Sea-Doo 2003 LRV DI Manuals

Manuals and User Guides for Sea-Doo 2003 LRV DI. We have 2 Sea-Doo 2003 LRV DI manuals available for free PDF download: Shop Manual, Operator's Manual

Sea-doo 2003 LRV DI Shop Manual

Sea-doo 2003 LRV DI Shop Manual (779 pages)

Brand: Sea-doo | Category: Boat | Size: 54 MB

Table of Contents

Table of Contents

5
- Safety Notice
  6
  - Hull Identification Number
    7
  - General Information
    11
  - Engine Emissions Information
    12
  - Tightening Torques
    16
Table of Contents

19
- Mandatory Service Tools
  
  20
  - Engine
    20
  - Cooling/Fuel/Oil Systems
    24
  - Propulsion System
    26
  - Steering System
    28
- Optional Service Tools
  
  29
  - Engine
    29
  - Cooling/Fuel/Oil Systems
    34
  - Propulsion System
    35
  - Body
    36
  - Watercraft Handling
    37
- Service Products
  
  38
Table of Contents

42
- Periodic Inspection Chart
  
  43
- Flushing and Lubrication
  
  47
  - General
    47
  - Procedure
    47
- Water-Flooded Engine
  
  52
  - General
    52
  - Procedure
    52
- Storage
  
  58
  - Engine Draining
    58
  - Propulsion System
    60
  - Fuel System
    60
  - Engine Oil Change and Filter
    61
  - Cooling System Flushing and Engine Internal Lubrication
    61
  - Engine Lubrication
    61
  - Battery
    62
  - Watercraft Cleaning
    62
  - Additional Recommended Protection
    62
  - Anticorrosion Treatment
    71
  - Checklist
    71
- Troubleshooting Chart
  
  72
Table of Contents

85
- Leak Test
  
  87
  - General
    87
  - Preparation
    87
  - Testing Procedure
    87
  - Engine Leakage Diagnostic Flow Chart
    93
- Removal and Installation
  
  95
  - General
    95
  - Engine Removal
    95
  - Cleaning
    100
  - Installation
    100
- Magneto System
  
  105
  - Disassembly
    108
  - Cleaning
    114
  - Assembly
    114
  - Magneto Flywheel
    116
- Top End
  
  119
  - General
    122
  - Disassembly
    124
  - Cleaning
    132
  - Inspection
    132
  - Used Piston Measurement
    133
  - Ring End Gap
    135
  - Assembly
    136
  - Adjustment
    145
- Bottom End
  
  147
  - Disassembly
    150
  - Cleaning
    157
  - Inspection
    158
  - Assembly
    162
- Rotary Valve
  
  170
  - Rotary Valve
    176
  - Rotary Valve Timing
    178
- Exhaust System
  
  180
  - Removal
    185
  - Tuned Pipe Repair
    190
  - Installation
    191
Table of Contents

198
- Leak Test
  
  200
- Leak Test Procedure
  
  200
  - Preparation
    200
  - Procedure
    201
  - Installation
    202
- Intake System
  
  203
  - Inspection
    206
  - Removal
    208
  - Assembly
    217
- Exhaust System
  
  222
  - Exhaust Pipe
    223
  - Exhaust Manifold
    226
  - Muffler (Lh)
    227
  - Muffler (Rh)
    228
  - Exhaust Outlet
    229
- Removal and Installation
  
  230
  - General
    230
  - Engine Removal
    230
  - Cleaning
    232
  - Installation
    232
- Pto Housing/Magneto
  
  235
  - General
    236
  - Pto Housing
    236
  - Pto Seal
    239
  - Coupling
    239
  - Stator
    240
  - Rotor and Encoder Wheel
    241
  - Ring Gear
    242
  - Starter Drive Ass'y
    243
  - Oil Spray Nozzle
    244
- Lubrication System
  
  245
  - General
    247
  - Oil Level Verification
    247
  - Engine Oil Pressure Test
    248
  - Oil Filter
    249
  - Oil Strainers
    250
  - Engine Oil Pressure Regulator
    253
  - Oil Pressure Pump
    254
  - Oil Suction Pump
    257
  - Oil Cooler
    259
  - Oil Separator
    260
- Cylinder Head and Valves
  
