Sea Doo Shop Manual (2005)

8/11/2019 Sea Doo Shop Manual (2005)

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Vehicle Shop M


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Legal deposit:

National Library of QuebecNational Library of Canada 2005

All rights reserved. No parts of this manual may be reproduced in any form without the ppermission of Bombardier Recreational Products Inc. (BRP)

Bombardier Recreational Products Inc. (BRP) 2005

Technical PublicationsBombardier Recreational Products Inc. (BRP)Valcourt (Quebec) Canada

Printed in Canada

TM

Registered trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.* Trademark of Bombardier Inc. used under license.

SEA-DOO

BOMBARDIER-ROTAX

BOMBARDIER LUBE

Sea-Doo Learning KeyTM

DESSTM

Rotax

O.P.A.S.TM

TOPSTM

This document contains the trademarks of the following companies:

Knights Spray-Nine is a trademark of Korkay System LtdGTX is a trademark of Castrol Ltd. Used under license


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SAFETY NOTICE ................ ................ ................. ..............

INTRODUCTION ................ ................ ................. ..............GENERAL INFORMATION.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ARRANGEMENT OF THIS MANUAL .... .... .... .... .... .... .... ... .... .... ... .... ....

ABBREVIATIONS USED IN THIS MANUAL ... ... .. ... ... .. ... ... .. ... ... .. ... ... .. ..

ILLUSTRATIONS AND PROCEDURES ...... ... .... .... .... .... .... .... .... ... .... ....

ENGINE EMISSIONS INFORMATION ... .... ... .... .... .... .... .... .... .... ... .... ....

SELF-LOCKING FASTENERS PROCEDURE ... ... .. ... ... .. ... ... .. ... ... .. ... ... .. ..

LOCTITE APPLICATION PROCEDURE...... .... ... .... .... ... ... ... .... .... ... .... ....TIGHTENING TORQUES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 MAINTENANCE01 MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 PRE SE AS ON P RE PARAT IO N .. .... .... .... ... .... .... ... ... ... .... .... ... .... ....

03 STO RAGE PRO CEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROPULSION SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL AND FILTER REPLACEMENT ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPENED LOOP COOLING SYSTEM ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOSED LOOP COOLING SYSTEM (ENGINE) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODY LUBRICATION.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANTIFREEZING PROTECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATERCRAFT CLEANING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANTICORROSION TREATMENT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOWING THE WATERCRAFT IN WATER.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUBMERGED WATERCRAFT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER-FLOODED ENGINE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 TROUBLESHOOTING01 TRO UBLESHO OTING C HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE WILL NOT START .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE HARD TO START.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED.. ... .. ... ... .. ... .. ... ... .. ... ..

ENGINE MISFIRES, RUNS IRREGULARLY.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE CONTINUALLY BACKFIRES... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE DETONATION OR PINGING.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE LACKS ACCELERATION OR POWER ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE STOPS RUNNING


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TABLE OF CONTENTS

03 ENGINE SYSTEM01 AIR IN TAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL LEVEL VERIFICATION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL TYPE AND SYSTEM CAPACITY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OIL FILTER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

03 COOL IN G SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOSED LOOP COOLING SYSTEM (ENGINE) .. ... ... .. ... ... .. ... ... .. ... ... .. ... ... .. ... ...

CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM LEAK TEST... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL SPECIFICATIONS.. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPENED LOOP COOLING SYSTEM (EXHAUST SYSTEM)... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL SPECIFICATIONS.. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04 EXHA UST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MUFFLER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESONATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST OUTLET.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

05 REMO VAL AND IN STALLAT IO N... .... .... .... .... ... .... .... ... .... .... ... ... ... .... .... .... ...

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04 ENGINE MANAGEMENT (1503 4-TEC)

01 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING PRINCIPLE... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE MANAGEMENT SYSTEM (EMS) ... .... .... .... .... .... .... .... .... ... .... .... ... ....

EMS ENGINE MANAGEMENT SYSTEM FUNCTIONS... .. ... .. ... .. ... ... .. ... .. ... ... ... ... .. ...

02 DIAGNOSTIC P ROCEDURES


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IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IGNITION TIMING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY LANYARD SWITCH VERIFICATION.. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ECM AND MPEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE WIRING HARNESS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE POSITION SENSOR (TPS).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDLE BYPASS VALVE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT POSITION SENSOR (CPS)... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CAMSHAFT POSITION SENSOR (CAPS)... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANIFOLD AIR TEMPERATURE SENSOR (MATS) .. ... .. ... .. ... .. .. ... .. ... .. ... ..

COOLANT TEMPERATURE SENSOR (CTS).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANIFOLD AIR PRESSURE SENSOR (MAPS) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST GAS TEMPERATURE SENSOR (EGTS)... .. ... ... .. ... .. ... ... .. ... .. ... ..

KNOCK SENSOR (KS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PRESSURE SENSOR (OPS) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOPS VALVE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL SEPARATOR PRESSURE SENSOR (OSPS) ... .. ... ... .. ... ... ... .. ... ... .. ... .. .

TOPS SWITCH.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

05 FUEL SYSTEM01 FUE L TANK AND FUE L PU MP .... .... .... .... .... .... .... .... .... .... ... .... ....

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

06 ELECTRICAL SYSTEM01 IG NITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUICK TEST WITH B.U.D.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VOLTAGE TEST.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARK PLUGS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 CHARGI NG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TESTING PROCEDURE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECTIFIER/REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY


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STARTER SPECIFICATION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 IN STR UMEN TS AN D A CC ESSO RIES .. ... .... .... .... .... .... .... .... .... .... ... .... .... ... ....

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .

COMPONENT DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

07 PROPULSION01 JET PUM P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .

JET PUMP INSPECTION ON WATERCRAFT... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP PRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

03 REVERSE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04 VAR IAB LE T RIM SY ST EM .... .... .... .... .... ... ... ... .... .... ... .... .... .... .... .... .... .... ... .

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

08 STEERING SYSTEM01 STEERIN G SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 OFF POWER ASSISTED STEERING SYSTEM (O P A S )


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09 HULL/BODY01 ADJU ST ME NT AN D RE PAIR ... .... .... .... .... .... .... .... ... .... .... ... .... ....

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COVER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT ADJUSTMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STORAGE COMPARTMENT INNER SHELL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STORAGE COVER SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STORAGE COMPARTMENT COVER ADJUSTMENT ... .. ... .. ... .. .. ... .. ... .. ... ..

MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFLECTOR AND/OR UPPER GRID... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INLET GRATE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDING PLATE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JET PUMP SUPPORT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRAIN PLUG INSTALLATION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT COVER REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BUMPER REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WAKE PYLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPONSON REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPONSON ADAPTOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BAILER PICK-UPS INSPECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DECALS REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HULL AND BODY REPAIR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOLS AND MATERIALS LIST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 TECHNICAL SPECIFICATIONS01 GT X, WAKE AN D G TX SC MO DELS .... .... .... .... ... ... ... .... .... ... .... ....

