assembly
Section 10 FUEL SYSTEM Subsection 02 (AIR INTAKE (2-STROKE)) Place protector pads on duct supports. Use slot in rubber to insert pad on bracket eyelet. Side tongue of protector pad should be toward outside of vehicle and bent downward toward the exhaust flange.
Page 526: Carburetor
Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) CARBURETOR For fuel system on RFI, DI and 4-TEC models, refer to appropriate ENGINE MANAGEMENT section. Mikuni BN-40i smr2004-Complete Line Up www.SeaDooManuals.net...
Page 527: General
To remove carburetor from engine, proceed as fol- a carburetor cleaner. Follow manufacturer's in- lows: structions. Remove air vent tube support (GTI and GTI LE WARNING models). Solvent with a low flash point such as gaso- Remove air intake silencer. Refer to AIR INTAKE.
Page 528: Disassembly And Inspection
Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) CAUTION: Heavy duty carburetor cleaner may WARNING be harmful to the rubber parts, O-rings, etc. Some fuel may be present in fuel pump. Be Therefore, it is recommended to remove these careful not to swallow fuel when under vacu- parts prior to cleaning.
Page 529 Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) Replace filter if damaged. F01F0YA TYPICAL 1. Pump gauge tester 1. Filter 2. Hose installed to inlet nipple 3. Outlet nipple obstructed Fuel Accelerator Pump Diaphragm no. 10 must stand pressure for 10 sec- Disconnect inlet and outlet hoses from accelerator onds.
Page 530: Assembly
Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) NOTE: Injectors are also equipped with check valves. F04F0JB TYPICAL F01F0ZA 1. Install pump gauge tester to injector hose 2. Injector 1. Metering chamber floor 2. Lever end 3. Flush Pump tester. Injector check valve should open at 19.4 kPa ±...
Page 531 Refer to the following table for pop-off pressure specifications: POP OFF PRESSURE MODELS min./max. kPa (PSI) GTI and GTI LE 248/414 (36/40) NOTE: Pressure test should be performed three times to obtain a valid reading. If pop-off pressure is not within specification, check control lever adjustment.
Page 532: Installation
Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) INSTALLATION Check Valve Assembly 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 533 Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) Throttle lever must reach handlebar grip without After throttle cable adjustment, always proceed causing strain to cable or carburetor cable bracket. with the oil injection pump cable adjustment. Re- fer to OIL INJECTION PUMP. CAUTION: Improper oil injection pump syn- chronization with carburetor can cause serious engine damage.
Page 534 Section 10 FUEL SYSTEM Subsection 03 (CARBURETOR) F02F1QA TYPICAL 1. Adjustment screw 2. Small gap NOTE: Turning the adjustment screw clockwise will increase the gap. Choke Cable Ensure choke lever has a free-play of 0.5 to 2.0 mm (1/64 to 5/64 in). F07F02A TYPICAL 1.
Page 535: Lubrication System (2-Stroke)
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 01 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM GTI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 536 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 01 (OIL INJECTION SYSTEM) XP DI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 537: General
Disconnect oil tank vent line on PTO side throttle body. Whenever repairing the oil injection system, al- GTI Models ways verify for water infiltration in reservoir. Connect pump gauge tester (P/N 529 021 800) to Also pressure test the oil injection system.
Page 538: Oil Injection Pump
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) OIL INJECTION PUMP 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 539 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 540 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) 947 DI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 541: Oil Pump Identification
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) OIL PUMP IDENTIFICATION Remove 2 Allen screws no. 6 with flat washers re- taining oil injection pump to intake manifold no. 2. Pump Lever Remove pump. Different engines need different pumps. See 947 DI Engines identification on lever.
Page 542 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) 947 DI Engines TYPICAL 1. Small oil line Oil Pump Gear Install gear no. 3 to oil injection pump shaft. Torque lock nut no. 4 to 6 N•m (53 lbf•in). NOTE: Make sure 1 washer is installed on each side of gear.
Page 543: Adjustment
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) 717 Engines F01D4RE 1. Cable end completely inserted TYPICAL 2. Cable end NOT seated on the steps 1. Jam nut 2. Adjustment nut 3. Aligned marks CAUTION: Ensure cable end is completely en- tered in its housing.
Page 544 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) F07F0WB 1. Oil pump cable 2. Adjustment nut 947 DI Engines Loosen jam nut and turn cable adjustment nut to obtain pump mark alignment. Refer to following photos. The adjustment is located under the throttle body bracket.
Page 545 Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (OIL INJECTION PUMP) CAUTION: Proper oil injection pump adjust- ment 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 en- gine.
Page 546: Checking Operation
Section 11 LUBRICATION SYSTEM (2-STROKE) Subsection 02 (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 529 035 981).
Page 547: Electrical System
Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM GENERAL 717 Engines The flywheel contains 4 permanent magnets and NOTE: For DI and 4-TEC models, refer to ENGINE spins around the generating coil. This electric cur- MANAGEMENT section. rent flows to the multi-purpose electronic module (MPEM).
Page 548: Multi-Purpose Electronic Module (Mpem)
Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) The RFI models use a digital inductive ignition sys- tem. The Bosch ECU controls the ignition timing and dwell time. It receives input from the CPS and signals the ignition coil when to fire. IGNITION TIMING Before checking ignition timing with a stroboscop- ic timing light (dynamic test), it is mandatory to...
Page 549 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Static Test All Engines – Disconnect MAG side spark plug wire and connect wire to grounding device then remove spark plug. CAUTION: Never crank engine with spark plugs removed unless spark plug cables are connect- ed to the grounding device.
Page 550 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) F01H5SB TYPICAL 1. Tool slot 2. Flywheel mark NOTE: This mark becomes the reference when using the stroboscopic timing light. F01H4LA CAUTION: The static test cannot be used as a TYPICAL timing procedure, therefore, always check the 1.
Page 551 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) F00H0GA F00H0IA 1. Tachometer pick-up 1. Timing light straight in line with tool slot CAUTION: If engine is to be run more than a – Connect timing light pick-up to MAG side spark few seconds, engine must be cooled using the plug wire.
Page 552 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) NOTE: If mark on PTO flywheel is perfectly aligned with timing mark pointer, no adjustment is required. If mark does not align with pointer, recheck PTO flywheel mark before adjusting igni- tion timing to ensure PTO flywheel has not loosen or moved.
Page 553 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) TYPICAL F01H5VA 1. Retaining screw 1. Retarded timing Example 1 In this case, turn armature plate counterclockwise When PTO flywheel mark is on right side of timing when facing it. tool slot, it indicates advanced timing. After adjustment, tighten armature plate retaining screws.
Page 554 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Electrical Connections All Connections IMPORTANT: When using the software B.U.D.S., DESS Post Connection ensure that the protocol matching the connec- Use adapters of the VCK and connect cable to the tion used is properly selected in “MPI” under vehicle DESS post.
Page 555 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) 9) Press any key to continue. Programmer will go back one level to Adjustment. 10)Press Menu to go back one level to Diagnosis. 11)Press Menu to go back one level to Bosch system.
Page 556: Procedure
Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Safety Lanyard Switch Verification TIMING CORRECTION CHART 787 RFI NOTE: The safety lanyard also controls the power MPEM PROGRAMMER IGNITION TIMING supply cut-off relay. Refer to INSTRUMENTS AC- NUMBER CORRECTION CESSORIES for its testing procedure. 4.50°...
Page 557 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Generating Coil Verification 4) Connect positive test probe of the multimeter to the RED/BLACK wire of the 4-pin magneto 717 Engines harness adapter. STATIC TEST 5) Connect negative test probe of the multimeter Disconnect magneto wiring harness connector.
Page 558 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Secondary Winding If the ignition coil test good, check the power sup- ply on the primary side. The spark plug caps must be removed from high tension cables, because they are resistor caps. Disconnect the ignition coil 3-pin connector.
Page 559: Spark Plugs
Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) SPARK PLUGS Fouling Fouling of the spark plug is indicated by irregular Disassembly running of the engine, decreased engine speed First unscrew the spark plug one turn. due to misfiring, reduced performance, and in- creased fuel consumption.
Page 560: Spark Plug Chart
Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) 1. Proper socket 2. Improper socket Spark Plug Chart SPARK ENGINE TORQUE PLUG 717 and 24 N•m 0.4 - 0.5 mm 787 RFI BR8ES (17 lbf•ft) (.016 - .020 po) engines NOTE: Refer to next page for NGK SPARK PLUG SYMBOL EXPLANATION.
Page 561 Section 12 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) NGK Spark Plug Symbol Explanation WIDE GAP PREFIX SUFFIX 10: 1.0 mm (.040") B R 8 E S 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Firing end Thread...
Page 562: Charging System
Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM GENERAL The rectifier/regulator could be the culprit of a blown fuse. To check, simply disconnect the Magneto rectifier/regulator from the circuit. The purpose of the charging system is to keep the If the fuse still burns, check for a defective wire.
Page 563 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) FUSE IDENTIFICATION 15 A: Battery TYPICAL 1. Fuse 787 RFI Engines The main electric system fuse is 20 A and locat- ed on the cut off relay. Also another 20 A fuse is mounted on the MPEM bracket to protect the rec- tifier/regulator.
Page 564 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) 1. Engine 2. MPEM 3. Main fuse 4. Charging system fuse DI Engines The charging system is protected by 2 fuses. A 25 A fuse is mounted on the MPEM and a 25 A fuse is located in the rear electrical box on the cut-off relay.
Page 565: Testing Procedure
Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) 1. Electrical box TYPICAL 1. MPEM 2. Charging system: Fuse connected to the RED/PURPLE wire TESTING PROCEDURE NOTE: First, ensure that battery is in good condi- tion prior to performing the following tests. Rectifier/Regulator STATIC TEST: CONTINUITY Due to internal circuitry, there is no static test avail-...
Page 566 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) 787 RFI Engines – Start engine. – Bring engine to approximately 6000 RPM. Proceed as follows: – Note the reading. This is the current actually Remove the fuse from the holder with the RED consumed.
Page 567 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Connect the positive probe of a multimeter to the STATIC TEST: INSULATION RED wire and the negative probe to the BLACK – Disconnect the magneto wiring harness con- wire. nector. Set multimeter to Vdc scale. –...
Page 568 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) – Connect test probes of the multimeter to the – Install the 6-pin magneto harness adapter YELLOW and BLACK/YELLOW wires of the (P/N 295 000 136) to the magneto wiring har- 4-pin magneto harness adapter. ness.
Page 569: Battery
If tercraft. there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be re- All Models except GTI Series placed or repaired. Proceed as follows: DYNAMIC TEST — AC Voltage –...
Page 570 Rinse elbow. with clear water and dry well. GTI Series Inspection Remove M6 bolts retaining seat support and re- Visually inspect battery casing for cracks or other move upper section from watercraft.
Page 571: Battery Storage
Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) A hydrometer measures the charge of a battery in SPECIFIC GRAVITY READING USING terms of specific gravity of the electrolyte. A fully A HYDROMETER charge battery will have a specific gravity between ELECTROLYTE TEMPERATURE STATE OF 1.265 to 1.280.
Page 572 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Clean battery terminals and cable connections us- ing a wire brush. Apply a light coat of dielectric grease on terminals. Clean battery casing and caps using a solution of baking soda and water. CAUTION: Do not allow cleaning solution to en- ter battery.
Page 573 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Step 1: Unplug battery charger Step 2: Disconnect - lead A17E0RB Step 3: Disconnect + lead 1. Battery electrolyte 2. Upper level line – Test battery state of charge. Use a hydrometer. –...
Page 574 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) All Models The battery charger must be equipped with an am- meter capable of accurately measuring current of Charging a Used Battery less than 1 ampere. Unless this procedure is properly followed, a good WARNING battery may be needlessly replaced.
Page 575: Cable Terminal Installation
– First connect RED positive cable. – Connect BLACK negative cable last. – Apply dielectric grease on battery posts. – Verify cable routing and attachment. GTI Series Reinstall seat support. CABLE TERMINAL INSTALLATION Carefully strip the wire approximately to 10 mm (3/8 in) in length, using a wire stripping tool or sharp blade/knife.
Page 576 Section 12 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) 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. CAUTION: Never weld the wire to the terminal. Welding can change the property of the wire and it can become brittle and break.
Page 577: Starting System
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM 717 Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 578 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 787 RFI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 579 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 947 DI Engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 580: General
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) GENERAL Engine Start/Stop Switch and Safety Lanyard Switch Causes of troubles are not necessarily related Refer to IGNITION SYSTEM or ENGINE MANAGE- to starter but may be due to a burnt fuse, faulty MENT or INSTRUMENTS AND ACCESSORIES.
Page 581: Starting System Troubleshooting
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM TROUBLESHOOTING SYMPTOM CAUSE REMEDY STARTER DOES NOT Burnt fuse (see text above). Check wiring condition and replace TURN. fuse. Poor contact of battery terminal(s). Clean and tighten terminal(s). Poor battery ground cable connection. Clean and tighten.
Page 582: Starter Removal
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTER REMOVAL Pull starter out. Lift starter enough to reach starter cable then disconnect from starter. Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Disconnect RED cable connection from battery.
Page 583 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Check that the radial play between the armature shaft and end frame is not greater than 0.20 mm (.008 in). Replace end frame if so. Tap the pinion stop collar no. 7 using a screw- driver.
Page 584 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) To remove brushes from yoke no. 1, loosen nut and remove washers. F06H1IA 1. Washers Remove armature no. 11. F06H1LA 1. Loosen nut and remove washers Remove brushes. To remove bearing and seal in end cover, release tabs of retainer.
Page 585 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 1. Through bolts Remove end cover. 1. Retaining circlip Remove thrust washer from armature shaft. 2. Starter bendix Locate index marks on yoke and end covers. TYPICAL 1. Thrust washers 1. Index marks Remove the other end cover with brushes and Loosen through bolts.
Page 586: Cleaning
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) WARNING Always wear safety glasses when using com- pressed air. Remove dirt, oil or grease from commutator using a clean cloth soaked in suitable solvent. Dry well using a clean, dry cloth. Clean engine ring gear teeth and drive unit (clutch).
Page 587: Starter Assembly
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 4-TEC Engines 1. New 2. Wear limit, 8.5 mm (.335 in) Check commutator condition with an indicator. If out of specification, replace the starter. Overrunning Clutch 2-Stroke Engines Pinion of overrunning clutch should turn smooth- ly in clockwise direction, and should not slip in a counterclockwise direction.
Page 588 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 1. Locating protrusion is the higher one 1. Armature shaft 2. Circlip 3. Pinion stop collar 4. Punch Yoke Assembly and Clutch Housing Align previously traced indexing marks. F01H0TA 1. Brush holder locating notch To ease end frame installation, retain brush hold- er with a small screwdriver while installing end frame.
Page 589: Starter Installation
Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Apply Loctite 271 (red) on through bolts no. 5 and torque to 6 N•m (53 lbf•in). STARTER INSTALLATION Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. Make sure that starter and engine mating surfaces are free of debris.
Page 590 Section 12 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: If starter does not mesh properly, try to pull WARNING it out and slightly rotate the starter gear; then re- Always connect RED positive cable first then install starter. One could also temporarily remove BLACK negative cable last.
Page 591: Starter Specification
Section 12 ELECTRICAL SYSTEM Subsection 03 (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) Performance specification at No load 11.5 V20 A max.
Page 592: Instruments And Accessories