  262
  - General
    263
  - Spark Plug
    263
  - Valve Cover
    263
  - Rocker Arm
    264
  - Camshaft Timing Gear
    268
  - Timing Chain
    269
  - Cylinder Head
    269
  - Camshaft
    271
  - Valve Spring
    272
  - Valve
    273
- Engine Block
  
  279
  - General
    281
  - Crankshaft Locking
    281
  - Crankshaft
    281
  - Timing Chain
    286
  - Chain Tensioner
    286
  - Balancer Shaft
    287
  - Engine Block
    289
  - Piston/Connecting Rod
    295
  - Piston Rings
    300
Table of Contents

302
- Overview
  
  304
- Fuel Delivery
  
  305
  - Fuel Pump
    305
  - Fuel Pressure Regulator
    305
  - Fuel Filters
    306
  - Fuel Pump Module
    306
  - Fuel Injectors
    306
- Air Induction
  
  305
- Electronic Management
  
  307
  - Electronic Control Unit (Ecu)
    307
  - MPEM (Multi-Purpose Electronic Module)
    307
- Diagnostic Procedures
  
  309
- VCK (Vehicle Communication Kit)
  
  309
  - Diagnostic Option Example Using Mpem Programmer
    309
- Fault Code Tables
  
  311
  - Ecu Faults
    311
  - Input Signal Faults
    311
  - Output Signal Faults
    312
- General
  
  313
- Component Inspection
  
  313
- Air Induction System
  
  315
  - Throttle Body
    315
- Fuel Delivery
  
  315
  - Fuel Filter
    315
  - Fuel Pump
    315
  - Regulator
    315
  - Fuel Injector
    316
  - Leak Test (Supply and Ventilation Circuits)
    317
  - HIGH PRESSURE TEST (Fuel Pump Circuit)
    317
- Electronic Management
  
  318
- Flooded Engine Feature
  
  324
- Spark Plug Inspection
  
  324
- Engine Cannot Reach Maximum Revolutions
  
  324
  - Throttle Position Sensor (Tps)
    325
- Engine Starts but Runs Poorly
  
  324
- Engine Does Not Start
  
  324
- Ecu Fault Codes
  
  324
- Troubleshooting Summary
  
  324
- Throttle Cable Adjustment
  
  325
  - Crankshaft Position Sensor (Cps)
    326
  - Air Temperature Sensor (Ats)
    326
  - Water Temperature Sensor (Wts)
    326
  - Air Pressure Sensor (Aps)
    326
- Fuel Pump Assembly
  
  326
Table of Contents

328
- Overview
  
  330
- Fuel Delivery System
  
  331
  - Basic Operation
    331
  - Air/Fuel Rail Assembly
    331
  - Fuel Pump Module
    332
- Air Induction
  
  331
- Air Compressor System
  
  331
- Operating Principle
  
  331
- Electronic Management
  
  333
  - MPEM (Multi-Purpose Electronic Module)
    333
  - Ignition System
    337
- General
  
  338
  - Fuel System
    338
  - Electrical System
    339
  - Amp Connector Pin-Out
    340
- Component Inspection and Adjustment
  
  338
- Quick Fuel Pressure Test
  
  341
- Air Induction System
  
  342
  - Throttle Body
    342
- Air Compressor
  
  346
  - Pressure Test
    346
  - Repair
    347
- Fuel Delivery
  
  350
  - Fuel Pressure Regulator
    350
  - Fuel Injector
    351
  - Air/Fuel Rail
    352
  - Direct Injector
    354
  - Fuel Pump
    355
- Electronic Management
  
  360
  - Mpem Replacement
    360
  - Throttle Position Sensor (Tps)
    361
  - Crankshaft Position Sensor (Cps)
    363
  - Manifold Air Temperature Sensor (Mats)
    365
  - Water Temperature Sensor (Wts)
    365
  - Manifold Air Pressure Sensor (Maps)
    366
  - Exhaust Gas Temperature Sensor (Egt)
    367
  - Knock Sensor (Ks)
    367
  - Rave Solenoid
    368
  - Ignition Coil
    369
  - Tdc Setting
    371
  - Spark Plugs
    375
  - Cranking System
    376
  - DI System Test Summary
    376
- Diagnostic Procedures
  