02 GT X L IMITED AND R XT MOD ELS ..... ... .... .... .... .... .... .... .... ... .... ....

03 R XP MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS01 E LE CTR ICAL CON NE CT OR S ... .... .... .... .... .... .... .... ... .... .... ... .... ....

DEUTSCH CONNECTORS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PACKARD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AMP CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ECM CONNECTORS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY AND STARTER CABLE TERMINALS... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02 WIRIN G DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRE COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRE DIGIT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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SAFETY NOTICE

SAFETY NOTICEThis manual has been prepared as a guide to correctly service and repair 2005 SEA-DOO wdescribe in the model list in the INTRODUCTION.

This edition was primarily published to be used by watercraft mechanical technicians who aremiliar with all service procedures relating to BRP made watercraft. Mechanical technicians shtraining courses given by BRP Training Dept.

Please note that the instructions will apply only if proper hand tools and special service tools

ThisVEHICLE SHOP MANUALuses technical terms which may be slightly different from thein the Parts Catalog.

It is understood that this manual may be translated into another language. In the event of anycy, the English version shall prevail.

The content depicts parts and/or procedures applicable to the particular product at time of wvice and Warranty Bulletins may be published to update the content of this manual. Make sand understand these.

In addition, the sole purpose of the illustrations throughout the manual, is to assist identificageneral configuration of the parts. They are not to be interpreted as technical drawings or exof the parts.

The use of BRP parts is most strongly recommended when considering replacement of any cDealer and/or distributor assistance should be sought in case of doubt.

The engines and the corresponding components identified in this document should not beproduct(s) other than those mentioned in this document.

WARNINGUnless otherwise specified, engine should be turned OFF and cold for all maintenance procedures.

This manual emphasizes particular information denoted by the wording and symbols:

WARNINGIdentifies an instruction which, if not followed, could cause serious personal injury inclsibility of death.

CAUTION:Denotes an instruction which, if not followed, could severely damage vehicnents.

NOTE:Indicates supplementary information needed to fully complete an instruction.

Although the mere reading of such information does not eliminate the hazard, your understaninformation will promote its correct use. Always use common shopsafety practice.


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I

INTRODUCTION

GENERAL INFORMATION

ThisVEHICLE SHOP MANUALcovers the following BRP made SEA-DOO 200should be used in conjunction with the1503 4-TEC ENGINE SHOP MANUAL.

MODEL COLOR ENGINE

GTX Twilight Blue Pearl 1503 Naturally Aspirated

GTX Limited Midnight Black Pearl 1503 Supercharged Intercooled

GTX Supercharged Twilight Blue Pearl 1503 Supercharged

RXP Apple Green 1503 Supercharged Intercooled

RXP Viper Red Metallic 1503 Supercharged Intercooled

RXT Apple Green 1503 Supercharged Intercooled

RXT Viper Red Metallic 1503 Supercharged Intercooled

WAKE Viper Red 1503 Naturally Aspirated

The use of RIGHT (starboard) and LEFT (port) indi-cations in the text, always refers to driving position(when sitting on watercraft).

Besides, in the marine industry, FRONT is calledBOW and REAR is called STERN.

F01L45B

1 2

1. Left (port)2. Right (starboard)

The information and component/system descrip-

This VEHICLE SHOP Mterms which may be diffthePARTS CATALOGS.

When ordering parts alwamodelPARTS CATALOGS

Hull Identification N

The Hull Identification Numdigits:

smr05-002-001_aen


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INTRODUCTION

It is located on footboard at the rear of watercraft.

F08L0QA 1

TYPICAL

1. Hull Identification Number (H.I.N.)

P C

ARRANGEMENT OF THISMANUAL

The manual is divided into many majoryou can see in the main table of contbeginning of the manual.

Several sections are divided in variotions. There is a table of contents at thof many sections.

ABBREVIATIONS USED INTHIS MANUAL

ABBREVIATION DESCRIPTION

4-TEC NA Naturally-Aspirated Engine

ADC Analog to Digital Conversio

AC Alternate Current

APS Air Pressure Sensor

ATS Air Temperature Sensor

B.U.D.S. BRP Utility and Diagnostic

CDI Capacitor Discharge Ignitio

CPS Crankshaft Position Senso

CSI Cooling System Indicator

DC Direct Current

DESS Digitally Encoded Security

DI Direct Injection

E.I.N. Engine Identification Numb

ECM Engine Control Module

ECU Electronic Control Unit

EPA Environmental Protection A

HP Horse Power

LED Light Emitting Diode

IC Intercooler

LED Light Emitting Diode

MAG Magneto

MPEM Multi-Purpose Electronic M


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I

ABBREVIATION DESCRIPTION

RAVE Rotax Adjustable Variable Exhaust

RFI Rotax Fuel Injection

RPM Revolution Per Minute

Sc Supercharger

STD Standard

TBD To Be Determined

TDC Top Dead CenterTPS Throttle Position Sensor

VDC Volt Direct Current

VCK Vehicle Communication Kit

Vdc Volt Direct Current

VTS Variable Trim System

WTS Water Temperature Sensor

ILLUSTRATIONS ANDPROCEDURES

The illustrations show the typical construction ofthe different assemblies and, in all cases, may notreproduce thefull detail or exact shape of the partsshown, however, they represent parts which havethe same or a similar function.

CAUTION:These watercraft are designed withparts dimensioned mostly in the metric sys-tem. However some components may be fromthe imperial system. When replacing fasten-ers, make sure to use only those recommendedby BRP.

Asmany of the procedures in this manual are inter-related, we suggest, that before undertaking anytask, you read and thoroughly understand the en-

tire section or subsection in which the procedureis contained.

A number of procedures throughout the book re-quire the use of special tools. Before undertakingany procedure, be sure that you have on hand allthe tools required, or approved equivalents.


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INTRODUCTION


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I


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INTRODUCTION

ENGINE EMISSIONSINFORMATION

Manufacturer's Responsibility

Beginning with 1999 model year engines, PWCmanufacturers of marine engines must determinethe exhaust emission levels for each engine horse-power family and certify these engines with theUnited States of America Environmental Protec-tion Agency (EPA). An emissions control informa-tion label, showing emission levels and enginespecifications, must be placed on each vehicle atthe time of manufacture.

Dealer Responsibility

When performing service on all 1999 and morerecent Sea-Doo watercrafts that carry an emis-

sions control information label, adjustments mustbe kept within published factory specifications.

Replacement or repair of any emission relatedcomponent must be executed in a manner thatmaintains emission levels within the prescribedcertification standards.

Dealers are not to modify the engine in any man-ner that would alter the horsepower or allow emis-sion levels to exceed their predetermined factoryspecifications.

Exceptions include manufacturer's prescribedchanges, such as altitude adjustments for exam-ple.

Owner Responsibility

The owner/operator is required to have enginemaintenance performed to maintain emission

levels within prescribed certification standards.

The owner/operator is not to, and should not al-low anyone to modify the engine in any mannerthat would alter the horsepower or allow emis-sions levels to exceed their predetermined factoryspecifications.