DESS switch and the cut-off re- lay test good, check the wiring harness. If it tests GTI Series and XP DI models good, the MPEM could be suspected. Try a new When the safety lanyard is on its switch, the re- one.
Page 593: Information Center
INFORMATION CENTER is pressed. GTI LE RFI and XP DI Models If start/stop button is held after engine has started, the MPEM automatically stops the starter when This is a LCD multifunction gauge. Different dis- the engine speed reaches 1000 RPM.
Page 594 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 1. To change display mode 1. Press to change display mode 2. To set or reset a function When you are satisfied with your choice, stop Resetting a Function pressing the button. The display you have chosen To reset a function (such as the chronometer, dis- will remain until it is changed.
Page 595 4 seconds. Other Functions 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): smr2004-Complete Line Up www.SeaDooManuals.net...
Page 596 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Chronometer While in the chronometer mode: 1. Press and hold for 2 seconds 1. Press to start or stop chronometer 1. Repeatedly press 1. Press and hold for 2 seconds to reset Chronometer is reset every time engine is turned off.
Page 597 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 4-TEC Models This is a multifunction gauge that supplies several real time useful information to the driver. Components Description TYPICAL 1. Fuel level indicator 2. Numerical section 3. Units and messages section 4.
Page 598 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) WARNING Never use the depth gauge as a warning de- vice to ride in shallow water. Use it as a navi- gation guide only. Not to be used for naviga- tion purposes. Compass (if so equipped): Displays the cardinal points to indicate the orientation of the watercraft.
Page 599 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Display Selection Language Option Repeatedly pressing the MODE button scrolls While in the compass mode: the following displays: Compass, tachometer, speedometer, average speed, distance, hourme- ter, water temperature, exterior temperature, depth gauge (if so equipped), and trip hour me- ter.
Page 600 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 1. Press to end 1. Press to start or stop trip hour meter English/Metric System Allows to display the units in the metric system or in the SAE English system. NOTE: This function is not available when infor- mation center displays the compass, hourmeter or trip hour meter.
Page 601: Addition Of Electrical Accessories
• check engine (CHK ENG) • sensor failure (vehicle electronic equipment) Information Center (SENSOR) GTI LE RFI and XP DI Models • invalid safety lanyard (KEY) • safety lanyard, learning key active (L KEY) The PURPLE wire is the 12 Vdc power source of the Information Center.
Page 602 6528.3 95 ± 4 95.8 ± 2.2 6/11 Exterior Temperature 81.5 ± 2.2 5/11 GTI LE RFI Model 67.2 ± 2.2 4/11 Disconnect the 2-circuit connector housing of the 52.9 ± 2.2 3/11 Information Center which contains a TAN/WHITE and BLACK/WHITE wires.
Page 603 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Fuel/Oil Gauge/Low Oil Warning Light RESISTANCE ( ) TEMPERATURE (°C) GTI, GTI LE and GTI RFI Models 4712 5 ± 2 The fuel gauge has a pointer which indicates fuel 3792 10 ±...
Page 604 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) RFI Models FUEL LEVEL AND RESISTANCE FUEL LEVEL (mm) RESISTANCE ( ) FLOAT HEIGHT (bottom of float with From 248.9 ± 5 and more 0 + 2.2 RESISTANCE bottom the sensor sends From 234.4 to 248.8 ±...
Page 605 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) 1. Measure resistance here 2. Sensor reservoir F00H0LA 1. Oil sensor To Reinstall Sensor: – Remove rubber seal from sensor. The bottom of the sensor has a small reservoir with two small holes underneath to let the oil en- –...
Page 606 Water Temperature Sensor If motor seems to jam and it has not reached the end of its stroke, the following test could be per- GTI LE RFI and 4-TEC Models formed. The water temperature sensor is integrated with First remove motor, refer to VARIABLE TRIM SYS- the speed.
Page 607 The PURPLE/YELLOW wire is the pulse signal from the speed sensor. Speed Sensor F07H02A GTI LE, GTI LE RFI, XP DI and 4-TEC Models 1. Compass The speedometer gives a reading through a speed Remove the compass from the support.
Page 608 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) To check if the speed sensor is operational, dis- Reconnect the PURPLE/YELLOW and BLACK/ connect the speed sensor connector housing from ORANGE wires in the receptacle housing. inside bilge. Connect the positive probe of a multimeter to Using an appropriate terminal remover (Snap-on speed sensor PURPLE/YELLOW wire and the TT600-4), remove the PURPLE/YELLOW and...
Page 609 Section 12 ELECTRICAL SYSTEM Subsection 04 (INSTRUMENTS AND ACCESSORIES) Removal Remove muffler. Turn depth gauge counterclockwise and pull it out. 1. Depth gauge Inspection Ensure the silicone pad is in good condition. There must be no air between the bottom of the depth gauge and the hull.
Page 610: Dess (Carbureted And Rfi Engines)
Section 12 ELECTRICAL SYSTEM Subsection 05 (DESS (CARBURETED AND RFI ENGINES)) DESS (CARBURETED AND RFI ENGINES) NOTE: For DI and 4-TEC models, refer to ENGINE MANAGEMENT section. GENERAL The Digitally Encoded Security System (DESS) features an anti-start protection against unautho- rized use of the watercraft.
Page 611 Section 12 ELECTRICAL SYSTEM Subsection 05 (DESS (CARBURETED AND RFI ENGINES)) Self-Diagnostic Mode It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme- diate monitoring. Refer to the following chart. SIGNAL CAUSE REMEDY 2 short beeps (when installing •...
Page 612: Dess Key Programming
Section 12 ELECTRICAL SYSTEM Subsection 05 (DESS (CARBURETED AND RFI ENGINES)) DESS KEY PROGRAMMING RFI Models It is also possible to disconnect the connector There is two tools available that can be used to shown in the following picture and install the RFI communicate with the MPEM in order to program DESS adapter (P/N 278 001 978).
Page 613 Section 12 ELECTRICAL SYSTEM Subsection 05 (DESS (CARBURETED AND RFI ENGINES)) 1. Select DESS protocol 2. Click Read MPEM Click on KEYS tab. Install key on MPI DESS post. Click on ADD NORMAL KEY button on bottom of screen. NOTE: The learning key mode is only for DI or 4-TEC models.
Page 614 Section 12 ELECTRICAL SYSTEM Subsection 05 (DESS (CARBURETED AND RFI ENGINES)) Programming Keys with the MPEM Programmer Connect the communication cable of the MPEM programmer to the vehicle DESS post. The following chart lays out the complete procedure to program a new key. Scroll to select PROGRAM KEY item.
Page 615: Propulsion
Section 13 PROPULSION Subsection 01 (JET PUMP) JET PUMP 2-Stroke Models 9 10 XP DI 3 N•m (27 lbf•in) 7.5 N•m All models except XP DI (66 lbf•in) 2.5 N•m (22 lbf•in) 2.5 N•m (22 lbf•in) 2.5 N•m (22 lbf•in) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 616: General
MATERIAL PITCH MODEL Progressive Stainless XP DI 271 000 920 pitch steel 15° - 21° Progressive Stainless GTI, GTI LE 271 001 297 pitch steel 10° - 20° Progressive GTI RFI, Stainless 271 001 370 pitch GTI LE RFI steel 11°...
Page 617 Section 13 PROPULSION Subsection 01 (JET PUMP) TYPICAL 1. Inspect impeller and boot Impeller/Wear Ring Clearance F01J0EA This clearance is critical for jet pump performance. TYPICAL — MEASURING FROM WATER INLET SIDE 1. Feeler gauge Clearance can be checked from water inlet open- ing or from venturi side.
Page 618: Removal
Section 13 PROPULSION Subsection 01 (JET PUMP) F01J5IA TYPICAL TYPICAL 1. Remove plug 1. Screws Check oil level, it should be at bottom of hole Using a fiber hammer, gently tap cover to release threads. it from housing cover. If oil level is low, check impeller shaft housing for Thoroughly clean reservoir and inside of cover leaks.
Page 619 Section 13 PROPULSION Subsection 01 (JET PUMP) Connecting Rod Remove: – reverse gate – pivot bolt no. 26. Withdraw connecting rod. Pivot Triangle Remove: – reverse gate – connecting rod – pivot triangle bolts no. 31. Withdraw pivot triangle no. 32. Pivot Arm Remove: –...
Page 620: Disassembly
Section 13 PROPULSION Subsection 01 (JET PUMP) Remove: – reverse gate – spring – pivot arm bolts no. 35 retaining pivot arm and VTS ring (if so equipped) to nozzle – nozzle. XP DI Models Disconnect steering cable from jet pump nozzle. Disconnect ball joint of VTS link rod.
Page 621 Section 13 PROPULSION Subsection 01 (JET PUMP) Using a fiber hammer, gently tap cover to release it from jet pump housing. Impeller Insert impeller shaft holder (P/N 295 000 082) on impeller shaft flat end. Using 2 screws previously removed from venturi, secure shaft holder to housing.
Page 622: Cleaning
Section 13 PROPULSION Subsection 01 (JET PUMP) Insert bearing remover then press tool using a ar- bor press until seal and bearings are out. How- ever, care should be taken not to damage bearing journals. TYPICAL TYPICAL 1. Snap-on HS3 F00J0MA After cutting ring, insert a screwdriver blade be- 1.
Page 623: Parts Inspection
