SeaDoo XP DI International Manuals

Manuals and User Guides for SeaDoo XP DI International. We have 1 SeaDoo XP DI International manual available for free PDF download: Shop Manual

SeaDoo XP DI International Shop Manual

SeaDoo XP DI International Shop Manual (801 pages)

Brand: SeaDoo | Category: Boat | Size: 61 MB

Table of Contents

Table of Contents
4
Safety Notice

15
Introduction

16
- Hull Identification Number (H.I.n.)
  16
- Engine Identification Number (E.I.n.)
  17
- Arrangement of this Manual
  18
- List of Abbreviations Used in this Manual
  21
- General Information
  21
- Illustrations and Procedures
  22
- Engine Emissions Information
  22
- Self-Locking Fasteners Procedure
  23
- Loctite Application Procedure
  23
- Threadlocker
  23
- Stripped Thread Repair
  24
- Gasket Compound
  25
- Mounting on Shaft
  25
- Case-In Components
  26
- Tightening Torques
  27
Service Tools and Products

28
- Mandatory Service Tools
  
  28
  - Engine
    28
  - Cooling/Fuel/Oil Systems
    32
  - Propulsion System
    33
  - Steering System
    35
- Optional Service Tools
  
  36
  - Engine
    36
  - Cooling/Fuel/Oil Systems
    41
  - Propulsion System
    41
  - Body
    42
  - Watercraft Handling
    42
- Service Products
  
  43
Maintenance

47
- Periodic Inspection Chart
  
  47
- Flushing and Lubrication
  
  53
  - General
    53
  - Procedure
    53
  - Anticorrosion Treatment
    58
- Water-Flooded Engine
  
  59
  - General
    59
  - Procedure
    59
- Storage
  
  65
  - Engine Draining
    65
  - Propulsion System
    66
  - Fuel System
    67
  - Engine Oil Change and Filter
    67
  - Cooling System Flushing and Engine Internal Lubrication
    67
  - Engine Lubrication
    67
  - Battery
    68
  - Watercraft Cleaning
    68
  - Additional Recommended Protection
    68
  - Anticorrosion Treatment
    74
  - Checklist
    74
Troubleshooting

75
Engine (2-Stroke)

88
- Leak Test
  
  88
  - General
    88
  - Preparation
    88
  - Testing Procedure
    88
  - Engine Leakage Diagnostic Flow Chart
    94
- Removal and Installation
  
  96
  - General
    96
  - Engine Removal
    96
  - Cleaning
    101
  - Installation
    101
- Magneto System
  
  107
  - Disassembly
    110
  - Cleaning
    117
  - Assembly
    117
- Top End
  
  122
  - General
    125
  - Disassembly
    127
  - Cleaning
    134
  - Inspection
    135
  - Used Piston Measurement
    136
  - Assembly
    139
  - Adjustment
    148
- Bottom End
  
  151
  - Disassembly
    154
  - Cleaning
    161
  - Inspection
    162
  - Assembly
    166
- Rotary Valve
  
  175
  - General
    176
  - Inspection on Watercraft
    176
  - Disassembly
    177
  - Cleaning
    179
  - Inspection
    179
  - Assembly
    180
  - Rotary Valve Timing
    184
- Exhaust System
  
  186
  - Removal
    189
  - Tuned Pipe Repair
    195
  - Installation
    195
Engine (4-Tec)

202
- Leak Test
  
  202
  - Leak Test Procedure
    202
    
    Preparation
    202
    
    Procedure
    203
    
    Installation
    204
  - Leak Test Procedure for Intercooler
    205
- Intake System
  
  206
  - Inspection
    210
  - Removal
    212
  - Disassembly
    219
  - Assembly
    222
  - Installation
    226
- Exhaust System
  
  229
  - Exhaust Pipe
    230
  - Exhaust Manifold
    233
  - Muffler
    234
  - Resonator
    234
  - Exhaust Outlet
    235
- Removal and Installation
  
  236
  - General
    236
  - Engine Removal
    236
  - Cleaning
    240
  - Installation
    240
- Pto Housing/Magneto
  
  243
  - General
    244
  - Pto Housing
    244
  - Pto Seal
    247
  - Coupling
    247
  - Stator
    248
  - Rotor and Encoder Wheel
    249
  - Ring Gear
    249
  - Starter Drive Ass'y
    250
  - Oil Spray Nozzle
    251
- Lubrication System
  