EPA Emission RegulationsAll new 1999 and more recent Sea-crafts manufactured by BRP are certEPA as conforming to the requiremregulations for the control of air polnew watercraft engines. This certificatingent on certain adjustments being sstandards. For this reason, the factoryfor servicing the product must be stric

and, whenever practicable, returned nal intent of the design.

The responsibilities listed above are gin no way a complete listing of the rulelations pertaining to the EPA requiremhaust emissions for marine productsdetailed information on this subject, yotact the following locations:

VIA U.S. POSTAL SERVICE:Office of Mobile Sources

Engine Programs and Compliance Div

Engine Compliance Programs Group (

401 M St. NW Washington, DC 2046

VIA EXPRESS or COURIER MAIL:

Office of Mobile Sources

Engine Programs and Compliance Div

Engine Compliance Programs Group (

501 3rd St. NW Washington, DC 2000

EPA INTERNET WEB SITE:

http:/www.epa.gov/omswww

SELF-LOCKING FASTENER

PROCEDUREThe following describes the most comcation procedures when working with fasteners.

Use a metal brush or a screwtap to clel th l t (M th l C


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I

LOCTITE APPLICATIONPROCEDURE

The following describes the most common ap-plication procedures when working with Loctiteproducts.

NOTE:Always use proper strength Loctite prod-uct as recommended in thisSHOP MANUAL.

ThreadlockerUncovered Holes (bolts and nuts)

1. Apply here2. Do not apply

Clean threads (bolt and nut) with solvent.

Apply Loctite Primer N (P/N 293 800 041) onthreads and allow to dry.

Choose proper strength Loctite threadlocker.

Fit bolt in the hole.

Apply a few drops of threadlocker at proposedtightened nut engagement area.

Position nut and tighten as required.

Blind Holes

1. On threads2. On threads and at the bottom

Clean threads (bolt and Apply Loctite Primer N

threads (bolt and nut) seconds.

Choose proper strength

Apply several drops alonat the bottom of the ho

Apply several drops on

Tighten as required.Stud in Blind Holes

1 On threads


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INTRODUCTION

Install stud. Install cover, etc.

Apply drops of proper strength Loctite on un-covered threads.

Tighten nuts as required.

Preassembled Parts

A00A3OA

1

2

1. Apply here2. Do not apply

Clean bolts and nuts with solvent.

Assemble components.

Tighten nuts.

Apply drops of proper strength Loctite onbolt/nut contact surfaces.

Avoid touching metal with tip of flask.

NOTE: For preventive maintenance on exist-ing equipment, retighten nuts and apply properstrength Loctite on bolt/nut contact surfaces.

Adjusting Screw

1. Apply here2. Plunger

Adjust screw to proper setting.

Apply drops of proper strength Loclocker on screw/body contact surfa

Avoid touching metal with tip of flas

NOTE:if it is difficult to readjust, heat a soldering iron (232C (450F)).

Stripped Thread Repair

1. Release agent2. Stripped threads3. Form-A-Thread4. Tape5. Cleaned bolt6 Plate


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I

b. Put waxed paper or similar film on the sur-faces.

Twist bolt when inserting it to improve threadconformation.

NOTE:NOT intended for engine stud repairs.

Repair of Small Holes/Fine Threads

Option 1: Enlarge damaged hole, then followSTANDARD THREAD REPAIR procedure.

Option 2: Apply FORM-A-THREAD on the screwand insert in damaged hole.

Permanent Stud Installation (light duty)

Use a stud or thread on desired length.

DO NOT apply release agent on stud.

Do a STANDARD THREAD REPAIR.

Allow to cure for 30 minutes.

Assemble.

Gasket Compound

A00A3SA

21

1 3

1

1. Proper strength Loctite2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518

(P/N 293 800 038) on both sides of gasket3. Loctite Primer N only

Apply GASKET ELIMIN038) on both sides of gplicator.

Place gasket on matingimmediately.

NOTE:If the cover is bolteapply proper strength Lothreads. Tighten.

If holes are sunken, applyon bolt threads.

Tighten as usual.

Mounting on Shaft

Mounting with a Press

1. Bearing2. Proper strength Loctite3. Shaft

Clean shaft external papart.

Apply a strip of proper scircumference at insert

NOTE:Retaining compou

when applied on shaft. DO NOT use anti-seize

product.

No curing period is req

Mounting in Tandem

1 A l t i i


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INTRODUCTION

Case-in ComponentsMetallic Gaskets

1. Proper strength Loctite

Clean inner housing diameter and outer gasketdiameter.

Spray housing and gasket with Loctite Primer N(P/N 293 800 041).

Apply a strip of proper strength Loctite on lead-ing edge of outer metallic gasket diameter.

NOTE:Any Loctite product can be used here. Alow strength liquid is recommended as normalstrength and gap are required.

Install according to standard procedure.

Wipe off surplus. Allow it to cure for 30 minutes.

NOTE:Normally used on worn-out housings toprevent leaking or sliding.

It is generally not necessary to remove gasketcompound applied on outer gasket diameter.

TIGHTENING TORQUES

Tighten fasteners to torque mentioned in explod-ed views and/or text, When they are not specified,refer to following table.

WARNINGT h ti ht i ifi ti

In order to avoid a poor assembliscrews, bolts or nuts in accordancfollowing procedure:

Manually screw all screws, bolts and

Apply the half of the recommended to

CAUTION:Be sure to use the propertorque for the proper strength grade

NOTE: When possible, always apply to

nut.

Torque to the recommended torque

NOTE:Always torque screws, bolts ana criss-cross sequence.


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I

FASTENER GRADE/TORQUEFASTENER

SIZE 5.8Grade 8.8 Grade 10.9Grade

M4 1.5 2 Nm(13 18 lbfin)

2.5 3 Nm(22 27 lbfin)

3.5 4 Nm(31 35 lbfin)

M5 3 3.5 Nm

(27 31 lbfin)4.5 5.5 Nm(40 47 lbfin)

7 8.5 Nm(62 75 lbfin)

M6 6.5 8.5 Nm

(58 75 lbfin)8 12 Nm

(71 106 lbfin)10.5 15 Nm(93 133 lbfin)

M8 15 Nm (11 lbfft) 24.5 Nm (18 lbfft) 31.5 Nm (23 lbfft)

M10 29 Nm (21 lbfft) 48 Nm (35 lbfft) 61 Nm (45 lbfft) M12 52 Nm (38 lbfft) 85 Nm (63 lbfft) 105 Nm (77 lbfft)

M14 85 Nm (63 lbfft) 135 Nm (100 lbfft) 170 Nm (125 lbfft)


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Section 0

Subsection 01 (MAI

MAINTENANCE CHARTThe schedule should be adjusted according to operating conditions and use.

NOTE:The chart gives an equivalence between number of hours and months/yenance operation to whatever time comes first.

IMPORTANT: Watercraft rental operations or intensive use of watercraft, will reof inspection and maintenance.

