LIBRO

2009
Shop Manual
RXT iS 255
GTX LIMITED iS 255
Legal deposit:
National Library of Quebec
National Library of Canada 2009
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
Bombardier Recreational Products Inc. (BRP) 2009
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
Sea-Doo
4-TEC
iTC
Sea-Doo Learning Key
D.E.S.S.
O.T.A.S.
VTS (Variable Trim System)
iBR
Rotax
RXT
XPS
iControl
iS
This document contains the trademarks of the following companies:
AMP is a trademark of Tyco Electronics Corporation
Gelcote is a trademark of Gelcote International Limited
GTX is a trademark of Castrol Ltd. Used under license
Loctite is a trademark of Loctite Corporation
Molykote is a trademark of Dow Corning Corporation
Snap-on is a trademark of Snap-on Tools Corporation
Spray-Nine is a trademark of Korkay System Ltd
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
MANUAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
FASTENER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVI
01 MAINTENANCE
01 MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
02 PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
03 STORAGE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPULSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
04 SPECIAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TOWING THE WATERCRAFT IN WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SUBMERGED WATERCRAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WATER-FLOODED ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAPSIZED WATERCRAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
02 ENGINE
01 ENGINE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 AIR INTAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR VENTILATION BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT VENTILATION BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SILENCER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SILENCER BAFFLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPERCHARGER AIR INLET HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
03 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLAME ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04 SUPERCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPERCHARGER INLET CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPERCHARGER CLUTCH SLIPPING MOMENT (ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
15
23
25
27
27
27
27
27
27
28
28
28
29
29
31
32
32
32
35
37
39
39
39
40
41
TABLE OF CONTENTS
02 ENGINE (contd)
04 SUPERCHARGER (contd)
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPERCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
05 INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERCOOLER FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERCOOLER ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
06 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST HOSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESONATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
07 PTO HOUSING AND MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER DRIVE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTOR AND TRIGGER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
08 LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE SWITCH (OPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION PUMP OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL SUCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL SPRAY NOZZLE (SUPERCHARGER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL SPRAY NOZZLES (PISTONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL SEPARATOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOW-BY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II
42
42
42
53
54
54
54
54
54
56
59
61
61
61
61
62
62
64
65
66
67
69
71
71
71
71
76
77
77
78
81
82
83
85
90
90
90
92
93
93
94
95
95
96
97
98
99
102
104
105
106
108
111
TABLE OF CONTENTS
02 ENGINE (contd)
09 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTARY SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUG TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
117
117
117
117
119
119
120
120
120
120
121
123
123
124
127
129
129
129
131
132
132
133
134
134
136
138
139
141
143
146
149
152
152
152
152
153
153
158
159
164
167
03 ELECTRONIC MANAGEMENT SYSTEMS

01 ENGINE MANAGEMENT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 iCONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iTC (INTELLIGENT THROTTLE CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR (INTELLIGENT BRAKE AND REVERSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iS (INTELLIGENT SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
173
175
175
177
177
177
177
178
III
TABLE OF CONTENTS
03 ELECTRONIC MANAGEMENT SYSTEMS (contd)

03 COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MPI-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.U.D.S. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04 MONITORING SYSTEM AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFIC FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
179
179
179
179
181
181
183
187
187
187
190
192
193
04 FUEL SYSTEM
01 INTELLIGENT THROTTLE CONTROL (iTC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE ACCELERATOR SENSOR (TAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 ELECTRONIC FUEL INJECTION (EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLOSED THROTTLE RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CONTROL MODULE (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TPS (THROTTLE POSITION SENSOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT POSITION SENSOR (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD AIR TEMPERATURE SENSOR (MATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST GAS TEMPERATURE SENSOR (EGTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOCK SENSOR (KS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
03 FUEL TANK AND FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM HIGH PRESSURE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL HOSES AND OETIKER CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV
213
213
213
214
214
216
219
219
220
221
221
222
222
222
223
223
230
232
236
239
241
243
245
247
248
249
250
253
256
256
258
258
262
262
263
263
264
268
269
TABLE OF CONTENTS
04 FUEL SYSTEM (contd)

03 FUEL TANK AND FUEL PUMP (contd)
PROCEDURES (contd)
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
05 ELECTRICAL SYSTEM
01 CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
03 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLTAGE REGULATOR/RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
05 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASIC STARTING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER SOLENOID FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE START/STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
06 DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.E.S.S. KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEEPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
277
277
277
278
278
281
283
283
284
286
286
286
287
287
289
289
289
289
289
290
290
290
294
297
297
297
298
298
300
300
300
301
313
313
313
313
313
313
314
314
315
317
322
325
325
325
326
326
330
V
TABLE OF CONTENTS
05 ELECTRICAL SYSTEM (contd)

06 DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) (contd)
PROCEDURES (contd)
D.E.S.S. POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
07 GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODE/SET AND UP/DOWN ARROW BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEPTH SOUNDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330
333
333
333
333
334
334
351
354
355
06 STEERING AND PROPULSION

01 STEERING AND O.T.A.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION (O.T.A.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O.T.A.S. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR SWITCH COVER (LH OR RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE AND iBR LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING COLUMN SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING TILT ADJUSTMENT HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O.T.A.S. SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O.T.A.S. MAGNETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 iBR AND VTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION (iBR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM DESCRIPTION (VTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR GATE BACKLASH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRICTION SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IBR GATE LOCKING SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IBR SYSTEM FUNCTIONAL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VTS FUNCTIONAL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR LEVER SENSOR (BRLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR GATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
"U" ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR GATE SUPPORT PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VTS CONTROL BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VI
359
361
361
361
361
362
362
362
362
363
364
364
366
366
368
369
369
370
371
373
375
375
378
379
379
380
381
381
381
382
382
382
383
383
387
393
397
398
400
403
TABLE OF CONTENTS
06 STEERING AND PROPULSION (contd)

03 JET PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JET PUMP MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER/WEAR RING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER SHAFT RADIAL PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SACRIFICIAL ANODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JET PUMP HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VENTURI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER SHAFT AND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALING RING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
407
409
409
409
409
409
409
410
411
411
411
414
414
416
418
419
427
429
429
429
430
430
435
07 BODY AND HULL

01 SUSPENSION (iS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC FLOW CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iS BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LATERAL SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LATERAL BELLOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION ARM SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOARDING PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPLASH DEFLECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECK EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOVING DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
437
440
440
441
441
441
443
445
445
446
446
449
451
453
457
458
458
459
460
461
463
467
467
467
467
468
468
469
475
VII
TABLE OF CONTENTS
07 BODY AND HULL (contd)

02 BODY (contd)
PROCEDURES (contd)
STORAGE COMPARTMENT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GLOVE BOX COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BODY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEED-TIE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GELCOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
03 HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INLET GRATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JET PUMP SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THRU-HULL FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPONSON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAILER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRAIN PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOW EYELET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STERN EYELETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HULL INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
476
477
478
478
479
480
481
482
482
484
493
493
497
500
500
500
501
503
504
506
506
507
507
509
509
08 TECHNICAL SPECIFICATIONS
01 RXT iS 255/GTX LIMITED iS 255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
09 WIRING DIAGRAM
01 WIRING DIAGRAM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02 CONNECTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNETO AND ENGINE CONNECTOR (DEUTSCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM CONNECTOR (MOLEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRLS, TAS AND STARTER SOLENOID CONNECTORS (DELPHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iBR AND iS POWER CONNECTORS (DELPHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPS CONNECTORS (BOSCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION CENTER CONNECTORS (DELPHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VTS, iS, MODE/SET AND UP/DOWN SWITCH CONNECTORS (DELPHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY CABLE TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VIII
517
517
517
517
519
519
519
521
524
524
525
525
525
526
SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to
correctly service and repair 2009 Sea-Doo watercraft as describe in the model list in the INTRODUCTION.
This edition was primarily published to be used
by watercraft mechanical technicians who are already familiar with all service procedures relating
to BRP made watercraft. Mechanical technicians
should attend training courses given by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
This Shop Manual uses technical terms which
may be slightly different from the ones used in
the PARTS CATALOG.
It is understood that this manual may be translated into another language. In the event of any
discrepancy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing.
Service and warranty bulletins may be published
to update the content of this manual. Make sure
to read and understand these.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or exact replicas of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
CAUTION Indicates a hazard situation

which, if not avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction which, if not
followed, could severely damage vehicle components or other property.
NOTE: Indicates supplementary information
needed to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understanding of the information will promote its correct
use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services
be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle
illegal under existing federal, provincial and state
regulations.
WARNING
Unless otherwise specified, engine should be
turned OFF and cold for all maintenance and
repair procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Indicated a potential hazard that, if not
avoided, could result in serious injury or
death.
smr2009-011
IX
INTRODUCTION
INTRODUCTION
This shop manual covers the following BRP made 2009 Sea-Doo watercraft models.
MODEL
GTX Limited iS
COLOR
ENGINE
MODEL NUMBER
Topaz mist metallic
1503 HO (255 HP)
189A, 189B
Bright yellow
1503 HO (255 HP)
349A, 349B
RXT iS
The information and component/system descriptions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, models or equipment without incurring obligation.
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
The Engine Identification Number is located on
front end of the engine.
VEHICLE INFORMATION
HULL IDENTIFICATION NUMBER
(H.I.N.)
The hull identification number is composed of 12
digits:
12345
YDV
L 4
95
Model year
Year of production
Month of production
Serial number (a letter may also be used as a digit)
Manufacturer
It is located on footboard at the rear of watercraft.

F18D03A
1. Engine Identification Number (E.I.N.)
WORKING ON WATERCRAFT
To work on watercraft, securely install it on a
stand. Thus, if access is needed to water inlet
area, it will be easy to slide underneath watercraft.
The LIFTING STRAP (P/N 529 036 171) MUST be
used to install watercraft on a stand.
smr2009-011-001_a
1. Hull Identification Number (H.I.N.)
NOTICE Using any other lifting strap kit than

the recommended one will cause damages to
the vehicle. Bumpers will be tear off and their
replacement will be required.
smr2009-011
INTRODUCTION
The owner/operator is not to, and should not allow anyone to modify the engine in any manner
that would alter the horsepower or allow emissions levels to exceed their predetermined factory
specifications.
EPA Emission Regulations
sbl2009-004-003
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Beginning with 1999 model year engines, PWC
manufacturers of marine engines must determine the exhaust emission levels for each engine
horsepower family and certify these engines
with the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
engine specifications, must be placed on each
vehicle at the time of manufacture.
Dealer Responsibility
When performing service on all 1999 and more
recent SEA-DOO watercrafts that carry an emissions control information label, adjustments must
be kept within published factory specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes, such as altitude adjustments for example.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
smr2009-011
All new 1999 and more recent SEA-DOO watercrafts manufactured by BRP are certified to
the EPA as conforming to the requirements of
the regulations for the control of air pollution
from new watercraft engines. This certification
is contingent on certain adjustments being set
to factory standards. For this reason, the factory procedure for servicing the product must
be strictly followed and, whenever practicable,
returned to the original intent of the design.
The responsibilities listed above are general and
in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products. For more
detailed information on this subject, you may contact:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
1200 Pennsylvania Ave. NW
Mail Code 6403J
Washington D.C. 20460
INTERNET WEB SITE: http://www.epa.gov/otaq
MANUAL INFORMATION
MANUAL LAYOUT
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Each section is divided in various subsections, and
again, each subsection has one or more division.
Illustrations and photos show the typical construction of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
NOTICE Most components of those vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
XI
INTRODUCTION
As many of the procedures in this manual are interrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the procedure is contained.
A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
The use of RIGHT (starboard) and LEFT (port) indications in the text, always refers to driving position (when sitting on watercraft).
Besides, in the marine industry, FRONT is called
BOW and REAR is called STERN.
smr2009-011-002_a
1. Left (port)
2. Right (starboard)
This manual uses technical terms which may be

different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.
XII
smr2009-011
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE
Subsection 01 (MAGNETO)
Subsection title
Indicates applicable
models.
Page heading
indicates section
and subsection.
MAGNETO
Models
Drop represents a
service product
to be applied.
Loctite 243
Exploded view assists

you in identifying parts
and their related
positions.
Model
Dotted box contains

parts applicable to a
specific model.
Bold face number
is used to identify
a part referred to
the text.
NEW indicates that the

part must be replaced
with a new one.
NEW
5 Nm
(44 lbfin)
Illustration number
for publishing process.
Document number for
publishing process.
XXX0000
mmr2008-001
55
Page number
Typical_iso_2008_en
smr2009-011
XIII
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be
carried out.
Reference to a
specific section
or subsection.
GENERAL
NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque values and service products as in the exploded
views.
Clean threads before applying a threadlocker. Refer to the SELF-LOCKING FASTENERS and LOCTITE APPLICATION sections at the beginning of
this manual for complete procedure.
TYPICAL
indicates a general
view which may
not represent exact
details.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones.
Indicates component
procedures apply to.
PROCEDURES
MAGNETO FLYWHEEL
1
TYPICAL
1. Starting pulley
NOTE: To remove starting pulley bolts, hold magneto flywheel with a socket as shown.
Call-outs pertaining
to above illustration.
Magneto Flywheel Cleaning

Clean all metal components in a non-ferrous metal
cleaner.
Indicates specific
procedure to be
carried out.
CAUTION: Clean magneto flywheel using only

a clean cloth.
Illustration always
follows text to which
it applies.
Magneto Flywheel Removal

Remove
section.
Remove
Remove
Remove
muffler, refer to the EXHAUST SYSTEM

acoustic panel.
rewind starter.
starting pulley no. 2.
mmr2007-016-002
TYPICAL
Models
Models
Remove the connecting flange retaining the
rewind starter to the engine housing.
mmr2008-001
Italic bold face typesetting indicates a

procedure applicable
to a specific
model(s).
57
Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en
XIV
smr2009-011
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to torque mentioned in exploded views and/or text, When they are not
specified, refer to following table.
2. Apply the half of the recommended torque

value.
NOTICE Be sure to use proper tightening
torque for the proper strength grade.
NOTE: When possible, always apply torque on
the nut.
3. Torque at the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in
a crisscross sequence.
WARNING
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones.
In order to avoid a poor assembling, tighten
screws, bolts or nuts in accordance with the
following procedure:
1. Manually screw all screws, bolts and/or nuts.
10.9
4.8
8.8
9.8
10.9
12.9
4.8
8.8
9.8
10.9
12.9
10
12.9
12.9
12
12
5
5
Property
class and
nut
markings
9.8
10
Property
class and
head
markings
8.8
4.8
A00A8BS
FASTENER
SIZE
FASTENER GRADE/TORQUE
5.8 Grade
8.8 Grade
10.9 Grade
12.9 Grade
M4
1.5 2 Nm
(13 18 lbfin)
2.5 3 Nm
(22 27 lbfin)
3.5 4 Nm
(31 35 lbfft)
4 5 Nm
(35 44 lbfft)
M5
3 3.5 Nm
(27 31 lbfft)
4.5 5.5 Nm
(40 47 lbfft)
7 8.5 Nm
(62 75 lbfft)
8 10 Nm
(71 89 lbfft)
M6
6.5 8.5 Nm
(58 75 lbfft)
8 12 Nm
(71 106 lbfft)
10.5 15 Nm
(93 133 lbfin)
16 Nm (142 lbfin)
M8
15 Nm (133 lbfin)
25 Nm (18 lbfft)
32 Nm (24 lbfft)
40 Nm (30 lbfft)
M10
29 Nm (21 lbfft)
48 Nm (35 lbfft)
61 Nm (45 lbfft)
73 Nm (54 lbfft)
M12
52 Nm (38 lbfft)
85 Nm (63 lbfft)
105 Nm (77 lbfft)
128 Nm (94 lbfft)
M14
85 Nm (63 lbfft)
135 Nm (100 lbfft)
170 Nm (125 lbfft)
200 Nm (148 lbfft)
smr2009-011
XV
INTRODUCTION
FASTENER INFORMATION
SELF-LOCKING FASTENERS
PROCEDURE
3. Choose proper strength Loctite threadlocker.

4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind

Holes
1
A00A6LA
TYPICAL SELF-LOCKING FASTENER
The following describes the most common application procedures when working with self-locking
fasteners.
Use a metal brush or a tap to clean the hole properly then use a solvent, let act during 30 minutes
and wipe off. The solvent utilization is to ensure
the adhesive works properly.
LOCTITE APPLICATION
PROCEDURE
The following describes the most common application procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite product as recommended in this shop manual.
Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
lmr2007-040-004_a
1. On threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole
and at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud in

Blind Holes
1
2
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

threads and allow to dry.
XVI
lmr2007-040-005_a
1. On threads
2. On threads and in the hole
3. Onto nut threads
1. Clean threads (stud and hole) with solvent.

smr2009-011
INTRODUCTION

threads and allow to dry.
3. Put 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole.
NOTE: To avoid a hydro lock situation, do not apply too much Loctite.
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on uncovered threads.
8. Tighten nuts as required.
Threadlocker Application for Adjusting

Screw
Threadlocker Application for

Pre-Assembled Parts
1. Apply here
2. Plunger
A00A3PA
1. Adjust screw to proper setting.

2. Apply drops of proper strength Loctite threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232C (450F)).
Application for Stripped Thread Repair

5
1
6
8
A00A3OA
1. Apply here
2. Do not apply
1. Clean bolts and nuts with solvent.

2. Assemble components.
3. Tighten nuts.
4. Apply drops of proper strength Loctite on
bolt/nut contact surfaces.
5. Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on existing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
smr2009-011
A00A3QA
1.
2.
3.
4.
5.
6.
7.
8.
Release agent
Stripped threads
Form-A-Thread
Tapes
Cleaned bolt
Plate
New threads
Threadlocker
Standard Thread Repair

Follow instructions on Loctite FORM-A-THREAD
81668 package.
If a plate is used to align bolt:
1. Apply release agent on mating surfaces.
2. Put waxed paper or similar film on the surfaces.
XVII
INTRODUCTION
3. Twist bolt when inserting it to improve thread

conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
STANDARD THREAD REPAIR procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (Light Duty)
1. Use a stud or thread on desired length.
2. DO NOT apply release agent on stud.
3. Do a STANDARD THREAD REPAIR.
4. Allow to cure for 30 minutes.
5. Assemble.
5. Place gasket on mating surfaces and assemble

immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.
Threadlocker Application for Mounting

on Shaft
Mounting with a Press
Gasket Compound Application
3
A00A3UA
1. Bearing
2. Proper strength Loctite
3. Shaft
lmr2007-040-006_a

2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only
1. Remove old gasket and other contaminants

with LOCTITE CHISEL (GASKET REMOVER)
(P/N 413 708 500). Use a mechanical mean
if necessary.
NOTE: Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or
2 minutes.
4. Apply LOCTITE 518 (P/N 293 800 038) on both
sides of gasket, using a clean applicator.
XVIII
1. Clean shaft external part and element internal

part.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
3. DO NOT use antiseize Loctite or any similar
product.
4. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
smr2009-011
INTRODUCTION
Threadlocker Application for Case-In

Components (Metallic Gaskets)
A00A3VA
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE PRIMER
N (P/N 293 800 041).
3. Apply a strip of proper strength Loctite on leading edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off surplus.
6. Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
smr2009-011
XIX
XX
smr2009-011
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE SCHEDULE)
MAINTENANCE SCHEDULE
The maintenance schedule should be adjusted according to operating conditions and use.
NOTE: The schedule provides an equivalence between number of hours and months/year. Maintenance
operations should be carried out following whichever time frame comes due first.
IMPORTANT: Watercraft rental operations or intensive use of watercraft, will require greater frequency
of inspection and maintenance.
When maintenance is completed, the maintenance reminders must be cleared using B.U.D.S. Refer to
the GAUGE subsection.
A:
C:
I:
L:
R:
FIRST 10 HOURS
Adjust
Clean
Inspect
Lubricate
Replace
25 HOURS OR 3 MONTHS
50 HOURS or 6 MONTHS
100 HOURS or 1 YEAR
200 HOURS or 2 YEAR
O: Operator
D: Dealer
TO BE PERFORMED BY
PART/TASK
NOTE
ENGINE
Engine oil
(1)
and filter
Rubber mounts
Corrosion protection
Supercharger clutch
(2)
(1) Check level before each ride.

(2) See NOTE 1 after maintenance
schedule.
EXHAUST SYSTEM
Exhaust system
I,
C
D/O
(3)
(3) Daily flushing in salt water or foul

water use.
COOLING SYSTEM
Hose and fasteners
(1)
Coolant
D
R
(1) Check level before each ride.
FUEL SYSTEM
Fuel cap, filler neck, fuel tank, fuel tank straps, fuel lines and
connections
I (4)
Fuel system leak test
Throttle body
I,
C
I,
C
(4) At storage period or after

100 hours of use whichever comes
first.
AIR INTAKE SYSTEM

Air intake silencer
Blow-by valve hose
ELECTRONIC MANAGEMENT SYSTEMS

EMS sensors
Fault codes (ECM, iBR, iS, Cluster)
smr2009-011
A:
C:
I:
L:
R:
FIRST 10 HOURS
Adjust
Clean
Inspect
Lubricate
Replace
100 HOURS or 1 YEAR
200 HOURS or 2 YEAR
O: Operator
D: Dealer
TO BE PERFORMED BY
PART/TASK
NOTE
ELECTRICAL SYSTEM
Spark plug
Electrical connections and fastening (ignition system, starting

system, fuel injectors etc.)
D.E.S.S. key/post
Monitoring beeper
Battery and fasteners
(5)
(6)
D
(5) Inspect operation before each ride.
(6) Inspect once a month. Add
electrolyte as required.
STEERING SYSTEM
Steering cable and connections
Steering nozzle bushings
I,
L
O.T.A.S.
(10)
iTC and iBR levers
(5) (7)
(5) Inspect operation before each ride.

(7) See NOTE 2 after
maintenance schedule.
(10) Check operation.
PROPULSION SYSTEM
Carbon ring and rubber boot (drive shaft)
Impeller boot
(4)
I, L
Impeller shaft seal, sleeve and O-ring
Drive shaft/impeller splines

(8)
Sacrificial anode (if so equipped)
Impeller and impeller wear ring clearance
Pump mounts
iBR gate backlash
iBR support plates
iBR friction sleeves
iBR connecting arms, sleeves, and bushings
iBR U lever, VTS trim ring, iBR gate and bushings
iBR locking sleeve
iBR protective guard
(9)
iS position sensor
(4) At storage period or

after 100 hours of use
whichever comes first.
(8) Inspect each month (more
often in salt water use) and change
when necessary.
iBR SYSTEM (intelligent Brake/Reverse)
iS SYSTEM (intelligent Suspension)

iS fluid
(9) Check pump reservoir fluid level

and check for system leaks.
smr2009-011
A:
C:
I:
L:
R:
FIRST 10 HOURS
Adjust
Clean
Inspect
Lubricate
Replace
100 HOURS or 1 YEAR
200 HOURS or 2 YEAR
O: Operator
D: Dealer
TO BE PERFORMED BY
PART/TASK
NOTE
HULL AND BODY

Hull
Ride plate and water intake grate
(1) The supercharger clutch requires replacement when the SUPERCHARGER MAINTENANCE REQUIRED message is displayed on the
information center every 100 hours of operation or earlier depending on the riding style (speed, engine's RPM, water conditions). This
is determined by the engine management system. The supercharger clutch will need to be replaced within 5 hours of the message
display. The supercharger maintenance reminder must be reset using B.U.D.S.
(2) The iTC and iBR levers should be inspected by depressing and releasing the levers to check for freedom of movement. If any friction
is felt, the lever must be taken apart, cleaned, inspected for wear and lubricated.
smr2009-011
Subsection 02 (PRESEASON PREPARATION)
PRESEASON PREPARATION
Proper vehicle preparation is necessary after the
winter months or when a vehicle has not been
used during several weeks.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
WARNING
Unless otherwise specified, engine should be
turned off during preseason preparation procedure.
Using the maintenance chart, performed items in
the columns indicated 100 HOURS OR 1 YEAR
and TO BE PERFORMED BY.
smr2009-013-001_a
1. Use these columns
Furthermore, proceed with the following:

Watercraft Prepared as per Storage Procedure
Reinstall the battery.
Test ride watercraft to confirm proper operation.
Watercraft Not Prepared as per Storage Procedure
Replace engine oil and filter.
Drain fuel tank and fill with fresh fuel.
Reinstall the battery.
Test ride watercraft to confirm proper operation.
smr2009-013
Subsection 03 (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
Description
Part Number
BRP FUEL STABILIZER .................................................................

DOW CORNING 111 .....................................................................
LOCTITE 767 (ANTISEIZE LUBRICANT) .......................................
XPS LUBE......................................................................................
413
413
293
293
408
707
800
600
PROCEDURES
PROPULSION SYSTEM
Jet Pump Cleaning
Clean jet pump by spraying water in its inlet
and outlet and then apply a coating of XPS LUBE
(P/N 293 600 016) or equivalent.
WARNING
Always remove safety lanyard cap from post
to prevent unexpected engine starting before
cleaning the jet pump area. Engine must not
be running for this operation.
Jet Pump Inspection
600
000
070
016
Page
............................................. 7
............................................. 9
............................................. 9
......................................... 7, 9
WARNING
Always stop the engine before refueling.
Fuel is inflammable and explosive under
certain conditions. Always work in a well
ventilated area. Do not smoke or allow open
flames or sparks in the vicinity. Fuel tank may
be pressurized, slowly turn cap when opening. When fueling, keep watercraft level.
Do not overfill or top off the fuel tank and
leave watercraft in the sun. As temperature
increases, fuel expands and might overflow.
Always wipe off any fuel spillage from the
watercraft. Periodically inspect fuel system.
NOTICE Should any water be trapped inside
fuel tank, severe internal damage will occur to
the fuel injection system.
Remove impeller cover and check if jet pump is

water contaminated; if so, refer to JET PUMP subsection for the repair procedure.
ENGINE
FUEL SYSTEM
Engine Oil and Filter Replacement
Fuel System Inspection
Change engine oil and filter. Refer to LUBRICATION SYSTEM subsection.
Verify fuel system. Check fuel hoses for leaks.

Replace damaged hoses or clamps if necessary.
Intercooler Draining
Fuel System Protection
It is important to expel any trapped water that may

have accumulated from condensation in the external intercooler.
The BRP FUEL STABILIZER (P/N 413 408 600) or

equivalent should be added in fuel tank to prevent fuel deterioration and fuel system gumming.
Follow manufacturer's instructions for proper
use.
NOTICE Fuel stabilizer should be added
prior to engine lubrication to ensure fuel system components protection against varnish
deposits.
Fill up fuel tank completely. Ensure there is no water inside fuel tank.
smr2009-014
NOTICE Failure to drain the intercooler may

cause severe damage to this components.
Proceed as follows:
1. Loosen the clamp retaining the intercooler outlet hose.
2. Remove the intercooler outlet hose from the intercooler.
NOTE: This hose feeds the inlet of the throttle
body.
3. Drape a couple of shop rags over the iS module
to protect it from any expelled water from the
intercooler.
7
smo2008-001-053_a
TYPICAL
1. Flushing adaptor (P/N 295 500 473)
2. Hose 13 mm (1/2 in)
3. Air hose male adapter
NOTICE Failure to drain the exhaust manifold may cause severe damage to this components.
Engine Coolant Replacement

smo2009-002-151_a
1.
2.
3.
4.
Hose alignment lines

Hose clamp
Intercooler outlet hose
iS module
4. Start engine and rev up to 4000 RPMs several

times. Water will be expelled from intercooler.
NOTE: Prevent air intake system from aspirating
foreign objects which may cause severe engine or
damage.
5. Stop engine.
6. Install intercooler outlet hose.
Exhaust System Protection

The exhaust system is self draining, but the exhaust manifold needs to be drained to avoid damages if watercraft is stored in area where freezing
weather is present.
Using the flushing connector located at the rear of
vehicle, inject pressurized air (at 380 kPa (55 PSI))
into system until there is no more water flowing
from jet pump.
Antifreeze should be replaced every 200 hours or

every two years to prevent antifreeze deterioration.
NOTICE Failure to replace the antifreeze as
recommended may allow its degradation that
could result in poor engine cooling.
If coolant is not replaced, test the coolant density
using an antifreeze hydrometer.
Replace coolant if necessary. For the coolant replacement procedure, refer to COOLING SYSTEM
subsection.
NOTICE Improper antifreeze density might
lead coolant to freeze if vehicle is stored in
area where freezing point is reached. This
would seriously damage the engine.
Engine Internal Lubrication

Engine must be lubricated to prevent corrosion on
internal parts.
Lubrication of the engine is recommended at the
end of the season and before any extended storage period to provide additional corrosion protection. This will lubricate the engine intake valves,
the cylinders and the exhaust valves.
To lubricate the engine, proceed as follows:
1. Open seat and remove the rear ventilation box.
2. Disconnect ignition coil connectors.
WARNING
smr2009-021-004_a
1. Flushing connector
The following hose can be fabricated to ease

draining procedure.
When disconnecting coil from spark plug, always disconnect coil from main harness first.
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
compartment as spark may cause fuel vapor
to ignite.
smr2009-014
NOTICE Never cut the locking ties of ignition

coil connectors. This would allow mixing the
wires between cylinders.
3. Clean ignition coil areas to avoid falling dirt into
cylinder.
4. Remove ignition coils.
5. Unscrew spark plugs.
6. Using an ignition coil as a puller, remove spark
plugs.
ELECTRICAL SYSTEM
Battery Removal
For battery removal, cleaning and storage, refer to
CHARGING SYSTEM subsection.
VEHICLE
Bilge Cleaning
Clean the bilge with hot water and mild detergent
or with bilge cleaner.
Rinse thoroughly.
Lift front end of watercraft to completely drain
bilge.
Body and Hull Cleaning

Wash the body with soap and water solution (only
use mild detergent). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
NOTICE Never clean body parts or hull with
strong detergent, degreasing agent, paint thinner, acetone, etc.
Replace damaged labels/decals.
smr2006-016-030_a
1. Ignition coil
2. Spark plug
7. Spray XPS LUBE (P/N 293 600 016) into each

spark plug hole.
8. Crank the engine a few turns to distribute the
oil on cylinder wall.
NOTE: To crank engine, use the drowned mode
to avoid injecting fuel. Fully depress throttle lever
and hold for cranking engine.
9. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on spark plug threads then
reinstall them.
10. Prior to inserting the ignition coil to its location, apply some DOW CORNING 111 (P/N 413
707 000) around the seal area that touches the
spark plug hole.
11. Reinstall ignition coils.
12. Ensure the seal seats properly with the engine
top surface.
13. Reconnect ignition coil connectors.
14. Install all other removed parts.
smr2009-014
Body Repair
If any repair is needed, refer to BODY subsection.
Anticorrosion Treatment
Wipe off any residual water in the engine compartment.
Spray XPS LUBE (P/N 293 600 016) over all metallic
components in engine compartment.
Vehicle Protection
Apply a good quality marine wax on body and hull.
The seat should be left partially open during storage. This will prevent engine compartment condensation and possible corrosion.
If the watercraft is to be stored outside, cover it
with an opaque tarpaulin to prevent sun rays and
grime from affecting the plastic components, watercraft finish as well as preventing dust accumulation.
NOTICE The watercraft should never be left
in water for storage, stored in direct sunlight
or stored in a plastic bag.
10
Subsection 04 (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE TOOLS
Description
Part Number
Page
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 12

SUCTION PUMP ........................................................................... 529 035 880 ........................................... 12
GENERAL
WATER-FLOODED ENGINE
Refer to the following special procedures according to the specific event.
If engine is water-flooded, it must be serviced

within a few hours after the event. Otherwise
engine will have to be overhauled.
PROCEDURES
TOWING THE WATERCRAFT IN
WATER
Special precautions should be taken when towing
a Sea-Doo watercraft in water.
Maximum recommended towing speed is
24 km/h (15 MPH).
This will prevent the exhaust system from filling
with water, which may lead to water being injected into and filling the exhaust system and the
engine. Without the engine running there is not
any exhaust pressure to push the water out the
exhaust outlet.
NOTICE Failure to do this may result in damage to the engine. If you must tow a stranded
watercraft in water be sure to stay well below the maximum towing speed of 24 km/h
(15 MPH).
SUBMERGED WATERCRAFT
Drain bilge.
If it was submerged in salt water, spray bilge and
all components with fresh water using a garden
hose to stop the salt corroding effect.
Engine Lubrication
Refer to WATER-FLOODED ENGINE in this subsection.
Fuel Inspection
Check fuel tank for water contamination. If necessary, siphon and refill with fresh fuel.
smr2009-015
NOTICE
Never try to crank or start the engine. Water
trapped in the intake manifold would enter
the combustion chamber through the intake
valves and may cause damage to the engine.
A water-flooded engine must be properly
drained, lubricant replaced (oil change), operated (boil out procedure), then lubricant
replaced again, otherwise parts will be seriously damaged.
Whenever the engine is stopped, all the valves
close thus preventing water from being ingested
in the engine.
Exhaust System Draining

If water is suspected to be in the exhaust system,
remove the exhaust pipe and the muffler. Drain
them or siphon the water out of them. Refer to
EXHAUST SYSTEM subsection.
Intake System Draining

If water is suspected in the intake manifold, remove the intake manifold and drain it. Then suck
out the water from the intake valve ports. Refer
to INTAKE MANIFOLD subsection.
If water is present in the air intake silencer, empty
it.
Remove air intake silencer and check for water
in the supercharger inlet hose. Remove hose to
empty it.
Remove the water from blow-by valve hose.
Throttle Body Lubrication

Throttle body should be lubricated to prevent corrosion.
11
Supercharger Servicing
If there was water in the oil or in the supercharger
inlet hose, it is recommended to take the supercharger apart, dry all the components, replace the
slip clutch needle bearings and shaft ball bearings.
Refer to SUPERCHARGER section.
8. Put a tape at 400 mm (16 in) from the end of the

suction pump tube.
9. Insert the tube in the PTO area until the tape
reach the cylinder-block edge. Then, siphon
contaminated oil out.
Engine Oil and Filter Replacement

If water gets in the oil (oil will be milky), change
the engine oil and filter as per procedure further
in this subsection.
Remove the deck extension. Refer to BODY subsection.
1. Using the SUCTION PUMP (P/N 529 035 880),
siphon the contaminated oil from the engine
reservoir through dipstick hole.
smr2006-006-003_a
TYPICAL
1. Suction pump tube with tape
2. Edge of cylinder-block
5290358802
NOTICE Never crank or start engine when

siphon tube is in dipstick hole. Never start
engine when there is no oil in engine.
2. Remove the suction pump tube from the dipstick hole.
3. Fully depress throttle lever and HOLD it for
cranking.
4. Crank the engine for 5 seconds.
5. Remove the oil filter cap and the oil filter. Refer
to LUBRICATION SYSTEM subsection.
6. Again, siphon the contaminated oil from the oil
filter reservoir.
7. Remove valve cover. Refer to CYLINDER
HEAD subsection.
10. Remove the suction pump tube.

11. Reinstall valve cover.
12. Install a NEW oil filter and reinstall the oil filter
cap.
13. Fill up the reservoir with fresh oil.
14. Proceed with the boil out procedure:
NOTE: The boil out procedure is intended to evaporate the water contained in the oil.
Boil Out Procedure in a Test Tank or Tied to a
Trailer with Watercraft in Water
1. Connect the vehicle to B.U.D.S. to monitor the
coolant temperature. It must exceed 100C
(212F) in order for the water boil out. Once
the boil point is reached, it won't take long to
evaporate the water.
2. Run the engine for 5 minutes at 3500 RPM.
WARNING
Make sure to safely secure the watercraft.
3. With the engine still running at 3500 RPM, install a LARGE HOSE PINCHER (P/N 529 032 500)
to the coolant line going to the oil cooler.
smr2006-006-001_a
1. Valve cover
12
smr2009-015
5290325002
WARNING
Certain components in the engine compartment may be very hot. Direct contact may result in skin burn. Do not touch any electrical
parts or jet pump area when engine is running.
smr2009-015-001_a
1. Oil cooler coolant inlet hose
4. Continue to run the engine at 3500 RPM for 15

more minutes (20 minutes total run time).
5. Shut the engine off.
6. Remove the hose pincher on the coolant line
going to the oil cooler.
NOTICE Hose pincher must be removed prior
to operating the watercraft. Failure to do this
will result in damage to the engine.
7. Change the oil and filter again.
8. Procedure is now completed.
CAPSIZED WATERCRAFT
Capsized for More Than 5 Minutes
Refer to WATER-FLOODED ENGINE in this subsection.
smr2009-015
13
14
Section 02 ENGINE
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
Description
Part Number
ALIGNMENT SHAFT ADAPTER ....................................................

ALIGNMENT SHAFT SUPPORT ....................................................
ALIGNMENT SHAFT .....................................................................
ENGINE ALIGNMENT PLATE ........................................................
FUEL HOSE DISCONNECT TOOL ................................................
529
529
295
529
529
035
035
000
036
036
719
506
141
170
037
Page
..................................... 2021
........................................... 21
..................................... 20, 22
........................................... 21
........................................... 17
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ..................................... 20, 23

PULLEY FLANGE CLEANER ......................................................... 413 711 809 ........................................... 20
GENERAL
During assembly/installation, use torque values
and service products from exploded views in the
appropriate sections.
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENER and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
stop nuts, self-locking fasteners, cotter pin,
smr2009-016-001_a
1. Vent box
2. Retaining latches
4. Remove the deck extension. Refer to BODY

subsection.
Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory standards.
PROCEDURES
ENGINE
Engine Removal
1. Place vehicle at workstation that will have access to a chain block, a hoist or other suitable
lifting equipment.
2. Remove the moving deck. Refer to BODY subsection.
3. Remove the rear ventilation box.
smr2009-016-002_a
1. Deck extension
5. Remove the air intake silencer. Refer to AIR INTAKE SYSTEM subsection.
smr2009-016
15
Section 02 ENGINE
6. Drain cooling system. Refer to COOLING SYSTEM subsection.

7. Cut locking tie securing exhaust water outlet
hose and engine blow-by hose.
8. Disconnect the exhaust water outlet hose from
the exhaust manifold.
9. Disconnect the hose from the blow-by valve.
smr2009-016-005_a
1. Exhaust hose clamp
10.3 Detach retaining strap.
smr2009-016-003_a
1.
2.
3.
4.
5.
Cut this locking tie

Exhaust water outlet hose
Blow-by hose
Blow-by valve
Exhaust manifold
10. Move muffler rearward.

10.1 Unplug the exhaust gas temperature sensor (EGTS).
smr2009-016-006_a
1. Muffler retaining strap
10.4 Unscrew exhaust clamp.

NOTICE Do not use pneumatic or electric tools on exhaust clamp as seizure
may occurs.
smr2009-016-004_a
1. EGTS sensor
2. Exhaust hose
10.2 Disconnect the exhaust hose.

smr2009-016-007_a
1. Exhaust clamp
10.5 Move muffler back.

11. Remove jet pump. Refer to JET PUMP subsection.
12. Remove the drive shaft. Refer to DRIVE
SHAFT subsection.
16
smr2009-016
Section 02 ENGINE
13. Connect B.U.D.S. Refer to COMMUNICA-
TION TOOLS AND B.U.D.S. SOFTWARE

subsection.
14. Release fuel pressure using B.U.D.S.
15. Using the FUEL HOSE DISCONNECT TOOL
(P/N 529 036 037) disconnect fuel hose from
fuel rail.
smr2009-016-011_a
1. Ground wires
529036037
19. On top of engine, cut locking ties securing vehicle harness and engine connector to engine.
20. Unplug the "B" connector from the ECM.
smr2009-016-009_a
1. Fuel rail
2. Fuel hose
3. Fuel hose disconnect tool
16. Disconnect battery. Refer to CHARGING SYSTEM subsection.

17. Cut locking tie securing wiring harness to oil
filler tube.
smr2009-016-010_a
1. Cut this locking tie

2. Oil filler tube
18. Unscrew ground wires from engine.
smr2009-016
smr2009-016-012_a
1. Locking tie retaining engine connector

2. Locking ties securing vehicle harness
3. "B" connector
21. Unplug the engine connector.
smr2009-016-013_a
1. Engine connector
22. Cut locking tie securing vehicle harness to

manifold air temperature sensor (MATS).
17
Section 02 ENGINE
smr2009-016-014_a

2. MATS sensor
3. Vehicle harness
23. At the rear of engine, unplug the magneto

connector and detach connector housing
from ECM support.
smr2009-016-017_a
1. Ride plate hoses

2. Water pump housing
26. Install a suitable lifting device.
smr2009-016-018_a
1. Engine lifting brackets

smr2009-016-015_a
1. Magneto connector
2. Connector housing
27. Remove front engine support screw.
24. Disconnect air intake hose from throttle body.
smr2009-016-019_a
1. Front engine support screw

smr2009-016-016_a
1. Air intake hose

2. Throttle body
28. Remove the rear starboard engine support

screw.
25. Disconnect ride plate hoses from water pump

housing.
18
smr2009-016
Section 02 ENGINE
smr2009-016-023_a
1. Water outlet hose

2. Exhaust manifold
smr2009-016-020_a
1. Rear engine support screw on starboard side

29. Cut locking tie from coolant hose alongside

throttle body that retains the vehicle harness.
smr2009-016-021_a

2. Throttle body
3. Coolant hose
33. Slightly lift engine to ease the remaining component removal.

34. Disconnect the water inlet hose from the exhaust manifold.
smr2009-016-024_a
1. Exhaust manifold water inlet hose
35. Unscrew starter cable nut.
30. Remove the rear engine support screw on

port side.
31. Cut locking tie securing coolant hoses, starter
cable and ground cable.
smr2009-016-025_a
1. Starter cable nut
36. Remove screw securing the ground cable to

engine.
smr2009-016-022_a
1. Rear engine support screw on port side

32. Disconnect the water outlet hose from the exhaust manifold.
smr2009-016
19
Section 02 ENGINE
smr2009-016-026_a
1. Ground cable screw on cylinder block
37. Carry on engine lifting to remove it from the

body opening.
NOTICE Be careful not to scratch body or to
hit any component.
38. Install the engine on an engine stand.
Check tightness and condition of engine rubber

mounts. Refer to ENGINE MOUNTS in this subsection.
Before completely lowering engine, install ground
cable, starter cable and both cooling hoses on exhaust manifold. Follow these guide lines.
Ensure contact surface is perfectly clean then
reconnect grounds cable to engine.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of ground cable screw or use a new
screw with self-locking product.
Tighten ground cable screw to 23 Nm
(17 lbfft).
Torque starter cable nut to 7 Nm (62 lbfin).
Install protective cap over the starter cable end.
Connect exhaust manifold water inlet and
outlet hoses. Tighten clamps to 1.7 Nm
(15 lbfin).
Place engine into vehicle.
Install engine support screws. Do not apply
threadlocker to engine support screws and do
not torque yet.
Align engine. Refer to ENGINE ALIGNMENT in
this subsection for complete procedure.
Install and properly align exhaust pipe. Refer to
EXHAUST SYSTEM subsection.
Reinstall all other removed parts.
Check hose condition and pressure test fuel system, refer to FUEL SYSTEM.
WARNING
Whenever doing any type of repair on watercraft or if any components of the fuel system are disconnected, a pressure test must
be done before starting engine.
F00B1XA
NOTE: A special mounting plate is required to fix

engine to support. This plate is not sold by BRP.
Engine Installation
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
NOTICE Whenever engine is removed from
watercraft, engine alignment must be performed at reinstallation.
Verify all electrical connections (ground wires and

battery).
Run engine and ensure there is no leakage.
NOTICE If watercraft is out of water, exhaust
system must be cooled using the flush kit.
Engine Alignment
Before beginning this procedure, install the ALIGNMENT SHAFT ADAPTER (P/N 529 035 719) on the
end of the ALIGNMENT SHAFT (P/N 295 000 141).
Wipe off any spillage in bilge. Clean with the PULLEY FLANGE CLEANER (P/N 413 711 809).
20
smr2009-016
Section 02 ENGINE
529 035 719
295 000 141
529036170
ENGINE ALIGNMENT PLATE
Trace two thin lines on alignment shaft. One

at 739 mm (29-3/32 in) and the other at 742 mm
(29-7/32 in).
smr2009-016-027_a
1. Engine alignment plate

2. Engine alignment support
smr2009-016-200_a
A. 739 mm (29-3/32 in)

B. 742 mm (29-7/32 in)
3. Secure the tool on ride plate using jet pump

socket screws.
NOTE: To perform this procedure the jet pump

and the drive shaft must be removed. Refer to
JET PUMP and DRIVE SYSTEM subsections.
To verify alignment proceed as follows:
1. Remove the sealing ring and the drive shaft
boot. Refer to DRIVE SHAFT subsection.
2. Install the ALIGNMENT SHAFT SUPPORT (P/N 529
035 506) on the ENGINE ALIGNMENT PLATE
(P/N 529 036 170).
smr2009-016-028_a
1. Jet pump socket screws
4. Install the ALIGNMENT SHAFT ADAPTER (P/N 529

035 719) in engine PTO housing.
529035506
ALIGNMENT SHAFT SUPPORT
smr2009-016
21
Section 02 ENGINE
NOTE: Use shim(s) (P/N 270 000 770) for the

front engine mount and shim(s) (P/N 270 000
762) for the rear engine mounts. Shims location
is between engine mount and engine mount
plate.
NOTICE Whenever shims are used to correct
alignment, never install more than 5 shims.
smr2009-016-029_a
1. Engine alignment adaptor
5. Carefully slide the ALIGNMENT SHAFT (P/N 295

000 141) into the engine alignment support.
smr2009-016-032_a
REAR STARBOARD ENGINE MOUNT SHOWN

1. Engine mount
2. Engine mount screws
3. Shim
4. Engine mount plate
smr2009-016-030_a
1. Alignment shaft
2. Engine alignment support
6. Insert alignment shaft end into alignment shaft

adapter. If the alignment is correct, the alignment shaft will slide easily without any deflection in alignment shaft adapter.
10. When engine alignment is correct, check the

longitudinal position of engine.
Engine Longitudinal Position Verification
With alignment shaft installed, check the location
of the marks (previously drawn at the beginning of
the engine alignment procedure).
Engine is properly positioned longitudinally when
the end of the alignment shaft support is between
both shaft marks.
If one mark is visible, the engine is properly positioned.
If both marks are visible, the engine must be
moved forward.
If no mark is visible, the engine must be moved
rearward.
smr2009-016-031_a
1. Alignment shaft
2. Alignment shaft adapter
7. If the alignment is correct, check the longitudinal position of engine. See procedure further.
8. If the alignment is incorrect, loosen engine
mount screws to align engine.
9. Add or removed shims as required.
22
smr2009-016-201_a
PROPER POSITION
1. Alignment shaft support end
2. Mark at 742 mm (29-7/32 in)
smr2009-016
Section 02 ENGINE
When alignment and longitudinal position of engine are correct, tighten engine mount screws.
Refer to ENGINE MOUNTS in this subsection.
Recheck engine alignment.
ENGINE MOUNTS
If engine mounts have been removed, apply LOCTITE 243 (BLUE) (P/N 293 800 060) on screw threads
or use new screws with self-locking product.
Torque all engine mount screws to 25 Nm
(18 lbfft).
Loctite
243
1
Loctite 243
1 Loctite
243
smr2009-016-033_a
1. Torque to 25 Nm (18 lbfft)

2. Position conical spring washer with its concave side towards hull
smr2009-016
23
24
Section 02 ENGINE
Subsection 02 (AIR INTAKE SYSTEM)
AIR INTAKE SYSTEM
1.7 Nm
(15 lbfin)
Blow-by
valve
6 Nm
(53 lbfin)
NEW
4 Nm
(35 lbfin)
6 Nm
(53 lbfin)
smr2009-017-001_a
smr2009-017
25
Section 02 ENGINE
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin)
smr2009-017-002_a
26
smr2009-017
Section 02 ENGINE
GENERAL
Rear Ventilation Box Installation

and service products as in the exploded views.
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
complete procedure.
The installation is the reverse of the removal procedure. However, pay attention to the following.
Before installing the ventilation box, check the
condition of its seal.
If the seal is damaged, replace the ventilation box
as an assembly.
WARNING
FRONT VENTILATION BOX

Front Ventilation Box Removal
1. Open the front storage cover and remove the
storage basket.
2. Remove screws securing the ventilation box to
fixed deck.

SYSTEM DESCRIPTION
This vehicle is equipped with two ventilation
boxes. The rear ventilation box is located over
the engine and the front underneath steering
column.
These ventilation boxes allow a good bilge ventilation and supply engine with fresh air.
PROCEDURES
REAR VENTILATION BOX
Rear Ventilation Box Removal
1. Open seat.
2. Release all retaining latches.
smr2009-017-003_a
1. Front ventilation box

2. Retaining screws
3. Remove the ventilation box.
Front Ventilation Box Installation

Before installing the ventilation box, check the
condition of its seal.
If the seal is damaged, replace the ventilation box.
Tighten ventilation box screws to 1.2 Nm
(11 lbfin).
AIR INTAKE DUCT

Air Intake Duct Removal
smr2009-017-010_a
1. Ventilation box
Remove engine. Refer to ENGINE REMOVAL

AND INSTALLATION subsection.
Remove the suspension base. Refer to iS SUSPENSION subsection.
Remove air intake duck from vehicle.
3. Remove the ventilation box.
smr2009-017
27
Section 02 ENGINE
Air Intake Duct Installation

Install suspension base. Refer to iS SUSPENSION
for complete procedure.
Install engine. Refer to ENGINE REMOVAL AND
INSTALLATION.
After deck extension installation, tighten screws
retaining the air intake duct to deck extension to
1.2 Nm (11 lbfin).
Tighten clamp to 1.7 Nm (15 lbfin).
AIR INTAKE SILENCER BAFFLE

Air Intake Silencer Baffle Removal
Remove AIR INTAKE SILENCER COVER, see procedure in this subsection.
Pull the baffle out of the air intake silencer.
smr2009-017-005_a
smr2009-042-020_a
1. Air inlet retaining screws
AIR INTAKE SILENCER COVER

Air Intake Silencer Cover Removal
Remove the deck extension. Refer to BODY subsection for procedure.
Release retaining latches.
Loosen clamp securing blow-by hose to cover.
1. Air intake silencer baffle
Air Intake Silencer Baffle Installation

Insert the end of the baffle into supercharger air
inlet hose. Using hose ears to retain hose, push
the baffle into supercharger air inlet hose.
smr2009-017-006_a
1. Baffle
2. Air intake hose
Install air intake silencer cover and all other removed parts.
smr2009-017-004_a
2. Loosen this clamp
Remove the cover.
Air Intake Silencer Cover Installation

Check the condition of the seal cover. Replace
seal as required.
28
AIR INTAKE TUBE

Air Intake Tube Removal
Remove the AIR INTAKE SILENCER COVER and
the AIR INTAKE SILENCER BAFFLE, see procedure in this subsection.
Release the three rubber latches securing the air
intake tube.
smr2009-017
Section 02 ENGINE
smr2009-017-009_a
smr2009-017-007_a
1. Rubber latches
1. Air intake silencer

2. Inlet hose groove
Install all other removed parts.
Remove air intake tube from vehicle.
Air Intake Tube Installation

The installation is the reverse of the removal procedure.
AIR INTAKE SILENCER

Air Intake Silencer Removal
Remove:
Deck extension, see BODY subsection for procedure
Air intake cover
Air intake tube.
Remove both screws securing air intake silencer.
SUPERCHARGER AIR INLET

HOSE
Supercharger Air Inlet Hose Removal
Remove the AIR INTAKE SILENCER, see procedure in this subsection.
Loosen clamp securing air inlet hose to supercharger.
Supercharger Air Inlet Hose

Installation
smr2009-017-008_a
1. Air intake silencer screws
Inside air intake silencer, squeeze the top of the

supercharger air inlet hose and move hose out of
air intake silencer.
Air Intake Silencer Installation

Squeeze the top of the supercharger air inlet hose
and move hose in air intake silencer.
Install the air intake silencer into hose groove.
smr2009-017
29
30
Section 02 ENGINE
Subsection 03 (INTAKE MANIFOLD)
INTAKE MANIFOLD
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 35
See ELECTRONIC
FUEL INJECTION
9 Nm
(80 lbfin)
9 Nm
(80 lbfin)
Loctite
243
Engine
oil
5.5 Nm
(49 lbfin)
See ELECTRONIC
FUEL INJECTION
Loctite 243
Loctite
243
Loctite
243
18 Nm
(159 lbfin)
See ELECTRONIC
FUEL INJECTION
9 Nm
(80 lbfin)
5.5 Nm
(49 lbfin)
NEW
Loctite
243
smr2009-018-001_a
smr2009-018
31
Section 02 ENGINE
GENERAL
and service products as in the exploded view.
complete procedure.
Cut all locking ties securing the harness to the intake manifold.
WARNING
smr2009-018-002_a
1. Cut these locking ties to release harness
PROCEDURES
INTAKE MANIFOLD
Intake Manifold Removal
Remove the moving deck and the deck extension.
Refer to BODY subsection.
Remove the air intake silencer. Refer to AIR INTAKE SYSTEM subsection.
Disconnect the intake hose at intake manifold.
smr2009-018-003_a
smr2009-018-020_a
1. Intake hose
Move the coolant expansion tank aside to make

room.
Remove the oil dipstick.
Release the fuel pressure.
Disconnect fuel hose connector at fuel rail. Refer
to ELECTRONIC FUEL INJECTION subsection.
32
smr2009-018-004_a
Unplug the ignition coil and fuel injector connectors.
smr2009-018
Section 02 ENGINE
smr2009-018-008_a
smr2009-018-005_a
1. Ignition coil connectors

2. Fuel injector connectors
Unplug the "B" connector from the ECM by pulling

the lock. Refer to WIRING DIAGRAM subsection
for procedure.
Unplug the manifold air pressure sensor (MAPS),
the engine connector and the manifold air temperature sensor (MATS).
1. Engine connector
2. ECM support
Unplug the knock sensor (KS), the magneto and

the throttle actuator connectors.
smr2009-018-009_a
1. KS connector
2. Magneto connector location
3. Throttle actuator connector
smr2009-018-007_a
1. MAPS connector
2. Engine connector location
3. MATS connector
Pull the knock sensor (KS) and magneto connectors out of the ECM support. For more details, refer to ELECTRICAL CONNECTORS.
Pull the engine connector out of the ECM support.
smr2009-018-010_a
1. KS connector
3. ECM support
smr2009-018
33
Section 02 ENGINE
Unplug the oil pressure switch (OPS).
R1503motr59A
smr2009-018-011_a
1. Oil pressure switch (OPS)
Lift intake manifold up to pull it out of the mounting brackets.
Unscrew ECM retaining screws and remove ECM

from its support.
R1503motr61A
smr2009-018-012_a
1. ECM retaining screws
Pull the engine wiring harness with the ECM

plugged away from intake manifold.
Remove manifold retaining screws and push the
oil dipstick tube out of the manifold slot.
1. Mounting brackets
Pull intake manifold out.
Intake Manifold Inspection

Check intake manifold for cracks, warping at
flanges or any other visible damage.
Check if intake manifold gaskets are cracked, brittle or otherwise damaged.
Replace damaged parts as necessary.
Intake Manifold Installation

For installation, reverse the removal procedure.
Pay attention to following details.
Ensure that all gaskets are properly installed and
in good condition.
34
smr2009-018
Section 02 ENGINE
smr2009-018-013_a
R1503motr62A
INTAKE MANIFOLD
1. Gaskets
First, position intake manifold on front mounting

bracket then push manifold toward engine to then
proceed with rear mounting bracket.
When installing the intake manifold, lift up the oil
dipstick tube a little bit to fit in the slot of the manifold.
1
Ensure to properly route and secure wiring harness with locking ties.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on the
ECM retaining screws and torque them to 9 Nm
(80 lbfin).
FLAME ARRESTER
Flame Arrester Location
The flame arrester is integrated in the intake manifold.
R1503motr59B
1. Oil dipstick tube

intake manifold screws.
Torque them to 9 Nm (80 lbfin) following the
tightening sequence as shown in next illustration.
smr2009-018-014_a
1. Flame arrester
Flame Arrester Inspection

The flame arrester in the intake manifold is maintenance free.
Flame Arrester Replacement

NOTE: The flame arrester can not be removed
from the intake manifold.
Replace intake manifold if necessary. Refer to INTAKE MANIFOLD in this subsection.
smr2009-018
35
36
Section 02 ENGINE
Subsection 04 (SUPERCHARGER)
SUPERCHARGER
SERVICE TOOLS
Description
Part Number
4-PIN SOCKET...............................................................................
BEARING SUPPORT/PUSHER ......................................................
CAMSHAFT LOCKING TOOL........................................................
SUPERCHARGER GEAR HOLDER................................................
SUPERCHARGER RETAINING KEY...............................................
SUPPORT PLATE...........................................................................
TORX ADAPTOR ...........................................................................
529
529
529
529
529
529
529
035
035
035
036
036
035
035
948
950
839
025
027
947
938
Page
..................................... 46, 48
........................................... 48
........................................... 40
........................................... 41
............................... 4446, 50
......................... 41, 44, 4748
..................................... 43, 51
SERVICE PRODUCTS
Description
Part Number
ISOFLEX GREASE TOPAS NB 52 .................................................

LOCTITE 243 (BLUE).....................................................................
LOCTITE 5910 ...............................................................................
SUPER LUBE GREASE..................................................................
293
293
293
293
smr2009-020
550
800
800
550
021
060
081
030
Page
........................................... 50
............................... 48, 5051
........................................... 51
........................................... 51
37
Section 02 ENGINE
Loctite 243
9 Nm
(80 lbfin)
Loctite
243
NEW
29 Nm
(21 lbfft)
NEW
NEW
29 Nm
(21 lbfft)
Loctite
5910
Loctite
243
9 Nm
(80 lbfin)
Engine
oil
Loctite
243
Engine
oil
Engine
oil
9 Nm
(80 lbfin)
Loctite
243
Isoflex grease
Topas NB62
Engine
oil
Super
Lube
grease
NEW
Isoflex grease
Topas NB62
29 Nm
(21 lbfft)
smr2009-020-001_a
38
smr2009-020
Section 02 ENGINE
GENERAL
During assembly/installation, use the torque values and service products as in the exploded view.
complete procedure.
WARNING
stop nuts, cotter pins, etc.) must be replaced
with new ones.
smr2009-020-011_a
MANY PARTS REMOVED FOR CLARITY PURPOSE

1. Support screws
Remove the air inlet hose from supercharger.

INSPECTION
SUPERCHARGER INLET
CLEANLINESS
NOTE: A lower than usual maximum RPM at full
throttle might be caused by a dirty supercharger
inlet.
Remove the deck extension. Refer to BODY subsection for proper procedure.
Remove the air intake silencer support.
smr2009-020-012_a
1. Air inlet hose

2. Hose clamp
Visually inspect supercharger inlet side for oil, salt

or any other deposits.
smr2009-020-010_a
1. Air intake silencer support
smr2006-012-010_a
1. Dirt here
If dirt is found, proceed as follows.

smr2009-020
39
Section 02 ENGINE
Remove supercharger and perform the clutch slipping moment test. Inspect bearings and friction
clutch. Replace bearings and clutch components
as necessary.
Separate supercharger housing.
NOTE: Since supercharger is disassembled, it is
recommended to completely inspect it.
Clean internal housing and turbine using a brush
and cleaning solvent to get rid of oil deposits.
Blow dry with compressed air.
NOTICE Do not let turbine spin when using
compressed air.
Complete usual assembly procedures as described in this subsection.
smr2009-020-012_a
1. Air inlet hose

2. Hose clamp
Remove cylinder head cover, refer to CYLINDER
HEAD subsection.
SUPERCHARGER CLUTCH
SLIPPING MOMENT (ON
ENGINE)
Remove the deck extension. Refer to BODY subsection for proper procedure.
Remove spark plugs.

Turn engine by rotating the supercharger nut
counterclockwise until the position lines on oil
separator cover are lined up as shown in the
following illustration.
smr2009-025-006_a
1. Position lines
smr2009-020-010_a
Lock camshaft with the CAMSHAFT LOCKING

TOOL (P/N 529 035 839) to prevent camshaft
rotation while checking slipping moment of supercharger.
529035839
smr2009-020-011_a

1. Support screws
40
smr2009-020
Section 02 ENGINE
SUPERCHARGER CLUTCH
SLIPPING MOMENT (BENCH
TEST)
Mount supercharger on the SUPPORT PLATE
(P/N 529 035 947).
smr2009-025-007_b
1. Camshaft locking tool
Check slipping moment counterclockwise by using a torque wrench with actual torque viewer. A
mirror is useful to see the viewer.
529035947
Use the SUPERCHARGER GEAR HOLDER (P/N 529

036 025) to retain supercharger gear while measuring slipping moment.
529036025
smr2009-020-004_a
1. Torque wrench
NOTE: Before checking the supercharger slipping

moment on a new or rebuilt supercharger, it is recommended to turn the clutch for a minimum of 3
complete revolutions. This will dissipate grease or
oil on the titanium shims for a precise reading.
Supercharger should start to turn at a torque
within the specified values.
SLIPPING MOMENT (NEW SUPERCHARGER)
9 Nm to 17 Nm (80 lbfin to 150 lbfin)
SLIPPING MOMENT (BREAK-IN SUPERCHARGER)
If the torque is not within specifications, repair

supercharger clutch. Verify supercharger clutch
components as per SUPERCHARGER INSPECTION in this subsection.
smr2009-020
smr2006-074-101
Check slipping moment counterclockwise by using a torque wrench with a viewer.
41
Section 02 ENGINE
ENGINE LACKS ACCELERATION OR

POWER (DOES NOT REACH MAXIMUM
RPM)
1. Supercharger inlet is dirty
- Check and clean supercharger inlet.
- Check engine oil. Siphon excess of oil.
2. Supercharger slipping clutch defective
- Check slipping clutch moment.
- Repair supercharger if out of specification.
smr2006-074-100_a
1. Torque wrench
2. Gear holder
NOTE: Before checking the supercharger slipping

moment on a new or rebuilt supercharger, it is recommended to turn the clutch for a minimum of 3
complete revolutions. This will dissipate grease or
oil on the titanium shims for a proper reading.
Supercharger should start to turn at a torque
within the specified values.
PROCEDURES
SUPERCHARGER
Supercharger Removal
Remove the moving deck. Refer to BODY subsection for proper procedure.
SLIPPING MOMENT (NEW SUPERCHARGER)

SLIPPING MOMENT (BREAK-IN SUPERCHARGER)
If the torque is not within specification, repair

supercharger clutch. Verify supercharger clutch
components as per SUPERCHARGER INSPECTION in this subsection.
smr2009-020-010_a
TROUBLESHOOTING
The following is provided to help in diagnosing the

probable source of troubles. It is a guideline and
it should not be assumed to list all possible problems.
Always check for fault codes. If a fault code is detected, service the fault code first. Refer to MONITORING SYSTEM AND FAULT CODES subsection.
ENGINE WILL NOT START (ENGINE DOES

NOT TURN OVER)
1. Supercharger seized or obstructed
- Inspect and repair supercharger.
smr2009-020-011_a

1. Support screws
42
smr2009-020
Section 02 ENGINE
smr2009-020-012_a
1. Air inlet hose

2. Hose clamp
Remove air outlet hose from supercharger.
smr2008-012-011_a
1. Rubber adapter
2. Exhaust pipe
Loosen clamp securing rubber adapter to exhaust

pipe.
Detach muffler strap.
Move muffler back ( 5 cm (2 in)).
Remove retaining screws and pull out the supercharger.
smr2009-020-013_a
1. Air outlet hose

2. Hose clamp
Unscrew blow-by valve screws and move it aside

to make room.
smr2009-020-005_a
1. Retaining screws
2. Upper retaining screw (hidden behind the supercharger)
NOTE: To remove the upper retaining screw, use

the TORX ADAPTOR (P/N 529 035 938).
smr2008-012-010_a
529035938
1. Blow-by valve
2. Supercharger
Using a marker, trace a mark on rubber adapter

and exhaust pipe.
smr2009-020
43
Section 02 ENGINE
R1503motr250A
1. Upper retaining screw

F00B28A
Supercharger Disassembly
NOTICE Be scrupulous when working on
supercharger parts. Supercharger rotation
reaches 45 000 RPM. Any modification, improper repair, assembly or damage on the
parts, may result in damage of the supercharger. Strictly follow the described procedures.
1. Retaining screws
2. Housing half (intake side)
3. Housing half (engine side)
1. Mount supercharger on the SUPPORT PLATE

(P/N 529 035 947).
F00B29A
PLASTIC HAMMER
529035947
2. Take apart supercharger housing.
3. Loosen cap nut (turn clockwise) on supercharger shaft turbine side while holding shaft
with the SUPERCHARGER RETAINING KEY
(P/N 529 036 027).
529035949
44
smr2009-020
Section 02 ENGINE
smr2009-020-006_a
1. Cap nut (left-handed thread)
4. Remove washer, turbine, O-ring and step collar

from supercharger shaft.
F00B2BA
1. Nut
2. Retaining key
NOTE: There are 40 loose needle bearings under

the gear. Do not reuse.
6. Remove L-ring, spring washers, lock washer,
drive gear and needle pins by turning the supercharger upside down.
smr2009-020-007_a
1.
2.
3.
4.
Washer
Turbine
O-ring
Step collar
5. Loosen nut on supercharger shaft engine side

while holding shaft with the SUPERCHARGER
RETAINING KEY (P/N 529 036 027).
smr2006-012-008_a
1.
2.
3.
4.
5.
6.
7.
Nut
L-ring
Spring washers (5x)
Lock washer
Titanium shims
Drive gear
Needle bearings
7. Carefully push out supercharger shaft towards

engine side by using a press.
smr2009-020
45
Section 02 ENGINE
NOTE: It may be necessary to heat the housing

with a heat gun to release the retaining disc.
F00B2CA
1. Supercharger shaft
8. Remove and discard ball bearing from supercharger shaft by using a press and the SUPERCHARGER RETAINING KEY (P/N 529 036 027).
F00B2AA
1. 4-pin socket
10. Discard the oil seal.

11. Remove and discard ball bearing from supercharger housing half (engine side) by using a
press and a suitable bearing pusher.
F00B2DA
2. Ball bearing
3. Retaining key
9. Screw out retaining disc with seal from housing half (engine side) by using the 4-PIN SOCKET
(P/N 529 035 948).
R1503motr236A
1. Supercharger housing half (engine side)

2. Bearing pusher
Supercharger Inspection
Supercharger Clutch Components and Gear
Check the wear limit on drive gear, lock washer
and driven plate on supercharger shaft. Check
drive gear for cracks.
NOTE: If parts are worn out or damaged, repair
supercharger only by using supercharger repair
kit.
529035948
46
smr2009-020
Section 02 ENGINE
SPRING WASHER PACKAGE HEIGHT
NEW
10.7 mm to 10.9 mm
(.4213 in to .4291 in)
SERVICE LIMIT
10.2 mm (.4016 in)
Supercharger Assembly
NOTICE Every time when supercharger shaft
has been removed, both ball bearings have to
be replaced.
R1503motr360A
NOTICE Both ball bearings have to be installed with cages facing turbine side.
A. Driven plate journal depth

B. Drive gear thickness
C. Lock washer thickness
DRIVEN PLATE JOURNAL DEPTH

NEW
14.460 mm to 14.500 mm
(.5693 in to .5709 in)
SERVICE LIMIT
14.600 mm (.5748 in)
1. Apply enough engine oil on NEW ball bearing.

2. Install ball bearing on supercharger shaft by using the SUPPORT PLATE (P/N 529 035 947) to hold
bearing.
DRIVE GEAR THICKNESS

NEW
11.000 mm to 11.050 mm
(.4331 in to .435 in)
SERVICE LIMIT
10.900 mm (.4291 in)
LOCK WASHER THICKNESS

NEW
4.050 mm to 4.150 mm
(.1594 in to .1634 in)
SERVICE LIMIT
3.950 mm (.1555 in)
Spring Washer
Put spring washer package together as it is assembled on the supercharger shaft. Measure the
height of the unloaded spring washer package.
529035947
NOTICE Ensure to position ball bearing

against protrusion of support plate for the installation. This way, the installation pressure
will be applied to the inner race and will not be
transmitted to the bearing balls which would
otherwise shorten the bearing life.
NOTICE To install ball bearings and supercharger shaft always use a press, never use
any beating force like a hammer.
R1503motr248A
A. Spring washer package height
smr2009-020
47
Section 02 ENGINE
529035947
F00B2FA
1.
2.
3.
4.
Supercharger shaft
Ball bearing
Bearing support plate
Protrusion of support plate on this side (underneath inner race)
6. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on

retaining disc. If a new retaining disc is used,
the threads are coated with a self-locking product.
7. Install the retaining disc in supercharger housing half by using the 4-PIN SOCKET (P/N 529 035
948).
8. Torque retaining disc to 29 Nm (21 lbfft).
3. Apply enough engine oil on NEW ball bearing.

4. Press in the ball bearing in supercharger housing half (engine side), by using BEARING SUPPORT/PUSHER (P/N 529 035 950).
529035948
529035950
F00B2IA
1. Retaining disc
2. 4-pin socket
F00B2EA
1. Bearing support/pusher
9. To press supercharger shaft in housing half (engine side), properly support bearing using the
SUPPORT PLATE (P/N 529 035 947) and the BEARING SUPPORT/PUSHER (P/N 529 035 950) under
supercharger housing half.
5. Mount supercharger housing half (engine side)

on the SUPPORT PLATE (P/N 529 035 947).
48
smr2009-020
Section 02 ENGINE
529035950
smr2006-012-032_a
1.
2.
3.
4.
5.
F00B2GA
Compressor shaft
Ball bearing
Supercharger housing half
Thrust washer
Distance sleeve
1. Support plate
2. Bearing support/pusher
3. Protrusion here
NOTICE Before pressing in the supercharger

shaft, be sure to properly support the inner
race of ball bearing in supercharger housing
half with the recommended tool. This way,
the installation pressure will be applied to the
inner race and will not be transmitted to the
bearing balls which would otherwise shorten
the bearing life.
10. Apply heat outside of the housing with a heat
gun to expand its diameter prior to inserting
the shaft. Ensure there is no O-ring on the
housing half prior to heating.
11. Apply engine oil on supercharger shaft. Press
shaft with thrust washer and distance sleeve
together in supercharger housing half.
F00B2HA
2. Distance sleeve
12. Apply engine oil on seal and push into retaining

disc by hand.
NOTE: Always use a NEW oil seal when assembling the supercharger.
1
R1503motr242A
1. Oil seal
smr2009-020
49
Section 02 ENGINE
13. Install step collar, O-ring, turbine and washer

on supercharger shaft. Apply LOCTITE 243
(BLUE) (P/N 293 800 060) on cap nut and temporary finger tight cap nut.
NOTE: The cap nut on the supercharger shaft has
a left-handed thread. The Loctite has to be applied
in a small dose into the nut.
20. Install the second titanium shim.

21. Install the lock washer.
22. Apply engine oil to the spring washers.
23. Position the spring washers as per illustration.
NOTICE When installing the spring washers,
take care of the exact installation direction of
the washers.
smr2006-012-009_a
1. Spring washers
smr2009-020-007_b
1.
2.
3.
4.
5.
Step collar
O-ring
Turbine
Washer
Cap nut
24. Install the L-ring on the compressor shaft.

the hexagonal nut threads. Torque to 29 Nm
(21 lbfft).
14. Complete installation of supercharger shaft,

engine side as follows:
NOTICE It is of the utmost importance that
all parts be absolutely clean. The compressor
shaft spins at up to 45 000 RPM and any debris
could cause a failure.
15. Install the first titanium shim.
NOTE: The titanium shims have the same inner
diameter.
NOTICE Manipulate titanium shims with
care, those parts are sensitive.
16. IMPORTANT: Apply ISOFLEX GREASE TOPAS
NB 52 (P/N 293 550 021) to the inner diameter of
the gear thrust surface on the shaft, titanium
shims, needle bearings, shaft surface and lock
washer.
NOTICE No other grease can be used, otherwise damage to bearings will occur.
smr2006-012-008_a
1.
2.
3.
4.
5.
6.
7.
Nut
L-ring
Spring washers
Lock washer
Titanium shims
Drive gear
Needle bearings
NOTE: The L-ring will preload the spring washers.

26. Hold the lock washer of the supercharger
shaft (engine side) using the SUPERCHARGER
RETAINING KEY (P/N 529 036 027).
17. Install the 40 needle bearings on the compressor shaft.

NOTE: The 40 needle bearings comes in a wax
strip with an adhesive backing.
18. Remove the adhesive backing.
19. Install the drive gear over the needle bearings.
50
smr2009-020
Section 02 ENGINE
Supercharger Installation
1. Grease sealing surface between supercharger
and PTO housing with SUPER LUBE GREASE
(P/N 293 550 030).
NOTE: Ensure O-rings are installed.
529035949
27. Tighten the cap nut to 29 Nm (21 lbfft).

28. Apply LOCTITE 5910 (P/N 293 800 081) on supercharger housing sealing surface.
1
R1503motr247A
1. Super Lube grease

R1503motr246A
1. Apply Loctite 5910 on sealing surface
29. Assemble supercharger housing halves. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on retaining screws and torque to 9 Nm (80 lbfin)
according to the following sequence.
2. Install supercharger on PTO housing.

the retaining screws.
4. Torque retaining screws to 9 Nm (80 lbfin).
4.1 To tighten and torque the upper retaining
screw, use the TORX ADAPTOR (P/N 529
035 938).
8
2
529035938
1
9
5. Ensure to install the tool perpendicularly (90) to

torque wrench to apply the proper torque to the
screw.
7
R1503motr227B
SUPERCHARGER TIGHTENING SEQUENCE
30. Verify the clutch slipping moment. Refer to
SUPERCHARGER CLUTCH SLIPPING MOMENT (BENCH TEST) in this subsection.

F00B1UA
1. Tool perpendicular (90) to torque wrench

A. 90
smr2009-020
51
Section 02 ENGINE
NOTICE Not installing the tool as shown will

change the torque applied to the screw. Proper
torque and tightening sequence are important.
6. After complete installation of the supercharger,
the slipping moment has to be rechecked.
Refer to SUPERCHARGER CLUTCH SLIPPING
MOMENT (ON ENGINE) at the beginning of
this subsection.
52
smr2009-020
Section 02 ENGINE
Subsection 05 (INTERCOOLER)
INTERCOOLER
SERVICE TOOLS
Description
Part Number
Page
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 55

VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 55
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
8 Nm
(71 lbfin)
NEW
8 Nm
(71 lbfin)
smr2009-019-001_a
smr2009-019
53
Section 02 ENGINE
GENERAL
Intercooler Cleaning

complete procedure.
If temperature in intake manifold is too high or if

engine is down in performance, intercooler may
require to be cleaned.
The exhaust system should be flushed first, as it
may unclogged the intercooler. If not, then proceed with the intercooler cleaning procedure as
detailed here.
NOTE: The exhaust temperature will decrease
when the intercooler is clogged because more
water is rerouted through the exhaust system.
To clean the intercooler, do the following:
WARNING
stop nuts, cotter pins, etc.) must be replaced
with new ones.
Hose, cables or locking ties removed during a
MAINTENANCE
NOTICE Never try to clean the intercooler

with chemical products. Only use fresh water.
Chemical products will permanently damage
the internal parts of intercooler.
1. Remove the INTERCOOLER from the watercraft. See procedure further in this section.
2. Pour fresh water into the water outlet fitting.
INTERCOOLER FLUSHING
Flushing the intercooler with fresh water is essential to neutralize corroding effects of salt or other
chemical products present in water. It will help to
clean up sand, salt, shells or other particles in intercooler.
NOTE: Intercooler is flushed with the exhaust
system, as they are on the same circuit.
Exhaust system and intercooler should be flushed
each time:
Watercraft is used in salt water and is not expected to be used further the same day.
Watercraft is used in foul water.
Watercraft is stored for any extended time.
Refer to EXHAUST SYSTEM subsection for flushing procedure.
NOTICE Failure to flush the system, when
necessary, will severely damage engine intercooler and/or exhaust system.
PROCEDURES
INTERCOOLER
WARNING
Let engine cool down prior to work on or near
intercooler.
54
smr2009-019-008_a
1. Intercooler water outlet fitting

2. Intercooler water inlet fitting
3. Let water into intercooler for many hours. Occasionally, shake the intercooler to soak off deposits.
4. Rinse the intercooler using a garden hose installed on water outlet.
5. Let water flows out of intercooler a few minutes to evacuate internal deposits.
6. Check water flow.
WATER FLOW
Low or erratic
1. Repeat cleaning procedure.

2. Replace the intercooler.
High and regular
Intercooler is not clogged.
smr2009-019
Section 02 ENGINE
smr2009-019-009_a
1. Garden hose installed on water outlet

2. High and regular water flow
7. Perform a leak test before installing the intercooler in the watercraft.
529021800
BLEED HOSE FITTING
Pressurize the intercooler.

PRESSURE TEST
Intercooler Leak Test

Using a LARGE HOSE PINCHER (P/N 529 032 500),
block intercooler water inlet and outlet hoses.
69 kPa (10 PSI) for 10 minutes min.
If there is a pressure drop, first spray tool, hoses

and adapters with a soapy water solution to ensure they are not leaking.
Otherwise, replace the intercooler.
Intercooler Removal
5290325002
Disconnect the bleed hose from intercooler.
smr2009-019-002_a
Open the boarding platform.

Remove both storage baskets.
From the LH opening, disconnect the intercooler
water hoses and the bleed hose.
smr2009-019-002_a

1. Intercooler
2. Intercooler water outlet hose
3. Intercooler water inlet hose
4. Bleed hose

1. Intercooler
2. Intercooler water outlet hose
3. Intercooler water inlet hose
4. Bleed hose
Install the VACUUM/PRESSURE PUMP (P/N 529 021

800) on bleed hose fitting.
Disconnect both air hoses.
smr2009-019
55
Section 02 ENGINE
smr2009-019-005_a
FIXED DECK REMOVED FOR CLARITY PURPOSE

1. iS module
2. Retaining latch
smr2009-019-003_a
1. Intercooler air inlet hose

2. Intercooler air outlet hose
Cut locking ties securing wiring harness to iS module support and front attachment.
Detach both intercooler straps.
smr2009-019-006_a
smr2009-019-004_a
1. Intercooler straps
Remove the iBR actuator. Refer to iBR AND VTS

subsection.
Remove the intercooler from vehicle by the LH
opening.
1. Cut these locking ties
Remove screws securing the front attachment to

the hull.
Intercooler Installation
NOTE: Ensure hoses are routed correctly and
locking ties are positioned at proper locations.
INTERCOOLER ATTACHMENTS
Front Attachment Replacement
NOTE: Front attachment and iS module support
are attached together with rivets.
Remove the INTERCOOLER, see procedure in
this subsection.
Detach iS module from its support and move the
module aside to make room.
smr2009-019-007_a
1. Retaining screws
Remove front attachment and iS module from vehicle.

