Sea-doo 2005 4-Tec Series Manuals

Manuals and User Guides for Sea-doo 2005 4-Tec Series. We have 1 Sea-doo 2005 4-Tec Series manual available for free PDF download: Shop Manual

Sea-doo 2005 4-Tec Series Shop Manual

Sea-doo 2005 4-Tec Series Shop Manual (314 pages)

2005 4-Tec Models

Brand: Sea-doo | Category: Boat | Size: 28 MB

Table of Contents

Table of Contents
4
Safety Notice

9
Introduction

10
- General Information
  10
- Arrangement of this Manual
  11
- Abbreviations Used in this Manual
  11
- Illustrations and Procedures
  12
- Engine Emissions Information
  15
- Self-Locking Fasteners Procedure
  15
- Loctite Application Procedure
  16
- Tightening Torques
  19
Maintenance

21
- Maintenance Chart
  
  21
- Preseason Preparation
  
  23
- Storage Procedures
  
  25
  - Propulsion System
    25
  - Fuel System
    25
  - Engine Oil and Filter Replacement
    25
  - Opened Loop Cooling System
    25
  - Closed Loop Cooling System (Engine)
    28
  - Engine Lubrication
    28
  - Throttle Body Lubrication
    28
  - Antifreezing Protection
    28
  - Battery
    29
  - Watercraft Cleaning
    29
  - Anticorrosion Treatment
    29
  - Checklist
    30
- Special Procedures
  
  31
  - Towing the Watercraft in Water
    31
  - Submerged Watercraft
    32
  - Water-Flooded Engine
    32
Troubleshooting

35
Engine System

46
- Air Intake System
  
  46
  - Inspection
    49
  - Removal
    49
  - Installation
    50
- Lubrication System
  
  51
  - General
    51
  - Oil Level Verification
    51
  - Oil Change
    52
  - Oil Type and System Capacity
    53
  - Oil Filter
    53
- Cooling System
  
  55
  - Closed Loop Cooling System (Engine)
    56
    
    Circuit
    57
    
    Cooling System Leak Test
    57
    
    Inspection
    58
    
    Coolant Replacement
    58
    
    Care
    60
    
    Technical Specifications
    60
  - Opened Loop Cooling System (Exhaust System)
    61
    
    Circuit
    63
    
    Care
    64
    
    Technical Specifications
    65
- Exhaust System
  
  66
  - Exhaust Pipe
    68
  - Exhaust Manifold
    71
  - Muffler
    72
  - Resonator
    73
  - Exhaust Outlet
    73
- Removal and Installation
  
  75
  - Engine Removal
    75
  - Cleaning
    79
  - Installation
    79
Engine Management (1503 4-Tec)

83
- Overview
  
  83
  - Operating Principle
    84
    
    Air Induction
    84
    
    Fuel System
    86
    
    Electrical System
    86
  - Engine Management System (Ems)
    88
    
    Ems - Engine Management System Functions
    90
- Diagnostic Procedures
  
  94
  - General
    94
  - Self-Diagnostic Mode
    96
  - Engine Management System Fault Codes
    97
  - Ems Fault Code Table
    100
  - Vck (Vehicle Communication Kit)
    120
- Component Inspection, Replacement and Adjustment
  
  122
  - General
    122
    
    Fuel System
    122
    
    Electrical System
    123
  - Testing Procedures
    126
    
    Idle Speed
    126
    
    Ignition Timing
    126
    
    Safety Lanyard Switch Verification
    126
    
    Ecm and Mpem
    127
    
    Engine Wiring Harness
    128
    
    Fuel Injector
    130
    
    Throttle Body
    132
    
    Throttle Body
    133
    
    Throttle Position Sensor (Tps)
    135
    
    Idle Bypass Valve
    137
    
    Crankshaft Position Sensor (Cps)
    137
    
    Camshaft Position Sensor (Caps)
    138
    
    Manifold Air Temperature Sensor (Mats)
    139
    
    Coolant Temperature Sensor (Cts)
    140
    
    Manifold Air Pressure Sensor (Maps)
    140
    
    Exhaust Gas Temperature Sensor (Egts)
    141
    
    Knock Sensor (Ks)
    142
    
    Oil Pressure Sensor (Ops)
    143
    
    Tops Valve
    143
    
    Oil Separator Pressure Sensor (Osps)
    144
    
    Tops Switch
    145
Fuel System

148
- Fuel Tank and Fuel Pump
  
  148
- General
  150
- Removal
  151
- Inspection
  152
- Installation
  154
- Testing Procedures
  155
Electrical System