Section 13 PROPULSION Subsection 01 (JET PUMP) F02J0VB F01J13A TYPICAL 1. Replaced if blunted round or damaged 1. Water passages 2. Oil passages Check impeller for cavitation damage, deep scratches or any other damage. Brush and clean impeller shaft threads, impeller and drive shaft splines with pulley flange cleaner (P/N 413 711 809) or equivalent.
Page 624 Section 13 PROPULSION Subsection 01 (JET PUMP) Install bearings, then install impeller shaft and ro- tate it. Make sure it turns smoothly. RADIAL PLAY Radial play is critical for jet pump unit life span. Radial play of impeller shaft is checked with shaft in housing, without impeller.
Page 625: Assembly
Section 13 PROPULSION Subsection 01 (JET PUMP) Thrust Washer and Thrust Bearing Seal Visually inspect thrust washer no. 9, thrust bear- Carefully inspect seal lips. Make sure that lips are ing no. 10 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 626 Section 13 PROPULSION Subsection 01 (JET PUMP) Seal and Needle Bearing Bearing no. 6 and seal no. 5 on impeller side will be properly installed in housing using bearing/seal installer tool (P/N 295 000 107). BEARING/SEAL INSTALLER TOOL 1. Seal side 2.
Page 627 Section 13 PROPULSION Subsection 01 (JET PUMP) F01J1HA 1. Seal seat 2. Stamped end of bearing 1. Stamped end this side A. 1.5 - 2.5 mm (.060 - .100 in) CAUTION: Never hammer the bearing into its Apply Loctite 518 (P/N 293 800 038) to seal hous- housing.
Page 628 Section 13 PROPULSION Subsection 01 (JET PUMP) F01J1HA 1. Press on tool until it stops 1. Stamped end this side CAUTION: Never hammer the bearing into its Apply synthetic grease (P/N 293 550 010) be- housing. tween seal lips. 1. Loctite 518 all around and behind 2.
Page 629 Section 13 PROPULSION Subsection 01 (JET PUMP) F00J0EA 1. Thrust washer seat 2. Stamped end of bearing 1. Thrust bearing on top of thrust washer A. 2 - 4 mm (.080 - .157 in) Impeller Shaft Thrust Washer To prevent seal lip damage when inserting im- Position jet pump housing with the stator vanes peller shaft, use impeller shaft guide (P/N 295 000 on top.
Page 630 Section 13 PROPULSION Subsection 01 (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 631 Section 13 PROPULSION Subsection 01 (JET PUMP) Anti-Rattle System Install spring no. 14 on slider no. 13. 1. Spring 2. Slider Insert slider and spring into cover. Install O-ring no. 15 to cover. Apply jet pump bear- ing grease on mating surface of cover. NOTE: Align the longer slider tab with hole.
Page 632 Section 13 PROPULSION Subsection 01 (JET PUMP) Place housing horizontally with a tilt angle of 15° with the filler plug located on top. Remove filler plug from cover. Pour SEA-DOO JET PUMP SYN- THETIC OIL (P/N 293 600 011) in reservoir until oil comes level with bottom of hole.
Page 633: Pump Pressurization
Section 13 PROPULSION Subsection 01 (JET PUMP) PUMP PRESSURIZATION INSTALLATION Whenever doing any type of repair on jet pump, a Jet Pump Housing pressure test should be done to check for leakage. Generously apply synthetic grease on drive shaft Proceed as follows: splines.
Page 634 Section 13 PROPULSION Subsection 01 (JET PUMP) Steering Cable NOTE: Trim ring has a tight fit; to install, insert both sides at the same time, taking care not to Refer to STEERING SYSTEM. break plastic bushings. Carefully use a plastic tip hammer if necessary.
Page 635 Section 13 PROPULSION Subsection 01 (JET PUMP) 4-TEC Naturally-Aspirated Models 6 N•m (53 lbf•in) 22 7.5 N•m (66 lbf•in) 2.5 N•m 2.5 N•m (22 lbf•in) (22 lbf•in) 33 2.5 N•m (22 lbf•in) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 636 Section 13 PROPULSION Subsection 01 (JET PUMP) 4-TEC Supercharged Models RXP 4-TEC 2.5 N•m (22 lbf•in) 2.5 N•m (22 lbf•in) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 637: General
Section 13 PROPULSION Subsection 01 (JET PUMP) GENERAL WATERCRAFT IMPELLER MATERIAL PITCH MODEL Progressive Stainless GTX 4-TEC 271 001 386 pitch steel 13° - 23° Progressive GTX 4-TEC Stainless 267 001 091 pitch Supercharged steel 13° - 23° Progressive Stainless 267 001 096 pitch steel...
Page 638: Removal
Section 13 PROPULSION Subsection 01 (JET PUMP) TYPICAL 1. Inspect impeller and boot Impeller/Wear Ring Clearance F01J0EA This clearance is critical for jet pump performance. TYPICAL — MEASURING FROM WATER INLET SIDE 1. Feeler gauge Clearance can be checked from water inlet open- ing or from venturi side.
Page 639: Reverse Gate
Section 13 PROPULSION Subsection 01 (JET PUMP) TYPICAL 1. “U” lever screws Disconnect steering and reverse cables. 1. Pivot bolt Disconnect O.P.A.S. hose from top of pump (if ap- 2. Screw plicable). Remove both reverse gate screws no. 32. RXP Models Pivot Support Disconnect VTS link rod.
Page 640 Section 13 PROPULSION Subsection 01 (JET PUMP) Connecting Rod Remove: – reverse gate – pivot bolt no. 38. Withdraw connecting rod. Pivot Triangle Remove: – reverse gate – connecting rod – pivot triangle bolts no. 39. Withdraw pivot triangle no. 37. Pivot Arm TYPICAL 1.
Page 641: Disassembly
Section 13 PROPULSION Subsection 01 (JET PUMP) Jet Pump Housing – pivot arm. Unplug O.P.A.S. hose from plastic elbow (if appli- Remove pump as an assembly or remove the fol- cable). lowing: – nozzle Remove retaining screws no. 24 and withdraw venturi no.
Page 642 Section 13 PROPULSION Subsection 01 (JET PUMP) Impeller Remove ring no. 1 and impeller boot no. 2. RXP Models Unscrew boot no. 1 CLOCKWISE. Check for presence of water in cone and bearing. If so, replace oil seal no. 7 and sleeve no. 14. Remove both O-rings no.
Page 643 Section 13 PROPULSION Subsection 01 (JET PUMP) Install pump over this tool. Use the impeller shaft pusher (P/N 529 035 955) to press out impeller shaft no. 18 of pump housing. Bearing no. 16, will come out with the impeller shaft.
Page 644: Cleaning
Section 13 PROPULSION Subsection 01 (JET PUMP) After cutting ring, insert a screwdriver blade be- tween jet pump housing and ring outside diame- ter. Push ring so that it can collapse internally. Pull ring out. CLEANING Properly clean all threads. Remove all O-rings and clean parts in a solvent.
Page 645 Section 13 PROPULSION Subsection 01 (JET PUMP) Ball Bearing and Impeller Shaft WEAR IMPORTANT: Make sure to reassemble ball cage, bearing inner and outer races to their original po- sition. Inspect ball bearing no. 16. Check for corrosion, scoring, pitting, chipping or other evidence of wear.
Page 646: Assembly
Section 13 PROPULSION Subsection 01 (JET PUMP) Seal Wear Ring Carefully inspect seal lips. Make sure that lips are Position wear ring so that its rounded edge is out- not worn, distorted, cracked or show signs of any wards. other damage. Replace after 100 hours. To install ring in housing, use a square steel plate of approximately 180 x 180 mm x 6 mm thick (7 x Bearing...
Page 647 Section 13 PROPULSION Subsection 01 (JET PUMP) Be careful when removing the plastic retainer from the bearing no. 16 to avoid the inner races from falling apart. Make sure to reassemble bear- ing parts to their original position. The bearing no. 16 can be installed either side. 1.
Page 648 Section 13 PROPULSION Subsection 01 (JET PUMP) 1. Lips facing up 1. O-ring at bottom 2. Sleeve Apply 4 cc of jet pump bearing grease (P/N 293 550 032) on bearing. 1. Seal/bearing pusher Install spacer no. 6 and seal no. 5. Ensure seal lip is facing up.
Page 649: Pump Pressurization
Section 13 PROPULSION Subsection 01 (JET PUMP) MODEL TOOL P/N GTX 4-TEC and Supercharged 529 035 820 529 035 956 Install partially screwed impeller on it. Use a 12 mm Allen key to torque impeller shaft to 80 N•m (59 lbf•ft) then remove tool. CAUTION: Never use any impact wrench to tighten impeller shaft.
Page 650: Installation
Section 13 PROPULSION Subsection 01 (JET PUMP) Proceed as follows: MODEL REDUCER COLOR – Remove impeller cover no. 21. Install pressure GTX 4-TEC and RXP Yellow cap (P/N 529 035 843) on pump housing. GTX 4-TEC Supercharged – Connect pump gauge tester (P/N 529 021 800) to fitting.
Page 651 Section 13 PROPULSION Subsection 01 (JET PUMP) Install nozzle on venturi no. 23; position its steer- ing arm on RH side. Apply Loctite 243 (blue) on screw threads (or use new self-locking screws). Install screws no. 30 and washer no. 29 then torque to 24 N•m (18 lbf•ft).
Page 652 Section 13 PROPULSION Subsection 01 (JET PUMP) Steering Cable Refer to STEERING SYSTEM. Reverse Cable Refer to REVERSE SYSTEM. Jet Pump Support and Riding Plate Refer to HULL AND BODY. smr2004-Complete Line Up www.SeaDooManuals.net...
Page 653: Drive System
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) DRIVE SYSTEM GTI Series smr2004-Complete Line Up www.SeaDooManuals.net...
Page 654 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) XP DI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 655 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) 4-TEC Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 656: General
Refer to JET PUMP for removal procedure. REMOVAL PTO Flywheel Guard GTI Series Remove seat(s). Remove vent tube support or seat support. Remove plastic wing nuts retaining PTO flywheel guard no. 1 to engine support.
Page 657 Detach coolant expansion reservoir from vent tube support then move away. Circlip and Floating Ring GTI Series and XP DI Models NOTE: On XP DI models, open rear access cover to reach boot no. 10 and floating ring no. 6.