  253
  - General
    255
  - Oil Level Verification
    255
  - Engine Oil Pressure Test
    256
  - Oil Filter
    258
  - Oil Strainers
    259
  - Engine Oil Pressure Regulator
    262
  - Oil Pressure Pump
    263
  - Oil Suction Pump
    266
  - Oil Cooler
    269
  - Oil Separator
    270
- Cylinder Head and Valves
  
  272
  - General
    273
  - Spark Plug
    273
  - Valve Cover
    273
  - Rocker Arm
    274
  - Camshaft Timing Gear
    277
  - Timing Chain
    279
  - Cylinder Head
    279
  - Camshaft
    280
  - Valve Spring
    282
  - Valve
    283
- Engine Block
  
  289
  - General
    291
  - Crankshaft Locking
    291
  - Crankshaft
    291
  - Timing Chain
    295
  - Chain Tensioner
    296
  - Balancer Shaft
    296
  - Engine Block
    299
  - Piston/Connecting Rod
    304
  - Piston Rings
    310
Engine Management (Rfi)

312
- Overview
  
  312
  - Air Induction
    313
  - Fuel Delivery
    313
    
    Fuel Pump
    313
    
    Fuel Pressure Regulator
    313
    
    Fuel Filters
    313
    
    Fuel Pump Module
    314
    
    Fuel Injectors
    314
  - Electronic Management
    314
    
    Electronic Control Unit (Ecu)
    314
    
    Mpem (Multi-Purpose Electronic Module)
    315
- Diagnostic Procedures
  
  317
  - Introduction
    317
  - Self-Diagnostic Mode
    317
  - Advanced Diagnostic
    317
  - Fault Code Tables
    319
  - Output Signal Faults
    320
- Component Inspection
  
  321
  - General
    321
  - Air Induction System
    323
    
    Throttle Body
    323
  - Fuel Delivery
    323
    
    Fuel Filter
    323
    
    Fuel Pump
    323
    
    Regulator
    323
    
    Fuel Injector
    324
    
    Leak Test (Supply and Ventilation Circuits)
    325
    
    High Pressure Test (Fuel Pump Circuit)
    325
  - Electronic Management
    326
    
    Throttle Position Sensor (Tps)
    326
    
    Crankshaft Position Sensor (Cps)
    327
    
    Air Temperature Sensor (Ats)
    328
    
    Water Temperature Sensor (Wts)
    328
    
    Air Pressure Sensor (Aps)
    329
    
    Rave Solenoid
    330
    
    Rfi Sensors Resistance Values
    331
- Troubleshooting Summary
  
  332
  - Engine Does Not Start
    332
  - Flooded Engine Feature
    332
  - Spark Plug Inspection
    332
  - Ecu Fault Codes
    332
  - Engine Starts but Runs Poorly
    332
  - Engine Runs Only on One Cylinder
    332
  - Engine Cannot Reach Maximum Revolutions
    333
- Adjustment
  
  334
  - Throttle Cable Adjustment
    334
  - Throttle Position Sensor (Tps)
    334
    
    Closed Tps
    334
    
    Idle Speed
    334
- Removal and Installation
  
  335
  - Mpem/Ecu
    335
  - Throttle Position Sensor (Tps)
    335
  - Air Temperature Sensor (Ats)
    335
  - Air Pressure Sensor (Aps)
    335
  - Water Temperature Sensor (Wts)
    335
  - Crankshaft Position Sensor (Cps)
    335
  - Fuel Pump Assembly
    335
    
    Regulator
    336
    
    Fuel Filter
    336
  - Fuel Injectors
    336
Engine Management (DI)

338
- Overview
  
  338
  - Operating Principle
    338
  - Air Induction
    338
  - Air Compressor System
    338
  - Fuel Delivery System
    338
    
    Basic Operation
    338
    
    Air/Fuel Rail Assembly
    339
    
    Fuel Pump Module
    339
  - Electronic Management
    340
    
    Mpem (Multi-Purpose Electronic Module)
    340
    
    Mpem - Engine Management Functions
    343
    
    Ignition System
    345
- Component Inspection and Adjustment
  
  346
  - General
    346
    
    Fuel System
    346
    
    Electrical System
    347
    
    Amp Connector Pin-Out
    348
  - Quick Fuel Pressure Test
    348
  - Air Induction System
    350
    