  379
- General
  
  379
- Fault Detection and Compensatory Actions
  
  380
  - Component Failure Warning System
    380
- VCK (Vehicle Communication Kit)
  
  382
- DI System Fault Codes
  
  383
Table of Contents

389
- Complete Electrical System Overview
  
  391
- Overview
  
  391
- Air Induction
  
  393
- Operating Principle of Engine Management
  
  393
- Magneto System and Power Supply
  
  393
- Fuel Delivery System
  
  394
  - Basic Operation
    394
  - Intake Manifold
    394
  - Fuel Pump Module
    395
- Electronic Management
  
  395
  - Ems (Engine Management System)
    395
  - Ems - General Functions
    396
  - Ems - Engine Management Functions
    398
  - Mpem - Multi-Purpose Electronic Module
    401
- Component Inspection and Adjustment
  
  402
- General
  
  402
  - Fuel System
    402
  - Electrical System
    403
  - Engine Connector Pin-Out
    404
  - Connectors on Engine
    405
- Air Induction System
  
  406
  - Throttle Body
    406
- Fuel Delivery
  
  409
  - Fuel Pump
    410
  - Fuel Rail
    412
  - Fuel Injector
    412
- Electronic Management
  
  414
  - Ems Ecu and Mpem Replacement
    414
  - Engine Wiring Harness
    416
  - Throttle Position Sensor (Tps)
    418
  - Idle Bypass Valve
    421
  - Crankshaft Position Sensor (Cps)
    421
  - Camshaft Position Sensor (Caps)
    423
  - Manifold Air Temperature Sensor (Mats)
    424
  - Coolant Temperature Sensor (Cts)
    425
  - Manifold Air Pressure Sensor (Maps)
    425
  - Exhaust Gas Temperature Sensor (Egt)
    426
  - Knock Sensor (Ks)
    427
  - Oil Pressure Sensor (Ops)
    428
  - Oil Separator Pressure Sensor (Osps)
    428
  - TOPS VALVE (Blow-By)
    430
  - Ignition Coils
    432
  - Tdc Setting (Top Dead Center)
    433
  - Engine Start/Stop Switch Verification
    433
  - Safety Lanyard Switch Verification
    434
  - Spark Plugs
    434
  - Cranking System
    435
- General
  
  436
- Diagnostic Procedures
  
  436
- Self-Diagnostic Mode
  
  438
- VCK (Vehicle Communication Kit)
  
  439
- 4-Tec System Fault Codes
  
  440
Circuit, Components and Care/Circuit, Components and Care

442
- Circuit, Components and Care
  443
- Circuit
  453
- Components
  457
- Care
  460
- Circuit
  462
- Cooling System Leak Test
  463
- Inspection
  464
- Coolant Replacement
  465
- Draining the System
  465
- Coolant Pump Housing
  466
- Thermostat
  467
- Coolant Pump Impeller
  468
- Rotary Seal
  469
- Care
  471
Table of Contents

473
- Fuel Circuit
  
  474
  - General
    479
  - Removal
    479
  - Inspection
    482
  - Assembly
    483
  - Fuel System Pressurization
    483
- Air Intake (2-Stroke)
  
  485
  - Removal
    488
  - Assembly
    490
- Carburetor
  
  491
  - General
    492
  - Removal
    492
  - Cleaning
    493
  - Disassembly and Inspection
    493
  - Assembly
    495
  - Installation
    497
  - Adjustments
    497
Table of Contents

500
- Oil Injection System
  
  501
  - General
    504
  - Oil System Pressurization
    504
- Oil Injection Pump
  
  505
  - Oil Pump Identification
    508
  - Removal
    508
  - Disassembly
    508
  - Cleaning
    508
  - Assembly
    509
  - Adjustment
    510
  - Checking Operation
    513
Table of Contents