Page 658 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) TYPICAL 1. Drive shaft holder 1. PTO seal support tool Disconnect EGTS sensor to make room. For the following operations, use the drive shaft/floating ring tool . 1. Insert in groove of PTO seal assembly MODEL TOOL P/N Remove jet pump.
Page 659 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) TYPICAL — DRIVE SHAFT/FLOATING RING TOOL 1. Small opening 2. Large opening Install tool as shown. TYPICAL 1. Largest opening here 2. Floating ring Turn screw clockwise so that the tool pushes the floating ring rearwards to expose the circlip.
Page 660 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) Reinstall drive shaft/floating ring tool as shown. Push floating ring rearwards to expose circlip and remove it. TYPICAL TYPICAL 1. Largest opening on PTO seal side 1. Largest opening here 2. Tell tale groove 3.
Page 661 NOTE: Use this sequence to minimize the amount of movement the drive will slide back into PTO seal assembly. Drive Shaft GTI Series Pull out drive shaft F08I04A NOTE: If the drive shaft is jammed into PTO fly- wheel, it may be necessary to remove PTO fly- 1.
Page 662 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) F08I04B 1. Remove bolts, lock nuts and sleeves 1. Remove cover Loosen bolts and lock nuts retaining the lower Loosen gear clamp retaining the outer boot of the support of the shock absorber. shock absorber.
Page 663: Inspection
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) With your finger nail, feel machined surface of drive shaft. If any irregular surface is found, re- new drive shaft. 1. Surface condition 2. Groove condition F05I05A 3. Splines condition 1. Nut (6) Excessive deflection could cause vibration and Bearing no.
Page 664 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) 4-TEC Models Discard damper no. 25 to install a new one. Floating Ring and O-Ring Inspect condition of O-rings no. 7 and floating ring contact surface. 1. Boot A. Measure here Push floating ring to compress boot; then, remove circlip out of drive shaft groove.
Page 665: Assembly
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) F01J51A 1. Spacer 1. Press bearing in its housing NOTE: Drive shaft must be removed to install NOTE: Bearing can also be installed with the same spacer. driver used at disassembly. Center bearing in lon- gitudinal axis of housing.
Page 666: Installation
Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) INSTALLATION Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. Seal Carrier of Mid Bearing XP DI Models Install any of the alignment washers no. 22 as shown.
Page 667 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) Install the large washer no. 28 and nuts no. 21. Slightly tighten nuts but keep loose so that the as- sembly still can move and self adjust when insert- ing the alignment shaft further in this procedure. NOTE: Completely tightening nuts would make the alignment more difficult.
Page 668 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) Front Drive Shaft XP DI Models Install front drive shaft no. 20. Rear Drive Shaft XP DI Models NOTE: Ensure the alignment washers are still loose. Install damper no. 13 to rear drive shaft no. 12. Install drive shaft and jet pump at the same time.
Page 669 243 (blue) on bolts and torque lock nuts to 10 N•m (89 lbf•in). Drive Shaft and Dampers GTI Series Install dampers no. 13 on drive shaft no. 12. NOTE: Make sure dampers were not left in PTO flywheel or impeller.
Page 670 Subsection 02 (DRIVE SYSTEM) 1. Engine rotation (counterclockwise) 2. Tail in opposite direction Small Clamp GTI Series CORRECT INSTALLATION To secure small clamp no. 4, place notch side of 1. Inner sleeve flush with outer circumference plier on clamp embossment and squeeze plier.
Page 671 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) CAUTION: Note that drive shaft features a tell tale groove. If exposed after installation, the installation is wrong and PTO seal assembly will be pressed into crankshaft splines which could rub a hole in seal thus creating an oil leak. 1.
Page 672 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) NOTE: If drive shaft does not enter into the PTO seal, check engine alignment. While someone is pushing drive shaft, slide float- ing ring rearward and guide drive shaft in PTO seal assembly. It may be necessary to move PTO seal assembly up and down to position it in the same axis as the drive shaft.
Page 673: Lubrication
Run watercraft then ensure there is no oil leak in PTO seal area. LUBRICATION PTO Flywheel GTI Series Using a grease gun, carefully lubricate PTO fly- wheel with synthetic grease (P/N 293 550 010), until boot is just beginning to expand. At this point, immediately stop greasing.
Page 674 Section 13 PROPULSION Subsection 02 (DRIVE SYSTEM) If drive shaft has been removed and lubricated be- fore installation, nothing more is required. Other- wise, proceed as follows. Drive shaft should be dry and clean prior to apply- ing the corrosion protectant. Place a plastic sheet underneath hull to recover the excess of sprayed corrosion protectant.
Page 675: Reverse System
Section 13 PROPULSION Subsection 03 (REVERSE SYSTEM) REVERSE SYSTEM GTI, RXP and GTX Series Synthetic grease Loctite 2 N•m (18 lbf•in) 2.5 N•m (22 lbf•in) Loctite 2.5 N•m (22 lbf•in) Loctite 2 N•m (18 lbf•in) 3.3 N•m (29 lbf•in) 4 N•m Loctite 2 N•m...
Page 676: Disassembly
Section 13 PROPULSION Subsection 03 (REVERSE SYSTEM) DISASSEMBLY Reverse Gate To remove reverse gate, refer to JET PUMP sec- tion. Reverse Cable Unscrew bolt no. 1, washers and the elastic stop nut retaining reverse cable no. 2 on pivot arm. 1.
Page 677: Shift Lever
Section 13 PROPULSION Subsection 03 (REVERSE SYSTEM) Shift Lever All Models On the interior lever no. 3, unscrew the elastic Unscrew the shift lever retaining bolt no. 4, wash- stop nut and the washer retaining the reverse ca- er and nut. ble.
Page 678: Inspection
Section 13 PROPULSION Subsection 03 (REVERSE SYSTEM) Handle Housing Reverse Gate Remove: Refer to JET PUMP section. – shift lever Reinstall removed parts. – interior lever ADJUSTMENT – reverse cable support – bolts no. 9. Put shift lever in forward position. Then, remove handle housing no.
Page 679: Variable Trim System
Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) VARIABLE TRIM SYSTEM RXP Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 680 Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) XP DI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 681: General
Section 13 PROPULSION Subsection 04 (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 and engine cover on RXP models and remove rear ac- cess cover on XP DI.
Page 682: Inspection
Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) Worm Inspect threads and splines of worm no. 9 for wear. If worm replacement is necessary, renew also sliding shaft. 1. Press tabs to remove cover Motor Disconnect wires from motor no. 8. 1.
Page 683: Installation
Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) 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). Apply synthetic grease to sliding shaft. Boot and Clamps Install rubber boot no.
Page 684 Section 13 PROPULSION Subsection 04 (VARIABLE TRIM SYSTEM) XP DI Models Push on VTS button up position until motor stops. When the nozzle is up (8°), nozzle edge must not interfere with venturi (there should be a gap of 1 mm (.039 in)). NOTE: Install safety lanyard to be able to position VTS.
Page 685: Steering System
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) STEERING SYSTEM GTI Series Carburetor-equipped engines smr2004-Complete Line Up www.SeaDooManuals.net...
Page 686 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) GTX 4-TEC Series and RXP 4-TEC RXP 4-TEC Models GTX 4-TEC Series GTX 4-TEC Supercharged LTD only smr2004-Complete Line Up www.SeaDooManuals.net...
Page 687: Disassembly
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) DISASSEMBLY Handle Grip and Grip Insert To remove handle grip no. 1, pull out cap no. 2 and NOTE: See farther in this document for proce- remove screw no. 3. dures pertaining to XP DI models. Pull out grip and remove grip insert from handlebar Adjustment Handle no.
Page 688 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Remove cover. GTX 4-TEC Series and RXP 4-TEC Remove 2 tapping screws no. 42. GTI SERIES 1. Set screw GTI Series Remove 4 screws no. 7. 1. Tapping screw 2. Handle bar housing Remove handlebar housing cover no.
Page 689 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Steering cover 2. Screws 1. Screws 2. Steering padding Unscrew DESS switch nut using safety lanyard switch tool (P/N 529 034 600). Handlebar Remove upper steering cover no. 4. GTX 4-TEC Supercharged Limited Models Only Remove 4 elastic stop nuts M8 retaining steering clamp no.
Page 690 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Retaining block TYPICAL 1. Rubber pad Loosen bolts no. 11 each side of steering support 2. Stopper no. 12. All Models except GTX 4-TEC Supercharged Limited Remove steering cover and steering padding as mentioned above.
Page 691 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) 1. Tie rap 1. Steering support 2. Connectors 2. Bolts Disconnect the steering cable from the steering Remove cable support no. 8. stem arm no. 15. Steering Support Cut locking tie securing wiring harness boot. F07K04A 1.