When reinstalling, tighten screws to 8 Nm
(71 lbfin).
Rear Attachment Replacement

Remove the INTERCOOLER, see procedure in
this subsection.
56
smr2009-019
Section 02 ENGINE
Remove plastic rivets and rubber pad.
smr2009-019-050_a
THROUGH THE LH REAR OPENING

1. Plastic rivet
2. Rubber pad
Remove and discard screw securing the attachment to the hull.
smr2009-019-051_a
THROUGH THE LH REAR OPENING

1. Retaining screw
2. Washer
3. LH rear attachment
Install a new attachment using a NEW screw.

Tighten screw to 8 Nm (71 lbfin).
smr2009-019
57
58
Section 02 ENGINE
Subsection 06 (EXHAUST SYSTEM)
EXHAUST SYSTEM
SERVICE TOOLS
Description
Part Number
Page
FLUSHING CONNECTOR ADAPTER ............................................ 295 500 473 ........................................... 62
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 67
smr2009-021
59
Section 02 ENGINE
9 Nm
(80 lbfin)
11 Nm
(97 lbfin)
16 Nm
(142 lbfin)
Loctite 243
Loctite 567
(pipe sealant)
7.5 Nm
(66 lbfin)
8 Nm
(71 lbfin)
4 Nm
(35 lbfin)
Loctite 518
16 Nm
(142 lbfin)
See EFI subsection
4 Nm
(35 lbfin)
5 Nm
(44 lbfin)
GTX
LIMITED
smr2009-021-001
60
smr2009-021
Section 02 ENGINE
GENERAL
complete procedure.
WARNING
must be strictly adhered to. Locking devices
(e.g.: locking tabs, elastic stop nuts, cotter
pins, etc.) must be replaced with new ones.
smr2008-013-008_a
Water exits exhaust pipe through holes at the end

of the water jacket and mixes with exhaust gas in
the muffler.
SYSTEM DESCRIPTION
The exhaust system is protected by its own cooling system, an opened loop type.
The water supply is provided by a pressurized area
in the jet pump between the impeller and venturi.
Water is directed first through the exhaust manifold fitting located at front of manifold.
Water enters the manifold end and is directed to
water jackets of exhaust manifold.
smr2008-013-009_a
1. Water packet holes
Water is evacuated from muffler then through the

exhaust outlet in transom area.
Exhaust System Technical

Specifications
smr2009-021-002_a
1.
2.
3.
4.
Exhaust
Exhaust
Exhaust
Exhaust
manifold water inlet

manifold
manifold water outlet (to pump support)
manifold water outlet (to exhaust pipe and muffler)
Water exits exhaust manifold through 2 hoses at

rear manifold.
TYPE
Total Loss Cooling System

(TLCS)
WATER FLOW
Flow from jet pump

(no water pump)
TEMPERATURE
CONTROL
Calibrated outlet fittings

(no thermostat)
SYSTEM BLEEDING
Self-bleed type
SYSTEM DRAINING
Self-drain type
MAINTENANCE
EXHAUST SYSTEM FLUSHING
Flushing the exhaust system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
smr2009-021
61
Section 02 ENGINE
help to clean up sand, salt, shells or other particles

in water jackets (exhaust system, intercooler and
hoses.
Exhaust system flushing should be performed
when the watercraft is not expected to be used
further the same day or when the watercraft is
stored for any extended time.
NOTICE Failure to flush the system, when
necessary, will severely damage intercooler
and exhaust system. Make sure engine operates during entire procedure.
WARNING
Perform these operations in a well ventilated
area. Certain components in the engine
compartment may be very hot. Direct contact may result in skin burn. Do not touch
any electrical part or jet pump area when
engine is running.
WARNING
When operating the engine while the watercraft is out of the water, the heat exchanger
in the ride plate may become very hot. Avoid
any contact with ride plate as burns may occur.
Connect a garden hose to connector located at the
rear of watercraft. Do not open water tap yet.
F00E05A
1. Quick connect adapter

2. Flushing connector adapter
To flush the exhaust system, start the engine then

immediately open the water tap.
NOTICE Always start the engine before
opening the water tap. Open water tap immediately after engine is started to prevent
overheating. Never run engine without supplying water to the exhaust system when
watercraft is out of water.
Run the engine about 20 seconds at a fast idle
between 4000 - 5000 RPM.
NOTICE Never run engine longer than 2 minutes. Drive line seal has no cooling when watercraft is out of water.
Ensure water flows out of jet pump while flushing.
Close the water tap, then stop the engine.
NOTICE Always close the water tap before
stopping the engine.
Disconnect the garden hose.
NOTICE Remove flushing connector adapter
after operation (if used).
PROCEDURES
MUFFLER
Muffler Removal
WARNING
smr2009-021-004_a
1. Water inlet connector
NOTE: The
optional FLUSHING CONNECTOR

ADAPTER (P/N 295 500 473) can be used with a
quick connect adapter to ease garden hose installation.
62
Certain components in the engine compartment may be very hot. Direct contact may
result in skin burn. Let exhaust system cool
down prior to removing parts.
2. Cut locking tie securing water outlet hose (exhaust system) and blow-by hose.
3. Disconnect the water outlet hose from the exhaust manifold.
smr2009-021
Section 02 ENGINE
4. Gently disconnect the hose from blow-by valve.
smr2009-016-005_a
1. Exhaust hose clamp

smr2009-016-003_a
1.
2.
3.
4.
5.
8. Detach retaining strap.
Cut this locking tie

Water outlet hose (exhaust system)
Blow-by hose
Blow-by valve
Exhaust manifold
5. Unscrew exhaust clamp.

NOTICE Do not use pneumatic or electrical
tools as seizure may occur.
smr2009-016-006_a
1. Muffler retaining strap
9. Remove the LH rear storage basket.

10. Move muffler backwards and slide it through
the rear opening.
Muffler Inspection
smr2009-016-007_a
1. Exhaust clamp
6. Unplug the exhaust gas temperature sensor

(EGTS).
Check muffler for:

Cracks
Corrosion
Other damages.
Check if exhaust hose is:
Brittle
Hard
Cracked
Otherwise damaged.
Replace any defective part.
Muffler Installation
smr2009-016-004_a
1. EGTS sensor
2. Exhaust hose
With a new muffler, install the EXHAUST GAS

TEMPERATURE SENSOR. See procedure further
in this subsection.
Open muffler adjusters by sliding adjuster blocks.
7. Disconnect the exhaust hose from muffler.
smr2009-021
63
Section 02 ENGINE
smr2008-013-025_a
1. Exhaust manifold mark

2. Exhaust pipe mark
smr2008-013-026_a
Step 1: Lift adjuster tab

Step 2: Move adjuster outward
Using the rear opening, slide the muffler in hull.

Align the exhaust pipe flange to the exhaust manifold. Rotate and move muffler so that the exhaust
pipe flange makes perfect contact with exhaust
manifold.
Slide both adjuster blocks against muffler to support it in position.
NOTE: Ensure muffler is in contact with both adjuster blocks. Readjust as required.
Install exhaust clamp with the nut upward.
Tighten clamp loosely.
Using a 50 mm (2 in) spacer (in this case a bolt),
position the exhaust pipe.
Tighten exhaust clamp to 11 Nm (97 lbfin).

NOTICE Do not use pneumatic or electric
tools as seizure may occur.
Install the muffler strap.
NOTICE Ensure not to rotate muffler during
strap installation. The use of a soapy water solution on inner side of muffler strap is recommended.
After installation, ensure there is no water or exhaust gas leak when engine is running.
Test run the engine while supplying water to the
exhaust system.
NOTICE Never run engine without supplying
water to the exhaust system when watercraft is
out of water.
EXHAUST HOSES
Front Exhaust Hose Replacement
Remove the LH rear storage basket.
Remove exhaust hose from muffler outlet.
smr2008-013-027_a
1. Engine lifting ring

2. Spacer
3. Exhaust pipe fitting
Confirm that the exhaust pipe mark is aligned with

the mark on the exhaust manifold.
smr2009-021-010_a
1. Retaining clamp
2. Exhaust hose

64
smr2009-021
Section 02 ENGINE
Move the coolant expansion tank aside and cut

locking tie retaining the starter cable (RED) to exhaust hose.
Remove exhaust hose from resonator.
Cut locking tie retaining bailer hose elbow fittings
to exhaust hose.
Remove front exhaust hose from vehicle.
When reinstalling exhaust hose, make sure to attach elbow fittings at the highest position that you
can on the exhaust hose.
Tighten retaining clamps to 4 Nm (35 lbfin).
After installation, ensure there is no water or exhaust gas leak when the engine is running. Test
run the engine while supplying water to the exhaust system.
smr2008-013-033_a
1. Water inlet hose

2. Exhaust pipe
Loosen rubber adapter clamps.

out of water.
Rear Exhaust Hose Replacement

Remove battery and battery holder. Refer to
Loosen clamps securing rear exhaust hose to resonator and iBR support plate.
Remove the rear exhaust hose from vehicle.
When reinstalling rear exhaust hose, tighten
clamps to 4 Nm (35 lbfin).
Reinstall all other removed parts.
out of water.
EXHAUST PIPE
Exhaust Pipe Removal
Remove MUFFLER, see procedure in this subsection.
Disconnect water inlet hose from exhaust pipe fitting.
smr2009-021
smr2008-013-034_a
1.
2.
3.
4.
Muffler
Rubber adapter
Clamps
Exhaust pipe
Remove exhaust pipe and the rubber adapter.
Exhaust Pipe Inspection

Inspect exhaust pipe for:
Cracks
Flange damages
Other damages.
Replace exhaust pipe as required.
Check if the rubber adapter is:
Brittle
Hard
Otherwise damaged.
Replace rubber adapter if necessary.
Exhaust Pipe Installation

Trace a mark to locate the middle of the muffler
bulge opening.
65
Section 02 ENGINE
smr2008-013-035_a
1. Bulge
2. Middle of the opening
Install the rubber adapter on exhaust pipe. Ensure

rubber adapter is properly seats against exhaust
pipe shoulder.
smr2008-013-037_a
1. Middle of rubber adapter strip

2. Center of the muffler bulge opening
Using a caliper, measure the distance between

the exhaust pipe shoulder and the outside of the
muffler bulge.
Position the
muffler to
95 mm 2 mm
(3.74 in .079 in). Check the distance in
several places.
smr2008-013-038_a
1. Exhaust pipe shoulder

2. Rubber adapter
Center the rubber adapter strip of the rubber

adapter between both exhaust pipe marks.
Tighten retaining clamp to 8 Nm (71 lbfin).
smr2008-013-039_a
1. Rubber adapter end

2. Outside of the muffler bulge
A. 95 2 mm (3.74 .0787 in)
Tighten retaining clamp to 8 Nm (71 lbfin).

Install muffler in vehicle. Refer to MUFFLER INSTALLATION in this subsection for complete procedure.
EXHAUST MANIFOLD
smr2008-013-036_a
1. Rubber adapter strip

2. Retaining clamp
3. Exhaust pipe marks
Slide the other clamp on the rubber adapter.

Insert the exhaust pipe into the muffler.
Align the center of the rubber adapter strip with
the mark previously traced on muffler.
66
Exhaust Manifold Removal

1. Remove the moving deck and the deck extension. Refer to BODY subsection.
2. Move muffler rearwards to make room. Refer
to MUFFLER REMOVAL in this subsection to
know how separate muffler from exhaust manifold.
smr2009-021
Section 02 ENGINE
3. Disconnect the exhaust manifold water outlet

hose.

threads of screws.
To help holding the manifold while installing
screws, first insert the exhaust manifold into the
exhaust pipe then, install the upper front screw.
Continue with the remaining screws.
Torque screws to 9 Nm (80 lbfin) as per following illustrated sequence. Repeat the procedure,
torquing screws again to 9 Nm (80 lbfin).
7
11
10
12
smr2009-016-023_a
1. Water outlet hose

2. Exhaust manifold
4. Disconnect exhaust manifold water inlet hose

from exhaust manifold.
R1503motr152A
smr2009-016-024_a
1. Exhaust manifold water inlet hose
run the engine while supplying water to the flushing connector.
5. Unscrew the exhaust manifold beginning with

the bottom screws. This will help holding the
manifold while you remove the screws.
6. Move the manifold rearwards to remove it from
vehicle.
RESONATOR
Exhaust Manifold Inspection
Resonator Removal
Inspect exhaust manifold condition paying attention for cracks or other damage. Check contact
surfaces and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
Clean all metal components in a solvent.
Remove engine from vehicle. Refer to ENGINE

REMOVAL AND INSTALLATION subsection.
Exhaust Manifold Installation

Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
NOTE: There is no gasket between cylinder block
and exhaust manifold.
smr2009-021

out of water.
Remove battery and battery holder. Refer to

Loosen clamp securing rear exhaust hose to resonator.
Remove the front exhaust hose from resonator.
Remove resonator from vehicle.
Resonator Inspection
Inspect parts condition paying attention for deformation, cracks or other damage. Check hoses.
Replace any defective part.
67
Section 02 ENGINE
Resonator Installation
Installation is the reverse of the removal procedures. However, pay attention to the following.
out of water.
68
smr2009-021
Section 02 ENGINE
Subsection 07 (PTO HOUSING AND MAGNETO)
PTO HOUSING AND MAGNETO

SERVICE TOOLS
Description
Part Number
3-PIN MAGNETO HARNESS ADAPTER........................................

BLIND HOLE BEARING PULLER SET...........................................
HANDLE ........................................................................................
IMPELLER REMOVER/INSTALLER ...............................................
OETIKER PLIERS...........................................................................
STARTER DRIVE SEAL PUSHER...................................................
SUCTION PUMP ...........................................................................
529
529
420
529
295
420
529
036
036
877
035
000
876
035
016
117
650
820
070
502
880
Page
..................................... 7879
........................................... 77
........................................... 78
........................................... 77
........................................... 77
........................................... 78
........................................... 72
SERVICE PRODUCTS
Description
Part Number
ISOFLEX GREASE TOPAS NB 52 .................................................

LOCTITE 243 (BLUE).....................................................................
LOCTITE 648 (GREEN) ..................................................................
PULLEY FLANGE CLEANER .........................................................
293
293
413
413
smr2009-022
550
800
711
711
021
060
400
809
Page
..................................... 78, 83
..................................... 76, 81
........................................... 77
..................................... 73, 76
69
Section 02 ENGINE
Oil
9 Nm
(80 lbfin)
9 Nm
(80 lbfin)
Loctite
Loctite
243
243
Oil
Isoflex grease
Topas NB 52
Loctite 243
9 Nm
(80 lbfin)
Isoflex grease
Topas NB 52
NEW
NEW
15 Nm
(133 lbfin)
+50
Oil
Loctite
648
250 Nm
(184 lbfft)
smr2008-014-007_b
70
smr2009-022
Section 02 ENGINE
GENERAL
NOTE: It is good practice to check for fault
codes using the B.U.D.S. software as a first troubleshooting step. Refer to the MONITORING
SYSTEM AND FAULT CODES subsection.
Always carry out electrical tests on components
before removing or installing them.
During assembly, use torque values and service
products as in the exploded view.
complete procedure.
WARNING
etc.) must be installed or replaced with new
ones.
Always disconnect the negative wire from the battery before working on the engine.
WARNING
Always disconnect the BLACK (-) cable first
and reconnect last.
WARNING
Before carrying out any inspection or maintenance procedure on the vehicle, wait until
the engine and exhaust have cooled down to
avoid potential burns.
TROUBLESHOOTING
should not be assumed to list all possible problems.
ENGINE WILL NOT START (ENGINE DOES

NOT TURN OVER)
1. Obstructed starter drive gear assembly
- Check and repair the starter drive.
ENGINE WILL NOT START (ENGINE

TURNS OVER)
1. Defective or loose CPS
- Check operation of CPS and replace if necessary.
2. Defective trigger wheel
- Check trigger wheel teeth if bent or damaged.
3. Defective starter drive gear assembly
- Check and repair the starter drive.
ENGINE CONTINUALLY BACKFIRES

- Check trigger wheel teeth if bent or damaged.
2. Defective or loose CPS
STARTER TURNS, BUT STARTER DRIVE

DOES NOT MESH WITH RING GEAR
1. Worn starter drive gear
- Replace starter drive assembly.
2. Defective starter drive
3. Poor movement of the drive on splines
- Clean and correct.
4. Worn drive bushing
5. Worn ring gear
- Replace ring gear.
OIL CONTAMINATION (WHITE

APPEARANCE)
1. Water ingestion through drive shaft and floating
ring
- Check if water is leaking between drive shaft and
floating ring. Repair or replace defective parts.
- Change engine oil and filter.
PROCEDURES
PTO HOUSING
PTO Housing Removal
1. Disconnect the battery.
smr2009-022
71
Section 02 ENGINE
WARNING
Always disconnect battery cables exactly in
the specified order, BLACK negative cable
first.
2. Remove the moving deck and deck extension.
Refer to BODY subsection.
3. Drain the engine oil. Refer to LUBRICATION
SYSTEM subsection.
4. Remove the cylinder head cover. Refer to
CYLINDER HEAD subsection.
5. Using SUCTION PUMP (P/N 529 035 880), insert
the tube in the lower area of the timing chain.
Syphon remaining oil.
smr2009-020-005_b
1. Supercharger
Refer to STEERING AND PROPULSION and remove the following:

Jet pump
Drive shaft
Drive shaft bellows.
Disconnect CPS connector from wiring harness.
smr2006-006-003_a
1. Oil siphoning tube

2. Edge of cylinder block
6. Drain engine coolant, refer to the COOLING

SYSTEM subsection.
Remove the supercharger air outlet hose.
Move muffler rearwards. Refer to EXHAUST SYSTEM subsection.
Remove the supercharger, refer to the SUPERCHARGER subsection.
72
smr2008-023-016_a
CPS CONNECTOR
Disconnect the magneto connector from wiring

harness. The connector is located between ECM
and throttle body.
smr2009-022
Section 02 ENGINE
Slightly lift aft end of engine and insert a safely

block under the engine to secure it in this position.
Remove LH rear engine support.
smr2009-016-015_b
2. ECM
3. Throttle body
Place rags under PTO housing to prevent oil

spillage.
NOTE: Up to 250 ml (8 U.S. oz) of oil could flow
out when removing PTO housing. If spillage occurs, clean immediately with the PULLEY FLANGE
CLEANER (P/N 413 711 809) to prevent oil stains.
Remove both rear engine support screws.
R1503motr50A
TYPICAL
1. Engine support
Remove water pump housing, refer to COOLING
SYSTEM subsection.
smr2007-016-003_c
smr2009-016-020_b
RIGHT SIDE OF VEHICLE

1. Rear engine support screw
Remove PTO housing retaining screws.
smr2009-016-022_b
LEFT SIDE OF VEHICLE

1. Rear engine support screw
smr2009-022
73
Section 02 ENGINE
PTO Housing Inspection

Inspect PTO housing for cracks or any other damages. Replace if necessary.
Inspect the needle bearing in the PTO housing
used to support the starter drive assembly shaft.
NOTE: Clean all disassembled metal components
in a non-ferrous metal cleaner.
WARNING
smr2009-022-001_a
1. PTO housing
2. CPS harness retaining clamp
3. CPS
NOTE: Note position of the CPS harness retaining

clamp position as illustrated above for reinstallation.
Remove PTO housing from engine.
Wear safety glasses and work in a well

ventilated area when working with strong
chemical products. Also wear suitable nonabsorbent gloves to protect your hands.
Inspect oil strainer for contaminants, debris or
other particles. Clean as required.
NOTICE To prevent damaging contact surfaces, be sure to use prying lugs to separate
PTO housing from engine.
NOTE: Carefully separate PTO housing from engine using two flat screwdrivers prying equally on
opposite sides of the housing and at the same
time. Proceed slowly to prevent starter gear disc
springs and washer from falling down into bilge
area.
R1503motr117A
1. PTO oil strainer
PTO Housing Installation

However, pay attention to the following.
Apply lubricants, sealers or thread locker as specified in exploded view.
Apply torques as specified in exploded view.
Position the disc springs and thrust washer onto
the starter drive assembly shaft as per following
illustration.
smr2005-034-002_a
1. Disc springs
2. Washer
3. Starter drive gear
Remove PTO housing gasket and discard.

74
smr2009-022
Section 02 ENGINE
smr2005-034-100_a
TYPICAL
1. Thrust washer
2. Disc springs
3. Starter drive assembly
NOTE: When installing a NEW starter drive assembly, oil the shaft and gear splines with engine
oil.
Install a new PTO housing gasket.
NOTE: When installing the PTO housing, you will
need to rotate the oil/water pump shaft slightly to
align it with the balance shaft for proper insertion.
smr2009-022-001_b
1. Screws M6 x 35
2. Screws M6 x 85
NOTE: Install the CPS harness retaining clamp

at the position noted during the PTO housing
removal.
NOTICE Pay particular attention to the PTO

housing gasket alignment to ensure that it
does not get pinched, or slide out of its surface contact area. Never force housing when
installing it. If there is a strong resistance, remove housing and check oil/water pump shaft
alignment and starter gear drive alignment.
NOTICE Ensure the starter drive gear shaft is
well aligned when engaging it in the PTO housing needle bearing.
smr2009-022-004_a
1. CPS harness retaining clamp
Install the PTO housing screws finger tight, then

torque them to 9 Nm (80 lbfin) as per sequence
numbered in the following illustration.
smr2009-022-002_a
1. Pay attention that gasket remains properly positioned

on this surface
Refer to the following illustration to identify the

locations of the various housing screws.
smr2009-022-001_c
smr2009-022
75
Section 02 ENGINE
Reinstall LH engine support. Apply LOCTITE 243

(BLUE) (P/N 293 800 060) on screw threads then
torque to 24 Nm (18 lbfft).
Remove block under engine.
Install both rear engine support screws.
Carry out an engine alignment, refer to the
ENGINE REMOVAL AND INSTALLATION subsection.
NOTICE An engine alignment procedure
must be carried out to ensure proper engine
alignment or severe component damage may
occur.
PTO Seal Removal

Place rags under PTO housing to prevent spillage.
If spillage occurs, clean immediately with PULLEY
FLANGE CLEANER (P/N 413 711 809) to prevent oil
stains.
NOTE: Note position of seal and orientation of
Oetiker clamp for installation.
Remove the Oetiker clamp retaining the seal to
the PTO housing.
Install all remaining parts, reconnect hoses and

electrical connectors. Refer to applicable subsections for procedures and specific details (torques,
service products or special instructions).
Refill engine with oil and cooling system with
coolant. Refer to LUBRICATION SYSTEM and
COOLING SYSTEM subsections.
PTO SEAL
PTO Seal Inspection
Inspect the PTO seal on the PTO housing. If brittle, hard or damaged, or if you see a sign of oil
leakage, replace it.
Inspect ball bearing within PTO seal for excessive
play and smooth operation.
Replace PTO seal if oil seal or ball bearing is damaged.
smr2009-022-007_a
TYPICAL
1. Oetiker clamps
2. PTO seal
Pull seal from PTO housing.
PTO Seal Installation

Insert a NEW Oetiker clamp over the seal.
Push seal onto PTO housing. Be sure to align seal
and clamp as noted at removal.
NOTICE When installing PTO seal on supercharged engines, make sure to position the
Oetiker clamps as illustrated.
smr2009-022-006_a
1. PTO seal
R1503motr367A
1. Oetiker clamps
76
smr2009-022
Section 02 ENGINE
Crimp Oetiker clamp using OETIKER PLIERS

(P/N 295 000 070).
PTO COUPLING
PTO Coupling Removal
Lock crankshaft. Refer to CYLINDER BLOCK subsection for the procedure.
Remove PTO seal as described in previous procedure.
Unscrew coupling from crankshaft using IMPELLER REMOVER/INSTALLER (P/N 529 035 820).
R1503motr49A
PTO Coupling Installation

Apply LOCTITE 648 (GREEN) (P/N 413 711 400) on
threads and torque PTO coupling to 250 Nm
(184 lbfft).
STARTER DRIVE BEARING

529035820
IMPELLER REMOVAL TOOL
NOTICE Apply engine oil to the removal tool

to protect the seal located within the PTO coupling.
smr2009-022-009_a
1. Starter drive bearing
Starter Drive Bearing Removal

smr2009-022-008_a
TYPICAL
1. Impeller removal tool
NOTE: PTO coupling has left hand threads.
Remove PTO housing, see procedure in this subsection.

Remove starter drive bearing from PTO housing using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117).
PTO Coupling Inspection

Inspect seal within coupling, if it is brittle, cracked
or hard, replace it.
Check coupling for worn or damaged splines. Replace as required.
smr2009-022
77
Section 02 ENGINE
smr2009-016-015_b
529036117
Starter Drive Bearing Installation

Prior to assembly grease starter drive bearing with
ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021).
Install starter drive bearing in PTO housing using
the STARTER DRIVE SEAL PUSHER (P/N 420 876 502)
and the HANDLE (P/N 420 877 650).
420876502
420877650
2. ECM
3. Throttle body
Install the 3-PIN MAGNETO HARNESS ADAPTER

(P/N 529 036 016) onto the magneto connector.
NOTE: Do not connect the magneto harness
adapter to the vehicle harness connector.
529036016
Set multimeter to Vac scale.

Start engine.
Connect multimeter between each pair of YELLOW wires as per following table. Measure voltage between each pair of wires.
STATOR
Stator Output Voltage Test
Disconnect the magneto wiring harness connector. This connector is located between the ECM
and the throttle body.
smr2009-022-101_a
STATOR OUTPUT VOLTAGE TEST

1. Connect adapter to magneto stator connector
2. Leave vehicle harness disconnected
Read voltage as per following table.
78
smr2009-022
Section 02 ENGINE
STATOR OUTPUT VOLTAGE TEST

TEST ENGINE
SPEED
TERMINAL
VOLTAGE (AC)
1 and 2
4000 RPM
1 and 3
Approx. 50 Vac
2 and 3
If voltage is lower than specification, carry out a

STATOR CONTINUITY TEST and a STATOR INSULATION TEST. See procedures in this subsection.
Stator Continuity Test

Disconnect the magneto wiring harness connector. This connector is located between the ECM
and the throttle body.
smr2009-022-101_b
STATOR CONTINUITY TEST

Read resistance.
STATOR CONTINUITY TEST
TERMINAL
RESISTANCE @
20C (68F)
1 and 2
1 and 3
0.1 - 1
2 and 3
If any result is out of specification, replace stator.
Stator Insulation Test

smr2009-016-015_b
2. ECM
3. Throttle body
Disconnect the magneto wiring harness connector.

Set multimeter to .
Connect multimeter between each pair of YELLOW wires.
smr2009-016-015_b
2. ECM
3. Throttle body

Set multimeter to .
Connect multimeter between any YELLOW wire
and engine ground.
smr2009-022
79
Section 02 ENGINE
smr2009-022-101_c
STATOR INSULATION TEST

Read resistance.
STATOR INSULATION TEST
TERMINAL
RESISTANCE @
20C (68F)
Any YELLOW wire and

engine ground
Infinity (open circuit)
smr2009-022-012_a
1. Stator screws
2. Stator
Stator Installation
NOTE: The position of the stator in the PTO housing is determined by a key on the stator and a
notch in the magneto housing.
If there is a resistance or continuity to engine

ground, the stator coils and/or the wiring is
grounded and need to be repaired or replaced.
Stator Removal
Remove stator cable holding plate from PTO housing.
smr2009-022-013_a
1. Notch for stator
Place the stator cable rubber grommet in the

notch provided in the PTO housing.
smr2009-022-011_a
TYPICAL
1. Screws
2. Holding plate
Remove stator retaining screws.

Remove stator from PTO housing.
80
smr2009-022
Section 02 ENGINE
Recheck reading on reference tooth to ensure

gauge has not changed position (gauge should
still read zero).
NOTE: The maximum allowable difference between teeth is 0.15 mm (.006 in). If the reading
exceeds the maximum allowable difference,
straighten the tooth or replace the trigger wheel.
smr2009-022-009_b
TYPICAL
1. Stator cable grommet

stator screw threads and stator cable holding plate
screw threads.
Torque stator and cable holding plate screws to
9 Nm (80 lbfin).
Install PTO housing as per procedures in this subsection.
ROTOR AND TRIGGER WHEEL
smr2009-022-015_a
1. Trigger wheel
2. Dial indicator
Rotor and Trigger Wheel Inspection
Properly reinstall cover.
Inspect rotor and trigger wheel condition. Pay

particular attention to the inside of the rotor for
cracks, rub marks or discoloration. If damaged,
replace faulty part.
Check the trigger wheel for bent teeth using the
following procedure.
Install a dial indicator on crankcase casting.
Position the gauge on a tooth and set it to zero
(0). Be sure to lock the indicator dial to prevent
movement of the dial during the remainder of the
procedure.
Draw a line on the tooth to indicate it as the first
tooth measured (reference tooth).
Gently lift the gauge contact point off the tooth
and rotate the flywheel to the next tooth.
NOTE: When lifting contact point off the tooth for
flywheel rotation, be careful not to move gauge
position or test readings taken on next tooth will
not be accurate with reference to the reference
tooth.
Gently set the gauge contact point on the next
tooth and read the dial indicator.
Repeat this procedure taking a reading at each
tooth.
Rotor and Trigger Wheel Removal
smr2009-022
Lock crankshaft, refer to CYLINDER BLOCK subsection for procedure.

Remove and discard the magneto rotor retaining
screws.
Pull rotor and trigger wheel off crankshaft end.
81
Section 02 ENGINE
4
3
3
2
1
1
1
R1503motr53A
TYPICAL
1. Rotor retaining screws
2. Rotor
3. Trigger wheel
Rotor and Trigger Wheel Installation

Align the trigger wheel to the crankshaft using the
location pin on the crankshaft end.
Install NEW OEM rotor screws and torque them
to 15 Nm (133 lbfin) using a crisscross pattern.
Finish tightening screws with an additional 50 rotation with a torque angle gauge.
R1503motr54A
TYPICAL
1. Magneto rotor retaining screws
2. Rotor
3. Trigger wheel
4. Ring gear
Ring Gear Inspection

Inspect ring gear for damages. Pay particular attention to teeth condition. If badly worn, cracked,
or broken teeth are found, replace ring gear.
Ring Gear Installation

Align the ring gear and trigger wheel to the crankshaft using the location pin on the crankshaft end.
NOTICE Always install NEW OEM screws

with pre-applied threadlocker. These are
stretch screws that are one time use only.
Not replacing rotor screws may lead to engine
damage and failure.
1
2
RING GEAR
Ring Gear Removal
Lock crankshaft. Refer to CYLINDER BLOCK subsection for procedure.
Remove the PTO housing cover, see procedure in
this subsection.
Remove and discard the magneto rotor retaining
screws.
Pull rotor and trigger wheel off crankshaft end.
Pull rotor, trigger wheel, and ring gear off crankshaft end.
R1503motr54B
TYPICAL
1. Location pin
2. Location pin holes
Install NEW OEM rotor screws and torque them

to 15 Nm (133 lbfin) in a crisscross pattern.
Finish tightening screws with an additional 50 rotation with a torque angle gauge.
NOTICE Always install NEW OEM screws
with pre-applied threadlocker. These are
stretch screws that are one time use only.
Not replacing rotor screws may lead to engine
damage and failure.
82
smr2009-022
Section 02 ENGINE
STARTER DRIVE
Starter Drive Removal
Remove the PTO housing and ring gear as described in this subsection.
Remove starter drive assembly.
If any part of the assembly shows signs of abnormal wear, cracks, broken teeth or malfunction
(sprag clutch), replace the faulty part.
Starter Drive Installation

NOTE: When installing a new starter drive assembly, oil the shaft, gear teeth and splines with engine oil.
Apply ISOFLEX GREASE TOPAS NB 52 (P/N 293 550
021) on the starter drive bearing located in the
cylinder block and in the PTO housing.
R1503motr55A
1. Starter drive assembly
NOTICE Be careful not to lose the disc

springs and thrust washer located on the
starter drive shaft.
R1503motr56A
1. Starter drive bearing (cylinder block)
smr2005-034-002_a
smr2009-022-009_a
1. Disc springs
2. Thrust washer
3. Starter drive gear
1. Starter drive bearing (PTO housing)
Starter Drive Inspection
NOTICE Be sure not to forget the disc springs

and washer on the starter drive shaft when reassembling.
Inspect all starter drive parts for excessive wear,

cracks and other defects. Pay attention to the
condition of the drive gear teeth.
Ensure proper operation of the starter drive sprag
clutch.
smr2009-022
83
84
Section 02 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
Description
Part Number
ADAPTER HOSE ...........................................................................

ECM ADAPTER TOOL...................................................................
FLUKE 115 MULTIMETER ............................................................
OIL SEAL GUIDE...........................................................................
PRESSURE GAUGE.......................................................................
SUCTION PUMP ...........................................................................
SUPERCHARGER OIL SPRAY NOZZLE TOOL .............................
WATER PUMP SEAL PUSHER......................................................
529
529
529
529
529
529
529
529
035
036
035
035
035
035
036
035
652
166
868
822
709
880
134
823
Page
........................................... 93
................................... 95, 109
......................................... 109
......................................... 101
........................................... 93
........................................... 91
......................................... 105
................................. 101102
SERVICE TOOLS OTHER SUPPLIER

Description
Part Number
FLUKE RIGID BACK PROBES ....................................................... tp88
Page
......................................... 109
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 111

LOCTITE 243 (BLUE)..................................................................... 293 800 060 .............................. 96, 9899,
LOCTITE 5910 ...............................................................................
SUPER LUBE GREASE..................................................................
XPS SUMMER GRADE OIL ..........................................................
smr2009-023
293
413
293
293
800
711
550
600
081
809
030
121
102, 104105, 112

........................................... 97
................................... 92, 102
........................................... 93
........................................... 90
85
Section 02 ENGINE
9 Nm
(80 lbfin)
NEW
Engine oil
Loctite
243
NEW
Loctite
243
9 Nm
(80 lbfin)
Engine oil
16 Nm
(142 lbfin)
18 Nm
(159 lbfin)
NEW
9 Nm
(80 lbfin)
Loctite 243
Engine oil
Loctite 243
NEW
9 Nm
(80 lbfin)
Engine
oil
Loctite
243
Engine
oil
9 Nm
(80 lbfin)
smr2009-023-001_a
86
smr2009-023
Section 02 ENGINE
9 Nm
(80 lbfin)
Engine oil
Loctite 243
9 Nm
(80 lbfin)
NEW
11 Nm
(97 lbfin)
Engine oil
9 Nm
(80 lbfin)
3 Nm
(27 lbfin)
Left hand
thread
Loctite
243
Loctite 243
NEW
NEW
Loctite 243
9 Nm
(80 lbfin)
Engine oil
19 Nm
(14 lbfft)
Engine oil
Loctite 243
Engine oil
13 Nm
(115 lbfin)
Loctite 5910
Loctite 243
Loctite 243
9 Nm
(80 lbfin)
smr2009-023-002_a
smr2009-023
87
Section 02 ENGINE
ENGINE LUBRICATION CIRCUIT

Legend
1
Pressurized oil
Scavenged oil
Blow-by gas
3
4
5
6
8
7
9
10
11
12
13
smr2009-023-100_en
1. Oil dipstick
2. Rocker arm (intake)
3. Rocker arm (exhaust)
4. Hydraulic valve lifter
5. Camshaft
6. Piston pin
7. Into PTO cover
8. From oil filter
9. Piston cooling
10. Connecting rod
11. Balance shaft
12. Crankshaft
13. Oil tank
88
smr2009-023
Section 02 ENGINE
ENGINE LUBRICATION CIRCUIT (CONT'D)

1
34
4
6
9
10
12
11
13
15
14
16
18
17
19
20
21
22
23
24
25
28
29
26
30
27
31
Legend
Pressurized oil
Scavenged oil
Blow-by gas
32
33
smr2009-023-101_en
1. To air intake silencer

2. Rocker arm (intake)
3. Rocker arm (exhaust)
4. Rocker arm axle
5. Camshaft
6. Pressure relief valve
7. Oil separator
8. Cylinder head
9. Blow-by valve
10. Supercharger (if so equipped)
11. Oil filter
12. Hydraulic chain tensioner
13. Supercharger bearing (if so equipped)
14. Friction clutch
15. Piston pin
16. Connecting rod
17. Piston cooling
smr2009-023
18. Oil spray nozzle

19. Drive shaft
20. Crankshaft
21. PTO seal
22. Oil pressure switch
23. Balance shaft
24. PTO cover
25. Pressure pump
26. Pressure relief valve
27. Oil strainer (pressure pump)
28. Scavenge pump
29. Oil tank
30. Oil strainer (scavenge pump)
31. Oil drainage (PTO cover)
32. Oil cooler
33. Scavenge of oil and blow-by gas
34. Oil filler cap
89
Section 02 ENGINE
GENERAL
complete procedure.
WARNING
MAINTENANCE
ENGINE OIL
Recommended Oil
Use XPS SUMMER GRADE OIL (P/N 293 600 121).
If XPSTM engine oil is not available, use a 10W40
mineral engine oil compatible with wet clutches.
NOTE: The XPS engine oil has been thoroughly
tested to be free of any additives that could impair
the functionality of the supercharger clutch.
NOTICE NEVER use synthetic oil. This would
impair the proper operation of the supercharger clutch. Do not add any additives to
the recommended oil. Mineral oils not recommended by BRP may also contain additives
(friction modifiers) that may cause inappropriate slippage of the supercharger and eventually lead to premature wear. For this reason,
XPS Summer Grade oil or a BRP approved
equivalent are the only recommended oils.
Use of any oil not recommended by BRP may
void BRP's limited warranty.
smo2009-002-003_b
1. Oil dipstick
Check the oil level as follows:

NOTE: It is of the utmost importance to follow
this procedure in order to obtain an accurate reading of the engine oil level.
1. Watercraft must be level. Check oil level either
with watercraft in water or out of water.
2. If the watercraft is out of water, link a garden
hose to the hose adapter. Refer to EXHAUST
SYSTEM FLUSHING in the EXHAUST SYSTEM
subsection.
NOTICE When watercraft is out of water:
Never run engine without supplying water to
the exhaust system.
Never run engine longer than 2 minutes.
Drive line seal has no cooling when watercraft is out of water.
3. Warm-up engine then let idle for 30 seconds
before stopping.
4. Stop engine.
5. Open seat and remove the ventilation box from
the deck extension to gain partial access to engine compartment.
NOTE: To remove the rear ventilation box, simply
release the 3 clips retaining it and lift it off the deck
extension.
Oil Level Verification

NOTICE Check level frequently and refill if
necessary. Do not overfill it would make
the engine smoke and reduce its power. Operating the engine with an improper level
may severely damage engine. Wipe off any
spillage.
90
smr2009-023
Section 02 ENGINE
lmr2007-053-100_a
1. Full
2. Add
3. Operating range
Otherwise, add oil until its level is between marks

as required.
To add oil, unscrew oil cap. Place a funnel into the
oil filler neck opening and add the recommended
oil to the proper level. Do not overfill.
smo2009-002-002_a
1. Rear ventilation box

2. Deck extension
3. Retaining clips
6. Wait at least 30 seconds for the oil to settle

in the engine, then pull dipstick out and wipe
clean.
WARNING
Engine oil may be hot. Certain components
in the engine compartment may be very hot.
Direct contact may result in skin burn.
Oil Change
NOTE: Oil and oil filter must be replaced at the
same time. Oil change and oil filter replacement
should be done with a warm engine.
Bring engine to its normal operating temperature.
the exhaust system.
Run engine for 10 seconds at 4000 RPM and shut
it off at this RPM. This will move oil from PTO
housing to oil tank to allow maximum oil draining.
Remove oil filler cap and dipstick.
WARNING
Engine oil may be hot. Certain components
in the engine compartment may be very hot.
Direct contact may result in skin burn.
smo2009-002-003_b
1. Oil dipstick
Using the SUCTION PUMP (P/N 529 035 880), siphon

oil through dipstick hole.
7. Reinstall dipstick, push in completely.

8. Remove dipstick and read oil level. It should be
between the FULL and ADD marks.
529035880
smr2009-023
91
Section 02 ENGINE
NOTICE Never crank or start engine when

suction pump tube is in dipstick hole. Never
start engine when there is no oil in engine.
NOTE: So that suction pump tube is located at
the proper height to siphon oil, it is suggested
to put some electrical tape on tube at 475 mm
(18-11/16 in) from its end. Then, insert the tube
until you reach the tape.
2
smr2009-023-003_a
1. Oil filter screw

2. Oil filter cover
3. Oil filter
NOTE: No tools are required to remove the oil filter cover, as it will pull off when the oil filter screw
is unscrewed.
Place rags in filler area to prevent spillage. If
spillage occurs, clean immediately with the PULLEY FLANGE CLEANER (P/N 413 711 809) to prevent
stains.
Oil Filter Inspection
R1503motr150A
Check oil filter cover O-rings and oil filter screw

O-ring, change if necessary.
Check and clean the oil filter inlet and outlet area
for dirt and other contaminations.
TYPICAL
1. Suction pump
2. Suction pump tube in dipstick hole
Pull suction pump tube out of dipstick hole then

crank engine (do not start) while in engine drown
mode (fully depress throttle lever and HOLD, then
crank engine).
Crank engine for 10 seconds. Siphon oil again.
Repeat the crank-siphon cycle 2 - 3 times.
Refill engine with the recommended oil, see RECOMMENDED OIL in this subsection.
Reinstall oil filler cap and dipstick.
Replace OIL FILTER, see procedure in this subsection.
OIL FILTER
Oil Filter Removal
Remove:
Oil filter screw
Oil filter cover
Oil filter.
92
smr2009-023-004_a
1. Inlet bore from the oil pump to the oil filter

2. Outlet bore to the engine oil providing system
Oil Filter Installation

Pay attention to the following details.
Install a NEW oil filter.
Install O-ring on oil filter cover.
smr2009-023
Section 02 ENGINE
Apply engine oil on filter ring, filter cover O-rings

and on oil filter screw O-ring.
NOTE: In salt water area, it is recommended to
coat mating surface of cover with SUPER LUBE
GREASE (P/N 293 550 030).
Torque oil filter screw to 9 Nm (80 lbfin).
INSPECTION
529035652
ENGINE OIL PRESSURE

NOTE: Depending on the oil pressure switch, the
threshold value to send a signal of low oil pressure
may vary from a minimum of 180 kPa (26 PSI) to a
maximum of 220 kPa (32 PSI).
Bring engine to its normal operating temperature.
WARNING
Certain components in the engine compartment may be very hot. Direct contact may result in skin burn.
the exhaust system.
Use the following table to compare the oil pressure at different RPM.
OIL PRESSURE
Idle (cold)
448 kPa - 648 kPa

(65 PSI - 94 PSI)
for a very short time
Idle (at 80C (176F))
Min. 228 kPa (33 PSI)
4000 - 7500
400 kPa - 496 kPa

(58 PSI - 72 PSI)
Test at the Oil Pressure Switch

Location
Remove oil pressure switch and install gauge.
The oil pressure is measured using the PRESSURE

GAUGE (P/N 529 035 709) and the ADAPTER HOSE
(P/N 529 035 652). A 1/8 NPT pipe extension may
ease the installation.
smr2009-023-005_a
INSTALLATION AT PRESSURE SWITCH LOCATION

1. Remove oil pressure switch and install gauge here
529035709
smr2009-023
To prevent the EMS to go in limp home mode (at

2500 RPM) or to generate a fault code, do the following:
1. Ground OPS to engine.
2. Plug OPS to harness.
3. Start engine.
4. While engine is running, unplug OPS from harness.
Read oil pressure at different RPM as per table
above.
93
Section 02 ENGINE
Reinstall oil pressure switch.
Test at the Cylinder Head Location

The oil pressure may be measured from cylinder
head if desired.
Remove plug located on cylinder head and install
gauge.
4. Oil pressure regulator valve sticks open, or

spring load is too small.
- Clean oil regulator piston and its bore. Replace if
necessary.
- Measure spring free length. Replace if too small.
5. Oil pump(s) worn or damaged.
- Check oil pump rotors and its bore for wear limits.
Replace if out of specification.
6. Engine oil strainers are clogged.
- Remove and clean engine oil strainers.
7. Heavy wear on plain bearings.
- Check radial clearance of plain bearings. Replace
if out of specification.
HIGH OIL CONSUMPTION

1. Oil in breathing system.
- Check if breather V-ring is brittle, hard or damaged. Replace V-ring.
2. Valve stem seals worn or damaged.
- Replace valve stem seals.
smr2009-023-006_a
INSTALLATION AT CYLINDER HEAD

1. Remove plug and install gauge here
Start engine and read pressure at different RPM

as per table above.
Reinstall plug.
TROUBLESHOOTING
Always check for fault codes. If a fault code is detected, service the fault code first. Refer to ENGINE MANAGEMENT section.
LOW OR NO ENGINE OIL PRESSURE

1. Oil level too low.
- Refill engine oil.
- Check for high oil consumption. See below.
- Check for oil leaks (oil leaking out of leak indicator hole, gaskets, oil seal or O-rings). Repair or
replace.
2. Oil pressure switch defective.
- Check and replace if necessary.
3. Oil filter clogged.
- Replace engine oil and oil filter at the same time.
94
3. Piston rings worn out (blue colored exhaust

smoke).
- Replace piston rings.
OIL CONTAMINATION (WHITE

APPEARANCE)
1. Oil seal and rotary seal on water pump shaft
leaking.
- Replace oil seal and water pump shaft assembly.
- Change engine oil and oil filter.
2. Cylinder head gasket leaking.
- Replace cylinder head gasket and tighten cylinder
head with recommended torque.
3. Cylinder head screws not properly tightened.
- Retighten screws with recommended torque.
- Change engine oil.
4. Oil cooler O-rings are leaking.
- Replace O-rings.
5. Cylinder block or cylinder head casting is leaking.
- Check for internal cracks in casting. Replace damaged components.
smr2009-023
Section 02 ENGINE
PROCEDURES
ENGINE RUNNING
OIL PRESSURE SWITCH (OPS)

Oil Pressure Switch Operation
The oil pressure switch activates if engine oil
pressure falls between 180 kPa and 220 kPa
(26 PSI and 32 PSI).
TEST PROBES
OPS
connector
(pin 1)
Engine
ground
RESISTANCE ( )
Infinitely high (OL)
when pressure reaches
180 kPa (26.11 PSI) and
220 kPa (32 PSI)
smr2009-023-102_a
If resistance values are incorrect, replace OPS.

If the values are correct, check the continuity of
the wiring harness.
smr2009-023-005_a
1. OPS
Oil Pressure Switch Inspection

First, carefully check the condition of the connector terminals. Clean to remove dirt and corrosion
that could affect proper operation of the OPS.
IMPORTANT: Do not apply dielectric grease on
terminal.
Before checking the function of the OPS, an oil
pressure test has to be performed to be sure the
oil pressure is not in fault. Refer to INSPECTION
in this subsection.
When the engine oil pressure tests good but the
OIL message in the information center is present
and the beeper sounds:
Ensure OPS connector is plugged to the switch.
Check the resistance of the OPS while engine
is off and while engine is running.
Oil Pressure Switch Resistance Test

Disconnect the connector from the OPS.
Use a multimeter to check the resistance as
shown.
Oil Pressure Switch Circuit Continuity

Test
Disconnect the ECM connector A from the ECM.
Use the ECM ADAPTER TOOL (P/N 529 036 166) and
a multimeter.
529036166
Check continuity of OPS circuit as per following

table.
ENGINE NOT RUNNING

TEST PROBES
OPS
connector
(pin 1)
smr2009-023
Engine
ground
RESISTANCE ( )
Close to 0 (normally
closed switch)
95
Section 02 ENGINE
OPS
CONNECTOR
Pin 1
ECM
ADAPTER
RESISTANCE
Pin E3
Close to 0
(continuity)
PTO OIL STRAINER

NOTE: The oil strainer does not need to be
cleaned at every oil change. Clean it during other
inspections, especially when the engine is disassembled.
PTO Oil Strainer Removal

Remove engine oil. See procedure in OIL
CHANGE in this subsection.
Remove the PTO housing. Refer to PTO HOUSING AND MAGNETO subsection.
Remove the oil strainer.
1
smr2009-023-102_b
If continuity test failed, repair or replace the connector and wiring between ECM connector and
OPS.
If continuity test succeeded, check the ECM. Refer to EFI subsection.
Oil Pressure Switch Removal

Remove the throttle body. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.

Unplug the OPS connector.
Unscrew and remove the oil pressure switch.
R1503motr117A
1. PTO oil strainer
PTO Oil Strainer Cleaning and

Inspection
Clean oil strainer with a part cleaner then use an
air gun to dry it.
Check and clean the oil outlet area for dirt and
other contaminations.
smr2009-023-005_a
1. OPS
Oil Pressure Switch Installation

threads of oil pressure switch.
Torque oil pressure switch to 9 Nm (80 lbfin).
96
smr2009-023
Section 02 ENGINE
R1503motr118A
1. Oil inlet to the oil pump

smr2006-014-022_a
PTO Oil Strainer Installation

Clean cylinder block to remove all remaining silicone residues in oil strainer area.
Apply a thin layer of LOCTITE 5910 (P/N 293 800 081)
on oil strainer side.
Install it in the PTO housing.
Install the PTO housing using the procedure described in the PTO HOUSING AND MAGNETO
subsection.
Refill engine at the proper level with the recommended oil. Refer to ENGINE OIL for the procedure.
1. Oil strainer
2. Suction pump cover
Suction Pump Oil Strainer Cleaning

and Inspection
Clean oil strainer with a part cleaner then use an
air gun to dry it.
Inspect rubber ring gaskets.
SUCTION PUMP OIL STRAINER

NOTE: The oil strainer does not need to be
cleaned at every oil change. Clean it during other
inspections, especially when the engine is disassembled.
Suction Pump Oil Strainer Removal

Remove oil filler tube and suction pump cover, refer to OIL SUCTION PUMP in this subsection.
Remove oil strainer from the suction pump cover.
smr2006-014-020_a
1. Suction pump cover gasket

2. Oil filler tube gasket
If rubber rings are brittle, cracked or hard, replace

them.
Clean both contact surfaces of oil suction pump
cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
smr2009-023
97
Section 02 ENGINE
smr2009-023-007_a
1. Oil inlet
2. Oil outlet
Suction Pump Oil Strainer Installation

threads of the suction pump cover screws and
tighten them to 9 Nm (80 lbfin).
Position screws according to their length as
shown.
smr2009-023-009_a
TIGHTENING SEQUENCE
ENGINE OIL PRESSURE

REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing.
smr2007-015-005_a
TYPICAL
1. Oil pressure regulator
smr2009-023-008_a
1. Screws M6 x 25
2. Screws stainless steel M6 x 45
Torque suction pump cover screws as per sequence illustrated below.
98
NOTE: The oil pressure regulator system opens

when the oil pressure exceeds 400 kPa (58 PSI).
Oil Pressure Regulator Removal

Remove engine oil. See procedure in OIL
Remove:
Oil pressure regulator plug
Compression spring
Valve piston
Valve piston guide.
smr2009-023
Section 02 ENGINE
Oil Pressure Pump Removal

1. Remove engine oil. See procedure in OIL
2. Remove the PTO housing. Refer to PTO
HOUSING AND MAGNETO subsection.
3. Remove water pump housing and the impeller.
Refer to COOLING SYSTEM subsection.
4. Remove screws securing the oil pump cover.
2
smr2007-015-005_b
TYPICAL
1. Valve piston guide
2. Valve piston
3. Compression spring
4. Oil pressure regulator plug
5. O-ring
WARNING
Oil pressure regulator plug on oil pump housing is spring loaded.
Oil Pressure Regulator Inspection

Inspect valve piston and valve piston guide for
scoring or other damages.
Check compression spring for free length.
R1503motr125A
1. Screws
2. Oil pump cover
5. Pull and remove the outer oil pump rotor.
COMPRESSION SPRING FREE LENGTH

NEW NOMINAL
58.2 mm (2.291 in)
SERVICE LIMIT
50.3 mm (1.98 in)
Replace parts if important wear or damage are

present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
Oil Pressure Regulator Installation

Be careful that the O-ring on plug screw is in
place.
threads of the oil pressure regulator plug.
Torque plug screw to 13 Nm (115 lbfin).
OIL PRESSURE PUMP

The oil pressure pump is located in the PTO housing and is driven by the balance shaft.
smr2009-023
R1503motr126A
1. Outer oil pump rotor
6. Refer to COOLING SYSTEM subsection and extract the water/oil pump shaft from outside PTO
housing.
7. Using a screwdriver, remove the rotary seal.
99
Section 02 ENGINE
R1503motr129A
1. Pittings on the teeth
Using a feeler gauge, measure the clearance between inner and outer rotors.
R1503motr127A
TYPICAL
NOTICE Be careful not to damage the surface

of the rotary seal bore in PTO housing cover.
8. Remove and discard the oil seal behind rotary

seal.
R1503motr130A
1. Outer rotor
2. Inner rotor
R1503motr128A
OUTER AND INNER ROTOR CLEARANCE
1. Oil seal
SERVICE LIMIT
Oil Pressure Pump Inspection
Inspect oil pump shaft, housing and cover for

marks or other damages.
Check inner rotor for corrosion pin-holes or other
damages. If so, replace oil pump shaft. Ensure
to also check oil pump housing and cover and replace if damaged.
100
0.25 mm (.0098 in)
If clearance between inner and outer rotors exceeds the tolerance, replace water/oil pump shaft.
Ensure to also check oil pump housing and cover
and replace if damaged.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the complete oil pump and the PTO housing.
Using a vernier depth gauge, measure side wear
as shown.
smr2009-023
Section 02 ENGINE
R1503motr131A
1. PTO housing surface

2. Vernier depth gauge
R1503motr128A
1. Oil seal
Install the new rotary seal by using the WATER

PUMP SEAL PUSHER (P/N 529 035 823).
529035823
R1503motr132A
1. Oil pump outer rotor surface

2. Vernier depth gage
NOTICE Never use a hammer for the rotary

seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.
Difference between pump housing and outer rotor should not exceed 0.1 mm (.004 in). If so, replace the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft increases, the oil pressure decreases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if damaged.
Oil Pressure Pump Installation

NOTE: Never use oil in the press fit area of the
rotary seal.
Push water/oil pump shaft oil seal in place by using thumb.
R1503motr141A
TYPICAL
1. Rotary seal
2. Rotary seal pusher
Install the OIL SEAL GUIDE (P/N 529 035 822) on the
end of coolant/oil pump shaft.
smr2009-023
101
Section 02 ENGINE
R1503motr142A
4. Detach the muffler from the exhaust manifold
and move muffler backwards. Refer to EXHAUST SYSTEM subsection.
5. Remove engine support mount screws.
6. Move engine backwards, just enough to reach
oil suction pump cover screws.
7. Remove retaining screws from oil filler tube.
1. Oil seal guide

2. Water/oil pump shaft
Using the WATER PUMP SEAL PUSHER (P/N 529

035 823) to support the PTO cover, install the
coolant/oil pump shaft.
1
smr2009-023-010_a
1. Oil filler tube screws
8. Remove oil filler tube.

9. Remove retaining screws.
R1503motr143A
1. Water/oil pump shaft with oil seal guide

2. Rotary seal pusher

threads of oil pump cover screws.
Tighten oil pump cover screws and torque to
9 Nm (80 lbfin).
After engine is completely reassembled, start engine and make sure oil pressure is within specifications.
OIL SUCTION PUMP

The oil suction pump is located on the front side of
the engine inside of the oil suction pump housing
at the bottom of the oil filler tube.
Oil Suction Pump Removal

1. Remove jet pump and drive shaft. Refer to
STEERING AND PROPULSION section.
102
smr2009-023-011_a
1. Suction pump cover screws
10. Place rags under cover to prevent spillage.

If spillage occurs, clean with the PULLEY
FLANGE CLEANER (P/N 413 711 809).
11. Remove the oil suction pump housing.
12. Remove oil pump screws and cover.
smr2009-023
Section 02 ENGINE
R1503motr137A
smr2008-015-006_a
TYPICAL
1. Oil pump cover
2. Oil pump screws
1. Pittings on the teeth
Using a feeler gauge, measure the clearance between inner and outer rotors.
13. Remove oil pump shaft.

14. Remove outer rotor.
A
R1503motr138A
1. Outer rotor
2. Inner rotor
smr2006-014-023_a
TYPICAL
1. Oil pump shaft
2. Outer rotor
OUTER AND INNER ROTOR CLEARANCE

SERVICE LIMIT
A
Oil Suction Pump Inspection
Inspect oil pump shaft, housing and cover for

marks or other damages.
Check inner rotor for corrosion, pin-holes or other
damages. If so, replace oil pump shaft. Ensure
to also check oil pump housing and cover and replace if damaged.
smr2009-023
0.25 mm (.0098 in)
If clearance between inner and outer rotors exceeds the tolerance, replace oil pump shaft. Ensure to also check oil pump housing and cover and
replace if damaged.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the complete oil pump and the PTO housing.
Using a vernier depth gage, measure side wear as
shown.
103
Section 02 ENGINE
R1503motr139A
smr2009-023-008_a
1. Screws M6 x 25
2. Screws M6 x 45
1. Oil pump housing surface

Tighten suction pump cover screws as per following sequence.
R1503motr140A
1. Oil pump outer rotor surface

Difference between pump housing and outer rotor should not exceed 0.1 mm (.004 in). If so, replace the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure decreases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if damaged.
smr2009-023-009_a
TIGHTENING SEQUENCE
Refer to the appropriate procedures and install all

other removed parts.
OIL SPRAY NOZZLE

(SUPERCHARGER)
Oil Spray Nozzle Removal
Remove the PTO housing. Refer to PTO HOUS-
Oil Suction Pump Installation
ING AND MAGNETO subsection.

threads of the suction pump cover screws and
tighten them to 9 Nm (80 lbfin).
Position screws according to their length as
shown.
Remove the Torx screw securing the oil spray nozzle support.
Unscrew the Banjo bolt.
104
smr2009-023
Section 02 ENGINE
smr2008-015-007_a
1.
2.
3.
4.
Banjo bolt
Oil spray nozzle
Oil spray nozzle support
Torx screw
Oil Spray Nozzle Inspection

Check oil spray nozzle for:
Dirt
Bend
Other damages.
Replace if necessary.
smr2008-015-008_a
A. 1 mm (0.039 in)
NOTE: Make sure that the oil spray nozzle is facing to the center of the tool. Not following this
procedure will lead to an insufficient oiling of the
supercharger and a supercharger failure can occurs. Adjust the oil spray nozzle if necessary by
slightly bending it, take care not to over bend the
oil spray nozzle.
Oil Spray Nozzle Installation

For installation reverse the removal procedure.
threads of Torx screw.
Install the oil spray nozzle support.
Tighten Torx screw to 9 Nm (80 lbfin).
Install oil spray nozzle with Banjo bolt.
Tighten Banjo bolt to 19 Nm (168 lbfin).
Adjust the position of the oil spray nozzle, by using the SUPERCHARGER OIL SPRAY NOZZLE TOOL
(P/N 529 036 134).
smr2008-015-009_a
1. Center of supercharger oil spray nozzle tool
OIL SPRAY NOZZLES (PISTONS)

The oil spray nozzles are located on the upper half
of cylinder block.
529036134
The distance between the adjustment tool and oil

spray nozzle must be within 1 mm (.039 in).
smr2009-023-012_a
1. Oil spray nozzles
smr2009-023
105
Section 02 ENGINE
NOTE: When the scope of repair work obligates

you to split the cylinder block, take this opportunity to clean the oil spray nozzles.
Oil Spray Nozzle Removal

Remove cylinder block lower half. Refer to CYLINDER BLOCK subsection.
Remove oil spray nozzle and Banjo fitting from
cylinder block upper half.
Oil Spray Nozzle Installation

NOTICE At assembly make sure the contact
surface of the oil spray nozzle is well fitted onto
the cylinder block. If this is not ensured, the oil
spray direction will change, causing potential
engine damage.
mmr2009-111-050_a
1. Oil spray nozzle

2. Contact surface
mmr2009-111-048_a
1. Banjo fitting
2. Oil spray nozzle
Oil Spray Nozzle Cleaning and

Inspection
Clean oil spray nozzle and Banjo fitting from dirt
and debris. Use a part cleaner, then an air gun and
dry the parts.
Check if ball inside Banjo fitting moves freely.
OIL SEPARATOR COVER

Oil Separator Cover Removal
1. Remove the blow-by valve. See procedure in
this subsection.
2. Remove camshaft position sensor.
smr2009-023-015_a
mmr2009-111-049_a
1.
2.
3.
4.
Ball
Spring
Banjo fitting
Oil spray nozzle
NOTE: If the oil spray nozzle is damaged or bent

during work in the cylinder block, it must be replaced immediately.
106
1. Camshaft position sensor

2. Screw
3. Remove cylinder head cover, refer to CYLINDER HEAD subsection.

4. Remove thrust washer from oil separator cover.
smr2009-023
Section 02 ENGINE
NOTE: Make sure not to loose thrust washer

when removing it from oil separator cover, otherwise thrust washer would fall into the PTO
housing.
smr2006-014-067_a
1. Camshaft
2. Oil separator cover
NOTE: Be careful not to break the holding clips

from oil separator cover when its removed from
the timing gear.
smr2009-023-016_a
1. Thrust washer
2. Oil separator cover
5. Remove spark plug tube.

6. Remove rocker arm shaft together with rocker
arms, refer to CYLINDER HEAD subsection.
7. Remove chain guide and camshaft guide.
Oil Separator Cover Inspection

Inspect oil separator cover for marks or other damages. Ensure to check also the holding clips of oil
separator cover and for thrust washer. If any damage is visible replace oil separator cover.
smr2006-014-066_a
1. Rocker arm
2. Camshaft guide
3. Chain guide
8. Move camshaft backwards as far as possible.

9. Remove oil separator cover from timing gear by
releasing the holding clips.
smr2009-023
smr2006-014-037_a
1. Holding clips
Oil Separator Cover Installation

Properly install oil separator cover and thrust
washer. They need to be in a perfect even position with timing gear.
NOTE: Make sure not to lose thrust washer when
installed on oil separator cover.
For installation of rocker arm shaft with rocker
arms, follow the procedure as it is described in
CYLINDER HEAD subsection.
107
Section 02 ENGINE
BLOW-BY VALVE
Blow-by Valve Description
The blow-by valve has two main functions:
It recirculates oil vapors.
It protects the engine in the event the watercraft tip over.
To a accomplish the second function, the blow-by
valve has a tip over protection switch (TOPS).
smr2009-023-019_a
NORMAL OPERATION
smr2009-023-018_a
1.
2.
3.
4.
5.
6.
Valve housing
Valve sleeve
Valve piston
Check ball
Valve pin (with magnet)
TOPS switch of the blow-by valve
Tip Over Protection Function

If the watercraft tips over, gravity causes a valve
piston to close and no engine oil will leak out of
the blow-by valve.
In this event, a pin (with magnet) opens a gap
to the TOPS switch (Hall effect sensor) and the
TOPS changes its state to "ON" and sends a signal to the ECM.
The ECM will shut down the engine by cutting the
ignition and the fuel injection.
Blow-By Valve Operation

Normal Operation
During its normal operation, the blow-by valve allows crankcase vapors to return in the intake system where they are harmlessly burned.
The TOPS switch TOPS state is "OFF", no signal
to the ECM.
smr2009-023-020_a
TIP OVER FUNCTION
By-Pass Function
If, for any reason, the valve piston gets stuck
at normal operation and the crankcase pressure
exceeds 40 kPa (6 PSI), the pressure unseats a
check ball and crankcase vapors can bypass the
valve piston.
108
smr2009-023
Section 02 ENGINE
NOTE: After voltage test, clear the fault codes in

the ECM using the B.U.D.S. software.
Blow-By Valve TOPS Switch Output

Voltage Test
Remove the blow-by valve.
Back-probe TOPS connector and check voltage
using the FLUKE 115 MULTIMETER (P/N 529 035
868).
NOTE: To easily probe wire terminals through the
back of the connector, use the FLUKE RIGID BACK
PROBES (P/N TP88) or an equivalent.
smr2009-023-021_a
BY-PASS FUNCTION
Blow-By Valve TOPS Switch Input

Voltage Test
Remove:
Deck extension, refer to BODY subsection
Air intake silencer, refer to AIR INTAKE SYSTEM subsection.
Disconnect the TOPS switch connector of the
blow-by valve.
Briefly press the START/STOP button to wake-up
the ECM.
Probe terminals as shown to check the voltage
output from the ECM.
TOPS SWITCH CONNECTOR
VOLTAGE
Pins 2 and 3
Approximately
5 Vdc
smr2009-023-050_a
BLOW-BY VALVE IN NORMAL POSITION

1. Blow-by valve
2. RED probe into pin 2
3. BLACK probe into pin 1
TOPS SWITCH
CONNECTOR
BLOW-BY
VALVE
POSITION
VOLTAGE
Pin 1 and pin 2
Normal position
0.4 0.1 Vdc
Pin 1 and pin 2
Upside down
4.4 0.2 Vdc
Pin 2 and pin 3
Normal position
or upside down
Approximately
5 Vdc
Replace TOPS switch if not within specification.
Blow-By Valve TOPS Switch Circuit

Continuity Test
smr2009-023-103_a

blow-by valve.
Disconnect the connector A from the ECM.
Use the ECM ADAPTER TOOL (P/N 529 036 166) and
a multimeter.
If voltage test is good, check the TOPS switch output voltage.

If voltage test is not good, check the continuity of
the blow-by valve TOPS switch circuit.
smr2009-023
109
Section 02 ENGINE
smr2009-023-051
529036166
Check continuity of the blow-by valve TOPS

switch circuit as per following table.
TOPS SWITCH
CONNECTOR
ECM
ADAPTER
Pin 1
Pin F4
Pin 2
Pin G1
Pin 3
Pin C4
When installing the TOPS switch, make sure

printed information is visible.
RESISTANCE
Close to 0
(continuity)
smr2009-023-052_a
1. TOPS valve inscriptions
Blow-By Valve Removal
smr2009-023-103_b
1. Pin 1
2. Pin 2
3. Pin 3
If continuity test is good, check ECM. Refer to

ELECTRONIC FUEL INJECTION (EFI) subsection.
If continuity test is not good, repair or replace defective wires or connectors.
Remove:
Deck extension, refer to BODY subsection
Air intake silencer, refer to AIR INTAKE SYSTEM subsection.
Remove ventilation hose from blow-by valve.
Remove the CPS connector from its support on
blow-by valve.
Blow-By Valve TOPS Switch

Replacement
Remove blow-by valve and turn it upside down.
Insert a small screwdriver between TOPS switch
and its retaining tab. Twist and hold the TOPS
switch then release the other retaining tab.
smr2009-023-013_a
1. Blow-by valve
2. CPS connector
110
smr2009-023
Section 02 ENGINE

blow-by valve.
Unscrew and remove the blow-by valve.
Blow air through inlet port. Air must flow freely to

the outlet port.
smr2009-023-023_a
smr2009-023-014_a
1. TOPS switch connector

2. Retaining screws
Turn valve upside down and blow air again. Air

must not flow out.
Remove O-ring and V-ring.

NOTE: The blow-by valve can not be disassembled.
smr2009-023-024_a
If test fails, replace blow-by valve.
Blow-By Valve Installation
smr2009-023-022_a
1. Blow by valve
2. V-ring
3. O-ring
Blow By Valve Inspection

If O-ring or V-ring are brittle, cracked or hard, replace them.
If blow-by valve is damaged, replace it.
Clean all contact surfaces of blow-by valve.
Place a clean rag on valve inlet.
smr2009-023
Install the blow-by valve with NEW O-ring and
V-ring.
threads of blow-by valve screws.
Tighten blow-by valve screws to 9 Nm
(80 lbfin).
Reinstall remaining removed parts.
OIL COOLER
The oil cooler is located below the air intake manifold.
111
Section 02 ENGINE
R1503motr148A
1. O-rings
smr2009-023-025_a
1. Oil cooler
Oil Cooler Removal

Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
Disconnect cooling hoses from oil cooler.
Remove screws securing oil cooler.
Oil Cooler Inspection

If O-rings are brittle, cracked or hard, replace
them.
Clean both contact surfaces of oil cooler.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
Oil Cooler Installation

Apply engine oil on O-rings.
threads of oil cooler screws.
Tighten screws to 9 Nm (80 lbfin).
smr2007-015-007_a
1. Oil cooler crews

2. Oil cooler
Remove oil cooler from engine. Ensure not to lose

O-rings located between oil cooler and engine.
112
smr2009-023
Section 02 ENGINE
Subsection 09 (COOLING SYSTEM)
COOLING SYSTEM
SERVICE TOOLS
Description
Part Number
OETIKER PLIERS...........................................................................
OIL SEAL GUIDE...........................................................................
TEST CAP ......................................................................................
VACUUM/PRESSURE PUMP ........................................................
WATER PUMP SEAL PUSHER......................................................
295
529
529
529
529
000
035
035
021
035
070
822
991
800
823
Page
......................................... 120
......................................... 125
......................................... 119
......................................... 119
................................. 125126
SERVICE PRODUCTS
Description
Part Number
Page
BRP PREMIXED COOLANT .......................................................... 219 700 362 ......................................... 117

LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 122
smr2009-024
113
Section 02 ENGINE
CLOSED LOOP COOLING SYSTEM
Expansion
coolant tank
Coolant temperature
sensor (CTS)
activates when
temperature exceeds
100C (212F)
Bleed hose
from cylinder
head to
expansion
coolant tank
Coolant housing
including thermostat
opens at 87C (188F)
and water pump
impeller
Coolant flows
to ride plate
Oil
cooler
Coolant
returns
from oil
cooler
Coolant flows
to oil cooler
Ride plate
(operates as heat
exchanger)
Coolant returns
from ride plate
smr2009-024-100_en
114
smr2009-024
Section 02 ENGINE
VEHICLE COMPONENTS
1.7 Nm
(15 lbfin)
1.7 Nm
(15 lbfin)
NEW
NEW
1.7 Nm
(15 lbfin)
1.7 Nm
(15 lbfin)
1.7 Nm
(15 lbfin)
1.7 Nm
(15 lbfin)
1.7 Nm
(15 lbfin)
NEW
5 Nm
(44 lbfin)
1.7 Nm
(15 lbfin)
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
smr2009-024-101_a
smr2009-024
115
Section 02 ENGINE
ENGINE COMPONENTS
NEW
17 Nm
(150 lbfin)
NEW
9 Nm
(80 lbfin)
9 Nm
(80 lbfin)
Loctite
243
9 Nm
(80 lbfin)
Loctite
243
Left hand
threads
3 Nm
(27 lbfin)
NEW
NEW
Engine oil
Engine oil
9 Nm
(80 lbfin)
Loctite
243
NEW
NEW
Engine
oil
Loctite 243
9 Nm
(80 lbfin)
Loctite 243
NEW
9 Nm
(80 lbfin)
smr2009-024-001_a
116
smr2009-024
Section 02 ENGINE
GENERAL
complete procedure.
WARNING
smr2009-024-002_a
1. Bleed nipple
2. Coolant temperature sensor (CTS)

NOTICE Never modify cooling system arrangement, otherwise serious engine damage
could occur.
SYSTEM DESCRIPTION
Technical Specifications
A closed loop cooling system is utilized on the

1503 4-TEC engines, which offers an efficient
engine cooling while keeping dirt and salt water
out of the cooling system. This system keeps
the temperature constant and prevents internal
engine corrosion.
A separate coolant expansion tank ensures that
enough engine coolant is in the circuit during any
operating condition.
The coolant flow comes from the water pump impeller into the cylinder block. It goes around the
cylinders and straight up to the cylinder head. A
smaller quantity of engine coolant enters the cylinder block on the exhaust side for a better cooling. In the cylinder head the water channels flow
around the exhaust and then the intake valves and
leave the engine through a large hose. From there
the coolant goes back to the water pump housing and depending on the engine temperature, it
flows through the thermostat directly back to the
water pump impeller, or it takes its way through
the heat exchanger.
Engine coolant is also directed towards the oil
cooler (coolant type).
Coolant temperature sensor and bleed nipple are
located on the cylinder head.
smr2009-024
TYPE
Closed loop cooling

system.
COOLANT FLOW
Flow from water pump.
TEMPERATURE
CONTROL
Thermostat.
SYSTEM BLEEDING
Self-bleed type through

expansion tank (hose at
uppermost point of circuit).
MONITORING
BEEPER
Turns on at 100C (212F)

on naturally aspirated
engines. Turns on at 110C
(230F) on supercharged
engines.
MAINTENANCE
ENGINE COOLANT
WARNING
To avoid potential burns, do not remove the
expansion tank cap or loosen the ride plate
drain plug if the engine is hot.
Recommended Coolant
Use BRP PREMIXED COOLANT (P/N 219 700 362) or
a blend of 50% antifreeze with 50% demineralized water.
NOTE: Using a blend of 40% antifreeze with 60%
demineralized water will improve the cooling efficiency when watercraft is used in particularly hot
weather and/or hot water condition.
117
Section 02 ENGINE
NOTICE Pure antifreeze will freeze at a higher

temperature than the optimal water/antifreeze
mix. A blend of 40% antifreeze with 60% demineralized water will improve the cooling efficiency. Using water tap instead of demineralized water, would contribute to make deposits
in cooling system and to reduce antifreeze efficiency. This could lead to engine overheating.
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands unless cooling system is completely flushed and
refilled.
NOTICE To prevent rust formation or freezing condition in cold areas, always replenish
the system with 50% antifreeze and 50% demineralized water. Pure antifreeze will freeze
at a higher temperature than the optimal water/antifreeze mix. Always use ethylene glycol
antifreeze containing corrosion inhibitors
specifically recommended for aluminum engines. Using water tap instead of demineralized water, would contribute to make deposits
in cooling system and to reduce antifreeze efficiency. This could lead to engine overheating.
Draining the System

WARNING
Never drain or refill cooling system when engine is hot.
Open seat and remove the rear ventilation box.
Remove the coolant expansion tank cap.
Install a drain pan underneath the ride plate.
Unscrew the drain plug on ride plate.
NOTE: Raising the front of the watercraft will contribute to drain the cooling system.
Cleaning the System

NOTICE Cleaning the cooling system as per
the following procedure is required when engine overheats (assuming everything else is
operating normally) or each time coolant is
replaced.
Drain the cooling system. Clean thoroughly using
the Valvoline Zerex Super Cleaner (or equivalent).
Add the cleaning product in coolant expansion
tank then fill cooling system with demineralized
water.
Reinstall cap on coolant expansion tank.
Install watercraft in a test basin or ride on a water
plane. Start engine and run for approximately 15
minutes.
IMPORTANT: Ensure thermostat opens so that
the cleaning product flows in ride plate properly.
Stop engine and let the cleaning product work for
12 to 16 hours.
Thereafter, engine can be run one last time to soak
off deposits.
Drain and thoroughly rinse the cooling system
with clean fresh water.
Refill cooling system as described below.
Refilling the System

Watercraft should be level, engine cold and drain
plug removed for refilling.
Place a container under drain plug to collect antifreeze.
Ask someone to pour recommended antifreeze in
expansion tank.
When antifreeze flows out from the ride plate
drain hole, reinstall drain plug. Torque drain plug
to 8 Nm (71 lbfin).
Continue to pour and fill expansion tank between
marks.
smr2009-024-102_a
1. Cooling drain plug
Dispose coolant as per local regulations.

Do not reinstall drain plug at this time.
118
smr2009-024
Section 02 ENGINE
INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns, do not remove the
expansion tank cap or loosen the ride plate
drain plug if the engine is hot.
smo2009-002-137_a
1. Level between marks when engine is cold

Install the TEST CAP (P/N 529 035 991) on the
coolant expansion tank.
Do not install pressure cap at this time.

Start engine and let run for a maximum of 2 minutes. Stop engine and wait 15 minutes to cool
down. Refill tank as necessary.
NOTE: Properly cool exhaust system by installing
a garden hose. Refer to EXHAUST SYSTEM subsection.
Repeat this run-stop cycle 2 - 3 times until thermostat opens and stop engine.
529035991
NOTE: It is not necessary to install a hose pincher

on overflow hose.
Connect the VACUUM/PRESSURE PUMP (P/N 529
021 800) to test cap and pressurize system
through coolant expansion tank to 90 kPa (13 PSI).
smr2009-024-003_a
1. This hose becomes hot when thermostat opens
Last, refill expansion tank and install pressure cap.

When engine has completely cooled down,
recheck coolant level coolant tank and top up if
necessary.
smr2009-024-103_a
1. Vacuum/pressure pump
2. Test cap
Check all hoses, ride plate, engine and oil cooler

for coolant leaks. Spray a soap/water solution and
look for air bubbles.
Check the leak indicator hole if there is oil or
coolant. If so, replace appropriate water pump
shaft seal.
smr2009-024
119
Section 02 ENGINE
PROCEDURES
PRESSURE CAP
Pressure Cap Inspection
Using a pressure cap tester, check pressure cap
efficiency. If the efficiency is feeble, install a new
90 kPa (13 PSI) cap (do not exceed this pressure).
CLAMPS
Clamp Replacement
To cut or secure Oetiker clamps of cooling system
hoses, use the OETIKER PLIERS (P/N 295 000 070).
smr2009-024-004_a
1. Leak indicator hole
TROUBLESHOOTING
ENGINE OVERHEATING
1. Low coolant level.
- Refill and check for leaks (coolant leaking out
of engine leak indicator hole, hoses or clamps
missing/defective, cylinder head gaskets leaks,
ride plate leaking, etc.). Repair or replace.
2. Air in cooling system
- Refill and bleed cooling system.
2
F01B2KA
1. Cutting clamp
2. Securing clamp
NOTE: Always check general condition of hoses

and clamp tightness.
3. Thermostat defective (does not open when engine gets hot)

- Replace thermostat housing.
4. Water pump failure
- Inspect and replace defective components.
5. Water temperature sensor defective
- Check or replace. Refer to ELECTRONIC FUEL
INJECTION.
6. Ride plate or hoses damaged
- Check or replace damaged components.
7. Exhaust system clogged
- Flush exhaust system.
8. Internal passage blocked in cooling system
- Inspect and clean.
120
smr2009-024
Section 02 ENGINE
WATER PUMP HOUSING
smr2009-024-105_a
1. Expansion tank hose
Disconnect exhaust hose from the resonator.

Place hose over muffler.
smr2009-024-004_b
Water Pump Housing Removal

Remove the moving deck. Refer to BODY subsection.
Remove both air hoses from intercooler to reach
supercharger.
smr2009-024-106_a
1. Exhaust hose
2. Cut these locking ties
3. Retaining clamp
Disconnect ride plate hoses from water pump

housing.
smr2009-024-104_a
1. Intercooler air inlet hose

2. Intercooler air outlet hose
Drain cooling system and engine oil.

Disconnect the coolant expansion tank hose from
water pump housing and move expansion tank
aside to make room.
smr2009-024-107_a
1. Ride plate outlet hose

2. Ride plate inlet hose
Disconnect the cylinder head outlet hose and oil

cooler hoses.
smr2009-024
121
Section 02 ENGINE
Check if thermostat is in good condition. Refer to

THERMOSTAT in this subsection.
Water Pump Housing Leak Test

Plug the connections of the oil cooler return hose,
coolant tank hose, ride plate return hose and cylinder head return hose with a rag.
smr2009-024-006_a
1.
2.
3.
4.
Water pump housing

Cylinder head hose
Oil cooler inlet hose
Oil cooler outlet hose
Remove water pump housing screws.
F18E12A
1.
2.
3.
4.
Oil cooler return connection

Coolant tank hose connection
Ride plate return hose connection
Cylinder head return hose connection
Fill the water pump housing with water.