514
- Ignition System (Carbureted Engines)
  
  515
  - General
    515
  - Multi-Purpose Electronic Module (Mpem)
    516
  - Ignition Timing
    516
  - Ignition System Testing Procedure
    523
  - Spark Plugs
    526
- Charging System
  
  529
  - General
    529
  - Testing Procedure
    530
  - Battery
    534
  - Cable Terminal Installation
    540
- Starting System
  
  542
  - General
    545
  - Starting System Troubleshooting
    546
  - Starter Removal
    547
  - Starter Disassembly
    548
  - Cleaning
    551
  - Parts Inspection
    552
  - Starter Assembly
    553
  - Starter Installation
    554
  - Starter Specification
    557
- Instruments and Accessories
  
  558
  - General
    558
  - Power Supply Cut-Off Relay Verification
    558
  - Multi-Purpose Electronic Module (Mpem)
    558
    
    Information Center
    560
    
    Other Functions
    562
  - Inspection
    567
- Dess (Carbureted and Rfi Engines)
  
  575
  - General
    575
- VCK (Vehicle Communication Kit)
  
  576
Table of Contents

577
- Jet Pump
  
  579
  - General
    581
  - Jet Pump Inspection on Watercraft
    581
  - Removal
    584
  - Disassembly
    586
  - Cleaning
    588
  - Parts Inspection
    589
  - Assembly
    591
  - Pump Pressurization
    598
  - Installation
    599
  - General
    602
  - Jet Pump Inspection on Watercraft
    602
  - Removal
    603
  - Pump Assembly
    603
  - Disassembly
    606
  - Cleaning
    608
  - Parts Inspection
    609
  - Assembly
    610
  - Pump Pressurization
    614
  - Installation
    615
- Drive System
  
  617
  - General
    620
  - Removal
    620
  - Inspection
    627
  - Assembly
    629
  - Installation
    630
  - Lubrication
    637
- Reverse System
  
  639
  - Disassembly
    640
  - Inspection
    641
  - Assembly
    641
  - Adjustment
    642
  - Disassembly
    645
  - Reverse Gate
    645
  - Inspection
    646
  - Assembly
    646
  - Adjustment
    647
- Variable Trim System
  
  648
  - General
    650
  - Removal
    650
  - Disassembly
    651
  - Inspection
    651
  - Assembly
    651
  - Installation
    652
  - Adjustment
    653
Table of Contents

654
- Steering System
  
  655
  - Disassembly
    657
  - Assembly
    662
  - Disassembly
    667
  - Assembly
    670
- Off-Power Assisted Steering System (O.p.a.s.)
  
  672
  - General
    673
  - Side Vane
    673
  - Cylinder Support Assembly
    674
  - Tie Rod
    675
  - Filter
    676
  - Sealed Tube
    676
  - Valve
    676
  - Cross Support Plate
    677
  - Water Hose
    677
- Alignment
  
  679
  - Direct Action Suspension
    682
Adjustment and Repair

685
- Adjustment and Repair
  686
- Glove Box
  707
- Seat Adjustment
  708
- Storage Compartment Inner Shell
  709
- Storage Cover Shock
  712
- Storage Compartment Cover Adjustment
  713
- Access Panel Adjustment
  714
- INFO CENTER (LCD Gauges)
  714
- Mirror
  714
- Deflector And/Or Upper Grid
  715
- Finition Plate
  715
- Inlet Grate
  716
- Riding Plate
  717
- Jet Pump Support
  718
- Deflector
  719
- Drain Plug Installation
  720
- Seat Removal
  720
- Bumper Replacement
  722
- Seat Cover Replacement
  722
- Wake Pylon
  723
- Sponson Replacement
  724
- Decals Replacement
  726
- Engine Compartment Cover Removal
  726
- Hull and Body Repair
  727
- Tools and Materials List
  729
- Thru-Hull Fitting Installation
  730
- Gti and Gti Le Models
  
  731
  - Gti Le Rfi Models
    735
  - Lrv DI Models
    743
  - Gtx 4-Tec Models
    748
- Wiring Diagrams
  