Page 692: Assembly
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Remove adjuster screw from block and detach steering support from steering stem. Unscrew threaded pivots to remove threaded block from steering stem no. 49. 1. Steering support 2. Retaining strip studs Remove steering support no. 12 with handlebar, wiring harnesses and cables.
Page 693 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Handle Grip and Grip Insert WARNING When installing the grip insert no. 21 in the han- Make sure the integrated flat keys of the steer- dlebar no. 22, ensure that it is properly inserted in ing stem arm and support are properly seat- the slot at the end of the handlebar tubing.
Page 694 Section 14 STEERING SYSTEM Subsection 01 (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 All Models Position handlebar no.
Page 695 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) TYPICAL 1. Ball joint below steering arm 2. Torque nut to 7 N•m (62 lbf• in ) STEERING ALIGNMENT For steering alignment procedure, refer to ALIGN- MENT. smr2004-Complete Line Up www.SeaDooManuals.net...
Page 696 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) XP DI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 697: Disassembly
Section 14 STEERING SYSTEM Subsection 01 (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 698 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) F08L0KB F08K06A 1. Remove link rod 1. Loosen Allen screws Remove bolt no. 13 and washer retaining lever Lift the top section of the engine cover and dis- no. 10 to steering support no. 18. connect wiring harnesses.
Page 699 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) F08K08A 1. Loosen bolts Loosen nuts and bolts retaining steering support 1. Remove support and steering stem arm no. 18. Steering Stem Disconnect wiring harnesses and throttle cable from engine. Remove steering stem no. 14. Steering Cable Remove glove box.
Page 700: Assembly
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) F08K0KA 1. Apply synthetic grease 1. Cable support Steering Stem Arm and Support 2. Remove M6 bolts Position steering stem arm no. 15 and support Disconnect ball joint no. 21 of steering cable from no.
Page 701 Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Torque screw to 7 N•m (62 lbf•in). Install cap no. 2. 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 702: Off-Power Assisted Steering System (O.p.a.s.)
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.) GTX Series GTX Series only GTI Series and RXP 4-TEC smr2004-Complete Line Up www.SeaDooManuals.net...
Page 703: General
Between 30% and 75% engine RPM, side vanes are gradually raised from lower position to upper position. 1. Side vane in lower position GTI Series and RXP Models These models do not have any vertical travel. SIDE VANE Disassembly Removal procedure for RH and LH side vane no. 9 is same.
Page 704: Cylinder Support
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Remove socket screw no. 11 and tie rod retaining screw no. 10. A. 45 ± 1 mm (1.65 ± .04 in) Assembly 1. Socket screw Assembly is the reverse process of disassembly. Torque tie rod retaining screw no.
Page 705: Tie Rod
5. Spring 1. Oetiker clamp 2. Water hose 3. Cylinder support Assembly GTI SERIES AND RXP 4-TEC Assembly is the reverse process of disassembly, 1. Pivot rod make sure of the following when doing assembly: 2. Spacer 3. Cylinder cap assembly GTX 4-TEC Series Unscrew tie rod stabilizing fitting no.
Page 706: Sealed Tube
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Remove O.P.A.S. “U” lever screw no. 2, flat washer no. 3, bushing no. 4 and venturi bushing no. 5 from nozzle. Remove jet pump (refer PROPULSION SYSTEM). Remove screw no. 6 and washers no. 7 to remove “U”...
Page 707: Valve
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) VALVE GTX 4-TEC Series Disassembly Remove O.P.A.S. “U” lever screw no. 2, flat washer no. 3, bushing no. 4 and venturi bushing no. 5 from nozzle. Remove jet pump, filter and formed hose no. 32 (refer PROPULSION SYSTEM).
Page 708: Cross Support Plate
Section 14 STEERING SYSTEM Subsection 01 (STEERING SYSTEM) Assembly – Verify the condition of gaskets before installa- tion, change if necessary. Assembly is the reverse process of disassembly, make sure of the following when doing assembly: – Water hose must be installed from the out side to the inside of hull by turning it, oriented to- wards valve.
Page 709: Alignment
1. Measure the distance on each side of the straight edge If necessary, steering alignment adjustment should be performed at steering cable support. GTI and GTX 4-TEC Series Open storage compartment cover and remove basket (if so equipped). Remove access panel (if so equipped).
Page 710 Section 14 STEERING SYSTEM Subsection 02 (ALIGNMENT) 1. Remove storage basket 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 lbf•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 (if so equipped).
Page 711: Suspension
Section 15 SUSPENSION Subsection 01 (DIRECT ACTION SUSPENSION) DIRECT ACTION SUSPENSION XP DI Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 712: Removal
Section 15 SUSPENSION Subsection 01 (DIRECT ACTION SUSPENSION) REMOVAL Shock Absorber Loosen 4 screws and remove bottom cover of seat. F08I03B 1. Loosen gear clamp Remove bolt no. 6 and lock nut no. 7 from shock absorber lower support no. 8. 1.
Page 713: Inspection
Section 15 SUSPENSION Subsection 01 (DIRECT ACTION SUSPENSION) Install shock absorber/coil spring assembly in spring compressor tool. 1. Loosen gear clamp Remove bolt no. 10 and lock nut no. 11 from shock absorber upper support. Compress spring and remove cup no. 13. Unload tool and remove spring from shock ab- sorber.
Page 714: Assembly
Section 15 SUSPENSION Subsection 01 (DIRECT ACTION SUSPENSION) ASSEMBLY Assembly is essentially the reverse of disassem- bly procedure. Refer to the main illustration at the beginning of this subsection for torque specifica- tions and service products to be used. smr2004-Complete Line Up www.SeaDooManuals.net...
Page 715: Hull/Body
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) ADJUSTMENT AND REPAIR GTI Series (bow) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 716 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTI Series (stern) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 717 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTI Series (cover) LE Models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 718 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTI Series (seats) GTI (seats) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 719 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) XP DI Models (bow) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 720 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) XP DI Models (stern) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 721 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) XP DI Models (engine cover) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 722 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) XP DI Models (front cover) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 723 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) XP DI Models (seat) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 724 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX 4-TEC Models (body-front view) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 725 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX 4-TEC Models (body-rear view) Some models Some models Some models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 726 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX 4-TEC Models (front storage compartment) Some models smr2004-Complete Line Up www.SeaDooManuals.net...
Page 727 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GTX 4-TEC Models (seats) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 728 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP Models (body-rear view #1) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 729 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP 4-TEC Models (body-rear view #2) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 730 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP 4-TEC Models (hull rear-rear view) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 731 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP 4-TEC Models (front storage compartment) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 732 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) RXP 4-TEC Models (seats) smr2004-Complete Line Up www.SeaDooManuals.net...
Page 733: General
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) GENERAL GTI Series Remove handle from shift lever. Verify hinges condition and latching mechanisms condition and operation. Replace any damaged components. GTX 4-TEC Series and RXP 4-TEC Models When applying threadlocker Loctite products...
Page 734 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Open front storage cover and remove the access panel. Detach the latch retaining vent tube to bracket. 1. Lock tabs RXP 4-TEC Models Place shift lever in forward position. Remove seat. Pull dart out. See illustration. 1.