If a bigger quantity of coolant leaks out at the ride
plate outlet connection, replace the water pump
housing.
If there is no leak, check the operation of the thermostat.
smr2008-016-004_a
Pull the water pump housing to remove it.
Water Pump Housing Inspection

Check if gasket is brittle, hard or damaged and replace as necessary.
1
Water Pump Housing Installation

The installation is the opposite of the removal procedure. However, pay attention to the following.
threads of water pump housing screws.
Install screws as per the following illustration.
F18E11A
1. Water pump housing gasket

122
smr2009-024
Section 02 ENGINE
2
1
1
1
F18E10A
F18E13A
1. Screws M6 x 25
2. Screws M6 x 105
1. Impeller
NOTICE To prevent leaking, take care that the

gaskets are exactly in groove when you reinstall the water pump housing.
Tighten screws to 9 Nm (80 lbfin) using the following sequence.
7
NOTICE Coolant/oil pump shaft and impeller

have left-hand threads. Remove by turning
clockwise and install by turning counterclockwise.
Water Pump Impeller Inspection

Check impeller for cracks or other damage. Replace impeller if damaged.
Water Pump Impeller Installation

6
5
The installation is the opposite of the removal procedure. Pay attention to the following details.
NOTICE Be careful not to damage impeller
wings during installation.
Torque impeller to 3 Nm (27 lbfin).
THERMOSTAT
F18E10B
WATER PUMP IMPELLER

Water Pump Impeller Removal
Remove the WATER PUMP HOUSING, see procedure in this subsection.
Unscrew the impeller clockwise.
The thermostat is a single action type.
Thermostat Removal
Remove the WATER PUMP HOUSING, see procedure in this subsection.
NOTE: The thermostat is located inside the water
pump housing.
Thermostat Test
To check the operation of the thermostat, put it in
water and heat water.
Look inside the cylinder head return hose connection to see the movement of the thermostat.
Thermostat should open when water temperature reaches 87C (189F).
If there is no operation, replace the water pump
housing.
smr2009-024
123
Section 02 ENGINE
Thermostat Installation
For installation, reverse the removal procedure,

paying attention to the following details.
Refer to WATER PUMP HOUSING in this subsection.
ROTARY SEAL
Rotary Seal Inspection
Check leak indicator hole for oil or coolant leak.
F18E14A
1. Oil pump cover screws

2. Oil pump cover
Remove oil pump cover.

Remove outer oil pump rotor.
1
smr2009-024-004_a
1. Leak indicator hole
Coolant leaking out of the hole indicates a defective rotary seal. Leaking oil indicates a faulty oil
seal.
However, if seal is disassembled both parts have
to be replaced together.
F18E15A
Rotary Seal Removal
1. Outer oil pump rotor
Remove WATER PUMP HOUSING, see procedure in this subsection.

Unscrew the impeller clockwise.
Extract the coolant/oil pump shaft from outside

PTO housing cover with a pusher.
NOTICE Always unscrew the impeller clockwise otherwise you can damage the components.
Remove PTO housing Refer to PTO HOUSING
AND MAGNETO subsection.
Remove oil pump cover screws.
124
smr2009-024
Section 02 ENGINE
NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push water pump shaft oil seal in place by using
thumb.
Install the NEW rotary seal using a press and the
WATER PUMP SEAL PUSHER (P/N 529 035 823).
F18E16A
1. Pusher
2. Coolant/oil pump shaft
529035823
NOTICE Never use a hammer for the rotary

seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.
Remove rotary seal with a screwdriver.
F18E17A
NOTICE Be careful not to damage the surface

of the rotary seal bore in PTO housing.
Always replace also the oil seal behind the rotary
seal.
F18E19A
1. Rotary seal
2. Rotary seal installer
Install the OIL SEAL GUIDE (P/N 529 035 822) on the
end of coolant/oil pump shaft.
529035822
F18E18A
1. Oil seal
Rotary Seal Installation

The installation is the opposite of the removal procedure. Pay attention to the following details.
smr2009-024
125
Section 02 ENGINE
F18E1AA
1. Oil seal protector

2. Coolant/oil pump shaft
Using the WATER PUMP SEAL PUSHER (P/N 529

035 823) to support the PTO cover, install the
coolant/oil pump shaft.
1
2
F18E1BA
1. Coolant/oil pump shaft with oil seal protector

2. Rotary seal installer
126
smr2009-024
Section 02 ENGINE
Subsection 10 (CYLINDER HEAD)
CYLINDER HEAD
SERVICE TOOLS
Description
Part Number
CAMSHAFT LOCKING TOOL........................................................

DRIVE SHAFT ADAPTER...............................................................
ENGINE LEAK DOWN TEST KIT ...................................................
VALVE GUIDE PUSHER (6 MM) ....................................................
VALVE GUIDE REMOVER (6 MM) ................................................
VALVE SPRING COMPRESSOR CUP............................................
VALVE SPRING COMPRESSOR ....................................................
529
529
529
529
529
529
529
035
035
035
036
036
036
035
839
985
661
087
086
073
724
Page
......................................... 138
......................................... 130
......................................... 130
......................................... 147
......................................... 146
......................................... 141
......................................... 141

Description
Part Number
SNAP-ON VALVE STEM SEAL PLIERS ......................................... YA8230
Page
......................................... 143
SERVICE PRODUCTS
Description
Part Number
Page
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ......................................... 139

LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................... 132, 137, 141
MOLYKOTE G-N ............................................................................ 420 297 433 ......................................... 147
smr2009-025
127
Section 02 ENGINE
Isoflex grease
Topaz NB52
9 Nm
(80 lbfin)
See LUBRIFICATION
SYSTEM
9 Nm
(80 lbfin)
NEW
Engine oil
NEW
Engine
oil
NEW
Loctite
243
Loctite
243
NEW
9 Nm
(80 lbfin)
Loctite
243
9 Nm
(80 lbfin)
20 Nm
(15 lbfft)
+ 90o
Engine
oil
Engine
oil
9 Nm
(80 lbfin)
Loctite
243
11 Nm
(97 lbfin)
Engine oil
Loctite
243
NEW
40 Nm
(30 lbfft)
+120 + 90o
See ELECTRONIC
FUEL INJECTION
Engine oil
Loctite 243
9 Nm
(80 lbfin)
NEW
smr2009-025-001_a
128
smr2009-025
Section 02 ENGINE
GENERAL
WARNING
NOTE: When diagnosing an engine problem, always perform an engine leak test. This will help
pin-point a problem. Refer to ENGINE LEAK TEST
in this subsection for procedures.
Always place the vehicle on level surface.
Always disconnect the negative wire from the battery before working on the engine.
Even if the removal of many parts is not necessary to reach another part, it is recommended to
remove these parts in order to check them.
When disassembling parts that are duplicated in
the engine, (e.g.: valves, bushings), it is strongly
recommended to note their position (cylinder 1, 2
or 3) and to keep them as a group. If you find
a defective component, it would be much easier
to find the cause of the failure within the group of
parts (e.g.: you found a worn valve guide. A bent
spring could be the cause and it would be easy to
know which one among the springs is the cause
to replace it if you grouped them at disassembly).
Besides, since used parts have matched together
during the engine operation, they will keep their
matched fit when you reassemble them together
within their group.
complete procedure.
Be careful to burns when working on a hot

engine.
Preparation
1. Remove any required parts to give access to
engine.
2. Remove safety lanyard.
WARNING
Safety lanyard must be removed to prevent
engine to be cranked while fuel rail is removed to prevent fuel to be sprayed out.
Fuel is flammable.
3. Remove jet pump (refer to JET PUMP subsection).
4. Remove coolant pressure cap.
WARNING
To avoid potential burns, only remove the
coolant pressure cap by wearing the appropriate safety equipment.
5. Remove oil dipstick.
WARNING
Hoses, cable or locking ties removed during the
removal must be reinstalled as per factory standards.
INSPECTION
smr2009-025-002_a
1. Oil dipstick
6. Unplug and remove ignition coils.

7. Remove spark plugs.
NOTE: Ignition coil may be used as an extractor.
ENGINE LEAK TEST

The procedure has to be done when engine operating temperature of approximately 70C (158F)
is reached.
smr2009-025
129
Section 02 ENGINE
Leak Test Procedure
smr2009-025-003_a
1. Ignition coil
2. Spark plug
NOTE: Cylinder numbers are molded on cylinder

head cover.
1. Rotate engine crankshaft counterclockwise until the cylinder no. 1 is at Top Dead Center (TDC)
compression stroke.
1.1 As the engine crankshaft is turned over,
observe the movement of intake rocker
arm of the cylinder to be checked.
1.2 After piston completes its cycle and the
intake valve closes, observe the piston.
1.3 When it reaches its uppermost position
this is TDC compression stroke.
1
8. Remove cylinder head cover cowl.

9. Unscrew and remove cylinder head cover.
R1503motr156A
1. Intake rocker arms

smr2009-025-004_a
1. Cylinder head cover screw (8)
10. Install the DRIVE SHAFT ADAPTER (P/N 529 035

985) on drive shaft end.
2. Secure the drive shaft adapter with a wrench

lever against hull to prevent further crankshaft
rotation.
3. Install gauge adapter from the ENGINE LEAK
DOWN TEST KIT (P/N 529 035 661) into spark
plug hole.
4. Connect to adequate air supply.
NOTE: Each tester will have specific instruction
on the gauge operation and required pressure.
Refer to manufacturer's instructions.
5. Set needle of measuring gauge to zero.
6. Supply combustion chamber with air.
529035985
11. To rotate engine crankshaft, use an appropriate wrench lever with drive shaft adapter.
130
smr2009-025
Section 02 ENGINE
OBSERVATION
3
2
Air escaping on intake

port
Leaking intake valve(s)
Air escaping on
exhaust port
Leaking exhaust valve(s)
Air escaping into

crankcase
Excessively worn and/or

broken piston rings
Air bubbles out of

coolant tank
Leaking cylinder head

gasket
Air/water
escaping from
cylinder-block/head
Damaged gasket and/or

loosened screws
Coolant escaping from

water pump housing
Damaged gasket and/or

loosened screws (refer to
COOLING SYSTEM)
Coolant escaping from

leak indicator hole
Damaged rotary seal on

water pump shaft (refer to
COOLING SYSTEM)
Oily contamination on
leak indicator hole
Damaged oil seal on water

pump shaft
R1503motr157A
TYPICAL
1. Leak down tester gauge
2. Gauge adapter
3. Air supply hose
7. Note the amount of leaking or percentage (depending on tester).

LEAKAGE
PERCENTAGE
ENGINE CONDITION
CAUSE
Reassembly
16% to 25%
Good condition
26% to 40%
Fair condition; engine will run

and performance might be
down in some cases
For reassembly, reverse the preparation procedure. Use torque values and service products
from the exploded views (refer to proper ENGINE
subsections).
Properly install ignition coils. Refer to IGNITION
SYSTEM subsection.
41% and higher
Poor condition, diagnose and

repair engine
TROUBLESHOOTING
Up to 15%
Excellent condition
8. Proceed the same way with remaining cylinders.
Diagnostic
Pressurize area to be tested, spray soap/water solution at the indicated location and look and/or listen for air bubbles.

probable source of problems. It is a guideline and
UNUSUAL ENGINE NOISE OR

VIBRATIONS
1. Incorrect camshaft timing adjustment
- Replace damaged components and readjust
camshaft timing.
2. Camshaft timing gear screws got loose
- Retighten screws with the recommended torque.
3. Rocker arm(s) hydraulic element is broken or
worn out (improper valve adjustment).
- Replace faulty rocker arm(s).
smr2009-025
131
Section 02 ENGINE
4. Rocker arm screw not properly tightened

- Retighten screws with recommended torquing
procedure.
4. Broken rocker arm(s)

- Replace defective parts.
5. Faulty chain tensioner

- Replace chain tensioner.
PROCEDURES
6. Chain guide is worn out

- Replace chain guide.
7. Stretched timing chain or worn out sprocket
- Replace timing chain and sprocket.
8. Camshaft is worn out
- Check if camshaft radial clearance is out of specification.
OIL LEAKAGE FROM CYLINDER HEAD

1. Cylinder head cover gasket is leaking
- Replace cylinder head cover gasket and retighten
screws with recommended torque.
- Check cylinder head cover for cracks or other
damage. Replace if necessary.
EXHAUST MANIFOLD
Exhaust Manifold Removal
3. Move muffler back. Refer to EXHAUST SYSTEM subsection.
4. Unscrew the exhaust manifold beginning with
the bottom screws. This will help holding the
manifold while you remove the screws.
2. Cylinder head cover screws are leaking

- Replace cylinder head cover screws.
3. Spark plug tube gasket is leaking
- Remove cylinder head cover and replace spark
plug tube gasket.
- Clean spark plug area from oil spillage.
4. Blow by valve is leaking
- Replace blow by valve O-ring.
5. Camshaft sensor O-ring is leaking
- Replace camshaft sensor O-ring.
6. Cylinder head gasket is leaking
- Remove cylinder head and check for damage.
- Replace cylinder head gasket and retighten
screws with recommended torquing procedure.

POWER
1. Incorrect camshaft timing adjustment
- Replace damaged components and readjust
camshaft timing.
2. Intake or exhaust valves are leaking
- Perform ENGINE LEAK TEST.
- Check if valve seats properly in valve seat.
- Repair or replace damaged components.
3. Broken valve spring(s)
- Replace defective parts.
132
smr2008-017-002_a
1. Exhaust manifold screws
5. Remove exhaust manifold.

6. Disconnect cooling hoses from exhaust manifold.
Exhaust Manifold Inspection

Inspect exhaust manifold condition paying attention for cracks or other damage. Check contact
surfaces and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with
a fine sand paper. Install sand paper on a surface
plate and rub part against oiled sand paper.
Exhaust Manifold Installation

NOTE: There is no gasket between cylinder block
and exhaust manifold.
threads of exhaust manifold screws.
smr2009-025
Section 02 ENGINE
Torque screws to 9 Nm (80 lbfin) as per following illustrated sequence.

7
11
smr2008-017-005_a
1. Cylinder head cover screws
5. Remove the cylinder head cover and its gasket.
R1503motr152A
10
12
CYLINDER HEAD COVER

Cylinder Head Cover Removal
1. Open seat.
2. Remove the rear ventilation cover.
3. Unplug and remove ignition coils.
smr2006-016-028_a
1. Cylinder head cover

2. Gasket
Cylinder Head Cover Inspection

Check if the gasket on the cylinder head cover
and the rubber bushing on the cylinder head cover
screws are brittle, cracked or hard. If so, replace
the gasket or the cylinder head cover screw accordingly.
Cylinder Head Cover Installation
smr2009-025-005_a
1. Ignition coils

Properly seat the gasket in the cover groove.
Install the cylinder head cover screws according
to following sequence.
4. Remove screws securing the cylinder head

cover.
smr2009-025
133
Section 02 ENGINE
smr2005-036-001_a
TYPICAL
1. Spark plug tube
2. Seal to the cylinder head cover
3. Seal to the cylinder head
Spark Plug Tube Installation

smr2006-016-026_a
Torque screws to 9 Nm (80 lbfin).

Pay attention to the following detail.
Apply engine oil on seals.
SPARK PLUG TUBES

Spark Plug Tube Removal
Remove the CYLINDER HEAD COVER, see procedure in this subsection.
Pull spark plug tubes to remove them.
1
ROCKER ARMS
Rocker Arm Removal
1. Remove the CYLINDER HEAD COVER, see
procedure in this subsection.
2. Remove spark plug tubes.
3. Remove and discard rocker arm shaft screws.
1
R1503motr83A
1. Spark plug tube
R1503motr93B
1. Rocker arm shaft screw
Spark Plug Tube Inspection

Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.
134
4. Remove rocker arm shaft with rocker arms.
smr2009-025
Section 02 ENGINE
1
3
A
R1503motr90A
A. Measure rocker arm shaft diameter here
ROCKER ARM SHAFT DIAMETER
R1503motr84A
1. Rocker arm shaft

2. Rocker arms (exhaust side)
3. Rocker arm (intake side)
Rocker Arm Inspection

Inspect each rocker arm for cracks and scored friction surfaces. If so, replace rocker arm assembly.
Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly as necessary.
NEW
19.980 mm - 19.993 mm
(.7866 in - .7871 in)
SERVICE LIMIT
19.965 mm (.786 in)
Any area worn excessively will require parts replacement.

Verify and clean oil orifices to ensure a good rocker
arm shaft lubrication.
1
smr2008-017-006_a
1.
2.
3.
A.
Rocker arm (intake side)

Rocker arm (exhaust side)
Rollers
Rocker arm inside diameter
R1503motr85A
1. Oil orifices from the camshaft to the rocker arm shaft, then to
the rocker arms and finally to the valve adjustment
Measure rocker arm inside diameter. If diameter

is out of specification, change the rocker arm assembly.
ROCKER ARM INSIDE DIAMETER
NEW
20.007 mm - 20.020 mm
(.7877 in - .7882 in)
SERVICE LIMIT
20.035 mm (.7888 in)
Press the hydraulic lifter with your thumb. If the

hydraulic lifter can be fully pressed in, replace
rocker arm. Lifter must turn freely in rocker arm
bore. Otherwise, replace.
Rocker Arm Shaft
Check for scored friction surfaces, if so, replace
parts.
Measure rocker arm shaft diameter.
smr2009-025
Rocker Arm Installation

NOTE: The rocker arm shaft can only be installed
in one specific position. Therefore the camshaft
has to be positioned with its locking pin when the
piston of cylinder no. 3 is on ignition TDC.
1. Lock camshaft. Refer to CAMSHAFT in this
subsection.
2. Make sure the position lines on oil separator
cover are lined up as shown in the following illustration.
135
Section 02 ENGINE
smr2009-025-006_a
1 3
R1503motr93A
1. Position lines
3. Apply engine oil on rocker arm shaft.

4. Position the rocker arm shaft with the notches
on top.
2
7. Retorque screws to 20 Nm (15 lbfft).

8. Finish tightening screws turning an additional
90 rotation with a torque angle gauge.
2
1
1
R1503motr92A
R1503motr91A
1. Rocker arm shaft

2. Rocker arm shaft notches
5. Install NEW rocker arm shaft screws. Torque as

per following procedure:
NOTICE This assembly uses stretch screws.
As the screws have been stretched from the
previous installation, it is very important to
use new screws at assembly. Failure to replace screws and to strictly follow the torque
procedure may cause screws to loosen and
lead to engine damage.
6. Torque screws at first to 10 Nm (89 lbfin) according to following sequence.
136
1. Rocker arm shaft screw

2. Torque angle gauge
CAMSHAFT TIMING GEAR

NOTE: Although it is not necessary to position
crankshaft to TDC for disassembly, it is a good
practice to do it, as a troubleshooting step, to
know before disassembly if valve timing was
appropriate.
Camshaft Timing Gear Removal

Lock crankshaft, refer to CYLINDER BLOCK subsection.
Remove CYLINDER HEAD COVER, see procedure above in this subsection.
Lock camshaft. Refer to CAMSHAFT in this subsection.
Remove the oil separator cover. Refer to LUBRICATION SYSTEM subsection.
smr2009-025
Section 02 ENGINE
Remove the chain tensioner. Refer to CYLINDER

BLOCK subsection.
Remove the chain guide.
Remove the Allen screws securing the camshaft
timing gear.
Remove the camshaft timing gear.
smr2008-017-007_a
1. Chain guide
2. Allen screws
3. Camshaft timing gear
NOTE: Secure timing chain with a retaining wire.
Camshaft Timing Gear Inspection

Check camshaft timing gear for wear or deterioration.
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft timing gear, refer to CYLINDER
BLOCK subsection.
Camshaft Timing Gear Installation

NOTICE Improper camshaft timing will damage engine components. Make sure camshaft
and crankshaft are still locked. If not, lock them
before beginning this procedure.
Install the camshaft timing gear with the writing
visible, i.e. to be able to see the position lines
when looking from outside of engine.
R1503motr97A
1. Good (with 1503 aligned)

2. Never
Install timing chain. Refer to CYLINDER BLOCK

subsection.
Ensure chain guides are in place.
Loosely install timing chain screws.
Install chain tensioner.
NOTE: There can be 2 different positions to install
the timing gear on the camshaft. Basically both
positions are working well, since the camshaft
and crankshaft are locked in their proper position.
Due to some tolerances, there could be one position which fits better than the other one. To
check this, perform the following test.
Check if timing chain screws are still loose. If
screws are squeezed by the timing gear, remove
the chain tensioner again and rotate timing gear
by one tooth clockwise. Then install the chain
tensioner again.
One at a time, remove timing chain screws and
apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads.
Tighten timing chain screws to 9 Nm (80 lbfin).
NOTICE Crankshaft and camshaft must be
locked on TDC position to place camshaft
timing gear and timing chain in the proper
position. To double check, take a look at the
timing gear lines. They must be parallel to the
cylinder head surface.
smr2009-025
137
Section 02 ENGINE
Camshaft Removal
Remove the CAMSHAFT TIMING GEAR, see procedure in this subsection.
Remove the ROCKER ARM, see procedure in this
subsection.
Remove the camshaft lock to remove the
camshaft.
1
2
R1503motr95A
1. Position lines
NOTICE Ensure to remove locking tools

when finished.
CAMSHAFT
Camshaft Locking Procedure
1. Remove CYLINDER HEAD COVER, see procedure in this subsection.
2. Lock crankshaft, refer to procedure in CYLINDER BLOCK subsection.
3. Lock camshaft using the CAMSHAFT LOCKING
TOOL (P/N 529 035 839).
R1503motr101A
1. Camshaft lock
2. Camshaft
Camshaft Inspection
Check each lobe and bearing journal of camshaft
for scoring, scuffing, cracks or other signs of wear.
Measure camshaft bearing journal and lobe height
using a micrometer.
Measure clearance between both ends of
camshaft and cylinder head.
D A B A C
529035839
C A B A C
C A B A C
4. Make sure the position lines on oil separator

cover are lined up as shown in the following illustration.
R1503motr102A
A.
B.
C.
D.
Camshaft
Camshaft
Camshaft
Camshaft
lobe (exhaust valves)

lobe (intake valves)
bearing journal
bearing journal engine front
CAMSHAFT LOBE HEIGHT EXHAUST VALVE

31.699 mm - 31.809 mm
NEW
(1.248 in - 1.2523 in)
31.670 mm (1.2469 in)
SERVICE LIMIT
smr2009-025-007_a
CAMSHAFT LOBE HEIGHT INTAKE VALVE

31.480 mm - 31.590 mm
NEW
(1.2394 in - 1.2437 in)
31.450 mm (1.2382 in)
SERVICE LIMIT
1. Camshaft locking tool

2. Position lines
138
smr2009-025
Section 02 ENGINE
Drain coolant, refer to COOLING SYSTEM subsection.

Unscrew blow-by valve from cylinder head. Refer
to LUBRICATION SYSTEM subsection.
Unplug the camshaft position sensors (CAPS).
Unplug the coolant temperature sensor (CTS).
Disconnect bleeding hose.
Disconnect the cylinder head outlet hose.
CAMSHAFT BEARING JOURNAL

39.892 mm - 39.905 mm
NEW
(1.5706 in - 1.5711 in)
39.860 mm (1.5693 in)
SERVICE LIMIT
CAMSHAFT BEARING JOURNAL
(ENGINE FRONT)
24.939 mm - 24.960 mm
NEW
(.9819 in - .9827 in)
24.910 mm (.9807 in)
SERVICE LIMIT
CAMSHAFT BEARING INNER DIAMETER
40.000 mm - 40.016 mm
NEW
(1.5748 in - 1.5754 in)
40.050 mm (1.5768 in)
SERVICE LIMIT
CAMSHAFT BEARING INNER DIAMETER
(ENGINE FRONT)
25.000 mm - 25.013 mm
NEW
(.9843 in - .9848 in)
25.050 mm (.9862 in)
SERVICE LIMIT
Replace parts that are not within specifications.
Camshaft Installation
Grease the camshaft bearing journals well by using the ISOFLEX GREASE TOPAS NB 52 (P/N 293 550
021) or a similar product.
Install camshaft then place the camshaft lock in
the slot.
smr2009-025-008_a

2. Bleeding nipple
3. Cylinder head outlet hose
Remove the exhaust manifold. Refer to EXHAUST SYSTEM subsection.

Unscrew the oil filler tube support from cylinder
head.
R1503motr101B
1. Camshaft lock position
For other parts, refer to the proper installation procedures in this subsection.
CYLINDER HEAD
smr2009-025-009_a
1. Retaining screws
2. Oil filler tube support
Remove the CAMSHAFT TIMING GEAR, see procedure in this subsection.

Remove the cylinder head screws M6.
Cylinder Head Removal

Lock crankshaft, refer to CYLINDER BLOCK subsection.
smr2009-025
139
Section 02 ENGINE
smr2009-025-010_a
1. Oil orifices
R1503motr98A
1. Cylinder head screws M6
Remove the cylinder head screws M11 securing

cylinder head to cylinder block.
Cylinder Head Inspection

Check for cracks between valve seats or other
damages, if so, replace cylinder head.
Check cylinder head mating surface for flatness,
using a straight edge.
R1503motr99A
smr2006-016-063_a
1. Cylinder head screws M11
Pull up cylinder head.

Remove gasket.
Cylinder Head Cleaning

Remove carbon deposits from combustion chamber, exhaust port and piston top.
Clean cylinder head, especially cylinder head
screw surface from oil spillage.
Blow out the oil orifices and check if they are not
clogged.
1. Cylinder head
2. Flat bar
3. Feeler gauge
Check cylinder head warpage.

CYLINDER HEAD WARPAGE
Maximum
0.15 mm (.006 in)
If warpage exceeds specification, resurface the

cylinder head as follows.
Use a 400 - 600 grit wet sandpaper on a surface
plate and gently grind off the mating surface.
NOTE: To ensure an even surface, rotate cylinder
head several times during resurfacing.
Replace cylinder head, if resurfacing fails.
Cylinder Head Installation

Ensure dowel pins are in place.
Install NEW cylinder head gasket.
140
smr2009-025
Section 02 ENGINE
NOTICE Each installation of the cylinder

head requires a new cylinder head gasket. Using a gasket twice will cause engine damage,
even if the engine had not run.

threads of screws M6.
Install screws M6 and manually tighten them.
Install NEW screws M11and tighten them manually.
NOTICE This assembly uses stretch screws.
As the screws M11 have been stretched from
the previous installation, it is very important to
replace the old screws by new ones at assembly. Failure to replace screws and to strictly follow the torque procedure may cause screws to
loosen and lead to engine damage.
Using the following sequence, tighten screws as
described below.
R1503motr100A
1. Cylinder screws M11

2. Angle torque wrench
Remove all locking tools.

Install all removed parts.
VALVE SPRINGS
Valve Spring Removal
Remove rocker arm shaft. Refer to ROCKER ARM
Remove CYLINDER HEAD, see procedure in this
subsection.
Compress valve springs, using theVALVE SPRING
COMPRESSOR (P/N 529 035 724) and the VALVE
SPRING COMPRESSOR CUP (P/N 529 036 073).
smr2005-036-002_a
1. First torque screws M11 to 40 Nm (30 lbfft).

2. Then tighten screws M11 turning a 120 rotation with a torque angle gauge and finish tightening with an additional 90 rotation.
3. Torque screws M6 to 9 Nm (80 lbfin).
5290357242
VALVE SPRING COMPRESSOR
529036073
VALVE SPRING COMPRESSOR CUP
smr2009-025
141
Section 02 ENGINE
2
1
smr2008-017-009_a
1.
2.
3.
4.
Valve cotters
Valve spring retainer
Inner valve spring
Outer valve spring
Valve Spring Inspection

R1503motr103A
1. Valve spring compressor clamp

2. Valve spring compressor cup
R1503motr104A
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE
Remove valve cotters.

Withdraw valve spring compressor, valve spring
retainer and valve springs.
Check valve springs for rust, corrosion or other

visible damages. If so, replace faulty valve
springs.
Check valve springs for free length and straightness.
Replace valve springs if not within specifications.
A
R610motr122A
A. Valve spring length
OUTER VALVE SPRING FREE LENGTH

NEW NOMINAL
45.45 mm (1.789 in)
SERVICE LIMIT
43.00 mm (1.693 in)
INNER VALVE SPRING FREE LENGTH

NEW NOMINAL
41.02 mm (1.615 in)
SERVICE LIMIT
38.8 mm (1.528 in)
Valve Spring Installation

Colored area of the valve spring must be placed
on top.
142
smr2009-025
Section 02 ENGINE
NOTE: Valve cotters must be properly engaged in

valve stem grooves.
R1503motr105B
1. Position of the valve spring
VALVES
R610motr125A
Valve Removal
Valve Inspection
Remove valve spring.

Push valve stem then pull valves out of valve
guides.
1
2
R1503motr106A
1. Intake valve 38 mm
2. Exhaust valve 31 mm
Valve Stem Seal

Inspection of valve stem seals is not needed
because NEW seals should always be installed
whenever cylinder head is removed.
Valve
Inspect valve surface, check for abnormal stem
wear and bending. If so, replace by a new one.
Valve Stem and Valve Guide Clearance
Measure valve stem and valve guide in three
places, using a micrometer and a small bore
gauge.
NOTE: Clean valve guide to remove carbon deposits before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction surface.
Remove valve stem seal with a valve stem seal

pliers such as the SNAP-ON VALVE STEM SEAL PLIERS (P/N YA8230).
smr2009-025
143
Section 02 ENGINE
Valve Face and Seat

2
R1503motr107A
R610motr126A
A. Valve stem diameter
VALVE STEM DIAMETER

NEW
Exhaust
5.946 mm - 5.960 mm
(.2341 in - .2346 in)
Intake
5.961 mm - 5.975 mm
(.2347 in - .2352 in)
SERVICE LIMIT
Exhaust
Intake
5.93 mm (.233 in)
Replace valve guide if it is out of specification or

has other damages such as wear or friction surface. Refer to valve guide replacement below.
VALVE GUIDE INNER DIAMETER
1. Valve seat
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning or pittings

and replace valve or cylinder head if there are
signs of damage.
Ensure to seat valves properly. Apply some lapping compound on valve face and work valve on
its seat with a lapping tool.
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
Measure valve seat width, using a caliper.
VALVE SEAT CONTACT WIDTH
NEW
Exhaust
1.25 mm - 1.55 mm
(.049 in - .061 in)
Intake
1.10 mm - 1.30 mm
(.043 in - .051 in)
NEW
Exhaust
Intake
5.994 mm - 6.018 mm
(.236 in - .2369 in)
SERVICE LIMIT
Exhaust
Intake
144
6.060 mm (.2386 in)
SERVICE LIMIT
Exhaust
2 mm (.079 in)
Intake
1.8 mm (.071 in)
If valve seat contact width is too wide or has dark

spots, replace the cylinder head.
smr2009-025
Section 02 ENGINE
INTAKE
55
35
45
35
45
55
R1503motr260A
A. Valve seat outer diameter INTAKE
V01C1HA
VALVE SEAT OUTER DIAMETER
A. Valve face contact width

B. Valve seat contact width
Valve Seat Grinding

NOTE: The valve seats may be reground with
a valve seat grinder which centers on the valve
guide.
1. Grind the valve seat at 45. Remove no more
material than absolutely necessary to clean the
seat up.
2. Using a 35 stone, narrow the valve seat until
the appropriate outer diameter is obtained.
EXHAUST
80
35
A
45
35
45
80
Intake
37.35 mm (1.4705 in)
Exhaust
30.3 mm (1.1929 in)
3. Using a 55 stone for the intake and an 80

stone for the exhaust valve, reduce the valve
seat contact width to the appropriate value
mentioned above.
4. Finally, coat the valve seating surface with a
fine paste of valve grinding compound using a
manual valve grinding mandrel. Lightly grind
the valves until a smooth, even, uniform sealing
surface of the appropriate inside and outside
diameter is obtained on both the valve and
the seat. Use only a hand held valve grinding
mandrel with a suction cup, rotating the valve
back and forth through about 45, and then
advancing the valve 45 before repeating this
operation.
Valve Installation
Install NEW valve stem seal.
R1503motr259A
A. Valve seat outer diameter EXHAUST
smr2009-025
145
Section 02 ENGINE
VALVE GUIDES
Valve Guide Replacement

NOTICE Do not heat cylinder head for this
procedure.
NOTICE The sharp edge near the top of the
valve guide must be machined away. Otherwise it will foul the valve guide hole in the
cylinder head and destroy the cylinder head,
as the valve guide is removed.
Use a special reamer as far as the top of the notch.
R1503motr254A
1. Valve stem seal
Apply engine oil on valve stem and install valve.

NOTICE Be careful when valve stem is
passed through sealing lips of valve stem
seal.
1
2
R1503motr258A
TYPICAL
1. Special reamer
2. Notch
R1503motr254B
Chase valve guide out of the cylinder head towards combustion chamber by using VALVE GUIDE
REMOVER (6 MM) (P/N 529 036 086).
1. Sealing lips of valve stem seal
To ease installation of cotters, apply oil or grease

on them so that they remain in place while releasing the spring.
After springs are installed, ensure valve springs
and valve spring retainer are properly locked by
tapping on valve stem end with a soft hammer so
that valve opens and closes a few times.
NOTICE An improperly locked valve spring
will cause engine damage.
146
smr2009-025
Section 02 ENGINE
A
R1503motr255A
TYPICAL
1. Punch
Check valve guide bore for abreased material.

The inlet and exhaust valve guides have the same
length and are interchangeable.
NOTE: If valve guide has caused scoring during
extraction, replace the cylinder head.
Grease the bore in cylinder head and the leading
end of valve guide with MOLYKOTE G-N (P/N 420
297 433).
R1503motr257A
TYPICAL
A. Protrusion
VALVE GUIDE PROTRUSION

MINIMUM
12.4 mm (.4882 in)
MAXIMUM
12.8 mm (.5039 in)
NOTE: After installing new guides, they must be

reamed with a standard 6 mm reamer tool. These
are available from various tool suppliers.
Clean cylinder head carefully. Check that the valve
seat is concentric with the new guide axis (check
contact surface with engineer's blue).
1
2
R1503motr256A
TYPICAL
1. Valve guide leading end
2. Cylinder head bore
3. Jig
With the VALVE GUIDE PUSHER (6 MM) (P/N 529 036

087), press the valve guide into the COLD cylinder
head as shown.
smr2009-025
147
148
Section 02 ENGINE
Subsection 11 (CYLINDER BLOCK)
CYLINDER BLOCK
SERVICE TOOLS
Description
Part Number
CRANKSHAFT LOCKING TOOL ....................................................

HANDLE ........................................................................................
PISTON CIRCLIP INSTALLER........................................................
STARTER DRIVE SEAL PUSHER...................................................
529
420
529
420
035
877
035
876
821
650
765
502
Page
.................160, 164, 166, 171

......................................... 169
......................................... 157
......................................... 169

Description
Part Number
SNAP-ON PISTON RING COMPRESSOR PLIERS ....................... RC980

SNAP-ON SMALL SLIDE HAMMER ............................................. CJ93B
Page
......................................... 157
......................................... 167
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 170

LOCTITE 5910 ............................................................................... 293 800 081 ......................................... 170
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ......................................... 170
smr2009-026
149
Section 02 ENGINE
Loctite 243
Engine
oil
Isoflex grease
Topas NB 52
9 Nm
(80 lbfin)
23 Nm
(17 lbfft)
21
Loctite 243
Engine
oil
22
Loctite 243
19
20
19
23 Nm
(17 lbfft)
17 Nm
(150 lbfin) 18
Engine
oil
9 Nm
(80 lbfin)
Loctite 243
Engine
oil
16
Loctite 243
17 19 Nm
(168 lbfin)
23 Nm
(17 lbfft)
Loctite
243
23 Nm
(17 lbfft)
Loctite 243
Engine
oil
9 Nm
(80 lbfin)
Loctite 243
7 23 Nm
(17 lbfft)
2
3 40 Nm
+ 55 Nm
(30 lbfft) (41 lbfft)
23 Nm
(17 lbfft)
smr2007-018-001_b
150
smr2009-026
Section 02 ENGINE
Engine oil
10
8
Engine
oil
Engine
oil
4
260 Nm
(191 lbfft)
23
Engine
oil
4
Loctite
anti-seize
Engine
oil
Engine
oil
Engine
oil
12
Engine
oil
Engine
oil
45 Nm
11 (33 lbfft) + 90
13
Engine
oil
6
Engine
oil
5
Engine
oil
15
Engine
oil
Engine
oil
Engine
oil
14
15
smr2009-026-001_a
smr2009-026
151
Section 02 ENGINE
GENERAL
When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.),
it is strongly recommended to note their position
(cylinder 1, 2 or 3) and to keep them as a group.
If you find a defective component, it would be
much easier to find the cause of the failure within
the group of parts. Besides, since used parts
have matched together during the engine operation, they will keep their matched fit when you
reassemble them together within their group.
complete procedure.
WARNING
TROUBLESHOOTING
UNUSUAL ENGINE NOISE OR

VIBRATIONS
1. Heavy wear on plain bearings
- Check radial play of plain bearings.
- Replace plain bearings if out of specification.
2. Crankshaft and balancer shaft are not properly
aligned
- Disassemble cylinder block and check if marks
are properly aligned.
3. Crankshaft or balancer shaft axial play out of

specification
- Measure crankshaft and balancer shaft axial play.
- If axial play is out of specification, replace thrust
washers.
4. Connecting rod axial play out of specification
- Measure connecting rod axial play on crankshaft.
- Replace connecting rod or crankshaft if out of
specification.
5. Connecting rod screws got loose
- Replace damaged components and retighten
screws with the recommended torque.
BLUE SMOKE IN THE EXHAUST

1. Oil scrapper rings worn out
ENGINE SUDDENLY TURNS OFF (POOR

IDLING)
1. Piston rings worn out
2. Piston/cylinder wall clearance out of specification
- Check piston/cylinder wall clearance.
- Replace if out of specification.
3. Melted or broken piston
- Check if oil spray nozzle is not clogged. Refer to
LUBRICATION SYSTEM subsection.
- Replace piston and cylinder block if necessary.
PROCEDURES
TIMING CHAIN
Timing Chain Inspection
Check timing chain on camshaft gear for excessive radial play.
Check chain condition for wear and rollers condition.
R610motr201A
1. Timing chain
If chain is excessively worn or damaged, replace

it as a set (camshaft timing gear and timing chain).
152
smr2009-026
Section 02 ENGINE
Timing Chain Removal
Remove:
Engine oil (refer LUBRICATION SYSTEM subsection)
Engine from vehicle (refer to ENGINE REMOVAL AND INSTALLATION subsection)
Cylinder head (refer to CYLINDER HEAD subsection)
PTO housing (refer to PTO HOUSING AND
MAGNETO subsection)
Crankshaft (refer to CRANKSHAFT in this subsection)
Timing chain.
Timing Chain Installation
R1503motr39A
The installation is essentially the reverse of the removal procedure but, pay attention to the following details.
Ensure to perform proper valve timing. Lock
crankshaft and camshaft at TDC (refer to CYLINDER HEAD subsection for the camshaft locking
procedure).
Install chain, then install chain tensioner.
1. Plug screw
2. Gasket ring
3. Chain tensioner
NOTICE Improper valve timing will damage

engine components.
The installation is essentially the reverse of the removal procedure but, pay attention to the following details.
Torque chain tensioner plug screw to 17 Nm
(150 lbfin).
CHAIN TENSIONER
Chain Tensioner Removal
NOTE: Removal of the intake manifold allows
easier access to the chain tensioner, but is not
necessary. Refer to INTAKE MANIFOLD subsection.
Remove:
Chain tensioner plug screw no. 18 with gasket
ring no. 19
Chain tensioner no. 20.
smr2009-026
Chain Tensioner Inspection

Check chain tensioner for excessive wear or
cracks. Also check free movement of the chain
tensioner piston.
Chain Tensioner Installation
PISTONS AND CONNECTING

RODS
Piston and Connecting Rod Removal
1. Disassemble CYLINDER BLOCK as per procedure in this subsection.
NOTE: It is recommended to measure connecting
rod big end axial play prior to remove connecting
rod. Refer to INSPECTION below.
2. Remove connecting rod cap screws.
153
Section 02 ENGINE
R1503motr27A
R1503motr08A
1. Connecting rod screws
NOTE: Before removing the connecting rod caps,

mark them to remember the right position when
reassembling.
3. Pull piston with connecting rod out of the cylinders.
4. Remove one piston circlip no. 8 and discard it.
1. Piston
2. Piston pin
3. Circlip
6. Detach piston no. 10 from connecting rod no. 5.
Connecting Rod Inspection

Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the worn part.
1
R610motr134A
1. Piston circlip
NOTE: The removal of both piston circlips is not

necessary to remove piston pin.
5. Push piston pin no. 9 out of piston.
R1503motr12A
1. Crankshaft
2. Feeler gauge
CONNECTING ROD BIG END AXIAL PLAY

NEW
0.150 mm - 0.302 mm
(.006 in - .012 in)
SERVICE LIMIT
0.500 mm (.02 in)
Connecting Rod Small End Radial Play

Measure connecting rod small end.
154
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Section 02 ENGINE
R610motr76A
R610motr73A
A. Connecting rod big end bearing
1. Bore gauge
2. Connecting rod
CONNECTING ROD BIG END DIAMETER
CONNECTING ROD SMALL END DIAMETER

NEW
23.01 mm - 23.02 mm
(.9059 in - .9063 in)
SERVICE LIMIT
23.07 mm (.908 in)
If the connecting rod small end diameter is out of

specification, replace small end bearing sleeve.
NOTE: For small end bearing sleeve replacement
contact a machine shop. After installing a NEW
small end bearing sleeve on the connecting rod,
the inner diameter and the oil holes need to be
machined to specification.
Measure piston pins (refer to PISTON PIN INSPECTION in this subsection). Compare to inside
diameter of connecting rod to obtain connecting
rod small end radial play.
45.080 mm (1.775 in)
SERVICE LIMIT
CONNECTING ROD BIG END

RADIAL PLAY
0.09 mm (.0035 in)
SERVICE LIMIT
Use NEW bearings no. 12, when connecting rod

big end diameter is out of specification.
Piston Pin Inspection

Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin. See the following illustration
for the proper measurement position.
CONNECTING ROD SMALL END RADIAL PLAY

SERVICE LIMIT
0.080 mm (.003 in)
Connecting Rod Big End Radial Play

Measure inside diameter of connecting rod big
end. Compare to crankshaft pin.
To measure the connecting rod big end diameter,
use the OLD screws no. 11.
Install the OLD bearings no. 12 as they were
mounted initially.
Do the torque procedure as described below.
smr2009-026
R610motr137A
A. Piston pin diameter in the area of the bushing
155
Section 02 ENGINE
PISTON PIN DIAMETER

NEW
22.996 mm - 23.000 mm
(.905 in - .906 in)
SERVICE LIMIT
22.990 mm (.905 in)
Measure connecting rod small end diameter (refer to CONNECTING RODS INSPECTION above)
to check connecting rod small end radial play.
Piston Inspection
Inspect piston for scoring, cracking or other damages. Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 18 mm
(.709 in) perpendicularly (90) to piston pin axis.
F00B08A
1. Micrometer set to the piston dimension
NOTE: Make sure used piston is not worn.

With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimension and set the indicator to 0 (zero).
2
A
R610motr136A
F00B09A
1. Measuring perpendicularly (90) to piston pin axis

A. 18 mm (.709 in)
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
The measured dimension should be as described

in the subsequent table. If not, replace piston.
PISTON MEASUREMENT
NEW NOMINAL
99.931 mm - 99.949 mm
(3.934 in - 3.935 in)
SERVICE LIMIT
99.90 mm (3.933 in)
Piston/Cylinder Wall Clearance

Adjust and lock a micrometer to the piston dimension.
1
F00B0AA
TYPICAL
1. Indicator set to 0 (zero)
156
smr2009-026
Section 02 ENGINE
NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Position the dial bore gauge 62 mm (2.44 in) above
cylinder base, measuring perpendicularly (90) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
NEW NOMINAL
0.044 mm - 0.076 mm
(.0017 in - .003 in)
SERVICE LIMIT
0.090 mm (.004 in)
R1503motr28A
1. Sleeve with piston circlip inside

2. Assembly jig from piston clip installer
If clearance exceeds specified tolerance, re-hone

cylinder sleeve and replace piston by an oversize
one.
NOTE: It is not necessary to have all pistons
replaced with an oversize if they are not all out of
specification. Mixed standard size and oversize
piston are allowed.
Piston and Connecting Rod Assembly

Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
Use the PISTON CIRCLIP INSTALLER (P/N 529 035
765) to assemble the piston circlip.
R610motr134B
CORRECT POSITION OF THE PISTON CIRCLIP
Piston and Connecting Rod Installation

1. Using a piston ring compressor such as the
SNAP-ON PISTON RING COMPRESSOR PLIERS
(P/N RC980), slide piston into cylinder.
529035765
NOTICE Secure piston pin with new piston

circlips.
NOTE: Take care that the hook of the piston circlip
is positioned properly.
R1503motr29A
NOTICE Install piston with punched arrow toward exhaust side.
smr2009-026
157
Section 02 ENGINE
NOTICE Failure to strictly follow this procedure may cause screw to loosen and lead to
engine damage. Knowing that the screws have
been stretched from the previous installation,
it is very important to use new screws at assembly.
R1503motr30A
1. Arrow toward exhaust side
2. Correctly install bearings and carefully clean

split surface on both sides (cracked area).
3
R1503motr31A
1. Angle torque wrench
PISTON RINGS
Piston Ring Removal
Remove piston as described above.
Remove rings.
Piston Ring Inspection

Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the
piston and the piston rings should be replaced.
R610motr79A
RING/PISTON GROOVE CLEARANCE
1. Half bearing of connecting rod big end

2. Split surface of the connecting rod
3. Protrusion of bearing in line with connecting rod groove
3. Torque NEW connecting rod screws no. 11 as

per following procedure:
3.1 Install screws and torque to 45 Nm
(33 lbfft). Do not apply any threadlocker
product.
3.2 Finish tightening the screws with an additional 90 turn using an angle torque
wrench.
158
NEW
RECTANGULAR
0.025 mm - 0.070 mm
(.001 in - .0028 in)
TAPER-FACE
0.015 mm - 0.060 mm
(.0006 in - .0024 in)
OIL SCRAPER RING
0.020 mm - 0.055 mm
(.0008 in - .0022 in)
SERVICE LIMIT
ALL
0.15 mm (.006 in)
smr2009-026
Section 02 ENGINE
1
2
3
A31C2NA
1. Rectangular ring
2. Taper-face ring
3. Oil scraper ring
R1503motr32A
NOTICE Ensure that top and second rings are

not interchanged.
1. Piston
2. Filler gauge
Ring End Gap

RING END GAP
NEW
RECTANGULAR
TAPER-FACE
0.35 mm - 0.50 mm
(.014 in - .02 in)
NOTE: Use a ring expander to prevent breakage

during installation. The oil ring must be installed
by hand.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120 apart and do
not align the gaps with the piston pin bore or the
thrust side axis.
OIL SCRAPER RING
SERVICE LIMIT
ALL
1.0 mm (.04 in)
Measure position for ring end gap in the area

of 8 mm to 16 mm (.315 in to .63 in) from top of
cylinder.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tolerance.
Piston Ring Installation

Install the oil scraper ring first, then the taper-face
ring with the word TO facing up, then the rectangular ring with the word T facing up.
A31C2OA
1. DO NOT align ring gap with piston trust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120
CRANKSHAFT
Crankshaft Locking Procedure
NOTICE The crankshaft must be locked at
TDC for removal and installation of crankshaft,
balancer shaft and camshaft.
NOTE: When the crankshaft is locked, the piston
of cylinder no. 3 is at ignition TDC.
smr2009-026
159
Section 02 ENGINE
Remove:
Intake manifold (refer to INTAKE MANIFOLD
subsection)
Spark plugs
Cylinder head cover (refer to CYLINDER HEAD
subsection
Crankshaft access plug screw.
smr2009-026-004_a
1. Position lines
Use a small screwdriver to check if the groove in

the crankshaft is aligned with the hole.
In this position, lock the crankshaft using the
CRANKSHAFT LOCKING TOOL (P/N 529 035 821).
smr2009-026-002_a
1. Crankshaft access plug screw

2. Gasket ring
529035821
Turn engine counterclockwise.

Bring piston of cylinder no. 3 to ignition TDC, using a dial gauge or another similarly suitable tool.
NOTICE Do not scratch or damage piston and
cylinder surface.
smr2009-026-003_a
Crankshaft Removal
1. Drain engine oil (refer to LUBRICATION SYSTEM subsection).
2. Remove engine from vehicle (refer to ENGINE
REMOVAL/INSTALLATION subsection).
3. Remove cylinder head (refer to CYLINDER
HEAD subsection).
4. Remove PTO housing (refer to PTO HOUSING
AND MAGNETO subsection).
5. Remove starter gear (refer to PTO HOUSING
6. Remove starter drive.
7. Remove oil suction pump (refer to LUBRICATION SYSTEM subsection).
8. Remove engine mounting brackets.
9. Remove oil reservoir plug screws no. 1 with
O-ring no. 2.
1. Dial gauge
NOTE: When the piston of cylinder no. 3 is at ignition TDC, the position lines on oil separator cover
must be lined up as shown in the following illustration.
160
smr2009-026
Section 02 ENGINE
NOTE: Before removing the connecting rod caps,

mark them to remember the right position when
reassembling. It is recommended to measure
connecting rod big end axial play prior to remove connecting rod. Refer to PISTONS AND
CONNECTING RODS in this subsection for the
procedure.
R1503motr05A
ENGINE UPSIDE DOWN

1. Oil reservoir plug screw with O-ring
10. Remove cylinder block screws no. 3 and no. 7.
R1503motr07A
1. Mark on connecting rod
13. Remove thrust washers no. 4.
R1503motr109A
BOTTOM VIEW OF ENGINE

1. Screws
11. Remove cylinder block lower half.

12. Remove connecting rod screws.
R1503motr09A
1. Thrust washer
14. Remove crankshaft no. 5.
R1503motr08A
1. Connecting rod screws
smr2009-026
161
Section 02 ENGINE
R1503motr13A
R1503motr10A
1. Micrometer
2. Crankshaft area for bearing
1. Crankshaft
Crankshaft Inspection
Crankshaft Gear Inspection
Replace crankshaft if the gears are worn or otherwise damaged.
2
CRANKSHAFT JOURNAL DIAMETER

NEW
49.991 mm - 50.01 mm
(1.9681 in - 1.9689 in)
SERVICE LIMIT
49.95 mm (1.9665 in)
CRANKSHAFT JOURNAL RADIAL CLEARANCE

0.07 mm (.0028 in)
SERVICE LIMIT
Crankshaft Pin
Measure all crankshaft pin diameters. Compare to
inside diameter of connecting rod bearings (elsewhere in this subsection).
1
1
R1503motr11A
1. Balancer gear
2. Crankshaft timing gear
Crankshaft Radial Play

Measure all crankshaft journals. Compare to inside diameter of crankshaft bearings (elsewhere
in this subsection).
R1503motr14A
1. Micrometer
2. Crankshaft pin area for bearing
CRANKSHAFT PIN DIAMETER
162
NEW
45.032 mm - 45.048 mm
(1.7729 in - 1.7735 in)
SERVICE LIMIT
45.029 mm (1.7728 in)
smr2009-026
Section 02 ENGINE
CRANKSHAFT PIN RADIAL CLEARANCE

SERVICE LIMIT
0.09 mm (.0035 in)
Crankshaft Axial Clearance

When assembling the cylinder-block, measure the
crankshaft axial clearance.
1
R1503motr17A
1. Mark on balancer shaft

2. Mark on crankshaft
For correct installation of the connecting rods, refer to PISTONS AND CONNECTING RODS in this
subsection.
2
R1503motr41A
1. Dial gauge
2. Crankshaft
CRANKSHAFT AXIAL CLEARANCE

NEW
0.08 mm - 0.22 mm
(.003 in - .009 in)
SERVICE LIMIT
0.35 mm (.014 in)
NOTICE It is absolutely necessary to follow

this procedure. Otherwise severe engine damage can occur.
Insert thrust washers no. 4 as soon as crankshaft
is in place as per following illustration.
NOTICE Never forget thrust washers on center of crankshaft to control axial adjustment.
Crankshaft Installation
NOTE: Before installing the crankshaft, make
sure that the timing chain is on the crankshaft
and the chain guide has been installed first. Those
parts cannot be installed when the crankshaft is
in place.
NOTICE Crankshaft and balancer shaft marks

have to be aligned.
R1503motr09A
THRUST WASHER INSERT DIRECTION

1. Thrust washer
NOTICE Thrust washers have to be flush with

the cylinder block sealing surface.
smr2009-026
163
Section 02 ENGINE
R1503motr16A
R1503motr18A
1. Thrust washer
2. Sealing surface
1. Crankshaft locking tool
Install cylinder block lower half. Refer to CYLINDER BLOCK in this subsection.
Install the crankshaft cover before mounting the
engine bracket. Apply engine oil on O-ring and
press cover in. Crankshaft cover has to be flush
with cylinder block surface.
1
R1503motr19A
BALANCER SHAFT
Balancer Shaft Removal
1. Drain engine oil (refer to LUBRICATION SYSTEM subsection).
2. Remove engine from vehicle (refer to ENGINE
REMOVAL AND INSTALLATION subsection).
3. Remove cylinder head (refer to CYLINDER
HEAD subsection).
4. Remove PTO housing (refer to PTO HOUSING
5. Remove starter gear (refer to PTO HOUSING
6. Remove starter drive.
7. Remove oil suction pump (refer to LUBRICATION SYSTEM subsection).
8. Remove engine mounting brackets.
9. Remove oil reservoir plug screws no. 1 with
O-ring no. 2.
1. O-ring
2. Crankshaft cover
Install the CRANKSHAFT LOCKING TOOL (P/N 529

035 821) right away to position crankshaft at TDC
before installing the camshaft and the rocker arms
(refer to CYLINDER HEAD subsection).
R1503motr05A
529035821
ENGINE UPSIDE DOWN

1. Oil reservoir plug screw with O-ring
10. Remove cylinder block screws no. 3.

164
smr2009-026
Section 02 ENGINE
R1503motr109A
1. Screws
R1503motr23A
11. Remove cylinder block lower half.

12. Remove thrust washers no. 6.
1. Micrometer
2. Balancer shaft area for bearing
BALANCER SHAFT SEAT DIAMETER
NEW
31.984 mm - 32.000 mm
(1.2592 in - 1.2598 in)
SERVICE LIMIT
31.960 mm (1.2583 in)
BALANCER SHAFT SEAT RADIAL CLEARANCE

SERVICE LIMIT
0.07 mm (.0028 in)
Balancer Shaft Axial Clearance

When assembling the cylinder-block, measure the
balance shaft axial play.
1
R1503motr20A
1. Thrust washer
13. Remove balancer shaft.
Balancer Shaft Inspection

Check balancer shaft and replace if damaged.
If the gear on the balancer shaft is damaged, replace balancer shaft.
Check gear on the crankshaft at the same time
and replace crankshaft if necessary (refer to
CRANKSHAFT above).
Balancer Shaft Bearing Seat Play
Measure all balancer shaft bearing seats. Compare to inside diameter of balancer shaft bearings
(elsewhere in this subsection).
smr2009-026
R1503motr42A
1. Dial gauge
2. Balancer shaft
BALANCER SHAFT AXIAL CLEARANCE

NEW
0.02 mm - 0.25 mm
(.001 in - .01 in)
SERVICE LIMIT
0.35 mm (.014 in)
165
Section 02 ENGINE
Balancer Shaft Installation

NOTICE Balancer shaft and crankshaft marks
have to be aligned.
R1503motr22A
1. Thrust washer
2. Sealing surface
Install cylinder block lower half. Refer to CYLIN-
DER BLOCK in this subsection.

R1503motr17A

1. Mark on balancer shaft

2. Mark on crankshaft
NOTICE Never forget thrust washers no. 6 on

PTO side to control axial adjustment on balancer.
Insert thrust washers as soon as balancer shaft is

in place as per following illustration.
1
R1503motr19A
1. O-ring
2. Crankshaft cover
R1503motr20B
THRUST WASHER INSERT DIRECTION

1. Thrust washer

NOTICE Thrust washers have to be flush with

the cylinder block sealing surface.
529035821
166
smr2009-026
Section 02 ENGINE
R1503motr18A
CYLINDER BLOCK
Cylinder Block Disassembly
Remove:
Engine oil (refer to LUBRICATION SYSTEM
subsection)
Engine from vehicle (refer to ENGINE REMOVAL AND INSTALLATION subsection)
Cylinder head (refer to CYLINDER HEAD subsection)
PTO housing (refer to PTO HOUSING AND
MAGNETO subsection)
Starter gear and starter drive (refer to PTO
HOUSING AND MAGNETO subsection)
Oil suction pump (refer to LUBRICATION SYSTEM subsection)
Balancer shaft (refer to BALANCER SHAFT
elsewhere in this subsection)
Crankshaft (refer to CRANKSHAFT elsewhere
in this subsection)
Piston with connecting rod (refer to PISTONS
AND CONNECTING RODS elsewhere in this
subsection).
Bearings
When bearings need to be removed from the
cylinder block, mark them to identify the correct
position at installation. See the following illustration for an example:
R1503motr37A
1. Mark on balancer shaft bearings

2. Mark on crankshaft bearings
Starter Drive Bearing

Check bearing no. 21 of starter drive assembly
no. 22 in cylinder block and replace it if damaged.
R1503motr40A
TYPICAL
1. Bearing of starter drive assembly
Starter drive bearing can be easily removed from

crankcase lower half using the a small slide hammer such as the SNAP-ON SMALL SLIDE HAMMER
(P/N CJ93B).
F01J0ZA
smr2009-026
167
Section 02 ENGINE
Close puller claws so that they can be inserted

in end bearing. Holding claws, turn puller shaft
clockwise so that claws open and become firmly
tight against bearing.
Slide puller hammer outwards and tap puller end.
Retighten claws as necessary to always maintain
them tight against bearing. Continue this way until bearing completely comes out.
Cylinder Out of Round

Measure cylinder diameter in piston axis direction
from top of cylinder. Take an other measurement
90 from first one and compare.
NOTE: Take the same measuring points as described in CYLINDER TAPER above.
Cylinder Block Inspection

Cylinder
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, replace cylinder.
Cylinder Taper
Measure cylinder bore and if it is out of specifications, re-hone cylinder sleeve and replace piston
with first oversize.
NOTE: It is not necessary to have all cylinders
re-honed if they are not all out of specification.
Mixed standard size and oversize cylinders are
allowed.
Measure cylinder bore at 3 recommended positions. See the following illustration.
A
B
R1503motr25A
A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis
CYLINDER OUT OF ROUND

NEW MAXIMUM
0.008 mm (.0003 in)
SERVICE LIMIT
0.015 mm (.0006 in)
2
A
1
Bearings
To measure the wear of the crankshaft bearings
no. 13 and no. 14 and balancer shaft bearings
no. 15, both cylinder block halves with OLD
bearings have to be screwed together as per
tightening procedure described below.
Measure the inside diameter of the bearings with
a bore gauge.
R1503motr24A
1.
2.
3.
A.
B.
First measuring diameter

Second measuring diameter
Third measuring diameter
60 mm (2.362 in)
110 mm (4.331 in)
CYLINDER TAPER IN DIAMETER

NEW MAXIMUM
0.038 mm (.001 in)
SERVICE LIMIT
0.090 mm (.004 in)
Distance between measurements should not exceed the service limit mentioned above.
R1503motr33A
ENGINE UPSIDE DOWN

1. Bore gauge
168
smr2009-026
Section 02 ENGINE
CRANKSHAFT BEARING INSIDE DIAMETER

50.1 mm (1.9724 in)
SERVICE LIMIT
Correctly install bearings. Top crankshaft bearing

halves have a bore which has to be placed in the
upper cylinder block.
2
3
R1503motr35A
R1503motr34A
1. Cylinder block upper half

2. Oil bore in cylinder block
3. Oil bore in bearing
ENGINE UPSIDE DOWN

1. Bore gauge
BALANCER SHAFT BEARING INSIDE DIAMETER

SERVICE LIMIT
32.11 mm (1.2642 in)
Bearings have to be flush with the cylinder block

split surface and their protrusions have to fit in the
notched areas in the cylinder block seat.
Replace bearings if they are out of specifications.
Cylinder Block Assembly

For assembly, reverse the disassembly procedure. Pay attention to the following details.
Torque Banjo screw to 19 Nm (168 lbfin).
To install starter drive bearing no. 21 of starter
drive assembly, use the STARTER DRIVE SEAL
PUSHER (P/N 420 876 502) and the HANDLE (P/N 420
877 650).
R1503motr36A
420876502
1. Bearing protrusion in cylinder block notch
420877650
Use NEW bearings when diameters are out of

specification.
If OLD bearings can be used again, make sure
they are at the same position as they were before.
smr2009-026
Apply engine oil on all bearings, in the bottom area

of the cylinder bore and also on the band of the
piston ring compressor tool.
For proper installation of pistons, refer to PISTONS AND CONNECTING RODS in this subsection.
NOTE: Before installing the crankshaft, make
sure that the timing chain is on the crankshaft
and the chain guide has been installed first. Those
parts cannot be installed after as the crankshaft
is in place.
169
Section 02 ENGINE
Clean oil passages and make sure they are not

clogged.
Clean all metal components in a solvent.
Cylinder block mating surfaces are best cleaned
using a combination of the LOCTITE CHISEL (GASKET REMOVER) (P/N 413 708 500) and a brass brush.
Brush a first pass in one direction then make the final brushing perpendicularly (90) to the first pass
(cross hatch).
NOTICE Do not wipe with rags. Use a new
clean hand towel only.
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is
suggested to have all you need on hand to save
time.
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform application without lumps. If you do not use the roller
method, you may use your finger to uniformly distribute this sealant.
Apply LOCTITE 5910 (P/N 293 800 081) on mating
surfaces.
NOTICE Do not use other products to seal
crankcase. Do not use an activator with the
Loctite 5910. Using other products or non silicone-based sealant over a previously sealed
crankcase with Loctite 5910 will lead to poor
adhesion and possibly a leaking crankcase.
F12R17A
Do not apply in excess as it will spread out inside

crankcase.
Tighten cylinder block screws as per following procedure:
screw threads.
Torque cylinder block screws no. 3 to 40 Nm
(30 lbfft) following sequence 1 to 8 and then to
55 Nm (41 lbfft) (repeat sequence).
Torque cylinder block screws no. 7 to 23 Nm
(17 lbfft) following sequence 9 to 23.
6
16 15
23
14 4 9 2 10
11 12 13
NOTE: Refer to the product label for the sealant

curing time. Respect the manufacturer's recommendations prior to start engine.
Use a plexiglass plate and apply some sealant
on it. Use a soft rubber roller of 50 mm - 75 mm
(2 in - 3 in) available in arts products suppliers for
printmaking, roll the sealant to get a thin uniform
coat on the plate (spread as necessary). When
ready, apply the sealant on crankcase mating
surfaces.
22 3 21
17
18 1 19
20
R1503motr06B
NOTE: Before continuing the assembly process,

the axial clearance of balancer shaft and crankshaft has to be checked. Refer to CRANKSHAFT
and BALANCER SHAFT in this subsection for the
procedure.
170
smr2009-026
Section 02 ENGINE

1
R1503motr19A
1. O-ring
2. Crankshaft cover

529035821
R1503motr18A
Install cylinder head, PTO housing and the other

parts in accordance with the proper assembly procedures.
smr2009-026
171
172
Section 03 ELECTRONIC MANAGEMENT SYSTEMS

Subsection 01 (ENGINE MANAGEMENT SYSTEM)
ENGINE MANAGEMENT SYSTEM

FRONT
MAPS
KS
ETA
OPS
CTS
TOPS
CPS
CAPS
MATS
ECM
INJECTOR 1, 2, 3
IGNITION COIL 1, 2, 3
EGTS
A
B
CAPS
CPS
CTS
ECM
EGTS
Engine Wiring Harness Connector

Vehicule Wiring Harness Connector
Camshaft Position Sensor
Crankshaft Position Sensor
Coolant Temperature Sensor
Engine Control Module
Exhaust Gas Temperature Sensor
KS
OPS
MAPS
MATS
ETA
TLS
TOPS
Knock Sensor
Oil Pressure Sensor
Manifold Absolute Pressure Sensor
Manifold Air Temperature Sensor
Electric Throttle Actuator
Throttle Lever Sensor
Tip-Over Protection System
IN
ECM
OUT
ECM
smr2009-027-002_en
smr2009-027
173

1503 4-TEC CONTROL SYSTEM

INPUTS
OUTPUTS
Relay
Throttle accelerator sensor (TAS)
Fuel pump
Throttle position sensor (TPS)

Crankshaft position (CPS)
Camshaft position (CAPS)
Starter solenoid
ENGINE CONTROL
MODULE (ECM)
Ignition coil (3)
Coolant temperature (CTS)
Fuel injector (3)
Manifold absolute pressure (MAPS)
Electric throttle
actuator (ETA)
Manifold air temperature (MATS)

Exhaust gas temperature (EGTS)
Controller area
network (CAN)
Oil pressure (OPS)

Knock sensor (KS)
Battery voltage (BV)
Digitally Encoded
Security System (D.E.S.S.)
Start/Stop switch
Tip-over protection system (T.O.P.S.)
Off-throttle assisted steering (O.T.A.S.)
Controller area network (CAN)
smr2009-027-003_en
174
smr2009-027

GENERAL
SYSTEM DESCRIPTION
There are 7 main systems in interaction with the
engine management system:
1. Electronic fuel injection
2. D.E.S.S. system
3. Ignition system
4. Starting system
5. O.T.A.S. (Off-Throttle Assisted Steering)
6. Lubrication system (T.O.P.S. (Tip-Over Protection System))
7. iControl system
Engine Control Module (ECM)
smr2009-027-005
ECM
The ECM controls the electrical system and the

engine management functions, by processing the
information given by various sensors.
It also exchange information with the other electronic systems through the CAN bus (information
center and iControl System.
The ECM is mounted on the intake manifold.
Engine RPM Limiter

The ECM will limit the maximum engine speed.
The ECM monitors engine RPM through the CPS
and it changes the fuel injection and ignition as
necessary.
Engine Speed Control
The ECM controls the engine idle RPM. It increases and reduces the engine speed by using
the throttle actuator. The throttle actuator allows
many functions for the iControl system.
Drowned Mode
If engine is fuel-flooded or water-flooded and does
not start, this special mode can be activated to
prevent fuel injection and ignition while cranking
in order to ventilate the engine to dry the cylinder
walls.
NOTE: This mode can also be used if engine is
water-flooded.
Proceed as follows to activate it.
With safety lanyard on its post while engine is
stopped, press and HOLD throttle lever.
Press the START/STOP button. The mode is now
on.
Releasing throttle lever will bring back to its normal mode.
If engine does not start, it may be necessary to
remove spark plugs and crank engine with rags
over spark plug holes. Refer to IGNITION SYSTEM subsection.
Monitoring System
The ECM monitors the electronic components of
the fuel injection system, the iControl system, the
information center (gauge) and also some components of the electrical system.
For more information, refer to MONITORING SYS-
TEM AND FAULT CODES.

Limp Home Mode
The ECM may automatically use default parameters for the engine management to ensure the adequate operation of the watercraft if a component
of the fuel injection system or iBR is not operating properly. For more information, refer to MONITORING SYSTEM AND FAULT CODES.
smr2009-027-006_a
1. ECM on intake manifold
smr2009-027
Diagnostic Mode
The ECM features a self-diagnostic mode when
pressing the START button. However, some components need the engine to be running so that
they can be monitored. Some problems will turn
on a warning lamp or beeper, or will set the engine
175

in limp home mode. Refer to MONITORING SYSTEM AND FAULT CODES subsection for more information.
176
smr2009-027

Subsection 02 (iCONTROL SYSTEM)
iCONTROL SYSTEM
GENERAL
The iControl (intelligent Control) system consist of
the following systems:
Intelligent Throttle Control (iTC)
Intelligent Brake and Reverse (iBR)
Intelligent Suspension (iS).
The gauge is used with the iControl system to navigate through and select several functions, modes
of operation and change certain settings and system parameters using the appropriate handlebar
control s.
iTC (INTELLIGENT THROTTLE

CONTROL)
The iTC is an electronic throttle control system
that includes a cableless throttle control located
on the RH side of handlebar and an electric throttle actuator (ETA) located on the throttle body.
For a comprehensive and complete description of
this system, refer to its subsection in the FUEL
SYSTEM section.
sdd2009-001-031_a
1. Throttle lever
2. Throttle accelerator sensor (TAS)
smo2009-002-119
INFORMATION CENTER (GAUGE)
3 6 7
8 2
smo2009-002-200_c
HANDLEBAR CONTROL S
1. Handlebar
2. Throttle lever
3. iBR lever
4. Cruise
5. Engine START/STOP button
6. VTS s (Variable Trim System)
7. iS s
8. Information center (gauge) control s

the information center, refer to GAUGE subsection in the ELECTRICAL SYSTEM section.
smr2009-047
sdd2009-001-030_b
1. Throttle body
2. Throttle actuator (inside)
iBR (INTELLIGENT BRAKE AND

REVERSE)
The iBR is a brake and reverse system that is used
to avoid obstacles, gradually slow down or stop
the watercraft by lowering the iBR gate that reverts the water flow at the outlet of the jet pump
nozzle.
177

Subsection 02 (iCONTROL SYSTEM)

this system, refer to IBR and VTS subsection in
the PROPULSION section.
iS (INTELLIGENT SUSPENSION)
The intelligent suspension is a mechanical system
of one spring and one shock absorber installed in
the lower fixed deck connecting to the upper moving deck to isolate the riders from the rough water.
this system, refer to its subsection in the BODY
and HULL section.
178
smr2009-047

Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE)
COMMUNICATION TOOLS AND

B.U.D.S. SOFTWARE
SERVICE TOOLS
Description
Part Number
Page
MPI-2 DIAGNOSTIC CABLE.......................................................... 710 000 851 ......................................... 182

MPI-2 INTERFACE CARD .............................................................. 529 036 018 ......................................... 182

Description
Part Number
MALE-FEMALE EXTENSION SERIAL CABLE............................... DB9
Page
......................................... 182
GENERAL
Refer to PROCEDURES for instructions on the
communication tools.
If communication problems occurs, refer to
TROUBLESHOOTING.
NOTE: Never use the D.E.S.S. POST INTERFACE.
vdd2006-001-151_b
Prerequisite for USB communication:

PC Computer turned on.
MPI-2 connected to PC computer.
USB LIGHT
STATUS
529036019_a
TROUBLESHOOTING
DIAGNOSTIC TIPS
IMPORTANT: Make sure all connections have
been made before starting B.U.D.S. to allow
proper operation.
MPI-2 Connection Troubleshooting
WHAT TO DO
Light is
OFF
Check USB connection between

MPI-2 and PC computer.
Check USB operation on PC computer
(hardware or Windows drivers).
Light is
GREEN
Connections are GOOD. Communication

can take place on USB side.
Prerequisite for CAN communication:

MPI-2 connected to diagnostic connector of vehicle.
ECM turned on (press the START button).
D.E.S.S. key installed on D.E.S.S. post of vehicle.
B.U.D.S. started and logged.
MPI-2 Status Lights

The MPI-2 includes 2 status lights to show the
connection conditions: USB and CAN. Both lights
must be GREEN so that MPI-2 works properly.
Otherwise, refer to the following charts.
smr2009-028
179

CAN LIGHT
STATUS
WHAT TO DO
Light is
OFF
Check connection between MPI-2 and

diagnostic connector of vehicle.
Light is
RED
Check CAN wires/connectors on vehicle.
Light is
GREEN
Connections are GOOD. Communication

can take place on CAN side.
Communication Problems with

B.U.D.S.
Missing Module
If an X is shown in the status bar, it means that
no "ECU" is communicating with the MPI.
Message Box: "No Vehicle Detected..."

If the following message box is displayed in
B.U.D.S.:
smr2008-020-003
1. Ensure both USB and CAN lights of MPI-2 are

GREEN. Refer to MPI-2 CONNECTION TROUBLESHOOTING subsection.
2. Check MPI-2 protocol. It must be set to
Kw2000 (500K).
mmr2009-020-001
Check the following:

MPI protocol in B.U.D.S.
Connections between the PC computer and the
vehicle.
If one or more ECU is (are) not communicating
with the MPI a module may not be powered or is
defective.
Check to find which module is missing in B.U.D.S.
The tab of the missing module will not be visible
at the bottom of B.U.D.S. screen.
rmr2008-020-003_en
Ensure the status bar shows the Kw2000 500K

and the number 4 to its right. Otherwise, refer
to MPI-2 CONNECTION TROUBLESHOOTING in
this subsection.
rmr2008-058-100
CONNECTION SUCCESSFUL
smr2009-028-001_a
1. iS tab not visible meaning this "ECU" is not communicating
Number 4 means that 4 ECUs are connected:

ECM
Information center
iBR
iS.
If a module is missing, check wiring and power

supply to that module.
180
smr2009-028

Message Box: "Some of the Information

Normally Displayed..."
B.U.D.S.:
NOTE: Never use the D.E.S.S. POST INTERFACE.
smr2009-028-016
1. Click on the OK button in B.U.D.S.

2. Remove and reinstall the D.E.S.S. key to make
a good contact with its post.
3. Briefly press the vehicle START button to activate the ECM. Do not hold START button to
avoid engine starting.
4. Click on the Read button in B.U.D.S.
529036019_a
Connections with Vehicle

Open the aft re-boarding platform.
Message Box: "Engine must be Stopped..."

B.U.D.S.:
smr2009-028-015
ssi2009-002-002_a
1. Click on the Cancel button in B.U.D.S.

2. Briefly press the vehicle START button to activate the ECM. Do not hold START button to
avoid engine starting.
3. Click on the Write button in B.U.D.S.
If message reappears, do the following:
1. Click on the Cancel button in B.U.D.S.
2. Remove the D.E.S.S. key.
3. Press the vehicle START button to activate the
ECM.
4. Reinstall the D.E.S.S. key and make sure it has
a proper contact with its post.
5. Click on the Write button in B.U.D.S.
1. Re-boarding platform
PROCEDURES
1. Starboard storage bin
Remove the starboard storage bin.
ssi2009-002-003_a
MPI-2
Disconnect the 6-pin diagnostic connector.
The MPI-2 (Multi-Purpose Interface-2) in conjunction with the MPI-2 diagnostic cable is used with
B.U.D.S. software to communicate with the ECM
(engine control module) and other modules.
smr2009-028
181

ssi2009-002-004_a
1. Diagnostic connector
Connect the MPI-2 DIAGNOSTIC CABLE (P/N 710

000 851) to vehicle connector.
529036018
NOTE: An optional MALE-FEMALE EXTENSION SERIAL CABLE (P/N DB9) available at electronic retail
outlets can be used between diagnostic cable and
MPI-2 interface. Do not exceed 7.6 m (25 ft).
710000851
529035697
OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE
Connect the MPI-2 INTERFACE CARD (P/N 529 036

018) to the USB port of a PC (personal computer).
smr2009-028-004_a
1. Diagnostic cable connected to vehicle
Connect the other end of diagnostic cable to the

MPI-2 INTERFACE CARD (P/N 529 036 018).
vdd2006-001-151
182
smr2009-028

Reading Data in ECM

Read ECM by clicking the Read Data button.
vmr2006-012-100_aen
mmr2006-079-200
MPI-2 INTERFACE CARD CONNECTED TO USB PORT
B.U.D.S. is now ready to use.
CAUTION If the computer you are using is

connected to the power outlet, there is a potential risk of electric shock when working in contact with water. Be careful not to touch water
while working with the computer.
Use B.U.D.S. software as described further in
B.U.D.S. SOFTWARE.
Electronic Modules ("ECU") Update

NOTICE Failure to strictly follow a procedure
to update a module may permanently damage
the module.
Whenever B.U.D.S. is started, check if there is an
update icon in B.U.D.S. status bar.
B.U.D.S. SOFTWARE
B.U.D.S. (Bombardier Utility and Diagnostic Software) is designed to program key(s), to allow
electrical component inspection, to diagnose and
monitor components and to carry out settings
such as the closed throttle.
For more information pertaining to the use of the
B.U.D.S. software, use its help which contains detailed information on its functions.
Ensure to use the latest B.U.D.S. version available
on BOSSWeb.
How to Start B.U.D.S.

IMPORTANT: Ensure all connections have been
made before starting B.U.D.S. to allow proper
operation. Refer to MPI-2 in this subsection.
Press the START button to power the ECM.
Connect D.E.S.S. key to vehicle D.E.S.S. post.
Start B.U.D.S. and logon.
IMPORTANT
When engine is not started, approximately 3 minutes
after pressing the START button, the ECM will stop
communicating with B.U.D.S. Therefore, operations
with B.U.D.S. will be interrupted.
mmr2009-069-001_a
TYPICAL
The icon indicates that a file is available in B.U.D.S.

to update any of the following electronic modules:
ECM
Information center (cluster)
iBR
iS.
Use the Module menu and check all modules one
at a time.
To initiate back the communication, briefly press the

START button. Do not hold START button to avoid
engine starting if engine starting is not desired.
smr2009-028
183

NOTE: When selecting the update menu in

B.U.D.S., a dialog box will appear and the update
file description may give some clue to find the
vehicle-related information in BOSSWeb.
smr2009-028-003
1. If the Update option is greyed out, no update

file is available for this module.
2. If the Update option is black, an update file is
available for this module.
mbg2008-022-100_a
TYPICAL
1. File description
Writing Data in ECM

When finished with B.U.D.S., save new data in
ECM as follows:
Click the Write Data button.
smr2009-028-002
1. Greyed out: No update to perform

Black: Update file available
Before applying an update, log in BOSSWeb and

look in Service for the Unit history to find out if
any information or publication related to the vehicle is available. If so, carefully follow the given instructions.
vmr2006-012-100_ben

B.U.D.S., briefly press the START button. Do
not hold START button to avoid engine starting.
mmr2009-118-011
SERVICE, UNIT HISTORY
smr2009-028-015
Click again the Write Data button.
184
smr2009-028

NOTE: If there is still a communication problem,

refer to COMMUNICATION PROBLEMS WITH
B.U.D.S. in this subsection.
After the write operation, remove D.E.S.S. key
from watercraft D.E.S.S. post to complete the
operation.
Disconnect MPI connections and reconnect vehicle harness in protective cap.
ssi2009-002-004_a
1. Diagnostic connector in its cap
NOTICE Failure to secure the 6-pin connector

in its protective cap would allow corrosion and
damage to the terminals.
NOTE: There is a 120 resistor in protective cap
to minimize the possibility of communication error.
smr2009-028
185
186

Subsection 04 (MONITORING SYSTEM AND FAULT CODES)
MONITORING SYSTEM AND FAULT

CODES
GENERAL
MONITORING SYSTEM
A system monitors the electronic components of
the EMS (engine management system), iBR, information center, iS and other components of the
electrical system to ascertain they are not faulty
or defective. This system comes active when the
START button is pressed.
NOTE: Some components need the engine to be
running so that they can be monitored (fuel injectors for example).
The following components or functions are monitored.
EMS MONITORING
INFORMATION CENTER MONITORING

Information center
VTS and iS switch
MODE and SET switch
Cruise switch
CAN
GPS
Fuel level sensor
Depth sounder
ECM
iBR module
iS module
Battery voltage
iS MONITORING
EMS sensors (TAS, TPS, CPS, CAPS, MAPS,

MATS, CTS, OPS, EGTS, TOPS, knock sensor).
Throttle actuator, ignition coils and fuel injectors
iS module and motor
ECM
Suspension position
Engine RPM
CAN
CAN
TOPS
D.E.S.S. system
Information center
START switch and starter solenoid
iBR module
Fuel pump
O.T.A.S.
Information center
iBR module
iBR MONITORING
iBR module and motor
BRLS
Engine RPM
Vehicle speed
iBR gate position
CAN
Lake temperature sensor
Information center
ECM
smr2009-029
Vehicle speed
When a malfunction is currently detected, the related electronic module:

Sets an active fault code.
Adapts the proper protection strategy according to the failure.
Sends out warning signals to the information
center/beeper codes to inform the rider of a particular condition.
When a minor or transient fault occurs, the fault
message and beeper will cease automatically if
the condition that caused the fault does not exist
anymore.
If a minor fault is active, engine will operate without noticeable loss of performance.
Releasing the throttle and letting the engine return
to idle speed may allow normal operation to come
back. If this does not work, try the following:
Remove D.E.S.S. key.
Wait 3 minutes so that ECM shuts down.
187

Start engine.
Check if fault code disappeared.
The electronic system will react differently depending on the fault type. In severe failure, the
engine may not be allowed to be started. In other
cases, the engine will operate in limp home mode
(reduced speed).
Limp Home Mode

When a major component of the EMS or the iBR
is not operating properly the limp home mode will
be set. Engine speed will be limited and therefore
vehicle speed. This mode allows the rider to go
back home which would not be otherwise possible without this advanced system. LIMP HOME
MODE will be displayed in the information center.
The performance-reduced modes or safety-related modes allow the rider to go back home
which would not be otherwise possible without
this advanced system.
Major Fault and Vehicle Reaction

The following EMS conditions will trigger a limp
home mode.
188
ENGINE PROBLEM
MAX ALLOWED
RPM
High engine temperature

(from 110C (230F))
3000
High exhaust temperature

(from 110C (230F))
3000
Low oil pressure

(below 180 - 220 kPa
(26 - 32 PSI))
2500
The following conditions will trigger a limp home

mode.
iBR PROBLEM
Any active fault code
related to the iBR that
prevents its proper
operation
SYSTEM BEHAVIOR
iBR gate will be moved
and locked in forward
position (if possible)
Engine will be set in limp
home mode (reduced
speed)
The following conditions will stop the suspension.

iS PROBLEM
Any active fault code
related to the iS that
prevents its proper
operation
SYSTEM BEHAVIOR
Suspension operation
will be disabled.
It will remain at the
position it was when the
fault code was set.
Indicator Lights and Message Display

Information
Indicator lights (pilot lamps), located in the
speedometer and tachometer indicator, inform
the rider of a selected function, a normal condition, a system anomaly, or a serious malfunction.
smr2009-029

PILOT LAMPS
(ON)
MESSAGE DISPLAY
DESCRIPTION
MAINTENANCE REMINDER
Maintenance required
LOW or HIGH BATTERY

VOLTAGE
Low/high battery voltage
LOW-FUEL
Low fuel level, approx. 25% tank capacity, 14 L

(3.7 U.S. gal.) or fuel level sensor disconnected
HIGH TEMPERATURE
Engine or exhaust system overheating
CHECK ENGINE or LIMP

HOME MODE
Check engine (minor fault req. maint.) or

LIMP HOME MODE (major eng. fault)
LOW OIL PRESSURE
Low oil pressure
CRUISE mode or SLOW SPEED MODE engaged
iBR system fault
O.T.A.S. system fault
Good GPS uplink
An indicator light may be accompanied by a scrolling message in the multifunction display.