4-TEC MODELSFIRST 10 HOURS

EVERY 25 HOURS OR 3 MO

EVERY 50 HOURS O

A: ADJUST

C: CLEAN

I: INSPECT

L: LUBRICATE

R: REPLACE

T: PROCEED WITH TASK EVERY 100 H

PART/TASK

GENERAL

Lubrication/corrosion protection T

ENGINE

Engine oil and filter (including cover's O-rings) R R (7)

Support and rubber mount I I

Seals and fasteners I I

Exhaust system fasteners (5) I I

Spark plug (5) R

Supercharger slipping moment (if so equipped) I

Supercharger drive gear, shaft and lock washer (if so equipped) I (10)

(5) Emission-re

(7) Replace for

of use whic

(10) Every 100

engines.

Every 200

intercoole

COOLING SYSTEM

Flushing (exhaust system) T (3)

Hose and fasteners I I

Coolant I R (7)

Coolant expansion tank cap/cooling system pressure test T (4)

(3) Daily flushi

(4) Perform ev

(7) Replace for

of use whic

FUEL SYSTEMThrottle cable I, A, L

Engine management system sensors I I

Fault code reading of engine management system (1) (5) I

Fuel lines, fuel rail, connections, pressure relief valve and fuel system

pressurization (5) I I

(1) In salt wate

(5) Emission-r


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Section 01 MAINTENANCE

Subsection 01 (MAINTENANCE CHART)

4-TEC MODELSFIRST 10 HOURS

EVERY 25 HOURS OR 3 MONTHS

EVERY 50 HOURS OR 6 MONTHS

A: ADJUST

C: CLEAN

I: INSPECT

L: LUBRICATE

R: REPLACE

T: PROCEED WITH TASK EVERY 100 HOURS OR 1 YEAR

PART/TASK LEGEND

ELECTRICAL SYSTEM

Electrical connections and fastening (ignition system, starting system,fuel injectors etc.)

I I

MPEM and ECM connectors I (1)

MPEM mounting brackets/fasteners I

Digitally Encoded Security System and safety lanyard/post I I

Monitoring beeper I I

Battery and fasteners I I

(1) In salt water use.

STEERING SYSTEM

Steering cable I, A, L I, A, L

O .P.A .S . s yst em i nc lu din g fil te r (if so e qu ip ped ) I , A I, A (8) I, A (8) E ve ry 25 ho ur s wh en rid in g i n

PROPULSION SYSTEM

Drive shaft corrosion protection L (9)

Drive shaft protection boot I (2)

Drive shaft/impeller splines (normally aspirated and supercharged

engines) L

Drive shaft/impeller splines (supercharged intercooled engines) L

Sacrificial anode I

Shifter system/cable I, A, L I, A, L

VTS (Variable Trim System) (if so equipped) I, A I, A

Impeller shaft seal, sleeve and O -ring I (6)

Impeller and impeller/wear ring clearance I (2)

Water intake grate I (2)

Ride plate including coolant leak I IDrive shaft/hull sealing system I I

(2) These items have to be initially25 hours. Thereafter, servicin

specified in this chart.

(6) Replace after the vehicle com

of use or 2 years.

(9) Perform at storage period or a

use whichever comes first.

HULL/BODY

Bailer pick-ups, check for obstructions I I

Hull I I

S f


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Section 0

Subsection 02 (PRESEAS

PRESEASON PREPARATIONTO BE PERFORMED BY

PRESEASON PREPARATIONCUSTOMER DEALER

GENERAL

Lubrication and corrosion protection

Spark plugs replacement (1)

ENGINEExhaust system condition and fasteners

Condition of seals and fasteners A

Oil level

COOLING SYSTEM

Coolant level

Hoses and components (3)

FUEL SYSTEM

Fuel injection sensors verification

Inspection of check valves, lines, fasteners andpressurization (2)

Filler neck, fuel tank and fuel cap condition (2)

Fuel tank straps

F

Refill fuel tank

ELECTRICAL SYSTEM

Battery condition/charging and installation

Connection and routing of electric harness (battery,starter, etc.) (2)

Digitally Encoded Security System (DESS) andmonitoring beeper verification

STEERING SYSTEM

Steering system adjustment and inspection (2)

Check O.P.A.S. system condition


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Subsection 02 (PRESEASON PREPARATION)

TO BE PERFORMED BYPRESEASON PREPARATIONCUSTOMER DEALER

REFER

PROPULSION SYSTEM

Shifter system condition and cable adjustment Reverse S

Variable Trim System (VTS) condition(if so equipped)

VTS Sys

Propulsion system inspection Jet Pump and D

HULL and BODYInspection of bailer pick-ups Hull/Bo

Ski/wakeboard post and fasteners(if so equipped)

Hull/Bo

(1) Before installing new spark plugs, it is suggested to burn the excess BOMBARDIER LUBE (P/N 2or equivalent by starting the engine using the old spark plugs.

(2) Safety item covered in the annual safety inspection.

(3) If antifreeze was not changed for storage, drain and replace with new antifreeze.

N.A.: Not applicable


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Section 0

Subsection 03 (STOR

STORAGE PROCEDURESSERVICE TOOLS

Description Part Number

flushing connector adaptor ................................................... 295 500 473 .........small hose pincher................................................................ 295 000 076 .........

SERVICE PRODUCTS


anticorrosion coating ............................................................ 219 700 304 .........Bombardier fuel stabilizer..................................................... 413 408 600 .........

BOMBARDIER LUBE lubricant............................................. 293 600 016 .........

Loctite 243 (blue).................................................................. 293 800 060 .........

PROPULSION SYSTEM

Jet Pump

Verify jet pump grease for water contamination.

Check for the presence of water in cone and bear-ing; if so, replace oil seal and sleeve.

CAUTION: Use only Bombardier jet pumpgrease or equivalent, otherwise componentsservice life could be reduced. Do not mixgrease brands or types.

FUEL SYSTEM

Verify fuel system. Check fuel hoses for leaks.Replace damaged hoses or clamps if necessary.

Bombardier fuel stabilizer (P/N 413 408 600) orequivalent should be added in fuel tank to preventfuel deterioration and fuel system gumming. Fol-low manufacturer's instructions for proper use.

WARFuel is inflammable acertain conditions. Alventilated area. Do not

flames or sparks in thmay be pressurized, sopening. When fuelingel. Do not overfill or toleave watercraft in the increases, fuel expandsAlways wipe off any fwatercraft. Periodically

ENGINE OIL ANDREPLACEMENT

Change engine oil and filTION SYSTEM in ENGINE


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Subsection 03 (STORAGE PROCEDURES)

Cooling system flushing should be performedwhen the watercraft is not expected to be usedfurther the same day or when the watercraft isstored for any extended time.

CAUTION:Failure to flush open loop coolingsystem, when necessary, will severely dam-age engine intercooler and/or exhaust system.Make sure engine operates during entire pro-cedure.

WARNINGPerform this operation in a well ventilatedarea. Do not touch any electrical part or jetpump area when engine is running.

Proceed as follows:

Clean jet pump by spraying water in its inlet andoutlet and then apply a coating of BOMBARDIERLUBE lubricant (P/N 293 600 016) or equivalent.

