User Manuals: Sea-doo 2003 XP DI Personal Watercraft

User Manuals: Sea-doo 2003 XP DI Personal Watercraft

Manuals and User Guides for Sea-doo 2003 XP DI Personal Watercraft. We have 1 Sea-doo 2003 XP DI Personal Watercraft manual available for free PDF download: Shop Manual

Sea-doo 2003 XP DI Shop Manual

Sea-doo 2003 XP 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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