MESSAGE DISPLAY INFORMATION
RIGHT KEYPAD ERROR
Gauge control button malfunction
LOW OIL PRESSURE
Engine low oil pressure detected
HIGH EXHAUST TEMPERATURE
High exhaust temperature detected
HIGH TEMPERATURE
High engine temperature detected
CHECK ENGINE
Engine management system malfunction or

maintenance required
HIGH BATTERY VOLTAGE
High battery voltage detected
LOW BATTERY VOLTAGE
Low battery voltage detected
LIMP HOME MODE
Major fault detected, engine power limited
FUEL SENSOR DEFECTIVE
Fuel level sensor fault
WATER TEMP SENSOR DEFECTIVE
Problem in iBR, not sending water temperature info
CALIBRATION CHECKSUM ERROR
Information center programming corrupted
MAINTENANCE REQUIRED
Watercraft maintenance required
SUPERCHARGER MAINTENANCE REQUIRED
Maintenance on supercharger required
smr2009-029
189

Beeper Signals
When one of the below conditions occurs, the
monitoring system emits the following beep signals.
BEEPER
CODES
Wrong D.E.S.S. key.

Use a D.E.S.S. key that has been
programmed for the watercraft.
Defective D.E.S.S. key.
Use another programmed D.E.S.S.
key.
Dried salt water in D.E.S.S. key.
Clean D.E.S.S. key with fresh
water to remove salt water.
Defective D.E.S.S. post.
Check.
Refer to DIGITALLY
ENCODED SECURITY SYSTEM

subsection.
Improper operation of ECM or
defective wiring harness.
Check. Refer to ELECTRONIC
FUEL INJECTION subsection.
A 2 seconds
beep every
15 minutes
interval
A 2 seconds
beep every
5 minutes
interval
190
Watercraft is upside down.

Turn watercraft upright.
TOPS switch is disconnected
of defective. Check. Refer to
LUBRICATION subsection.
Engine management
fault.
Read the fault code.
system
Low fuel level.

Refill fuel tank. If problem
persists, check sensor and circuit.
Refer to FUEL TANK AND FUEL
PUMP.
Fuel tank level sensor or circuit
malfunction.
Check sensor and circuit. Refer to
FUEL TANK AND FUEL PUMP.
DESCRIPTION
High
engine
temperature
coolant.
Refer to COOLING SYSTEM
subsection.
DESCRIPTION
Bad D.E.S.S. system connection.
Reinstall D.E.S.S. key correctly
over post.
1 long beep
(while installing
D.E.S.S. key on
watercraft post
if ECM is on)
BEEPER
CODES
Continuously
beeps
High exhaust temperature.

Refer to ELECTRONIC FUEL
INJECTION.
Low oil pressure.
Turn off engine as soon as
possible. Check oil level and
refill. Refer to LUBRICATION
subsection.
FAULT CODES
A fault code is an indication that a glitch or malfunction is detected by the monitoring system of
the vehicle.
A fault code consists of a letter followed by a number with 4 digits. The letter defines the type of
fault code while the number refers to a unique
fault.
Verify if the check engine light is ON. If so, look
for fault codes to diagnose the trouble. The fault
codes recorded in the related module can be
checked on the information center or by using
the software B.U.D.S.
NOTE: Many fault codes at the same time is likely
to be burnt fuse(s) or a bus bar connection in fuse
box(es).
For more information pertaining to the fault codes
(state, count, first, etc.) and report, refer to
B.U.D.S. online help.
When the fault is not active anymore, its status is
changed from active to occurred and it is stored in
the related module. Stored fault codes are kept in
the module even if the battery is disconnected.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
referred as A-M4 for instance. It means ECM connector A and the circuit wire M4 as found in the
WIRING DIAGRAM.
IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the related module. Refer to CLEARING FAULT CODES USING
B.U.D.S. SOFTWARE in this subsection.
smr2009-029

Fault Code Types

There are 4 types of fault codes used on the vehicle:
B for information center and switches faults
(Bxxxx)
C for iBR and iS faults (Cxxxx)
P for power train faults (Pxxxx)
U for CAN communication faults (Uxxxx).
There are 4 modules that stores the fault codes:
ECM (Engine Control Module)
iBR (Intelligent Brake and Reverse)
Cluster (Information Center)
iS (Intelligent Suspension)
The ECM stores mainly P codes and some U
codes.
The iBR stores mainly C codes and a few U
codes.
The Cluster mainly B codes and a few P
codes.
The iS stores mainly C codes and a few U
codes.
smo2009-002-114_w
FAULT CODE DISPLAY FUNCTION
Fault Code Reading on the Information

Center
NOTE: Only active faults will be displayed.
Press the MODE button repeatedly until the
FAULT CODE function is visible in the multifunction display.
Press the SET button or the UP or DOWN arrow
button to enter the function and display the first
fault code, then press the UP or DOWN arrow button repeatedly to display each subsequent code.
NOTE: When the last fault code has been displayed and the button is pressed again, the
system loops back to the first fault code displayed, and all fault codes can again be displayed.
If there was one active fault code when entering
the FAULT CODE mode, and it becomes occurred
(no longer active), a NO ACTIVE FAULT CODE
message will scroll in the display.
To exit the FAULT CODE display function, the
MODE or SET button must be pressed once.
There is no time out on this function.
smo2009-002-114_x
TYPICAL - ENGINE FAULT CODE EXAMPLE
Fault Code Reading Using B.U.D.S.

Software
Refer to COMMUNICATION
B.U.D.S. SOFTWARE section.
TOOLS
AND
Clearing Fault Codes using B.U.D.S.

Software
The fault(s) (occurred state) can be cleared by
pressing the shown button in B.U.D.S.
NOTE: An active fault code cannot be cleared. In
other words, the problem must be repaired before
clearing the fault.
rmr2008-039-009
FAULTS TAB, ALL FAULTS
smr2009-029
191

This will reset the appropriate counter(s) and will

also record that the problem has been fixed in the
related module memory.
SPECIFIC FAULT CODES

Several Fault Codes are Active at once
If this occurs, check the following:
Check the 30 A fuses in fuse box 2.
Check the bus bar condition and connections in
fuse box(es).
Check the diagnostic connector for the presence of water or corrosion.
Check the CAN wires.
Fault Code C2121, C2221

iBR or iS application parameters corrupted
(backup no. 1 or no. 2). This fault may occasionally appear as occurred. It happens when
power to the module is cut before the module
normally completed its shutdown. Normal operation is not affected. If it occurs often, check
supply voltage to module.
Fault Code C2122, C2222

iBR or iS last session interrupted. This fault may
occasionally appear as occurred. It occurs when
power to the module is cut before the module normally completed its shutdown. Normal operation
is not affected.
Fault Code C2130, C2150, C2233,

C2250
iBR or iS motor or system current software
breaker. Motor or module current too high. This
fault may occasionally appear as occurred. Normal operation is not affected. If it the count is
high, check the moving mechanism of the system
if it is stiffer than normal to operate.
Fault Code C2232

Motor open. If suspension operates when using
the Up/Down s, the suspension will operate normally when riding even if this fault is active. In
this case, the fault can be ignored. The fault will
be set to "occurred" when the iS module will be
shut down. If suspension does not operate when
using the Up/Down s, refer to SUSPENSION (iS)
subsection.
192
Fault Code U0129

CAN communication error between ECM and iBR
modules or iBR CAN message timeout or validity.
This fault may occasionally appear as occurred.
Normal operation is not affected. If it the count
is high, check the related components.
Fault Code P0562

Battery voltage too low. It occurs when both battery voltage and engine RPM conditions are met.
See chart.
BATTERY VOLTAGE
ENGINE SPEED
Lower than 6.5 Vdc
Lower than 1280 RPM
Lower than 11.8 Vdc
Greater than 1280 RPM
Fault Code P0563

Battery voltage too high. It occurs when battery
voltage is above 16 Vdc when engine is running.
Refer to CHARGING SYSTEM.
Fault Code U016A

Loss of vehicle speed. This fault may occasionally appear as occurred. Normal operation is not
affected. If it the count is high, check the related
components.
Fault Code U0300

Incorrect ECM or information center for the engine. Installed part is not appropriate for the vehicle. Engine will crank but will not start. Refer
to PARTS CATALOGS for proper part according to
vehicle.
Fault Code U16A1, U16A2, U16A3,

U16A4, U16A5
Cluster or iBR CAN timeout error-missing CAN ID
xxxh. This fault may occasionally appear as occurred. Normal operation is not affected. If it the
count is high, check the related components.
Fault Code U401, U0457

ECM or cluster CAN message timeout or validity.
This fault may occasionally appear as occurred.
Normal operation is not affected. If it the count
is high, check the related components.
smr2009-029

FAULT CODE TABLE

FAULT
MODULE
CODE
POSSIBLE CAUSE
SERVICE ACTION
Cluster
Left keypad fault

(switch kept activated
more than 60
seconds)
Problem with left keypad
The switch may be defective, verify the

functionality of the switch or the wires.
Refer to the Shop Manual for switch
diagnosis/testing procedure.
Cluster
Suspension UP/
DOWN switches
shorted to ground
fault
Look for pin B if shorted to ground or

pin C.
B2212
Cluster
Suspension UP/
DOWN switches
disconnected fault
Look for pin B if disconnected

to pin 14 on the cluster.
Look for pin C if disconnected to
pin 15 on the cluster.
B2213
Cluster
VTS UP/DOWN
switches shorted
to ground fault
Look for pin A if shorted to ground or

pin C.
Cluster
VTS UP/DOWN
switches
disconnected fault
Look for pin A if disconnected

B2220
Cluster
Right keypad fault

(switch kept activated
more than 60
seconds)
Problem with right

keypad
The switch may be defective, verify the

functionality of the switch or the wires.
Refer to the Shop Manual for switch
diagnosis/testing procedure.
B2221
Cluster
MODE/SET switches
shorted to ground
fault
Problem with right

keypad
Look for pin B if shorted to ground or

pin C.
B2222
Cluster
MODE/SET switches
disconnected fault
Problem with right

keypad

B2223
Cluster
UP/DOWN switches
shorted to ground
fault
Problem with right

keypad
Look for pin A if shorted to ground or

pin C.
Cluster
UP/DOWN switches
disconnected fault
Problem with right

keypad

pin 18 on the cluster
Brake Lever Sensor

(BRLS) signals A
open/shorted to
ground
Damaged sensor,
damaged circuit wires,
damaged connector
or damaged iBR pins.
Fault detected when
the engine is running or
stopped
Check system circuits C03-6pos and

C01-12pos.
Check for 0.5 to 3 V on pin F
and 0.25 to 1.5 on pin C.
B2210
B2211
B2214
B2224
C0042
smr2009-029
iBR
DESCRIPTION
193

FAULT
MODULE
CODE
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
Damaged sensor,
damaged connector
Fault detected when
stopped

C01-12pos.
Check for 0.5 to 3 V on pin F and
0.25 to 1.5 on pin C.
C0043
iBR
Brake Lever Sensor

(BRLS) signals B
open/shorted to
ground
C0073
iBR
Torque request failure
ECM software failure
Perform ECM software update if

available or replace ECM.
C2100
iBR
Sensors calibration is
corrupted
Incompatible firmware or
memory failure
Replace iBR unit.

Refer to the Service Manual for
more details.
iBR
Actuator movement
The iBR gate cannot

move to the desired
position.
Clean and check for damage in

the iBR gate and nozzle area.
Refer to the Service Manual for more
details.
C2101
iBR
Actuator movement
warning
The iBR gate cannot

move to the desired
position within expected
time

details.
C2110
iBR
iBR gate position

sensor error
iBR malfunction
Replace iBR unit.

more details.
C2110
iBR
Angle position sensor

warning
iBR malfunction
Replace iBR unit.

more details.
iBR
iBR overheat
iBR cooling system

failure.
iBR unit failure
Check iBR cooling circuit.

Replace iBR unit.
more details.
iBR
Monitoring CPU
message time out
or validity
iBR malfunction
Perform an iBR software update

if available.
Replace the iBR unit.
more details.
iBR malfunction

if available.
more details.
memory failure

if available.
more details.
Battery power lost or

memory failure
Perform an electrical system shut

download to clear fault.
Verify starting and charging system
circuits.
Refer to the Service Manual
for more details.
C2100
C2110
C2110
C2110
C2120
C2121
194
iBR
Monitoring CPU limp

force
iBR
Application calibration
is corrupted
iBR
Application
parameters corrupted
(backup no. 1
or no. 2)
smr2009-029

FAULT
MODULE
CODE
DESCRIPTION
Unexpected battery
power lost
iBR
Motor current
software breaker
Motor current too high

details.
iBR
iBR DC motor shorted

to ground or 12 V
iBR motor failure.

iBR motor wires damaged
Check iBR circuit A and B.

more details.
Brake Lever Sensor

(BRLS) signals A
shorted to battery
Damaged sensor,
damaged connector
Fault detected when
stopped

C01-12pos.
0.25 to 1.5 on pin C.
Brake Lever Sensor

(BRLS) signals B
shorted to battery
Damaged sensor,
damaged connector
Fault detected when
stopped

C01-12pos.
0.25 to 1.5 on pin C.
Brake Lever Sensor

(BRLS) power shorted
to battery
Damaged sensor,
damaged connector
Fault detected when
stopped

C01-12pos.
Check for 4.5 to 5 volts on sensor
connector pin A & D.
more details.
Brake Lever Sensor

(BRLS) power shorted
to ground
Damaged sensor,
damaged connector
Fault detected when
stopped

C01-12pos.
connector pin A & D.
more details.
iBR
Brake Lever Sensor

(BRLS) signals A/B
reading difference
Damaged sensor,
damaged connector
Fault detected when
stopped

C01-12pos.
Check for 0.5 to 3 V on pin F and 0.25
to 1.5 on pin C.
iBR
System current
software breaker
iBR input current too high

details.
Last session
interrupted
C2130
C2131
C2142
C2143
C2144
C2145
C2146
C2150
smr2009-029
SERVICE ACTION
down and clear fault.
Verify starting and charging system
circuits.
for more details.
iBR
C2122
POSSIBLE CAUSE
iBR
iBR
iBR
iBR
195

FAULT
MODULE
CODE
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
iBR
System disabled and

need activation
System is locked.
Need activation
Use B.U.D.S. iBR unlock function.

details.
iBR
Water temperature
sensor overheat
iBR cooling system

failure.
iBR unit failure
Check iBR cooling circuit.

Replace iBR unit.
more details.
iBR
Low voltage detected
Battery failure, rectifier

failure, damaged circuit
wires, battery terminal
connection, damaged AC
generator or damaged
connectors
C2200
iS
Sensors calibration is
corrupted
memory failure (Internal
memory failure, return to
supplier)
Defective iS module, replace module

and return to supplier.
C2210
iS
Bridge/CPU
temperature sensor
overheat
Hardware failure or
external heat source
Check for over utilization/heat.
C2220
iS
Application calibration
is corrupted
memory failure (B.U.D.S.
should repair that)
Program calibration with B.U.D.S.
C2221
iS
Application
parameters corrupted
(backup no. 1
or no. 2)
Battery power lost or

memory failure (Reset
after power-down-up,
clear fault.
If happens often, verify
supply voltage)
Check power wiring and fuse.
C2222
iS
Last session
interrupted
Unexpected battery
power lost
Check power wiring and fuse.
C2230
iS
Internal motor drive

failure
Motor voltage feedback

not fitting with the
command
Defective iS module, replace module

and return to supplier.
C2231
iS
Motor shorted to
ground/battery
Current leak detected

when the bridge is off
Check suspension actuator pump

wiring.
C2232
iS
Motor open
No current while
activated
Check suspension actuator pump

and/or wiring.
C2233
iS
Motor current
software breaker
Motor current too high
Check suspension actuator pump.
C2240
iS
Seat position sensor

error Open, Shorted
to Gnd
Sensor not connected
Check system circuit at iS module

(refer to WIRING DIAGRAM).
C2250
iS
System current
software breaker
Battery input current too

high
Check suspension actuator pump.
C2251
iS
System disabled and

need activation
System is locked
for safety.
Need activation
Activate iS using B.U.D.S. activation

function.
C2151
C2155
C2161
196
Check fuses 15 (refer to WIRING
DIAGRAM).
Check ground continuity to the
engine block.
more details.
smr2009-029

FAULT
MODULE
CODE
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
Check for 12 volts on sensor connector
pin A.
Check continuity for circuits B-H1,
B-H3.
Check fuse 10 (refer to WIRING
DIAGRAM) refer to the Service Manual
for more details.
C2252
iS
TOPS active
Warning only: TOPS

detected by the system,
the suspension is disable
while the TOPS is "ON"
C2260
iS
System under voltage
System under voltage

warning
Check battery and charging system.
Sensing port dirty or

blocked.
Sensor failure or
unexpected reading
at idle.
Sensor fallen out of
housing or leaking inlet
Check system circuits A-B4, A-G4,

A-H2.
Make sure that the sensor housing is
correctly inserted into the manifold.
Check sensor connector for:
a) 5 volts on pin 1.
b) 0 volt on pin 2.
c) 0 volt on pin 3.
for more details.

blocked.
Sensor failure or
unexpected reading
at idle.

A-H2.
b) 0 volt on pin 2.
c) 0 volt on pin 3.
for more details.

blocked.
Sensor failure or
unexpected reading
at idle.

A-H2.
b) 0 volt on pin 2.
c) 0 volt on pin 3.
for more details.
Damaged sensor,
damaged connector or
damaged ECM pins
Check the sensor for approximately

2280 to 2736 ohms at 19 to 21C
(66 to 70F).
Check for approximately 2280 to
2736 ohms at 19 to 21C
(66 to 70F) between ECM
connector pins A-H3 and A-J3.
details.
P0106
P0107
P0108
P0112
smr2009-029
ECM
ECM
ECM
ECM
Intake pressure
sensor out of range
Manifold absolute
pressure sensor
shorted to ground
Manifold absolute
pressure sensor open
circuit or shorted to
battery
Intake manifold
temperature sensor
shorted to ground
197

FAULT
MODULE
CODE
P0113
P0116
P0117
P0118
P0122
198
ECM
ECM
ECM
ECM
ECM
DESCRIPTION
Intake manifold
temperature sensor
open circuit or
shorted to battery
Engine temperature
sensor functional
problem
Engine temperature
sensor voltage too
low
Engine temperature
sensor voltage too
high
TAS (Throttle
Accelerator sensor) 1
fault (short circuit to
GND)
POSSIBLE CAUSE
SERVICE ACTION
Damaged sensor,
damaged ECM pins

2280 to 2736 ohms at 19 to 21C
(66 to 70F).
connector pins A-H3 and A-J3.
details.
Damaged sensor,
damaged ECM pins
Check for debris or blockage in

cooling system.
2280 to 2736 ohms at 19 to 21C
(66 to 70F).
Check for approximately 2280
to 2736 ohms at 19 to 21C
connector pins A-A1 and A-J2.
details.
Damaged sensor,
damaged ECM pins
Check for debris or blockage in cooling

system.
2280 to 2736 ohms at 19 to 21C
(66 to 70F).
to 2736 ohms at 19 to 21C
details.
Engine overheated or
damaged sensor
Check for debris or blockage in cooling

system.
2280 to 2736 ohms at 19 to 21C
(66 to 70F).
details.
Damaged sensor,
damaged ECM pins
Check system circuits B-E1, B-K1, B-K3.

Check for 0 volt on sensor
connector pin E.
Check for 5 volts on sensor
connector pin D.
connector pin F.
more details.
smr2009-029

FAULT
MODULE
CODE
P0123
P0127
P0201
P0202
P0203
smr2009-029
ECM
ECM
ECM
ECM
ECM
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
TAS (Throttle
battery)
Damaged sensor,
damaged ECM pins.
Check system circuits B-E1, B-K1, B-K3.

Check for 0 volt on sensor connector
pin E.
pin D.
connector
pin F.
for more details.
Intercooler system
fault
High air intake

temperature detected.
Fault detected when the
engine is running and
stopped.
Blocked intercooler water
circuit
Clean intercooler water circuit system.

details.
Damaged injector,
damaged ECM output
pins
Check for 11.4 to 12.6 ohms

between engine connector pin 2 and
ECM connector pin A-K1.
Check for 12 volts on pin 2 of
injector connector.
DIAGRAM).
Check for damaged circuit wires.
details.
Damaged injector,
damaged ECM output
pins

injector connector.
DIAGRAM).
details.
Damaged injector,
damaged ECM output
pins

ECM connector pin A-J1.
injector connector.
DIAGRAM).
details.
Injection Power
Stage fault - open
line/Cylinder 1
Injection Power
Stage fault - open
line/Cylinder 2
Injection Power
Stage fault - open
line/Cylinder 3
199

FAULT
MODULE
CODE
P0217
P0222
P0223
P0231
P0232
200
ECM
ECM
ECM
ECM
ECM
DESCRIPTION
High engine coolant

temperature detected
TAS (Throttle
GND)
TAS (Throttle
battery)
Fuel pump open

circuit or short to
ground
Fuel pump short

circuit to battery
POSSIBLE CAUSE
SERVICE ACTION
Engine overheated or
damaged sensor
Check for debris or blockage in

cooling system.
2280 to 2736 ohms at 19 to 21C
(66 to 70F).
details.
Damaged sensor,
damaged ECM pins
Check system circuits B-A3, B-B3, B-J3.

pin B.
pin A.
Check for 0.25 to 1.5 volts on sensor
connector pin C.
for more details.
Damaged sensor,
damaged ECM pins
Check system circuits B-A3, B-B3, B-J3.

pin B.
pin A.
Check for 0.25 to 1.5 volts on sensor
connector pin C.
for more details.
Damaged pump,
damaged ECM output
pins.
Check for approximately 1 ohm

between pins A and B of the fuel
pump connector.
DIAGRAM).
Check for damaged connector,
damaged ECM output pins or ECM
failure.
for more details.
Damaged pump,
damaged ECM output
pins
Check for approximately 1 ohm

between pins A and B of the fuel
pump connector.
DIAGRAM).
Check for damaged connector,
damaged ECM output
pins or ECM failure.
more details.
smr2009-029

FAULT
MODULE
CODE
P0261
P0262
P0264
P0265
P0267
smr2009-029
ECM
ECM
ECM
ECM
ECM
DESCRIPTION
Injector 1 open circuit

or shorted to ground
Injector 1 shorted to
battery

battery

POSSIBLE CAUSE
SERVICE ACTION
Damaged injector,
damaged ECM output
pins

ECM connector pin A-B3.
Check for 12 volts on pin 2 of injector
connector.
DIAGRAM).
details.
Damaged injector,
damaged ECM output
pins

ECM connector pin A-B3.
connector.
DIAGRAM).
details.
Damaged injector,
damaged ECM output
pins

connector.
DIAGRAM).
details.
Damaged injector,
damaged ECM output
pins

connector.
DIAGRAM).
details.
Damaged injector,
damaged ECM output
pins

connector.
DIAGRAM).
details.
201

FAULT
MODULE
CODE
DESCRIPTION
Damaged injector,
damaged ECM output
pins
Knock sensor fault
Damaged sensor,
damaged ECM output
pins
Bring engine to 5000 RPM. If fault

code appears then check for
approximately 5 Mohms between
system circuits A-C3 and A-G2.
details.
Crankshaft signal
error
Damaged sensor,
damaged connector,
damaged ECM pins or
damaged tooth wheel
For the CPS, check for 700 to

900 ohms between terminals
A-H1 and A-K2 of ECM connector.
details.
Damaged sensor,
damaged connector,
damaged ECM pins or
damaged tooth wheel
For the CAPS, check for 12 volts on

sensor connector pin 3.
Check continuity for circuits A-D4, A-E2
and terminal 4 on engine connector.
DIAGRAM).
more details.
Damaged coil, damaged

circuit wires, damaged
connector or damaged
ECM output pins

between engine connector pin 1
and ECM connector pin A-M4.
Check for 12 volts on pin 2 of coil
connector.
DIAGRAM).
for more details.
ECM
battery
P0300
ECM
Multiple misfire
detected
P0301
ECM
Misfire cylinder 2
(physical cylinder 1)
P0302
ECM
Misfire cylinder 0
P0303
ECM
Misfire cylinder 1
P0335
P0340
P0351
202
ECM
ECM
ECM
ECM
SERVICE ACTION
connector.
DIAGRAM).
details.
P0268
P0325
POSSIBLE CAUSE
Camshaft 1 signal
error
Ignition coil 1 open

ground or to battery
smr2009-029

FAULT
MODULE
CODE
P0352
P0353
P0354
P0355
P0356
P0357
smr2009-029
ECM
ECM
ECM
ECM
ECM
ECM
DESCRIPTION


Ignition Power Stage

fault - short circuit to
GND/Cylinder 1

GND/Cylinder 2

GND/Cylinder 3

V+/Cylinder 1
POSSIBLE CAUSE
SERVICE ACTION

ECM output pins

between engine connector pin
1 and ECM connector pin A-M2.
coil connector.
DIAGRAM).
more details.

ECM output pins

ECM connector pin A-M1.
coil connector.
DIAGRAM).
more details.

ECM output pins

coil connector.
DIAGRAM).
more details.

ECM output pins

coil connector.
DIAGRAM).
more details.

ECM output pins

coil connector.
DIAGRAM).
more details.

ECM output pins

coil connector.
DIAGRAM).
more details.
203

FAULT
MODULE
CODE
P0358
P0359
ECM
ECM
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION

ECM output pins

coil connector.
DIAGRAM).
more details.

V+/Cylinder 3

ECM output pins

coil connector.
DIAGRAM).
more details.
Verify 5 A fuse.
the starter relay.
more details.

V+/Cylinder 2
P0512
ECM
Starter power stage

detects high current
Damaged solenoid,
damaged ECM
P0513
ECM
Invalid D.E.S.S. Key

detected
Key not programmed in

ECU
Program a good key.
Oil pressure switch

functional problem
Engine leak, oil pump

failure, damaged sensor,
damaged ECM pins
Check resistance at 0 RPM and

above 3500 RPM.
Switch is normally closed, ECM
connector pin A-E3.
When blow-by pressure exceeds
40 kPa (6 PSI), the resistance is
infinitely high.
more details.
ECM
Oil pressure sensor

fault
Engine leak, oil pump

failure, damaged sensor,
damaged ECM pins.
Fault detected when
stopped
Check resistance at 0 RPM and

above 3500 RPM.
When blow-by pressure exceeds
40 kPa (6 PSI), the resistance is
infinitely high.
more details.
ECM
Low oil pressure

condition
Low oil level, engine leak,

oil pump fault.
Check oil level.

Check impedance of sensor.
details.
Exhaust gas
temperature sensor
functional problem
Damaged sensor,
damaged ECM output
pins

to 2736 ohms at temperature of
19 to 21C (66 to 70F) between
system circuits A-H4 and A-J4.
details.
P0520
P0523
P0524
P0544
204
ECM
ECM
smr2009-029

FAULT
MODULE
CODE
P0545
P0546
P0560
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
details.
ECM
Exhaust gas
temperature sensor
shorted to ground
Damaged sensor,
damaged ECM output
pins
ECM
Exhaust gas
temperature sensor
open circuit or
shorted to battery
Damaged sensor,
damaged ECM output
pins

details.
Battery voltage not

plausible

connectors

DIAGRAM).
engine block.
more details.
DIAGRAM).
engine block.
more details.
ECM
P0562
ECM
Battery voltage too

low

connectors
P0563
ECM
Battery voltage too

high

failure or battery terminal
connection
Check for regulator-rectifier failure.

details.
P0564
Cluster
Cruise switch fault
The cruise switch is

shorted or activated more
than 60 seconds
Verify the cruise switch if it is normally

open and close when activated.
P0606
ECM
ECM ADC fault
Damaged ECM
Replace ECM.
Damaged sensor,
damaged ECM pins
Check system circuits B-E1, B-K1,

B-K3, B-A3, B-B3, B-J3.
pin B & E.
pin A & D.
connector pin F and 0.25 to 1.5 on C.
details.
Damaged sensor,
damaged ECM output
pins
Check for 2.6 ohms (full tank) to 93.6

ohms (empty tank) between pin C
and pin D at the fuel pump connector.
Check system circuit at the gauge Pin
2 and 3 (refer to WIRING DIAGRAM).
ECM
TAS (Throttle
Accelerator sensor)
synchronization error
P060E
ECM
Throttle Actuator
- Controller Faultdigital position control
exceeds limit
P0610
ECM
Variant coding fault
P060D
P0629
smr2009-029
Cluster
Fuel sensor
disconnected fault
205

FAULT
MODULE
CODE
DESCRIPTION
P062F
ECM
ECM EEPROM fault exchange ECM
P06B6
ECM
ECM Fast ADC fault

(knock detection line)
ECM
P1120
P1264
P1502
P1503
P1504
P1505
ECM
ECM
ECM
ECM
ECM
POSSIBLE CAUSE
SERVICE ACTION
Damaged ECM.
Replace ECM.
Throttle positions
calculated from TPS
1 and TPS 2 not
corresponding
Damaged throttle
actuator, damaged
ECM
Check system circuit, perform

closed throttle with B.U.D.S.
Replace throttle actuator, replace ECM.
Ignition Power stage

overload

ECM output pins
Fault detected when
the engine is running
N/A
TOPS functional
problem
Boat or sensor upside

down, damaged
ECM output pins
Check continuity for circuits A-C4,

A-G1, A-F4.
more details.
TOPS switch short

circuit to 12 V

down, damaged
ECM output pins

A-G1, A-F4.
more details.
TOPS switch short

circuit ground

down, damaged
ECM output pins

A-G1, A-F4.
more details.
TOPS switch fault

non plausible state

down, damaged
ECM output pin

A-G1, A-F4.
more details.

down, damaged
ECM output pins

A-G1, A-F4.
more details.
P1506
ECM
TOPS switch open

circuit
P1509
ECM
N/A
N/A
N/A
P1550
ECM
O.T.A.S. sensor
voltage not plausible
Damaged sensor,
damaged ECM
Check continuity for circuits B-H3,

B-H1 and FB1 -B5.
more details.
P1606
ECM
ECM ADC fault exchange ECM
Damaged ECM
No service action available for fault

P1606.
206
smr2009-029

FAULT
MODULE
CODE
P160E
P1610
P1611
P1612
P1613
P1614
P1615
P1616
P1619
P1620
smr2009-029
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
Throttle Actuator
- Controller Fault digital position control
below limit
Damaged throttle
actuator, damaged
ECM
Check system circuit, perform closed

throttle with B.U.D.S.
Replace throttle actuator, replace
ECM.
Throttle Actuator Power Stage fault
Damaged throttle
actuator, damaged
ECM

ECM.
Damaged throttle
actuator, damaged
ECM

ECM.
Damaged throttle
actuator, damaged
ECM

ECM
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Throttle Actuator Return-Spring check

not passed/Spring
does not close
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Throttle Actuator Position monitoring

fault
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Throttle Actuator
- Default position
check or learning fault
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Throttle Actuator Adaptation of upper

mechanical limit failed
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Throttle Actuator Adaptation of lower

mechanical limit failed
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
ECM
ECM
ECM
207

FAULT
MODULE
CODE
P1621
P1622
P1654
P1657
P1658
DESCRIPTION
POSSIBLE CAUSE
ECM
Throttle Actuator Abortion of adaptation
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Throttle Actuator Repeated abortion of

adaptation
Damaged throttle
actuator, damaged
ECM

ECM.
ECM
Voltage of D.E.S.S.
key switch out of
range
Damaged D.E.S.S.
key switch, damaged
ECM output pins
Remove D.E.S.S. key and check

system circuit B-B2.
more details.
ECM
Electrical fault
of D.E.S.S. key
communication line
Damaged D.E.S.S.
key switch, damaged
ECM output pins

more details.
Faulty D.E.S.S. key

communication
Damaged D.E.S.S.
key switch, damaged
ECM output pins

more details.
Remove D.E.S.S. key.
down.
Clear fault.
Perform iBR software update if
available or replace iBR.
ECM
P1661
ECM
iBR malfunction
iBR fault detected by

ECM
P1662
ECM
iBR torque request is

not plausible

ECM
P16B6
ECM
ECU Fast ADC fault

P16B7
ECM
ECU Fast ADC fault

P16B8
ECM
ECU Fast ADC fault

P16C0
ECM
Fault of ECM ADC
P16C1
ECM
Fault of ECM ADC
P16C2
ECM
Fault of ECM
monitoring module
P16C3
ECM
Monitoring fault due

to Accelerator Sensor
check
P16C4
ECM

to engine speed
check
208
SERVICE ACTION
smr2009-029

FAULT
MODULE
CODE
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
P16C5
ECM
Safety fuel cut off

activ - Monitoring
level 1
P16C6
ECM
Safety fuel cut off

activ - Monitoring
level 2
ECM

to throttle valve
plausibility check
Damaged throttle
actuator, damaged
ECM

ECM
Monitoring fault
due to exceeding
permitted throttle
valve position
Damaged throttle
actuator, damaged
ECM

ECM
Monitoring detected
non plausible D.E.S.S.
key state
Damaged D.E.S.S.
key switch, damaged
ECM output pins

more details.
Exhaust temperature
not plausible
Damaged sensor,
damaged ECM output
pins

details.
Exhaust temperature
sensor fault
Intremittent connection.
Damaged sensor,
damaged ECM output
pins

details.
Electrical lower-range
violation TPS 2
Damaged throttle
actuator, damaged
ECM

Electrical upper-range
violation TPS 2
Damaged throttle
actuator, damaged
ECM

Damaged sensor,
damaged ECM pins
Check system circuits B-E1, B-K1,

B-K3, B-A3, B-B3, B-J3.
pin B & E.
pin A & D.
connector pin F and 0.25 to 1.5 on C.
details.
P16C7
P16C8
P16C9
P2080
P2081
P212C
P212D
P2159
smr2009-029
ECM
ECM
ECM
ECM
ECM
TAS (Throttle
Accelerator sensor)
signal not plausible
209

FAULT
MODULE
CODE
P2428
P2620
P2621
ECM
ECM
ECM
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
High exhaust
Exhaust overheat,
damaged sensor or
damaged circuit wires.
Check cooling system for blockage.

Check if the exhaust injection
valve is properly calibrated.
more details.
TPS value not

plausible
Damaged throttle
actuator, damaged
ECM

Electrical lower-range
violation TPS 1
Damaged throttle
actuator, damaged
ECM

Damaged throttle
actuator, damaged
ECM

P2622
ECM
Electrical upper-range
violation TPS 1
P3999
ECM
Dummy
ECM
CAN communication
error between ECM
and iBR module

ECM CAN circuit failure,
iBR or ECM failure
Check CAN circuits wires.

Replace iBR.
more details.
iS
iBR CAN messages

time out or validity
Warning only: the

iS module lost
communication with
the iBR
If fault ACTIVE, verify CAN connection

between iBR and iS.
Check CAN circuits wires, replace
instrument Cluster.
more details.
U0129
U0129
U016A
ECM
Loss of vehicle speed
Instrument cluster fault

detected by ECM CAN
circuit failure, instrument
Cluster or ECM failure
U0300
ECM
Exchange security Wrong ECM
Incorrect ECM or cluster

for engine
Install proper recommended ECM or

cluster for vehicle.
iBR
ECM CAN messages

CAN circuit failure, ECM

software failure

Replace ECM.
more details.
iS
ECM CAN messages

Warning only: the

iS module lost
communication with
the engine ECU

between ECM and iS.
Cluster CAN
messages timeout
or validity
CAN circuit failure,

Cluster software failure

Replace instrument Cluster.
more details.
Cluster CAN
messages time out or
validity
Warning only: the

iS module lost
communication with
the Cluster

between Cluster and iS.
U0401
U0401
U0457
U0457
210
iBR
iS
smr2009-029

FAULT
MODULE
CODE
U16A1
U16A2
U16A3
U16A4
U16A5
U16A6
U16A7
U16A8
U16A9
smr2009-029
DESCRIPTION
POSSIBLE CAUSE
SERVICE ACTION
ECM
Cluster CAN Time out

error-Missing CAN ID
514h
Cluster fault detected by

Instrument cluster or
ECM failure

more details.
ECM

230h

ECM failure

more details.
ECM

408h

ECM failure

more details.
ECM
iBR CAN Time out

010h

iBR or ECM failure

Replace iBR.
more details.
ECM
iBR CAN Timeout

012h

iBR or ECM failure

Replace instrument iBR.
more details.
ECM
Cluster check sum

error - CAN ID230h

ECM failure

more details.
ECM
Cluster check sum

error - CAN ID408h

ECM failure

more details.
ECM
iBR check sum error CAN ID010h


Replace iBR.
more details.
ECM
iBR check sum error CAN ID012h


Replace iBR.
more details.
211
212
Section 04 FUEL SYSTEM

Subsection 01 (INTELLIGENT THROTTLE CONTROL (iTC))
INTELLIGENT THROTTLE CONTROL

(iTC)
SERVICE TOOLS
Description
Part Number
Page
DIAGNOSTIC HARNESS ............................................................... 529 036 179 ......................................... 215

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 215, 217
SERVICE PRODUCTS
Description
Part Number
Page
DIELECTRIC GREASE ................................................................... 293 550 004 ......................................... 218
GENERAL
SYSTEM DESCRIPTION
The iTC is an electronic throttle control system
that includes a cableless throttle control located
on the RH side of handlebar, an electric throttle actuator (ETA) located on the throttle body and the
engine control module (ECM). The iTC is often referred to as a "throttle by wire" system.
sdd2009-001-030_b
1. Throttle body
2. Throttle actuator
sdd2009-001-031_a
1. Throttle lever
smr2009-050
The throttle lever operates the throttle accelerator sensor (TAS). It is a double output hall effect
sensor. The redundancy is used for security purposes.
The throttle actuator (ETA) is a DC motor on the
throttle body that regulates the throttle plate via a
drive gear. Pulse width modulation (PWM) is used
to control the motor. In the throttle body, there is
a double throttle position sensor (TPS). The redundancy is used for security purposes. The TPS is
a potentiometer that supplies the ECM the actual
angle position of the throttle plate.
According to the torque demand from the TAS,
the ECM powers the ETA motor which is rotated
to open or close the throttle plate. When the ECM
acknowledges that the throttle plate reached the
targeted opening through the TPS, the ECM stops
the throttle actuator to this position.
The iTC allows the throttle actuator to be moved irrespective of the accelerator sensor position since
it is not directly linked by a throttle cable.
213

While the throttle lever might be fully depressed

and held, the ECM could close the throttle plate,
instead of opening it, if the iBR lever were depressed. Then, the ECM could open the throttle
plate to accelerate the engine to increase the braking effect. All those different throttle plate movements could be achieved while the throttle lever
was still fully depressed. This is one of the great
flexibility of the iTC.
The use of the iTC allows these additional engine
modes of operation.
the driver initiates a full turn. When handlebar is

brought back to its center position, the throttle
reverts to idle.
The throttle plate will open and close as necessary
to assist the steering.
Learning and Rental Keys
THROTTLE ACCELERATOR
SENSOR (TAS)
Learning and Rental keys limit the watercraft maximum speed. The full stroke of the throttle lever
is used while only a partial stroke of the throttle
plate is achieved. Therefore, greater throttle lever
movement is used while a smaller engine speed
variation is applied through the throttle actuator.
This permits a more accurate and easier throttle
operation to control the engine within a maximum
speed for a learner.
Limitations
The O.T.A.S. system cannot help maintaining control or prevent collisions in all situations.
PROCEDURES
General
The throttle accelerator sensor (TAS) is a double
hall effect sensor that sends a signal to the ECM
which is proportional to the throttle lever angle.
Cruise Control
Cruise control allows the operator to set a desired
maximum speed of the watercraft when operating above 3800 RPM.
Cruise control limits watercraft speed but does
not maintain it. The operator must hold the throttle lever depressed to maintain forward speed,
unlike an automotive type cruise control which
maintains a constant speed while throttle pedal
is released.
As the throttle lever is kept fully depressed, the
throttle plate will open and close as necessary to
maintain the maximum set speed.
Slow Speed Mode

Slow speed mode is a function of cruise control
which allows the operator to adjust and set idle
speed corresponding to a watercraft speed of
1.6 km/h to 8 km/h (1 MPH to 5 MPH). The throttle lever should not be depressed while operating
in slow speed mode.
The throttle plate will open and close as necessary
to maintain the set speed.
O.T.A.S. TM System (Off-Throttle

Assisted Steering)
The O.T.A.S. (Off-Throttle Assisted Steering)
system provides additional maneuverability in
off-throttle situations. The O.T.A.S. system is
electronically activated and slightly increases
engine speed under a predefined RPM when
214
sdd2009-001-031_a
1. Throttle lever
First ensure the throttle lever works adequately.

Fully depress lever then release it. It must reach
the wide open position and return to the idle position freely when released. Otherwise, refer to
STEERING SYSTEM for an inspection.
TAS Voltage Test

Check the voltage of the throttle accelerator sensor as follows.
Lift suspension using the iS up button to gain access.
NOTE: If more height is required or if the iS cannot be used, manually lift suspension by the anchor points close to handlebar and safely lock in
this position. Do not lift the watercraft from the
anchor points.
From under the moving deck steering area, disconnect the 8-pin and the 12-pin connectors.
smr2009-050

smr2009-042-005_c
smr2009-030-033_a
1. 8-pin connector
2. 12-pin connector
Connect the DIAGNOSTIC HARNESS (P/N 529 036

179) to make an in-line connection between the
disconnected connectors.
Test on the 12-pin Connector of Diagnostic

Harness
12-PIN CONNECTOR
IDLE POSITION
PIN
WIDE OPEN
POSITION
VOLTAGE (Vdc)
10
11
11
12
4.9 - 5.1
0.4 - 0.6
2.9 - 3.1
529036179
NOTE: Plug only the connectors that have been

disconnected.
Install the D.E.S.S. key on its post.
Briefly press the START button to wake up the
ECM.
Use the FLUKE 115 MULTIMETER (P/N 529 035 868)
and select Vdc.
Measure the voltage readings on the installed diagnostic harness connector as follows.
Test on the 8-pin Connector of Diagnostic
Harness
8-PIN CONNECTOR
PIN
IDLE POSITION
WIDE OPEN
POSITION
VOLTAGE (Vdc)
Test Results
If voltage is as per specification, the TAS sensor
is functional.
If voltage is out of specification, check continuity
of all wires between the ECM and the sensor. If
continuity is good, replace sensor.
Reinstall removed components.
TAS Replacement
4.9 - 5.1
0.15 - 0.35
smr2009-030-033_b
1.4 - 1.6
Remove steering cover. Refer to STEERING SYS-
TEM.
Disconnect connector from TAS sensor.
Pry out lock tabs of sensor and pull out sensor.
smr2009-050
215

smr2009-030-100_a
Step 1: Pry out

Step 2: Pull out sensor
Revert removal procedure for installation. Pay attention to the following.

Align sensor pins into their holes.
smr2009-030-102_a
1. Route harness here
When installation is completed, ensure throttle

lever works properly.
CRUISE SWITCH
Cruise Switch Test
If pressing the cruise switch does not engage the
CRUISE or SLOW SPEED modes, test the cruise
switch as per following procedure.
1. Connect the watercraft to the latest B.U.D.S.
software. Refer to COMMUNICATION TOOLS
AND B.U.D.S. SOFTWARE subsection for details.
2. In B.U.D.S., select the Monitoring tab then the
Cluster tab.
3. Press the vehicle cruise button and look for the
Cruise indicator light to come on in the Switch
inputs area.
smr2009-030-101_a
1. Align pin into hole
Snap sensor in position. Ensure it is properly

locked in place.
Route harness into the notched bracket.
216
smr2009-050

smr2009-042-002_a
smr2009-036-002_b
1.
2.
3.
4.
Read Data
Monitoring tab
Cluster tab
Cruise indicator light
If the test succeeded, the switch and wiring are

good and the problem may be related to the information center or ECM. Check for related fault
codes. Refer to MONITORING SYSTEM AND
FAULT CODES.
1. Gauge connector
2. Pull out to unlock connector
6. Use the FLUKE 115 MULTIMETER (P/N 529 035

868).
7. Select the (ohm) function.
8. Test the cruise button switch as per following
table.
CRUISE SWITCH TEST
SWITCH
GAUGE CONNECTOR
POSITION
Switch
released
Pin 7
Pin 10
Switch
depressed
RESISTANCE
OL
Close to 0
If the test failed, replace the cruise switch.

If the test succeeded, the problem may be internal
to the information center. Try a new one.
smr2009-036-012_b
1. Cruise indicator light
Cruise Switch Replacement

1. Disconnect information center connector.
If the test failed, test the switch and wiring as described in the following steps.
4. Remove the gauge support cover. Refer to
GAUGE subsection.
5. Disconnect the gauge connector.
NOTICE Pull connector lock out sideways.
Do not twist the screwdriver.
smr2009-042-002_a
1. Gauge connector
2. Remove terminal 7 (GRAY wire) and 10 (BLACK

wire) from the gauge connector.
smr2009-050
217

10
12
12. Reconnect gauge connector.

13. Properly insert cruise switch wiring in slot in
switch support before installing MODE/SET
and UP/DOWN arrow switches.
11
smr2009-036-003_a
GAUGE CONNECTOR PIN-OUT
3. Attach a string approximately 1.2 m (4 ft) to the

end of the wires which will be used for drawing the new switch wires through the harness
protective sheath.
4. Remove steering cover. Refer to STEERING
AND O.T.A.S. subsection.
5. Remove the MODE/SET and UP/DOWN arrow
switches from its support.
NOTE: It is not necessary to disconnect
switches.
smr2009-036-014_a
SOME PARTS REMOVED FOR CLARITY

1. Cruise switch
2. Wiring in slot
3. MODE/SET and UP/DOWN arrow switch connector
14. Complete installation in reverse order of removal.
smr2009-036-013_b
1. MODE/SET and UP/DOWN arrow switches

2. Cruise switch
6. Remove the cruise switch by lifting it off its support.

7. Cut the locking ties from the harness sheath as
necessary.
8. Carefully pull the wires out of the harness.
Ensure the string draws through the harness
sheath.
9. Tie the string to the new cruise switch wire
ends and pull the new wires through the harness.
10. Install new switch terminals in the gauge connector.
11. Apply a small amount of DIELECTRIC GREASE
(P/N 293 550 004) on switch terminals.
218
smr2009-050

Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))
ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
Description
Part Number
Page
DIGITAL INDUCTION TACHOMETER ........................................... 529 014 500 ......................................... 222

ECM ADAPTER TOOL................................................................... 529 036 166 ........................ 225, 235, 242,
246247, 249, 251

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................ 225, 234235,
240, 244, 246, 248

FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ......................................... 230

Description
Part Number
FLUKE RIGID BACK PROBE ......................................................... TP88
Page
......................................... 244
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 231, 242

LOCTITE 518 ................................................................................. 293 800 038 ......................................... 250
GENERAL
Use the B.U.D.S. software to release the fuel
pressure in the system. Refer to FUEL SYSTEM.
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appropriate safety equipment when working on pressurized fuel system. Wear safety glasses.
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors. Proceed with
care when removing/installing high pressure
test equipment or disconnecting fuel line
connections. Use the B.U.D.S. software to
release fuel pressure prior to removing a
hose. Cover the fuel line connection with an
absorbent shop rag. Slowly disconnect the
fuel hose to minimize spilling. Wipe off any
fuel spillage in the bilge. Fuel is flammable
and explosive under certain conditions. Always work in a well ventilated area. Always
disconnect battery prior to working on the
fuel system.
When the repair is completed, ensure that hoses

from fuel rail going to fuel pump are properly secured in their supports. Then, pressurize the fuel
system. Refer to FUEL TANK AND FUEL PUMP
subsection.
WARNING
Ensure to verify fuel line connections for
damage and that NO fuel line is disconnected prior to pressing the START button.
Always perform the high pressure test if any
component has been removed.
To check fuel rail for leaks, first pressurize the
system then spray soapy water on all hose connections, regulators and injectors. Air bubbles
will show the leaking area. Check also for leaking
fuel or fuel odor.
WARNING
Thoroughly rinse an dry fuel hoses from the
soapy solution after the leak test. Failure to
clean fuel lines from soap might lead to fuel
line deterioration over time.
WARNING
Never use a hose pincher on high pressure
hoses.
smr2009-030
219

WARNING
If any gasoline leak and/or odor are present,
do not start the engine. Repair the leak.
SYSTEM DESCRIPTION
The electronic fuel injection system (EFI) on
this engine is based on the open-loop Bosch
ME-Motronic system. It comprises all the sensors for detecting the ongoing operating from
the engine and watercraft and comprises all the
actuators that perform the required adjustment to
the engine. The ME-Motronic uses an electronically controlled throttle valve. There is no idle air
control valve (IACV). Also, this system introduces
torque management functions.
From the input signals (e.g. throttle lever, iBR
lever), the ECM acknowledges the driver demand
and convert it to engine operation through a
torque requirement by calculation of several variables. Then, the ECM controls the iTC (intelligent
Throttle Control), the injection system and the
ignition system to meet the torque requirement.
The ECM manages several engine torque requirements to control engine operation such as to delivering engine performance, fuel economy, meeting
emission regulations, limiting engine speed etc.
Since the ECM has several torque requirements
at the same time and even contradictory demands
(if the throttle lever is fully depressed and the iBR
lever is fully squeezed for example) it must prioritize the most important requirement according to
predefined conditions and then applies the proper
action by triggering the actuators.
Air Induction
Air Intake Silencer
Air is drawn through the air intake silencer located
above rear part of engine.
The air entry is above the front part of engine and
a rubber baffle is used to prevent the ingestion
of water. If water was drawn, baffles inside the
air intake silencer would separate the water from
the air. Water would then flow out through a drain
valve at bottom of the air intake silencer.
An air duct is used to bring the air to the supercharger.
220
smr2009-030-017_a
1. Air entry behind rubber baffle

smr2009-030-018_a
AIR INTAKE SILENCER LIFTED FOR CLARITY

2. Air duct
3. Supercharger
An intercooler cools down the air from the supercharger.

Intercooler
The intercooler is mounted externally of intake
manifold and is located above drive shaft.
Air that exits the supercharger has been warmed
up by the air compression. The air that enters the
intercooler is cooled down by circulating across
small tubes in which cooling water flows. The
cooling water is supplied by the jet pump. The
end result is that the air density is higher and you
get more air into the engine.
smr2009-030

Flame Arrester
The flame arrester is a tube inside the intake manifold. It prevents flames leaving through the intake
system if the engine backfires.
EFI Sensors
smr2009-030-019_a
1.
2.
3.
4.
5.
6.
7.
8.
9.
Supercharger
Supercharger inlet
Supercharger outlet
Intercooler
Intercooler air inlet warm air from supercharger
Intercooler air outlet cooled air
Throttle body
Cooling water outlet warmed water
Intercooler cooling water inlet cold water
The ECM reads the inputs from the sensors,

makes computations, uses pre-determined parameters and activates the outputs (injectors,
ignition coils etc.).
Signals from sensors are used by the ECM to
determine the injection and ignition parameters
(such as fuel maps required for optimum air-fuel
ratio).
Fuel Rail
Throttle Body
A 62 mm throttle body is mounted on the intake
manifold. Fitted on the throttle body, an electric
throttle actuator (ETA) allows the ECM to control
the throttle plate opening to regulate the engine
speed.
Air for combustion is drawn at the back of the engine by a mechanically-driven supercharger. The
compressed air flows through the throttle body
and is controlled by a throttle plate. The air continues through the intake manifold and goes into
the cylinder head.
One fuel rail is mounted on the intake manifold.

The fuel rail ensures all the time, that enough fuel
can be delivered to the fuel injectors. The fuel rail
is fed by the fuel pump with the properly regulated
fuel pressure.
Intake Manifold
The intake manifold is mounted on the side of the
cylinder block. It provides support for the fuel injectors, the fuel rail, the ECM, the flame arrester
and the throttle body. The intake manifold is a resonator between the throttle body and the cylinder
head.
The engine wiring harness is connected to the

vehicle harness through the engine connector. It
connects all sensors, injectors and ignition coils.
Fuel Injectors
Three fuel injectors are used to inject fuel into the
intake ports of the cylinder head. One injector is
used per cylinder.
Engine Wiring Harness
smr2009-030-039_a
1. Engine harness
2. Engine connector
ADJUSTMENT
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INTAKE MANIFOLD
1. Engine Control Module (ECM)
2. Fuel rail
3. Injector
4. Throttle body
5. Ignition coil
6. Manifold absolute pressure sensor (MAPS)
7. Manifold air temperature sensor (MATS)
smr2009-030
IDLE SPEED
The idle speed is not adjustable. The ECM controls the idle speed of the engine with the iTC.
If desired, the engine RPM can be measured following this procedure:
221

Use a DIGITAL INDUCTION TACHOMETER (P/N 529

014 500).

ECM. Engine must not crank.
In B.U.D.S., click on the Reset button.
529014500
Wrap the tachometer's wire a few times around

the protruding part of ignition coil.
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SETTING AND ECM TABS

1. Click Reset button
The following message will confirm the operation.
smr2009-030-003
A32CCIA
TYPICAL
Start engine to verify engine RPM.

NOTE: If idle speed is not within specifications,
check if there is any occurred or active fault
code(s). If not, proceed with the Closed Throttle
reset. If idle speed is still not adequate, there is
probably a mechanical problem.
CLOSED THROTTLE RESET

General Information
This operation performs a reset of the TPS values
of the throttle body in the ECM.
Closed throttle reset must be done only when:
Replacing throttle body.
Replacing ECM.
Closed Throttle Reset Procedure

Use the B.U.D.S. software to perform this setting. Refer to COMMUNICATION TOOLS AND
B.U.D.S. SOFTWARE subsection.
222
Reset is completed.
NOTE: It is not necessary to click on the Write
button in B.U.D.S. Exit B.U.D.S.
NOTE: If throttle valve was not within the allowed range while resetting the Closed Throttle,
nothing would tell you that it was wrong. No
error message would be displayed. However, a
fault code would be set when engine would be
started.
Start engine and make sure it operates normally
through its full engine RPM range. Check for
fault codes in B.U.D.S. If fault a code related
to the throttle actuator appears, clear it then do
the reset closed throttle procedure again. To
clear faults, refer to MONITORING SYSTEM AND
FAULT CODES subsection.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
fuel injection system.
smr2009-030

It is important to ensure that the mechanical integrity of the engine/propulsion system are intact.
For diagnostics purposes, use B.U.D.S. software.
See COMMUNICATION TOOLS AND B.U.D.S.
SOFTWARE subsection.
After a problem has been solved, ensure to clear
the fault(s) in the ECM using the B.U.D.S. software.
WARNING
All electrical actuators and electronic modules are powered as soon as the START
button is depressed. Always disconnect the
battery prior to disconnecting any electrical
or electronic parts.
PROCEDURES
ENGINE CONTROL MODULE
(ECM)
ECM Connector Access
NOTE: For connector information, cleaning and
probing, refer to WIRING DIAGRAM subsection.
Open seat.
Remove rear ventilation box. Refer to AIR INTAKE
SYSTEM.
Remove deck extension. Refer to BODY.
Never use a battery charger to substitute temporarily the battery, as it may cause the ECM
to work erratically or not to work at all. Check
related-circuit fuse solidity and condition with an
ohmmeter. Visual inspection could lead to false
results.
IMPORTANT: Use genuine wires only. Otherwise
wires will not fit properly.
Electrical Related Problems

It is important to check the following in the electrical system:
Battery voltage
Fuses
Bus bar condition in fuse boxes
Ground connections
Wiring connectors.
Ensure that all electronic components are genuine. Any modification on the wiring harness may
lead to generate fault codes or bad operation.
smr2009-030-025_a
1. ECM
2. ECM connectors
ECM Connector Identification

There are 2 connectors connected to the ECM.
The engine harness female connector is connected on the module male connector A and the
vehicle system control harness female connector
is connected to the module male connector B.
The ECM connectors have 48 pins.
Electrical Connections
Pay particular attention to ensure that terminals
and pins are not out of their connectors or out of
shape.
When probing terminals, pay attention not to bend
the terminal as this could bring a loose connection
that would be difficult to troubleshoot.
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ECM CONNECTORS
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223

ECM Power Supply Troubleshooting

ECM Power Supply Diagram
Battery
A1
FB#2
Fuse F17
FB#2
Bus bar (Vdc)
B2
B7 B8
FB#2
Relay
B12
B5
D1
A12
FB#2
Fuse F21
D2
B10
A10
D6
FB#1
Start switch
Bus bar (Vdc)

D4
D3
Fuse F20
FB#2
A4
B-M4
Switched
power
ECM
Signal
Wake up
B-H2
B-D1
B-L1, B-M2, B-M3

E9, E11, E10
FB#2
Bus bar (ground)
FB = Fuse box
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ECM Wake Up Basics

When the START button is depressed:
ECM pin B-D1 receives current from battery via
the START switch. ECM is woken up.
ECM pin B-H2 provides a ground to the relay
coil in fuse box #2 (FB).
The relay contacts close and fully powers the
ECM at pin B-M4.
The relay also powers the other components in
the electrical system.
ECM pin B-E4 monitors if a key is present.
When a key is installed, the magnet in the key
closes the reed switches in the D.E.S.S. post
and the ECM pin B-F2 provides a ground. This
tell the ECM a key is present.
ECM pin B-B2 reads the D.E.S.S. key and determines if it is valid. If so, the engine can be
started.
ECM Shut Down Basics
When engine is running and Stop button is depressed:
ECM stops the engine.
After 5 seconds, the information center turns
off.
After 60 seconds, ECM pin B-H2 removes the
ground to the relay coil.
224
Relay contacts open and power to the ECM is

cut.
Power is cut on all the electrical system except
the GPS supply in the information center.
When engine is running and the D.E.S.S. key is
removed from its post:
ECM stops the engine.
After 5 seconds, the information center turns
off.
After 10 seconds, ECM pin B-H2 removes the
ground to the relay coil.
cut.
When engine is not running and the START button
is briefly pressed without starting engine:
The information center turns on and remains on
until ECM turns off.
When there is no D.E.S.S. key installed, ECM
pin B-H2 removes the ground to the relay coil
after 3 minutes.
When a D.E.S.S. key installed, ECM pin B-H2
removes the ground to the relay coil after 4 minutes.
cut.
ECM Power Supply Validation
Briefly press the START button.
This should wake up the ECM and continuously
activate the relay in FB#2.
QUICK INDICATION THAT ECM IS NOT POWERED
(assuming the observed component is working)
Information center does not turn on.
Fuel pump does not turn on for approximately 5
seconds.
Throttle actuator does not initialize.
If
ECM does not turn on, check the following:

Fuses F16, F17 and F20 in fuse box #2 (FB)
Battery voltage. Refer to CHARGING SYSTEM
The power bus bars in FB#1 and FB#2
The ground bus bar in FB#2
smr2009-030

Relay and wiring. Refer to POWER DISTRIBU-
TION
ECM power supply wires and ground wires.
See below.
ECM Power Supply Test

Remove cover of fuse box #2 (FB). Refer to
POWER DISTRIBUTION subsection.
ECM.
and select Vdc.
Probe the fuse F20 as shown.
NOTE: This will validate the fuse at the same
time.
FUSE BOX #2
BATTERY
POST
VOLTAGE
Fuse F20
terminal at D4
Ground
Battery voltage
smr2009-030-010

868) and select .
4. Probe terminals as follows.
FUSE BOX
#2
ECM
ADAPTER
RESISTANCE
Terminal D4
Pin B-M4
Close to 0
smr2009-030-009_b
ECM Ground Test

smr2009-030-009_a
If voltage is not as per specification, check the

wiring and connections between relay output and
F20 output. Refer to WIRING DIAGRAM.
If voltage is as per specification, check the continuity of wiring and connections between FB2 and
ECM as follows.
1. Disconnect B connector from ECM.
2. Install ECM ADAPTER TOOL (P/N 529 036 166) on
ECM connector.
smr2009-030
Disconnect B connector from ECM.

Install ECM ADAPTER TOOL (P/N 529 036 166) on
ECM connector.
and select .
Probe adapter terminals as follows.
ECM
ADAPTER
BATTERY
POST
RESISTANCE
Pins B-L1,
B-M2 and B-M3
Ground
Close to 0
(continuity)
225

smr2009-030-010_a
If measurement is out of specification, check

ground bus bar in fuse box #2 and continuity
of its wires and connections with the engine
grounds. Also check battery ground and engine
grounds.
smr2009-016-026_b
LH SIDE OF ENGINE
1. Battery ground cable
2. Exhaust manifold water inlet fitting
If everything tests good and ECM does not

power up, try a new ECM. Refer to ECM REPLACEMENT.
ECM Removal
NOTE: If a new ECM is to be installed, first read
the procedures in the ECM REPLACEMENT in this
subsection.
Disconnect battery cables.
WARNING
Battery BLACK negative cable must always
be disconnected first and connected last.
smr2009-027-010_e
1. Ground bus bar in fuse box #2
Disconnect both ECM connectors from ECM.

Unscrew all retaining screws and remove the engine ECM from intake manifold.
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FRONT OF ENGINE
1. Engine grounds
smr2009-030-025_b
1. ECM
2. Retaining screws
ECM Installation
Reverse removal procedure but pay attention to
the following.
Install ECM to the engine.
226
smr2009-030

NOTICE Always replace ECM by the same

part number or by an approved equivalent.
Reconnect ECM connectors to ECM.
Reconnect battery cables.
If a new ECM is installed, refer to ECM REPLACEMENT in this subsection.

From B.U.D.S., choose ECM, Replace under
Module menu.
ECM Replacement
Prior to replacing a suspected ECM, ensure that all
the recommendations in the general introduction
of this section have been followed.
When installing a new ECM, data must be entered
and a reset is required.
To transfer/enter data to the new ECM, there are
2 possible methods.
If the faulty ECM can be read with B.U.D.S.,
refer to ECM AUTOMATED DATA TRANSFER.
If the faulty ECM cannot be read with B.U.D.S.,
refer to ECM MANUAL DATA ENTRY.
smr2009-030-004
B.U.D.S. will automatically write the data from the

PC computer into the new ECM.
Then, B.U.D.S. will display the following box.
ECM Automated Data Transfer

To transfer the previous ECM recorded information to the new ECM, do the following.
Use the B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection.
In B.U.D.S., click the Read Data button to load the
information from the faulty ECM into B.U.D.S.
smr2009-030-005
Remove D.E.S.S. key from its post.

Wait until the message disappears in B.U.D.S. so
that all data is written into the ECM.
NOTE: The message will disappear approximately 3 minutes after the D.E.S.S. key has been
removed.
Perform the Closed throttle reset. Refer to
Closed Throttle Reset (TPS) in ADJUSTMENTS
in this subsection.
ECM Manual Data Entry
vmr2006-012-100_aen
Keep B.U.D.S. running while replacing ECMs. The

data will remain stored in the PC computer as long
as B.U.DS. is running.
Remove the old ECM. Refer to ECM REMOVAL
in this subsection.
Install and connect the new ECM. Refer to ECM
INSTALLATION in this subsection.
smr2009-030
There are 2 possible methods to collect the required information. The 1st being the easiest.
1. Use B.U.D.S. software and get the data from a
saved .mpem file on your PC computer.
2. Collect the information from the vehicle and
BOSSWeb.
1st Collecting Method: Get the Data from a
Saved .mpem File
Use the B.U.D.S. software.
NOTE: It is not necessary to perform any connection. The PC computer can be used alone.
227

Click on the Open button.
mmr2009-023-080
Click once on the Folder Up button in the Open

box.
smr2009-030-006
IMPORTANT: Ensure to use the file that specifically matches the vehicle you are servicing.
NOTE: The file name structure is as follows:
BUDS version_VIN_date read (yyyymmdd)_hour read
(hhmmss).mpem
Example:
P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem
Therefore:
B.U.D.S. version: P2.3.22.12
VIN: 2BPSBK8C68V000168
Date: 2009 02 06
Hour: 11h 16m 40s
mmr2009-023-081_a
Double click on the AutoSave folder.
Go in the Vehicle tab and record the following information.

1. Vehicle serial number
2. Engine serial number (without the leading
M)
3. Vehicle model number
4. Customer name.
mmr2009-023-082_a
NOTE: You may have to go to another AutoSave

folder from a previous version of B.U.D.S.
Choose the latest file saved for this specific vehicle.
smr2009-030-007_a
VEHICLE TAB
Enter recorded data in ECM as detailed in ENTER-
ING THE COLLECTED INFORMATION INTO THE

ECM.
2nd Collecting Method: Collect the
Information from the Vehicle and BOSSWeb
Record engine serial number.
228
smr2009-030

Entering the Collected Information Into the

ECM
Remove the faulty ECM.
Install and connect the new ECM.
Use the B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection.
In B.U.D.S., click the Read Data button to read the
new empty ECM.
1
vmr2006-012-100_aen
F18D03A
1. Engine serial number
The following window will pop up.
Record the following numbers using BOSSWeb.

Look in Service menu and choose Unit history.
2. Vehicle model number
3. Customer name.
smr2008-023-100
mmr2009-118-011
SERVICE, UNIT HISTORY
Enter the recorded data in ECM as detailed in ENTERING THE COLLECTED INFORMATION INTO
THE ECM.
smr2009-030
smr2008-023-100_b
Go in the Vehicle tab and enter the information

you recorded previously.
2. Engine number (do not enter the leading M)
229

3. Customer name
4. Enter the old ECM serial number in the Part
Replacement under History tab. Click on Add
Part in History.
Perform the Closed throttle reset. Refer to

Closed Throttle Reset (TPS) in ADJUSTMENTS
in this subsection.
FUEL RAIL
Fuel Rail Removal
Open seat.
SYSTEM.
Pull out relay in fuse box #2 to prevent fuel pump
to turn on unexpectedly. Refer to POWER DISTRI-
BUTION.
smr2009-030-008
HISTORY AND PART REPLACEMENT TABS
NOTE: The ECM serial number can be found on

the ECM sticker that also shows the part number.
Go to the Keys tab and Erase All Keys.
Fuel Rail Hose Disconnection

1. Release fuel pressure. Refer to FUEL PUMP in
FUEL TANK AND FUEL PUMP subsection.
2. Disconnect fuel hose from fuel rail using the
FUEL HOSE DISCONNECT TOOL (P/N 529 036
037).
529036037
mmr2009-023-087
1. Program the desired key(s). Refer to D.E.S.S.
SYSTEM.
2. Briefly press the vehicle START button to wake
up the ECM. Engine must not crank.
3. Click on the Write Data button.
lmr2006-008-010
NOTE: It may be necessary to rotate fuel hose fitting to align the tool ends with the openings of the
locking mechanism.
NOTE: Wrap a rag around the hose end to catch
fuel leakage.
vmr2006-012-100_ben
230
smr2009-030

Fuel Rail Removal

Cut locking ties retaining engine harness to fuel
rail.
smr2009-030-027_a
1. Fuel rail
Unplug all injector connectors.

Pull fuel rail out with fuel injectors.
Fuel Rail Installation

smr2009-030-011_b
1. Cut locking ties
Remove retaining screws of fuel rail.
Reverse the removal procedure. However, pay attention to the following.

Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on fuel
rail retaining screws.
Torque fuel rail retaining screws to 9 Nm
(80 lbfin).
smr2009-030-026_a
1. Retaining screws
Gently pull fuel rail side to side (wiggle).

smr2009-030-026_a
1. Retaining screws
Properly install new locking ties to secure engine

harness to fuel rail.
smr2009-030
231

FUEL INJECTOR
Fuel Injector Operation Test with
B.U.D.S. (Dynamic)
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.

2. Start engine.
3. Using the B.U.D.S. software, shut down each
engine cylinder, one at a time.
smr2009-030-011_b
1. New locking ties
Fuel Rail Hose Connection

1. Apply engine oil on O-rings of fitting.
mmr2009-120-006_a
MONITORING AND ECM TABS

1. Click on the desired cylinder number
mmr2009-121-022_a
1. Apply oil on O-rings
2. Connect fuel hose to fuel rail.

IMPORTANT: Push fuel hose fitting on fuel rail until you hear a "click". Try pulling fuel hose to ensure
fitting is properly locked.
Pressurize the fuel system. Refer to FUEL SYSTEM PRESSURIZATION in FUEL TANK AND FUEL
PUMP subsection.
WARNING
Failure to pressurize the fuel system may result in severe injury or a life threatening situation should a leak occur.
3. Reinstall all remaining removed parts.
232
If the engine RPM drops when clicking on a cylinder, the injector and the ignition of this cylinder are
working.
If the engine RPM does not drop when clicking
on a cylinder, this cylinder is not working properly.
Check the following:
Fuel injector operation. Refer to FUEL INJECTOR OPERATION TEST.
Spark plug and ignition coil. Refer to IGNITION
SYSTEM.
Engine condition.
Fuel Injector Operation Test with

B.U.D.S. (Static)
NOTICE After fuel injector activation using B.U.D.S., always crank engine in drowned
mode to ventilate engine to prevent a potential
backfire due to fuel accumulation in engine.
Connect B.U.D.S. Refer to COMMUNICATION
Install D.E.S.S. key on its post.
ECM. Do not start engine.
Energize the desired fuel injector in B.U.D.S.
smr2009-030

5. Fuel pressure must be within specification. Refer to FUEL TANK AND FUEL PUMP subsection. Re-activate fuel pump as necessary.
6. In B.U.D.S., energize the fuel injector no. 1.
smr2009-030-013_a
ACTIVATION AND ECM TABS

1. Injector of cylinder no. 1 shown
Listen to the injector.

If you can hear the injector, it validates its operation. Carry out the FUEL INJECTOR BALANCE
TEST.
If you do not hear the injector, carry out the INJECTOR INPUT VOLTAGE TEST.
Fuel Injector Balance Test with

B.U.D.S.
smr2009-030-013_a

1. Injector of cylinder no. 1 shown
7. Record the fuel pressure drop for injector no. 1.

8. In B.U.D.S., click the Fuel Pump button to activate fuel pump.
NOTICE After fuel injector activation using B.U.D.S., always crank engine in drowned
mode to ventilate engine to prevent a potential
backfire due to fuel accumulation in engine.
1. Install a fuel pressure gauge as described in
FUEL PUMP PRESSURE TEST of FUEL TANK
AND FUEL PUMP subsection.

3. Install D.E.S.S. key on its post.
4. In B.U.D.S., click the Fuel Pump button to activate fuel pump.
smr2009-030-014_a

1. Fuel pump
9. Repeat the procedure for fuel injectors no. 2

and no. 3 and record their pressure drops.
10. The maximum fuel pressure drop between injectors should not exceed the following specification:
MAXIMUM FUEL PRESSURE DROP ALLOWED
BETWEEN FUEL INJECTORS
10 kPa (1.5 PSI)
smr2009-030-014_a

1. Fuel pump
smr2009-030
11. If pressure drop of any fuel injector is greater

than the specification, replace that injector
then repeat the test.
12. Use the valve on the fuel pressure gauge to release the pressure (if so equipped). Remove
fuel pressure gauge and reinstall removed
parts.
233

Fuel Injector Input Voltage Test

Open seat.
SYSTEM.
Disconnect fuel injector connectors.
NOTE: Push against tab underneath connector as
shown to unlock it.
smr2009-030-029_a
If input voltage is good, carry out the INJECTOR

CONTROL CIRCUIT TEST.
If input voltage is not good, check continuity between fuse box #1 and injector as follows.
Remove cover of fuse box 1. Refer to POWER
DISTRIBUTION subsection.
Remove the long bus bar.
smr2009-030-028_a
PUSH HERE TO UNLOCK
smr2009-027-011_f
1. Long bus bar

and select .
Read resistance of the desired injector circuit.
INJECTOR
INJECTOR
CONNECTOR
FUSE BOX
#1
MEASUREMENT
smr2009-030-011_a
1. Fuel injector connectors
1 (rear)
Install D.E.S.S. key on its post.

ECM.
and select Vdc.
Read voltage of the desired injector.
INJECTOR CONNECTOR
MEASUREMENT
VIOLET wire with a tracer

and battery ground
Battery voltage
234
2
3
VIOLET wire
with a tracer
Terminal
C11
Terminal C9
Close to 0
Terminal C7
smr2009-030

Disconnect the ECM A connector.

ECM connector.
Remove the long bus bar from fuse box #1.
smr2009-030-015_j
If continuity is good, wiring and connectors are

functional.
If continuity is faulty, repair/replace wiring from
fuse box terminal to injector.
Reinstall bus bar and cover.
Fuel Injector Control Circuit Test

Disconnect ECM A connector.
ECM connector.
and select .
Probe terminals as follows.
INJECTOR
ECM
ADAPTER
1 (rear)
Pin A-B3
Pin A-K1
Pin A- J1
INJECTOR
MEASUREMENT
BROWN
wire with
a tracer
smr2009-027-011_f
1. Long bus bar

and select .
Measure resistance value between terminals as
follows.
INJECTOR
FUSE BOX #1
ECM
RESISTANCE @
TERMINAL ADAPTER PIN 20C (68F)
C11
A-B3
C9
A-K1
C7
A-J1
11.4 - 12.6
Close to 0
smr2009-030-015_i
smr2009-030-010_c
If control circuit is faulty, repair/replace wiring/connectors.

If control circuit and all tests applicable to the injector are good, try a new ECM. Refer to ECM.
Fuel Injector Resistance Test

(at ECM Connector)
Reconnect the injector connector.
smr2009-030
If resistance value is correct, injector coil is in

good condition.
If resistance value is incorrect, repeat test at injector connector.
Fuel Injector Resistance Test (at

Component)
Remove injector connector and check resistance
value between injector pins as follows.
235

INJECTOR PIN
1
RESISTANCE @
20C (68F)
See above
Insert the fuel injector in place on fuel rail.

Secure injector to fuel rail with its clip.
Install fuel rail. Refer to FUEL RAIL in this subsection.
THROTTLE BODY
smr2009-030-030_a
If readings are out of specifications, replace injector.

If readings are good, repair/replace wiring/connectors from ECM to injector.
Fuel Injector Removal

Remove fuel rail. Refer to FUEL RAIL in this subsection.
Remove the injector clip.
3
R1503motr164A
smr2009-030-016_a
1.
2.
3.
4.
Throttle
Throttle
Throttle
Throttle
body
plate
actuator (electric motor inside)
position sensor (TPS) (inside)
To disconnect connector from throttle body, press

connector tab as shown.
FUEL RAIL ASSEMBLY

1. Fuel injector
2. Injector clip
3. O-ring
smr2009-030-031_a
PRESS HERE TO UNLOCK
Pull out the fuel injector from the fuel rail.
Fuel Injector Installation

Reverse the removal procedure. Paying attention
to the following details.
If you reinstall a used injector, carefully inspect
O-ring condition before reinstallation. Replace
O-ring with a new one if damaged.
Apply a thin film of engine oil to O-rings.
236
smr2009-030

Throttle-Body Faults and Effects

NOTE: Among other things, a weak or broken
spring and a sticky throttle plate (carbon build-up,
dried salt water etc) are validated by the throttle
body diagnostic mode.
smr2009-030-032_a
CONNECTOR PIN-OUT
Throttle Actuator Operating Positions

Two torsional springs are connected with the
throttle plate. A main spring and another one in a
plunger mechanism.
When there is no power on the throttle actuator
(ETA), the plunger mechanism maintains the throttle plate to a rest position. This also serves as the
limp home position.
When the throttle plate is opened by the ETA, it
acts against the main spring. If the ETA failed, the
return spring would bring back the throttle plate to
the limp home position.
ECM
OFF
ON
ENGINE
THROTTLE BODY
Stopped
Throttle actuator: Off.

Throttle plate: Rest position, maintained
opened at approximately 8 (1). This is
also the limp home position.
Not
started
Throttle actuator: On.

Throttle plate: Moves from the
rest position to approximately 14. It
then moves back to the rest position.
This is the diagnostic mode where the
rest position, actuator opening force to
overcome the return springs and the
motor return rate are monitored. If any
of these parameter are out of range, a
fault code is initiated.
ON
Started.
Normal
operation
at idle

Throttle plate: Moves from the
rest position to idle position
(approximately 1-3) according to
ECM injection and ignition maps.
Throttle plate is opened and closed as
necessary to control the idle speed.
ON
Started.
Normal
operation
at various
RPM

Throttle plate: Opens and closes
according to ECM torque management
priorities.
(1) Degree values are given from the fully closed position.
smr2009-030
FAULT
EFFECT
Partial failure
of TAS sensor
(one internal
sensor only)
Limp home mode. Engine speed limited to idle.