  755

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Sea-Doo 2003 LRV DI Operator's Manual

Sea-Doo 2003 LRV DI Operator's Manual (88 pages)

Jetski

Brand: Sea-Doo | Category: Boat | Size: 4 MB

Table of Contents

Table of Contents
4
Foreword

7
- Safety Measures
  
  8
- General
  8
- Operation
  8
- Maintenance
  10
List of Distributors

11
Bombardier Limited Warranty North America

12
Bombardier Limited Warranty Sold

15
And Registered in California

15
Bombardier Limited Warranty International

18
Registration Number Location

21
Location of the Important Labels

22
Identification Numbers

25
- Hull
  25
- Engine
  25
Controls, Components and Instruments Location

26
Controls, Components and Instruments Functions

28
- Safety Lanyard (Engine Cut-Off Cord)
  28
- Handlebar
  29
- Throttle Lever
  29
- Engine Start/Stop Button
  29
- Shift Lever
  29
- Speedometer
  30
- Information Center Gauge/Buttons (if so Equipped)
  30
- Glove Box
  34
- Fuel Tank Cap
  34
- Oil Injection Reservoir Cap
  34
- Front Storage Compartment Cover
  34
- Front Storage Compartment Cover Latch
  35
- Side Storage Compartments
  35
- Underseat Storage Compartments
  35
- Tool Kit
  35
- Air Intake Opening
  35
- Seat Strap
  35
- Seat Latch
  35
- Seat Extension Latch
  36
- Rear Storage Basket (if so Equipped)
  36
- Sun Deck
  36
- Bow and Stern Eyelets
  37
- Fender Cleats
  37
- Footboard
  37
- Boarding Platform
  37
- Boarding Step
  37
- Cooling System Bleed Outlet
  38
- Deck Drains
  38
- Flushing Connector
  38
- Bilge Drain Plugs
  38
- Automatic Bilge Pump
  39
- Jet Pump Nozzle
  39
- Reverse Gate
  39
- Jet Pump Water Intake
  39
- Fuses
  39
- Battery
  39
Fuel and Lubrication

40
- Fueling Procedure
  40
- Recommended Fuel
  40
- Recommended Oil
  40
- Oil Injection System
  41
Break-In Period

42
- 10-Hour Inspection
  42
Pre-Operation Checks

43
- Hull
  44
- Jet Pump Water Intake
  44
- Bilge
  44
- Battery
  44
- Fuel Tank and Oil Reservoir
  44
- Engine Compartment
  44
- Steering System
  44
- Throttle System
  45
- Shifter System
  45
- Storage Compartment Covers and Seat
  45
- Safety Lanyard and Engine Start/Stop Button
  45
Operating Instructions

46
- Principle of Operation
  46
- Boarding the Watercraft
  48
- Starting
  50
- Rough Water or Poor Visibility Operation
  51
- Crossing Waves
  51
- Stopping/Docking
  51
- Beaching
  51
- Shutting off the Engine
  51
Post-Operation Care

52
Special Procedures

55
- Limp Home Mode
  55
- Engine Overheating
  55
- Jet Pump Water Intake and Impeller Cleaning
  55
- Capsized Watercraft
  56
- Submerged Watercraft
  56
- Water-Flooded Engine
  57
- Out of Fuel
  57
- Towing the Watercraft in Water
  57
- Low-Charge Battery Condition
  58
Maintenance

59
- Engine Emissions Information
  59
- Lubrication
  60
- Periodic Inspection
  61
- Periodic Inspection Chart
  62
- Throttle Cable Inspection
  64
- Fuel Injection System
  64
- Fuel and Oil Filters
  64
- Steering Alignment
  64
- Vacuum Bailer Pick-Ups
  64
- Fuses
  65
- General Inspection and Cleaning
  66
Trailering, Storage and Pre-Season Preparation

67
- Trailering
  67
- Storage
  67
- Pre-Season Preparation
  71
Troubleshooting

73
Specifications

77
Si Metric Information

79
Abbreviations Used in this Manual

80
Privacy Information

81
Change of Address

83

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