159
- Ignition System
  
  159
  - General
    161
  - Quick Test with B.u.D.s
    161
  - Voltage Test
    161
  - Ignition Coil
    161
  - Spark Plugs
    163
  - Ignition Timing
    163
- Charging System
  
  164
  - General
    166
  - Testing Procedure
    166
    
    Rectifier/Regulator
    167
    
    Stator
    168
    
    Battery
    170
- Starting System
  
  176
  - Starting System Troubleshooting
    179
  - General
    180
  - Starter Removal
    181
  - Starter Disassembly
    181
  - Starter Cleaning
    182
  - Starter Inspection
    183
  - Starter Assembly
    183
  - Starter Installation
    183
  - Starter Specification
    184
- Instruments and Accessories
  
  185
  - General
    185
  - Component Description
    185
  - Procedures
    189
Propulsion

194
- Jet Pump
  
  194
  - General
    197
  - Jet Pump Inspection on Watercraft
    197
  - Removal
    198
  - Disassembly
    201
  - Cleaning
    204
  - Parts Inspection
    204
  - Assembly
    205
  - Pump Pressurization
    210
  - Installation
    210
- Drive System
  
  213
  - General
    215
  - Removal
    215
  - Inspection
    218
  - Installation
    219
  - Lubrication
    223
- Reverse System
  
  224
  - Disassembly
    226
  - Shift Lever
    227
  - Inspection
    228
  - Assembly
    228
  - Adjustment
    228
- Variable Trim System
  
  229
  - General
    231
  - Removal
    231
  - Disassembly
    231
  - Inspection
    232
  - Assembly
    232
  - Installation
    232
  - Adjustment
    233
Steering System

234
- 1 Steeringsystem
  
  236
  - Disassembly
    236
  - Assembly
    241
  - Alignment
    243
- Off-Power Assisted Steering System (O.p.a.s.)
  
  245
  - General
    248
  - Side Vane
    248
  - Cylinder Support
    249
  - Tie Rod
    252
  - Sealed Tube
    252
  - Filter
    253
  - Valve
    253
  - Water Hose
    254
  - Cross Support Plate
    254
Hull/Body

256
- Adjustment and Repair
  
  256
- General
  267
- Glove Box
  267
- Engine Cover
  268
- Seat Adjustment
  268
- Storage Compartment Inner Shell
  269
- Storage Cover Shock
  274
- Storage Compartment Cover Adjustment
  275
- Mirror
  275
- Cluster
  276
- Deflector And/Or Upper Grid
  276
- Side Molding
  277
- Inlet Grate
  277
- Riding Plate
  278
- Jet Pump Support
  279
- Drain Plug Installation
  280
- Seat Cover Replacement
  281
- Bumper Replacement
  281
- Wake Pylon
  281
- Sponson Replacement
  283
- Sponson Adaptor
  283
- Bailer Pick-Ups Inspection
  283
- Decals Replacement
  284
- Hull and Body Repair
  285
- Tools and Materials List
  287
Technical Specifications

288
- Gtx, Wake and Gtx Sc Models
  
  288
- Gtx Limited and Rxt Models
  
  292
- Rxp Models
  
  296
Electrical Connectors and Wiring Diagrams

300
- Electrical Connectors
  
  300
  - Deutsch Connectors
    300
  - Packard Connector
    303
  - Amp Connector
    303
  - Ecm Connectors
    307
  - Battery and Starter Cable Terminals
    310
- Wiring Diagrams
  
  312
  - Wire Color Codes
    312
  - Wire Digit Codes
    312

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