ECM will use the remaining TAS sensor.
Fault code set and beeper
activated to emit warning signals.
Check engine light is turned ON.
Driveability could be reset by releasing
and reapplying the throttle.
Complete
failure of
TAS sensor
(both internal
sensors)
Limp home mode. Engine

speed limited to 2500 RPM.
Any throttle
body failure
Limp home mode. Engine

speed limited to 2500 RPM.
Engine speed can still be increased up
to 3200 RPM using the throttle lever.
NOTE: When one of these fault is active, OTAS and iBR will
continue to monitor their input signals. However, since the
engine speed is limited, the OTAS will not be activated. Also,
since the ECM cannot control the throttle body, the iBR might
come in fault because the ECM does not react to his specific
torque request. It all depends on the circumstances when the
iBR is applied. (vehicle and engine speed will be a factor).
Throttle Body Lubrication

No lubrication is required.
Throttle Body Cleaning

To gain access to throttle body, remove the required parts as described in THROTTLE BODY RE-
MOVAL.
Check throttle body cleanliness using a flashlight.
Fully open throttle plate and verify:
Throttle body bore
Throttle plate edge.
Look for:
Dirt
Oily surfaces
Carbon deposits on throttle plate and the surrounding bore.
Clean as necessary.
Use a throttle body cleaner such as GUNK INTAKE
MEDIC or the equivalent.
237

NOTICE Only use an appropriate throttle

body cleaner that will not damage O-rings and
EFI sensors.
WARNING
Use the product in well ventilated area. Refer
to product manufacturer's warnings. Wipe
off any product leakage in bilge.
To avoid getting dirt into engine, spray cleaner on
a clean rag (outside the bilge) then rub rag against
throttle plate and bore. A toothbrush works well
too.
WARNING
First ensure ECM is off. Otherwise, if ECM
would turn off, it would quickly close the
throttle plate and this could cause serious
finger injuries if you were working in this
area.
Manually open throttle and hold fully open to
reach all surfaces.
WARNING
Ensure nobody presses the START button.
The ECM would turn on and throttle actuator
would cycle. This could cause serious finger
injuries as throttle plate quickly moves.
To remove residual dirt, spray cleaner on throttle
plate and on bore.
Reinstall removed parts.
Throttle Body Inspection

Always check for corroded terminals or damaged
wiring when diagnosing throttle body.
WARNING
Keep your fingers out of the throttle plate
area while the ECM turns on. The throttle
actuator will cycle. This could cause serious finger injuries as throttle plate quickly
moves.
Throttle plate should quickly move from the rest
position to a partially open position (approximately
14). It will then move back to the rest position.
Ask someone to gradually and evenly depress
and then release the same way the throttle lever.
Throttle plate should open then close according
to throttle lever position.
If any test failed, proceed with the STATIC TESTS.
Static Tests
WARNING
First ensure ECM is off. Otherwise, if ECM
would turn off, it would quickly close the
throttle plate and this could cause serious
finger injuries if you wsere working in this
area.
WARNING
During the test, ensure nobody presses the
START button. The ECM would turn on and
throttle actuator would cycle. This could
cause serious finger injuries as throttle plate
quickly moves.
Check that the throttle plate opens smoothly
when manually pushing on throttle plate in throttle body.
Dynamic Tests
MOVAL.
Look at throttle plate when the engine is stopped.
Throttle plate should be in the rest position
(slightly opened).
Ask someone to briefly press the START button
to wake up the ECM while watching the throttle
plate. Do not start engine.
smr2009-030-016_b
1. Push here to open
238
smr2009-030

Throttle plate must fully open and when released,

must return freely to the rest position (slightly
opened).
Push throttle plate where shown. It must completely close and when released, freely return to
the rest position (slightly opened).
smr2009-030-024_a
1. Throttle body
2. Inlet hose
3. Connector
4. Remove retaining screws from throttle body.
smr2009-030-016_c
1. Push here to close
If throttle plate does not move smoothly or does

not return freely to the position, the problem is
mechanical. Check for salt accumulation on throttle plate shaft. It may also be an actuator or gear
problem. Replace throttle body as necessary.
If throttle plate operates normally, the problem
is electrical. Check throttle actuator (ETA) wiring
continuity, throttle position sensor (TPS) and
throttle accelerator sensor (TAS).
WARNING
Replace throttle body when throttle plate
does not return properly.
Throttle Body Replacement

Removal
Open seat.
SYSTEM.
1. Lift suspension using the iS up button to gain
access.
NOTE: If more height is required or if the iS cannot be used, manually lift suspension by the anchor points close to handlebar and safely block in
anchor points.
2. Disconnect inlet hose from throttle body.
3. Disconnect throttle body connector.
smr2009-030
smr2009-030-022_a
1. Throttle body
2. Screws
5. Pull throttle body out.

Installation
Installation of the new throttle body is the reverse
of the removal procedure. However, pay attention
to the following.
Torque retaining screws in a criss-cross sequence
to 9 Nm (80 lbfin).
Perform the Closed Throttle reset. See procedure in ADJUSTMENTS.
TPS (THROTTLE POSITION

SENSOR)
General
NOTE: The TPS is part of the throttle body.
The throttle position sensor (TPS) is a double potentiometer that sends a signal to the ECM which
is proportional to the throttle plate angle. The TPS
is located inside the throttle body.
TPS Wear Test

While engine is not running, activate throttle and
pay attention for smooth operation without physical stops.
239


Connect B.U.D.S. Refer to COMMUNICATION

In B.U.D.S., select the Monitoring tab then the
ECM tab. Use the Throttle Opening.
smr2009-030-016_b
1. Push here
mmr2009-120-001
MONITORING AND ECM TABS
Slowly and regularly depress the throttle lever.

Observe the needle movement.
NOTE: An initial slight delay after the throttle lever
is depressed and before the needle starts to move
is normal.
Needle should change gradually and regularly
as you move the throttle lever. If the needle
sticks, bounces or suddenly drops, it may indicates a worn TPS that needs to be replaced.
If the needle behavior is not as expected, perform
the following.
Manually move the throttle plate in throttle body
using a screwdriver (without sharp tip).
WARNING
Do not move throttle plate with your fingers.
Otherwise, if ECM would turn off, it would
quickly close the throttle plate and this could
cause serious finger injuries if you were
working in this area.
Check needle movement again.

If needle moves as expected, check the throttle
accelerator sensor (TAS) of throttle lever. Refer
to THROTTLE ACCELERATOR SENSOR (TAS)
in this subsection.
If needle does not move as expected, perform
the TPS VOLTAGE TEST and the TPS RESISTANCE TEST in this subsection.
TPS Resistance Test

MOVAL.
Ensure the throttle body connector is plugged.
Disconnect the ECM connector A from the ECM.
and select .
Probe circuit as per following table while using
your hand to manually move throttle plate.
ECM
ADAPTER
FULLY CLOSED
THROTTLE
PLATE (1)
FULLY OPEN
THROTTLE
PLATE
RESISTANCE ( )
PIN
MIN.
MAX.
MIN.
MAX.
A-A2
A-K4
875
1625
875
1625
A-A2
A-K3
954
1934
228
585
A-A2
A-F3
254
634
980
1983
A-K3
A-K4
228
585
954
1934
A-K3
A-F3
1385
2315
1385
2315
A-K4
A-F3
980
1983
254
634
(1)
To obtain the fully closed position, it is necessary

to push against throttle plate in throttle body
with your hand and hold it in this position for the
measurement.
240
smr2009-030

vmr2008-022-005_a
If any resistance value is incorrect, check wire

continuity between ECM and throttle body. If
continuity is good, replace throttle body.
If resistance values are correct, try a new ECM.
Refer to ENGINE CONTROL MODULE (ECM) in
this subsection.
CRANKSHAFT POSITION
SENSOR (CPS)
smr2008-023-016_a
TYPICAL

ECM.
Probe terminals while cranking, as shown.
CPS CONNECTOR
MEASUREMENT
PIN
VOLTAGE
Approximately 2.3 Vac
smr2006-020-100_a
TYPICAL
1. Crankshaft Position Sensor (CPS)
NOTE: Take into account that a CPS fault can

be triggered by a bent or missing trigger wheel
tooth. First check fault codes then CPS as per
following procedure; if it tests good, verify trigger
wheel teeth condition. Refer to PTO HOUSING
AND MAGNETO in the ENGINE section.
lmr2006-021-002_a
TYPICAL
CPS Resistance Test

Disconnect CPS connector.
Probe terminals as follows.
CPS CONNECTOR
MEASUREMENT
PIN
RESISTANCE
@ 20C (68F)
CPS Voltage Test

To gain access to the CPS, remove the required
parts as described in CPS REPLACEMENT.
smr2009-030
700 - 900
241


Remove air intake silencer. Refer to AIR INTAKE
SYSTEM.
Drain oil from PTO housing. Refer to PTO HOUSING AND MAGNETO.
NOTE: It is not necessary to drain oil from engine.
lmr2006-021-002_b
TYPICAL
If resistance is not within specifications, replace

the CPS.
If resistance tests good, reconnect the CPS and
disconnect the ECM connector A on the ECM.
Using a multimeter and the ECM ADAPTER TOOL
(P/N 529 036 166).
Select and check circuit resistance as per table.
ECM ADAPTER
MEASUREMENT
PIN
RESISTANCE
@ 20C (68F)
A-H1
A-K2
smr2008-023-016_a
TYPICAL
Remove wire retaining clip if applicable.

Remove CPS retaining screw.
See above
smr2006-020-100_b
vmr2008-022-005_a
If resistance value is correct, check ECM. Refer to

ENGINE CONTROL MODULE (ECM) in this section.
If resistance value is incorrect, repair the connectors or replace the wiring harness between ECM
connector and the CPS.
CPS Replacement
Open seat.
SYSTEM.
242
1. Wire retaining clip

2. CPS retaining screw
Pull out CPS.

Reverse procedure for installation. However, pay
attention to the following.
screw threads then torque to 9 Nm (80 lbfin).
Refill engine oil and check oil level, refer to LUBRICATION SYSTEM subsection.
smr2009-030

Trigger Wheel Inspection

Refer to PTO HOUSING AND MAGNETO in the
ENGINE section.
CAPS CONNECTOR
MEASUREMENT
PIN
VOLTAGE
1
Battery voltage
CAMSHAFT POSITION SENSOR

(CAPS)
smr2009-030-035_a
smr2006-020-057_a
TYPICAL
1. CAPS
CAPS Voltage Test (Harness Side)

First check fuse F2 in fuse box #1 (FB).
To gain access to the CAPS, remove the required
parts as described in CAPS REPLACEMENT.
Disconnect CAPS connector.
If battery voltage is read, proceed with CAPS DYNAMIC TEST further.

If battery voltage is not read, probe circuit as
shown.
CAPS CONNECTOR
MEASUREMENT
PIN
VOLTAGE
Battery ground
Battery voltage
smr2009-030-035_b
smr2009-030-034_a
1. CAPS connector
Install D.E.S.S. key.

ECM.
Probe terminals as shown.
smr2009-030
If voltage is now read, check ground circuit between CAPS pin 1 and ECM pin A-D4 for continuity. Repair wire/connector if defective.
If voltage is still not read, check power supply circuit for continuity as follows.
Remove cover of fuse box #1. Refer to POWER
DISTRIBUTION.
243

vmr2007-050-004
They can be inserted at the end of the standard

probes of the FLUKE 115 MULTIMETER (P/N 529 035
868).
smr2009-027-011_f
1. Pull out

and select .
Read resistance of the CAPS circuit.
FUSE BOX #1
TERMINAL
C10
CAPS
CONNECTOR
RESISTANCE
vmr2007-050-005
PIN
3
Close to 0
(continuity)
CAPS
CONDITION
CAPS
CONNECTOR
Free
VOLTAGE
Close to 0 Vdc
smr2009-030-015_e
If continuity is good, wiring and connectors are

functional.
If continuity is faulty, repair/replace wiring from
fuse box terminal to CAPS.
CAPS Dynamic Test

To gain access to the CAPS, remove the required
parts as described in CAPS REPLACEMENT.
Remove CAPS sensor from engine.
Back-probe connector and read voltage as follows.
NOTE: To easily probe wire terminals through
the back of their connectors, FLUKE RIGID BACK
PROBE (P/N TP88) or equivalent can be used.
244
smr2007-021-010_a
CAPS
CONDITION
Metallic object
on sensor
CAPS
CONNECTOR
3
VOLTAGE
Battery voltage
smr2009-030

smr2009-030-034_a
1. CAPS connector
smr2007-021-009_c
1. Metallic object
If voltage is appropriate, check/repair wiring/connector between sensor and ECM. If it is good,

check ECM. Refer to ENGINE CONTROL MODULE (ECM).
If voltage is wrong, try a new CAPS.
CAPS Replacement
Unscrew the retaining screw.

Pull out CAPS from engine.
Install the CAPS. Ensure to reinstall O-ring.
Apply Loctite 243 (blue) on thread and torque to
9 Nm (80 lbfin).
MANIFOLD AIR TEMPERATURE

SENSOR (MATS)
Open seat.
SYSTEM.
SYSTEM.
Detach CPS connector from its holder.
smr2009-030-036_b
1. Manifold air temperature sensor (MATS)
MATS Resistance Test

smr2008-023-016_a
TYPICAL
To gain access to the MATS, remove the required

parts as described in MATS REPLACEMENT.
Disconnect the MATS connector.
Disconnect CAPS connector.
smr2009-030
245

TEMPERATURE
C
- 30
- 20
F
- 22
- 4
RESISTANCE (OHMS)
NOMINAL
12600
11400
LOW
11800
11000
HIGH
13400
11800
- 10
14
9500
8000
11,000
32
5900
4900
6900
10
50
3800
3100
4500
20
68
2500
2200
2800
30
86
1700
1500
1900
40
104
1200
1080
1320
50
122
840
750
930
60
140
630
510
750
1. MATS connector
70
158
440
370
510

and select .
Probe sensor terminals.
80
176
325
280
370
90
194
245
210
280
100
212
160
210
110
230
195
145
125
160
120
248
115
100
125
smr2009-030-036_a
vmr2008-022-005_a
lmr2006-021-004_a
The resistance should be as per following chart.

Otherwise, replace the MATS.
If resistance value is good, reconnect the MATS
and disconnect the ECM connector A on the ECM.
Install the ECM ADAPTER TOOL (P/N 529 036 166) to
ECM harness.
Probe adapter terminals as follows.
ECM ADAPTER
PIN
A-J3
246
MEASUREMENT
RESISTANCE
A-H3
See table below

connector and the MATS.
MATS Replacement
Open seat.
SILENCER.
Disconnect the connector of the MATS.
Screw MATS out and install the new one. Torque
to 17 Nm (150 lbfin).
smr2009-030

COOLANT TEMPERATURE
SENSOR (CTS)
If resistance tests good, reconnect the CTS connector and disconnect the ECM connector A on
the ECM.
(P/N 529 036 166), check the circuit resistance as
per table.
ECM ADAPTER
MEASUREMENT
PIN
A-A1
RESISTANCE
A-J2
See table below
TEMPERATURE
smr2006-020-057_b
TYPICAL
NOTE: Overheat signals will appear when coolant

temperature reaches:
RESISTANCE (OHMS)
NOMINAL
LOW
HIGH
- 30
- 22
12600
11800
13400
- 20
- 4
11400
11000
11800
- 10
14
9500
8000
11,000
32
5900
4900
6900
10
50
3800
3100
4500
20
68
2500
2200
2800
30
86
1700
1500
1900
ENGINE
TEMPERATURE
40
104
1200
1080
1320
All 1503
110C (230F)
50
122
840
750
930
60
140
630
510
750
CTS Resistance Test
70
158
440
370
510
To gain access to the CTS, remove the required

parts as described in CTS REPLACEMENT.
Disconnect the connector from the CTS and check
the resistance of the sensor itself.
80
176
325
280
370
90
194
245
210
280
100
212
195
160
210
110
230
145
125
160
120
248
115
100
125
vmr2008-022-005_a
lmr2006-021-005_a

Otherwise, replace the CTS.

ECM elsewhere in this section.
connector and the CTS.
CTS Replacement
Open seat.
smr2009-030
247

SYSTEM.
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 18 Nm
(159 lbfin).
MANIFOLD ABSOLUTE
PRESSURE SENSOR (MAPS)
smr2009-030-036_d
1. Disconnect

ECM.
and select Vdc.
Read voltage as per this table.
CONNECTION
VOLTAGE
Terminal 1 with battery ground
Approx. 5 V
Approx. 0 V
Approx. 0 V
smr2009-030-036_c
TYPICAL
1. Manifold absolute pressure sensor (MAPS)
NOTE: This sensor is a dual function device.

When engine is started and it runs at idle speed,
the sensor takes the atmospheric pressure and
stores it in the ECM. Thereafter, it takes the manifold absolute pressure at operating RPMs.
Ensure sensor is correctly installed on intake manifold. Otherwise, the MAPS could generate a fault
code for an unexpected sensor range at idle when
it reads the atmospheric pressure. Remove sensor and check for oil or dirt on its end and if problem persists, check throttle plate condition/position and the wiring harness. Perform the following tests.
MAPS Voltage Test

To gain access to the MAPS, remove the required
parts as described in CTS REPLACEMENT.
Disconnect connector from MAPS.
lmr2006-021-006_a
If voltage test is good, replace the MAPS.

If voltage test is not good, check the continuity of
the MAPS circuit.
MAPS Resistance Test

Disconnect the ECM connector A on the ECM.
248
smr2009-030


(P/N 529 036 166), check the resistance of circuit
A-B4, A-G4 and A-H2.
If wiring harness is good, check ECM. Refer to
Otherwise, repair the connectors or replace the
wiring harness between ECM connector and the
MAPS.
MAPS Replacement
Open seat.
SYSTEM.
Disconnect MAPS connector and remove the
MAPS.
Install the new MAPS paying attention to index
its tab into the adaptor notch. Apply Loctite 243
(blue) on screw then torque to 10 Nm (89 lbfin).
EXHAUST GAS TEMPERATURE

SENSOR (EGTS)
smr2008-023-018_a

Otherwise, replace the EGTS.
If resistance tests good, reconnect the EGTS and
disconnect the ECM connector A on the ECM.
(P/N 529 036 166), check the circuit resistance as
per following table.
ECM ADAPTER
PIN
A-J4
RESISTANCE
A-H4
TEMPERATURE
smr2009-030-040_a
1. Muffler
2. Exhaust gas temperature sensor (EGTS)
NOTE: Overheat signals will appear when exhaust temperature reaches:
See table below

RESISTANCE (OHMS)
NOMINAL
LOW
HIGH
- 30
- 22
- 4
12600
11800
13400
- 20
11400
11000
11800
- 10
14
9500
8000
11,000
32
5900
4900
6900
10
50
3800
3100
4500
20
68
2500
2200
2800
30
86
1700
1500
1900
40
104
1200
1080
1320
50
122
840
750
930
60
140
630
510
750
ENGINE
TEMPERATURE
70
158
440
370
510
All 1503
110C (230F)
80
176
325
280
370
EGTS Resistance Test

To gain access to the EGTS, remove the required
parts as described in EGTS REPLACEMENT.
Disconnect the connector from the EGTS and
check the resistance of the sensor itself.
smr2009-030
MEASUREMENT
90
194
245
210
280
100
212
160
210
110
230
195
145
125
160
120
248
115
100
125
249

KNOCK SENSOR (KS)
vmr2008-022-005_a

If resistance value is incorrect, repair the connector or replace the wiring harness between ECM
connector and the EGTS.
EGTS Replacement
Remove the LH rear storage basket.
Disconnect the exhaust hose from muffler.
Unplug the EGTS connector.
Unscrew EGTS from muffler.
Apply LOCTITE 518 (P/N 293 800 038) on the middle
threads of EGTS.
smr2008-013-041_a
1. Apply Loctite 518 in this area
Install the EGTS.

Tighten the sensor to 16 Nm (142 lbfin).
Plug the EGTS connector.
250
R1503motr174A
1. Knock sensor (KS)
KS Dynamic Test
Using the B.U.D.S. software, monitor the knock
sensor using the Faults section.
Start the engine and bring engine RPM above
5000 RPM. If no fault code occurs, the knock
sensor is good.
Otherwise, do the following.
Ensure sensor and cylinder head contact surfaces
are clean and mounting bolt and washer are correct and properly torqued down.
NOTE: It is necessary to remove intake manifold
to inspect contact surfaces. Refer to INTAKE
MANIFOLD AND INTERCOOLER section.
Check the knock sensor resistance.
KS Resistance Test
To gain access to the KS, remove the required
parts as described in KS REPLACEMENT.
Disconnect the connector from knock sensor harness.
smr2009-030

vmr2008-022-005_a
smr2009-030-038_a
1. KS connector
Using a multimeter, check the resistance between both terminals on the knock sensor.
If wiring harness is good, check ECM. Refer to

Otherwise, repair the connector or replace the
wiring harness between ECM connector and
knock sensor.
KS Replacement
smr2009-030-037_a
The resistance should be as per the following

chart.
If resistance is not good, replace knock sensor.
If resistance is good, reconnect the knock sensor
connector and disconnect connector A from ECM.
(P/N 529 036 166), check circuit resistance as per
following table.
ECM ADAPTER
MEASUREMENT
PIN
RESISTANCE
@ 20C (68F)
A-C3
smr2009-030
A-G2
Open seat.
SYSTEM.
SYSTEM.
Remove the intake manifold. Refer to INTAKE
MANIFOLD AND INTERCOOLER in the ENGINE
section.
Disconnect KS sensor connector.
Unscrew and remove knock sensor.
Clean contact surface, apply Loctite 243 in
threaded hole then install the new knock sensor.
Torque screw to 23 Nm (17 lbfft).
NOTICE Improper torque might prevent sensor to work properly and lead engine to severe
damage of internal components.
Replug connector.
5 M
251
252

Subsection 03 (FUEL TANK AND FUEL PUMP)
FUEL TANK AND FUEL PUMP

SERVICE TOOLS
Description
Part Number
DIAGNOSTIC HARNESS ...............................................................

ECM ADAPTER TOOL...................................................................
FUEL HOSE ADAPTER..................................................................
FUEL PUMP MODULE SOCKET...................................................
OETIKER PLIERS...........................................................................
PRESSURE GAUGE.......................................................................
SMALL HOSE PINCHER ...............................................................
529
529
529
529
529
295
529
295
529
smr2009-031
036
036
035
036
036
000
035
000
021
179
166
868
023
125
070
709
076
800
Page
......................................... 271
......................................... 265
................................. 265, 272
......................................... 262
......................................... 267
......................................... 264
......................................... 262
................................. 259, 261
......................................... 258
253

FUEL TANK AND FUEL PUMP
4.5 Nm
(39 lbfin)
NEW
NEW
NEW
NEW
NEW
60 Nm
(44 lbfft)
NEW
NEW
NEW
NEW
3.5 Nm
(31 lbfin)
smr2009-031-001_a
254
smr2009-031

FUEL SYSTEM DIAGNOSTIC FLOW CHART

Fuel pump does not run
Fuel pump runs

for 2 sec. then stops
Press Start button

Install fuel pressure gauge
on fuel pressure line
Check fuses.
Check fuel pump operation.
Repair or replace if necessary.
Replace fuel
pump module
Press Start button

Fuel pump runs
Fuel pressure is
303 kPa (44 PSI)
or 399 kPa (58 PSI)*
Fuel pressure less

than 303 kPa (44 PSI)
Repair or
replace
Fails
Fuel pressure more

Check fuel line/

rail for leaks
OK
Perform fuel pump test
Fails
Crank or start
engine
OK
Fuel pressure more
Fuel pressure less

Fast
pressure drop
Fuel pressure is
303 kPa (44 PSI)
No
Yes
Verify fuel
pump check
valve
OK
Check
fuel line/
rail for leaks
Repair or
replace
Fails
OK
Fails
Check fuel
injector
OK
FUEL SYSTEM OK
Fails
Perform fuel
pump test
Replace fuel
pump module
Retest
OK
* Supercharged Interooled models only.
smr2009-031-028_en
smr2009-031
255

GENERAL
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appropriate safety equipment when working on a
pressurized fuel system. Wear safety glasses.
WARNING
Always disconnect battery prior to working
on the fuel system. Fuel is flammable and
explosive under certain conditions. Always
work in a well ventilated area. Do not allow fuel to spill on hot engine parts and/or
on electrical connectors. Proceed with care
when removing/installing high pressure test
equipment or disconnecting fuel line connections. Use B.U.D.S. software to release fuel
pressure prior to removing a hose. Cover
the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose to
minimize spilling. Wipe off any fuel spillage
in the bilge. Before reconnecting battery,
make sure there is no unusually strong fuel
odor present and if so, vent the bilge area
thoroughly.
NOTICE Whenever repairing the fuel system,

always check for water infiltration in the fuel
tank. Replace any damaged, leaking or deteriorated fuel line.
SYSTEM DESCRIPTION
The fuel system is comprised of:
A fuel tank
A non-vented fuel tank cap
A fuel pump module mounted inside the fuel
tank
A fuel vent system, and
A variety of hoses.
The fuel pump module is basically comprised of:
1. An electric fuel pump mounted inside a canister
type pump reservoir
2. A lower inlet filter
3. An upper outlet filter
4. A pressure regulator
5. A float type fuel level sensor.
WARNING
When the repair is completed, ensure that
hoses and connections from fuel rail to the
fuel pump are properly secured. Then, pressurize the fuel system. After carrying out a
fuel pump pressure test, use the valve on the
fuel pressure gauge to release the pressure
(if so equipped).
WARNING
The fuel pump is energized for a few seconds
each time the START button is depressed.
It builds fuel system pressure very quickly.
Prior to pressing the START button, ensure
there are no disconnected or damaged fuel
lines that may leak fuel in the vehicle. A
high pressure leak test must be carried out
whenever a fuel system component has been
disconnected.
WARNING
Ensure wires and hoses are routed and secured away from any vibrating, rotating,
moving or hot components or sharp edges.
Use appropriate shields and fastening devices as per factory standards.
256
smr2008-022-007_a
FUEL PUMP MODULE

1. Fuel pump reservoir
2. Lower inlet filter
3. Upper outlet filter
4. Fuel pressure regulator
5. Float type fuel level sensor
Fuel Pump Operation

When the pump is in operation, it draws fuel into
the canister through a lower inlet filter and a disk
type valve.
The pressurized fuel is pushed through an upper
outlet filter to the fuel rail.
Excess fuel pressure generated by the pump is
routed from the upper filter back to the pump canister reservoir by a pressure regulator mounted on
the pump reservoir cover.
smr2009-031

When the START button is pressed, the electrical

system is powered. The fuel pump will come on
for approximately 2 seconds to pressurize the fuel
rail in preparation for the engine start.
The ECM supplies the ground signal to turn on the
fuel pump motor.
The pressure regulator will ensure appropriate
fuel pressure is supplied to the injectors.
When the ECM receives a signal to shut down
the engine (START/STOP switch, safety lanyard,
or T.O.P.S. sensor) it removes the fuel pump
ground signal.
smr2009-031-003_a
RH SIDE OF FRONT VENTILATION BOX

1. Inlet valve
Fuel Level Indication

An electric float type fuel level sensor is mounted
on the side of the fuel pump reservoir. As the
float moves with changing fuel levels, it varies a
resistance that changes the voltage signal coming fromthe information center (multifunction
gauge).This signal is representative of the fuel
level.
The information center interprets the fuel level
voltage signal that comes back from the fuel level
sensor. It then displays the proper fuel level bars
and a low fuel warning message when required.
The information center will also trigger the beeper
which produces the appropriate beep signal to
warn the driver of a low fuel condition.
The fuel level sensor resistance is at its lowest
value when the fuel tank is full, and at its highest
value when the tank is empty.
Refer to the FUEL LEVEL SENSOR in this subsection for fuel level sensor testing procedures.
smr2009-031-004_a
RH SIDE OF HULL (FRONT PART)

1. Outlet valve
The inlet valve is located high in the watercraft to

prevent water entry in fuel tank.
The inlet valve is a check valve that allows air to
enter fuel tank to prevent fuel starvation. It also
prevents fuel to flow out of fuel tank.
Fuel Tank Vent System Operation
smr2009-031-002_b
1. Inlet valve
smr2009-031-002_a
1.
2.
3.
4.
Fuel tank
Fuel tank cap
Inlet valve (check valve)
Outlet valve (fuel pressure relief valve)
smr2009-031
The outlet valve is a pressure relief valve that is

normally closed to prevent water entry in fuel
tank. It also prevents air to flow out.
257

smr2009-031-002_c
1. Outlet valve
If pressure in fuel tank build up and exceed

2.8 kPa - 7.6 kPa (.4 PSI - 1.1 PSI), the outlet valve
opens and let excess pressure evacuate outside
fuel tank.
smr2009-031-008_a
1. Ventilation box
Visually inspect condition of hoses and clamps.

Pull out inlet valve from its grommet.
smr2009-031-002_d
1. Outlet valve
INSPECTION
smr2009-031-009_a
1. Pull out inlet valve
FUEL TANK LEAK TEST

Fuel Tank Test
Fill up fuel tank.
Close fuel tank cap.
Open front storage compartment cover and remove storage bin.
Remove front ventilation box.
Make sure that grommets of inlet and outlet

valves are not plugged.
Use the VACUUM/PRESSURE PUMP (P/N 529 021
800).
529021800
NOTE: A Y-fitting and a check valve can be installed to use compressed air for quick pressure
build-up when fuel tank is not full.
258
smr2009-031

smr2009-031-101_a
TEST SETUP
mmr2009-121-004_a
1. Y-fitting P/N 293 710 059

2. Check valve P/N 275 500 505
3. Apply compressed air here
Install the vacuum/pressure gauge on inlet valve

end.
Slowly apply pressurized air.

NOTE: If pressure rises quickly within a few
strokes of pump, inlet valve is likely clogged.
Refer to INLET CHECK VALVE TEST in this subsection.
When pressure has reached 2.8 kPa - 7.6 kPa
(.4 PSI - 1.1 PSI) the pressure relief valve should
open preventing a further increase in pressure.
When valve opens, pressure must drop at pump
gauge.
If pressure increases above specification or gauge
does not drop to zero, replace outlet valve.
Install a SMALL HOSE PINCHER (P/N 295 000 076)
near outlet valve.
smr2009-031-010_a
1. Inlet valve end

2. Vacuum/pressure pump
3. Compressed air supply
Set vacuum/pressure pump to pressure.

295000076
NOTE: To validate outlet hose, connection and

valve altogether, a test cap (P/N 293 000 105) or
an equivalent hand made plug (such as a capped
vent hose) can be installed to the outlet nipple of
the valve.
smr2009-031-012_a
1. Pressure selected
smr2009-031
259

WARNING
If a leak is found, do not start the engine.
Wipe off any fuel that leaked and ventilate
the hull thoroughly to remove any accumulated fuel vapors. Do not use electric
powered tools on watercraft unless system
has passed the leak test.
Open fuel tank cap to release pressure in fuel
tank.
smr2009-031-102_a
TEST SETUP
Slowly apply pressurized air close to the pressure

specification.
NOTICE Do not exceed the specification
when pressurizing the fuel tank.
Bring the test pressure to the specification by
manually pumping the vacuum/pressure pump.
FUEL TANK LEAK TEST
PRESSURE
TIME WITHOUT PRESSURE

DROP
21 kPa (3 PSI)
10 minutes
If the pressure drops, locate fuel leak(s), repair/replace leaking component(s) and carry out a new
fuel system leak check to validate repair and ensure there are no other leaks.
NOTE: Possible leak areas: Inlet valve, fuel tank,
fuel tank neck, fuel tank cap, fuel pump gasket,
vent hoses, connections and valves, filler hose
and connections, fuel hose and connections, fuel
rail and injector(s).
To locate a leak, check for a fuel smell or leaking
fuel.
If a fuel smell is detected but a leak is not visible,
spray a soapy water solution on components to
ease locating the leak(s); bubbles will indicate leak
location(s).
NOTE: If pressure does not stand and no leak has
been found, it is likely a leaking fuel injector. Refer
to ELECTRONIC FUEL INJECTION.
Check Valve and Pressure Relief Valve

Test
Pressure Relief Valve Function Test
Valve is checked when performing the FUEL
TANK LEAK TEST.
WARNING
If pressure relief valve is stuck, the pressure
in fuel system will build up and it may cause
fuel leakage in engine compartment.
When replacing valve, always reinstall it with the
arrow pointing as shown.
smr2009-031-016_a
Reinstall valve in its grommet.

Inlet Check Valve Test
Disconnect vent hose from fuel pump.
NOTICE When the fuel system leak test is

complete, thoroughly rinse all components
of the soapy water solution with clear water.
A soapy water residue may cause premature
deterioration and must be rinsed away.
smr2009-031-014_a
1. Disconnect here
260
smr2009-031

Set the vacuum/pressure pump to vacuum.
smr2009-031-012_a
smr2009-031-013_a
1. Vacuum selected
Squeeze the vacuum/pressure pump handle several times to pressurize air to the inlet valve.
Install a SMALL HOSE PINCHER (P/N 295 000 076)

near outlet valve.
295000076
Connect vacuum/pressure pump to the vent hose

end.
smr2009-031-015_b
TEST SETUP
Valve should hold 34.5 kPa (5 PSI) without leakage. Otherwise, replace inlet valve.
When replacing valve, always reinstall it with the
black side as shown.
smr2009-031-015_a
TEST SETUP
Squeeze the vacuum/pressure pump handle several times to draw air in through the inlet valve.
Air should be drawn in freely and vacuum pressure indication on gauge should remain at zero. If
vacuum value rises, replace inlet valve.
Set vacuum/pressure pump to pressure.
smr2009-031
smr2006-026-004
Reinstall valve in its grommet.

Reinstall remaining removed components.
261

FUEL SYSTEM HIGH PRESSURE

LEAK TEST
WARNING
A high pressure leak test must be carried
out before starting the engine anytime a fuel
system component has been disconnected
for maintenance, or replacement.
Visually inspect fuel system to ensure all fuel system connections are installed.
Lightly pull on hoses at each connection to ensure
they are properly locked at the quick connect fittings.
Remove D.E.S.S. key from its post to prevent engine starting.
Press the START button to turn on the fuel pump
for a few seconds and pressurize the fuel system.
Check for fuel odor and visually inspect hoses, fittings and components for leaking fuel.
If a leak is detected, repair or replace the leaking
component and repeat leak test after the repair.
If no leak is found, engine can be started.
FUEL PUMP PRESSURE TEST
smr2009-031-008_a
1. Ventilation box
Ensure hoses and fittings are not leaking. Repair

any leak.
Ensure there is enough gas in fuel tank.
WARNING
The fuel hose may be under pressure. Cover
the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose to
release any residual pressure. Wipe off any
fuel spillage inside bilge.
Disconnect the pressure outlet hose from the fuel
pump.
Preparation
Before proceeding, ensure the battery is fully
charged.
The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and tests for leaks in the
system.
Release fuel pressure. Refer to FUEL PUMP in
this subsection.
Open front storage compartment cover.
Remove the storage basket.
smr2009-031-017_a
1. Outlet hose
Install the PRESSURE GAUGE (P/N 529 035 709)

and the FUEL HOSE ADAPTER (P/N 529 036 023)
between disconnected hose and fuel pump fitting
(inline installation).
262
smr2009-031

MODELS
FUEL PRESSURE (when

pressing the START
button)
1503 4-TEC
supercharged
intercooled
386 - 414 kPa (56 - 60 PSI)
Test when Cranking or Starting Engine

529035709
smr2009-031-018_a
1. Connect to fuel pump

2. Connect to outlet hose
Test when Engine Is Stopped

Press the START button and observe fuel pressure. Repeat twice. Release pressure in system
using the valve on the pressure gauge between
each test so that the reading returns to zero (0).
Crank or start engine and observe fuel pressure.

The fuel pressure should be the same as above.
If pressure is good, fuel pump and pressure regulator are functioning correctly.
A rapid pressure drop indicates leakage either
from the fuel rail or from the fuel pump check
valve. Check fuel rail for leaks.
If leak occurs while pressing the START button
and fuel rail is not leaking, then replace fuel pump
module.
A slow pressure drop indicates leakage either
from a fuel injector or from the fuel pressure
regulator in the fuel pump module. To check
fuel injectors for leaks, refer to the ELECTRONIC
FUEL INJECTION (EFI) subsection. If injectors
are not leaking, then replace fuel pump.
Release fuel pressure in system using the valve
on the pressure gauge.
Remove pressure gauge and reinstall fuel hose on
fuel pump module.
WARNING
Wipe off any fuel spillage in the bilge. Fuel
is flammable and explosive under certain
conditions. Always work in a well ventilated
area.
Reinstall all removed parts.
PROCEDURES
FUEL HOSES AND OETIKER
CLAMPS
Fuel Hose Inspection
Inspect all fuel hoses for wear, kinks, cracks or any
other types of damages.
Inspect all clamps for tightness.
Fuel Hose Replacement

smr2009-031-019_a
FUEL PUMP PRESSURE TEST

1. Valve on gauge
smr2009-031
When replacing fuel lines on all SEA-DOO watercraft models, be sure to use A1 type hose
approved by BRP for pressurized hoses, and
263

B1 type hose approved by BRP for ventilation

hoses. These hoses available from BRP meet our
system requirements and will ensure continued
proper and safe operation.
WARNING
Use of fuel lines other than those recommended by BRP may compromise fuel system integrity.
WARNING
Whenever removing a hose in the fuel system, always use new Oetiker clamps at assembly. Then, validate fuel tightness by performing a fuel tank leak test or a high pressure leak test as applicable.
F01B05A
1. Securing clamp in limited access
FUEL PUMP
How to Release Fuel Pump Pressure
Oetiker Clamp Replacement
Connect to the latest B.U.D.S. software, refer to
To secure or cut Oetiker clamps on fuel lines, use

OETIKER PLIERS (P/N 295 000 070).
COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection.

Select the Activation tab then the ECM tab.
On the RH side of the activation page, click Fuel
Press Relief button to release the fuel pressure in
the system.
1
F01B03A
1. Cutting clamp
smr2009-031-020_a
RELEASING FUEL SYSTEM PRESSURE

1. Activation tab
2. ECM tab
3. Click Fuel Press Relief
Run engine until it runs out of gas.
Fuel Pump Operation Test

F01B04A
1. Securing clamp
264
Disconnect throttle body connector to prevent the

throttle actuator to initialize.
NOTE: This step is recommended to minimize
noise to validate fuel pump operation.
smr2009-031

smr2009-030-024_a
1. Throttle body
2. Inlet hose
3. Connector

Press START button.
The fuel pump should run for 2 seconds to build
up fuel system pressure.
If fuel pump runs, carry out the FUEL PUMP
PRESSURE TEST in this subsection.
If the fuel pump does not run:
Ensure ECM is powered. Refer to ELECTRONIC FUEL INJECTION subsection.
Check fuse F6. If fuse is faulty, replace it and
repeat test. If fuse is good, carry out the FUEL
PUMP INPUT VOLTAGE TEST in this subsection.
Reconnect throttle body connector.
smr2008-022-017_b
If battery voltage is read, power circuit is good.

Test the fuel pump circuit. Refer to FUEL PUMP
CIRCUIT TEST.
If battery voltage is not read, power circuit is
faulty. Test continuity of power circuit between
fuse box #1 and fuel pump.
Fuel Pump Circuit Test

Reconnect the fuel pump harness connector.
Fuel Pump Input Voltage Test

Disconnect fuel pump harness connector. Refer
to FUEL PUMP REMOVAL.
Use the FLUKE 115 MULTIMETER (P/N 529 035 868).
Select Vdc.
Press START button.
Read voltage at fuel pump harness connector as
per following table.
INPUT VOLTAGE TEST
TEST PROBES
Pin B
(+ probe)
smr2009-031
Battery
ground
(- probe)
VOLTAGE
Battery voltage
smr2009-027-011_f
1. Long bus bar
Remove ECM connector B and install it on the

ECM ADAPTER TOOL (P/N 529 036 166).
265

529036166
Set multimeter to
following table.
and test pump circuit as per
PUMP CIRCUIT TEST THROUGH FUEL PUMP

TEST PROBES
Fuse box #1
terminal C1
ECM
connector B
pin B-M1
smr2009-031-021_a
RESISTANCE @
20C (68F)
Approx. 12
smr2009-031-021_b
Repair or replace wiring as required.

If every test succeeded and fuel pump still does
not work, try a new ECM. Refer to ELECTRONIC
smr2009-030-015_g
If test succeeded, the fuel pump and its wiring

harness are good.
If test failed, test wiring continuity as per table.
FUEL PUMP HARNESS CONTINUITY
TEST (WIRING ONLY)
TEST PROBES
Pump harness
connector pin B
Fuse box #1
terminal C1
Pump harness
connector pin A
ECM
connector B
pin B-M1
266
RESISTANCE @
20C (68F)
Fuel Pump Removal

Release fuel pressure. Refer to FUEL PUMP in
this subsection.
NOTE: Removing dashboard may help to give
some light on the working area.
Close to 0
(continuity)
smr2009-031

smr2009-031-008_a
1. Ventilation box
Disconnect the negative battery terminal, refer to

Disconnect fuel pump electrical connector.
Disconnect the vent tube from the fuel pump.
Wrap shop rags around the high pressure fuel
hose fitting, then press on the release button of
the quick connect fitting and disconnect the hose.
smr2009-031-022_a
1. Fuel pump module socket

2. Fuel pump retaining nut
NOTICE While pulling out the fuel pump

module, pay attention to the corrugated tubes
and fuel sensor float arm. Float arm can get
caught up and bend which will reduce fuel sensor accuracy. If fuel pump module is dropped
or damaged, it must be replaced.
Slowly pull fuel pump module up through opening
until corrugated tubes contact sides of opening.
Tilt the fuel pump module as you slowly pull the
pump upwards.
WARNING
The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will
drain out when fuel pump module is not in an
upright position.
Carefully pull fuel pump module out.
smr2009-031-017_b
1. Quick connect fitting (high pressure fuel hose)

2. Vent hose
3. Harness connector
Unscrew the fuel pump retaining nut using the

FUEL PUMP MODULE SOCKET (P/N 529 036 125).
smr2009-031-023_a
1. Pull out fuel pump module
smr2009-031
267

WARNING
Always wipe off any fuel spillage from the
watercraft. When working with fuel or fuel
system and its components, always work in
a well ventilated area.
Fuel Pump Installation

Reverse the removal procedure however, pay attention to the following.
Carefully insert fuel pump module in fuel tank so
as not to bend float arm.
Install a new fuel pump module gasket each time
the module is reinstalled.
NOTE: Wipe off parts to prevent fuel pump from
turning while torquing fuel pump nut.
Align arrow on top of fuel pump module with index
mark on top of fuel tank or fuel sensor accuracy
will be affected.
NOTE: Index mark and arrow locations are highlighted for clarity in following illustration.
smr2009-031-025_a
1. Fuel filter
Fuel Filter Removal

NOTE: The lower fuel filter on the fuel pump module does not require replacement under normal
operating conditions. Replace only if permanently
clogged or damaged.
Remove fuel pump. Refer to FUEL PUMP in this
subsection.
WARNING
upright position.
Turn fuel pump upside down.
Using a small flat screwdriver, pry up the filter
locking tabs.
smr2009-031-024_a
FUEL PUMP MODULE INDEXING

1. IAlign marks
Apply torque values as per exploded view.

Carry out a FUEL TANK LEAK TEST and a FUEL
SYSTEM HIGH PRESSURE LEAK TEST. See procedures in this subsection.
FUEL FILTER
Fuel Filter Inspection
Check if fuel filter is dirty. If so, replace it.
smr2008-022-013_a
1. Fuel filter locking tab (x2)

2. Filter locking pin (x2)
Pull filter off fuel pump reservoir housing.
Fuel Filter Installation

Align new filter with pump reservoir housing.
268
smr2009-031

Press new filter on by hand. Ensure it is fully

seated and locked onto the pump reservoir housing.
Reinstall fuel pump as per procedure in this subsection.
Carry out a FUEL SYSTEM HIGH PRESSURE
LEAK TEST as described in this subsection.
FUEL TANK
NOTE: A fuel tank is comprised of 2 components:

the tank and the filler neck. The necks are injection molded and the tank is then blow molded over
the necks. During the molding process, a small
molding seam may appear on the inner side of the
necks at approximately 4 mm (5/32 in) from the
base of the neck. It is a normal situation to have a
molding seam and it should not be confused with
a crack.
4
Fuel Tank Inspection

NOTE: Removing dashboard may help to give
some light on the working area.
F07F06A
1.
2.
3.
4.
5.
A.
Tank upper surface area

Inspect outer upper surface at filler neck
Normal molding seam
Inspect upper surface area inside filler neck
Base of filler neck
Approx. 4 mm (5/32 in)
Install filler hose.

Fuel Tank Removal

smr2009-031-008_a
1. Ventilation box
Inspect fuel tank retaining straps for wear, cracks

or any other damages. Inspect strap clip anchors
and bolts.
Inspect fuel tank for wear caused by any abnormal
contact or rubbing with other component(s).
Disconnect fuel filler hose from fuel tank.
Inspect fuel tank filler hose for wear, cracks or
other damages.
Visually inspect the inside and outside of the fuel
tank filler necks for crack(s). If crack(s) are found,
replace fuel tank.
With your fingers, feel the inside and outside surfaces of fuel tank, especially near the filler neck.
Flex fuel tank necks to ensure there are no hidden
cracks.
smr2009-031
Release fuel pressure. Refer to FUEL PUMP.

Remove moving deck. Refer to BODY.
Remove engine. Refer to ENGINE REMOVAL
AND INSTALLATION.
Remove suspension base. Refer to SUSPENSION.
Siphon fuel tank.
Disconnect fuel pump connections.
269

Place fuel tank retaining strap ends in anchoring

clips. Temporarily use tape to hold straps on the
top of fuel tank.
smr2009-031-017_b
1. Quick connect fitting (high pressure fuel hose)

2. Vent hose
3. Harness connector
Disconnect filler hose from fuel tank.

NOTE: Removing retaining screws of the filler
neck may help to disconnect hose from fuel tank.
smr2009-031-027_a
1. Fuel tank retaining strap

2. Clip anchor securing strap to hull
Secure a long retaining strap end with a short

strap end on top of fuel tank.
NOTE: Fuel tank retaining straps are paired one
long and one short together, and two consecutive
pairs are installed in opposing directions to stagger the metal retainers. See following illustration.
smr2009-031-026_a
1. Filler hose
2. Retaining clamp
NOTE: Take note of wiring harness, hoses and

cable routing for proper reinstallation. Also note
method used for securing with locking ties.
Detach fuel tank retaining straps.
Remove fuel tank from the vehicle.
Remove fuel pump as necessary. Refer to FUEL
PUMP in this subsection.
Inspect hull and flotation foams for wear.
Fuel Tank Installation

NOTE: Apply torque values as specified in the exploded view.
Reinstall fuel pump if it was removed. Refer to
FUEL PUMP in this subsection.
Ensure flotation foams are properly positioned.
Insert fuel tank in hull.
270
smr2008-022-016_a
REAR FUEL TANK RETAINING STRAPS ILLUSTRATED

1. Long retaining straps
2. Short retaining straps
Properly secure wire harness, cables and hose as

prior to removal using appropriate locking ties.
Install fuel tank filler hose as shown. Torque retaining clamps as per exploded view.
smr2009-031

Fuel Level Troubleshooting

FUEL LEVEL TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSE
Fuel gauge always

display EMPTY
Wiring/connectors
Fuel level sensor
Float stuck in low position
Fuel gauge always

display FULL
Water in fuel pump

connector
Float stuck in full position
Fuel level sensor fault Wiring/connectors

code
Fuel level sensor
smr2009-031-024_b
INDEXING WITH FUEL TANK

1. Align mark with the writing on hose
Reinstall all other removed parts. Refer to their

subsections.
When vehicle reassembly is complete, carry out
a FUEL TANK LEAK TEST and a FUEL SYSTEM
HIGH PRESSURE LEAK TEST as described in this
subsection.
FUEL LEVEL SENSOR

Fuel Level System Overview
A float type fuel level sensor mounted on the fuel
pump module sends a signal to the information
center.
smr2008-022-007_b
TYPICAL FUEL PUMP MODULE

1. Fuel level sensor
The information center interprets this signal and

turns on the appropriate number of segments of
a bar type fuel level indication in the lower RH side
of the digital screen in the information center.
smr2009-031
Fuel gauge displays

wrong level
Low battery voltage

Use B.U.D.S. to check for a fault code. Refer to

MONITORING SYSTEM AND FAULT CODES.
Fuel Level Sensor Voltage Test

First ensure battery is fully charged.
Lift suspension using the iS up button to gain access.
NOTE: If more height is required or if the iS cannot be used, manually lift suspension by the anchor points close to handlebar and safely lock in
anchor points.
From under the moving deck steering area, disconnect the 6-pin connector.
smr2009-042-005_d
1. 6-pin connector

disconnected connector.
271

Remove diagnostic harness and reconnect connector.
Fuel Level Sensor Resistance Test at

Information Center
529036179
NOTE: Plug only the connector that has been disconnected.

ECM.
and select Vdc.
Measure the voltage on the installed diagnostic
harness connector as follows.
FUEL TANK
LEVEL
Full
Empty
6-PIN
CONNECTOR
OF
DIAGNOSTIC
HARNESS
Pins 2 and 3
VOLTAGE
Disconnect information center (multifunction

gauge) connector. Refer to GAUGE subsection.
and select .
Alternately drain then fill fuel tank and measure
the sensor resistance between pins 19 and 20 as
follows.
RESISTANCE ( )
FLOAT HEIGHT (MM)
4.8 2.2
268.9 3.0 (FULL)
17.8 2.2
240.6 3.0
27.8 2.2
219.1 3.0
37.8 2.2
193.8 3.0
47.8 2.2
161.9 3.0 (HALF)
57.8 2.2
128.3 3.0
67.8 2.2
94.1 3.0
77.8 2.2
60.6 3.0
89.8 2.2
28.8 3.0 (EMPTY)
0.14 Vdc
2.7 Vdc
A. Float height
smr2009-030-033_c
NOTE: Voltage could be slightly different depending on battery voltage but should remain relatively
close to this range. If fuel tank is not full or empty,
the voltage value will be proportional to the fuel
level (somewhere in-between).
If voltage is as per specifications the fuel level circuit and sensor are good. If fuel level does not
work in information center, try a new one.
If voltage is out of specifications, perform the
NOTE: If fuel tank is not full or empty, the resistance value will be proportional to the fuel level
(somewhere in-between).
If readings are as per specifications, the fuel level
circuit and sensor are good. If fuel level does not
work in information center, try a new one.
If readings are out of specifications, perform the
FUEL LEVEL SENSOR RESISTANCE TEST AT

FUEL PUMP.
Reconnect information
gauge) connector.
center
(multifunction
Fuel Level Sensor Resistance Test at

Fuel Pump
Disconnect fuel pump module connector.
FUEL LEVEL SENSOR RESISTANCE TEST AT

INFORMATION CENTER as described in this subsection.
272
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Fuel Level Sensor Removal
smr2008-022-018_f
TYPICAL FUEL PUMP MODULE

1. Fuel pump module connector
Alternately drain then fill fuel tank and measure

the sensor resistance between pins C and D of the
fuel pump connector. See table in FUEL LEVEL
SENSOR RESISTANCE TEST AT INFORMATION

CENTER.
smr2008-022-029
FUEL LEVEL SENSOR
Remove fuel pump module from fuel tank, see

FUEL PUMP REMOVAL in this subsection.
WARNING
upright position.
Drain all fuel from the upper fuel filter and fuel
pump reservoir in an appropriate container.
NOTE: Note routing of fuel level sensor wires
prior to disconnecting the sensor from the fuel
pump module flange.
Disconnect the fuel level sensor connector from
the fuel pump module upper flange.
smr2008-022-018_e
TYPICAL FUEL LEVEL SENSOR RESISTANCE TEST
If readings are out of specifications, replace sensor.

When everything else has been tested and fuel
level is still not working, try a new information
center.
smr2008-022-021_a
1. Fuel level sensor connector
Disconnect the ground wire from the pressure

regulator. Be careful not to bend the ground contact on the pressure regulator.
smr2009-031
273

Once the pressure regulator is rotate over the

locking tab, pull up on it to remove it from the
pump reservoir cover.
smr2008-022-022_a
1. Pressure regulator
2. Ground wire contact on pressure regulator
3. Ground wire disconnected
Using a flat screwdriver, press down on the locking tab just below the pressure regulator to release it from the pump reservoir cover, and rotate
it clockwise simultaneously so that it slips over
the locking tab.
smr2008-022-025_a
1. Pressure regulator alignment tabs

2. Fuel pump reservoir alignment tabs
NOTE: The pressure regulator cover must not be

removed from the pressure regulator housing assembly.
smr2008 022-023_a
1. Pressure regulator
2. Pressure regulator locking tab
smr2008-022-028_a
1. Do not remove pressure regulator cover at locking tabs

2. Pressure regulator cover
3. Pressure regulator housing
Push in on the release tabs at the top of the fuel

level sensor to unlock it from the fuel pump reservoir housing, and simultaneously pull up on the
fuel level sensor to remove it.
smr2008-022-024_a

2. Pressure regulator rotated clockwise over locking tab
274
smr2009-031

Align the fuel pressure regulator tabs into the

pump reservoir cover and turn it counterclockwise until it locks properly.
smr2008-022-026_a
1. Fuel level sensor release tabs

2. Locking pins
smr2008-022-025_b
PRESSURE REGULATOR INSERTION INTO PUMP RESERVOIR

COVER
1. Pressure regulator alignment tabs
2. Fuel pump reservoir alignment tabs
smr2008-022-027_a
1. Pull up on fuel level sensor
Fuel Level Sensor Installation

Installation is the reverse of the removal procedure however, pay attention to the following.
Ensure fuel level sensor locking pins are properly
engaged into the fuel pump reservoir.
smr2008-022-030_a
TAB UP WHEN PRESSURE REGULATOR PROPERLY LOCKED

Reconnect the ground wire onto the pressure regulator.
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1. Ensure engagement of sensor locking pins
smr2008-022-031_a
1. Pressure regulator ground wire installed
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275

Ensure fuel level sensor connector is locked into

the module flange connector.
smr2008-022-021_a
1. Fuel level sensor connector
Carry out a FUEL LEVEL SENSOR RESISTANCE

TEST as described in this subsection.
Reinstall the fuel pump module. Refer to FUEL
PUMP INSTALLATION in this subsection.
276
smr2009-031
Section 05 ELECTRICAL SYSTEM

Subsection 01 (CONTROLLER AREA NETWORK (CAN))
CONTROLLER AREA NETWORK (CAN)

SERVICE TOOLS
Description
Part Number
Page
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 279

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 279
GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an ISO standard for serial data communication.
The CAN bus is the nervous system of the iControl system and the engine management system (EMS).
It links the electronic modules (ECU's) together so that they communicate to interact as required.
Two wires connect each component and they are in constant communication with each other at a rate
of about every 10 or 20 milliseconds depending on the component. CAN lines consist of a pair of wires
(WHITE/BLACK and WHITE/RED).
The CAN is also used to communicate with the B.U.D.S. software. Refer to COMMUNICATION TOOLS
AND B.U.D.S. SOFTWARE.
C1
C5
C3
CAN BUS - LOW
Engine Control Module

Intelligent Brake and Reverse module
Intelligent Suspension module
iBR
3
C4
C12
WH/RD
WH/RD
C8
WH/RD
C10
DEPTH
SOUNDER
DIAGNOSTIC
CONNECTOR
WH/BK
iS
WH/BK
WH/BK
ECM
iBR
iS
WH/RD
WH/RD
GAUGE
(FUSE BOX 2)
WH/BK
WH/BK
B-C2
WH/BK
WH/RD
ECM
C9
B-C1
C11
C7
CAN BUS - HI
C2
(FUSE BOX 2)
C6
WH/BK = WHITE/BLANK
WH/RD = WHITE/RED
smr2009-027-004_en
CAN BUS DIAGRAM
smr2009-048
277

TROUBLESHOOTING
DIAGNOSTIC TIPS
Check the fault codes using B.U.D.S. software as a first troubleshooting step. Refer to MONITORING
SYSTEM/FAULT CODES section.
CAN Communication Problems

The following chart gives some symptoms and behaviors relative to the CAN component in cause. The
list is not exhaustive, only the most significant items are given to help troubleshooting.
CAN FAULTY
WIRES (NO
COMMUNICATION)
VEHICLE BEHAVIOR OR OBSERVATION

IN INFORMATION CENTER
Short circuit in CAN

wires
Engine is set to limp home mode.

iBR gate will not move. "Locked" in neutral.
iBR light is ON.
Check engine light is ON.
B.U.D.S. will not be able to communicate

with any electronic module.
No vehicle detected message will be
displayed in B.U.D.S.
Information center
(cluster)

iBR light is ON.
Some functions not displayed
such as: iS, VTS, RPM.
3 modules instead of 4 will be active.

"Cluster" tab and its data will not be present.
ECM, iBR and iS will report a cluster CAN
problem.
ECM (Engine
Control Module)

iBR light is ON.
iBR gate "locked" in neutral.
Some functions not displayed such as:
engine hours, RPM.

ECM tab and its data will not be present.
iBR and iS will report an ECM CAN problem.
iBR (intelligent
Brake and Reverse)

iBR gate will not move. "Locked" in neutral.
iBR light is ON.
Some functions not displayed
such as: Lake water temperature, no VTS,
no F,N,R indication.

iBR tab and its data will not be present.
ECM and iS will report an iBR CAN problem.
iS (intelligent
Suspension)
iS handlebar controls have no effect.

No DOCK mode. Suspension will remain
to its last position before the CAN problem.
iS position is not displayed.

iS tab and its data will not be present.
Depth sounder
The menu Depth Sounder

Indicator will not be visible.
The Depth menu will not be available.
Nothing will be observable.
Nothing will be observable.
B.U.D.S. will not be able to communicate

with any electronic module.
No vehicle detected message will be
displayed in B.U.D.S.
Diagnostic
connector
278
OBSERVATION IN B.U.D.S.
smr2009-048

CAN Continuity Tests

If a communication problem is present, perform
the appropriate continuity test relating to the component reported by B.U.D.S.
Test wire continuity between the corresponding
terminal of the CAN bus bar in fuse box no. 2 and
the suspected component as follows.
Remove cover from fuse box no. 2.
The following gives an example between the CAN

LO wire and the ECM.
NOTE: When working with the ECM, install the
ECM ADAPTER TOOL (P/N 529 036 166) on ECM "B"
connector.
ECM
CONNECTOR
FUSE BOX
TERMINAL
RESISTANCE
B-C2
FB2-C1
Close to 0
(continuity)
2009-027-009_a
1. Fuse box no. 1

2. Fuse box no. 2
smr2009-048-001_a
Pull out both CAN bus bars.
EXAMPLE CHECKING ECM CAN LO WIRE
If continuity is good, CAN lines are functional.

If continuity is not good, check wiring, connectors
and terminals condition.
NOTE: It may be necessary to check the continuity to more than one component.
Reconnect connectors and reinstall removed
parts.
smr2009-027-010_d
FUSE BOX #2
1. CAN LO bus bar
2. CAN HI bus bar
Inspect bus bar condition.

Disconnect the connector from the component to
be tested. Refer to its appropriate subsection.
and select .
Refer to the CAN BUS DIAGRAM above and read
wire resistance between the proper bus bar terminal and the component terminal. Check the continuity of the WHITE/RED wire and the continuity
of the WHITE/BLACK wire.
smr2009-048
279
280

Subsection 02 (POWER DISTRIBUTION)
POWER DISTRIBUTION
SERVICE TOOLS
Description
Part Number
Page
SERVICE PRODUCTS
Description
Part Number
Page
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281

SIMPLIFIED ELECTRICAL SYSTEM SCHEMATIC

B-M4
D4
A1
A3
ECM
(power)
F17 (30 A)
A5
FUSE BOX
NO. 2
BAT
A2
D11
D1
E3
E1
Voltage regulator/rectifier
iBR (power)
iS (power)
START/STOP switch
Diagnostic connector
Multifunction gauge (GPS)
A9
D12 A4
F23 (3 A)
A8
F22 (15 A)
B4
F21 (3 A)
B6
F16 (30 A)
B5
F18 (30 A)
A6
F15 (30 A)
A7
D2
E4
E2
B8
B7
A12
B12
B10
Power
relay
F20 (15 A)
B2
A10
D3
D6
D4
BATTERY POWER
ECM
B-H2
FUSE BOX
NO. 1
D8
C9
C11 C3
C1
C12
A4
B4
A6
A8
A10 B8
B10 B12 B6
A2
A12
F11 (5 A)
F4 (5 A)
F3 (3 A)
F2 (15 A)
F9 (10 A)
F8 (10 A)
A3
B3
A7
A9
B7
B9
A5
B11 B5
A1
F1 (3 A)
C10 C7
F6 (10 A)
C8
F10 (3 A)
C4
F7 (10 A)
C5
F5 (5 A)
C6
C2
A11
iBR (control)
12
Multifunction gauge
iS (control)
Fuel pump
Starter solenoid (coil)
O.T.A.S. Sensor
Depth sounder
Fuel injector
Ignition coil
No. 1
CAPS
Fuel injector
Ignition coil
No. 2
Fuel injector
Ignition coil
No. 3
SWITCHED POWER
CAPS
ECM
iBR
iS
GPS
Camshaft Position Sensor

Electronic Control Module
Intelligent Brake and Reverse Module
Intelligent Suspension
Global Positioning System
smr2009-027-008_en
282
smr2009-049

GENERAL
It is highly recommended to disconnect the battery when replacing any electric or electronic component.
WARNING
Always disconnect battery exactly in the
specified order, BLACK (-) cable first, RED (+)
cable last. Always reconnect BLACK (-) cable
last. Do not place tools on battery.
smr2009-027-011_d
COMPONENT DESCRIPTION
Fuse Boxes
Fuse Box Location
To access the fuse boxes, open the boarding platform and remove the RH storage bin.
TYPICAL - CONTACT COORDINATES (FRONT VIEW FB1)
Coordinates are used to identify the terminal position in the fuse box. For example, if B5 (or FB1B5) is given to reference a terminal, it would be
located at the intersection of row B and column 5
in fuse box 1.
NOTE: Contact coordinates in FB2 are identified
using the same method.
NOTE: Although the contacts in the fuse boxes
are in reality sockets, they will be referred to as
pin numbers (ex. pin B6) in the procedures.
Fuse Identification
FUSE BOX 1 (FB1)
FUSE # RATING
DESCRIPTION
1
3 A
Gauge (Information center)
2009-027-009_a
1. Fuse box #1
2. Fuse box #2
Fuse Box Pin Out Identification

Fuse box contacts are identified on the back of the
fuse box (wire side) with letters to identify rows,
and numbers to identify columns. The combined
letter and number identify the coordinate of a contact that is used in the wiring diagram.
Since the fuses and fuse contacts are normally accessed from the front of the fuse box, the following illustration gives the coordinates as seen from
the front.
smr2009-049
3 A
CAPS
3
4
3 A
Depth sounder (if so equipped)
5 A
Starter solenoid
5 A
iBR control
6
7
10 A
Fuel pump
10 A
Cyl. 1 (ignition coil and injection)
10 A
10 A
10
11
3 A
O.T.A.S. switch
5 A
iS control
FUSE BOX 2 (FB2)
FUSE # RATING
DESCRIPTION
15
30 A Charge (Charging system)
16
17
30 A
iS (Power)
30 A
Battery
18
30 A
iBR (Power)
20
15 A
ECM (Main power)
21
3 A
START/STOP switch
22
15 A
Diagnostic Tool
23
3 A
GPS
283

Fuse box Cover Installation

When installing a fuse box cover, ensure the seal
is properly seated. If the seal has been removed,
ensure to reinstall it as illustrated.
smr2009-016-011_a
FRONT OF ENGINE
1. Engine grounds
A cable connected to the engine behind the exhaust manifold, is connected at the other end to
the battery ground post to complete the ground
circuit.
smr2007-027-003_a
TYPICAL
1. Wider lip here
Bus-bars
A bus-bar is a conductive aluminum bar with two
or more terminals that plug into the fuse box
contacts in the same way that a fuse does. It
receives current from one terminal and conducts
the current to all other terminals into which it
is connected. The terminals conduct current
through their circuit wires to the electrical components.
smr2009-016-026_b
LH SIDE OF ENGINE
1. Battery ground cable
2. Exhaust manifold water inlet fitting
CAN Distribution Bus-bars

The CAN bus-bars in fuse box 1 connect the
LO and HI bars to different CAN enabled components. This effectively links the components
together so they may communicate between
each other as required for proper system operation. Refer to CONTROLLER AREA NETWORK
(CAN) for more details.
smr2009-027-012
BUS BAR
These bus-bars are also used for low power signal

circuits (CAN bus), and for ground circuits with a
common grounding point.
Ground Distribution Bus-bar
The ground bus-bar collects the grounds from different components and connects them to the engine grounds through terminal E5 in fuse box 2
(FB2-E5).
284
POWER DISTRIBUTION
As can be seen in the simplified diagram, the
battery directly powers two bus-bars in fuse box
2 (FB2) through terminals A1 and A5, which in
turn redistribute power to other components.
That power is then available for the components
to utilize when they are activated.
Terminals A3 to A4 supply 12 Vdc power through
a 30 A fuse to the iS module for the iS motor.
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smr2009-027-010_b
FUSE BOX 2 BUS BAR IDENTIFICATION

1. 12 Vdc from battery
2. 12 Vdc from battery
3. CAN LO
4. CAN HI
5. Ground bus-bar
The power relay in FB2 is connected directly to

one of two 12 Vdc bus bars in FB2. When the
START/STOP button is pressed, it completes a
12 Vdc circuit to wake up the ECM, which in turn
completes the power relay ground circuit.
smr2009-027-011_a
FUSE BOX 1 BUS BAR IDENTIFICATION

1. Primary switched power
2. Secondary switched power
If the electrical system is energized and the engine is not started, the ECM will open the power
relay ground circuit to shut off power after approximately 3 minutes, unless the START button
is pressed again.
When the power relay open, it isolates the battery from the electrical components, including
the ECM, therefore preventing excessive battery
drain.
The only current drain on the battery when power
is switched off by the ECM is for the GPS in the
information center. It receives power through pin
1 of the information center (not illustrated). This is
used to maintain the GPS memory of the satellite
locations for approximately two hours.
Electrical System Activation

smr2009-027-010_c
1. Power relay
When the power relay closes, it applies 12 Vdc

to a bus bar located in fuse box 1 (FB1) through
terminal D6, which in turn distributes power to
the other 12 Vdc bus-bar and the remainder of the
fused circuits.
Terminal D4 of FB1 then supplies the main ECM
power through a 15 A fuse in FB2.
smr2009-049
1. Press the START/STOP button to energize the

electrical system.
2. Install the safety lanyard (D.E.S.S. key) on its
post to maintain the Information Center active
when testing procedures require it.
Installing the D.E.S.S. key without pressing the
START/STOP button will not turn on electrical
power.
Pressing the START button without the D.E.S.S.
key installed on its post will turn on electrical
power without starting the engine; the information center will cycle through a self-test function
and shut off its display after a few seconds. However, the electrical system will stay powered up
for approximately three minutes after the START
button was depressed.
NOTE: If the START/STOP button is pressed and
held without the D.E.S.S. key installed, the information center will stay on as long as the START
button is held without cranking the engine.
285

If B.U.D.S. is being used for communicating with

the electronic modules, or if the information center must be ON for testing, selecting modes of
operation, changing key settings, or for other
functions accessed through the information center, the D.E.S.S. key must be installed.
NOTE: To prevent the electrical power from
shutting down after approximately 3 minutes,
press the START button before the three minute
power-up period ends.
Keep in mind that an electrical component may

require more than one fuse, one low amperage
rated fuse for its control circuit, and another higher
rated fuse for the main component power. These
two fuses may not be in the same fuse box.
1
2
3
TROUBLESHOOTING
DIAGNOSTIC TIPS
NOTE: It is a good practice to check for fault
codes using B.U.D.S. software as a first troubleshooting step. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection.
IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.
Circuit Testing
Check the related-circuit fuse condition with a
fuse tester or ohmmeter. A visual inspection on
its own could lead to an incorrect conclusion.
Electrical Connection Inspection

When replacing an electric or electronic component, always check electrical connections. Make
sure they are tight, make good contact, and are
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a
system or component malfunction.
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors.
Ensure all wire terminals are properly crimped on
wires, and connector housings are properly fastened.
Check for signs of moisture, corrosion or dullness.
Clean pins properly and coat them with DIELECTRIC GREASE (P/N 293 550 004) or other appropriate lubricant (except if otherwise specified) when
reassembling them.
Pay attention to ground wires.
Fuse Inspection
If an electrical system fault occurs, check the
fuses. If a fuse is burnt, replace it with a fuse of
the same rating.
286
A15E0KB
1. Fuse
2. Check if melted
3. Ampere rating
A visual inspection of a fuse may not be conclusive.

Two metal contacts are visible at the top of the
fuses. They can be used for testing the fuse using a fuse tester or a multimeter. They can also be
used for testing the circuit the fuse protects without removing the fuse.
However, when testing a fuse using an ohmmeter, the fuse should always be removed from the
fuse box.
WARNING
When replacing a fuse, do not use a higher
rated fuse than recommended. Use of a
higher rated fuse can lead to severe component or circuit damage, an overheat condition, and possibly and electrical fire. If a fuse
has burnt out, the source of the malfunction
should be identified and corrected before
applying power to the vehicle.
TESTING SEQUENCE
Electrical Power Does Not Come ON
Electrical system power up is normally identified
by the information center powering up and cycling
through its self-test function.
If the information center does not come on, check
the following:
Ensure battery is properly connected.
Check the BATT. fuse in FB2.
Check for activation of the power relay in FB2.
smr2009-049

Check the ECM fuse in FB2.

Check the GAUGE fuse in FB1.
If you cannot feel the power relay activating when
pressing the START button, or if you suspect that
it does not function correctly, refer to POWER RELAY in this subsection.
PROCEDURES
If no voltage is measured, test the wire jumper

between FB1-D6 and FB2-A10.
Also test for a voltage drop across the power relay
main contact between the long bus-bar in FB2-B7
and FB1-D6. If a voltage drop is measured, the
relay power contact or wire jumper connections
may be bad. Refer to POWER RELAY CONTINUITY TEST in this subsection.
POWER RELAY
Power Relay Ground Circuit Continuity

Test
The power relay is a plug-in type that may be inverted by 180 at installation and still function correctly.
If the power relay operation is suspected, try a
known good relay before carrying out other tests.
If the replacement relay does not function, refer
to POWER RELAY INPUT VOLTAGE TEST.
If you do not have a replacement relay, refer to
POWER RELAY CONTINUITY TEST.
Test continuity of wire between FB2-B10 and

ECM connector pin B-H2. This wire provides the
ground to the power relay from the ECM.
If the relay, relay power and ground circuits test
good, refer to STARTING SYSTEM. The START
switch circuit may not be powering the ECM.
If the START switch and its circuit test good, then
refer to ELECTRONIC FUEL INJECTION as the
ECM may not be providing the ground for the
relay to close.
Power Relay Input Voltage Test

1. Remove the power relay from the fuse box.
2. Set multimeter to Vdc.
3. Probe fuse box as per following table.
RELAY INPUT VOLTAGE TEST
FUSE BOX PIN
VOLTAGE
A12 to battery ground (coil)

B12 to battery ground
(main contact)
Battery voltage
Battery voltage
If battery voltage is not read at A12, check the following items in FB2:
Fuse 17 (30 A BATT.).
Wiring/connectors from battery to pin FB2-A1.
12 Vdc Bus bar connecting B1 through B8 for
proper contact.
Wire jumper A2 to B2 (behind fuse box).
Wire jumper B8 to A12 (behind fuse box).
If battery voltage is read at A12 and B12, refer to
POWER RELAY GROUND CIRCUIT CONTINUITY.
If voltage is read at contact A12 but not at B12,
check fuse box jumper between B12 and B7.
Power Relay Output Voltage Test
Power Relay Continuity Test

To test the power relay, carry out the following.
1. Remove the relay from the fuse box.
868), and select the
position.
3. Probe relay as per following table.
TERMINAL
30
RESISTANCE
87
Open circuit (OL)
smr2007-027-050_a
4. Connect a 12 Vdc battery as in following illustration and probe relay again.
The power relay output voltage is applied to the

short bus-bar in FB1.
To check for relay output voltage, slightly lift the
short bus-bar in FB1 and test for battery voltage
at a bus-bar contact.
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287

smr2007-027-060_a
TERMINAL
30
288
87
RESISTANCE
max.
0.5
(continuity)
smr2009-049

Subsection 03 (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
Description
Part Number
Page
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 292

SERVICE PRODUCTS
Description
Part Number
Page
DOW CORNING 111 ..................................................................... 413 707 000 ......................................... 293
GENERAL
SYSTEM DESCRIPTION
The ignition system is a digital inductive type system.
Ignition system parameters such as ignition timing, spark duration, and firing order, are controlled
by the ECM in order to meet engine operational
requirements.
Three separate ignition coils receive power from
three separate fuses.
When a ground signal is provided by the ECM to
an ignition coil primary winding, a high voltage is
induced in the coil secondary winding that is used
to produce a spark at the spark plug electrode.
The ECM is programmed with data (ignition mappings), which it uses along with data it receives
from a variety of sensors to establish optimum
ignition timing under all engine operating conditions.
The firing of each spark plug is independent of the
others.
Knock Sensor
A knock sensor is mounted on the cylinder block
behind the intake manifold. It detects specific vibrations that would typically be generated by engine detonation.
If detonation occurs, the knock sensor detects
it and the ECM goes into a specific operating
mode whereby it temporarily retards the ignition
advance until detonation stops.
The ECM is able to identify in which cylinder the
knocking occurs and modifies the ignition advance
on that cylinder only.
Refer to the ELECTRONIC FUEL INJECTION section for testing and replacement procedures.
TROUBLESHOOTING
DIAGNOSTIC GUIDELINES
smr2009-032-002_a

1. Ignition coils
Ignition Timing
Ignition timing is not adjustable.
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289

ENGINE WILL NOT START (ENGINE

TURNS OVER)
1. Fouled or defective spark plug
- Replace.
2. Defective CPS
Refer to ELECTRONIC FUEL INJECTION section.
- Check. Refer to PTO HOUSING/MAGNETO.
4. Defective ignition circuit
- Check.
ENGINE HARD TO START

1. Spark plug faulty, fouled or worn out
- Check spark plug condition. Replace if necessary.
ENGINE MISFIRES, RUNS IRREGULARLY

1. Fouled, defective, worn spark plugs
- Check/verify heat range/gap/replace.
2. Defective T.O.P.S. sensor
- Check. Refer to LUBRICATION.
3. Damaged trigger wheel/loose CPS
- Check. Refer to PTO HOUSING/MAGNETO.
4. Defective ignition circuit
- Check ignition coil, and wiring condition.
5. Poor engine grounds
- Check/clean/repair.
ENGINE CONTINUALLY BACKFIRES

1. Fouled, defective spark plugs
- Clean/replace.
2. Damaged trigger wheel/defective or loose CPS
- Check, refer to ELECTRONIC FUEL INJECTION.
IGNITION SYSTEM TESTING

If a primary winding of an ignition coil or a circuit
is at fault, a fault code will be set. Refer to MONITORING SYSTEM AND FAULT CODES subsection.
Ignition System Testing Sequence

Ensure fuses 7, 8 and 9 (in fuse box #1) are good.
If a fuse is burnt, test for a short circuit or faulty
component on that fuse circuit before replacing
the fuse.
WARNING
Due to the possibility of flammable vapors accumulating in the bilge, you should always
test for a short circuit which may produce a
spark and ignite the vapors before replacing
a burnt fuse.
If one cylinder is not firing and there is no fault
code, replace each spark plug with a known good
spark plug until the faulty plug is located.
If the fault is not found, carry out an IGNITION
COIL QUICK TEST USING B.U.D.S.
PROCEDURES
IGNITION COILS
WARNING
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
compartment as a spark may cause fuel vapors which may have accumulated in the
bilge to ignite.
ENGINE DETONATION OR PINGING

1. Knock sensor disconnected or faulty
- Check, refer to ELECTRONIC FUEL INJECTION.

POWER
1. Weak spark
- Check/replace spark plugs.
290
Ignition Coil Test Using B.U.D.S.

Open seat.
SYSTEM.
Connect to the latest applicable B.U.D.S. software. Refer to COMMUNICATION TOOLS AND
In B.U.D.S., select the Activation tab and the
ECM tab.
Energize the desired ignition coil by selecting it on
the engine illustration.
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smr2008-024-005_b
smr2009-032-001_a
IGNITION COIL INPUT VOLTAGE TEST
IGNITION COIL ACTIVATION

1. Activation tab
2. ECM tab
3. Click on the desired ignition coil
You should hear the spark occurring. If in doubt,

use a sealed vapor proof spark tester available
from tool suppliers to prevent a spark from occurring in the bilge. If there is no spark, carry out
the following checks.
NOTE: Keep in mind that even if the tester indicates that there is a spark during this static test,
the voltage required to produce a spark in the
combustion chamber is higher when the engine
is running. The ignition coil or spark plug may
not be functioning properly during actual engine
operation. Replacing the ignition coil or spark
plug may be necessary as a test.
If there is no ignition at one or more coils, carry
out a IGNITION COIL INPUT VOLTAGE TEST.
If test succeeded, refer to IGNITION COIL

POWER CIRCUIT TEST.
If test failed, refer to IGNITION COIL CONTROL
CIRCUIT TEST.
Ignition Coil Power Circuit Test

Ignition Coil Input Voltage Test

Disconnect the desired ignition coil connector.
Remove safety lanyard from the D.E.S.S. post.
Press the START button to activate the ECM.
Select Vdc.
Measure voltage as per following table.
TEST PROBES
VOLTAGE
VI/BU wire
(ignition coil no. 1)
VI/GN wire
VI/OR wire
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Battery
ground
Battery
voltage
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1. Long bus bar

and select .
Read resistance of the desired ignition coil circuit.
IGNITION
COIL
IGNITION
COIL WIRE
FUSE BOX
#1
1
(rear)
VI/BL
Terminal
C11
VI/GN
Terminal C9
VI/OR
Terminal C7
MEASUREMENT
Close to 0
291

smr2009-030-015_h
If test succeeded, wiring and connectors are functional.

If test failed, repair/replace wiring from fuse box
terminal to ignition coil.
Ignition Coil Control Circuit Test

Disconnect ECM connector "A". Refer to ELECTRONIC FUEL INJECTION.
Install ECM connector on the ECM ADAPTER TOOL
(P/N 529 036 166).
smr2007-023-003_d
IGNITION COIL CONTROL CIRCUIT TEST
If test failed, repair the connector or replace the

engine wiring harness.
If test succeeded, wiring and connectors are functional.
Ignition Coil Resistance Test

An ignition coil with a good resistance measurement can still be faulty. Current leakage can occur
at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.
Remove ignition coil. Refer to IGNITION COIL REMOVAL below.
Perform a visual inspection of ignition coil for corrosion.
Using a multimeter, test the resistance in both primary and secondary windings.
529036166
Disconnect ignition coil connector.

Test for continuity of circuit as per following table.
COIL
IGNITION COIL
WIRE
ECM
ADAPTER
Cylinder 1
(rear)
BR/BK
A-M4
Cylinder 2
BR/OR
A-M2
Cylinder 3
BR/YL
A-M1
292
RESISTANCE
Close to 0
(continuity)
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PRIMARY WINDING
CIRCUIT
TERMINAL
Primary
winding
1 and 2
RESISTANCE @
20C (68F)
0.85 - 1.15
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smr05-015-002_b
SECONDARY WINDING
CIRCUIT
TERMINAL
Secondary
winding
1 and spark
plug terminal
RESISTANCE @
20C (68F)
9.5 - 13.5 k
If any test failed, replace ignition coil.
Ignition Coil Removal

Open seat.
SYSTEM.
Disconnect ignition coil connector.
sbs2009-011-001_a
1. Apply product here
3. Pull rubber seal back on its seat making sure the

tabs on the ignition coil and the slots in the seal
properly match together.
4. Leave a ring of grease on top of the seal as
shown to act as a water barrier. Wipe off the
excess.
NOTICE Do not remove the ignition coil before disconnecting the input connector or the
wires may be damaged. Do not pry up ignition
coil with a screwdriver to avoid damage.
NOTE: Twist ignition coil in both directions as you
pull it up to ease removal.
Remove ignition coil from spark plug.
Ignition Coil Installation

Prior to inserting the ignition coil on its spark plug,
apply sealant as described in following procedure:
1. Pull rubber seal down.
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1. Correctly shaped excess of product
5. Apply DOW CORNING 111 (P/N 413 707 000) on

rubber seal contact area.
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1. Apply product here

sbs2009-011-002_a
1. Rubber seal pulled down
2. Apply DOW CORNING 111 (P/N 413 707 000) to

rubber seal seat as shown.
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6. Install coil in cylinder head hole.