WARNINGAlways remove safety lanyard cap from postto prevent unexpected engine starting beforecleaning the jet pump area. Engine must notbe running for this operation.

Procedure Using Flushing Connectoron Jet Pump Support

All Models

Connect a garden hose to connector located at therear of watercraft on jet pump support. Do notopen water tap yet.

WARNINGWhen operating the engine while the water-craft is out of the water, the heat exchangerin the ride plate may become very hot. Avoidany contact with ride plate as burns may oc-cur.

1. Quick connect adapter2. Flushing connector adapter

TYPICAL

1. Flushing connector

2. Quick connect adapter and flushing connector ad3. Garden hose

To flush the exhaust cooling systemengine then immediately open the wa

WARNINGCertain components in the enginement may be very hot. Direct conta

sult in skin burn. Do not touch anypart or jet pump area when engine i

CAUTION:Never flush a hot enginstart the engine before opening theOpen water tap immediately afterstarted to prevent overheating.


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Section 0

Subsection 03 (STOR

Close the water tap, then stop the engine.CAUTION:Always close the water tap beforestopping the engine.

Disconnect the garden hose.

CAUTION:Remove flushing connector adapterafter operation (if used).

Procedure Using Flushing Connector

in Engine CompartmentGTX 4-TEC Limited Models

This flushing connectorallows to flush the exhaustcooling system directly by the engine compart-ment. The access is easier than the connectoron the jet pump support but requires the use ofa small hose pincher.

Remove seat to gain access.

Install a small hose pincheplied inside vehicle tool kThis prevent water from dcooling system.

This prevents water fromcooling system.

1. Coupler hose2. Small hose pincher

Attach other end of coupleDo not open water tap ye

To flush the exhaust cooligine then immediately op

WARCertain components inment may be very hot

S i MAINTENANCE


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CAUTION: Never run engine without supplyingwater to the exhaust cooling system when wa-tercraft is out of water.

CAUTION: Never run engine longer than 5 min-utes. Drive line seal has no cooling when wa-tercraft is out of water.

Run the engine about 20 seconds at a fast idlebetween 4000 - 5000 RPM.

Ensure water flows out of jet pump while flushing.

Close the water tap, then stop the engine.

CAUTION:Always close the water tap beforestopping the engine.

Unlock and remove coupler hose. Reinstall dustcap over flushing connector.

Remove hose pincher from water outlet hose.

CAUTION:Serious damage to exhaust system

can occur if hose pincher is not removed.

CLOSED LOOP COOLINGSYSTEM (ENGINE)

Antifreeze should be replaced for the storage pe-riod to prevent antifreeze deterioration.

Make sure to perform an antifreeze density test.

For the coolant replacement procedure, refer toCOOLING SYSTEM section.

CAUTION: Improper antifreeze mixture mightallow freezing of the liquid in the cooling sys-tem if vehicle is stored in area where freezingpoint is reached. This would seriously damagethe engine. Failure to replace the antifreezefor storage may allow its degradation thatcould result in poor cooling when engine will

be used.

ENGINE LUBRICATION

Engine must be lubricated to prevent corrosion oninternal parts.

F i f th i i d d t th d

Spray liberally BOMBARDIER LUB(P/N 293 600 016) into the intake po

Crank engine several times while ketle fully depressed (drown engine mtribute lubricant in cylinders, on inand exhaust valves.

Carefully inspect O-rings conditioninstalling fuel injectors. Replace Onew ones if damaged. Lubricate O

injection oil prior to installing. Reinstall the injectors.

Apply Loctite 243 (blue) (P/N 293 8torque the two bolts to 9 Nm (80 hold the fuel rail on.

Make sure there is no leak at injecranking the engine in the upcomin

WARNINGIf a leak is present, immediately stgine. Do not start engine until thepaired.

WARNINGAt preseason preparation, ensure ta fuel pressure test and ensure thleak. Also run engine and check

Refer to FUEL TANK AND FUEL Ption.

THROTTLE BODY LUBRICA

It is recommended to lubricate the thto prevent corrosion on external and inespecially if the craft is used in salt wa

Remove the air intake hose from throt

Open the throttle body valve by pressthe throttle lever and spray BOMBARlubricant (P/N 293 600 016) through body bore to lubricate valve mechan

l th t l t

S ti 0


29/314

Section 0

Subsection 03 (STOR

Let the intercooler drain, then connect the bot-tom hose.

Pour approximately 200 mL (6.76 oz U.S.) ofantifreeze into the intercooler.

Thenpour approximately300mL (10.14 oz U.S.)of antifreeze into the exhaust manifold.

Reconnect the upper hose.

CAUTION: It is highly recommended to pourantifreeze into the intercooler and exhaustmanifold. Failure to do so, may cause severedamage to these components.

CAUTION: Use only undiluted antifreeze (100%concentration). The premixed antifreeze avail-able from BRP is NOT suitable for this par-ticular application. Its concentration will bereduced when mixed with remaining watertrapped in water jackets.

NOTE: When available, it is recommended touse biodegradable antifreeze compatible withinternal combustion aluminum engines. This willcontribute to protect the environment.

NOTE:The engine will not have to run during thisoperation but should have been ran before, to ex-haust as much water as possible, from coolingsystem components.

BATTERYFor battery removal, cleaning and storage, refer toCHARGING SYSTEM.

WATERCRAFT CLEANING

Clean the bilge with hot water and mild detergentor with bilge cleaner. Rinse thoroughly. Lift front

end of watercraft to completely drain bilge. If anyrepairs are needed to body or to the hull, touchup paint and Gelcote repair kit are available. Re-place damaged labels/decals.

Wash the body with soap and water solution (onlyuse mild detergent). Rinse thoroughly with fresh

If the watercraft is to be with an opaque tarpaulin grime from affecting the ptercraft finish as well as plation.

CAUTION:The watercrawater for storage. Nevestored in direct sunlight

ANTICORROSIONWipe offany residual watement.

Spray BOMBARDIER LUB016) over all metallic compartment.

Lubricate the throttle cabLUBE lubricant (P/N 293 6

Apply the anticorrosion coon drive shaft. Refer to D

The seat and the seat extly left opened during storagine compartment condenrosion.



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CHECKLISTOPERATION

Verify jet pump grease.

Verify fuel system.

Add Bombardier fuel stabilizer.

Fill up fuel tank.

Change engine oil and filter.

Check engine drain hose(s).

Flush exhaust cooling system.

Replace antifreeze. Check solutionconcentration in the cooling system (in coolregions).

Lubricate the engine.

Lubricate throttle body.

Add antifreeze into intercooler and exhaustmanifold (where temperatures are belowfreezing).

Remove, clean and store the battery.

Clean the bilge.

Wash the body.

Spray BOMBARDIER LUBE lubricant (P/N 293600 016) over all metallic components in enginecompartment and in throttle cable.

Apply the anticorrosion coating (P/N 219 700304) on drive shaft.

Partially lift the seat and the seat extension.