    Throttle Body
    350
  - Air Compressor
    353
    
    Pressure Test
    353
    
    Repair
    354
  - Fuel Delivery
    357
    
    Fuel Pressure Regulator
    357
    
    Fuel Injector
    359
    
    Air/Fuel Rail
    360
    
    Direct Injector
    361
    
    Fuel Pump
    363
    
    Fuel Filters
    365
  - Electronic Management
    368
    
    Mpem Replacement
    368
    
    Throttle Position Sensor (Tps)
    369
    
    Crankshaft Position Sensor (Cps)
    371
    
    Manifold Air Temperature Sensor (Mats)
    373
    
    Water Temperature Sensor (Wts)
    373
    
    Manifold Air Pressure Sensor (Maps)
    374
    
    Exhaust Gas Temperature Sensor (Egts)
    375
    
    Knock Sensor (Ks)
    375
    
    Rave Solenoid
    376
    
    Ignition Coil
    377
    
    Ignition Timing
    379
    
    Spark Plugs
    383
    
    Cranking System
    384
    
    DI System Test Summary
    384
- Diagnostic Procedures
  
  387
  - General
    387
  - Fault Detection and Compensatory Actions
    389
    
    Component Failure Warning System
    389
  - Vck (Vehicle Communication Kit)
    391
  - DI System Fault Codes
    392
Engine Management (4-Tec)

400
- Overview
  
  400
  - Complete Electrical System Overview
    400
  - Magneto System and Power Supply
    402
  - Operating Principle of Engine Management
    402
  - Air Induction
    402
  - Fuel Delivery System
    403
    
    Basic Operation
    403
    
    Fuel Pump Module
    405
  - Electronic Management
    405
    
    Ems (Engine Management System)
    405
    
    Ems - General Functions
    406
    
    Ems - Engine Management Functions
    408
    
    Mpem - Multi-Purpose Electronic Module
    411
- Component Inspection and Adjustment
  
  412
  - General
    412
    
    Fuel System
    412
    
    Electrical System
    413
    
    Engine Connector Pin-Out
    414
    
    Connectors on Engine
    415
  - Air Induction System
    416
    
    Throttle Body
    416
  - Fuel Delivery
    420
    
    Fuel Pump
    421
    
    Fuel Filter
    423
    
    Fuel Rail
    423
    
    Fuel Injector
    424
  - Electronic Management
    426
    
    Ecm and Mpem Replacement
    426
    
    Engine Wiring Harness
    428
    
    Throttle Position Sensor (Tps)
    430
    
    Idle Bypass Valve
    432
    
    Crankshaft Position Sensor (Cps)
    433
    
    Camshaft Position Sensor (Caps)
    434
    
    Manifold Air Temperature Sensor (Mats)
    435
    
    Coolant Temperature Sensor (Cts)
    436
    
    Manifold Air Pressure Sensor (Maps)
    437
    
    Exhaust Gas Temperature Sensor (Egts)
    438
    
    Knock Sensor (Ks)
    438
    
    Oil Pressure Sensor (Ops)
    440
    
    Oil Separator Pressure Sensor (Osps)
    440
    
    Tops Valve (Blow-By)
    442
    
    Ignition Coils
    445
    
    Ignition Timing
    446
    
    Engine Start/Stop Switch Verification
    446
    
    Safety Lanyard Switch Verification
    446
    
    Spark Plugs
    447
    
    Cranking System
    447
- Diagnostic Procedures
  
  448
  - General
    448
  - Self-Diagnostic Mode
    450
  - Vck (Vehicle Communication Kit)
    452
  - 4-Tec System Fault Codes
    453
    
    4-Tec System Fault Codes Chart
    456
    
    Burnt Fuse and Related Fault Code
    474
Cooling System

475
- Circuit, Components and Care
  
  475
- Circuit
  481
- Components
  484
- Care
  488
- Circuit
  496
- Cooling System Leak Test
  496
- Inspection
  498
- Draining the System
  498
- Cleaning
  498
- Coolant Replacement
  499
- Coolant Pump Housing
  500
- Thermostat
  501
- Coolant Pump Impeller
  502
- Rotary Seal
  502
- Care
  504
Fuel System

507
- Fuel Circuit
  
  507
  - General
    513
  - Removal
    514
  - Inspection
    516
  - Assembly
    517
  - Fuel System Pressurization
    517
- Air Intake (2-Stroke)
  
  519
  - General
    521
  - Removal
    521
  - Assembly
    522
  - Removal
    524
  - Assembly
    525
- Carburetor
  
  526
  - General
    527
  - Removal
    527
  - Cleaning
    527
  - Disassembly and Inspection
    528
  - Assembly
    530
  - Installation
    532
  - Adjustments
    532
Lubrication System (2-Stroke)

535
- Oil Injection System
  
  535
  - General
    537
  - Oil System Pressurization
    537
- Oil Injection Pump
  
  538
  - Oil Pump Identification
    541
  - Removal
    541
  - Disassembly
    541
  - Cleaning
    541
  - Assembly
    541
  - Adjustment
    543
  - Checking Operation
    546
Electrical System