Page 735: Engine Cover
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. Coolant expansion tank Remove Bombardier logo at rear. RELEASE SIDE MOLDED PART FROM GLOVE BOX Slightly lift glove box to free it. Proceed with the other side the same way to fi- nally pull glove box out.
Page 736: Seat Adjustment
The threads on new lock pin are coated with a self-locking prod- uct, do not apply Loctite 243 on threads. GTI SERIES — FRONT SEAT 1. Lock pin 2. Adjustment nut (apply Loctite 243). Torque to 5 N•m (44 lbf• in ) A.
Page 737: Storage Compartment Inner Shell
1. Gently pull starting this end 2. Finish with this end For installation, proceed as follows: GTI SERIES — REAR SEAT 1. Lock pin • Sand both inner and outer shells in area to be 2. Adjustment nut (apply Loctite 243). Torque to 5 N•m (44 lbf• in ) glued (except GTI models).
Page 738 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. One long retaining screw (front) 2. Short retaining screw (one on each side to the back) – Remove storage cover. 1. Access panel 2. Multi-function connector – Remove seven inner skin short screws (flanged screws).
Page 739 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. Storage cover 2. Inner skin 3. Rubber hammer – Remove connector harness from the inner skin by cutting tie-raps. 1. Inner skin 2. Temperature sensor 3. Compass 1. Inner skin 2. Storage cover 1.
Page 740 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Install new inner skin in the reverse process. For installation, proceed as follows: – Install the compass and secure it with the two darts. – Install the temperature sensor in grommet. – Install the tie-raps around wire harnesses. –...
Page 741 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) A. 44 mm (1.73 in) B. 23 mm (.91 in) C. 2 x 25 mm (1 in) dia. holes – From top of storage compartment, drill 2 access holes as shown. 1. Green glue in this area CAUTION: Attempting to disassemble a glued inner shell will permanently damage the parts.
Page 742 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) CAUTION: Be careful to drill through inner skin only. – You can now reach and remove the remaining screws that retain the front grill. From inside storage compartment, carefully re- lease the locking tabs. CAUTION: Proceed with caution.
Page 743 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Lift the end of top tubes and remove retaining screws. 1. Align cover tab with inner shell slot. Install front screws. This will properly move inner shell forward and lock it into cover tabs. 1.
Page 744: Storage Cover Shock
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Reinstall inner shell. STORAGE COVER SHOCK All Models except XP DI To remove storage cover shock proceed as fol- lows: WARNING Make sure to have a 2 x 4 piece of wood around the work bench to support the stor- age cover while changing the cover shock.
Page 745: Storage Compartment Cover Adjustment
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) All Models Adjust lock pin no. 3 as per following specifica- tions: 1. Bottom support bracket 2. Shock bottom locking device FIXED TYPE LOCK PIN 1. Lock pin (apply Loctite 243) 2. Adjustment nut. Torque to 5 N•m (44 lbf• in ) A.
Page 746: Access Panel Adjustment
MIRROR 1. Lock pin. Torque to 4 N•m (35 lbf• in ) A. 13.4 mm (17/32 in) GTI LE and GTI LE RFI ACCESS PANEL ADJUSTMENT Place the mirror frame in hot water to “soften” the material to allow mirror installation in its frame.
Page 747: Info Center (Lcd Gauge)
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) INFO CENTER (LCD GAUGE) DEFLECTOR AND/OR UPPER GRID GTX 4-TEC Series and RXP 4-TEC Models Removal and Installation GTX 4-TEC Supercharged Limited Removal and Installation To remove the deflector and/or the upper grid pro- To remove the Info center (Speedometer and LCD ceed as follows: Info gauge) proceed as follows:...
Page 748: Finition Plate
Remove the two darts holding the grid to the body. loosen tight screws. Make a hole into the luggage compartment as shown in the illustration below to gain access to GTI Series and RXP Models the finition plate screw. When reinstalling inlet grate, apply Loctite 271 on threads.
Page 749: Riding Plate
4-TEC Models Drain cooling system. Refer to COOLING SYS- Installation TEM. GTI Series and XP DI Model From inside hull, disconnect hoses from ride plate. Apply Loctite 5900 (P/N 293 800 066) as indicated Unscrew hose fittings from ride plate.
Page 750: Jet Pump Support
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Reinstall hoses to ride plate and refill cooling sys- tem. Refer to COOLING SYSTEM. JET PUMP SUPPORT Removal Remove jet pump. Refer to JET PUMP. Remove inlet grate and riding plate. Remove ball joint, boot, nut, half rings and O-rings from steering cable.
Page 751: Drain Plug Installation
Torque to 31 N•m (23 lbf•ft). 1. Drain plug 2. Silicone sealant (P/N 293 800 086) around the middle hole and in the screw holes 3. Torque screws to 2.2 N•m (19 lbf• in ) GTI SERIES AND XP DI MODELS smr2004-Complete Line Up www.SeaDooManuals.net...
Page 752: Seat Removal
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) SEAT REMOVAL XP DI Models Loosen 4 screws and remove bottom cover no. 17 of seat. 1. Gear clamp Remove bolt and lock nut from shock absorber upper support. 1. Remove cover Loosen gear clamp of outer boot;...
Page 753: Seat Cover Replacement
Tilt seat. BUMPER REPLACEMENT Loosen screws no. 24 on each side of seat retain- ing the side covers. GTI Series and XP DI Models Lower seat. – Remove trim no. 5 from side bumper rail no. 4. Remove side covers.
Page 754: Wake Pylon
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) TYPICAL TYPICAL 1. Front bumper 1. Front bumper 2. Corner bumper 2. Corner bumper 3. Straight section 3. Straight section 4. Bow section 4. Bow section Slide bumper rail no. 2 under front bumper no. 6. –...
Page 755 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) 1. U-clamp Remove finition U-clamp no. 21, and screws no. 25 and pull out wake post no. 20. Disassembly 1. Safety lock pin Loosen the stopper screw. Assembly Before assembly verify the physical condition of cylinder groove and adjustment holes.
Page 756: Sponson Replacement
Pry out sponson cover from back end with screw- surplus driver. Remove seat (access cover for the XP DI models). Remove seat support (GTI Series). Remove muffler. Remove battery. From inside bilge, remove lock nuts no. 10 using a 10 mm deep socket with an extension.
Page 757: Decals Replacement
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Disconnect wiring harnesses of start/stop button, Remove half of the decal back protective film and monitoring beeper, safety lanyard switch and align decal with marks. Start sticking it from cen- gauges. ter and remove the other half of the film to stick it completely.
Page 758: Hull And Body Repair
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) HULL AND BODY REPAIR FILLING THE CAVITY The prepared surface must be cleaned with ace- General tone on a cloth. Use a gelcoat repair kit. Follow Gelcoat is the smooth and durable cosmetic fin- the mixing instructions in the kit when preparing ish which coats the fiberglass hull and body of a the gelcoat putty.
Page 759 Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) In case of fractures which have not penetrated SANDING past the gelcoat layer, the repair concerns the gel- Wash the polyvinyl alcohol off with water. De- coat only. If flex cracking or impact are evident, pending on the size of the area repaired, you can then additional reinforcement may be necessary.
Page 760: Tools And Materials List
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) Inside SANDING For the interior repair, you can grind more. This Outside will allow for more fiberglass material which will This surface will have to be prepared for applica- strengthen the area. If the fracture opening is too tion of gelcoat.
Page 761: Thru-Hull Fitting Installation
Section 16 HULL/BODY Subsection 01 (ADJUSTMENT AND REPAIR) – medium compound (white) – fine compound (white) – wax. THRU-HULL FITTING INSTALLATION All Models except 4-TEC Models For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw. 1.
Page 762: Technical Data
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 Exhaust system Water injection fitting (head) 3.5 mm (.139 in) Water injection fitting (cone) 3.5 mm (.139 in)
Page 763 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 ±...
Page 764 Section 17 TECHNICAL DATA Subsection 01 (GTI AND GTI LE MODELS) PROPULSION GTI LE Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Crowned splines Oil type...
Page 765: Gti Rfi And Gti Le Rfi Models
Section 17 TECHNICAL DATA Subsection 02 (GTI RFI AND GTI LE RFI MODELS) GTI RFI AND GTI LE RFI MODELS ENGINE GTI RFI GTI LE RFI Engine type BOMBARDIER-ROTAX 787 Induction type Rotary valve Type Water cooled, water injected with regulator Water injection fitting (head) 4.0 mm (.157 in)
Page 766 Section 17 TECHNICAL DATA Subsection 02 (GTI RFI AND GTI LE RFI MODELS) ELECTRICAL SYSTEM GTI RFI GTI LE RFI Magneto generator output 270 W @ 6000 RPM Ignition system type Digital, inductive Make and type NGK BR8ES Spark plug 0.61 - 0.71 mm (.024 - .028 in)