Section 0


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Section 0

Subsection 04 (SPE

SPECIAL PROCEDURESSERVICE TOOLS


large hose pincher................................................................ 529 032 500 .........oil pump cover fitting............................................................ 293 710 037 .........pump ....................................................................................

529 035 880 .........

SERVICE PRODUCTS


Loctite 243 (blue).................................................................. 293 800 060 .........

pulley flange cleaner............................................................. 413 711 809 .........

TOWING THE WATERCRAFTIN WATER

Special precautions should be taken when towinga Sea-Doo watercraft in water.

Maximum recommended towing speed is24 km/h (15 MPH).

When towing your watercraft in water, pinch thewater supply hose from the jet pump housing tothe engine with a large hose pincher (P/N 529 032500).

Snugly install the hose pinply hose as shown in the

NOTE: Pinch the hose wequipped).



32/314


Subsection 04 (SPECIAL PROCEDURES)

TYPICAL

1. Hose pincher

CAUTION: When finished towing the wa-tercraft, the hose pincher must be removedbefore operating it.

SUBMERGED WATERCRAFT

Drain bilge if water is present.

If it was submerged in salt water, spray bilge andall components with fresh water using a gardenhose to stop the salt corroding effect.

Engine

Refer to WATER-FLOODED ENGINE to validate ifi i i

Throttle Body

Throttle body should be lubricated corrosion if watercraft was submergeSTORAGE for procedure.

WATER-FLOODED ENGINE

If engine is water-flooded, it must bwithin a few hours after the event. Ot

gine will have to be overhauled.CAUTION: A water-flooded engineproperly lubricated, operated thenagain, otherwise parts will be serioaged.

Check fuel reservoir for water contamnecessary, siphon and refill with fresh

To limit damages to the engine, perfo

lowing procedure as soon as possibleDrain bilge if water is present.

If it was submerged in salt water, spraall components with fresh water usinhose to stop the salt corroding effect.

CAUTION:Never try to crank or stgine. Water trapped in the intakewould enter the combustion chambthe intake valves and may cause dthe engine.

Whenever the engine is stopped, allclose thus preventing water from beinin the engine.

If water is suspected to be in the intaexhaust system, it must be drained as

Remove the intake manifold and drasuck out the water from the intake vRefer to1503 4-TEC ENGINE SHOP M

Remove the water from oil/air separathose.

Remove the exhaust pipe and drain it. remove the mufflers to drain them or

Section 0


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Section 0

Subsection 04 (SPE

SuperchargerSupercharged 4-TEC Engines

If there was water in the oil or in the intake mani-fold, it is recommended to take the superchargerapart, dry all the components, replace the slipclutch needle bearings and shaft ball bearings.Refer to1503 4-TEC ENGINE SHOP MANUAL.

Oil Change Procedure

(water-contaminated oil) Using the pump (P/N 529 035 880), siphon oil

from reservoir through dipstick hole.

CAUTION:Never crank or start engine whensiphon tube is in dipstick hole. Never start en-gine when there is no oil in engine.

Remove the pump from the dipstick hole.

While in drowned engine mode, crank the en-

gine for 5 seconds. Remove the oil filter cap and the oil filter.

Again, siphon oil from the reservoir.

Put a rag under the scavenge oil pump cover.

Remove the scavenge oil pump cover drain plugand install the oil pump cover fitting (P/N 293710 037).

1. Scavenge oil pump cover drain

Connect the pump (P/

fitting. The front of the engine

proximately 15 degreesof the oil. Raise the realy. Siphon the oil from

Level the engine.

Remove thepump andt243 (blue) (P/N 293 80drain plug.

NOTE:If spillage occurs, the pulley flange cleaner (vent oil stains.

Install a new oil filter acap.

Fill up the reservoir wit

Boil out the remaining w

Recommended procCEDURE IN A TESTTRAILER WITH WAT

Optional procedureDURE CONNECTED

Refer to instructions belo



34/314

Subsection 04 (SPECIAL PROCEDURES)

WARNINGMake sure to safely secure the watercraft.

With the engine still running at 3500 RPM, in-stall a hose pincher to the coolant line going tothe oil cooler.

WARNINGCertain components in the engine compart-ment may be very hot. Direct contact may re-sult in skin burn. Do not touch any electricalparts or jet pump area when engine is run-ning.

1. Oil cooler coolant inlet hose

Continue to run the engine at 3500 RPM for 15more minutes (20 minutes total run time).

Shut the engine off.

Remove the hose pincher on the coolant line

going to the oil cooler.CAUTION:Hose pincher must be removed pri-or to operating the watercraft. Failure to dothis will result in damage to the engine.

Change the oil and filter again.

Procedure is now completed.

CAUTION: Never run engine withouwater to the exhaust cooling systemtercraft is out of water.

Run the engine for 5 minutes at 30

With the engine still running at 300stall a hose pincher to the coolant lithe oil cooler.

WARNING

Certain components in the enginement may be very hot. Direct contasult in skin burn. Do not touch anyparts or jet pump area when engining.

1. Oil cooler coolant inlet hose

Continue to run the engine at 3000 more minutes (20 minutes total run

Shut off the engine.

Remove the hose pincher on the c

going to the oil cooler.CAUTION:Hose pincher must be reor to operating the watercraft. Fathis will result in damage to the eng

Change the oil and filter again.

Move rearward the ring seal carrier

Section 02 TR


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Subsection 01 (TROUBLE

TROUBLESHOOTING CHARTThe following is provided to help in diagnosing the probable source of troubleshould not be assumed to show all causes for all problems.

NOTE:On fuel injection models, always check for fault codes. If a fault code fault code and recheck operating conditions. Refer to DIAGNOSTIC PROCEDAGEMENT section.

ENGINE WILL NOT START

OTHER OBSERVATION POSSIBLE CAUSE R

Wrong safety lanyard Use one that has

DESS operation non functional If 2 short beeps installing safety lMANAGEMENT

Safety lanyard switch faulty or

disconnected or harness damaged

Replace

Burnt fuse: battery, starting system.Also fuel pump

Check wiring the

Starting system fuse keeps on burning Check wiring, stand MPEM

Discharged or disconnected battery Check/recharge

Defective or disconnected start/stopswitch

Check, refer to S

Battery connections Check/clean/tigh

Poor/bad or corroded ground contacts(engine, starter etc.)