7. Push the ignition coil down to securely install it
on the spark plug tip.
8. Ensure the seal seats properly with top surface
of engine valve cover.
293

Unscrew spark plug then use the ignition coil to

take spark plug out of spark plug hole.
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1. Seal properly seated
SPARK PLUGS
Spark Plug Removal
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Open seat.
SYSTEM.
Disconnect the ignition coil input connector.
Remove ignition coil. Refer to IGNITION COIL REMOVAL in this subsection.
WARNING
Never remove an ignition coil from a spark
plug without disconnecting it from the wiring
harness. Flammable vapors may be present
in the bilge. Should the safety lanyard be installed on the D.E.S.S. post, a spark could be
generated at the coil spark plug end which
could cause an explosion.
Using a spark plug socket, release the torque applied to the spark plug.
1. Ignition coil
2. Spark plug
Troubleshooting a Fouled Spark Plug

Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased
engine speed due to misfiring, reduced performance, and increased fuel consumption.
Other possible causes are: a incorrect or bad
fuel, defective ignition system, incorrect spark
plug gap, loss of compression, or lubricating oil
entering the combustion chamber.
The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.
Spark Plug Analysis
2
A00E0AA
TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
A00E0BA
1. Approved socket
2. Improper socket
The plug face reveals the condition of the engine,

operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
Clean the spark plug and cylinder head with pressurized air.
294
smr2009-032

the spark plug at prescribed intervals, examining

the plug face (i.e. the part of the plug projecting
into the combustion chamber).
Spark Plug Installation

Prior to installation, ensure the contact surfaces of
the cylinder head and spark plug are free of grime.
1. Using a wire feeler gauge, set electrode gap as
specified in the following chart.
ENGINE
SPARK
PLUG
TORQUE
GAP
mm (in)
1503
NGK
DCPR8E
Hand tighten
+ 1/4 turn with
a socket
0.75 (.030)
2. Apply anti-seize lubricant over the spark plug

threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head.
Then, tighten the spark plug clockwise an additional 1/4 turn with an approved spark plug
socket.
Install ignition coil. Refer to IGNITION COIL INSTALLATION in this subsection.
Complete the installation in the reverse order of
the removal.
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295
296

Subsection 04 (CHARGING SYSTEM)
CHARGING SYSTEM
SERVICE TOOLS
Description
Part Number
Page
ENGINE LEAK TEST KIT................................................................ 295 500 352 ......................................... 302

Description
Part Number
ELECTRO SPECIALTIES BATTERY LOAD TESTER....................... 710

EXTECH INDUCTIVE AMMETER .................................................. 380941
Page
......................................... 306
......................................... 298
GENERAL
Voltage Regulator/Rectifier
NOTICE When performing a test with the engine running above approximately 4500 RPM
for 3 seconds, be aware that suspension will
move up to its predefined position then, it will
stop in that position. Wait until suspension
is stopped before working on the watercraft.
Keep away from moving parts.
The rectifier receives AC current from the magneto and transforms it into direct current (DC).
The voltage regulator, included in the same unit,
limits voltage to a maximum level to prevent any
damage to electrical components.
SYSTEM DESCRIPTION
The purpose of the charging system is to maintain
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.
Magneto
The magneto is the primary source of electrical
energy. It transforms a magnetic field into an electric current (AC).
The magneto has a 3 phase, delta wound, 18 pole
stator that is rated at 380 watts.
smr2008-025-001_a
1. Voltage regulator/rectifier unit
Battery
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to every electrical and electronic system in the vehicle as well
as all accessories.
At low engine RPM operation and high current
load conditions, it supplements the magneto
output and helps to maintain a steady system
voltage.
F18H1RA
TYPICAL
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297

INSPECTION
CHARGING SYSTEM OUTPUT
First ensure that battery is in good condition prior
to performing the following tests.
NOTE: It is good practice to check for fault
codes using the B.U.D.S. software as a first
troubleshooting step. Refer to MONITORING
SYSTEM/FAULT CODES section.
Output Voltage Test Using B.U.D.S.

Connect to the latest applicable B.U.D.S. software. Refer to COMMUNICATION TOOLS AND
In B.U.D.S., select the Monitoring tab then the
ECM tab.
Start engine.
NOTE: Connect a garden hose to cool exhaust
system. Refer to EXHAUST SYSTEM subsection.
Bring engine RPM as specified in the following table and read voltage in B.U.D.S.
smr2009-033-002_a
CHARGING SYSTEM VOLTAGE TEST AT BATTERY POSTS
Start engine.
Bring engine RPM as specified in the following table and read voltage with the multimeter.
OUTPUT VOLTAGE TEST USING A MULTIMETER
TEST ENGINE SPEED
VOLTAGE (DC)
5500 RPM
14.5 .5 Vdc
OUTPUT VOLTAGE TEST USING B.U.D.S.

TEST ENGINE SPEED
VOLTAGE (DC)
5500 RPM
14.5 .5 Vdc
If voltage is above specification, replace voltage

regulator/rectifier.
If voltage is below specification, check stator
output and wiring harness prior to concluding that
voltage regulator/rectifier is defective. Refer to
PTO HOUSING AND MAGNETO subsection.
Output Current Test with an Inductive

Ammeter
smr2009-033-001_a
1. Monitoring tab
2. ECM tab
3. Battery voltage
Use an inductive ammeter such as the EXTECH INDUCTIVE AMMETER (P/N 380941) or equivalent.
Turn on the ammeter and select 40 Adc.
NOTE: Zero set the ammeter before use or reading may be erroneous.
Detach fuse box #2 from its support. Move fuse
box aside to gain access to charging system wire.
If voltage is above specification, replace voltage

regulator/rectifier.
If voltage is below specification, check stator
output and wiring harness prior to concluding that
voltage regulator/rectifier is defective. Refer to
PTO HOUSING AND MAGNETO subsection.
Output Voltage Test Using a

Multimeter
Set multimeter to Vdc.
Connect multimeter to battery posts.
298
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smr2009-034-002_c
1. Fuse box #2
Locate the RED/BLUE wire on terminal A9 of fuse

box and clamp the ammeter over it.
TEST ENGINE
SPEED
CURRENT
5500 RPM
Approx. 10 A (while
suspension does not move)
NOTE: Initial current reading will be higher than

specified due to the battery drain from the engine
start. This is an indication that the charging system is operating normally. Current load will come
down as the battery recovers its charge.
If current reading is far below specification, test
stator output and wiring harness prior to concluding that voltage regulator/rectifier is faulty.
NOTE: If battery is in poor condition or is not at a
full state of charge, current reading will be above
specification. Refer to BATTERY in this section for
battery testing.
Output Current Test with a Multimeter

NOTICE Charging current may rise over multimeter current reading capacity (usually 10 A)
possibly causing testing equipment damage. It
is preferable to use an inductive ammeter to
test the charging system current.
Remove charging system fuse.
Set multimeter to Adc.
Connect probes to fuse holder terminals.
smr2009-033-003_a
1. Terminal A9
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smr2009-033-004_a
1. Inductive ammeter
Start engine.
Bring engine RPM as specified in the following table and read current with the multimeter.
Start engine.
Bring engine RPM as specified in the following table and read current with the ammeter.
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299

OUTPUT CURRENT TEST

TEST ENGINE
SPEED
CURRENT (DC)
5500 RPM
Approx. 10 A (while
suspension does not move)
NOTE: Initial current reading will be higher than

specified due to the battery drain from the engine
start. This proves the charging system works.
Current load will come down as the battery recovers its charge.
If current is below specification, carry out a stator
output test and wiring harness prior to concluding
that rectifier is faulty.
PROCEDURES
VOLTAGE
REGULATOR/RECTIFIER
Voltage Regulator Continuity Test
Due to internal circuitry, there is no static test
available to check continuity.
Voltage Regulator/Rectifier
Replacement
Voltage Regulator/Rectifier Removal
Remove components to reach voltage regulator/rectifier as described in BATTERY REMOVAL
of this subsection.
Disconnect connectors from voltage regulator/rectifier.
Lift and push the top of electrical component support forward to unlock it from the battery holder.
CHARGING SYSTEM FUSE

The charging system is protected by a 30 A fuse
(F15).
If the battery becomes discharged, check the
charging system fuse condition, located in fuse
box #2.
Remove fuse box cover. Refer to POWER DISTRIBUTION.
ssi2009-002-008_a
1. Electrical component support
Lift electrical component support to reach the bottom locking tab of voltage regulator/rectifier.
Unlock the bottom locking tab of voltage regulator/rectifier and pull out voltage regulator/rectifier.
2009-027-009_a
1. Fuse box #1
2. Fuse box #2
The voltage regulator/rectifier could be the culprit

of a blown charging system fuse. To test for this
possibility, simply disconnect the voltage regulator/rectifier from the circuit and install a new fuse.
If the fuse still burns, check for a shorted wire or
connector pins.
NOTICE Do not use a fuse of a higher rating
as this can cause severe electrical system and
component damage.
300
smr2009-033-006_a
Step 1: Push and hold

Step 2: Pull out
smr2009-033

Voltage Regulator/Rectifier Installation

Installation is the reverse of removal procedure.
Lock voltage regulator/rectifier in position. Wiggle
it to make sure it is safely locked.
NOTE: Key Off or parasitic loads may be loads

due to installed accessories. Parasitic loads may
also be due to water infiltration in connectors, or
partial short circuits that slowly drain a battery
without causing a fuse to burn.
NOTE: A battery that continually necessitates the
addition of distilled water indicates an over voltage
situation. Carry out a CHARGING SYSTEM VOLTAGE TEST.
Battery Vent and Check Valve

WARNING
Battery caps do not have vent holes. Ensure
vent line is not obstructed and check valve is
functioning properly.
Check vent line condition.
smr2009-033-006_b
1. Locked here
Reinstall remaining removed components.
BATTERY
Troubleshooting
SYMPTOM: DISCHARGED OR WEAK BATTERY
CAUSE
REMEDY
Clean battery terminals,
Battery posts and/or cable
posts, and coat with
terminal oxidized.
dielectric grease.
Check for wiring and
connector tightness,
Loose or bad
frayed or broken wires.
connections.
Repair or replace cables
or connectors.
Faulty battery (sulfated,
fretting, shorted plates
Replace battery.
or cell, damaged casing,
loose post).
First check fuse(s). If in
Burnt fuse(s) or faulty
good condition, check
rectifier.
voltage regulator/rectifier.
Test stator and replace as
Faulty stator.
required.
Isolate, reduce or
eliminate such loads,
recharge battery as
Parasitic or Key Off
recommended if vehicle
current loads.
is not used for extended
periods of time.
smr2009-033-009_b
1. Vent line
Make sure that grommet of check valve is not

plugged.
Disconnect vent hose from battery.
smr2009-033-009_a
1. Disconnect here
smr2009-033
301

Use the vacuum/pressure pump in the ENGINE
Set vacuum/pressure pump to VACUUM.
LEAK TEST KIT (P/N 295 500 352).
295500352
Set vacuum/pressure pump to PRESSURE.
smr2009-031-013_a
1. Vacuum selected
Squeeze the vacuum/pressure pump handle several times to draw air in through the check valve.
Check valve must hold air with 10 in Hg (-34 kPa)
of vacuum without leaking.
smr2009-031-012_a
Connect vacuum/pressure pump to the vent hose

end.
Squeeze the vacuum/pressure pump handle several times to push air out through the check valve.
Check valve must let air flow out.
smr2009-033-010_b
MUST HOLD AIR IN THIS POSITION
If any test failed, check the vent hose and if good,

replace check valve.
At installation, ensure to position check valve with
black side connected to vent line and ORANGE
side inserted in the grommet protruding through
the hull as shown.
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AIR MUST FLOW OUT

302
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ssi2009-002-003_a
1. Storage bin
3. Disconnect the diagnostic connector from its

holder.
smr2006-023-003_a
Battery Removal
WARNING
The BLACK negative battery cable must always be disconnected first and reconnected
last. Never charge or boost battery while installed in watercraft.
1. Open the boarding platform.
ssi2009-002-004_a
1. Disconnect
4. Disconnect the BLACK (-) battery cable.
WARNING
Always disconnect battery cables exactly in
the specified order, BLACK (-) battery cable
first then the RED (+) cable last.
ssi2009-002-002_a
1. Boarding platform
5. Disconnect the RED (+) cable.
2. Remove the starboard (RH) storage bin.
ssi2009-002-005_a
1. BLACK (-) cable

2. RED (+) cable
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303

6. Remove the electrical component support from

the battery holder.
6.1 Lift and push the top of electrical component support forward to unlock it from battery holder.
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1. Disconnect here
ssi2009-002-008_a
6.2 Pull up the components support to unhook

from battery holder and move it aside to
make room for removing battery.
7. Remove and discard both screws securing battery holder to battery holder base.
9. Install a piece of hose (same type as vent hose)

with a cap or small hose pincher onto the battery vent to prevent electrolyte spillage when
removing the battery.
10. Remove battery with battery holder from vehicle.
CAUTION Be careful not to disconnect the
hose from the battery vent and cause an electrolyte spill in the watercraft.
ssi2009-002-009_a
1. Retaining screws
2. Battery holder
8. Disconnect the vent hose from battery.
smr2009-033-008_a
1. Vent plugged for removal
WARNING
Electrolyte is poisonous and corrosive. Avoid
contact with eyes, skin and clothing. Wear a
suitable pair of non-absorbent gloves when
removing the battery by hand. Rinse any
affected area with clear running water for
at least 15 minutes, then seek professional
medical attention.
304
smr2009-033

NOTICE Should any electrolyte spillage occur, immediately wash off area with a solution
of baking soda and water, then rinse thoroughly.
Remove retaining screws from battery holder if
applicable.
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Remove battery holder from battery.
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1. Remove screws
Unlock the upper tabs then slightly open battery

holder.
smr2009-005-007
Battery Cleaning
Clean the battery casing, caps, cables and battery
posts using a solution of baking soda and water.
NOTICE Do not allow cleaning solution to enter battery.
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1. Unlock here
Separate lower tabs to unlock them.
smr2009-033
Remove corrosion from battery cable terminals

and battery posts using a firm wire brush. Rinse
with clear water then dry well.
Battery Inspection
Visually inspect battery casing for cracks or
other possible damages. If casing is damaged
or shows signs of acid leaking, replace battery
and thoroughly clean battery tray and surrounding
area with a solution of water and baking soda.
Inspect battery posts for corrosion and security of
mounting.
Inspect for cracked or damaged battery caps, replace defective caps.
NOTE: Hand tighten caps then tighten an additional 1/4 turn using a 20 mm (3/4 in) socket.
Using any other tool could damage the plastic
battery caps.
305

WARNING
Battery electrolyte is caustic. To prevent
spillage, ensure battery cell caps are sufficiently tight to properly seal each cell.
Battery Electrolyte Level
Check electrolyte level in each cell, add distilled
water up to the upper fill level line.
NOTICE Add only distilled water in an activated battery.
Battery Testing
Battery Voltage Test (No Load)

NOTE: Be aware that the voltage test can indicate that the battery is in good condition even
though the battery does not have enough stored
energy to crank the engine. A load test gives a
more accurate indication of the condition of the
battery.
If the battery has just received a charge, allow it to
rest for 1-2 hours before taking a voltage reading.
Set multimeter to Vdc and measure voltage at battery terminals.
FULLY CHARGED BATTERY VOLTAGE (NO LOAD)
There are 3 types of battery tests.

TEST
METHOD
12.6 Vdc minimum
COMMENT
Voltage
test (load
applied)
A dynamic voltage test with a load

applied gives an accurate indication
of the condition of the battery. This
is the most recommended method.
Voltage test
(no load)
A static voltage test is carried out

without discharging current. It is
the simplest and most commonly
used but the most likely to give false
results.
Battery
electrolyte
reading
Gives an accurate indication of the

charge condition of each cell.
Battery Electrolyte Reading

NOTE: Do not top up cell electrolyte level with
distilled water prior to taking an electrolyte reading.
Check charge condition of each cell using a hydrometer.
NOTE: A hydrometer measures the charge of a
battery in terms of specific gravity of the electrolyte.
BATTERY ELECTROLYTE SPECIFICATION
BATTERY CONDITION
SPECIFIC GRAVITY
Fully charged
1.265 - 1.280
Battery Voltage Test (Load Applied)

Use a load testing device such as the ELECTRO
SPECIALTIES BATTERY LOAD TESTER (P/N 710). It
has a 500 A carbon pile adjustable load.
Follow battery load tester instructions.
Apply a load of 3 times the ampere-hour rating
of the battery for 14 seconds, then check battery
voltage.
BATTERY VOLTAGE TEST (LOAD APPLIED)

TIME TO MEASURE
INTO TEST
VOLTAGE
14 seconds
10.5 Vdc min.
A17E0JA
If battery voltage has dropped below specification, the battery storage capacity has decreased
appreciably and the battery should be replaced.
306
1. Hydrometer
Most hydrometers give a true reading at 21C

(70F).
In order to obtain the correct value, adjust the initial reading by adding or substracting the number
indicated in the following table.
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ELECTROLYTE
TEMPERATURE
C
38
100
32
90
27
80
21
70
16
60
10
50
40
- 1
30
OPERATION TO
PERFORM
.012
Add to the
reading:
.008
.004
CORRECT READING
.004
Subtract
from the
reading:
.008
.012
.016
EXAMPLE NO. 1
EXAMPLE NO. 2
TEMPERATURE ABOVE 21C (70F):

Hydrometer reading: 1.250
Electrolyte temperature: - 1C (30F)
Subtract .016
Corrected: 1.234
TEMPERATURE ABOVE 21C (70F):

Hydrometer reading: 1.235
Electrolyte temperature: 38C (100F)
Add .012
Corrected: 1.247
STATE OF CHARGE AS PER HYDROMETER

READING (CORRECTED)
SPECIFIC GRAVITY
STATE OF
CHARGE
@ 27C (80F)
@ 4C (40F)
100%
1.26 - 1.27
1.27 - 1.28
75%
1.21 - 1.22
1.22 - 1.23
50%
1.16 - 1.17
1.17 - 1.18
25%
1.12 - 1.13
1.13 - 1.14
0%
1.10 or less
1.11 or less
Battery Storage
Disconnect and remove battery from watercraft
as explained in BATTERY REMOVAL.
NOTICE Battery storage is critical for battery
life. Regularly charging the battery during
storage will prevent cell sulfation. Keeping the
battery in vehicle for storage may lead to contacts degradation/corrosion and case damage
if freezing occurs. A discharged battery will
freeze and crack in areas where freezing conditions are experienced. Electrolyte leakage will
damage surrounding parts. Always remove
battery from vehicle for storage and regularly
recharge it to keep an optimal condition.
Check electrolyte level in each cell.
Add distilled water up to upper level line as necessary.
The battery must always be stored fully charged.

If required, recharge until the recommended specific gravity obtained prior to storage.
NOTICE Battery electrolyte temperature
must not exceed 50C (122F) during charging.
The battery casing should not feel hot to the
touch.
Clean battery terminals and cable connections using a wire brush.
Apply a light coat of dielectric grease on terminals.
Clean battery casing and caps using a solution of
baking soda and water.
NOTICE Do not allow cleaning solution to enter battery.
Rinse battery with clear water and dry well using
a clean cloth.
Store battery in a cool dry place. Such conditions
reduce self-discharging and keep fluid evaporation
to a minimum. Keep battery away from dew, high
moisture and direct sunlight.
During the storage period, recheck electrolyte
level and specific gravity readings at least every
month. If necessary, top up the electrolyte level
with distilled water, then recharge (trickle charge).
Recharge frequency depends on battery condition and storage temperature. Maintain battery
as per following table.
AMBIENT
TEMPERATURE
CHARGING
FREQUENCY
Below 16C (60F)
Every month
Above 16C (60F)
Every 2 weeks
WARNING
Batteries must always be stored out of reach
of children.
Activation of a New Battery

WARNING
Never charge or boost battery while installed
in watercraft.
Perform the following operations anytime a new
battery is to be installed.
Remove the sealing tube from the vent fitting.
NOTICE Do not overfill.

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307

WARNING
Failure to remove the sealing tube could result in an explosion.
1. Remove caps and fill battery to UPPER LEVEL

line with electrolyte (specific gravity: 1.265 at
21C (70F)).
NOTE: This battery may fill slower than others
due to the anti-spill check ball design.
A17E0RB
1. Battery electrolyte
2. Upper level line
4. Connect a 2 A battery charger for 3 to 5 hours.

3
1
2
A17E0FB
1. Sealing tube removed

2. Battery electrolyte
3. Upper level line
A17E0IA
NOTE: Place the cell caps over the cell openings

engaging only the first thread to prevent cell
contamination and acid splatter during charging.
Do not screw caps on tightly.
2. Allow the battery to stand for 30 minutes MINIMUM to allow the electrolyte time to soak
through the battery cells plates.
1
A17E0GA
1. 30 minutes
Step 1: Connect + lead to battery + post

Step 2: Connect - lead to battery - post
Step 3: Connect battery charger to AC outlet
WARNING
Gases given off by a battery being charged
are highly explosive. Always charge in a well
ventilated area. Keep battery away from cigarettes, open flames, welding operations and
any other types of ignition. Always turn battery charger off prior to disconnecting cables.
Otherwise a spark will occur possibly causing
the battery to explode.
NOTICE If charging rate increases above
2.4 A reduce it immediately. If cell temperature rises above 50C (122F) or if the casing
feels hot, discontinue charging temporarily or
reduce the charging rate.
5. Disconnect battery charger.
3. Readjust the electrolyte level to the UPPER

LEVEL line.
308
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1
2
For best results, battery should be charged when

it is at room temperature. A battery that is cold
may not accept current for several hours after
charging has begun.
Do not charge a frozen battery. If the battery
charge is very low, the battery may freeze. If
you suspect the battery to be frozen, move it to a
heated area for about 2 hours (or more if required)
to let it thaw out before charging.
A17E0IB
Step 1: Disconnect battery charger from AC outlet

Step 2: Disconnect - lead
Step 3: Disconnect + lead
6. Test battery state of charge. Use a hydrometer.
A17E0JA
1. Hydrometer
7. If electrolyte level has dropped after charging,

fill with distilled water to UPPER LEVEL line.
After water is added, continue charging for 1 to
2 hours to mix water with electrolyte.
8. Reinstall caps and clean any electrolyte spillage
using a solution of baking soda and water.
NOTE: Hand tighten caps then tighten an additional 1/4 turn using a 20 mm (3/4 in) socket.
Using an other tool could damage the plastic
battery caps.
WARNING
Battery electrolyte is caustic. To prevent
spillage, battery cell cap should be sufficiently tight to properly seal.
Charging a Used Battery

WARNING
WARNING
Always charge a battery in a well ventilated
area.
The time required to charge a battery will vary depending on several factors, such as:
Battery temperature: The charging time is increased for a cold battery as charging current
accepted by a cold battery will be lower than
for a warm battery. As the battery warms up,
it will accept a higher rate of charge.
State of charge: As a battery discharges, it
gives up its stored energy. The greater the discharge, the longer it will take to fully recharge
it.
Type of charger: Battery chargers vary in the
amount of voltage and current that they can
supply.
Charging a Very Flat or Completely
Discharged Battery
The battery charger used should have an adjustable charging rate. A unit which can be
adjusted in small increments is acceptable.
The battery charger must be equipped with an ammeter capable of accurately measuring current of
less than 1 ampere.
Unless this procedure is properly followed, a good
battery may be needlessly replaced.
1. Measure the voltage at the battery posts with
an accurate voltmeter. If it is below 10 volts,
the battery will accept current at very low rate.
It could be some time before the charging rate
increases. Such low current flow may not be
detectable on some charger ammeters and the
battery will not seem to accept the charge.
2. Exceptionally for this particular case, set the
charger to a high rate.
Never charge battery while installed in watercraft.
smr2009-033
309

NOTE: Some chargers have a polarity protection feature which prevents charging unless the
charger leads are connected to the correct battery
terminals. A completely discharged battery may
not have enough voltage to activate this circuitry,
even though the leads are connected properly.
This will make it appear that the battery will not
accept a charge. Follow the charger manufacturer's instruction on how to bypass or override
this circuitry so that the charger will turn on and
charge a low-voltage battery.
3. Since battery chargers vary in the amount of
voltage and current they provide, the time required for the battery to accept a measurable
charger current may be up to 10 hours or more.
4. If the charging current is not up to a measurable
amount after 10 hours, the battery should be
replaced.
5. If the charging current is measurable before
the end of the 10 hour period, the battery is
good and charging should be completed at a
lower rate as specified in ACTIVATION OF A
NEW BATTERY.
6. It is recommended that any battery recharged
using this procedure be tested under load prior
to returning it to service.
Battery Installation
5. Remove the temporary hose used to plug the

battery vent.
6. Reconnect the watercraft vent hose to the battery vent outlet. Make sure vent hose is not
pinched or bent.
WARNING
Vent hose must be free and open. Avoid skin
contact with electrolyte.
smr2009-033-009_a
1. Connect here
7. Attach the electrical component support to the

battery holder.
1. Install battery in its holder and lock holder.

2. Secure battery holder with its retaining screws
if they were present at removal.
ssi2009-002-008_a
WARNING
smr2009-005-004_a
Always connect battery cables in the specified order, RED positive cable first, BLACK
negative cable last.
1. Torque to 6 Nm (53 lbfin)
3. Install the battery in the watercraft using new

screws.
4. Tighten battery holder screws to 14 Nm
(124 lbfin).
310
8. Connect RED (+) cable.

9. Connect BLACK (-) cable last.
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ssi2009-002-005_a
1. BLACK (-) cable

2. RED (+) cable
10. Apply dielectric grease on battery posts.

11. Verify cable routing and attachments.
12. Insert diagnostic connector in its holder.
13. Install remaining removed components.
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311
312

Subsection 05 (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
Description
Part Number
Page

ECM ADAPTER TOOL................................................................... 529 036 166 ................................. 317319
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 315318
SERVICE PRODUCTS
Description
Part Number
Page

ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ......................................... 323
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 323
GENERAL
BASIC STARTING SYSTEM
OPERATION
Engine Cranking Conditions
The following conditions must be met to allow engine cranking:
The D.E.S.S. key must be on its post and recognized by the ECM as valid (2 short beeps)
START/STOP button pressed and held.
Starting System Logic

If the ECM recognizes a valid D.E.S.S. key, it allows engine cranking by providing the ground to
the starter solenoid when the START/STOP button is pressed and held.
If the START/STOP button is activated while the
throttle lever is depressed more than 60%, the engine will crank but will not start (engine drowned
mode).
If the START/STOP button is held after engine has
started, the ECM automatically stops the starter if
engine speed reached at least 1400 RPM.
If the START/STOP button is pressed when engine is running, the engine will be shut down.
TROUBLESHOOTING
DIAGNOSTIC TIPS
codes using B.U.D.S. software as a first troubleshooting step. Refer to MONITORING SYSTEM/FAULT CODES section.
smr2009-034
Starting system failures are not necessarily related to the starter but may be due to one the
following:
Starter solenoid fuse F4
Battery. Refer to CHARGING SYSTEM
START/STOP switch
Starter solenoid
D.E.S.S. post
ECM
Wiring/connections.
Check these components before removing the
starter.
NOTE: This section assumes the problem is related to an electrical component of the starting
system. If starting system tests good, ensure engine and jet pump integrity. Refer to applicable
section.
ENGINE DOES NOT CRANK

1. D.E.S.S. operation non functional or wrong
D.E.S.S. key
- If 2 short beeps are not heard when pressing
the START/STOP button, refer to DIGITALLY ENCODED SECURITY SYSTEM.
2. Burnt fuse: battery, starting system
- Check wiring then replace fuse.
313

3. Discharged battery
- Check/recharge. Refer to CHARGING SYSTEM.
STARTER TURNS, BUT STARTER DRIVE

DOES NOT MESH WITH RING GEAR
4. Defective START/STOP switch

- Check.
1. Worn starter drive gear

- Replace starter drive. Refer to PTO HOUSING
AND MAGNETO.
5. Battery connections
- Check/clean/tighten.
6. Poor/bad or corroded ground contacts (engine,
starter etc.)
- Check/clean/repair.
7. Starter solenoid
- Check.
2. Defective drive
- Replace starter drive. Refer to PTO HOUSING
AND MAGNETO.
3. Poor movement of drive on splines
- Clean and correct. Refer to PTO HOUSING AND
MAGNETO.
8. Starter malfunction
- Check.
4. Worn starter drive bushing

- Replace clutch. Refer to PTO HOUSING AND
MAGNETO.
9. Obstructed starter drive gear assembly

- Check/repair, refer to PTO HOUSING AND MAGNETO.
5. Worn ring gear

- Replace ring gear. Refer to PTO HOUSING AND
MAGNETO.
ENGINE CRANKS SLOWLY
STARTER KEEPS RUNNING
1. Loose battery cables

- Check/clean/tighten.
1. Shorted solenoid winding

- Replace solenoid.
2. Discharged/weak battery
- Check/charge/replace. Refer to CHARGING SYSTEM.
2. Melted solenoid contacts

- Replace solenoid.
3. Worn starter
- Check, refer to STARTING SYSTEM.
3. Sticking or defective starter drive

- Lubricate or replace. Refer to PTO HOUSING
AND MAGNETO.
STARTER DOES NOT TURN
PROCEDURES
1. 2 short beeps are not heard when pressing the

START/STOP button
- Refer to DIGITALLY ENCODED SECURITY SYSTEM.
2. Burnt fuse
- Check wiring condition and replace fuse.
3. Poor contact of battery terminal(s)
- Clean and tighten terminal(s).
4. Poor battery ground cable connection
- Clean and tighten.
5. Weak battery
- Recharge or replace battery.
6. Poor contact of START/STOP switch or solenoid
- Check connectors and clean contacts. Check and
replace defective parts.
7. Open circuit: START/STOP switch or solenoid
- Check. Replace if necessary.
314
WARNING
When carrying out any kind of maintenance
on the starting system, always disconnect the
battery ground cable. This will eliminate the
possibility of shorting out a power cable, and
generating a spark which could result in a fire
or and explosion. Do not place tools on the
battery.
STARTER SOLENOID FUSE

Check starter solenoid fuse (F4) condition in fuse
box 1. If it is burnt, it can be quickly identified by
the following symptoms:
The information center will come on and turn
off after 5 seconds.
A fault code will be set.
Engine will not crank when pressing the
START/STOP button.
smr2009-034

NOTE: The solenoid may be the cause of a burnt

fuse (F4).
If fuse is good, proceed with the STARTER QUICK
TEST.
ENGINE START/STOP SWITCH
Measure resistance through switch as per following table.

START/STOP SWITCH OPERATION TEST
SWITCH
POSITION
Start/Stop Switch Operation Test

Open the front storage cover and remove the storage bin.
Lift suspension using the iS up button.
NOTE: If more height is required or if the iS cannot be used, manually lift suspension by the anchor points close to handlebar and safely block in
this position.
Released
Pressed and held
8-PIN
CONNECTOR
OF
DIAGNOSTIC
HARNESS
Pins 1 and 2
RESISTANCE
Infinite (OL)
Close to 0
NOTICE Stop lifting as soon as suspension

has fully extended.
Disconnect the 8-pin connector below the moving
deck in the steering area.
smr2009-030-033_d
If switch does not test as specified, replace the

engine START/STOP switch.
If switch tests as specified, perform the
START/STOP SWITCH INPUT VOLTAGE TEST.
Start/Stop Switch Input Voltage Test

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1. 8-pin connector here

disconnected connector.
Keep the same test setup as for the START/STOP

SWITCH OPERATION TEST.
and select Vdc.
529036179

and select .
smr2009-034
315

START/STOP SWITCH INPUT VOLTAGE TEST

8-PIN
CONNECTOR
OF
DIAGNOSTIC
HARNESS
SWITCH
POSITION
Released
Pressed and held
Pins 1 and 2
VOLTAGE
Battery voltage
Close to 0 Vdc
If test succeeded, problem is in the control circuit

going to ECM. Perform the START/STOP SWITCH
CONTROL CIRCUIT TEST.
Start/Stop Switch Power Circuit Test

Remove cover from fuse box 2. Refer to POWER
DISTRIBUTION.
smr2009-030-033_a
If both tests succeeded, the START/STOP switch

and its circuit, the control circuit and ECM are
functional.
If any test failed, perform the following test.
START/STOP SWITCH INPUT VOLTAGE TEST
SWITCH
POSITION
8-PIN CONNECTOR
OF DIAGNOSTIC
HARNESS
VOLTAGE
Released
Pin 2 and battery

ground
Battery voltage
2009-027-009_a
1. Fuse box 1
2. Fuse box 2
Slightly raise the end of the long bus bar just

enough to probe the fuse box terminal without
losing contact between all the terminals and the
bus bar.
smr2009-034-001_a
1. Slightly raise this end
smr2009-030-033_e

and select .
Test continuity of the circuit as per following table.
If test failed, problem is in the power circuit coming from fuse box 2. Perform the START/STOP
SWITCH POWER CIRCUIT TEST.
316
smr2009-034

CONTROL CIRCUIT TEST
POWER CIRCUIT TEST

8-PIN
CONNECTOR
OF DIAGNOSTIC
HARNESS
FUSE BOX 2
Pin 2
Terminal B2
RESISTANCE
8-PIN
CONNECTOR
OF DIAGNOSTIC
HARNESS
ECM
CONNECTOR
B
RESISTANCE
Close to 0
(continuity)
Pin 1
B-D1
Close to 0
(continuity)
smr2009-030-033_f
smr2009-030-033_g
If test succeeded, the circuit is functional.

If test failed, repair wiring/connectors.
If test succeeded, circuit is functional.

If test failed, repair harness/connectors.
Start/Stop Switch Control Circuit Test
STARTER SOLENOID

Disconnect the B connector from ECM.
ECM connector.
529036166

and select .
Test continuity of the circuit as per following table.
smr2009-034
Solenoid is located below fuse box 2.
smr2009-034-002_b
1. Fuse box 2
2. Solenoid
To reach the solenoid, detach fuse box 2 from its

rack. Move fuse box aside to gain access.
317

smr2009-034-006_a
If test succeeded, carry out a SOLENOID CON-
TROL CIRCUIT TEST.
smr2009-034-002_c
1. Fuse box 2
If test failed, carry out a POWER CIRCUIT TEST

as follows.
Solenoid Input Voltage Test

(at Solenoid Connector)
Solenoid Power Circuit Test
Disconnect solenoid connector.
Remove relay in fuse box 2.

Set multimeter to .
Test continuity of wiring as per following table.
SOLENOID POWER CIRCUIT TEST
SOLENOID
CONNECTOR
FUSE BOX 2
TERMINAL
RESISTANCE
Pin A
A10
Close to 0
(continuity)
smr2009-034-007_a
1. Solenoid connector
Install D.E.S.S. key.

Press the START/STOP button to activate ECM.
andselect Vdc.
SOLENOID INPUT VOLTAGE TEST
(SOLENOID CONNECTOR)
TEST PROBES
Pin A
318
Battery
ground
VOLTAGE
READING
Battery
voltage
smr2009-034-006_b
If test failed, repair or replace wiring/connectors.

If test succeeded, power circuit is functional.
Solenoid Control Circuit Test

and select .
ECM connector.
Test continuity of wiring as per following table.
smr2009-034

SOLENOID CONTROL CIRCUIT TEST

SOLENOID
CONNECTOR
ECM
CONNECTOR
B
RESISTANCE
Pin B
B-L4
Close to 0
(continuity)
smr2009-034-008_a
If test failed, replace solenoid.

If test succeeded, perform the following test.
Disconnect battery negative cable.
Test solenoid main contacts as per following table.
smr2009-034-006_c
If test failed, repair or replace wiring/connectors.

If test succeeded, carry out a SOLENOID COIL
RESISTANCE TEST
Solenoid Coil Resistance Test
SOLENOID MAIN CONTACTS TEST

SOLENOID POSTS
Post coming
from battery
Post going to
starter
RESISTANCE
OL
(open circuit)
Plug harness connector to solenoid.

Remove relay in fuse box 2.
ECM connector.
Set multimeter to setting.
Measure solenoid coil resistance as per following
table.
SOLENOID COIL RESISTANCE TEST
FUSE BOX 2
ECM
CONNECTOR
B
RESISTANCE
Terminal A10
B-L4
Close to 0
(continuity)
smr2007-025-004_a
TYPICAL SOLENOID MAIN CONTACTS TEST (BATTERY

DISCONNECTED)

If test succeeded, perform a SOLENOID DYNAMIC TEST.
Reconnect battery cable.
smr2009-034
319

Solenoid Dynamic Test
SOLENOID DYNAMIC TEST (ENGINE CRANKING)
Ensure battery and starter solenoid are properly

connected.
Set ECM in engine drowned mode: Depress
throttle lever and install a rubber band to hold
lever in full throttle position.
Set multimeter to Vdc.
Install the D.E.S.S. key.
Depress the START/STOP button.
As engine is cranking, measure the voltage as
per following tables.
TEST PROBES
Solenoid
battery post
Solenoid
starter post
VOLTAGE (DC)
0.2 Vdc max.

TEST PROBES
Solenoid
battery post
Battery ground
VOLTAGE (DC)
Battery voltage
smr2009-034-010_c
1. Starter motor
2. Starter solenoid

If all solenoid dynamic tests are as specified, carry
out a STARTER QUICK TEST.
Remove rubber band from throttle lever.
Solenoid Removal
smr2009-034-010_a
1. Starter motor
2. Starter solenoid
If test failed, check battery and cable from battery

to solenoid.
If test succeeded, continue with next test.
TEST PROBES
Solenoid
battery post
Battery ground
VOLTAGE (DC)
1. Disconnect battery. Refer to CHARGING SYSTEM section.

2. Detach fuse box 2 from its bracket.
3. Detach diagnostic connector from battery
holder.
4. Detach electrical component support from battery holder.
5. Disconnect voltage regulator/rectifier connectors.
6. Disconnect starter solenoid connector.
Battery voltage
smr2009-034-010_b
1. Starter motor
2. Starter solenoid

If test succeeded, continue with next test.
320
smr2009-034

smr2009-034-005_a
smr2009-034-002_d
1.
2.
3.
4.
5.
Fuse box 2
Diagnostic connector
Electrical component support
Voltage regulator/rectifier connectors
Starter solenoid connector
7. Push locking tab and HOLD it.
1. Cables
Solenoid Installation
Revert removal operations and pay attention to
the following.
Connect cables to solenoid as shown.
smr2009-034-003_a
1. Locking tab
8. Slide solenoid out.
smr2009-034-005_b
1. Cable from battery

2. Cable to starter motor
Ensure to push solenoid until a click is heard

(locking tab engagement).
smr2009-034-004_a
1. Solenoid
9. Disconnect solenoid cables.

smr2009-034-003_b
1. Solenoid locked here
smr2009-034
321

NOTE: It may be necessary to pull retaining tab to

ensure proper locking.
Wiggle solenoid to ensure it is securely locked.
Reinstall remaining components.
Reconnect battery and test starter solenoid operation.
BLACK booster cable:

Connect one clip to the negative (-) battery terminal in the vehicle.
Momentarily apply the second clip to the negative
(-) terminal of the external battery.
STARTER
Starter Quick Test

To easily bypass the starter solenoid and the start
control circuits, proceed as follows.
Use a fully charged 12 V battery with a capacity
of at least 30 A-h. Use an external battery to
prevent connection sparks in hull.
Use a set of booster cables to power the
starter.
This procedure tests the following:
electric starter
starter power cable
battery to engine ground cable.
WARNING
Fuel, oil, or electrolyte vapors are flammable
and may become explosive if certain conditions are met. These vapors may collect
near the bottom of the hull when present. All
types of ignition including electrical sparks
are to be avoided when maintaining or testing vehicle.
WARNING
Always use an external battery for this test.
Always connect the BLACK booster cable clip
last to the external battery negative (-) terminal. Do not short starter solenoid contacts
across the main power connections on the
relay with a tool which would cause a spark.
Failure to follow this procedure may result in
an explosion.
WARNING
Always wear safety glasses when working
with or around batteries.
Connect booster cables in this strict order:
RED booster cable:
Connect one clip to the starter post on the starter
solenoid.
Connect the other clip to the positive (+) terminal
on the external battery.
322
smr2009-034-011_a
Step
Step
Step
Step
1:
2:
3:
4:
Connect cable to solenoid starter post

Connect cable to vehicle battery positive post
Connect cable to external battery negative post
Make a momentary contact
If engine does not crank (or slowly cranks), check

the following:
Booster cable connections
Vehicle battery ground cable connections to engine
Starter power cable/connections from solenoid
to starter.
If the above items all test good, replace the
starter.
Starter Removal
Open seat.
SYSTEM.
Remove deck extension. Refer to BODY .
Lower moving deck.
SYSTEM.
Disconnect battery. Refer to CHARGING SYSTEM section.
WARNING
Always disconnect the BLACK (-) battery cable first and reconnect last.
NOTE: To have a better access starter, work from
the RH side of vehicle and lay across the moving
deck.
smr2009-034

Disconnect starter power cable.

Remove starter retaining screws.
Starter Gear Installation

Installation is the reverse of removal procedure.
However, pay particular attention to the following.
Use a new circlip.
Starter Installation
Installation is the reverse of the removal procedure. However, pay particular attention to the following.
Ensure starter and engine mating surfaces are
free of debris. Serious problems may arise if
starter is not properly aligned.
Apply ISOFLEX GREASE TOPAS NB 52 (P/N 293 550
021) on starter O-rings.
smr2007-025-008_a
TYPICAL REAR OF WATERCRAFT IN ON RH SIDE OF

ILLUSTRATION
1. Exhaust manifold
2. Starter
3. Starter retaining screws
4. Starter power cable retaining nut
Starter Gear Removal

Remove starter.
Remove gear retaining circlip and pull out starter
gear.
smr2007-025-009_a
1. Apply Isoflex grease Topas NB 52
F18H0NA
1. Retaining circlip
2. Starter gear
smr2009-034
Install starter.
NOTE: If starter does not mesh properly with
the intermediate gear: Pull starter out, slightly
rotate the starter gear then reinstall the starter.
Temporarily removing both O-rings makes it easier to align both gears. Once gears are aligned,
remove starter to install O-rings being careful not
to rotate starter gear out of position, then reinstall
the starter.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on retaining screws and torque to 10 Nm (89 lbfin).
Connect the RED positive cable to the starter and
torque retaining nut to 7 Nm (62 lbfin).
323

WARNING
To prevent electric shock whenever connecting the RED power cable to the starter motor,
ensure the BLACK (-) battery cable is disconnected.
Apply DIELECTRIC GREASE (P/N 293 550 004) on terminal and nut.
Ensure to install rubber protector over starter
power cable retaining nut.
smr2007-025-008_b
1. Torque power cable retaining nut to 7 Nm (62 lbfin) and apply

dielectric grease
2. Install rubber protector
A. 10 Nm (89 lbfin)
324
smr2009-034

Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
DIGITALLY ENCODED SECURITY

SYSTEM (D.E.S.S.)
SERVICE TOOLS
Description
Part Number
Page

ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 331
GENERAL
SYSTEM DESCRIPTION
The D.E.S.S. system allows starting the engine
only with safety lanyard(s) that has been programmed to operate a specific watercraft.
NOTE: If desired, a D.E.S.S. key can be used on
other watercraft equipped with the D.E.S.S. It only
needs to be programmed for that watercraft.
The following components are specially designed
for this system: ECM, D.E.S.S. key and D.E.S.S.
post.
The D.E.S.S. key cap contains a magnet and a
ROM chip.
The magnet actually closes the reed switches
inside the post which is the equivalent of a mechanical ON/OFF switch.
The chip has a unique digital code which is the
equivalent of the notch pattern on a conventional key.
The D.E.S.S. system is quite flexible. Up to 10 different keys may be programmed in the memory of
the ECM. They can also be erased individually.
The memory of the ECM is programmed to recognize the digital code of the D.E.S.S. key. The
programming is achieved with the B.U.D.S. software.
D.E.S.S. Key Types

For best results, it is recommended to use the
D.E.S.S. key with the oval shaped float. It is identified as the iControl key.
smr2009-035
smr2009-035-006
In addition to the normal D.E.S.S. key, other special keys can be programmed so that the vehicle
can be run only up to a limited speed. Such a feature is ideal for first time riders or renters.
The D.E.S.S. keys are color-coded to differentiate
them.
D.E.S.S.
KEY TYPE
COLOR
Normal key
YELLOW or BLACK
Learning key
GREEN
Rental key
ORANGE
NOTE: When a Learning or a Rental key is used,

the DOCK MODE is always active. Refer to SUSPENSION (iS) subsection for more information
about DOCK MODE.
The Learning and Rental keys can be set through
5 settings to control the maximum watercraft
speed. Refer to SETTING MAXIMUM SPEED
FOR LEARNING AND RENTAL KEYS.
D.E.S.S. Key Beeper Codes

When a D.E.S.S. key is present on the vehicle
D.E.S.S. post while the START button is pressed,
the key is identified by the ECM and coded
beeper signals are emitted according to the key
recognition. See table:
325

BEEPER
SIGNIFICATION
2 short
beeps
Indicate a working D.E.S.S. key.

Engine starting can take place.
1 long
beep
Indicates a wrong D.E.S.S. key is being

used or something is defective.
Engine starting is not allowed.
Other beeps can be heard. The ECM features

a self-diagnostic mode. Refer to MONITORING
SYSTEM AND FAULT CODES for more information.
Start B.U.D.S. and logon.

IMPORTANT
Approximately 3 minutes after pressing the START
button, the ECM will stop communicating with
B.U.D.S. Therefore, operations with B.U.D.S. will be
interrupted.
To initiate back the communication, briefly press the
START button. Do not hold START button to avoid
engine cranking.
Read ECM using Read Data button.
PROCEDURES
D.E.S.S. KEY
D.E.S.S. Key Recognition
To help the key recognition, the following steps
are recommended:
ECM.
Install the key on watercraft D.E.S.S. post.
Press the START button to start engine.
vmr2006-012-100_aen
Click on Keys tab.
D.E.S.S. Key Programming

Perform the required connections for B.U.D.S. Refer to COMMUNICATION TOOLS AND B.U.D.S.
SOFTWARE for proper connection instructions.
Use the latest B.U.D.S. software available from
BOSSWeb.
IMPORTANT: Ensure all connections have been
made before starting B.U.D.S. to allow proper
operation.
Briefly press START button to power the ECM.
Install a D.E.S.S. key, to be added or erased, on
watercraft D.E.S.S. post.
smr2005-072-001_en
Adding a Key
Click on the desired Add Key button on bottom
of screen according to the type of key you want
to program.
WARNING
If programming a Learning or Rental key,
make sure to use the proper key type (color)
to avoid possible confusion.
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1. Key to be added or erased

326
smr2009-035

smr2009-035-003_c
After approximately 10 seconds, the following

window will pop up confirming the new key has
been saved in the PC computer.
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1. Key to be erased
Click on Erase Key button at bottom of B.U.D.S.

screen.
smr2008-020-008
If programming is complete, write the changes to

the ECM. Refer to WRITING CHANGES TO ECM
in this subsection.
Adding Another Key
Remove the key on D.E.S.S. post.
Install the next key to be programmed on D.E.S.S.
post.
Click on the desired Add Key button.
in this subsection.
smr2009-035-004_a
1. Click on this button
After approximately 10 seconds the following

message will appear.
Erasing One Key

Install the key to be erased to the watercraft
D.E.S.S. post.
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The key is now erased in the PC computer.

in this subsection.
Erasing Another Key
Remove the key from watercraft D.E.S.S. post.
Install the next key to be erased on D.E.S.S. post.
Click on Erase Key button.
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327


in this subsection.
After the write operation, remove key from

D.E.S.S. post.
Try the key(s) on the watercraft.
Erasing All Keys

Click on Erase All Keys button at bottom of
screen.
Setting Maximum Speed for Learning

and Rental Keys
NOTE
The maximum speed setting chosen will be
applicable to any programmed Learning or Rental
keys.
Changing key setting is only available when the
engine is not running.
A programmed normal D.E.S.S. key is required to set
the Learning or the Rental key.
To change Learning or Rental Key settings, carry

out the following:
1. Briefly press the START button to wake up the
electrical system.
smr2009-035-004_b
1. Click on this button
NOTE: No message will be displayed in B.U.D.S.

When done, add at least a new key to the vehicle.
Refer to ADDING A KEY in this subsection.
in this subsection.
Writing Changes to ECM
Save the changes made in B.U.D.S. into the ECM
as follows.
Briefly press the START button to prevent ECM
communication interruption during the write
process. Do not hold START button to avoid
engine cranking.
Click the Write Data button.
sdd2009-001-019_e
1. START button
2. Wait for the information center to complete its

self-test.
3. Install a programmed normal D.E.S.S. key to
watercraft D.E.S.S. post.
4. Press the MODE button repeatedly until KEY
MODE is visible in the information center.
vmr2006-012-100_ben
NOTE: If for some reason the writing operation

fails, exit B.U.D.S. Restart B.U.D.S. and reenter all
the previously lost information.
328
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sdd2009-001-024_e
1. MODE button
smo2009-002-114_c
NOTE: Pressing the SET button twice will enable

the Rental key setting function.
6. Press the UP or DOWN arrow button to toggle the key setting between 1 and 5. Refer to
MAXIMUM WATERCRAFT SET SPEED TABLE.
smo2009-002-114_b
5. Press the SET button to enable Learning key

mode setting. The display will change to L-Key.
smo2009-002-114_ii
EXAMPLE: LEARNING KEY SET TO 5
7. Press the SET button once to save the setting,

twice to exit the function, or simply wait for the
function to time-out. The change will be automatically saved.
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1. SET button
sdd2009-001-024_f
1. SET button
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329

MAXIMUM WATERCRAFT SET SPEED TABLE

D.E.S.S. KEY
TYPE
KEY SETTING
APPROX.
MAX. SPEED
58 km/h
(36 MPH)
55 km/h
(34 MPH)
50 km/h
(31 MPH)
47 km/h
(29 MPH)
42 km/h
(26 MPH)
74 km/h
(46 MPH)
69 km/h
(43 MPH)
63 km/h
(39 MPH)
58 km/h
(36 MPH)
51 km/h
(32 MPH)
Learning key
Rental key
529036179
smr2009-030-033_d

NOTE: The table indicates the approximate maximum speed given the type of key used. Depending on riding and environment conditions, the
given values can vary. At high altitude, variations
could be greater if impeller is not replaced.
BEEPER
Beeper Troubleshooting
If no beep is heard when installing the D.E.S.S.
key on the post and engine can be started, refer
to GAUGE to check the beeper operation.
If no beep is heard when installing the D.E.S.S.
key on the post and engine can NOT be started,
refer to ELECTRONIC FUEL INJECTION.
D.E.S.S. POST
D.E.S.S. Post Continuity Test
NOTE: For the following tests, the DIAGNOSTIC
HARNESS (P/N 529 036 179) can be used to make an
529035868_a
Open front storage cover.

Remove storage tray.
D.E.S.S. Key Removed from Post
From under the moving deck steering area, disconnect the 8-pin connector attached to the
D.E.S.S. post harness.
in-line connection between the disconnected connectors.
330
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smr2009-035-001_b
D.E.S.S. Key on Post

Probe D.E.S.S. post terminals to check continuity
as follows.
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8-PIN CONNECTOR
D.E.S.S. POST HARNESS
Set multimeter to .
Probe D.E.S.S. post terminals to check continuity
as follows.
8-PIN CONNECTOR
Pin 3
Pin 5
Pin 3
Pin 5
RESISTANCE
@ 20C (68F)
Close to 0
RESISTANCE
@ 20C (68F)
Open circuit
smr2009-035-002_a
Reconnect D.E.S.S. post connectors.

If any continuity test fails, replace D.E.S.S. post.
D.E.S.S. Post Vehicle Harness

Continuity Test
Disconnect the 8-pin connector attached to the
vehicle harness of the D.E.S.S. post.
smr2009-035-008_a
8-PIN CONNECTOR
Pin 4
Post
terminal
RESISTANCE
@ 20C (68F)
Close to 0
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8-PIN CONNECTOR
Pin 3
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Post ring
RESISTANCE
@ 20C (68F)
Disconnect the "B" connector from ECM. Refer to

ELECTRONIC FUEL INJECTION subsection.
Install the ECM ADAPTER TOOL (P/N 529 036 166)
on ECM connector.
Probe vehicle harness terminals to check continuity as follows.
Close to 0
331

8-PIN CONNECTOR
ECM ADAPTER RESISTANCE
D.E.S.S. POST VEHICLE
TOOL
@ 20C (68F)
HARNESS
5
B-E4
B-B2
B-F2
Close to 0
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Reinstall removed components.

If any continuity test failed, check wiring harness
between D.E.S.S. connector and ECM connector.
If problem persists and all tests have been performed, try a new ECM. Refer to FUEL INJECTION section.
332
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Subsection 07 (GAUGE)
GAUGE
SERVICE TOOLS
Description
Part Number
Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 344, 353
SERVICE PRODUCTS
Description
Part Number
Page
DIELECTRIC GREASE ................................................................... 293 550 004 ......................... 333, 350, 354
GENERAL
NOTE: For a complete overview of the vehicle
electrical system, refer to POWER DISTRIBUTION.
WARNING
TROUBLESHOOTING
DIAGNOSTIC TIPS
connections first.

1. Press the START/STOP button.
NOTE: Pressing the START/STOP button without
the D.E.S.S. key installed on it's post will turn on
electrical power without starting the engine; the
information center will cycle through a self-test
function and shut off its display after a few seconds. However, the electrical system will stay
powered up for approximately three minutes after
the START button was depressed.
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2. Install safety lanyard (D.E.S.S. key) to activate

ECM and Information Center when testing procedures require the device or system to be supplied with electrical power.
IMPORTANT: When B.U.D.S. is being used,
the ECM will stop communicating with B.U.D.S.
approximately 3 minutes after the START button was pressed. Therefore, operations with
B.U.D.S. will be interrupted. To re-initiate the
communication, briefly press the START button.
Do not hold the START button to avoid engine
starting.
Circuit Testing
fuse tester or ohmmeter (a visual inspection
could lead to a wrong conclusion).

Clean pins properly and coat them with DIELECTRIC GREASE (P/N 293 550 004) or other appropriate
lubricant when reassembling them, except if otherwise specified such as for the ECM connectors.
Pay attention to ground wires.
333

PROCEDURES
INFORMATION CENTER
Information Center Overview
The information center (cluster) is a multifunction
gauge that supplies several real time useful informations to the driver.
The information can be displayed in three languages (English, French, or Spanish).
Units of measurement can be displayed either
in Imperial system or in the metric system. Use
B.U.D.S. to change the language and units of
measurement settings.
The operator can view at a glance several indications such as speed, engine RPM, fuel quantity
and engine temperature. The gauge can also
be used to navigate through and select several
gauge functions, system modes of operation, and
to change certain settings and system parameters.
Indicator lamps advise the operator of selected
functions or abnormalities.
The gauge itself is an electronic module. Both the
left and right handlebar switches send input signals to the gauge. The gauge interprets the signals from the switches and translates the signals
into the appropriate CAN (protocol).
The translated information is then sent out of the
gauge through the CAN bus to the appropriate
module so that it can initiate the specific action
commanded.
In addition, the gauge receives CAN signals from
other modules and is able to translate those signals into the appropriate gauge display.
The inputs to the gauge include but are not limited
to, the VTS, iS, MODE/SET, UP/DOWN arrows,
cruise and fuel level sensor.
The gauge incorporates a GPS (Global Positioning
System) that it uses for compass and speedometer indications, and to provide speed signals to
other systems as required for their operation.
The beeper is also incorporated in the information
center.
tion). This self test function allows the driver

time to ensure that all indications are functioning
properly.
It also validates the information centers internal
circuits, however, this does not validate proper operation of the individual external circuits and sensors that provide inputs to the information center.
If a system fault is detected by the ECM, the applicable message and/or indicator light will be displayed, and a beep code may be heard.
If the safety lanyard is not installed, the indications
in the information center will shut off a few seconds after the self test function, but the electrical
system power stays on for approximately 3 minutes. Installing the D.E.S.S. key on its post will
turn the indications back on.
NOTE: If the START/STOP button is pressed and
held without the D.E.S.S. key installed, the information center will stay on as long as the START
button is held.
Self Test Function

When the START/STOP button is pressed momentarily and the vehicle powers up, all LCD
segments and indicator lights in the information
center will turn ON for 3 seconds (self test func-
334
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Gauge Description
9
10 11 13
12
14
smo2009-002-119_a
1. Speedometer
2. Tachometer
3. Digital screen
4. Indicator lights
5. Fuel level
6. VTS position
7. iS position
8. Numerical display
9. Multifunction display
10. Depth sounder indicator
11. Water temperature display
12. Hour meter display
13. iBR position
14. Compass
1) Speedometer
The speedometer, located in the LH side of the
information center, provides an analog indication
of the speed of the watercraft in miles per hour
(MPH) and kilometers per hour (km/h).
The speed indication is based on a GPS (Global Positioning System) incorporated within the information center.
An indicator light seen in the tachometer lights
up when the GPS is receiving a good signal. See
COMPASS for illustration.
If for some reason the GPS signal is lost, a default mode is used whereby, the speed is calculated using information received from other systems to provide an estimated watercraft speed.
smr2009-036
2) Tachometer
The tachometer provides an analog indication of
the revolutions per minute (RPM) of the engine.
Multiply the indicated number by 1000 to obtain
the actual engine RPM.
3) Digital Screen
The digital screen, located in the center of the information center, is capable of providing 10 separate indications simultaneously.
Fuel level
VTS position
iS display
Numerical display
Multifunction display
Water temperature
Engine hourmeter
iBR position
Compass active indicator
Depth sounder indicator.
335

The numerical and multifunction displays in the

digital screen can be used to display various indications, or for selecting modes of operation and
changing settings as explained in their respective
subsections.
PILOT
LAMPS
(ON)
MESSAGE
DISPLAY
DESCRIPTION
CRUISE mode or
SLOW SPEED MODE
engaged
iBR system fault
O.T.A.S. system fault
Good GPS uplink
5) Fuel Level
A bar gauge located in the bottom RH side of the
digital screen continuously indicates the amount
of fuel in the fuel tank while riding.
smo2009-002-114_j
DIGITAL SCREEN
4) Indicator Lights
Indicator lights (pilot lamps), located in the
speedometer and tachometer indicator, inform
you of a selected function, a normal condition, a
system anomaly, or a serious malfunction.
An indicator light may be accompanied by a
scrolling message in the multifunction display.
PILOT
LAMPS
(ON)
MESSAGE
DISPLAY
DESCRIPTION
MAINTENANCE
Maintenance required
REMINDER
LOW or HIGH
BATTERY
VOLTAGE
Low/high battery
voltage
LOW-FUEL
Low fuel level, approx.

20% tank capacity,
14 L (3.7 U.S. gal.)
or fuel level sensor
disconnected
Engine or exhaust
HIGH
TEMPERATURE system overheating
336
smo2009-002-114_k
FUEL LEVEL INDICATION
CHECK
ENGINE or
LIMP HOME
MODE
Check engine (minor

fault req. maint.) or
LIMP HOME MODE
(major eng. fault)
LOW OIL
PRESSURE
Low oil pressure
When the fuel tank is full, 8 segments (bars) of

the indicator are turned on. The top segment is
not used.
When there is only 2 segments of fuel indicated
(approximately 20% fuel tank capacity or 14 L
(3.7 U.S. gal.), the low fuel indicator light will
come on to advise you of the low fuel condition.
See INDICATOR LIGHTS.
An audible warning (one long beep) will be heard
periodically as long as the low fuel condition exists.
6) VTS Position
The VTS position indication located in the bottom
LH side of the digital screen indicates the riding
attitude of the watercraft.
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A single segment of a bar gauge type indicator is

turned on to indicate the relative position of the
watercraft bow.
pears and a single segment of the bar gauge is

turned on to indicate the position of the suspension.
Refer to SUSPENSION (iS) for more details.
8) Numerical Display
A numerical display is used to provide a variety of
indications as selected by the operator:
Engine RPM
Watercraft speed
Lake temperature
Water depth (GTX LTD iS).
1
2
smo2009-002-114_l
VTS POSITION INDICATION
Refer to IBR AND VTS subsection for more details.

7) iS Position
The iS position display (intelligent Suspension)
provides a visual indication of the relative height
of the suspension.
It also indicates if the suspension is in AUTO
mode of operation.
2
1
smo2009-002-114_m
1. iS position indicator
2. iS AUTO mode indicator
smo2009-002-114_n
EXAMPLE - NUMERICAL DISPLAY

1. Water depth indication (GTX LTD iS)
2. Numerical display
When the information center is first powered up,

the numerical display defaults to the last selected
indication.
The numerical display is also used to display various system mode settings such as:
VTS PRESET
LEARNING KEY setting
RENTAL KEY setting
SLOW SPEED MODE setting.
Changing Numerical Display Indication
To change the indication in the numerical display,
press the MODE button on the RH handlebar repeatedly until DISPLAY is visible in the multifunction display.
When the suspension system is operating in

AUTO mode, the AUTO indicator and all bar segments of the position indicator will be on.
When the suspension height is adjusted manually
using the iS , the system switches to MANUAL
mode of operation. The AUTO indication disap-
smr2009-036
337

9) Multifunction Display
When the watercraft is being operated, the multifunction displays provides and indication of compass direction, scrolling messages from the fault
monitoring system, or a scrolling DOCK MODE
ON message when the function is active.
The display also allows for the selection of various functions which, permit changing the numerical display indication, system modes of operation,
settings, and displaying system fault codes used
for troubleshooting.
WARNING
smo2009-002-114_p
DISPLAY MODE FUNCTION
Press the UP or DOWN arrow button to the right

of the MODE button until the preferred indication
name is visible in the multifunction display.
RPM
SPEED
LAKE TEMPERATURE.
DEPTH.
NOTE: The DEPTH selection is only available if a
depth sounder is installed.
smo2009-002-114_q
Selecting various numerical displays, system modes of operation or changing settings

should only be carried out with the watercraft
stopped. Selecting these various functions
while operating the watercraft at speed is
not recommended as it deters your attention
from situational awareness and can result in
severe injury.
To display system fault codes in the multifunction
display, refer to the MONITORING SYSTEM AND
FAULT CODES subsection.
smo2009-002-114_o
EXAMPLE - RPM SELECTION
MULTIFUNCTION DISPLAY - COMPASS ILLUSTRATED
Press the SET button to select and save the preferred indication, or wait for the display function
to time out. The last indication visible will be automatically saved. The numerical display will then
switch to the new indication with a small abbreviation of the indication type to its right:
FT or M
RPM
MPH or Km/h
F or C.
Selecting Functions
When operating at speed, the multifunction display normally provides an indication of the compass direction and azimuth the watercraft is traveling.
To select the various functions available through
the multifunction display, press the MODE button
repeatedly until the desired function is visible:
DISPLAY
VTS MODE
FAULT CODES
338
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KEY MODE
SETTINGS.
Press the SET button (or the UP or DOWN arrow
button) to enter the desired function.
NOTE: The fault codes function is available only
when there is an active fault. The settings function is only available when the engine is shut off.
Each available function is explained in its applicable subsection.
For the DISPLAY function, refer to NUMERICAL
DISPLAY in this subsection.
For VTS MODE, refer to the IBR AND VTS subsection.
For SETTINGS which provides access to DOCK
MODE and iBR OVERRIDE, refer to SUSPENSION (iS) or iBR AND VTS subsections as applicable.
For KEY MODE, refer to DIGITALLY ENCODED
SECURITY SYSTEM (D.E.S.S.) subsection.
For FAULT CODES, refer to MONITORING SYSTEM AND FAULT CODES subsection.
WELCOME ABOARD
SEA-DOO
Power up display
NORMAL KEY
Normal key detected

L-KEY
For changing learning

key setting
R-KEY
For changing rental key

setting
SETTINGS
For accessing DOCK

MODE and iBR-OVR
settings
DOCK MODE
Dock mode function

menu
DOCK MODE OFF
Dock mode disable
DOCK MODE AUTO
Dock mode enable
DOCK MODE ON
Suspension moving to
DOCK position
iBR-OVR
iBR mode function menu
OVR OFF
iBR-OVR function disable
OVR ON
iBR-OVR function enable
SLOW SPEED MODE
Slow speed mode

acknowledgement
AUTOMATIC
SUSPENSION
Automatic suspension
acknowledgement
MANUAL SUSPENSION
Manual suspension
acknowledgement
RIGHT KEYPAD ERROR
MODE/SET, UP/DOWN
arrow button
malfunction
LOW OIL PRESSURE
Engine low oil pressure

detected
HIGH EXHAUST
TEMPERATURE
High exhaust
HIGH TEMPERATURE
High engine temperature

detected
LEARNING KEY
Learning key detected
RENTAL KEY
Rental key detected
DISPLAY
Display menu for

numerical display
indication
DEPTH
Water depth indication

selection
RPM
RPM indication selection
SPEED
Watercraft speed
indication selection
CHECK ENGINE
Engine system
malfunction or
maintenance required
LAKE TEMPERATURE
Lake temperature
indication selection
HIGH BATTERY
VOLTAGE
High battery voltage

detected
VTS MODE
VTS preset menu
PRESET 1
For changing PRESET 1
LOW BATTERY
VOLTAGE
Low battery voltage

detected
PRESET 2
For changing PRESET 2
LIMP HOME MODE
Major fault detected,

engine power limited
FAULT CODE
Fault code menu for

viewing codes
FUEL SENSOR
DEFECTIVE
NO ACTIVE FAULT
CODE
No active fault code to

display
KEY MODE
Key mode menu
WATER TEMP SENSOR

DEFECTIVE
Problem in iBR,
not sending water
temperature info.
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339


CALIBRATION
CHECKSUM ERROR
Cluster programming
corrupted
MAINTENANCE
REQUIRED
Watercraft maintenance
required
SUPERCHARGER
MAINTENANCE
REQUIRED
Maintenance on
supercharger required
10) Depth Sounder Indicator
GTX Limited iS Model

The NUMERICAL DISPLAY can be selected to
provide an indication of the lake water depth.
The system is capable of indicating water depth
under the hull in single increments up to 50 m
(164 ft).
NOTE: Under certain conditions, the digital
screen may stop displaying. The digital screen's
ability to display the depth depends on the conditions of use.
To activate the digital depth indication, refer to
CHANGING NUMERICAL DISPLAY INDICATION

in this subsection.
smo2009-002-114_t
WATER TEMPERATURE DISPLAY
The numerical display may also be selected to display water temp. See NUMERICAL DISPLAY in
this subsection.
To change the unit of measurement (C or F), refer to SETTING LANGUAGE AND UNITS OF MEASUREMENT in this subsection.
12) Hour Meter Display (HR)
Continuously displays cumulative hours of engine
use.
2
1
smo2009-002-114_r
smo2009-002-114_s
1. Depth sounder indicator

2. Water depth indication
HOUR METER DISPLAY
NOTE: The DEPTH sounder indicator is only on

when a depth sounder is installed and detected.
WARNING
Never use the depth gauge as a warning device to ride in shallow water.
13) iBR Position

Provides an indication of the iBR position (iBR
gate).
N (neutral)
F (forward)
R (reverse).
11) Water Temperature Display

Continuously displays surface water temperature
in degrees Celsius (C) or Fahrenheit (F).
340
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Setting Language and Units of

Measurement
smo2009-002-114_u
IBR POSITION - FORWARD ILLUSTRATED (F)
14) Compass
A GPS incorporated in the information center provides the indication in the multifunction display.
The cardinal points, intermediate cardinal points,
as well as the azimuth the watercraft is travelling
are displayed in the multifunction display by default when the watercraft is moving.
For a compass indication to be displayed, the GPS
must first have a good link with the navigation
satellites as confirmed by the COMPASS active
indicator being on in the digital screen. The watercraft must also be traveling at a speed over
5 km/h (3 MPH).
Connect vehicle to the latest applicable B.U.D.S.

software, refer to the COMMUNICATION TOOLS
AND B.U.D.S. SOFTWARE subsection.
electrical system.
NOTE: You will need to press the START button
every three minutes or the electrical system will
shut off.
2. Select the Read Data button.
3. Choose the Setting tab at the top of the page.
At the bottom LH side of the setting page, select
the Cluster tab.
smr2009-036-001_a
1. Read Data
2. Setting tab
3. Cluster tab
In the Cluster Language field, choose the desired

unit of language, English, French or Spanish.
In the Cluster Units field, choose the desired unit
of measurement, Imperial or Metric.
2
smo2009-002-114_v
TYPICAL
1. Compass indication
2. Compass active indicator
WARNING
Use the compass as a guide only. Not to be
used for precision navigation purposes.
smr2008-028-002_a
1. Cluster Language field

2. Cluster Units field
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341

Clearing the Maintenance Reminder

Indicators
When the watercraft, engine or supercharger is
due for maintenance, the maintenance reminder
indicator light in the speedometer will come on,
and a scrolling MAINTENANCE REQUIRED or
SUPERCHARGER MAINTENANCE REQUIRED
message will scroll in the digital screen. These
maintenance reminders must be cleared using
B.U.D.S.
1. Connect vehicle to the latest applicable
B.U.D.S. software, refer to the COMMUNI-
CATION TOOLS AND B.U.D.S. SOFTWARE

subsection.
electrical system.
shut off.
4. Choose the Vehicle tab at the top of the page.
5. At the bottom RH side of the vehicle page
in the Last Service field, choose Reset Service/Maint or Reset Supercharger Maintenance button as applicable.
NOTE: If the supercharger maintenance was carried out before the reminder appeared in the information center, the supercharger maintenance
reminder must be reset in order to reset the supercharger maintenance hour counter and prevent
the reminder from appearing prematurely.
Information Center Pin-Out

INFORMATION CENTER PIN-OUT
PIN
NO.
1
GPS back-up power
CAN HI
CAN LOW
Spare (Buzzer external GND)
Spare (Buzzer external GND)
Not used
Cruise switch signal Vdc
Spare (digital input)
Not used
10
Cruise switch ground
11
Gauge GND
12
Gauge input Vdc power
13
VTS switch signal (UP or DOWN)
14
iS switch signal (UP or DOWN)
15
VTS and iS switch common
16
UP or DOWN arrow switch signal
17
MODE and SET switch signal
18
MODE/SET, UP/DOWN arrow switch

common
19
Fuel level sensor VDC signal
20
Fuel level sensor GND
FUNCTION
Information Center Troubleshooting

Press the START/STOP button and install the
D.E.S.S. key on the D.E.S.S. post.
NOTE: Information center should come on, cycle
through its self test function, and stay on for
approximately 3 minutes after which all electrical
power will turn off. Briefly press the START/STOP
button every 3 minutes to reenergize the electrical system. Do not hold the START/STOP button
to avoid engine starting.
smr2009-036-011_a
TYPICAL
1. Read Data
2. Vehicle tab
3. Reset Service/Maint button
4. Reset Supercharger Maintenance button
342
Information Center Does Not Turn ON

When the information center does not turn ON
when the START/STOP button is pressed, the
power circuit or ground circuit to the information
center is probably open.
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Double click the iS button to move the suspension to the up position. If the suspension does not
move to the up position, the problem is related
to the electrical power system. Refer to POWER
If the suspension moves to the up position, test
the 3 A GAUGE fuse (fuse 1) in fuse box 1 (FB1).
If the GAUGE fuse tests good, carry out an INFORMATION CENTER INPUT VOLTAGE TEST.
If the information center input voltage test is
good, test for continuity of the gauge ground
circuit (gauge connector pin 11 (BLACK wire) to
the ground bus-bar (pin E12) in FB2.
Refer to WIRING DIAGRAM for circuit details.
Information Center Turns ON with Some
Indications Missing
1. Connect to the latest applicable B.U.D.S. software, refer to COMMUNICATION TOOLS AND
B.U.D.S. SOFTWARE subsection.
2. Read the fault codes.
If a fault code is related to a communication problem, carry out a continuity test of the CAN bus
wires between the applicable module and the
CAN bus-bars in FB2.
NOTE: The information center, ECM, iS module,
iBR module, and the diagnostic connector are
linked together through CAN bus-bars in fuse box
2. If one wire of the two wire CAN bus system
is open, communication will be slower than normal. Multiple fault codes may be generated and
the ECM will put the watercraft in LIMP HOME
mode.
If one module cannot be seen in B.U.D.S., the
fault may be the wires that link the module to
the CAN bus bars or internal to that module. Test
the CAN bus wires from the faulty module to the
bus-bars in FB2 for continuity before assuming
the problem is the module.
Information Center Goes Blank Except for:
GPS indicator ON
Compass ON (if watercraft moving)
Fuel level ON
iBR fault indicator light ON
Indicated speed
No other indications visible.
There is no communication between the information center and all other modules (ECM, iS, iBR).
smr2009-036
Carry out a continuity check of the CAN bus wires

from the CAN bus-bars in FB2 to the information
center (pins 2 and 3). Refer to the WIRING DIAGRAM for more details.
If an open circuit is detected, carry out same test
from the 12 pin steering connector (C01 pins 8 and
9).
All Indications ON Except for:
No LAKE WATER TEMP indication
No VTS indication
No iBR position indication
CHECK ENGINE light is on.
The iBR CAN bus circuit is open or the iBR module
is at fault.
NOTE: The ECM will generate several fault codes
and engage LIMP HOME mode.
from the CAN bus-bars in FB2 to the iBR module
(pins 2 and 3). Refer to the WIRING DIAGRAM for
more details.
NO RPM Indication and NO Engine Hour
Display
If there is NO RPM indication and NO engine
hour display, and the watercraft is in LIMP HOME
mode, the CAN bus to the ECM is open.
from the CAN bus-bars in FB2 to the ECM module, connector B pins C1 and C2 (B-C1 and B-C2).
Refer to the WIRING DIAGRAM for more details.
NO iS Position Display
If there is no iS position display (suspension position), the iS module is at fault, or its CAN bus circuit is open.
from the CAN bus-bars in FB2 to the iS module
(pins 2 and 3). Refer to the WIRING DIAGRAM for
more details.
NO Fuel Level Indication
If there is no fuel level indication, test the fuel
level sensor and its wiring circuit to the information center. Refer to FUEL TANK AND FUEL
PUMP subsection.
NO Depth Gauge Indication
If there is no depth gauge indication available and
the depth sounder active indicator is not on, refer
to DEPTH GAUGE in this subsection.
343

NO Speed or Compass Indication

If there is no speed or compass indication, look
for the GPS indicator icon. If the GPS indicator is
off, either the GPS cannot uplink with the satellites, or the GPS system in the information center
is at fault. If another watercraft nearby displays a
good GPS uplink (GPS indicator light on in cluster),
replace the information center.
NOTE: If the GPS uplink is lost while navigating
at speed, the speedometer will provide an estimated speed indication based on other parameters. The compass indication will not be available
until a good satellite uplink is reestablished.
Speed and Compass Indication Slow to Come
ON
When initially powering up the watercraft and driving away, the speed and compass indications may
be slow to come on. This is normal as the GPS
requires time to establish an uplink with the navigation satellites (cold start).
If the watercraft was run long enough to display
the compass and speed indications, shut down
for a short period of time and restarted (hot start),
and the speed and compass indications take more
than 30 seconds to come on, test for the following:
GPS fuse 23 in FB2
Battery voltage at pin 1 of the information center
Continuity of wire between information center
(pin 1) and contact B4 of FB2.
NOTE: This circuit provides 12 Vdc to the GPS in
the information center so that it memorizes the
satellites it was linked to for a period of two hours.
This allows the indications to be available within
a few seconds of restarting the watercraft (hot
start). After a two hour period, the GPS will have
to reestablish new satellite links.
Beeper Does Not Function
The beeper is incorporated within the information
center.
If no beep code is heard when installing the
D.E.S.S. key, first ensure ECM is powered. Refer
to ELECTRONIC FUEL INJECTION subsection.
If the ECM is powered and the ECM and information center are communicating properly through
the CAN bus, replace the information center.
344
Information Center Input Voltage Test

(at Gauge Connector)
1. Remove the gauge support cover, refer to INFORMATION CENTER REMOVAL in this subsection.
NOTICE Pull on connector with your hand as
you pull the connector lock out with the screwdriver. Do not twist the screwdriver.
smr2009-042-002_a
1. Gauge connector
3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.
4. Press the START button and install the safety
lanyard on the D.E.S.S. post.
5. Measure the information center input voltage
as per following table.
INPUT VOLTAGE TEST AT GAUGE CONNECTOR
PROBE
VOLTAGE
Pin 12 (Violet)
Pin 11 (Black)
Pin 12 (Violet)
Battery ground
12
Battery voltage
11
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INPUT VOLTAGE TEST AT GAUGE CONNECTOR (12 TO 11)
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4. Carry out an input voltage test at the steering

connector (vehicle harness side) as per following table.
12
INFORMATION CENTER INPUT VOLTAGE

TEST (STEERING CONNECTOR)
INFORMATION CENTER
VOLTAGE
STEERING CONNECTOR
Pin 7 (Violet)
Pin 6 (Black)
Battery voltage
Pin 7 (Violet)
Battery ground
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INPUT VOLTAGE TEST AT GAUGE CONNECTOR (12 TO

BATTERY GROUND)
If battery voltage is measured as specified in table, replace the information center.

If battery voltage is measured to battery ground
but not to pin 11, carry out a CONTINUITY TEST
OF GAUGE GROUND WIRE circuit from the
gauge connector to the ground bus-bar contact in
FB2 as described further in this subsection.
6. If battery voltage is not measured at the gauge
connector, carry out an INFORMATION CEN-
TER INPUT VOLTAGE TEST (AT STEERING

CONNECTOR).
Information Center Input Voltage Test

(at Steering Connector)
1. Open the front storage compartment cover and
remove the storage bin.
2. Reach in over top of front ventilation box and
disconnect the 12 pin steering connector (C0112POS).
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PIN-OUT - 12 PIN STEERING CONNECTOR

A. Connector alignment keys
If battery voltage is read atf steering connector

(vehicle harness side) as specified in previous table, but was not measured to pin 11 at the gauge
connector (gauge ground wire), repair or replace
the black ground wire between the gauge connector and the steering connector.
If battery voltage is measured to battery ground
but not to pin 6, carry out a CONTINUITY TEST OF
GAUGE GROUND WIRE described further in this
subsection.
If no voltage is measured, carry out the following
steps.
5. Open the boarding platform and remove the RH
storage bin.
6. Test the battery voltage at the battery terminals.
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2. 12 pin steering connector
3. Press the START/STOP switch and install the

safety lanyard on the D.E.S.S. post.
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345

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VOLTAGE TEST AT FUSE CONTACTS
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BATTERY VOLTAGE TEST
7. Remove the cover from fuse box 2 (FB2).
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If battery voltage is measured at A12 but not at

A11 (with fuse installed), replace the fuse.
If no voltage is measured at fuse contact A12,
slightly lift one corner of the long bus-bar (12
contacts long).
10. Measure for battery Vdc between the bus-bar
and battery ground.
2009-027-009_a
1. Fuse box #1
2. Fuse box #2
8. Press the START/STOP button to energize electrical system and install the D.E.S.S. key.
9. Test for battery voltage between each of the
terminals atop the gauge fuse and battery
ground as per following table.
VOLTAGE TEST AT FB1
GAUGE FUSE
Fuse pin
numbers
TEST PROBES
A12
(Violet)
A11
(Violet)
Battery (-)
post
READING
Battery
Vdc
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VOLTAGE TEST AT LONG BUS-BAR
If battery voltage is measured at the long bus-bar,

repair or replace the wire jumper C12 to A12 (behind fuse box).
If no voltage is measured at the long bus-bar,
test for voltage at the short bus-bar, refer to the
POWER DISTRIBUTION subsection.
346
smr2009-036

Continuity Test of Gauge Power Wire

1. Remove lanyard.
2. Disconnect gauge connector.
5. Set multimeter to setting.

6. Test the information center power wire continuity as per following table.
CONTINUITY TEST OF GAUGE POWER WIRE
GAUGE
STEERING
FUSE
CONNECTOR CONNECTOR BOX 1
READING
Pin 12 (Violet)
Pin 7 (Violet)
Close to
0
Pin 12 (Violet)
A11
Close to
0
Pin 7 (Violet)
A11
Close to
0
10
smr2009-042-002_a
1. Gauge connector
3. Disconnect 12 pin steering connector.
12
11
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4. Remove the gauge fuse in FB1.
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12 PIN STEERING CONNECTOR PIN-OUT (STEERING SIDE)

A. Connector alignment keyways
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FB1
1. Remove gauge fuse (F1)
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347

Remove the RH rear storage bin, refer to BODY

subsection.
Remove the cover from fuse box 2.
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12 PIN STEERING CONNECTOR PIN-OUT (VEHICLE SIDE)

A. Connector alignment keys
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1. Fuse box #1
2. Fuse box #2
Remove the ground bus-bar.
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7. Repair or replace wiring/connectors as required.
Continuity Test of Gauge Ground Wire

Open front cover and remove the front storage
bin, refer to BODY subsection.
Disconnect the 12 pin steering connector (C0112POS).
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FB2
1. Ground bus bar
Set multimeter to selection and carry out a continuity test as per following table. Refer to the
WIRING DIAGRAM for circuit details.
CONTINUITY TEST OF GAUGE GROUND WIRE
MULTIMETER PROBES
GAUGE
STEERING
FUSE
CONNECTOR CONNECTOR BOX 2
smr2009-036-004_a

READING
Pin 11 (Black)
E12
Close to
0
Pin 11 (Black)
Pin 6 (Black)
Close to
0
Pin 6 (Black)
E12
Close to
0
Open the boarding platform, refer to BODY subsection.