Page 767 Section 17 TECHNICAL DATA Subsection 02 (GTI RFI AND GTI LE RFI MODELS) PROPULSION GTI RFI GTI LE RFI Propulsion system BOMBARDIER Formula Pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive...
Page 768: Xp Di Model
Section 17 TECHNICAL DATA Subsection 03 (XP DI MODEL) XP DI MODEL ENGINE 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 Water injection fitting (cone) Not applicable...
Page 769 Section 17 TECHNICAL DATA Subsection 03 (XP DI MODEL) ELECTRICAL 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 ± 0.30 (.212 ± .011) (direct) measured through direct injector hole mm (in) 7.87 ±...
Page 770 Section 17 TECHNICAL DATA Subsection 03 (XP DI MODEL) PROPULSION XP DI Propulsion system BOMBARDIER Formula pump Jet pump type Axial flow single stage Impeller rotation (seen from rear) Counterclockwise Transmission Direct drive Coupling type Rubber coupling, split FR & RR Oil type XP-S synthetic jet pump oil 75W90 GL5...
Page 771 Section 17 TECHNICAL DATA Subsection 03 (XP DI MODEL) PERFORMANCE XP DI Estimated pump power 53.7 kW (72 HP) Maximum fuel consumption at wide open throttle 47 L/h (12.4 U.S. gal/h) Fuel tank without reserve 60 minutes Cruising time at full throttle Fuel tank reserve (from low level signal) 12 minutes ADDITIONAL INFORMATION:...
Page 772: Rxp 4-Tec Models
Section 17 TECHNICAL DATA Subsection 04 (RXP 4-TEC MODELS) RXP 4-TEC MODELS ENGINE RXP 4-TEC 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) Bore Standard 100 mm (3.9 in)
Page 773 Section 17 TECHNICAL DATA Subsection 04 (RXP 4-TEC MODELS) ENGINE RXP 4-TEC Rectangular 0.3 mm (.012 in) Taper-face Minimum (new) 0.15 mm (.006 in) Oil scraper ring 0.15 mm (.006 in) Ring end gap Rectangular 0.5 mm (.020 in) Taper-face Maximum (new) 0.3 mm (.012 in) Oil scraper ring...
Page 774 Section 17 TECHNICAL DATA Subsection 04 (RXP 4-TEC MODELS) ENGINE RXP 4-TEC Minimum (new) 23.010 mm (.9059 in) Connecting rod small end diameter Maximum (new) 23.020 mm (.9063 in) Wear limit 23.070 mm (.9080 in) Minimum (new) 22.99 mm (.9051 in) Piston pin diameter Maximum (new) 23.000 mm (.9055 in)
Page 775 Section 17 TECHNICAL DATA Subsection 04 (RXP 4-TEC MODELS) ELECTRICAL RXP 4-TEC TOPS 10 A Battery fuse 30 A Cylinder 1, ignition coil and injection 10 A Cylinder 2, ignition coil and injection 10 A Cylinder 3, ignition coil and injection 10 A Electric bilge pump (optional) Fuse...
Page 776 Section 17 TECHNICAL DATA Subsection 04 (RXP 4-TEC MODELS) COOLING RXP 4-TEC Liquid cooled. Closed loop for engine Type (see also exhaust system) Ethylene-glycol 50%/50% antifreeze/water. Coolant containing corrosion inhibitors for internal Coolant combustion aluminum engines Thermostat 87°C (188°F) Monitoring beeper setting 100°C (212°F) ADDITIONAL INFORMATION: PROPULSION...
Page 777 Section 17 TECHNICAL DATA Subsection 04 (RXP 4-TEC MODELS) MATERIALS RXP 4-TEC Hull Composite Inlet grate Aluminum Steering cover Thermoplastic Impeller housing/stator/venturi/nozzle Aluminum/aluminum/aluminum/aluminum Air intake silencer N.A. Flame arrester Tubular integrated with intercooler Steering padding Thermoplastic Fuel tank Polyethylene Oil injection reservoir Polyethylene Seat Polyurethane foam...
Page 778: Gtx 4-Tec Models
Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) GTX 4-TEC MODELS ENGINE GTX 4-TEC GTX 4-TEC SUPERCHARGED BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke, Single Over Engine type Head Camshaft (SOHC), liquid cooled Number of cylinders Number of valves 12 valves with hydraulic lifters (no adjustment) Bore Standard 100 mm (3.9 in)
Page 779 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) ENGINE GTX 4-TEC GTX 4-TEC SUPERCHARGED Upper compression ring Piston ring type and quantity Lower compression ring Oil scraper ring Rectangular 0.3 mm (.012 in) Taper-face Minimum (new) 0.15 mm (.006 in) Oil scraper ring 0.15 mm (.006 in) Ring end gap...
Page 780 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) ENGINE GTX 4-TEC GTX 4-TEC SUPERCHARGED Minimum (new) 0.135 mm (.0053 in) Connecting rod big end axial play Maximum (new) 0.287 mm (.0113 in) Wear limit 0.500 mm (.0197 in) Crankshaft deflection 0.050 mm (.002 in) Minimum (new) 23.010 mm (.9059 in)
Page 781 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) ELECTRICAL GTX 4-TEC GTX 4-TEC SUPERCHARGED TOPS 10 A Battery fuse 30 A Cylinder 1, ignition coil and injection 10 A Cylinder 2, ignition coil and injection 10 A Cylinder 3, ignition coil and injection 10 A Electric bilge pump (optional) Fuse...
Page 782 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) FUEL SYSTEM GTX 4-TEC GTX 4-TEC SUPERCHARGED Inside north America Recommended: Premium unleaded gasoline with Regular unleaded 90 octane (Ron + Mon)/2 gasoline with specification for 87 octane (Ron + Mon)/2 optimum performance specification Minimum: Regular unleaded...
Page 783 Section 17 TECHNICAL DATA Subsection 05 (GTX 4-TEC MODELS) DIMENSIONS GTX 4-TEC GTX 4-TEC SUPERCHARGED Number of passenger (driver incl.) Overall length 331 cm (130 in) Overall width 122 cm (48 in) Overall height 113 cm (44 in) 393 kg (867 lb) Dry weight 385 kg (850 lb) Limited: 397 kg (875 lb)
Page 784: Wiring Diagram
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS WIRE COLOR CODES Removal from Engine Connector Bracket First color of a wire is the main color. Second color GTX 4-TEC Models is the tracer. To remove Deutsch connectors from engine con- Example: YELLOW/BLACK (YL-BK) is a YELLOW nector bracket, remove the expansion coolant wire with a BLACK tracer.
Page 785 Section 18 WIRING DIAGRAM 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 disengage, press the release button and disconnect them. 1.
Page 786 Section 18 WIRING DIAGRAM 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 terminal inside connector. NOTE: Before extraction, push wire forward to To remove terminals from connector, proceed as relieve pressure on retaining tab.
Page 787: Packard Connector
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) – Pull back on the terminal wire to be sure the WARNING retention fingers are holding the terminal. Ensure all terminals are properly crimped on – After all required terminals have been inserted, wires and connector are properly fastened.
Page 788 Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Terminal Removal SIGNAL WIRE Insert a screwdriver blade between the connector and the wedge lock tab. Release the locking tab and at the same time, pry the wedge lock to the open position. CAUTION: The wedge lock should never be re- moved from the connector for insertion or re- moval of the signal wire terminals.
Page 789 Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Step 1: Rotate wire back and forth Step 2: Pull wire POWER WIRE TERMINAL NOTE: The wedge lock must be removed to ex- tract power terminal. Open the wedge lock. Pull both locking tabs and remove wedge lock from connector.
Page 790: Identification Of Connector Pins
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Terminal Installation 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 791: Ecm Connectors
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) AMP Connectors of Wiring Harness CAUTION: Probe on top of terminal only. Do not try to probe inside terminal or to use a pa- per clip to probe inside terminal, it can damage the square-shaped terminal.
Page 792 Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Insert the tool tip into the terminal cavity as shown, and locate its wire in the back of the con- nector. You may have to pry the tool tip against the locking tab to release it, then remove the terminal from the connector.
Page 793 Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) When re-inserting the terminal, the locking tab must be installed facing the smaller cutout of the terminal cavity. TYPICAL A. 3 mm (1/8 in) max. Position wire in terminal. Squeeze the terminal tabs with your fingers to temporarily retain terminal in place.
Page 794: Main Fuse Holder Joint Connector
Section 18 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) DEUTSCH JOINT CONNECTOR TOOL (NO. 114010) 1. Top of terminal tabs 2. Align tabs with pliers edge Crimp terminal. Ensure no tiny wire goes out of terminal. This might cause strange problems of the electrical system.
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SeaDoo GTI Shop Manual

Safety Notice

Introduction

Service Tools and Products

Mandatory Service Tools

Optional Service Tools

Service Products

Maintenance

Periodic Inspection Chart

Flushing and Lubrication

Water-Flooded Engine

Storage

Troubleshooting

Troubleshooting Chart

Engine (2-Stroke)

Leak Test

Removal and Installation

Magneto System

Top End

Bottom End

Rotary Valve

Exhaust System

Engine (4-Tec)

Leak Test

Intake System

Exhaust System

Removal and Installation

Pto Housing/Magneto

Lubrication System

Cylinder Head and Valves

Engine Block

Engine Management (Rfi)

Overview

Diagnostic Procedures

Component Inspection

Troubleshooting Summary

Adjustment

Removal and Installation

Engine Management (DI)

Overview

Component Inspection and Adjustment

Diagnostic Procedures

Engine Management (4-Tec)

Overview

Component Inspection and Adjustment

Diagnostic Procedures

Quick Links

Troubleshooting

Related Manuals for SeaDoo GTI

Summary of Contents for SeaDoo GTI