Check/clean/repa

Water/fuel hydro-lock Check, refer to M

Starter malfunction Check, refer to E

Starter solenoid Check, refer to E

Obstructed starter drive gear assembly Check/repair, refHOUSING/MAG4-TEC ENGINE

Seized or obstructed engine Check/repair, refENGINE SHOP

Engine does not turn over

Section 02 TROUBLESHOOTING


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Subsection 01 (TROUBLESHOOTING CHART)

OTHER OBSERVATION POSSIBLE CAUSE REMEDYLoose 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

Partial engine hydro-lock Check, refer to MAINTENANC

Partial engine seizure Check compression, refer to t4-TEC ENGINE SHOP MAN

Worn starter Check, refer to ELECTRICAL S

Timing chain not guided by chain guide ) Check, refer to the1503 4-TESHOP MANUAL

Oil is too thick. Change oil vis

Engine turns slowly

Outside temperature too low

Battery capacity is not sufficietemperature

Faulty component in the fuel injectionsystem

Check for fault codes. Refer DIAGNOSTIC PROCEDURES MANAGEMENT

Engine drowned mode is active Release throttle lever

Low battery voltage Recharge or replace battery

Check fuel pump pressure out

Check fuel pump fuse

Low or no fuel pressure

Check wiring harness

Check fuel injector operation. necessary

Fuel injectors not working

Check output signal from MPE

No spark at the spark plug Check spark plugs condition aas necessary

Check ignition system and repDefective MPEM or ECM

Replace MPEM or ECM (as ap

Defective CPS Check operation of CPS and rnecessary

Wat ta i at d f l Ch k/ i h d fill

Engine turns over

Section 02 TR


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Defective encoder/trigger wheel Check, refer to E

Incorrectly aligned flywheel and triggerwheel

Properly positionwheel, refer to thSHOP MANUA

Insufficient engine compression Replace defectiv

Engine turns over (cont'd)

Idle bypass valve stuck or notfunctioning

Check, refer to E

Spark plug faulty, fouled or worn out Check spark plug

Ignition Check, refer to E

No spark at spark plugs

Faulty ECM Replace ECM

ENGINE HARD TO START


Defective idle bypass valve Refer to ENGINE

Wrong TPS zero setting Refer to ENGINE

Throttle cable adjustment Refer to ENGINE

Temperature too low for availablebattery capacity

Battery capacity temperature

Air lock in fuel rail Refer to ENGINE

Water in intake system (defective MAPsensor)

Check and remoSPECIAL PROCE

Water in fuel reservoir or contaminatedfuel

Flush reservoir a

Check cylinder c

Check for cylinde

Mechanical engine failure

Check starting sy

Spark plug faulty, fouled or worn out Check spark plug

Check fuel pumpFUEL TANK AND

Low fuel pressure

Check fuel press


S b ti 01 (TROUBLESHOOTING CHART)


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ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

OTHER OBSERVATION POSSIBLE CAUSE REMEDY

The system is in limp home mode Refer to ENGINE MANAGEMcheck the fault codes

Broken or loose throttle cable Change/readjust

ENGINE MISFIRES, RUNS IRREGULARLY


Fouled, defective, worn spark plugs Check/verify heat range/gap/re

Faulty ECM or MPEM Check, refer to ENGINE MANA

Defective trigger wheel/CPS Check, refer to ENGINE MANA

Bad ignition coil wiring Check wiring condition and pgrounding of ignition coil

Faulty ignition coil, or bad connector Check coil. Refer to ENGINEMANAGEMENT or ELECTRICSYSTEM

Weak spark

Poor engine ground Check/clean/repair

Low fuel pressure Check pump, regulator, injectopinchers or if filter is plugged.if necessary

Stale or water fouled fuel Check/siphon and refill

Fuel filter dirty or restricted Check/clean/replace

Clogged fuel injectors Remove and clean fuel injecto

Lean fuel mixtureDry spark plug (exceptwhen water fouled)

Defective sensor or ECM Check faulty codes in ECM meto ENGINE MANAGEMENT

Flame arrester dirty or restricted Check/replace

Faulty fuel injector(s) Remove and replace fuel injec

to ENGINE MANAGEMENT

Defective sensor or ECM Check fault codes. Refer to EMANAGEMENT

Fuel pressure fluctuating Inspect fuel pressure regulatoFUEL SYSTEM

Rich fuel mixtureFouled spark plug

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Check spark plug condition, check faultcodes, check fuel pressure.

Check, refer to IENGINE MANAGhas been performsure injector wiremixed. Refer tofor wire colors a

Starts, but runs poorly

Bent or missing tooth on trigger wheel Check, refer to E

Injector wiring reversed Refer to the WIRAlso fuel injectionmisinjecting

Damaged fuel injector Check, refer to E

ENGINE CONTINUALLY BACKFIRES


Weak spark Fouled, defective spark plugs Clean/replace

Spark plugs Ignition coil wiring reversed Refer to WIRING

Incorrect setting Check/reset, refeSYSTEMIgnition timing

Defective trigger wheel/CPS Check, refer to E

Engine Intake or exhaust valve(s) leak Pressure check e

4-TEC ENGINE

ENGINE DETONATION OR PINGING


Ignition Spark plug heat range too high Check/change to

Engine overheats and exhaust overheats Check, see ENGsection

Fuel octane too low of poor fuel quality Use good quality

Knock sensor disconnected or faulty Check, refer to E

Bad knock sensor connection Check, refer to E

Engine/exhaust hightemperature

Bad ECM connection Check, refer to E




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ENGINE LACKS ACCELERATION OR POWER


Weak spark Check/replace, refer to IGNITSYSTEM

Throttle does not open fully Check/readjust, refer to ENGIMANAGEMENT

Low compression Check/repair, refer to the150

ENGINE SHOP MANUALWater in fuel Check/siphon/replace

Impeller leading edge damaged Check/replace, refer to PROPUSYSTEM

Too much engine oil Siphon or adjust level. Refer LUBRICATION SYSTEM

Poor fuel quality Siphon then refill with fresh fu

Clogged fuel injectors Remove and clean fuel injecto

Low fuel pressure Check fuel line and fuel pump

Incorrect throttle position sensor (TPS)adjustment

Check and adjust TPS, refer toMANAGEMENT

Improper timing chain alignment Refer to CYLINDER HEAD in t4-TEC ENGINE SHOP MAN

Defective supercharger Check/repair, refer to the150

ENGINE SHOP MANUAL

Overheated engine See ENGINE OVERHEATS in t

Engine revs lower thanits maximum operationalRPM

Limp home mode activated Refer to ENGINE MANAGEME

ENGINE STOPS RUNNING


Contaminated or inappropriate fuel Syphon reservoir and refill witEngine stalls at idle

Air in fuel rail Refill fuel tank

Engine running out of fuel Check fuel delivery system forEngine start but stops

Section 02 TR



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ENGINE CANNOT REACH MAXIMUM RPM


Low fuel pressure Check fuel pump

Jet pump related problem Check propulsionJET PUMP

Limp home mode activated Refer to ENGINE

Exhaust system blockage/muffler

damage

Check and repair

Exhaust gases in bilge (leak) Check exhaust s

Defective supercharger Check/repair, refENGINE SHOP

Battery voltage is too low Check/repair, refSYSTEM

ENGINE RUNS TOO FAST (VEHICLE CANNOT REACH IT


Faulty rev limiter Check, refer to E

Improper impeller pitch (too low) Check/replace, rSYSTEMEngine RPM too high

Damaged impeller Replace impeller

SYSTEMDamaged leading or trailing edge ofimpeller

Check/replaceNOTE:Leading eto poor performaedge damage coperformance and

Jet pump cavitation

Sealing of ride plate, jet pump support orjet pump

Check/reseal, rePROPULSION SY




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ENGINE OVERHEATS


Coolant level low Refill/check for leaks

Coolant leaking out of weep hole(PTO housing)