348
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10
12
11
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smr2009-027-010_f
Repair wiring and connectors as required.
Information Center Removal
smr2009-036-005_b
1. Open the front cover.

2. Move the steering to its highest position, refer
to BODY subsection.
3. Using a long flat screwdriver, insert the blade
between the lower locking tabs (one each side)
of the gauge support cover, and carefully pry
the tabs outwards to release them from the
gauge support.
12 PIN STEERING CONNECTOR PIN-OUT (STEERING SIDE)

A. Male connector alignment keyways
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12 PIN STEERING CONNECTOR PIN-OUT (VEHICLE SIDE)

A. Female connector alignment keys
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1. Long flat screwdriver

2. Locking tab
3. Gauge support cover
4. Pull the bottom of the panel outwards to remove it from the gauge support.
349

Information Center Installation
smr2009-042-067_a
1. LH side tab
2. Upper retaining tabs

Installation of the information center is the reverse

of the removal procedure. However, pay attention
to the following.
1. Insert and align the bottom of the gauge into
the support first, then push the top into the support and ensure it properly locks into the retaining tab.
2. When reinstalling the gauge support cover,
first insert the top of the cover into the support. Then align the bottom of the cover with
the locking tabs on the outside of the gauge
support and push it in until it snaps back in
place.
(P/N 293 550 004) to the gauge connector pins.
NOTE: If you are installing a replacement information center, refer to INFORMATION CENTER REPLACEMENT in this subsection.
Information Center Replacement

NOTICE Before replacing the information
center, it is very important to retrieve the
"approximate time left to Supercharger maintenance" in B.U.D.S. (on the Vehicle page), and
to advise the customer when the watercraft
needs to be brought in for supercharger maintenance.
smr2009-042-002_a
1. Gauge connector
2. Pull out to unlock
6. Insert a flat screwdriver between the upper

gauge locking tab and gauge support.
The new information center will start counting the "supercharger time to maintenance due
hours" from zero as the hours are calculated and
stored in the gauge cluster (old cluster), not in
the ECM. The SUPERCHARGER MAINTENANCE
REQUIRED indicators will then come on past the
real maintenance due hours. Indicated engine
hours in new gauge will be correct as they are
calculated in the ECM.
1. Connect watercraft to the latest B.U.D.S. software, refer to COMMUNICATION TOOLS AND
B.U.D.S. SOFTWARE.
3. In the Run Time field of the vehicle page, note
the accumulated Total Hours and the Supercharger maintenance (Approximate time left)
hours.
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GAUGE REMOVAL
1. Insert screwdriver here
7. Hold back of the gauge with one hand and carefully compress the retaining tab to release the
information center from the gauge support.
350
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smr2009-036-011_b
1.
2.
3.
4.
Read Data button

Vehicle page tab
Total Hours
Supercharger maintenance hours (approximate time left)
4. Add the approximate time left to supercharger

maintenance hours to the total hours to calculate the hours at which the next supercharger
maintenance is due.
Example: 104.08 + 95.52 = 200
The next supercharger maintenance will be due at
200 hours (Total Hours in B.U.D.S or hours indicated in the information center hour meter).
5. Advise customer to bring the watercraft in for
supercharger maintenance at the calculated
"Total Hours" even if the supercharger maintenance advisory message did not come on in
the information center.
If the "approximate time left to Supercharger
maintenance" hours cannot be retrieved in
B.U.D.S. (because old cluster cannot be read
by B.U.D.S.), and the engine hours (Total Hours)
at which the last supercharger maintenance was
carried out are known, then add 100 to the last
known Total Hours at which the last supercharger
maintenance was carried out.
Once the supercharger maintenance has been
carried out, the time left to supercharger maintenance must be reset using the Reset Supercharger Maintenance function in B.U.D.S. This
ensures the following supercharger maintenance
advisory message comes on as per normal intervals. Refer to CLEARING MAINTENANCE
REMINDER INDICATORS in this subsection.
smr2009-036
smr2009-036-011_c
1. Reset Supercharger maintenance button
NOTE: Replacement information centers are delivered already programmed.

After the information center has been replaced,
connect the watercraft to the latest applicable
B.U.D.S. software and carry out any updates (if
required). Refer to COMMUNICATION TOOLS
Once the information center has been updated
(if required), select the applicable settings as described in SETTING LANGUAGE AND UNITS OF
MEASUREMENT in this subsection.
MODE/SET AND UP/DOWN

ARROW BUTTONS
Overview
The MODE/SET and UP/DOWN arrow buttons
assembly contains a series of 4 diodes for the
MODE and SET switches, and another 4 diodes
for the UP/DOWN arrow switches. Refer to
WIRING DIAGRAM.
The center wire to the switches (pin C), is common to both sides of the switch assembly (somewhat like a ground wire). The other two wires
(pins A and B), act as signal wires for each set of
switches to the information center. They actually
each form one branch of an electronic circuit
within the information center.
Each diode (in circuit) drops a nominal 0.6 Vdc
when conducting electricity. If the circuit current
passes through all four diodes (say MODE and
SET switches open), a drop of 2.4 Vdc would be
measured across the 4 the diodes (pin B to pin C).
This 2.4 Vdc at pin B tells the gauge the MODE
and SET switches are open.
351

If the MODE switch is pressed, 2 diodes are bypassed. The remaining two diodes in the circuit
drop 1.2 Vdc (at pin B).
If the SET switch is pressed, 1 diode is bypassed.
The remaining three diodes in the circuit drop 1.8
Vdc (at pin B).
The gauge senses these voltages through pin 17
of the gauge connector, and interprets them as
signals that tell it which switch is activated. The
same is true for the UP/DOWN arrow switches,
iS switches and VTS switches on their respective
circuits.
If the command generated by the closure of a
switch concerns another module, a circuit within
the gauge will translate it to CAN protocol and
transmit it through the CAN bus. The applicable
module will react to the command, carry out the
function, and transmit the result back through the
CAN bus.
The information center will use the signals from
the switches and the transmitted information
from the other modules, convert them to an indication, and cancel the command signal it sent
out once the function has been carried out.
Command signals from the MODE and SET
switches are used by the information center
only. VTS and iS switch commands are translate
and sent to the modules. The UP/DOWN arrow
switch commands are used by the gauge for certain functions and settings only. The UP/DOWN
button command signals will also be translated
and sent out through the CAN bus to be used by
the ECM for the CRUISE and SLOW SPEED functions (increasing or decreasing speed when the
functions are active), and by the iBR for iBR gate
positioning in SLOW SPEED mode of operation.
NOTE: The above stated voltages vary slightly depending on the actual voltage applied to the circuit
and the current flow through the diodes. When
using a Fluke 115 multimeter for testing in diode
test mode, the voltage and current applied by the
multimeter are lower than in circuit. The quality
of probe contact, the actual probes and leads, and
the precision of the meter calibration will all affect
the results, which will most likely be slightly lower
than nominal values stated.
MODE/SET and UP/DOWN Arrow

Buttons Test Using B.U.D.S.
1. Connect the watercraft to the latest B.U.D.S.
AND B.U.D.S. SOFTWARE.
352

electrical system.
shut off.
4. Choose the Monitoring tab at the top of the
page.
5. At the bottom LH side of the monitoring page,
select the Cluster tab.
smr2009-036-002_a
1.
2.
3.
4.
Read Data button

Monitoring tab
Cluster tab
Switch inputs field
6. Press each of the MODE/SET and UP/DOWN

arrow buttons and look for the applicable indicator light to come on in the Switch inputs field
on lower RH side of the cluster page (Mode ,
Set , UP or Down).
smr2009-036-012_a
SWITCH INPUTS
1. MODE/SET and UP/DOWN arrow button indicator lights
If each of the gauge button indicator lights come

on when the applicable switch is pressed, the
problem may be related to the information center.
smr2009-036

If one or all of the indicator lights does not come

on, refer to MODE/SET AND UP/DOWN ARROW
SWITCH TEST USING A MULTIMETER.
MODE/SET and UP/DOWN Switch Test

Using a Multimeter
1. Remove the gauge support cover, refer to INFORMATION CENTER REMOVAL in this subsection.
NOTICE Pull connector lock out. Do not twist
the screwdriver.
4. Test the MODE/SET and UP/DOWN arrow

switches as per following tables.
MODE/SET SWITCH TEST
SWITCH
POSITION
Switch
released
MODE
depressed
SET
depressed
FLUKE
115
GAUGE
VOLTAGE
CONNECTOR
Red lead
Black lead
Pin 17
Pin 18
Approx.
2 Vdc
Black lead
Red lead
Pin 17
Pin 18
OL
Red lead
Black lead
Pin 17
Pin 18
Approx.
1.1 Vdc
Black lead
Red lead
Pin 17
Pin 18
OL
Black lead
Red lead
Pin 17
Pin 18
Approx.
1.6 Vdc
Black lead
Red lead
Pin 17
Pin 18
OL
UP/DOWN ARROW SWITCH TEST

SWITCH
POSITION
smr2009-042-002_a
1. Gauge connector

868) to the diode test function.
NOTE: It is important to set the multimeter
to the diode check function when testing the
MODE/SET and UP/DOWN arrow switches as it
contain diodes.
Switch
released
UP
depressed
DOWN
depressed
FLUKE
115
GAUGE
VOLTAGE
CONNECTOR
Red lead
Black lead
Pin 16
Pin 18
Approx.
2 Vdc
Black lead
Red lead
Pin 16
Pin 18
OL
Red lead
Black lead
Pin 16
Pin 18
Approx.
1.1 Vdc
Black lead
Red lead
Pin 16
Pin 18
OL
Red lead
Black lead
Pin 16
Pin 18
Approx.
1.6 Vdc
Black lead
Red lead
Pin 16
Pin 18
OL
NOTE: Remember that each diode should drop

approximately 0.6 Vdc when positively biassed,
and read as an OL (open circuit) when negatively
biassed (leads reversed).
When measuring between pins 17 and 18, or 16
and 18, if an OL is obtained with both positive
and negative diode biassing, test the continuity of
each wire between the gauge and switch assembly. If continuity is good, replace the switch assembly.
If any reading is significantly different than specified, carry out the same test at the switch connector, refer to the wiring diagram. If you obtain the
same results, replace the switch assembly.
vmr2006-020-005
smr2009-036
353

If voltages measured on every switch are as specified (or very close to it), the switches and the
wiring harness are good. The fault may be within
the gauge. Replace the gauge and carry out a
new MODE/SET AND UP/DOWN TEST USING
B.U.D.S. to ensure the problem is solved.
MODE/SET and UP/DOWN Switch

Assembly Replacement
1. Remove steering cover, refer to STEERING
AND O.T.A.S.
2. Disconnect connector from switch assembly.
smr2009-036-013_a
1. MODE/SET, and UP/DOWN switch connector
6. Install connector on new switch assembly.

7. Insert switch assembly in switch support.
8. Install steering cover, refer to STEERING AND
O.T.A.S.
WATER TEMPERATURE SENSOR

The water temperature sensor is located within
the iBR module that is part of the iBR actuator. It
cannot be tested or replaced separately.
Water from the jet pump passes through the iBR
actuator where the sensor measures its temperature, generating a signal that is interpreted by the
iBR module. The iBR module then sends the information through the can-bus to the information
center that translates it into a temperature indication.
If the temperature sensor is defective, the temperature indication will not be displayed and a
WATER TEMP SENSOR DEFECTIVE message
will scroll in the multifunction display.
A lake water temperature sensor fault code
should be generated if the sensor is defective.
Refer to MONITORING SYSTEM AND FAULT
CODES.
If the lake water temp sensor is defective, replace
the iBR actuator.
3. Remove switch assembly from support by lifting it off the support.

4. Ensure wiring from cruise switch is properly inserted in slot provided before installing
MODE/SET and UP/DOWN arrow switch assembly.
smr2009-036-014_a
1. Cruise switch
2. Wiring in slot provided in support
3. MODE/SET and UP/DOWN arrow switch connector

(P/N 293 550 004) on switch contact pins.
354
smr2009-036

DEPTH SOUNDER
Depth Sounder Removal
GTX Limited iS Models
Depth Sounder Troubleshooting

DEPTH SOUNDER TROUBLESHOOTING
SYMPTOM
POSSIBLE
CAUSE
Depth sounder
not connected.
Depth sounder
not properly
installed.
Nothing is
displayed in
the information
center
12 Vdc wire or
ground wire to
depth sounder
open.
REMEDY
Properly connect
depth sounder.
Make sure
depth sounder
is properly
installed in
battery holder
base. There
must be no air
gap between
hull and gel
pad(s).
ssi2009-002-002_a
1. Re-boarding platform
2. Remove the starboard (RH) storage bin.
Check fuse 3 in
FB1 and wiring
harnesses.
Check
WHITE/BLACK
and WHITE/RED
wires to CAN
bus-bars in FB1.
Launch
Watercraft is not watercraft in
in water.
water and
recheck.
There is air
between gel
pad and depth
Remove depth
sounder or
sounder.
between depth
Replace gel pad.
sounder and
battery holder
base.
Depth sounder Try a new depth
is defective.
sounder.
Problem with
communication
link wires.
- - - - (ft or m)
is displayed
ssi2009-002-003_a
1. Starboard storage bin
3. Disconnect the diagnostic connector from its

holder.
ssi2009-002-004_a
1. Diagnostic connector
4. Remove the electrical component support from

the battery holder, refer to CHARGING SYSTEM.
smr2009-027-011_c
1. Depth sounder 3A fuse (FB1)

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355

5. Remove the battery (with holder) from the watercraft, refer to CHARGING SYSTEM.
WARNING
Always disconnect the battery cables exactly
in the specified order, BLACK (-) battery cable
first then the RED (+) cable last.
6. Unlock the depth sounder clocking tabs from
the battery holder base and pull the depth
sounder out from the base.
ssi2009-002-013_a
1. Gel pad
2. Depth sounder
Depth Sounder Installation
ssi2009-002-014_a
1. Locking tabs
2. Battery holder base
1. Insert the depth sounder in the battery holder

base while paying attention to the position of
the wiring on the sounder with the groove in the
battery holder base.
2. Press firmly on the depth sounder until both
locking tabs are locked into the base.
3. Connect the sounder connector to the wiring
harness and route the wiring in the groove provided in the battery holder base.
7. Disconnect the depth sounder connector from

the wiring harness.
Depth Sounder Inspection

Ensure the silicone pad is in good condition.
NOTE: There must not be any air trapped between the bottom of the depth sounder and the
bilge. Otherwise, the sounder will not function
correctly.
If the silicone gel pad is damaged, replace it.
Depth Sounder Gel Pad Replacement

1. Place the flat side of the depth sounder on a
level surface.
2. Remove the old gel pad from the bottom of the
depth sounder.
3. Clean the concave surface of depth sounder.
4. Remove both protectors from the gel pad.
5. Apply gel pad on depth sounder.
NOTICE Make sure do not trap air between
gel pad and depth sounder. Otherwise, the device will not work.
356
ssi2009-002-014_b
1. Depth sounder connector

2. Wiring harness
4. After installation:
4.1 Try pulling the sounder out to ensure it
is properly locked in the battery support
base.
4.2 Try pushing on depth sounder. You must
feel a resistance (no air gap).
NOTE: An air gap can be eliminated by adding an
additional gel pad.
5. Install the battery and electrical component
support in the reverse order of removal, refer
to CHARGING SYSTEM.
smr2009-036

6. Install the diagnostic connector in its holder.

7. Carry out the following procedure: TESTING
DEPTH SOUNDER OPERATION.
Testing Depth Sounder Operation

1. Press START/STOP button.
2. Install the D.E.S.S. key on the D.E.S.S. post.
3. Check information center to confirm depth
sounder operation. The depth sounder icon
is visible in the information center when the
depth sounder is detected.
ssi2009-002-018_a
1. Depth sounder icon
4. Reinstall all other removed parts.

5. Launch watercraft in water and check depth
sounder operation. Refer to INFORMATION
CENTER for instructions on how to select the
DEPTH indication in numerical display.
WARNING
Never use the depth gauge as a warning device to ride in shallow water. Use it as a navigation guide only. Not to be used to get precise navigation data.
smr2009-036
357
358
Section 06 STEERING AND PROPULSION

Subsection 01 (STEERING AND O.T.A.S.)
STEERING AND O.T.A.S.

SERVICE TOOLS
Description
Part Number
D.E.S.S. POST REMOVER ............................................................

ECM ADAPTER TOOL...................................................................
STEERING CABLE TOOL ..............................................................
529
529
529
295
035
036
035
000
943
166
868
145
Page
......................................... 364
......................................... 370
......................................... 370
......................................... 367
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 363

XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 366
smr2009-037
359

6 Nm
(53 lbfin)
2.5 Nm
(22 lbfin)
16 Nm
(142 lbfin)
7 Nm
(62 lbfin)
10 Nm
(89 lbfin)
5 Nm
(44 lbfin)
7 Nm
(62 lbfin)
7 Nm
(62 lbfin)
0.7 Nm
(6 lbfin)
7 Nm
(62 lbfin)
0.7 Nm
(6 lbfin)
6 Nm
(53 lbfin)
7 Nm
(62 lbfin)
7 Nm
(62 lbfin)
XPS
synthetic
grease
7 Nm
(62 lbfin)
smr2009-037-001_a
360
smr2009-037

GENERAL
ADJUSTMENT

complete procedure.
STEERING ALIGNMENT
WARNING
Raise the iBR gate by activating the iBR override

function. Refer to IBR AND VTS subsection.
Install two bungee cords to maintain steering during the procedure.
Position steering so that the edge of the steering
column cover and edge of the gauge support are
equal.

SYSTEM DESCRIPTION (O.T.A.S.)

The O.T.A.S. (Off-Throttle Assisted Steering) provides additional maneuverability in off-throttle situations.
The system uses a pair of magnets mounts on the
steering column and a Hall effect switch mounts
underneath steering column support.
When activated by a magnet, the O.T.A.S. switch
sends a signal to the ECM.
The ECM activates a pre- programmed RPM setting when the driver initiates a full turn after releasing throttle lever. The engine RPM is controlled
by the intelligent Throttle Control (iTC).
The O.T.A.S. system is activated when the following conditions are achieved:
The engine speed must be above 4000 RPM for
at least 1.5 second (approximately).
The throttle lever must be released completely.
The steering must be fully turned within approximately 4 seconds after throttle release.
The O.T.A.S. will stay activated for a random
period of time as long as the O.T.A.S. switch is
closed.
O.T.A.S. will be deactivated if:
The throttle is reapplied, or
The steering is turned sufficiently to open the
O.T.A.S. switch for more than one second.
smr2009-037
smr2009-037-055_a
1. Steering column cover edge

2. Gauge support edge
Check jet pump nozzle position by placing a

straight edge on nozzle outer end. Measure the
distance on each side of the straight edge. It
must be equalled.
smr2009-037-003_a
1. Straight edge places against nozzle
If necessary, steering alignment adjustment

should be performed at steering column.
Open storage compartment cover and remove
basket.
Loosen steering column clamp bolts securing the
steering cable clamp at the bottom of steering column.
Turn adjusting nut as required.
361

smr2009-042-007_a
1.
2.
3.
4.
Steering
Steering
Steering
Steering
column
column clamp bolts
column clamp
cable adjusting nut
smr2009-037-034_a
After adjustment, torque steering column clamp

bolts to 6 Nm (53 lbfin).
MONITORING AND IBR TABS

1. O.T.A.S. "LED"
NOTICE Verify when the handlebar is turned

completely to the left or right side, that there is
no interference with jet pump or reverse parts.
O.T.A.S. OPERATION
Then, engine speed will gradually decrease to idle

speed within approximately 5 seconds.
Repeat test for the other side.
If O.T.A.S. system LED does not turn on, check
for fault codes.
If the RPM does not behave as described, check
the O.T.A.S. switch.
This test is to be performed with the watercraft in

the water (test tank or on a trailer).
PROCEDURES
INSPECTION
NOTICE If the test is performed on a trailer,

ensure no debris or rocks can damage the jet
pump.
NOZZLE
Connect B.U.D.S.Refer to COMMUNICATION

Start engine.
Raise engine speed higher than 4000 RPM for
more than 1 second.
Release throttle while steering is in the straight
ahead position.
Within 1 to 3 seconds, turn handlebar all the way
to one side.
The O.T.A.S. should come on by keeping or
increasing engine speed to approximately
3000 RPM.
Immediately look in B.U.D.S. to see if the O.T.A.S.
system LED turns on.
Raise the iBR gate by activating the iBR override

function. Refer to IBR AND VTS subsection.
Disconnect steering cable from nozzle arm.
Nozzle Removal
smr2009-037-004_a
1. Steering cable bolt

2. Nozzle arm
From the top and underneath nozzle, remove

hexagonal screws retaining nozzle link rod to nozzle arm and socket screws securing the nozzle to
the VTS trim ring.
362
smr2009-037

smr2009-037-007_a
smr2009-037-041_a
1.
2.
3.
4.
5.
6.
Nozzle
Nozzle arm
Hexagonal screw
Nozzle link rod
Socket screw
VTS trim ring
Remove nozzle from watercraft.
1. Grip insert
NOTE: Verify grip insert for damage.
Handlebar Grip Installation

When installing the grip insert in the handlebar,
ensure that it is properly inserted in the slot at the
end of the handlebar tubing.
Nozzle Installation
hexagonal screw threads (or use new self-locking
screws).
Tighten hexagonal screws to 10 Nm (89 lbfin).
Secure steering cable to nozzle. Refer to STEERING CABLE in this subsection.
Perform the STEERING ALIGNMENT, see the procedure in this subsection.
smr2009-037-008_a
1. Grip insert
HANDLEBAR GRIP
Handlebar Grip Removal
To remove handlebar grip, pull out cap and remove
screw.
Install handlebar grip on handlebar matching it to

the notch in the handlebar.
screw threads.
Install flat washer and handlebar grip screw.
NOTICE Ensure to install flat washer otherwise screw will damage grip end.
Torque handlebar grip screw to 7 Nm (62 lbfin).
Install cap.
smr2009-037-006_a
1. Handlebar grip
2. Handlebar grip screw
Pull out handlebar grip and remove grip insert

from handlebar.
smr2009-037
363

smr2009-037-009_a
1.
2.
3.
4.
5.
Grip insert
Grip
Flat washer
Screw
Cap
HANDLEBAR SWITCH COVER (LH

OR RH)
Handlebar Switch Cover Removal (LH
or RH)
1. Insert the end of a small screwdriver in one of
cover slots.
smr2009-037-012_a
RH SIDE SHOWN
1. Front tab
Press on the cover to lock it.
STEERING COVER
Steering Cover Removal
1. Using the D.E.S.S. POST REMOVER (P/N 529 035
943), remove the nut retaining the D.E.S.S.
post.
smr2009-037-010_a
RH SIDE SHOWN
1. Cover slots
2. Turn screwdriver to open cover.

3. Remove the switch cover.
529035943
Handlebar Switch Cover Installation

(LH or RH)
Install the round rubber button in the cover.
Insert the front tab and tilt the cover over the
switches.
smr2009-037-015_a
2. Remove both handlebar switch covers. See

364
smr2009-037

3. Unlock steering cover from steering.

3.1 Insert a small tool, such as an Allen key,
into a steering cover hole. Press the tool
against the retaining tab to unlock it. Repeat for the other side.
NOTICE The tool must be inserted perfectly straight to avoid breaking the tab
holder.
smr2009-037-013_a
1. Allen key
3.2 In both cavities at the back of steering

cover, release both inner retaining tabs
using a long screwdriver.
3.4 Remove foam inside the steering cover.

3.5 Remove D.E.S.S. post from steering
cover.
Steering Cover Installation

1. Install the D.E.S.S. post.
1.1 Index the alignment pin of the D.E.S.S.
post with the notch of steering cover.
smr2009-037-017_a
1. Steering cover notch
1.2 Press the D.E.S.S. post until retaining tab

is positioned correctly.
smr2009-037-018_a
smr2009-037-014_a
1. Rear cavity
3.3 Release the five retaining tabs at the rear

of steering
1. Retaining tab
2. Install D.E.S.S. post nut and tighten it to 2 Nm

(18 lbfin).
3. Install the foam.
4. Place the D.E.S.S. harness in foam slot.
5. Install the steering cover.
5.1 Check if all harnesses are route properly.
All harness must be inserted in its slot.
smr2009-037-016_a
1. Retaining tabs
smr2009-037
365

smr2009-037-019_a
1. Harness slots
5.2 Clip the top of the cover.

5.3 Stretch the bottom of the steering cover
until the cover edge passes over the inner
ribs.
smr2009-037-031_a
1.
2.
3.
4.
Retaining screw
Washer
Bushings
Throttle lever
4. Clean throttle lever area from dust or any deposits.

5. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
on shaft that receives throttle lever and on the
end of the return tab.
smr2009-037-020_a
STEERING REMOVED FOR CLARITY PURPOSE

1. Inner ribs
5.4 Push both side of the cover to lock it with

the steering column.
5.5 Install switch covers.
THROTTLE AND iBR LEVERS

NOTE: The following procedure demonstrates
the replacement of the throttle lever but the same
procedure will be used for the iBR lever.
Lever Replacement
1. Remove STEERING COVER, see procedure in
this subsection.
2. Remove the screw and washer securing throttle lever.
3. Remove throttle lever and its bushings.
smr2009-037-032_a
1. Apply grease here
6. Install the lever.

6.1 Install both bushings in lever hole.
6.2 Insert sensor lever end into throttle lever
fork.
6.3 Position the return tab against the handlebar.
6.4 Secure the lever with washer and screw.
6.5 Tighten the lever screw to 0.7 Nm
(6 lbfin).
7. Reinstall all removed parts using appropriate
procedure.
STEERING CABLE
Steering Cable Replacement
366
smr2009-037

2. Remove the adjusting nut from steering cable

end.
3. At the rear of the vehicle, disconnect ball joint
from jet pump nozzle arm.
smr2009-037-022_a
1. Steering cable
2. Steering cable nut
6. Remove steering cable nut, half rings and

O-ring.
smr2009-037-004_a
1. Steering cable bolt

2. Nozzle arm
4. Remove ball joint and jam nut from cable.
smr2009-037-023_a
PUMP AND IBR SYSTEM REMOVED FOR CLARITY PURPOSE

ONLY
1. Steering cable
2. Steering cable nut
3. Half rings
4. O-ring
smr2009-037-021_a
1. Steering cable
2. Jam nut
3. Ball joint
5. Using the STEERING CABLE TOOL (P/N 295 000

145), loosen steering cable nut.
295000145
smr2009-037
7. Remove the adjusting nut from the new steering cable.

8. Using a piece of hose, attach one end of each
cable together.
NOTE: Ensure to attach different ends together
to avoid installing the new cable in the wrong way.
9. Pull the old cable slowly through the vehicle
then separate cable ends.
10. Secure the steering cable to hull fitting.
10.1 Install O-ring and half rings.
10.2 Secure steering cable with the steering
cable nut.
10.3 Tighten nut to 6 Nm (53 lbfin).
11. Install the ball joint on the end of the steering
cable.
11.1 The threaded portion of steering cable inserts into ball joint should have between
9 mm 1 mm (.354 in .039 in).
367

2. Remove the gauge support. Refer to GAUGE

subsection.
3. Disconnect the four connectors under moving
deck.
smr2006-031-006_a
A. 9 mm 1 mm (.354 in .039 in)
11.2 Tighten jam nut to 2.5 Nm (22 lbfin).

11.3 Position the steering cable ball joint to the
nozzle as per following illustration.
smr2009-042-005_a
1. Disconnect these connectors
4. Remove both screws securing the steering column.
smr2009-037-025_a
1.
2.
3.
4.
Ball joint bolt

Ball joint under nozzle arm
Washer
Nut
11.4 Tighten ball joint nut to 6 Nm (53 lbfin).

12. Check if the cable bellows is properly positioned all around steering cable.
smr2009-037-027_a
1. Steering column screws
5. Pull steering column out of its support. Ensure

to not damage wiring harness connectors and
O.T.A.S. magnets.
Steering Column Inspection
smr2009-037-026_a
1. Check fit
13. Reinstall the moving deck. Refer to BODY

subsection for complete procedure.
14. Check steering alignment.
Check steering column for:

Cracks
Stress marks
Wear indications.
Replace the steering as required.
Check both wear bushings in steering column
support. Replace if necessary.
STEERING COLUMN
Steering Column Removal
storage basket.
368
smr2009-037

3. On both side of vehicle, remove both pivot

bushings (steering column support and steering adjustment handle).
smr2009-037-028_a
1. Upper bushing
2. Steering column support
3. Lower bushing
Check wear sleeve behind the steering column

arm.
smr2009-037-033_a
1. Pivot bushing of steering column support

2. Pivot bushing of steering adjustment handle
NOTE: Pivot bushings retaining steering column

could be hard to remove, in this case remove the
retaining screw from the center hole and tighten it
into the offset hole. Tighten screw until the pivot
bushing comes out of steering column support.
smr2009-037-029_a
1. Wear sleeve
2. Steering column arm
3. Steering column support
Steering Column Installation

The installation is essentially the reverse of the removal procedure. However, pay attention to the
following.
Carefully, drive steering column through steering
column support. Ensure to not hit the O.T.A.S.
magnet during steering column installation.
Tighten steering column screws to 6 Nm
(53 lbfin).
Reinstall all removed parts using appropriate procedure.
STEERING COLUMN SUPPORT

Steering Column Support Removal
1. Refer to BODY and remove the following parts:
Storage cover
Front grille
Body covers.
subsection.
smr2009-037
smr2009-037-040_a
1. Center hole
2. Offset hole
4. Remove steering column support and steering

adjustment handle from vehicle.
5. Remove STEERING COLUMN from its support.
See the procedure in this subsection.
Steering Column Support Installation

STEERING TILT ADJUSTMENT

HANDLE
Steering Tilt Adjustment Handle
Replacement
Use the same procedure as for STEERING COL-
UMN SUPPORT.
369

O.T.A.S. SWITCH
O.T.A.S. Switch Dynamic Test
Connect B.U.D.S. software. Refer to COMMUNICATION TOOLS AND B.U.D.S. SOFTWARE subsection.
Briefly press the START/STOP button to wake up
the ECM.
Completely turn steering in one direction and keep
it in this position.
Look in B.U.D.S. to see if the O.T.A.S. system
LED turns on.
O.T.A.S. Switch Power Wire Continuity Test

Check continuity between O.T.A.S. switch 3-pin
connector and fuse block (FB1).
3-PIN
CONNECTOR
FUSE BLOCK
(FB1)
PIN "A"
C3
RESISTANCE
.5
If there is no continuity, check fuse 6 (FB1), wiring,

connector and terminals.
If continuity is good, check continuity of the
O.T.A.S. switch ground wire.
O.T.A.S. Switch Ground Wire Continuity Test
Check continuity between O.T.A.S. switch 3-pin
connector and ECM connector "B" using the ECM
ADAPTER TOOL (P/N 529 036 166)
3-PIN
CONNECTOR
ECM
ADAPTER
TOOL
PIN "B"
H3
RESISTANCE
.5
smr2009-037-034_a
MONITORING AND IBR TABS

1. O.T.A.S. "LED"
Repeat test for the other side.

If O.T.A.S. system LED does not turn on,
check for fault codes then check other tests for
the O.T.A.S. switch.
O.T.A.S. Switch Voltage Test

Press the START/STOP button to activate the
electrical system.
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), perform the following test.
TEST PROBES
PIN "A"
(3-pin
connector)
PIN "B"
(3-pin
connector)
VOLTAGE
(VDC)
Battery voltage
If there is voltage present, carry out the O.T.A.S.

switch continuity test.
If there is no voltage, check continuity of the
O.T.A.S. switch power wire.
370
smr2009-037-024_a
If continuity is good, check ECM ground. Refer to

POWER DISTRIBUTION subsection for complete
procedure.
If there is no continuity, repair or replace wiring,
connector or terminals.
O.T.A.S. Switch Continuity Test

Unplug the pin "C" from the 3-pin connector.
Briefly press on START/STOP button to wake up
the ECM.
Measure the resistance of switch as follows.
smr2009-037

STEERING
POSITION
Center position
Fully turned
MULTIMETER
LEAD
POSITION
Pin "C" and
vehicle ground
O.T.A.S. MAGNETS
RESISTANCE
1935 - 2365
324 - 396
If continuity test is out of specification, try any

good magnet and bring it in front of the switch. If
continuity test is now good, replace the magnets.
If continuity test is still out of specification with a
new magnet, check wires, connectors and terminals. If all is good, replace the O.T.A.S. switch.
Magnets Replacement
1. Remove STEERING COLUMN, see procedure
in this subsection.
2. Remove wiring harness from the center of
steering column.
3. Using a long tool, press on retaining tabs to release the magnets.
O.T.A.S. Switch Replacement

1. Remove STEERING COLUMN SUPPORT, see
2. Remove steering column from its support by
removing both retaining screws.
smr2009-037-039_a
1. Magnets
2. Retaining tabs
3. Lower end of steering column
Reverse removal procedure to reinstall the magnets.
smr2009-037-027_a
1. Steering column screws
3. Using a small screwdriver, unlatch the switch

from steering support.
smr2009-037-038_a
1. Switch retaining tabs
Reverse removal procedure to reinstall the

O.T.A.S. switch.
smr2009-037
371
372

Subsection 02 (iBR AND VTS)
iBR AND VTS

SERVICE TOOLS
Description
Part Number
Page
DIAGNOSTIC HARNESS ............................................................... 529 036 179 ................................. 384, 386

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................. 384, 389390, 404
SERVICE PRODUCTS
Description
Part Number
Page
DIELECTRIC GREASE ................................................................... 293 550 004 ................................. 392, 405

LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 392
smr2009-037
373

12 Nm
Loctite 243
(106 lbfin)
NEW
12 Nm
(106 lbfin)
12 Nm
(106 lbfin)
24 Nm
(18 lbfft)
NEW
24 Nm
(18 lbfft)
NEW
18 Nm
(24 lbfft)
NEW
12 Nm
(106 lbfin)
NEW
6 Nm
(53 lbfin)
Silicone
sealant
5150
10 Nm
(88 lbfin)
NEW
8 Nm
(71 lbfin)
NEW
4 Nm
(35 lbfin)
24 Nm
NEW (18 lbfft)
NEW
4 Nm
(35 lbfin)
NEW
24 Nm
(18 lbfft)
NEW
24 Nm
(18 lbfft)
Loctite 243
12 Nm
(106 lbfin)
NEW
8 Nm
(71 lbfin)
smr2009-038-100_a
374
smr2009-037

GENERAL
and service products as indicated in the exploded
view.
complete procedure.
WARNING
sdd2009-001-039_b
1. iBR gate
2. iBR module and motor
3. Jet pump
When the iBR lever is pulled in, it operates the

brake and reverse lever sensor (BRLS). It is a double output hall effect sensor. The redundancy is
used for security purposes.
SYSTEM DESCRIPTION (iBR)

This watercraft uses an electronically controlled
braking and reverse system called the iBR system
(intelligent Brake and Reverse).
The iBR module controls the position of the iBR
gate to provide forward thrust, reverse thrust,
braking thrust, and neutral.
The operator commands the position of the iBR
gate using either the throttle lever for forward
thrust, or the iBR lever for neutral, reverse, and
for the braking function.
The iBR lever is located on the LH side of the handlebar.
sdd2009-001-036_a
1. iBR lever (intelligent Brake and Reverse)
smr2009-037
sdd2009-001-029_a
1. iBR lever
2. BRLS sensor
The BRLS sends the signals to the iBR module.

The iBR module controls an electric motor that in
turn raises or lowers the iBR gate through a mechanical drive unit.
NOTE: The iBR gate will move when commanded
by the iBR lever only if the engine is running. For
maintenance purposes, the iBR OVERRIDE function available through the gauge can be used to
electrically move the gate to the desired position.
The iBR module is programmed with various parameters that it compares to the input signals and
information it obtains through the CAN bus from
the other electronic modules.
Depending on vehicle speed and how far the iBR
lever is depressed, the iBR module will automatically adjust the iBR gate movement speed and
stroke.
375

NOTE: The iBR lever must be pulled in at least

25% of its travel (approximately) before the iBR
gate starts to move. The first 25% of iBR lever
travel has no effect on the iBR gate.
Every time the iBR gate moves when commanded
by the iBR lever, engine RPM is momentarily reduced to idle speed as the gate moves.
WARNING
If it is necessary to remove any foreign object caught in the iBR gate, nozzle or linkages,
strictly observe the following before proceeding:
Remove D.E.S.S. key from post.
Wait at least 5 minutes.
Do not press on START/STOP button. If
START/STOP button is pressed, wait another 5 minutes.
Forward Mode
To engage forward:
Start engine
Tap on the throttle lever.
The iBR gate will automatically move to the forward position (full up).
NOTE: The full up position of the iBR gate is dependent on the selected VTS trim position.
Reverse Mode
If the watercraft speed is below 8 km/h (5 MPH)
when the iBR lever is pulled in, reverse mode is
engaged.
When the iBR lever is pulled in to engage reverse,
the following occurs:
Engine RPM is reduced to idle.
The iBR gate moves to the reverse position.
Engine RPM ramps up to the engine power
commanded by the throttle lever.
When operating in reverse mode, the iBR lever
controls the iBR gate position and the engine RPM
is controlled by the throttle lever.
The iBR gate position can be modulated anywhere
between the neutral and full reverse positions depending on the position of the iBR lever. If the
iBR lever position is varied during reverse operation, engine RPM is reduced to idle every time the
iBR gate moves. It is therefore recommended to
maintain the iBR lever completely pulled in.
Maximum engine RPM in reverse is 5000 RPM.
376
Braking Mode
If the watercraft speed is 8 km/h (5 MPH) per hour
and above when the iBR lever is pulled in, braking
mode is engaged.
When the iBR lever is pulled in to engage braking,
the following occurs:
Engine RPM is reduced to idle.
The iBR gate moves to the maximum down position.
Engine RPM ramps up to the engine power
commanded by the iBR lever.
When operating in braking mode, the iBR gate always moves to the maximum down position. The
throttle lever signal is overridden and engine RPM
is now dependent on watercraft speed and how
far the iBR lever is pulled in.
If watercraft speed is high when braking is applied, engine power will be initially low and
then ramp up to the power commanded by the
iBR lever position. The engine RPM may be increased, as necessary, to apply a stronger braking
effect with the jet pump thrust when the conditions dictate.
As the watercraft slows to less than 8 km/h
(5 MPH), the following occurs:
Braking mode ceases.
Reverse mode takes over if the iBR lever is not
released.
Throttle control reverts back to the throttle
lever.
Neutral Mode
Every time the iBR lever is pulled in and released,
the iBR gate will default to the neutral position
except if the throttle lever is still pulled in when
the iBR lever is released. If the throttle lever is
still pulled, the iBR gate will move to the forward
position when the iBR lever is released and the
watercraft will accelerate forward.
iBR Override Function

To permit easy access to the jet pump, nozzle, iBR
gate, and various linkages for inspection, maintenance, cleaning or removal of debris, the iBR system provides for an iBR override function which,
is accessible through the information center.
When iBR override is activated, it allows the
user to electrically move the iBR gate and nozzle
through its full range of motion using the VTS
control button.
smr2009-037

NOTICE An object or tool caught in the iBR

gate, nozzle or linkages when using the iBR
override function may cause damage to these
components. Remove any foreign object that
may obstruct the iBR gate travel.
Activating iBR Override Function
WARNING
When using the iBR override function, ensure no personnel stands near the rear of the
watercraft. Movement of the iBR gate may
squeeze fingers.
To use the iBR override function, carry out the following step.
2. Install the D.E.S.S. key.
sdd2009-001-019_g
Step 1: Press START/STOP button

Step 2: Install D.E.S.S. key
NOTE: Do not start the engine. The D.E.S.S. key

must be installed to ensure the information center will not shut off all indications after its self test
function. Electrical power will stay ON for approximately 3 minutes.
3. Press the Mode button on the RH handlebar repeatedly until SETTINGS is visible in the digital
display of the information center.
smo2009-002-114_y
4. Press the SET button (RH handlebar) to display

DOCK MODE.
smo2009-002-114_bb
5. Press the UP/DOWN arrow button to display

iBR OVR.
smo2009-002-114_ff
6. Press the SET button to enter iBR OVR function

and display OVR OFF.
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377

WARNING
When moving the iBR gate using the iBR
override function, ensure nobody stands
near the rear of the watercraft. Movement of
the gate may squeeze fingers.
SYSTEM DESCRIPTION (VTS)
smo2009-002-114_hh
7. Press the UP/DOWN arrow button (RH handlebar) to display OVR ON.
smo2009-002-114_gg
8. Press the SET button to select the OVR ON

function. The gauge will return to its normal display.
9. Press the VTS UP or DOWN arrow button to
move the iBR gate.
Deactivating iBR Override Function
To deactivate the iBR override function, carry out
one of the following:
1. Repeat previous steps and press the SET button when OVR OFF is visible.
2. Wait for the electrical power to shut off (wait 4
minutes).
3. Start the engine.
NOTE: When the engine is started, the iBR OVR
function is deactivated and the iBR gate will move
to the neutral position.
378
This watercraft is equipped with a programmable

high performance VTS (Variable Trim System).
The VTS system is actually part of the iBR system.
It provides watercraft pitch trim adjustments by
adjusting the vertical position of the jet nozzle.
The VTS can be manually trimmed to desired attitude, or to one of two preset trim positions.
Press VTS control button (up or down arrow) to
adjust riding attitude of the watercraft.
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TYPICAL - VTS CONTROL

1. Bow up
2. Bow down
The VTS switch sends command signals to the

gauge. The gauge converts them to CAN protocols and sends them through the CAN bus to the
iBR module on the iBR actuator. The actuator then
moves the iBR gate which moves the nozzle to
the desired trim position.
NOTE: The nozzle and iBR gate move together
in the VTS trim range up to the maximum nozzle down position. If NEUTRAL, BRAKING or REVERSE is engaged, the iBR gate moves past the
VTS full down position. When FORWARD thrust
is reengaged, the nozzle and iBR gate move up to
the last selected VTS trim position.
The nozzle trim position can be seen on the VTS
position indicator in the information center.
NOTE: Changing the VTS trim position without
the engine running in forward thrust mode only
changes the indication. The nozzle will move
to the selected VTS trim position when forward
thrust is engaged.
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smr2009-038-026_a
PULL DOWN SLIGHTLY ON iBR GATE

sdd2009-001-042_a
INFORMATION CENTER VTS POSITION INDICATOR

1. Bow up
2. Bow down
NOTE: Only the segment indicating the relative

position of the VTS will be on. The illustration
shows all segments on as can be seen during the
self test function.
3. Using a machinists ruler, measure the distance

between the bottom of the guard and the
trailing edge of the iBR gate (example 48 mm
(1.89 in)). Note as measurement "A".
MAINTENANCE
iBR GATE BACKLASH CHECK
1. Using the iBR override function, move the iBR
gate to the up position. Refer to SYSTEM DESCRIPTION (iBR) in this subsection.
smr2009-038-018_a
1. iBR guard
2. Measurement "A"
smr2009-038-017_a
4. Without using excessive force, push up on the

trailing edge of the iBR gate to pick up the
backlash in the gate mechanism. As you hold
the gate up, measure the distance between
the trailing edge of the guard and the trailing
edge of the iBR gate again (example 41 mm
(1.61 in). Note as measurement "B".
1. iBR gate moved to up position
2. Take hold of the lower edge of the iBR gate and

pull down on it slightly, then release it.
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379

7. Check iBR gate backlash and gate operation after parts replacement and reassembly.
FRICTION SLEEVE
REPLACEMENT
The 4 friction sleeves on the VTS trim ring should
be replaced if they show signs of advanced wear
(flat spots), or every 100 hours as per the maintenance schedule.
smr2009-038-019_a
1. iBR guard
2. Lift up on iBR gate
3. Measurement "B"
5. Subtract measurement "B" from "A" to obtain

the iBR gate backlash (A - B = iBR gate backlash).
Example:
48 mm - 41 mm = 7 mm
1.89 in - 1.61 in = 0.28 in.
iBR GATE BACKLASH
A - B = BACKLASH
MAXIMUM
1. To replace the friction sleeves, remove the iBR

gate and VTS ring as an assembly, refer to iBR
GATE AND VTS RING REMOVAL in this subsection.
25 mm (.98 in)
6. Ensure iBR gate backlash is within specified

limits.
If backlash is excessive, inspect and replace iBR
gate parts as required in the following order:
1. iBR locking sleeve (iBR key)
2. Friction sleeves
3. Bushings
4. Contact points (VTS trim ring, "U" arm, iBR
gate)
5. iBR actuator.
NOTE: Look for rotation of the locking sleeve
and "U" arm as you move the iBR gate by hand
which may indicate excess play in the iBR actuator mechanism. Always replace the iBR locking
sleeve first and recheck iBR backlash.
If the backlash is still not within specification after replacing the iBR locking sleeve, continue disassembly of the iBR gate replacing the previously
listed parts as required.
NOTE: If the contact points on the VTS trim ring
and "U" arm are excessively worn, or the friction
sleeve cams in the "U" arm are worn, replace them
as required.
380
smr2009-038-021_a
1. Worn friction sleeve (flat spot)
smr2009-038-013_a
1. Friction sleeves (2 each side)
2. Remove the worn friction sleeves from the VTS

ring and install new ones.
3. Apply service products, torques, and install
new screws with Scotch Grip threadlocker as
specified in exploded view.
smr2009-037

IBR GATE LOCKING SLEEVE

REPLACEMENT
4. Install new screw(s) with Scotch Grip threadlocker and torque as specified in exploded view.
NOTE: The iBR locking sleeve (iBR key) should be

replaced if it is cracked, broken, show signs of advance wear, is loose fitting in the "U" arm or on the
iBR actuator shaft, or every 100 hours as per the
maintenance schedule.
INSPECTION
IBR SYSTEM FUNCTIONAL TEST
Test on Dry Land
NOTE: This test requires two people. One person
to start watercraft and operate controls, and one
person to observe iBR gate movement.
1. Provide adequate ventilation of exhaust gases
or move watercraft outside.
NOTICE Do not install an exhaust ventilation
hose in the iBR gate area or damage may occur when the iBR gate moves downward during operation.
smr2009-038-020_a
1. Worn locking sleeve
1. Move the iBR gate to the forward position (full

up), refer to iBR OVERRIDE in SYSTEM DESCRIPTION (iBR) of this subsection.
NOTICE Do not try to move the iBR gate by
hand if the locking sleeve (iBR key) is installed
or component damage will occur.
CAUTION Wait at least 5 minutes for watercraft electrical power to shut down before
working in the iBR gate area.
2. Remove and discard the hexagonal screw(s) securing the iBR gate locking sleeve (iBR key) and
remove the sleeve from the iBR "U" arm and actuator.
smr2009-038-002_a
1. Hexagonal screw(s)
2. Locking sleeve
2. Connect a water hose to the watercraft to provide exhaust system cooling when operating
engine. Refer to EXHAUST SYSTEM subsection for procedure.
NOTICE
Ensure there are no tools or other object that
may interfere with the iBR gate movement.
Do not run watercraft for more than 2 minutes out of water or damage may occur to
drive shaft seal carrier.
WARNING
The person observing the iBR gate movement must stand to the side of the stern well
clear of the iBR gate and pump nozzle, and
in full view of the operator.
3. Start watercraft and allow to run at idle RPM.
NOTE: If iBR gate was not in the neutral position,
it will move to the neutral position on engine start
up.
4. Depress the throttle lever slightly and visually
confirm the iBR gate moves to the forward position (up to the VTS trim position), then release
throttle. The iBR gate must remain in the forward position.
5. Depress the iBR lever fully and confirm the iBR
gate moves to the full down position.
6. Release the iBR lever completely and confirm
the iBR gate moves to the neutral position.
7. Shut engine off and disconnect water hose.
3. Insert a new locking sleeve.
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381

Test With Watercraft on a Waterway

1. Start watercraft and allow engine to run at idle
RPM.
NOTE: If iBR gate is not in the neutral position before the engine start, it will move to the neutral
position on engine start up.
2. Depress the throttle lever slightly, then release
it. Forward movement of the watercraft confirms the iBR gate has moved to the forward
position.
3. Depress the iBR lever fully. Rearward movement of the watercraft confirms the iBR gate
has moved to the reverse position.
4. Release the iBR lever completely. Reverse
thrust should cease and the watercraft should
continue to drift rearward on momentum.
5. Apply a small amount of forward thrust to stop
rearward velocity, then tap the iBR lever to return the iBR gate to neutral.
6. Shut engine off.
VTS FUNCTIONAL TEST

NOTE: This test requires two people. One person
to start watercraft and operate controls, and one
person to observe iBR gate movement.
1. Provide adequate ventilation of exhaust gases
or move watercraft outside.
NOTICE Do not install an exhaust ventilation
hose in the iBR gate area or damage may occur when the iBR gate moves downward during operation.
2. Connect a water hose to the watercraft to provide exhaust system cooling when operating
engine. Refer to EXHAUST SYSTEM subsection for procedure.
NOTICE
Ensure there are no tools or other object that
may interfere with the iBR gate movement.
Do not run watercraft for more than 2 minutes out of water or damage may occur.
WARNING
The person observing the iBR gate movement must stand to the side of the stern well
clear of the iBR gate and pump nozzle, and
in full view of the operator.
3. Start watercraft.
382
4. Pull in and release the iBR lever to engage forward thrust, allow to run at idle RPM
5. Push the VTS up and down arrow button alternately to check VTS operation. Confirm nozzle
movement and VTS position indication change
in the information center.
6. Double click the VTS UP and DOWN button alternately to test the VTS preset trim positions.
If double clicking the VTS UP and DOWN button
does not cause the nozzle position or indication
to change, navigate to VTS MODE function in the
gauge and check for recorded PRESET 1 and PRESET 2 settings. If no presets are recorded, record
PRESET 1 bow up and PRESET 2 bow down, exit
the function, a carry out a new test.
If both PRESET 1 and PRESET 2 have the same
setting, note the operator's setting and change
one PRESET, exit the function, and carry out a
new test. Return the setting to the operator's
preference after testing is complete.
NOTE: The VTS system cannot be tested without
the engine operating in forward thrust. If the engine is not running in forward thrust, only the VTS
indication will change when the VTS control button is pressed; the nozzle will not change position
until forward thrust is engaged by pulling the throttle lever.
TROUBLESHOOTING
The iBR system is self monitoring. If a fault occurs in the iBR system, it will raise a fault code and
communicate it to the information center through
the CAN bus. The information center will turn on
the iBR indicator light to advise the operator of
the iBR system fault. If the fault remains active, it
may be displayed in the gauge. If it becomes occurred, B.U.D.S. must be used to read the fault.
TESTING SEQUENCE
To troubleshoot the iBR system, carry out the following in this order:
Ensure the iBR gate movement is not obstructed in any way.
Ensure the iBR gate mechanisms (gate, VTS
ring, "U" arm and linkages) are all in good condition and do not show signs of excessive wear
or friction.
Cycle the iBR gate up and down using the iBR
OVERRIDE function as described in this subsection.
smr2009-037

Check the 30 A iBR power fuse in FB2 and the

5 A iBR control fuse in FB1 if the gate did not
move using the iBR OVERRIDE function.
Connect the watercraft to B.U.D.S. to check
for iBR system or CAN bus related fault
codes. Carry out service actions as indicated
in B.U.D.S.
If a CAN bus communication fault with the iBR
module is indicated, or the iBR module is not
visible in B.U.D.S., carry out a continuity test
of the CAN bus wires between the iBR module
and the CAN bus-bars in FB2. Refer to CONTROLLER AREA NETWORK (CAN) subsection.
Try moving the iBR using the iBR UP and iBR
DOWN s on the iBR activation page in B.U.D.S.
Carry out an iBR SYSTEM FUNCTIONAL TEST
to check for proper gate and actuator movement.
Visually inspect system connectors for moisture ingress, corrosion, and proper contact.
Check for excessive backlash in the gate mechanism.
Remove the locking sleeve (iBR key) and ensure it is in good condition. Move the gate up
and down by hand to check for freedom of
movement.
sdd2009-001-019_g

NOTE: Electrical power will shut off after approximately 3 minutes. Briefly press the START/STOP
button to reactivate the electrical system when required.
3. Set the suspension to its maximum height by
double clicking the iS UP button. This will provide better access to the steering connectors.
PROCEDURES
iBR LEVER SENSOR (BRLS)
BRLS Test Using B.U.D.S.
NOTE: The BRLS is composed of a twin hall effect sensor. A resistance test of the sensor cannot be carried out.
B.U.D.S. SOFTWARE.
2. Check for an applicable fault code, refer to
3. If a fault is indicated, follow service actions as
indicated in B.U.D.S.
BRLS Voltage Test
sdd2009-001-019_f
Step 1: Suspension to maximum height by pressing and holding

the iS UP
NOTE: If more height is required or if the iS system cannot be used, manually lift the suspension
using a hoist and the anchor points close to handlebars. Then safety lock it in the up position.
NOTICE Do not lift the watercraft using the
anchor points.
4. Open the front storage compartment cover and
remove the storage bin.
Test for BRLS input voltage as well as BRLS signal

voltages as per following steps.
2. Install the D.E.S.S. key to energize the electrical
system.
NOTE: DO NOT start engine.
smr2009-037
383

NOTE: Connect only the test harness 12 and 6

pin connectors to both sides of same steering harness connectors.
smo2009-002-124_a
Step 1: Push storage bin latches backwards (one each side)

Step 2: Lift and tilt forward to remove storage bin
5. Remove the D.E.S.S. key and wait approximately 3 minutes for the electrical system
power to shut off.
6. Reach in under the moving deck (steering area)
and disconnect the 6-pin and the 12-pin steering connectors located just behind the forward
ventilation box.
smr2009-042-005_e
1. 6-pin connector
2. 12-pin connector
8. Press the START/STOP button to wake up the

electrical system.
9. Install the D.E.S.S. key on its post.
sdd2009-001-019_g

smr2009-036-004_c
1. Forward ventilation box

2. 12-pin connector to disconnect
3. 6-pin connector to disconnect
7. Connect the DIAGNOSTIC HARNESS (P/N 529 036

179) in series between the disconnected steering connectors.
10. Using a FLUKE 115 MULTIMETER (P/N 529 035
868) set to Vdc, measure the BRLS voltages
from the installed diagnostic harness connectors as per following tables.
529036179
384
smr2009-037

6-PIN CONNECTOR
OF DIAGNOSTIC
HARNESS
PIN
iBR LEVER
RELEASED
iBR LEVER
PULLED IN
VOLTAGE (Vdc)
4.9 - 5.1
0.15 - 0.35
1.4 - 1.6
Continuity Test of BRLS Wiring

Harness
1. Ensure the steering connector (C01-12 POS
and C03-6 POS) pins are clean, make good
contact, and properly connected.
2. Remove the steering cover, refer to BODY subsection.
3. Disconnect the BRLS connector.
smr2009-030-033_c
BRLS VOLTAGE TEST AT 6 PIN CONNECTOR
12-PIN CONNECTOR
OF DIAGNOSTIC
HARNESS
PIN
iBR LEVER
RELEASED
iBR LEVER
PULLED IN
VOLTAGE (Vdc)
4.9 - 5.1
0.4 - 0.6
smr2009-038-001_a
1. BRLS
2. BRLS connector
4. Open the boarding platform and remove the LH

storage bin.
2.9 - 3.1
smr2009-030-033_b
BRLS VOLTAGE TEST AT 12 PIN CONNECTOR
11. If voltage measured is as specified, the BRLS

sensor is functioning properly.
NOTE: When moving iBR lever, BRLS voltage
change should increase or decrease in a steady
linear fashion.
12. If voltage is out of specification, carry out a
continuity test of the wiring between the iBR
module and the BRLS sensor, refer to CONTINUITY TEST OF BRLS WIRING HARNESS.
smr2009-037
smo2009-002-127_b
Step 1: Open the boarding platform

Step 2: Remove the LH storage bin
5. Disconnect the 12 pin connector from the iBR

actuator.
385

smr2009-036-004_c
1. Forward ventilation box

2. 12 pin steering connector to disconnect
3. 6 pin steering connector to disconnect
smr2009-038-003_b
Step 1: Disconnect the 12 pin connector
6. Measure for continuity from the BRLS connector to the 12 pin iBR actuator connector as per
following table.
CONTINUITY TEST OF BRLS WIRING HARNESS
BRLS
CONNECTOR
12 PIN iBR
CONNECTOR
Pin A (VI/YL)
Pin 4 (VI/YL)
Pin B (BK)
Pin 6 (BK)
Pin C (YL/BK)
Pin 8 (YL/BK)
Pin D (VI/YL)
Pin 7 (VI/YL)
Pin E (BK)
Pin 9 (BK)
Pin F (YL/WH)
Pin 5 (YL/WH)
RESISTANCE
Close to 0
(continuity)
If continuity is good, replace BRLS.

If an open circuit or a higher than normal resistance is measured, carry out the following continuity tests to find the problem wire or connection:
From the BRLS to the steering connectors
(C01-12 POS and C03-6 POS)
From the steering connectors to the iBR actuator 12 pin connector.
386
NOTE: Connecting the DIAGNOSTIC HARNESS

(P/N 529 036 179) to the steering connectors
(steering side only then vehicle side only) will
facilitate access. Resistance readings may be
slightly higher than normal (maximum .5 ) with
test harness installed.
CONTINUITY TEST BRLS TO STEERING
CONNECTORS
BRLS
12 PIN
STEERING
6 PIN
STEERING
Pin A
(VI/YL)
Pin 4
(VI/YL)
Pin B
(BK)
Pin 5 (BK)
Pin C
(YL/BK)
Pin 6
(YL/BK)
Pin D
(VI/YL)
Pin 5
(VI/YL)
Pin E
(BK)
Pin 4 (BK)
Pin F
(YL/WH)
Pin 3
(YL/WH)
RESISTANCE
Close to 0
(continuity)
smr2009-037

CONTINUITY TEST STEERING CONNECTORS

TO iBR CONNECTOR
12 PIN
6 PIN
STEERING STEERING
12 PIN
iBR
Pin 5
(VI/YL)
Pin 7
(VI/YL)
Pin 4 (BK)
Pin 9
(BK)
Pin 3
(YL/WH)
Pin 5
(YL/WH)
Pin 4
(VI/YL)
Pin 4
(VI/YL)
Pin 5 (BK)
Pin 6
(BK)
Pin 6
(YL/BK)
Pin 8
(YL/BK)
RESISTANCE
Close to 0
(continuity)
7. Repair or replace wiring/connector as required.
BRLS Removal
AND O.T.A.S.
2. Remove connector from the BRLS.
3. Open the sensor retaining tabs and lift the sensor from its support. Depress the lever as required to ease sensor removal.
smr2009-038-001_b
1. Wire harness routed in slot
3. Ensure there are no fault codes. Connect watercraft to the latest B.U.D.S. software, refer to
4. Carry out an iBR SYSTEM FUNCTIONAL TEST
using the iBR lever (engine must be running).
iBR ACTUATOR
NOTICE The iBR actuator motor must never
be tested by applying 12 Vdc directly to it's
connector. Doing so may cause a lock-up and
damage internal actuator components, necessitating replacement of the iBR actuator
assembly.
iBR Actuator Operation Test Using

B.U.D.S.
B.U.D.S. SOFTWARE.
3. Check for applicable fault codes on the Faults
page.
4. Select the Activation page tab.
5. In the lower LH corner of the activation page,
select the iBR tab.
smr2009-038-001_c
1. BRLS
2. BRLS connector
3. Sensor retaining tabs
BRLS Installation
1. Install BRLS sensor in the reverse order of removal.
2. Ensure wiring harness is properly routed
through slot provided in sensor support before installing steering cover.
smr2009-037
387

smr2009-038-029_a
1. iBR position indication
smr2009-038-028_a
1. Read Data
2. Activation page tab
3. iBR tab
6. Select the iBR UP and iBR DOWN s alternately

and look for a change in iBR Position (Deg).
2. Press and hold the VTS UP button on the LH

handlebar to position the iBR to the full up position and look for the iBR Motor Current indication in B.U.D.S. Also look for a change of iBR
Position (Deg) indication.
NOTE: Current draw indication will not be stable.
High and low peaks will be observed. Look for the
maximum average current draw.
smr2009-038-028_b
1. iBR UP/DOWN s
2. iBR position indication
If the iBR moves using these s but does not move

using the iBR lever, refer to BRLS VOLTAGE TEST
in this subsection.
If the iBR does not move, check the iBR fuse in
FB2. If fuse is good, refer to iBR ACTUATOR INPUT VOLTAGE TEST in this subsection.
smr2009-038-032_b
Step 1: Note iBR current draw

Step 2: Note iBR position indication change
3. Press and hold the VTS DOWN button and look

for the iBR Motor Current draw indication.
Also look for a change of iBR Position (Deg)
indication.
iBR Actuator Motor Current Test Using

B.U.D.S.
1. On the iBR activation page in B.U.D.S., note the
iBR Position (Deg) indication.
388
smr2009-037

smr2009-038-030_a
1. iBR motor harness connector

2. iBR motor module connector
smr2009-038-033_b
Step 1: Note iBR current draw

Step 2: Note iBR position indication change
iBR ACTUATOR CURRENT DRAW

DOWN SELECTION
-5 to -15 A
UP SELECTION
+10 to +20 A

868) to Vdc selection.
3. Install insulated clips on the multimeter leads
and clip leads to pins in the motor connector on
the iBR module.
If current draw is abnormally high (between 20

and 30 A), check the following:
Ensure iBR gate is free of debris.
Remove iBR gate key and check for excessive
friction in gate movement.
Check iBR gate friction sleeves and bushings.
Check for proper voltage to the iBR motor, see
iBR MOTOR VOLTAGE TEST in this subsection
Check for fault codes using B.U.D.S.
Remove debris, replace iBR gate components, or
replace the iBR actuator as applicable.
smr2009-038-031_a
iBR Motor Voltage Test
TEST OF iBR MODULE OUTPUT VDC TO iBR MOTOR
1. Disconnect the iBR actuator motor connector

from the electronic module on the actuator.
4. Using the iBR override function (see SYSTEM

DESCRIPTION (iBR in this subsection), press
the VTS UP button and read the iBR module
motor output voltage.
NOTE: The iBR UP button on the iBR Activation
page in B.U.D.S. may be used instead of the iBR
override function.
smr2009-037
389

iBR Actuator Input Voltage Test

1. Disconnect the 3 pin and 12 pin connectors
from the iBR actuator.
sdd2009-001-019_c
1. VTS UP
2. VTS DOWN
5. Press the VTS DOWN button (or the iBR DOWN
button on the iBR Activation page in B.U.D.S.),
and read the iBR module motor output voltage.
iBR MOTOR VOLTAGE TEST
Battery voltage (over 12 Vdc)
NOTE: Voltage measured should be battery voltage in both UP or DOWN directions. Voltage polarity should reverse as UP or DOWN button is
pressed alternately.
If battery voltage is not measured, refer to iBR
ACTUATOR INPUT VOLTAGE TEST in this subsection.
If battery voltage is measured in both directions, refer to iBR POWER TEST USING A TEST
LIGHT in this subsection.
If battery voltage is measured and the test light
is bright for both iBR UP or DOWN selections,
the iBR motor is at fault and the iBR actuator
must be replaced.
If battery voltage is low or test light is dim in
both directions, refer to iBR ACTUATOR INPUT
VOLTAGE TEST in this subsection.
If battery voltage is measured and test light is
dim in one direction, replace the iBR actuator.
iBR Power Test Using a Test Light
1. Connect the clip of a 12 Vdc test light to the
battery ground (or engine ground).
2. Touch the test light probe to each pin of the
motor output connector on the iBR module as
you select the iBR up and down alternately.
The test light should come on bright for one pin
only in each direction (alternating 12 Vdc and
ground with change of iBR direction).
390
smr2009-038-003_a
1. 3 pin connector
2. 12 pin connector
NOTE: The 3 pin connector provides battery

power directly to the iBR module for the actuator
motor through a 30 A fuse. The 12 pin connector
provides BRLS signals, CAN bus, and a switched
12 Vdc power to the iBR module through a 5 A
fuse.
868) to Vdc selection.
3. Measure for the 30iA battery input voltage to
the iBR actuator as per following table.
iBR ACTUATOR INPUT VOLTAGE TEST
(30 AMP BATTERY POWER)
3 PIN CONNECTOR
BATTERY
READING
Battery
voltage
Pin 2
Pin 1
Pin 2
Neg. (-) post
smr2009-038-027_a
iBR 12 PIN CONNECTOR PIN-OUT

A. Connector keys
smr2009-037

If battery voltage is not measured, check the following:

30 A iBR fuse in FB2
Battery voltage at fuse contact D11 of FB2
Wire continuity pin 2 iBR 3 pin connector to D12
of FB2
Jumper continuity fuse contact FB2-D11 to
FB2-A6 of 12 Vdc bus-bar.
If voltage is good to the negative battery post but
not to pin 1 of the connector (ground wire to engine), check for an open or bad ground wire (loose,
corroded, or pitted terminals, wire continuity, etc.)
If battery voltage measured is as specified, carry
out same test using a 12 Vdc test light. Test light
should be bright.
If test light is not bright to pin 1 only, look for a
bad contact on the ground circuit (loose, corroded,
pitted, etc.).
If test light is not bright to the negative battery
post, first check voltage at battery terminals to
ensure battery is not discharged. If battery voltage is good, look for a bad contact in the 12V iBR
unswitched power circuit (loose, corroded, pitted,
etc.).
If un-switched 12 Vdc power to the iBR actuator
is good, test for the switched 12 Vdc as per following steps.
4. Briefly press the START/STOP button to wake
the electrical system.
iBR ACTUATOR INPUT VOLTAGE TEST

(5 AMP SWITCHED)
iBR CONNECTORS
BATTERY
READING
Pin 1
Ground post
Battery
voltage
12 PIN
3 PIN
Pin 1
Pin 1
NOTE: The 5 A switched power to the iBR actuator is for the iBR electronic module and BRLS.
If battery voltage is not measured at all, check the
following:
5 A iBR control (CRTL) fuse in FB1
Battery voltage at fuse contact A4 of FB1
Wire continuity pin 1 iBR 12 pin connector to A3
of FB1
Jumper continuity fuse contact FB1-A4 to
FB1-C2 of 12 Vdc accessory bus-bar.
If voltage is good to the negative battery post
but not to pin 1 of the connector (ground wire to
engine), check for an open or bad ground wire
(loose, corroded, or pitted terminals, wire continuity, etc.).
If battery voltage measured is as specified, carry
out same test using a 12 Vdc test light. Test light
should be bright.
If test light is not bright to pin 1 of the 3 pin connector, look for a bad contact on the ground circuit
(loose, corroded, pitted, etc.).
If test light is not bright to battery negative terminal, first check voltage at battery terminals to
ensure battery is not discharged. If battery voltage is good, look for a bad contact in the 12 V
iBR switched power circuit (loose, corroded, pitted, etc.).
If the iBR actuator input voltages and ground circuit are good, and there is no CAN bus or BRLS
fault, replace the iBR actuator.
iBR Actuator Removal

sdd2009-001-019_g

5. Measure for the switched input voltage to the

iBR actuator as per following table.

up) using the iBR OVERRIDE function. Refer
to SYSTEM DESCRIPTION (iBR) in this subsection.
hand with the locking sleeve (iBR key) installed
CAUTION Wait at least 5 minutes for watercraft electrical power system to shut down
before working in the iBR gate area.
smr2009-037
391

2. Open the boarding platform and remove the LH

storage bin.
3. Disconnect the two aft electrical connectors
from the iBR actuator. The forward electrical
connector (iBR motor power) does not need to
be removed.
smr2009-038-002_a
2. Locking sleeve
6. Remove the five hexagonal screws securing

the iBR actuator to the LH support plate.
smr2009-038-003_a
1. iBR actuator 3 pin connector

2. iBR actuator 12 pin connector
4. Disconnect the three water pressure hoses indicated in the following illustration from the iBR
actuator.
smr2009-038-005_a
1. Hexagonal screws to remove (1 screw not visible)
7. Pull the iBR actuator from the support plate.
iBR Actuator Installation
smr2009-038-004_a
1. Pressure hose from jet pump

2. Pressure hose to intercooler
3. Pressure hose to exhaust manifold
5. Remove and discard the hexagonal screw(s) securing the iBR gate locking sleeve (iBR key) and
remove the sleeve from the iBR "U" arm and actuator.
392
Installation is the reverse of the removal procedure however, pay attention to the following:
Clean all actuator mounting screw threads and
apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads (or install new screws with Scotch
grip).
Install the iBR locking sleeve using a new
hexagonal screw with Scotch grip.
Torque hexagonal screws securing iBR actuator
and iBR locking sleeve as specified in exploded
view.
Torque gear clamps securing water pressure
hoses to 2 Nm (18 lbfin).
Apply a small amount of DIELECTRIC GREASE
(P/N 293 550 004) to the connector pins before
installing the connectors on the iBR actuator.
smr2009-037

iBR GATE
iBR Gate Removal (with VTS Trim Ring
and Steering Nozzle)
up) using the iBR OVERRIDE function. Refer
to SYSTEM DESCRIPTION (iBR) in this subsection.
hand with the locking sleeve (iBR key) installed
CAUTION Wait at least 5 minutes for
watercraft electrical power to shut off before
working in the iBR gate area.
2. Remove the hexagonal screw(s) securing the
iBR gate locking sleeve (iBR key) and remove
the sleeve from the iBR "U" arm and actuator.
smr2009-038-006_a
1. Disconnect here
2. Linkage arms
5. Move the "U" arm up over the jet pump to ease

access.
6. Disconnect the steering cable from the steering
nozzle lever.
smr2009-038-002_a
2. Locking sleeve
3. Using your hand, move the iBR gate to the

down position.
4. Disconnect the iBR gate at the linkage arms
that connect the gate to the "U" arm by removing hexagonal screws (one each side).
smr2009-038-007_a
1. Steering cable hexagonal screw

2. Nozzle lever
7. Remove the VTS trim ring retaining hexagonal

screws and washers.
smr2009-037
393

iBR Gate and VTS Trim Ring

Disassembly
VTS Trim Ring Removal
Remove the two hexagonal screws securing the
iBR gate to the VTS trim ring.
smr2009-038-008_a
1. Trim ring hexagonal screw (LH side)
smr2009-038-011_a
1. iBR gate retaining hexagonal screws to remove
smr2009-038-009_a
Trim Ring Inspection

1. Inspect trim ring and metal spacers for cracks,
oblong holes, evidence of wear and deformation.
2. Inspect plastic bushings and friction sleeves for
cracks, deformation and signs of wear.
1. Trim ring hexagonal screw (RH side)
8. Remove the spacer sleeves from the VTS trim

ring.
smr2009-038-012_a
VTS TRIM RING (WITH NOZZLE AND STEERING ARM)

1. Friction sleeves (2 each side)
2. Plastic bushings (x8)
smr2009-038-010_a
1. Trim ring spacer sleeve to remove (LH side illustrated right side
similar)
NOTE: iBR gate, VTS trim ring and nozzle will

come off as a unit when the trim ring spacer
sleeves are removed. Secure the assembly with
one hand as you remove the spacer sleeves.
394
smr2009-037

smr2009-038-022_a
TYPICAL - WORN AND DEFORMED PLASTIC BUSHING

smr2009-038-025_a
TYPICAL - WEAR MARK ON VTS RING AND iBR GATE

CONTACT POINTS
1. Wear mark on VTS ring
2. Wear mark on iBR gate
NOTE: Wear marks on VTS ring and iBR gate contact points are normal up to 3.175 mm (.125 in).
This wear affects nozzle backlash, not iBR gate
backlash.
4. Replace parts as required.
smr2009-038-023
NOTE: Friction sleeves should be replaced as

specified in maintenance chart or if they show
signs of wear (flat surfaces). Plastic bushings
are press fit and should be replaced if they show
signs of wear, deformation, or if the iBR gate
backlash is beyond service limit.
3. Inspect VTS ring and iBR gate contact points for
signs of wear.
Steering Nozzle Removal

1. Remove the 2 hexagonal screws securing the
steering arms (links) to the steering nozzle (top
and bottom).
smr2009-038-012_b
1. Hexagonal screws to remove (top and bottom)
2. Remove the 2 socket head screws securing the

nozzle to the VTS trim ring (1 top and 1 bottom).
smr2009-038-024_a
TYPICAL - WEAR MARK ON VTS RING AND iBR GATE

CONTACT POINTS
1. Wear mark on VTS ring
2. Wear mark on iBR gate
smr2009-037
395

2. Replace as required.
Steering Nozzle Lever Inspection
1. Inspect steering nozzle lever, steering arms,
and spacers for cracks, elongated holes, evidence of wear, deformation and other damages.
smr2009-038-012_c
1. Socket head screws to remove (top and bottom)
Steering Nozzle Lever Removal

1. Remove the hexagonal screws securing the
steering arms (links) to the steering nozzle
lever, top and bottom.
iBR Gate Inspection

1. Inspect the iBR gate and its plastic liner for
cracks, out of round holes, evidence of wear,
deformation and other damages.
2. Inspect plastic bushings (x4) for cracks, wear,
and deformation.
smr2009-038-014_a
1. Plastic liner
2. Plastic bushings
smr2009-038-012_d
iBR Gate and VTS Ring Reassembly
2. Remove the hexagonal screws securing the

steering nozzle lever to the VTS trim ring, top
and bottom.
Install all parts removed in the reverse order of removal, however pay attention to the following:
Install new friction sleeves (as required).
Install new plastic bushings (as required).
Install new hexagonal screws with Scotch Grip
threadlocker.
Torque all retaining screws as per exploded
view.
When installing the iBR gate onto the VTS ring,
position the VTS ring so that the small end of the
steering nozzle is facing you with the steering
lever towards the RH side.
Position the iBR gate over the ring so that the
warning label is facing you (right side up) and
install the mounting hardware as seen in the
exploded view. The attachment points for the
linkage arms will be facing away from you (not
visible in following illustration of iBR gate and VTS
ring assembly).
smr2009-038-012_e
Steering Nozzle Inspection

1. Inspect steering nozzle for cracks, wear, deformation, and other damages.
396
smr2009-037

smr2009-038-011_b
1. Small end of nozzle

2. Steering lever
3. Warning label
iBR Gate Installation (with VTS Trim

Ring and Steering Nozzle)
Install all new hexagonal screws with Scotch
Grip threadlocker.
Lift the 2 linkage arms on the "U" ring as you
insert the iBR gate and VTS ring between the
mounting plates.
Secure the VTS ring to the mounting plates,
then secure the linkage arms to the iBR gate.
Torque all retaining screws as specified in exploded view.
smr2009-038-015_a
1.
2.
3.
4.
"U" arm
Hexagonal screw and washer
Spacer sleeve
Actuator shaft
"U" Arm Inspection

1. Inspect "U" arm and linkage arms (x2) for cracks,
wear, and signs of twisting and bending.
2. Ensure the VTS cams on the "U" arm are not
worn, cracked or broken.
3. Inspect the plastic bushings (x5) for cracks,
wear and deformation.
4. Replace parts as required.
"U" ARM
"U" Arm Removal
1. Carry out the iBR GATE REMOVAL (WITH VTS
TRIM RING) procedure as detailed in this subsection.
2. Remove the RH "U" arm retaining hexagonal
screw and washer.
3. Secure the "U" arm with one hand and remove
the RH spacer sleeve.
4. Remove "U" arm from actuator shaft.
smr2009-037
smr2009-038-016_a
1. Linkage arms
2. Plastic bushings (x5)
3. VTS cams
"U" Arm Installation

Install all new hexagonal screws with Scotch
Grip threadlocker.
Torque all retaining screws as per exploded
view.
397

iBR GATE SUPPORT PLATES

iBR Gate Support Plate Removal
NOTE: The following steps must be carried out
when removing the LH or RH support plates.
2. Remove the following listed items, see procedures in this subsection:
iBR gate, VTS trim ring, and the steering nozzle as an assembly
iBR "U" arm.
NOTE: Two locking tabs on the inner plate locks

it to the outer plate exhaust nozzle.
5. Using a small screwdriver or a scriber, lift the
upper locking tab slightly to help release the
plates and avoid breaking the tabs.
RH Support Plate Removal

1. Remove the RH storage bin, refer to the BODY
subsection.
2. Remove the battery, refer to CHARGING SYSTEM subsection.
3. Disconnect the exhaust hose from the RH inner
support plate.
smr2009-043-003_a
1. Locking tab x2 (top and bottom)
6. Carefully pull the RH inner support plate off the

outer plate.
smr2009-043-001_a
1. Exhaust hose
2. Clamp to loosen
4. Remove and discard the 2 hexagonal screws

securing the outer support plate to the inner
support plate.
smr2009-043-004_a
1. RH inner support plate
7. Pull the outer plate off the hull.