547
- Ignition System
  
  547
  - General
    547
  - Multi-Purpose Electronic Module (Mpem)
    548
  - Ignition Timing
    548
  - Procedure
    556
  - Spark Plugs
    559
  - Spark Plug Chart
    560
- Charging System
  
  562
  - General
    562
  - Testing Procedure
    565
    
    Battery
    569
    
    Battery Storage
    571
    
    Cable Terminal Installation
    575
- Starting System
  
  577
  - General
    580
  - Starting System Troubleshooting
    581
  - Starter Removal
    582
  - Starter Disassembly
    582
  - Cleaning
    586
  - Parts Inspection
    586
  - Starter Assembly
    587
  - Starter Installation
    589
  - Starter Specification
    591
- Instruments and Accessories
  
  592
  - General
    592
  - Power Supply Cut-Off Relay Verification
    592
  - Multi-Purpose Electronic Module (Mpem)
    592
  - Information Center
    593
  - Addition of Electrical Accessories
    601
  - Inspection
    601
- Dess (Carbureted and Rfi Engines)
  
  610
  - General
    610
  - Dess Key Programming
    612
Propulsion

615
- Jet Pump
  
  615
  - General
    616
  - Jet Pump Inspection on Watercraft
    616
  - Removal
    618
  - Disassembly
    620
  - Cleaning
    622
  - Parts Inspection
    623
  - Assembly
    625
  - Pump Pressurization
    633
  - Installation
    633
  - General
    637
  - Jet Pump Inspection on Watercraft
    637
  - Removal
    638
    
    Pump Assembly
    638
    
    Reverse Gate
    639
  - Disassembly
    641
  - Cleaning
    644
  - Parts Inspection
    644
  - Assembly
    646
  - Pump Pressurization
    649
  - Installation
    650
- Drive System
  
  653
  - General
    656
  - Removal
    656
  - Inspection
    663
  - Assembly
    665
  - Installation
    666
  - Lubrication
    673
  - Reverse System
    675
  - Disassembly
    676
  - Shift Lever
    677
  - Inspection
    678
  - Assembly
    678
  - Adjustment
    678
- Variable Trim System
  
  679
  - General
    681
  - Removal
    681
  - Disassembly
    681
  - Inspection
    682
  - Assembly
    682
  - Installation
    683
  - Adjustment
    683
Steering System

685
- 1 Steeringsystem
  
  687
  - Disassembly
    687
  - Assembly
    692
  - Disassembly
    697
  - Assembly
    700
  - Off-Power Assisted Steering System (O.p.a.s.)
    702
    
    General
    703
    
    Side Vane
    703
    
    Cylinder Support
    704
    
    Tie Rod
    705
    
    Sealed Tube
    706
    
    Filter
    706
    
    Valve
    707
    
    Water Hose
    707
    
    Cross Support Plate
    708
- Alignment
  
  709
Suspension

711
- Direct Action Suspension
  
  711
- Removal
  712
- Inspection
  713
- Assembly
  714
Hull/Body

715
- Adjustment and Repair
  
  715
- General
  733
- Glove Box
  733
- Engine Cover
  735
- Seat Adjustment
  736
- Storage Compartment Inner Shell
  737
- Storage Cover Shock
  744
- Storage Compartment Cover Adjustment
  745
- Access Panel Adjustment
  746
- Mirror
  746
- Info Center (Lcd Gauge)
  747
- Deflector And/Or Upper Grid
  747
- Finition Plate
  748
- Inlet Grate
  748
- Riding Plate
  749
- Jet Pump Support
  750
- Drain Plug Installation
  751
- Seat Removal
  752
- Seat Cover Replacement
  753
- Bumper Replacement
  753
- Wake Pylon
  754
- Sponson Replacement
  756
- Engine Compartment Cover Removal
  756
- Decals Replacement
  757
- Hull and Body Repair
  758
- Tools and Materials List
  760
- Thru-Hull Fitting Installation
  761
Technical Data

762
- Gti and Gti Le Models
  
  762
- Gti Rfi and Gti Le Rfi Models
  
  765
- Xp DI Model
  
  768
- Rxp 4-Tec Models
  
  772
- Gtx 4-Tec Models
  
  778
Wiring Diagram

784
Wiring Diagrams

784
- Wire Color Codes
  784
- Wire Digit Codes
  784
- Deutsch Connectors
  784
- Packard Connector
  787
- Amp Plug Connector
  787
- Identification of Connector Pins
  790
- Ecm Connectors
  791
- Main Fuse Holder Joint Connector
  794

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