Replace seal

Hoses or clamps missing/defective Repair/replace

Cylinder head gasket leaks

(white exhaust gas)

Replace cylinder head gasket

Thermostat failure Replace

Coolant pump failure Replace

Coolant level too low

Internal passage blockage Inspect and clean

Temperature sensor defective Check/replace. Refer to ENGMANAGEMENT

Worn water pump impeller Check/replaceCooling system restriction Check/flush, refer to MAINTE

Damaged ride plate or hoses Check, refer to COOLING SYSHULL/BODY

Monitoring beepersounds continuously

Thermostat defective Check/replace

ENGINE SMOKE IN THE EXHAUST


Coolant leak Check/repair. Refer to COOLSYSTEM

Intercooler leak(if so equipped)

Check/repair. Refer to the15ENGINE SHOP MANUAL

Damaged cylinder head gasket Check/replace cylinder head g

Water ingestion Inspect intake manifold for winfiltration

White smoke

Valve guide seals Check/replace valve guide seato CYLINDER HEAD in the15ENGINE SHOP MANUAL

Oil l l t hi h Si h f il

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(

LOW OR NO ENGINE OIL PRESSURE

OTHER OBSERVATION POSSIBLE CAUSE

Oil level too low Refill. See TECspecifications

Leaking gasket Replace

Oil leaking out of weep hole (PTO housing) Replace oil seal

Oil pressure sensor defective Check/replace

Oil pump malfunctioning Clean rotor and

Oil regulator valve sticks open, or springload too small

Clean/replace

Heavy wear on plain bearings Replace

ENGINE OIL CONTAMINATION (MILKY)

OTHER OBSERVATION POSSIBLE CAUSE

Oil seal and rotary seal on coolant pumpshaft leaking

Replace both seHOUSING in theSHOP MANUAL

Cylinder head gasket leaking Replace gasket.4-TEC ENGINEChange oil

Loose screws on cylinder head, PTOhousing or oil separator Retorque. Chan

Oil contamination due to metal or plasticparticles

Replace possiblChange oil

Water and oil mixtureleaking out of leak

indicator hole (PTOhousing)

Water ingestion (intake manifold, TOPSvalve, dipstick)

Refer to MAINT

The same causes as above apply. However, look at the folloWater and oil mixturewithout leaking out at

leak indicator hole(PTO housing)

Leak indicator hole plugged Check/clean lea




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UNUSUAL ENGINE NOISE AND/OR VIBRATION


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)is worn out (valve adjustment) or lifterdamaged

Replace faulty rocker arm(s) a

Rocker arm screws not tightened Retorque

Heavy wear on crankshaft and/or balancershaft bearings

Replace

Crankshaft and balancer shaft not aligned Check marks and readjust sha

Heavy wear on thrust washers, or thrustwashers missing

Check/replace

Defective supercharger (if so equipped) Check/repair, refer to the150ENGINE SHOP MANUAL

Missing/defective air intake hose Check/replace air intake hose refer to AIR INTAKE SYSTEM

INAPPROPRIATE SPEEDOMETER READING


Faulty speed sensor or related circuits. Refer to INSTRUMENTS ANACCESSORIES

MPEM was replaced and speedometercalibration data were not transferred tonew MPEM.

Install latest B.U.D.S version in BOSSWeb then connect towith VCK and it will automatupdate MPEM. Refer to ENG

MANAGEMENT

ABNORMAL NOISE FROM PROPULSION SYSTEM


Section 02 TR



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NOTE:Prior to replacing an ECM or MPEM, refer to the appropriate ECM/MPEM

replacement in the ENGINE MANAGEMENT section and read carefully the testan ECM/MPEM that could otherwise be good.

Section 03

Subsection 01 (AI


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AIR INTAKE SYSTEMSERVICE TOOLS


hook tool............................................................................... 529 035 989 .........

Section 03 ENGINE SYSTEM

Subsection 01 (AIR INTAKE SYSTEM)


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4-TEC Naturally Aspirated Engine

Section 03

Subsection 01 (AI


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4-TEC Supercharged and Supercharged Intercooled Engines


Subsection 01 (AIR INTAKE SYSTEM)


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INSPECTION

Check for water in air silencerno. 1. If so, replacecheck valvesno. 2. Check collar tightness. En-sure there is no water trapped in tubeno. 3(if soequipped).

Inspect silencer, tube and hose condition. Re-place any damaged part.

REMOVAL

From storage compartment, remove/disconnect:

hoseno. 4.

front access door (if so equipped)

rectifier/voltage regulator

wiring harness from air silencer

fuel tank straps (refer to FUEL SYShook tool (P/N 529 035 989).

Pull air silencer out.

Section 03

Subsection 01 (AI


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1. Lift lock tab

coolant expansion tank

Step 1: Push tab (each side) to releaseStep 2: Pull tank out

vent tube support

1. Vent tube support2. Remove retaining screws3. Pay attention to nuts undernea

tube from air intake hosPull tube out.

INSTALLATION

Reverse removal operatiotion to the following.

Section 03

Subsection 02 (LUB


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LUBRICATION SYSTEMSERVICE TOOLS


suction pump........................................................................ 529 035 880 .........

SERVICE PRODUCTS


pulley flange cleaner............................................................. 413 711 809 .........

GENERALPrior to changing the oil, ensure vehicle is on alevel surface.

Oil and oil filter must be replaced at the sametime. Oil change and oil filter replacement shouldbe done with a warm engine.

WARNING

The engine oil can be very hot. Wait until en-gine oil is warm.

Dispose oil and filter as per your local environmen-tal regulations.

OIL LEVEL VERIFICATION

CAUTION:Check level frequently and refill if

necessary. Do not overfill - it would make theengine smoke and reduce its power. Operatingthe engine with an improper level may severelydamage engine. Wipe off any spillage.


Subsection 02 (LUBRICATION SYSTEM)


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Check the oil level as follows:

NOTE: It is of the utmost importance to follow thisprocedure in order to obtain an accurate reading ofthe engine oil level.

Watercraft must be level. Check oil level eitherwith watercraft in water or out of water. Engineshould bewarm.

CAUTION: Never run engine without supplyingwater to the exhaust cooling system when wa-

tercraft is out of water. If out of water, raise trailer tongue and block in

position when bumper rail is level. Link a gar-den hose to the hose adapter. Refer to STOR-AGE PROCEDURES in MAINTENANCE sectionand follow the procedures.

CAUTION:Failure to flush exhaust cooling sys-tem, when watercraft is out of water, may se-verely damage engine and/or exhaust system.

Warm-up engine then let idle for 30 secondsbefore stopping.

Stop engine.

Wait at least 30 seconds then pull dipstick outand wipe clean.

WARNINGEngine oil may be hot. Certain components

in the engine compartment may be very hot.Direct contact may result in skin burn.

CAUTION: Never run engine longer than 5 min-utes. Drive line seal has no cooling when wa-tercraft is out of water.

Reinstall dipstick, push in completely.

Documents

Sea Doo Shop Manual (2005)