LH Support Plate Removal
1. Remove the iBR actuator, refer to procedure in
this subsection.
2. Cut the locking ties and disconnect the 2 bailer
hoses from the jet pump venturi.
smr2009-043-002_a
1. Support plate retaining screws
398
smr2009-037

smr2009-043-006_a
smr2009-039-002_a
1. Bailer hoses
3. Loosen the gear clamp and disconnect the water pressure hose from the jet pump.
smr2009-039-003_a
1. Water pressure hose
4. Remove the LH storage bin, refer to the BODY

subsection.
5. Disconnect the four hoses connected to the fitting plate mounted in the iBR support plate.
smr2009-037
TYPICAL
1. Bailer hoses (x2)
2. Intercooler bleed hose
3. Pump water pressure hose
6. Remove the FITTING PLATE from the support

plate as described in this subsection (this step
is only applicable to models with a metal retainer on the support plate).
7. Remove and discard the 5 hexagonal screws
securing the outer support plate to the inner
support plate.
smr2009-043-011_a
TYPICAL - MODEL WITH PLASTIC RETAINING TABS

ILLUSTRATED
1. Hexagonal screws to remove
2. Outer support plate
8. From the iBR actuator side, carefully compress the outer support plate tab retaining the
two support plates together using a common
screwdriver.
399

4. Install 5 new hexagonal screws to secure iBR

support plates and torque as per exploded view.
5. Install the fitting plate, refer to FITTING PLATE
in this subsection.
6. Install remaining parts in reverse order of removal. Refer to appropriate subsections for
procedures, products and torques.
FITTING PLATE
The fitting plate connects the bailer and pressure
hoses inside the hull to the hoses that are connected to the jet pump. It also provides the drain
fitting for the intercooler drain hose.
smr2009-043-008_a
TYPICAL - MODEL WITH PLASTIC RETAINING TABS

ILLUSTRATED
1. Fitting plate tab
2. Inner plate tab
3. Outer plate tab to compress
9. Pull the inner support plate off the outer support

plate.
10. Pull the outer support plate from the hull.
iBR Support Plate Installation

RH Support Plate Installation
1. Ensure formed seals are in good condition and
properly installed on each support plate.
2. Position the RH inner support plate in front of
its mounting position in the hull.
3. As you hold the inner support plate, insert exhaust fitting on the outer support plate through
the hull. Push the outer plate in until it snaps
onto the inner plate.
4. Install 2 new hexagonal screws to secure iBR
support plates and torque as per exploded view.
5. Install the exhaust hose on the support plate
fitting and torque the gear clamp to 4 Nm
(35 lbfin).
6. Install the battery, refer to CHARGING SYSTEM
subsection.
7. Install remaining parts in the reverse order of
removal.
Fitting Plate Removal

Models With a Metal Retainer on Fitting Plate
NOTE: The metal fitting plate retainer in the following step is applicable to certain models.
1. Remove the iBR actuator for access to the fitting plate, refer to iBR ACTUATOR in this section.
2. Disconnect the four hoses connected to the fitting plate (inside hull).
smr2009-043-006_a
TYPICAL
3. Remove the hexagonal screw and metal retainer from the fitting plate.
LH Support Plate Installation

1. Ensure formed seals are in good condition and
properly installed on each support plate.
2. Position the LH inner support plate in front of
its mounting position in the hull.
3. As you hold the inner support plate, insert the
round extension on the outer support plate
through the hull. Push the outer plate in until it
snaps onto the inner plate.
400
smr2009-037

smr2009-043-005_a
TYPICAL
1. Hexagonal screw
2. Metal fitting plate retainer
smr2009-039-003_a
4. Cut the locking ties and disconnect the 2 bailer

hoses from the jet pump venturi.
6. Pull the fitting plate out of the outer support

plate from the jet pump side.
Models With Plastic Retaining Tabs

on Fitting Plate
NOTE: On models with plastic retaining tabs on
the fitting plate, the procedure is the same as
models with a metal retaining tab except for the
following.
1. Compress the fitting plate retaining tab and pull
the fitting plate from the outer support plate.
smr2009-039-002_a
1. Bailer hoses
5. Loosen the gear clamp and disconnect the water pressure hose from the jet pump.
smr2009-043-012_a
1. Fitting plate tabs
2. Discard the fitting plate.

NOTICE When the fitting plate retaining tabs
are compressed for removal, the tabs become
deformed and weakened. Do not reinstall a
used fitting plate. Always install a new fitting
plate. Failure to comply with this notice can
result in water seeping into the bilge.
smr2009-037
401

Fitting Plate Installation

Models With a Metal Retainer on Fitting Plate
1. Ensure the "O" ring seal is properly installed on
the fitting plate and in good condition.
2. Insert the fitting plate through the outer iBR
support plate.
3. Install the metal retainer and tighten the hexagonal screw until it is snug.
NOTICE Do not attempt to torque the hexagonal screw or screw threads in the plastic fitting plate will be damaged.
smr2009-043-007_a
NEW FITTING PLATE

1. Good retaining tabs
smr2009-043-005_a
smr2009-043-009_a
OLD FITTING PLATE (DO NOT REUSE)

1. BAD retaining tabs (compressed and deformed)
1. Hexagonal screw
2. Metal retainer
4. Install the four hoses on the inner fitting plate.

Torque gear clamps to 1.7 Nm (15 lbfin).
smr2009-043-006_a
smr2009-043-010_a
OLD FITTING PLATE (BAD RETAINING TAB CONTACT)

1. Retaining tab
TYPICAL
5. Install the three hoses on the jet pump.

6. Torque the gear clamp securing pressure hose
to the jet pump to 1.7 Nm (15 lbfin).
402
smr2009-037


removal, refer to appropriate procedure in this
subsection.
Models With Plastic Retaining Tabs

on Fitting Plate
NOTE: Installation is the same as the model with
metal retainer except for the following.
1. Insert the fitting plate through the outer plate.
2. Push the fitting plate in until it bottoms out and
the retaining tabs (x2) snap securely into position.
NOTICE Ensure both tabs are properly locked
to secure fitting plate to the support plate. If
fitting plate is not properly locked in position,
water may seep into the bilge.
smr2009-043-008_b
1. Top fitting plate retaining tab (bottom tab similar)

removal, refer to appropriate procedure in this
subsection.
VTS CONTROL BUTTON

VTS Button Overview
The VTS button contain a series of 4 diodes for the
UP and DOWN arrow switches. Refer to WIRING
DIAGRAM.
The center wire to the switches (pin C), is common for iS button and VTS button (somewhat like
a ground wire). The other two wires (pins A and
B), act as signal wires for each set of switches to
the gauge. They actually each form one branch of
an electronic circuit within the gauge.
passes through all four diodes (say VTS switch
open), a drop of 2.4 Vdc would be measured
smr2009-037
across the 4 the diodes (pin A to pin C). This 2.4

Vdc at pin B tells the gauge the VTS switch is
open.
If the VTS UP button is pressed, 2 diodes are bypassed by the closed switch. The remaining two
diodes in the circuit drop 1.2 Vdc (at pin A).
If the VTS DOWN button is pressed, 1 diode is bypassedby the closed switch. The remaining three
diodes in the circuit drop 1.8 Vdc (at pin A).
of its connector, and interprets them as signals
that tell it which is activated (VTS UP or VTS
DOWN).
Since the command generated by the closure of
a VTS switch concerns the VTS module, a circuit
within the gauge will translate it to CAN protocol and transmit it through the CAN bus. The VTS
module will react to the command, carry out the
function, and transmit the result back through the
CAN bus.
The gauge will use the signals from the switches
and the transmitted information from the other
modules, convert them to an indication, and
cancel the command signal it sent out once the
function has been carried out.
VTS Control Button Functional Test

Using iBR OVERRIDE Function
2. Install D.E.S.S. key to power up the electrical
system.
3. Activate the iBR override function, refer to SYSTEM DESCRIPTION (iBR) in this subsection.
4. Press and hold the VTS DOWN arrow button.
The iBR gate and steering nozzle will move
downwards together up to the full VTS down
position. The iBR gate will then continue moving to the full reverse/braking position alone.
403

5. Depress and hold the VTS UP arrow button and

ensure the iBR gate moves up to the forward
position.
NOTE: If the VTS button is released before full
travel of the iBR gate, movement of the iBR gate
will cease.
If the iBR does not respond to VTS button commands (UP or DOWN), carry out the following VTS
SWITCH TEST USING B.U.D.S.
smr2009-041-051_b
1. VTS UP and VTS Down indicator lights
VTS Control Button Test Using

B.U.D.S.
B.U.D.S. SOFTWARE.
3. Check for an applicable fault code on the
FAULTS page.
4. Select the Monitoring page tab.
5. In the lower LH corner of the monitoring page,
select the Cluster tab.
6. Press the VTS UP arrow and DOWN arrow button alternately and look for the VTS UP and VTS
Down indicator lights to come on in the Cluster
Lamp Active field.
smr2009-036-002_c
1.
2.
3.
4.
Read Data button

Monitoring tab
Cluster tab
Cluster Lamp Active field
404
If each of the gauge button indicator lights come

on when the applicable switch is closed, the VTS
control button switches and wiring are good. The
problem may be related to the information center
or iBR module.
If one or all of the indicator lights do not come on,
refer to VTS CONTROL BUTTON TEST USING A
MULTIMETER.
VTS Control Button Test Using a

Multimeter
1. Remove the gauge support cover, refer to
GAUGE subsection.
NOTICE Pull connector lock out. Do not twist
the screwdriver.
smr2009-042-002_a
1. Gauge connector
3. Use a FLUKE 115 MULTIMETER (P/N 529 035 868)

set to the diode test function. Test the VTS button switches as per following tables.
NOTE: It is important to set the multimeter to the
diode check function when testing the VTS control
switches.
smr2009-037

fault may be within the gauge. Replace the gauge

and carry out a new VTS BUTTON TEST USING
B.U.D.S. to ensure the problem is solved.
VTS Control Button Removal

NOTE: The VTS and iS control s come as a switch
assembly which must be replaced as a unit.
AND O.T.A.S.
2. Remove connector from switch assembly.
vmr2006-020-005
NOTE: Pay attention to multimeter lead position

for diode biasing during test. Remember that
each diode should drop approximately 0.6 Vdc
when positively biassed, and read as an OL (open
circuit) when negatively biassed (leads reversed).
VTS CONTROL TEST
SWITCH
POSITION
MULTIMETER
LEAD
GAUGE
CONNECTOR
VOLTAGE
Red lead
Black lead
Pin 13
Pin 15
Approx.
2 Vdc
Black lead
Red lead
Pin 13
Pin 15
OL
Red lead
Black lead
Pin 13
Pin 15
Approx.
1.1 Vdc
Black lead
Red lead
Pin 13
Pin 15
OL
Red lead
Black lead
Pin 13
Pin 15
Approx.
1.6 Vdc
Black lead
Red lead
Pin 13
Pin 15
OL
smr2009-038-034_a
Switch
released
UP
depressed
DOWN
depressed
1. VTS/iS switch connector
3. Remove switch assembly from support by lifting it off the support.
VTS Control Button Installation

(P/N 293 550 004) on switch contact pins.
2. Install connector on new switch assembly.
3. Ensure wiring from START switch is properly
inserted in slot provided before installing VTS
and iS control button assembly.
When measuring between pins 13 and 15, if an

OL is obtained with both positive and negative
diode biassing, test the continuity of each wire
between the gauge and switch assembly. If continuity is good, replace the switch assembly.
If any reading is significantly different than specified, carry out the same test at the switch connector, refer to the wiring diagram. If you obtain the
same results, replace the switch assembly.
If voltages measured on the VTS UP and DOWN
switch are as specified (or very close to it), the
switches and the wiring harness are good. The
smr2009-037
405

smr2009-038-035_b
1. START/STOP switch
2. Wiring routed in slot provided in support
3. VTS/iS switch connector
4. Insert switch assembly in switch support.

5. Install steering cover, refer to STEERING AND
O.T.A.S.
6. Carry out an operational test of the VTS and
iS systems to ensure proper operation of new
switch assembly.
406
smr2009-037

Subsection 03 (JET PUMP)
JET PUMP
SERVICE TOOLS
Description
Part Number

IMPELLER SHAFT BEARING TOOL .............................................
IMPELLER SHAFT PUSHER..........................................................
PRESSURE CAP ............................................................................
SEAL/BEARING PUSHER ..............................................................
529
529
529
529
529
529
529
035
035
036
035
036
035
021
820
956
168
955
172
819
800
Page
......... 416, 418419, 421, 424

......... 416, 418419, 421, 424
................................. 420, 422
................................. 420, 422
......................................... 410
......................................... 423
......................................... 410
SERVICE PRODUCTS
Description
Part Number
JET PUMP BEARING GREASE .....................................................

LOCTITE 243 (BLUE).....................................................................
LOCTITE 577 (THREAD SEALANT) ...............................................
LOCTITE 767 (ANTISEIZE LUBRICANT) .......................................
XPS LUBE......................................................................................
XPS SYNTHETIC GREASE.............................................................
293
293
293
293
413
293
293
smr2009-039
550
800
800
800
711
600
550
032
060
050
070
809
016
010
Page
......................... 415, 422, 424

................................. 413414
......................................... 418
......................................... 417
......................................... 413
................................. 413, 417
................................. 413, 418
407

XPS synthetic grease

125 Nm
(92 lbfft)
Loctite 577
(thread sealant)
NEW
Jet pump bearing

grease
Loctite 767
(antiseize lubricant)
Jet pump bearing grease
(24 ml (.81 U.S. oz))
NEW
125 Nm
(92 lbfft)
Jet pump
bearing grease
(4 ml (.14 U.S. oz))
8 Nm
(71 lbfin)
Jet pump bearing grease

(23 ml (.78 U.S. oz))
7.5 Nm
(66 lbfin)
21 Nm
(16 lbfft)
NEW
1.7 Nm
(15 lbfin)
30 Nm
(22 lbfft)
NEW
See
iBR AND VTS
subsection
NEW
NEW
10 Nm
(89 lbfin)
NEW
4.5 Nm
(40 lbfin)
Loctite 243
21 Nm
(16 lbfin)
smr2009-039-001_a
408
smr2009-039

GENERAL
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENER and LOCTITE
complete procedure.
WARNING
etc.) must be replaced.
JET PUMP MAIN COMPONENTS
IMPELLER/WEAR RING
CLEARANCE
This clearance is critical for jet pump performance.
To check clearance, remove jet pump.
Using a feeler gauge, measure clearance between
impeller blade tip and wear ring. Measure each
blade at its center.
smr2007-028-001_a
TYPICAL UNDERNEATH HULL

1. Impeller
2. Impeller boot
3. Wear ring
1
3
2
smr2006-027-011_a
TYPICAL
1. Nozzle
2. Venturi
3. Jet pump housing
4. Wear ring
5. Impeller
6. Stator
INSPECTION
smr2006-027-008
MODEL
All models
MAXIMUM WEAR
CLEARANCE
mm (in)
0.35 (.014)
IMPELLER CONDITION
IMPELLER SHAFT RADIAL PLAY
Condition of impeller, impeller boot and wear

ring can be quickly checked from underneath the
watercraft. With the vehicle on the trailer, use
a flashlight to visually inspect them through the
inlet grate.
Radial play is critical for jet pump life span.

To check radial play, remove jet pump.
Make sure impeller shaft turns freely and
smoothly.
1. Retain housing in a soft jaw vise making sure
not to damage housing lug.
2. Set a dial gauge and position its tip onto metal
end, close to the end of the impeller hub.
3. Move shaft end up and down. Difference between highest and lowest dial gauge reading is
radial play.
smr2009-039
409

5290218002
smr2009-006-008_a
TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY

1. Dial gauge
2. Measure close to impeller hub end
RADIAL PLAY
0 mm (0 in)
Excessive play can come either from worn bearing

or damaged jet pump housing bearing surface.
LEAK TEST
Whenever performing any type of repair on the jet
pump, a leak test should be carry out.
Proceed as follows:
1. Remove impeller cover. Refer to IMPELLER
COVER in this subsection.
2. Install the PRESSURE CAP (P/N 529 036 172) on
pump housing.
smr2008-029-005
TYPICAL
4. Pressurize pump.
LEAK TEST PRESSURE
Maximum 70 kPa (10 PSI)
5. Pump must maintain this pressure for at least

5 minutes.
NOTICE Repair any leak. Failure to correct a
leak will lead to premature wear of pump components.
529036172
3. Connect the VACUUM/PRESSURE PUMP (P/N 529

021 800) to the pressure cap fitting.
410
NOTE: If there is a pressure drop, spray soapy

water around cover. If there are no bubbles, impeller shaft, impeller shaft seal, or jet pump housing is leaking through porosity and has to be replaced. Jet pump unit has to be disassembled.
NOTE: There may be 2 or 3 bubbles coming out
from the seal on the impeller side. This small leak
is acceptable. Leaks from other areas must be repaired.
smr2009-039

Sacrificial Anode Removal

Unscrew sacrificial anode hexagonal screw and
remove anode.
smr2009-006-002_a
TYPICAL
1. Small leak here is acceptable
6. Disconnect pump and remove pressure cap.

7. Reinstall impeller cover. Refer to IMPELLER
PROCEDURES
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, cracks, split,
break, porosity, cavitation, deformation, distortion, heating discoloration, wear pattern, defective plating, missing or broken balls in ball bearing,
water damage diagnosed by black-colored spots
on metal parts, etc. Renew any damaged part.
As a quick check, manually feel clearance and end
play, where applicable, to detect excessive wear.
smr2006-027-009
Sacrificial Anode Installation

Installation is the reverse of the removal procedure.
Torque anode retaining screw as specified in exploded view.
JET PUMP HOUSING

NOTE: The jet pump housing can be removed as
an assembly with the venturi. This is the preferred
procedure when either the drive shaft or engine
removal is required.
SACRIFICIAL ANODE
Jet Pump Housing Removal
Sacrificial Anode Inspection
1. Remove the iBR gate and VTS trim ring, refer

to iBR AND VTS subsection.
2. Cut locking ties and disconnect both bailer
hoses from the venturi.
Check for wear. If worn more than half, replace

anode.
smr2009-039-009_a
1. Sacrificial anode location

smr2009-039-002_a
1. Bailer hoses
smr2009-039
411

3. Loosen gear clamp and remove the hose from

the water pressure outlet fitting on the jet pump
housing.
Jet Pump Housing Inspection and

Cleaning
1. Visually inspect jet pump housing. Pay attention to the stator. Ensure the assembly is clean
and free of any debris and defects.
2. Blow low pressure compressed air through the
pressure outlet fitting and make sure it is clear.
3. Ensure the neoprene seal is in good condition.
Replace as required.
smr2009-039-003_a
4. Remove the socket screws that retain the 4 jet

pump adapters to the ride plate.
smr2009-039-005_a
1. Pressure hose fitting

2. Neoprene seal
NOTE: The end of the pressure outlet fitting

screwed into the pump housing is perforated
with many small holes. These holes must remain
clear to ensure an adequate water supply for the
intercooler and exhaust system.
smr2009-039-004_a
1. Socket screws to remove (x4)
5. Pull back jet pump housing to remove it from

the pump support. It may be necessary to wiggle it slightly as you pull back on the pump.
NOTE: The jet pump housing is held tightly in the
pump support due to the neoprene seal at the forward end of the pump. There are no fasteners securing the jet pump housing to the pump support.
412
smr2009-039-010_a
1. Fitting
2. Holes in fitting
4. Check the 4 pump adapters. Ensure they are

free of any cracks.
NOTE: Do not remove the jet pump housing
adapters from the pump unless it is necessary to
do so.
smr2009-039

2. Install the pump on a spare ride plate, the

mounting screws should be tight, but it is not
required to torque them.
3. Torque hexagonal screws retaining the
adapters to the jet pump housing as specified in the exploded view.
4. Remove the jet pump housing from the spare
ride plate and install it on the watercraft ride
plate.
Jet Pump Housing Installation

smr2009-039-006_a
1. jet pump housing adapters (x4)
Jet Pump Housing Adapter

Replacement
Adapters incorporate a keyway at the pump housing end of the adapter that provide for a small
amount of play for mounting the jet pump.
Brush and clean impeller splines and drive shaft

splines with PULLEY FLANGE CLEANER (P/N 413
711 809) or equivalent. Splines must be free of
any residue.
Lubricate drive shaft splines, impeller splines and
the inside of the impeller boot with XPS SYNTHETIC GREASE (P/N 293 550 010).
NOTE: Slightly lubricate wear ring with XPS LUBE
(P/N 293 600 016) to minimize friction during initial
start.
Ensure the neoprene seal is properly installed on
the jet pump.
smr2009-039-007_a
1. Adapter key
smr2009-039-005_b
1. Neoprene seal
smr2009-039-008_a
1. Pump housing adapter keyway
If adapters are removed or replaced, or a new

pump housing is installed, adapters may be
aligned to the pump housing using a spare ride
plate as a jig. Carry out the following steps.
1. Install the four adapters on the jet pump housing leaving the hexagonal screws slightly loose.
smr2009-039
While holding the pump housing with the pump

adapters downwards, align the pump with the
drive shaft and carefully push the pump into the
pump support.
adapter screw threads (or use new self-locking
screws).
Torque screws retaining pump adapters to ride
plate as specified in exploded view.
413

VENTURI
Venturi Removal
Jet Pump Housing installed
1. Remove the iBR gate and VTS trim ring as an
assembly. Refer to iBR AND VTS subsection.
2. Cut locking ties and remove the 2 bailer hoses
from the venturi.
3. Refer to JET PUMP HOUSING REMOVED to
continue procedure.
Jet Pump Housing Removed
1. Remove the three hexagonal screws retaining
the venturi to the jet pump housing.
F18J0LA
TYPICAL
3. Using a fiber hammer, gently tap impeller cover

to help release it from the jet pump housing.
4. Use a flat screwdriver in the slots provided as
pry points to remove it from the jet pump housing.
smr2009-039-002_b
1. Bailer hoses
2. Venturi retaining screws (x3)
Venturi Installation
The installation is the reverse of the removal procedure. Pay attention to the following.
threads of venturi screws or install new self-locking screws.
Install venturi screws and flat washers.
Torque venturi hexagonal screws to 21 Nm
(15 lbfft).
Ensure bailer hoses and fittings are in good condition.
sdd2009-001-114_b
1. Slot
IMPELLER COVER
Impeller Cover Removal
1. Remove the venturi.
2. With pump housing in vertical position, remove
and discard the 3 retaining screws.
F18J0MA
TYPICAL
414
smr2009-039

5. Remove both O-rings.
Check impeller boot and O-rings condition on impeller. Replace as required.
smr2009-006-004_a
smr2009-006-003_a
TYPICAL
1. O-rings
1. Impeller boot
2. Impeller O-ring
3. Pump housing O-ring
Impeller Cover Inspection
Impeller Cover Installation
Check for presence of water in cover and bearing

area. If water is found, replace seals on impeller
side. Also replace O-rings and/or impeller cover.
1. Install O-rings in their respective groove.
F18J0NA
smr2009-006-002_a
1. Seal on impeller side
TYPICAL
2. Put 23 ml (.8 U.S. oz) of JET PUMP BEARING

GREASE (P/N 293 550 032) in the cover.
F18J18A
smr2009-006-003_a
1. Cover O-rings
smr2009-039
TYPICAL
415

3. Install impeller cover by aligning the cover index

mark with the pump top fin as shown.
sdd2009-001-114_c
1. Align mark with top fin
NOTE: Cover can only be installed in one position

as screw holes are not located symmetrically.
4. Secure cover with NEW self-locking screws.
NOTE: Push cover against pump housing while
alternately tightening screws. Make sure O-rings
are positioned correctly and they are not damaged
when pushing the cover.
5. Torque cover screws to 7.5 Nm (66 lbfin).
6. Perform a leak test. Refer to LEAK TEST in this
subsection.
F19J06A
TYPICAL
1. Unscrew clockwise
4. Mount the flat sides of impeller shaft in a vise.
IMPELLER
Impeller Removal
NOTE: If impeller shaft is to be disassembled,
loosen the impeller shaft nut prior to removing
the impeller.
1. Remove jet pump from the watercraft. Refer to
JET PUMP HOUSING in this subsection.
3. Remove impeller boot by turning it clockwise
(LH threads).
smr2009-006-005_a
TYPICAL
1. Flat side
5. Mount in the impeller splines the appropriate

impeller remover/installer tool according to engine type.
MODEL
130 and 155
engines
215 and 255
engines
416
TOOL
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 820)
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 956)
smr2009-039

529035820
TOOL FOR 130 AND 155 ENGINES
smr2009-006-005_a
TYPICAL
1. Flat side
2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT)

(P/N 293 800 070) on threads of impeller shaft.
529035956
TOOL FOR 215 AND 255 ENGINES
6. Unscrew the impeller counterclockwise.

NOTE: It may be necessary to heat the impeller
to ease removal.
NOTICE Never use an impact wrench to
loosen impeller.
smr2009-006-002_b
TYPICAL
1. Antiseize lubricant
3. Apply XPS LUBE (P/N 293 600 016) on the wear

ring surface.
smr2009-006-006_b
TYPICAL
7. To pull impeller out of the pump, apply a rotating

movement as you pull on the impeller.
Impeller Installation
1. Mount the flat sides of the impeller shaft in a
vise.
smr2009-039
smr2009-006-002_c
TYPICAL
1. XPS Lube
4. Start screwing the impeller on its shaft.

417

WEAR RING
Wear Ring Inspection
Check wear ring for:
Deep scratches
Irregular surface
Any apparent damage.
Check IMPELLER/WEAR RING CLEARANCE, see
procedure at the beginning of this subsection.
Wear Ring Removal

smr2009-006-007
TYPICAL

MODEL
130 and 155 engines
215 and 255 engines
TOOL
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 820)
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 956)
6. Torque impeller to 125 Nm (92 lbfft), then remove tool.

NOTICE Never use an impact wrench to
tighten impeller shaft.
1. Remove the iBR gate, VTS trim ring and the

steering nozzle as an assembly. See procedure
in IBR AND VTS subsection.
2. Remove jet pump from watercraft. Refer to
JET PUMP HOUSING in this subsection.
3. Remove impeller from jet pump housing, refer
to IMPELLER in this subsection.
4. Place jet pump housing in a vise with soft jaws.
It is best to clamp housing using a lower ear.
5. Cut wear ring at two places.
NOTICE When cutting ring, be careful not to
damage jet pump housing.
NOTE: Wear ring can be cut using a jigsaw, a
small grinder or a low clearance hacksaw.
6. After cutting ring, insert a screwdriver blade between jet pump housing and ring outside diameter.
7. Push ring so that it can collapse internally.
8. Pull ring out.
Wear Ring Installation

To install wear ring in housing, use a square steel
plate of approximately 180 x 180 mm x 6 mm thick
(7 x 7 in x 1/4 in) and a press.
Manually engage ring in housing making sure it is
equally inserted all around. Press ring until it seats
into bottom of housing.
smr2009-006-006_a
TYPICAL
7. ApplyLOCTITE 577 (THREAD SEALANT) (P/N 293

800 050) on impeller boot threads.
8. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
inside impeller boot.
9. Install impeller boot on impeller and tighten
counterclockwise.
418
smr2009-039

2. Mount in a vise the appropriate impeller remover/installer tool according to engine type.
MODEL
130 and 155 engines
215 and 255 engines
TOOL
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 820)
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 956)
1
2
F01J1DA
1. Rounded edge
2. Press wear ring
If a press is not readily available, a piece of wood

such as a 2 x 4 in x 12 in long, can be used.
Manually engage ring in housing making sure it
is equally inserted all around. Place wood piece
over ring. Using a hammer, strike on wood to
push ring. Strike one side then rotate wood piece
about 90 and strike again. Frequently rotate
wood piece so that ring slides in evenly until it
seats into bottom of housing.
F18J0PB
TYPICAL
1. Impeller remover/installer tool
3. Install jet pump housing over impeller remover/installer tool.
1
F01J1FA
1. Piece of wood
2. Rounded edge
3. Wear ring
IMPELLER SHAFT AND BEARING

Impeller Shaft and Bearing Removal
smr2009-039
F18J0QA
TYPICAL
4. Using a 30 mm socket, unscrew the impeller

shaft nut counterclockwise.
NOTE: If impeller loosens instead of shaft nut,
refer to IMPELLER SHAFT NUT REMOVAL IF
IMPELLER HAS LOOSENED further in this procedure.
419

8. Use the IMPELLER SHAFT PUSHER (P/N 529 035

955) to press impeller shaft out of pump housing.
NOTE: Bearing will come out with the impeller
shaft.
smr2009-006-009_a
TYPICAL
5. Remove impeller shaft nut.
529035955_a
smr2009-006-010_a
smr2009-006-003_b
TYPICAL
TYPICAL
1. Nut
6. Remove impeller as described in this subsection.

7. From the impeller side, remove circlip, seals,
spacer and O-ring.
smr2009-006-011
TYPICAL
9. Use the IMPELLER SHAFT BEARING TOOL

(P/N 529 036 168) to press bearing off impeller
shaft.
smr2006-027-007_b
TYPICAL
1. Circlip
2. Seal
420
smr2009-039

smr2009-006-012_a
smr2009-006-006_a
TYPICAL
1. Impeller shaft and bearing
2. Bearing tool on INNER race
TYPICAL
Impeller Shaft Nut Removal if Impeller has

Loosened
1. Turn pump upside down and mount the flat
sides of impeller shaft in a vise.
4. Turn pump upside down and retry unscrewing

impeller shaft nut.
smr2009-006-009_a
TYPICAL
smr2009-006-005_a
TYPICAL
1. Flat side

MODEL
130 and 155 engines
215 and 255 engines
TOOL
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 820)
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 956)
5. If impeller still loosens instead of nut, retighten

impeller more and retry. Repeat until nut
loosens.
6. Remove impeller as described in this subsection.
7. Return to step 5 in the IMPELLER SHAFT AND
BEARING REMOVAL main procedure.
Impeller Shaft and Bearing Inspection

With your finger nail, feel seal lip contact surface
on shaft. If any irregular surface is found, replace
shaft and seals.
Check condition of shaft threads.
3. Torque impeller more than impeller shaft nut.
smr2009-039
421

smr2009-006-019_a
TYPICAL
1. Threads
2. Seal lip contact surface
3. Threads
Inspect ball bearing for corrosion.

smr2009-006-014_a
Impeller Shaft and Bearing Installation

Bearing Installation
following.
1. Using the IMPELLER SHAFT BEARING TOOL
(P/N 529 036 168) on the bearing inner race,
press the bearing on the impeller shaft.
2. Use the IMPELLER SHAFT PUSHER (P/N 529 035
955) to protect the impeller shaft threads.
NOTE: The bearing can be installed in either direction.
TYPICAL
1. Bearing tool
2. Press bearing until it bottoms.

NOTE: Ensure impeller shaft turns freely and
smoothly.
3. Turn pump upside down.
4. Coat shaft surface with JET PUMP BEARING
GREASE (P/N 293 550 032).
5. Install O-ring at bottom.
F19J07A
smr2009-006-013_a
TYPICAL
1. Impeller shaft bearing tool on INNER race
3. Impeller shaft installer/pusher tool
3. Press bearing until it bottoms.
TYPICAL
1. O-ring at bottom
2. Coat surface
6. Apply 4 ml (.1 U.S. oz) of JET PUMP BEARING

GREASE (P/N 293 550 032) on bearing.
Impeller Shaft Installation

NOTE: Ensure there is no O-ring in pump housing
on the cover side.
1. From the outlet side of pump, press impeller
shaft assembly into housing using the IMPELLER SHAFT BEARING TOOL (P/N 529 036
168).
422
smr2009-039

F18J12A
F18J14B
TYPICAL
7. Press a NEW double lip seal using the

SEAL/BEARING PUSHER (P/N 529 035 819) until
seal bottoms. Make sure seal lip are facing
upwards.
TYPICAL
1. Seal/bearing pusher
8. Install spacer and then the other seal (thin). Ensure seal lip is facing up.
smr2009-006-016_a
smr2009-006-015_a
1. Seal lip facing up
1. Seal lip up
9. Install circlip.
smr2006-027-007_c
F18J13A
1. Seal lip facing up
TYPICAL
1. Circlip
10. Turn pump upside down.

11. Install the two O-rings in pump housing.
smr2009-039
423

smr2009-006-017_a
TYPICAL
1. O-rings
F18J0QA
12. Before installing any other parts, pressurize jet

pump to insure proper seal installation. Refer
to LEAK TEST in this subsection.
13. Install impeller. Refer to IMPELLER in this
subsection.
14. Mount in a vise the appropriate impeller remover/installer tool according to engine type.
MODEL
130 and 155 engines
215 and 255 engines
TYPICAL
16. Using a 30 mm socket, screw the impeller

shaft nut on clockwise.
17. Torque nut as specified in exploded view.
TOOL
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 820)
IMPELLER
REMOVER/INSTALLER
(P/N 529 035 956)
1
smr2009-006-009_b
18. Apply 24 ml (.8 U.S. oz) of JET PUMP BEARING

GREASE (P/N 293 550 032) on the bearing (nut
side).
F18J0PB
1. Impeller remover/installer tool
15. Install jet pump housing over this tool.
smr2009-006-018
424
smr2009-039

19. Install the impeller cover. Refer to IMPELLER

smr2009-039
425
426

Subsection 04 (DRIVE SHAFT)
DRIVE SHAFT
SERVICE TOOLS
Description
Part Number
Page
DRIVE SHAFT ADAPTER............................................................... 529 035 985 ................................. 431, 433

DRIVE SHAFT WRENCH ............................................................... 529 036 167 ................................. 431, 434
SERVICE PRODUCTS
Description
Part Number
Page
LOCTITE 577 (THREAD SEALANT) ............................................... 293 800 050 ......................................... 433
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ......................................... 432
smr2009-040
427

NEW
Engine oil
Loctite 577
(thread
sealant)
XPS synthetic
grease
8 turns
+
125 Nm
(92 lbfft)
LH threads
smr2009-040-001_a
428
smr2009-040

GENERAL
The jet pump must be removed to replace any
component of the drive system. Refer to JET
PUMP for removal procedure.
and service products as specified in the exploded
view.
complete procedure.
WARNING
smr2009-007-012_a
WRONG
1. Rubber sealing lip NOT fully engaged
TROUBLESHOOTING
DIAGNOSTIC TIPS
Leaks at PTO Seal
If water enters engine, or oil leaks from engine at
PTO seal, check if drive shaft is fully engaged in
sealing ring.
Compress the drive shaft boot to visually check
for proper contact.
smr2009-007-013_a
CORRECT
1. Rubber sealing lip fully engaged
smr2009-010_a
NOTE: If drive shaft boot cannot be compressed

enough for the inspection, remove jet pump and
torque drive shaft. If this does not work, remove
drive shaft and inspect drive shaft threads. Refer
to DRIVE SHAFT in this subsection.
1. Drive shaft boot
Rubber sealing lip of drive shaft must be fully engaged into flange of sealing ring.
smr2009-040
429

PROCEDURES
DRIVE SHAFT
Drive Shaft Removal
To prevent oil spillage when pulling out drive shaft,
carry out the following:
Start engine.
Bring engine to 4000 RPM for 10 seconds.
Stop engine at this RPM.
NOTE: If engine cannot be started, remove oil
from the PTO area by following the procedure
detailed in PTO HOUSING REMOVAL of the PTO
HOUSING AND MAGNETO subsection.
1. Position watercraft at a workstation that has access to a chain block, a hoist or other suitable
lifting equipment.
2. Disconnect the rear control arm and tilt the
moving deck forward fir access. Refer to
BODY subsection.
3. Remove the aft ventilation box located above
the engine.
smr2009-016-002_a
1. Deck extension
5. Lower the moving deck onto the fixed deck and

install a few hexagonal screws on the aft control arm to hold the deck steady for the duration
of the procedures.
7. Remove the iBR gate and VTS ring as an assembly. Refer to IBR AND VTS subsection.
8. Remove the jet pump assembly. Refer to JET
PUMP subsection.
9. Reach in behind the engine and lift the rubber
protector to expose the PTO seal at the engine
side of the driveshaft.
smr2009-016-001_a
1. Vent box

subsection.
smr2009-040-002_a
1. Rubber protector
430
smr2009-040

smr2009-040-003_a
1. Sealing ring
smr2009-007-002_a
TYPICAL
1. Drive shaft wrench
12. From rear of watercraft, install the DRIVE

SHAFT ADAPTER (P/N 529 035 985) on drive
shaft end.
smr2009-007-001_a
TYPICAL
1. Rubber protector
10. Remove all spark plugs from engine. Refer to

IGNITION SYSTEM.
NOTE: Spark plug removal will ease engine rotation for drive shaft removal.
11. In engine compartment, install the DRIVE
SHAFT WRENCH (P/N 529 036 167) on the
hexagon of sealing ring.
smr2009-040
smr2009-007-003_a
TYPICAL
1. Drive shaft adapter
13. While a coworker holds the drive shaft wrench

in the engine compartment, unscrew the drive
shaft clockwise (LH threads).
431

smr2009-007-006_a
smr2009-007-003_b
TYPICAL - CLOCKWISE TO UNSCREW
CAUTION Ensure to unscrew clockwise

on LH threads (opposite of usual threads).
14. Place rags under PTO housing to prevent oil
spillage. If spillage occurs, clean immediately
with the PULLEY FLANGE CLEANER (P/N 413
711 809) to prevent oil stains.
15. Pull out drive shaft.
NOTE: A slight jerk to the rear may be required to
remove the drive shaft from the PTO seal.
16. Remove sealing ring. Refer to SEALING RING
in this subsection.
1.
2.
3.
4.
5.
Splines
Threads
Taper
Rubber sealing lip
Rubber coating
4. Measure drive shaft deflection. Excessive deflection could cause vibration and damage to
drive shaft splines, impeller or PTO seal.
5. Place drive shaft on V-blocks and set-up a dial
gauge in center of shaft. Slowly rotate shaft;
difference between highest and lowest dial
gauge reading is deflection. Refer to the following illustration.
6. IMPORTANT: When rotating drive shaft and
reading the deflection, the gauge needle will
bump on the molding flash mark. This is a
normal situation, ignore this deflection peak.
Drive Shaft Inspection

1. Inspect condition of drive shaft splines, taper
surface and threads. If damage is found, replace drive shaft.
2. Carefully inspect the rubber sealing lip condition. Damage would allow water to enter engine or oil to leave engine. If damaged, replace
drive shaft.
CAUTION The rubber sealing lip is critical
for proper sealing of engine at drive shaft connection into engine.
3. Inspect the rubber coating of drive shaft. If
cracked or otherwise damaged, shaft corrosion
will occur.
2
smr2009-007-200_a
TYPICAL MEASURING DRIVE SHAFT DEFLECTION

1. Dial gauge
2. V-blocks
DRIVE SHAFT DEFLECTION

Maximun .75 mm (.03 in)
Drive Shaft Installation

1. Install sealing ring. Refer to SEALING RING
subsection.
432
smr2009-040

2. Remove the damper at the end of drive shaft

and replace it with a NEW one.
smr2009-007-010_a
LOCTITE 577 APPLICATION

A. First 5 threads
B. 3 mm (1/8 in)
smr2006-028-004_a
1. Damper
3. Wipe clean the sealing ring and the carbon seal

contact surfaces.
4. Properly align sealing ring with carbon seal.
8. From rear of watercraft, engage drive shaft

through the drive shaft boot.
9. Continue pushing drive shaft towards engine
carefully guiding it through the sealing ring, the
PTO seal and finally into the crankshaft splines.
NOTE: It may be necessary to move sealing ring
and PTO seal up and down to position them in the
same axis as the drive shaft.
NOTE: If drive shaft does not enter into the PTO
seal, check engine alignment. Refer to ENGINE
subsection.
10. Trace an index mark on the drive shaft which
will be used for counting the turns the drive
shaft will be rotated to fully engage drive shaft.
smr2009-007-001_b
1. Sealing ring aligned with carbon seal

smr2009-007-014_a
5. Wipe clean the threads and the tapered surface

on drive shaft.
6. Apply engine oil to the tapered surface on drive
shaft.
1. Mark
11. Install the DRIVE SHAFT ADAPTER (P/N 529 035

985) on drive shaft end.
smr2009-007-016_a
1. Clean taper then coat with engine oil
7. Apply 2 beads of LOCTITE 577 (THREAD

SEALANT) (P/N 293 800 050) on threads as
shown.
smr2009-040
433

smr2009-007-002_a
smr2009-007-003_a
TYPICAL
1. Drive shaft adapter
NOTE: Make sure all spark plugs are removed

from engine.
12. Removing spark plugs helps to engage
threads more easily thus preventing
cross-threading the sealing ring.
Carefully rotate drive shaft counterclockwise (LH
threads) to engage threads in sealing ring. Be
careful not to engage cross-thread.
TYPICAL
1. Drive shaft wrench
15. While a coworker holds the drive shaft wrench

in engine compartment, continue turning drive
shaft counterclockwise (LH threads) to a total
of 8 turns.
16. IMPORTANT: The number of turns is only a
reference to give you an idea of the drive shaft
engagement in the sealing ring. It is useful if
you suspect cross-threading. When the number of turns has been reached, the torque is
mandatory to properly secure the drive shaft.
smr2009-007-003_c
TYPICAL
13. Rotate drive shaft 1-1/2 to 2 turns then try

pulling drive shaft out to ensure it is engaged.
14. In engine compartment, install the DRIVE
SHAFT WRENCH (P/N 529 036 167) on the
hexagon of sealing ring.
434
smr2009-007-003_c
17. Torque drive shaft to 125 Nm (92 lbfft).

18. Reposition rubber protector above sealing
ring.
19. Install jet pump. Refer to JET PUMP section.
20. Install iBR gate and VTS ring, refer to IBR AND
VTS subsection.
21. Check engine oil level. Refill as necessary.
22. Install spark plugs on engine, refer to ENGINE
subsection.
smr2009-040

23. Run watercraft then ensure there is no oil leak

in PTO seal area.
24. Properly reinstall the deck extension, moving
deck and ventilation box. Refer to BODY subsection.
SEALING RING
Sealing Ring Removal
1. Remove drive shaft. Refer to DRIVE SHAFT in
this subsection.
2. Carefully pry out sealing ring from PTO seal
working alternately from side to side while
retaining PTO seal.
smr2009-007-005_a
1. Tapered surfaces
Sealing Ring Installation

1. Carefully insert sealing ring in the PTO seal.
2. Ensure sealing ring is completely inserted in the
PTO seal.
NOTE: The sealing ring flange must be flush with
the PTO seal flange.
smr2009-007-007_a
Sealing Ring Inspection

Inspect condition of threads, tapered surfaces,
carbon seal contact surface and seal lip contact
surface. If damage is found, replace sealing ring.
Sealing Ring Cleaning

Clean the following sealing ring surfaces and
threads.
smr2009-007-009_a
CORRECT
1. Sealing ring fully inserted into PTO seal
smr2009-007-004_a
1. Seal lip contact surface

2. Threads (inside)
3. Carbon seal contact surface
smr2009-040
435

smr2009-007-008_a
WRONG
1. Sealing ring incompletely inserted into PTO seal
436
smr2009-040
Section 07 BODY AND HULL

Subsection 01 (SUSPENSION (iS))
SUSPENSION (iS)
SERVICE TOOLS
Description
Part Number
Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................. 447, 449450, 452
MAGNETO HARNESS 6 PINS....................................................... 295 000 136 ......................................... 447
SUPERTITANIUM DRILL BIT 3/16"................................................ 529 031 800 ......................................... 459
SERVICE PRODUCTS
Description
Part Number
Page

LOCTITE 243 (BLUE)..................................................................... 293 800 060 ................................. 456, 458
smr2009-041
437

FRONT
48 Nm
NEW (35 lbfft)
10 Nm
NEW (89 lbfin)
NEW
12 Nm
NEW (106 lbfin)
25 Nm
(18 lbfft)
NEW
25 Nm
NEW (18 lbfft)
NEW
12 Nm
(106 lbfin) NEW
10 Nm
NEW (89 lbfin)
10 Nm
(89 lbfin)
NEW
NEW
25 Nm
(18 lbfft)
NEW
75 Nm
(55 lbfft)
6 Nm
(53 lbfin)
NEW
25 Nm
(18 lbfin)
NEW
25 Nm
(18 lbfft)
75 Nm
(55 lbfft)
NEW
85 Nm
(18 lbfft) 10 Nm
(89 lbfin)
NEW
NEW
4 Nm
(35 lbfin)
NEW
25 Nm
(18 lbfft)
NEW
25 Nm
(18 lbfft)
NEW
48 Nm
(35 lbfft)
10 Nm
(89 lbfin)
NEW
25 Nm
(18 lbfft)
NEW
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
Loctite 243
8 Nm
(71 lbfin)
smr2009-041-001_a
438
smr2009-041

REAR
NEW
12 Nm
(106 lbfin)
NEW
25 Nm
(18 lbfft)
NEW
25 Nm
(18 lbfft)
NEW
12 Nm
(106 lbfin)
NEW
10 Nm
(89 lbfin)
NEW
25 Nm
(18 lbfft)
25 Nm
(18 lbfft)
25 Nm
NEW (18 lbfft)
10 Nm
NEW (89 lbfin)
smr2009-041-002_a
smr2009-041
439

GENERAL
NOTE: For a complete overview of the vehicle
electrical system, refer to POWER DISTRIBUTION subsection.
WARNING
SYSTEM DESCRIPTION
The intelligent suspension is a mechanical system
of two springs and one shock absorber installed in
the fixed deck connecting to the moving deck to
isolate the riders from the rough water.
sdd2009-001-206_b
1.
2.
3.
4.
Rear suspension arm

Front suspension arm
Springs
Shock absorber
An actuator is mounted underneath springs to

control the spring preload and therefore the suspension height.
smr2009-041-038_a
1. Springs
2. Actuator
smr2009-041-080
MOVING DECK
The iS module controls the electric motor of the

hydraulic pump to adjust the actuator height. It
also sets the suspension height according to the
active mode of operation and input signals.
sdd2009-001-202
FIXED DECK
smr2009-041-039_a
REAR STARBOARD SIDE

1. iS module
The iS module is programmed with various parameters that it compares to the input signals and information it obtains through the CAN bus from the
other electronic modules.
440
smr2009-041

The suspension can be set to the AUTO or MANUAL mode.

In AUTO mode, suspension height is factory
preset and the iS module constantly monitors
the stroke of the suspension and it automatically
readjusts suspension height for changing water
conditions and passenger load.
In MANUAL mode, the driver may choose to set
the suspension higher or lower by using the UP
and DOWN s on the handlebar.
A DOCK mode is available where the suspension
is set to its lowest position.
TROUBLESHOOTING
DIAGNOSTIC TIPS
It is important to determine first if the problem is
electrical or mechanical related. If you hear the hydraulic motor running when pressing the steering
suspension , check for related mechanical problem.
codes using B.U.D.S. software as a first troubleshooting step when suspecting an electrical
problem. Refer to COMMUNICATION TOOLS
connections first.

NOTE: Pressing the START/STOP button without
the D.E.S.S. key installed on its post will turn on
electrical power without starting the engine; the
information center will cycle through a self-test
function and shut off its display after a few seconds. However, the electrical system will stay
powered up for approximately three minutes after
the START/STOP button was depressed.
2. Install D.E.S.S. key to activate ECM and the information center when testing procedures require the device or system to be supplied with
electrical power.
NOTE: When using B.U.D.S.,briefly press the
START/STOP button to initiate back the communication after the electrical system has shutt off.
Circuit Testing
fuse tester or ohmmeter (relying solely on a
visual inspection could lead to an incorrect conclusion).

Clean pins properly and coat them with DIELECTRIC GREASE (P/N 293 550 004) or other appropriate lubricant (except if otherwise specified) when
reassembling them.
Pay attention to the ground wire connections are
clean, tight and free of corrosion.
SUSPENSION DOES NOT MOVE.

1. Check gauge display for iS informations.
- No information, refer to the diagnostic flow chart
(electrical) in this subsection.
- iS information appears, refer to the diagnostic
flow chart (hydraulic/mechanical) in this subsection.
SUSPENSION DOES NOT LOWER IN

DOCK MODE POSITION.
1. Something stuck under moving deck.
- Remove object(s) between moving deck and
fixed deck.
2. Vehicle is not level.
- Place vehicle level
3. Hydraulic fluid level to low.
- Refill hydraulic pump reservoir.
4. Shock absorber is damaged.
- Replace shock absorber.
smr2009-041
441

5. Leak on hydraulic circuit.

- Repair or replace defective part(s).
6. Faulty suspension position sensor.
- Test sensor and replace as required.
SUSPENSION BOTTOMS HARD.

1. Spring(s) out of specification or broken.
- Replace the defective spring(s).
7. Actuator is damaged.
- Replace the actuator.
2. Shock absorber is damaged.

- Check shock absorber resistance. Replace shock
absorber.
8. Hydraulic pump cannot build enough pressure.

- Replace hydraulic pump.
3. Bump stops damaged or worn.

- Replace both bump stops.
SUSPENSION MOVES ERRATICALLY.
SUSPENSION QUIT WORKING BUT

MAY OPERATES MOMENTARILY AFTER
RESTARTING THE ENGINE.
1. Defective shock absorber.

- Replace the shock absorber.
2. Broken spring(s).
- Replace spring(s).
SUSPENSION NOISE (DURING A TURN).
1. Hydraulic pump current draw is too high.

- Check hydraulic pump.
2. Internal problem inside iS module.
- Replace iS module.
1. Front or rear suspension arm shaft supports position.

- Supports must be leaned against both ends of
shaft. Reposition shaft in its supports.
2. Worn arm shaft bushings.
- Check front and rear arm shaft bushings condition
and replace as required.
3. Snap rings on both sides of the rear lower arm
shaft are not properly positioned.
- Reposition shaft in its supports.
SUSPENSION NOISE (FRONT OF SEAT).

1. Screws retaining holders are loosened.
- Tighten shock absorber and actuator holder
screws to recommended torque.
2. Shock absorber screws are loosened.
- Tighten shock absorber screws to recommended
torque.
3. Link under actuator holder loosened or not installed.
- Install link properly.
- Tighten bolts to recommended torque.
SUSPENSION IS LOWER THAN THE DOCK

MODE POSITION.
1. Spring (s) out of specification or broken.
- Replace the defective spring(s).
2. Bump stops damaged or worn.
- Replace both bump stops.
442
smr2009-041

DIAGNOSTIC FLOW CHARTS

iS Electrical Troubleshooting
Suspension does not move
NO
Can you see iS display?
Check CAN
bus
YES
Check for
hydraulic
or mechanical
problem, see is
hydraulic/mechanical
troubleshooting
flow chart
Can you hear the

hydraulic pump running
when pressing iS button(s)
on steering?
YES
NO
Suspension
moves?
YES
NO
Install the latest
version of B.U.D.S.
softward and
check fault codes
Is there a
fault code?
System is ok
YES
Follow service
action
NO
In B.U.D.S. activation
page, activate iS UP
and iS DOWN
buttons
Check the
suspension position
sensor and
the iS buttons
YES
NO
Suspension
moves?
YES
System is ok
Suspension moves?
NO
Suspension
moves? *
NO
Perform hydraulic
pump operation test
Perform iS
module test
YES
System is ok
Hydraulic pump
can be activated?
NO
* If all input voltage tests good but suspension

does not activate with switches but does with
B.U.D.S., suspect gauge issue.
Replace
hydraulic
pump
YES
NO
Suspension
moves?
YES
System is OK
smr2009-041-100_en
smr2009-041
443

iS Hydraulic/Mechanical Troubleshooting
Suspension does not move
Can you hear the

hydraulic pump running
when pressing iS button(s)
on steering?
Check for
an electrical
problem, see
iS electrical
troubleshooting
flow chart
NO
YES
NO
Level
vehicle
Is there something
stuck under
moving deck?
YES
Remove
object(s)
NO
Suspension
moves?
NO
NO
Is vehicle level?
YES
YES
YES
Check hydraulic fluid level
System is OK
Is fluid level good?
Suspension
moves?
System is OK
NO
Refill reservoir
YES
NO
Check for leak(s)
Suspension
moves?
YES
YES
Repair or replace
defective part(s)
Is there visual
leak(s)?
System is OK
NO
Suspension
moves?
NO
Replace hydraulilc
cylinder
Check hydraulic cylinder
YES
System is OK
Is cylinder good?
YES
NO
NO
Suspension
moves?
YES
Replace
hydraulic
pump
System is OK
smr2009-041-101_en
444
smr2009-041

PROCEDURES
SHOCK ABSORBER
Shock Absorber Removal
2. Remove tapes securing central bellows to
mounting plate.
3. Move down central bellows to reach shock
holder screws.
4. Remove and discard the four screws securing
the shock holder.
NOTE: Using lateral supports, raise front arm to
reach front screws.
smr2009-041-005_a
1. Shock absorber lower bolt (discard)

2. Shock holder
7. Detach the top of shock absorber from mounting plate. Discard bolt.
smr2009-041-006_a
1. Shock absorber upper bolt (discard)

2. Mounting plate
smr2009-041-003_a
1. Front retaining screws
Shock Absorber Inspection

NOTE: Because of gas pressure, strong resistance is felt when compressing shock.
To inspect shock operation, or if suspecting an internal leak between oil chamber and gas chamber,
check shock as follows:
1. Grab the shock absorber body firmly and press
the other end against the floor.
1.1 Verify the compression stroke when the
rod is fully extended.
1.2 Make sure that shock absorber rod can be
completely inserted in the shock body.
smr2009-041-004_a
1. Rear retaining screws
5. Remove shock absorber with mounting plate

and shock holder.
NOTE: Take care not to let the spring protector fall
into the hull.
6. Remove and discard the bolt securing shock absorber to shock holder.
smr2009-041-040_a
smr2009-041
445

2. The shock should extend unassisted. Rod must

come out at a steady speed.
If any problem is detected, replace the shock absorber.
Shock Absorber Installation

Secure the shock absorber using NEW bolts.
Tighten bolts to 75 Nm (55 lbfft).
Install NEW shock holder screws and tighten
them to 25 Nm (18 lbfft).
smr2009-041-090_a
1. Zone where presence of rust is normal
Check the curve line of long spring.

LONG SPRING SHAPE
Maximum
7 mm (9/32 in)
SPRINGS
Spring Removal
1. Remove SHOCK ABSORBER, see procedure in
this subsection.
2. Remove the spring protector, the long spring,
the spacer, the short spring and the spring
holder.
smr2009-041-041_a
A. 7 mm (9/32 in) maximum
Replace spring if out of specification.
Spring Installation
smr2009-041-007_a
1.
2.
3.
4.
5.
Spring protector
Long spring
Spacer
Short spring
Spring holder
Spring Inspection
Inspect both springs and replace if one of the following damage is detected:
Crack in the paint
Rust
Other visible damages.
Replace spring if one of these problems is detected.
NOTE: If rust is present ONLY on the first 1/4 of
coil, the spring should not be replaced.
446
SUSPENSION POSITION
SENSOR
The suspension position sensor is a potentiometer that sends a signal to the iS module which is
proportional to the front suspension arm angle.
NOTE: Prior to testing the sensor, ensure that
components of suspension are good and installed
correctly.
If a problem occurs with the suspension, several
fault codes pertaining to the suspension position
sensor will be generated. Refer to MONITORING SYSTEM AND FAULT CODES subsection for
more information.
smr2009-041

Suspension Position Sensor Input

Voltage Test
At Sensor Connector
SUSPENSION POSITION
SENSOR CONNECTOR
Pin 1
Pin 2
VOLTAGE
5 Vdc
295000136
5. Using the FLUKE 115 MULTIMETER (P/N 529 035

868), check voltage as per the following table.
Using the 6-pin Magneto Harness Tool

2. Using B.U.D.S., raise suspension in fully up position.
529035868
SUSPENSION
POSITION
(% in B.U.D.S.)
smr2009-041-053_b
ACTIVATION AND IS TABS

1. iS UP
2. iS down
NOTE: If the seat is moving up and the number

does not increase in B.U.D.S. but it is between 10
and 100%, check the suspension position sensor
fork.
3. Unplug the 6-pins connector from the iS module. The module is located in front of the battery in the same compartment.
MAGNETO
HARNESS
(wire lead color)
VOLTAGE
(Vdc)
All positions
BK
BK/YL
4.99
100%
WH
BK/YL
3.23
100%
BK
WH
1.75
88%
WH
BK/YL
3.09
88%
BK
WH
1.89
75%
WH
BK/YL
2.99
75%
BK
WH
1.98
53%
WH
BK/YL
2.81
53%
BK
WH
2.16
35%
WH
BK/YL
2.68
35%
BK
WH
2.30
6. Remove the 6-pin magneto harness tool.
Suspension Position Sensor

Resistance Test
smr2009-041-009_a
At iS Module Connector
868), check resistance values on iS connector
as per the following table.
1. Suspension position sensor connector on iS module
4. Connect the MAGNETO HARNESS 6 PINS

(P/N 295 000 136) to iS module for voltage
checks.
smr2009-041
447

529035868
smr2009-041-011_a
SUSPENSION
POSITION
(% in B.U.D.S.)
iS MODULE
(6-pin
connector)
RESISTANCE
All positions
1803 - 2203
100%
1957 - 2391
100%
1361 - 1663
88%
1904 - 2327
88%
1410 - 1724
75%
1871 - 2287
75%
1448 - 1770
53%
1799 - 2199
53%
1516 - 1852
35%
1752 - 2142
1. Sensor connector
2. Hydraulic pump reservoir
4. Remove screws securing the suspension position sensor.
smr2009-041-012_a
1. Retaining screws
35%
1565 - 1913
Suspension Position Sensor

Replacement
5. Remove bolts securing the sensor and its cover

to the sensor support and the sensor lever.
The suspension position sensor is located on suspension base, under the hydraulic pump reservoir.
subsection.
2. Remove the air intake tube. Refer to AIR INTAKE SYSTEM subsection.
3. Unplug the suspension position sensor connector.
smr2009-041-013_a
1.
2.
3.
4.
5.
6.
Retaining bolt
Sensor
Support
Lever
Cover
O-rings
NOTE: If water is present into sensor always replace sensor even if it seems in good condition.
6. Check condition of O-rings on sensor and sensor lever.
7. Reinstall all parts.
448
smr2009-041

NOTE: When reassembling parts, index sensor

lever shaft with sensor inner slot. The sensor
lever must be positioned to 180 with the sensor
electrical connector.
smr2009-041-055_a
Repeat the test using a test light.

TEST LIGHT POSITION
Pin 1 of
iS Module 6-pin
connector
smr2009-041-014_a
1. Lever
2. Lever shaft
3. Sensor
8. Reinstall and connect the sensor in vehicle.
iS MODULE
iS Module Overview
The iS module communicates via CAN protocol
with the multifunction gauge.
The iS module receives information from the multifunction gauge and a comparison is made with
the input from the suspension position sensor. If
the suspension is not in the proper position, the iS
module will then send an output signal to the hydraulic pump to either raise or lower the suspension to pre-programmed positions.
Negative
battery post
RESULT
Bright light
If the input voltage test is good, check the iS module input voltage (battery power).
If there is no voltage, check 5 A fuse (FB1, item
11) for voltage.
If the fuse is good and there is voltage present
at the fuse, check the continuity of the iS module
switched power wire.
Continuity Test of iS Module Switched

Power Wire
iS MODULE
6-PIN
CONNECTOR
FUSE BOX PIN

(FB1)
Pin 1
B3
RESISTANCE
.5
iS Module Input Voltage Test

(Switched Power)
Press the START/STOP button to activate the
electrical system.
Install the D.E.S.S. key.
MULTIMETER LEAD POSITION
Pin 1 of
iS Module 6-pin
connector
Negative
battery post
VOLTAGE
(VDC)
Battery voltage
smr2009-041-056_a
CONNECTOR PIN 1 TO FUSE BOX PIN B3
If the reading is not to specification, check the

wires, connectors and terminals from the iS module 6-pin connector to fuse box (FB1).
If the continuity test is good, check the iS module
input voltage test (battery power).
smr2009-041
449

iS Module Input Voltage Test

(Battery Power)
Continuity Test of iS Module Battery

Power Wire

iS MODULE
3-PIN
CONNECTOR
BATTERY
VOLTAGE
(VDC)
Pin 1
Positive post
Battery voltage
Pin 2
Negative post
Battery voltage
iS MODULE
3-PIN
CONNECTOR
FUSE BOX
(FB1)
Pin 2
A4
RESISTANCE
.5
smr2009-041-057_c
PIN 2 TO FUSE BOX PIN A4
FUSE BOX (FB2)

smr2009-041-057_a
PIN 1 TO BATTERY POSITIVE POST
A3
A4
FUSE BOX
(FB2)
STARTER
SOLENOID
A3
Battery terminal
connection
RESISTANCE
.5
RESISTANCE
.5
iS Module Output Voltage Test
smr2009-041-057_b
PIN 2 TO BATTERY NEGATIVE POST
Repeat the test using a test light.

iS MODULE
3-PIN
CONNECTOR
BATTERY
RESULT
Pin 1
Positive post
Bright light
Pin 2
Negative post
Bright light
At the 2-pin connector, connect multimeter leads.

Activate the iS either UP and DOWN with
B.U.D.S. or with iS button on steering.
There will be either a positive 12 Vdc or a negative
12 Vdc reading.
Activate the opposite UP or DOWN and the reading should reverse polarity.
If the test passes, perform the test again using
a 12 V test light to ensure the circuit can supply
enough current to operate the hydraulic pump.
The light should be bright in both the UP or DOWN
positions.
iS Module Removal
If there is nothing from pin 1 to positive battery
post, check engine ground.
If there is nothing from pin 2 to negative battery
post, check voltage at the 30 A fuse (item 16) in
fuse box 2 (FB2).
If the fuse is good and there is voltage present,
check the continuity of the iS module battery
power wire.
450
1. Open boarding platform and remove the starboard storage bin.

2. Disconnect the suspension position sensor
connector from the iS module.
smr2009-041

smr2009-041-037_a
smr2009-041-034_a
1. Suspension position sensor connector
3. Detach the retaining latch.
1. iS module input voltage connector
NOTE: The locking tab of input voltage connector

is located underneath.
6. Remove the iS module from vehicle.
iS Module Installation
iS BUTTON
iS Button Overview
smr2009-041-035_a
1. Retaining latch
4. Disconnect the hydraulic motor connector.
smr2009-041-036_a
1. Hydraulic motor connector
5. Disconnect the iS module input voltage connector.
smr2009-041
The iS button contain a series of 4 diodes for the

UP and DOWN arrow switches.
The center wire to the switches (pin C), is common for iS button and VTS button. The other two
wires (pins A and B), act as signal wires for each
set of switches to the gauge. They actually each
form one branch of an electronic circuit within the
gauge.
passes through all four diodes (if the iS switch
is open), a drop of 2.4 Vdc would be measured
across the 4 the diodes (pin B to pin C). This
2.4 Vdc at pin B tells the gauge the iS switch is
open.
If the iS UP switch is pressed, 2 diodes are bypassed. The remaining two diodes in the circuit
If the iS DOWN switch is pressed, 1 diode is bypassed. The remaining three diodes in the circuit
of its connector, and interprets them as signals
that tell it which switch is activated.
If the command generated by the closure of a
switch concerns the iS module, a circuit within
the gauge will translate it to CAN protocol and
451

transmit it through the CAN bus. The module will

react to the command, carry out the function, and
transmit the result back through the CAN bus.
The gauge will use the signals from the switches
and the transmitted information from the other
modules, convert them to an indication, and
cancel the command signal it sent out once the
function has been carried out.
Command signals from the iS button are translate
and sent to the iS module.
smr2009-042-002_a
1. Gauge connector
2. Slide out gauge connector tab to unlock

868) set to the diode test function, test the iS
Up or DOWN switches as per following tables.
NOTE: In diode test mode, the multimeter will
test the voltage drop through the diodes.
iS Button Operation Test

If iS UP or DOWN switches do not allow the selection, test the switches as follows:
Check the iS button operation using B.U.D.S.
AND B.U.D.S. SOFTWARE subsection to connect B.U.D.S.
Check if there is any occurred or active fault
code(s). If not, proceed with the following test.
Depress the iS UP switch on steering and check
if the suspension UP light turn on.
Repeat with the iS DOWN switch. Suspension
Down light should turn on.
vmr2006-020-005
smr2009-041-051_a
MONITORING AND CLUSTER TABS

1. Suspension UP light
If one switch does not function, replace iS button.

If both switches stay off, do the following to verify
the circuit.
1. Remove the gauge support cover.
452
smr2009-041

Hydraulic Pump Fluid Level

Verification
iS SWITCH TEST
SWITCH
POSITION
Switch
released
UP
depressed
DOWN
depressed
MULTIMETER
LEAD/GAUGE
CONNECTOR
VOLTAGE
RED lead/Pin 14
BLACK lead/Pin 15
Approx. 2 Vdc
BLACK lead/Pin 14
Red lead/Pin 15
OL
RED lead/Pin 14
BLACK lead/Pin 15
Approx.
1.1 Vdc
BLACK lead/Pin 14
RED lead/Pin 15
OL
RED lead/Pin 14
BLACK lead/Pin 15
Approx.
1.6 Vdc
BLACK lead/Pin 14
RED lead/Pin 15
OL
NOTE: Remember that each diode should drop

approximately 0.6 Vdc when positively biassed,
and read as an OL (open circuit) when negatively
biassed (leads reversed).
If, when measuring between pins 14 and 15 an
OL is obtained with both positive and negative
diode biassing, test the wiring harness continuity between the gauge and switch assembly. If
harness continuity is good, replace the switch
assembly.
If any reading is significantly different than listed,
carry out the same test at the switch connector,
refer to the wiring diagram. If you obtain the same
results, replace the switch assembly.
If voltages measured on every switch are as
listed in the previous tables (or very close to it),
the switches and the wiring harness are good.
The fault may be within the gauge, or in the circuit
or component the function applies to.
NOTE: The fluid level will drop slightly during

break-in period because the actuator uses a small
amount of fluid to lubricate its moving parts. If a
large amount of fluid is required, check components for leaks.
Reservoir in Vehicle
Place the vehicle level (longitudinally and transversally). Make sure suspension is in DOCK MODE
position.
The fluid should be near reservoir plug.
smr2009-041-043_a
1. Fluid level
Reservoir Out of Vehicle

Place the reservoir vertically.
Using a ruler, measure the fluid level. The
reservoir is full when fluid level reaches
130 mm 5 mm (5-1/8 in 13/64 in).
HYDRAULIC PUMP
Hydraulic Pump Recommended Fluid
Always use automatic transmission fluid (ATF)
Dexron III.
NOTICE To avoid serious damage to hydraulic pump and actuator, use only ATF
Dexron III. Do not use fluids other than the
recommended one, nor mix different types of
fluids for topping up.
smr2009-041-044_a
A. 130 mm 5 mm (5-1/8 in 13/64 in)
To Add Fluid
Remove the plug on the end of reservoir.
Using a syringe, fill up the reservoir to the recommended level.
smr2009-041
453

Reinstall reservoir plug and tighten it to 1 Nm

(9 lbfin).
If the current draw is excessive, replace the hydraulic pump.
Hydraulic Pump Operation Test
Hydraulic Pump Removal

(as a Unit with Actuator)
Connect a jumper from the positive (30 A fused

jumper) and negative side of the battery to the hydraulic pump connector (2-pins connector).
The hydraulic pump should activate and suspension should go up or down.
Reverse the jumpers and the suspension should
reverse direction.
If the hydraulic pump does not run, check connectors and wires. Replace hydraulic pump as required.
If hydraulic pump turns, perform the HYDRAULIC
PUMP CURRENT DRAW test to confirm pump operation.
To work on many parts of suspension system, the

removal of the hydraulic pump and actuator as an
unit is necessary.
1. Remove SHOCK ABSORBER and SPRINGS.
See procedures in this subsection.
2. Unplug the hydraulic pump connector from the
iS module.
3. Cut any locking ties securing the pump harness
to vehicle harness.
4. Remove clamp and bolt securing the hydraulic
pump from suspension base.
Hydraulic Pump Current Draw

If the current draw is to high, the iS module activates an internal protection.
This operation can be done using B.U.D.S. software. Refer to COMMUNICATION TOOLS AND
B.U.D.S. SOFTWARE subsection to connect
B.U.D.S.
Activate the suspension by pressing iS up and iS
Down s and check voltage.
smr2009-041-016_b
1. Hydraulic pump clamp

2. Retaining bolt
5. Remove actuator link bolt.
smr2009-041-053_a
ACTIVATION AND IS TABS

1. B.U.D.S. ammeter
2. iS UP
3. iS down
smr2009-041-029_a
CURRENT
iS UP
16 - 20 A
iS Down
15 - 18 A
1. Actuator link bolt

2. Link support on the top of suspension base
6. Remove screws retaining the actuator holder.
If values is near specifications, check connections

and wires.
If wires and connectors are good, perform the iS
module output voltage test. Refer to IS MODULE
in this subsection.
454
smr2009-041

smr2009-041-028_a
1. Actuator holder screws
7. Remove the suspension position sensor to

avoid damaging it.
8. Remove screws securing both rear ends of
front suspension arm to suspension base.
smr2009-041-045_a
VIEW FROM THE REAR OF VEHICLE

1. Secure hydraulic hose to hydraulic pump
2. Secure hydraulic hose, fuel hose and vehicle wiring harness
smr2009-041-046_a
VIEW FROM THE FRONT OF VEHICLE

1. Position both ends of hydraulic hose on same side
smr2009-041-027_a
1. Retaining screws
9. Lift the rear of the front suspension arm to

make room for hydraulic pump.
10. Remove hydraulic pump with actuator by
lifting them through the suspension bellows
opening.
Hydraulic Pump Installation

(as a Unit with Actuator)
following.
Make sure to secure the actuator link to suspension base. Tighten actuator link bolt to 25 Nm
(18 lbfft).
Install the FRONT SUSPENSION ARM. See procedure in this subsection.
Hydraulic Pump Removal

(Without Actuator)
subsection.
2. Remove the air intake tube. Refer to AIR INTAKE SYSTEM subsection.
3. Unplug the hydraulic pump connector from the
iS module.
4. Cut any locking ties securing the pump harness
to vehicle harness.
5. Cut locking tie securing the hydraulic hose to
pump.
NOTICE Failure to do so might result in

spring failure.
Hydraulic hose routing is very critical to avoid
problems with hydraulic unit. Use the following
illustration to route and attach the hydraulic hose
properly.
smr2009-041
455

smr2009-041-016_a

2. Hydraulic hose
6. Unscrew the retaining clamp completely and remove it.
smr2009-041-019_a
1. Socket screw
2. Hydraulic hose lock
9. Remove hose from pump and plug hose to

avoid oil spillage.
10. Place your finger on pump opening and remove pump from vehicle.
NOTE: Wipe any oil spillage.
Hydraulic Pump Installation

(Without Actuator)
smr2009-041-017_a
1. Install hydraulic hose on pump and secure hose

using the the hydraulic hose lock.
NOTE: The hose must turn freely. Do not inserted
hose into lock hook.
1. Retaining clamp
2. Hydraulic pump
7. Remove hydraulic pump retaining bolt.
smr2009-041-020_a
WRONG POSITION
smr2009-041-018_a
1. Retaining bolt
2. Hydraulic pump
8. At the bottom of pump housing, remove socket

screw securing hydraulic hose lock.
smr2009-041-021
RECOMMENDED POSITION

threads of lock screw.
3. Tighten screw to 8 Nm (71 lbfin).
456
smr2009-041

4. Secure hydraulic pump to suspension base.

4.1 Install pump retaining screw and tighten it
to 10 Nm (89 lbfin).
4.2 Install retaining clamp and tighten it to
2 Nm (18 lbfin).
5. Secure hose to reservoir with a new locking tie.
6. Route pump harness and secure it with new
locking ties.
7. Connect the hydraulic pump connector to iS
module.
8. Install a weight of 90 kg (200 lb) on moving
deck and using suspension controls on steering, cycle the suspension fully up and fully
down 3 times. This action will remove air
bubbles trapped into hose and pump during
installation.
9. Check for leaks.
10. Install all other removed parts.
smr2009-041-048_a
1. Retaining screws
2. Alignment support
4. Turn actuator up side down and remove hydraulic hose.
ACTUATOR
Actuator Inspection
Check actuator for leaks at hose opening and
around inner piston.
Replace actuator if any leak is detected.
Actuator Removal
1. Refer to HYDRAULIC PUMP REMOVAL (AS A
UNIT WITH ACTUATOR) and remove the pump
from the vehicle.
2. Remove and discard the screw securing actuator link to alignment support.
smr2009-041-049_a
1. Retaining socket screw

2. Hydraulic hose lock
5. Remove and discard the three socket screws

securing actuator holder halves and split the actuator holder.
smr2009-041-050_a
1. Socket screws
2. Actuator holder halves
Actuator Installation
smr2009-041-047_a
1. Actuator link
2. Retaining screw
3. Alignment support
Install hydraulic hose in accordance with the following illustration.
3. Remove the alignment support from actuator

holder. Discard screws
smr2009-041
457

smr2009-041-052_a
1. Hose fully inserted in lock slot

2. Position hydraulic hose in lock hook

threads of lock screw.
Tighten screw to 8 Nm (71 lbfin).
Install the hydraulic pump in vehicle. Make sure
to route the hydraulic hose properly. See HY-
DRAULIC PUMP INSTALLATION (AS A UNIT

WITH ACTUATOR) in this subsection.
Install a weight of 90 kg (200 lb) on moving deck
and using suspension controls on steering, cycle
the suspension fully up and fully down 3 times.
This action will remove air bubbles trapped into
hose and pump during installation.
Check for leaks.
smr2009-041-023_a
1. Lateral support screw
4. Remove lateral support from lateral bellows.
Lateral Support Installation

Apply soapy water solution on bellows opening
and insert the lateral support.
Index lateral supports with the front suspension
shaft ends. Lateral supports can be inserted in
one position only.
Tighten lateral support screw to 48 Nm
(35 lbfft).
Install a new Oetiker clamp. Position the ear of
clamp rearwards.
LATERAL SUPPORT
Lateral Support Removal
NOTE: The following instruction can be used for
RH or LH support.
2. Cut the Oetiker clamp retaining lateral bellows
to lateral support.
smr2009-041-066_a
RH SIDE SHOWN
1. Ear of clamp rearwards
LATERAL BELLOWS
Lateral Bellows Removal
1. Remove lateral support screw.
smr2009-041-022_a
1. Lateral support
2. Oetiker clamp
3. Remove the lateral support screw.

458
smr2009-041

smr2009-041-026_a
smr2009-041-024_a
2. Decouple lateral support from suspension

shaft.
3. Using the SUPERTITANIUM DRILL BIT 3/16"
(P/N 529 031 800), remove all rivets (12) securing the lateral bellows ring to body.
529031800
1. Ring pin
2. Bellows alignment hole
3. Body hole
Install new rivets. If the head of rivet tool cannot be inserted in ring opening, use the sleeve
(P/N 707 000 181) to offset the rivet tool and well
lean the rivet head against ring.
Index lateral supports with the front suspension
shaft ends. Lateral supports can be inserted in
one position only.
Tighten lateral support screw to 48 Nm
(35 lbfft).
Install a new Oetiker clamp. Position the ear of
clamp rearwards.
smr2009-041-025_a
1. Rivet location
4. Remove lateral ring.

5. Cut Oetiker clamp securing bellows to lateral
support.
6. Separate lateral support from bellows.
RH SIDE SHOWN
1. Ear of clamp rearwards
Lateral Bellows Installation
Front Suspension Arm Removal
Apply soapy water solution on bellows opening
and insert the lateral support.
Index suspension shaft with the lateral support.
The lateral support can be inserted in one position
only.
Install the retaining ring. Align the ring pin with
holes in bellows and body.

2. Remove the engine. Refer to ENGINE REMOVAL AND INSTALLATION subsection.
3. Remove both lateral support screws.
smr2009-041
smr2009-041-066_a
FRONT SUSPENSION ARM
459

2. Using a marker, trace the shape of suspension

base at the bottom of the hull to reposition it
at the same place.
3. Remove and discard suspension base screws.
smr2009-041-024_a
RH SIDE SHOWN
4. Decouple lateral supports from suspension arm

shaft.
5. Refer to HYDRAULIC PUMP REMOVAL (AS A
UNIT WITH ACTUATOR) and remove the pump
from the vehicle.
6. Remove screws securing both shaft supports
to suspension base.
7. Move front suspension arm rearward to remove it from the vehicle.
smr2009-041-031_a
STARBOARD SIDE
1. Suspension base screws
Front Suspension Arm Installation

If a shaft support has been loosen from the
suspension arm shaft, see SUSPENSION ARM
SHAFTS for proper installation procedure.
smr2009-041-032_a
PORT SIDE
1. Suspension base screws
4. Remove suspension base with the rear vent

duct.
smr2009-041-063_a
1. Shaft support (one on each side)
SUSPENSION BASE
Suspension Base Removal
smr2009-041-033_a
1. Suspension base
2. Rear vent duct
1. Refer to the appropriate procedures and remove the following parts:

Moving deck
Engine
Shock absorber and springs
Hydraulic pump (with actuator)
Suspension position sensor.
460
smr2009-041

Suspension Base Installation

1. Install the suspension base.
1.1 Position the base in accordance with the
reference marks previously drawn at the
bottom of the hull.
NOTE: If no marks are available, see SUS-
4.2 If required, move suspension base until

both distances are equal.
4.3 Tighten suspension base rear screws to
25 Nm (18 lbfft).
PENSION BASE INSTALLATION WITHOUT

REFERENCE MARKS.
1.2 Install NEW suspension base screws.
1.3 Tighten suspension base screws to
25 Nm (18 lbfft).
2. Refer to the appropriate procedures and install
all other removed parts.
Actuator and hydraulic pump
Front suspension arm
Engine
Moving deck.
Suspension Base Installation Without
Reference Marks
1. Install the suspension base in vehicle using
NEW screws. Do not tighten them yet.
2. Install the front arm on suspension base and
tighten screws to 25 Nm (18 lbfft), use the
OLD screws.
3. Install lateral supports.
3.1 Index lateral supports with the front suspension shaft ends. Lateral supports can
be inserted in one position only.
3.2 Tighten lateral support screws to 48 Nm
(35 lbfft).
4. Align suspension base in vehicle.
4.1 On both sides, measure the distance between the end of lateral support and fixed
deck.
smr2009-041-065_a
TIGHTENING SEQUENCE
5. Refer to the appropriate procedures and install

all other removed parts.
Actuator and hydraulic pump
Engine
Moving deck.
REAR SUSPENSION ARM

Rear Suspension Arm Removal
2. Remove bolts securing both rear suspension
arm covers.
smr2009-041-072_a
1. Rear suspension arm cover
3. Unclip and remove both lateral rear panels.
smr2009-041-064_a
A. Same distance on LH and RH sides

smr2009-041
461

NOTE: If the upper arm shaft or one of its arm

shaft support has been removed or loosened, refer to SUSPENSION ARM SHAFTS for proper installation procedure.
2. Tighten screws to 25 Nm (18 lbfft).
3. Carefully lower and secure the rear suspension
arm to the fixed deck.
3.1 Position the rear suspension arm brackets
in accordance with the reference marks
previously draw on fixed deck.
NOTICE If no mark was traced, refer to
smr2009-041-073_a
1. RH lateral rear panel
4. Mark position of rear suspension arm brackets

for proper reinstallation.
5. Remove and discard screws securing rear suspension arm to fixed deck.
REAR SUSPENSION ARM INSTALLATION

WITHOUT REFERENCE MARKS for proper
procedure to install and align the rear suspension arm.
3.2 Install NEW screws to secure rear suspension arm brackets.
3.3 Tighten screws to 25 Nm (18 lbfft).
Rear Suspension Arm Installation Without
Reference Marks
1. Lower the rear suspension arm on fixed deck.
2. Position the square openings of rear suspension arm brackets so that the threaded inserts
in fixed deck are centered.
smr2009-041-074_a
1. Rear suspension arm screws
6. Remove and discard screws securing the top of

rear suspension arm.
smr2009-041-076_a
1. Square opening
2. Threaded insert
smr2009-041-075_a
1. Retaining screws
7. Remove the rear suspension arm from vehicle.
Rear Suspension Arm Installation

1. Using NEW screws, install the top of rear suspension arm.
462
3. On each bracket, install the retaining plate and

one screw.
4. Install a weight of 90 kg (200 lb) on vehicle to
lower the moving deck.
5. Check moving deck position in comparison to
fixed deck.
5.1 Check the gap between moving deck
wipers and fixed deck. It should be the
same on both sides.
5.2 Check front and rear gaps. Moving deck
should be able to move without having
contact with the fixed deck.
smr2009-041

5.3 Reposition rear suspension arm brackets

on fixed deck until positioning of moving
deck is satisfactory.
6. Secure the rear suspension arm to the fixed
deck.
6.2 Remove and replace screws installed during alignment.
6. InstallNEW support screws and tighten them to

25 Nm (18 lbfft).
7. Secure both supports to shaft using NEW
socket screws. Tighten them to 12 Nm
(106 lbfin).
Removal of Rear Suspension Arm

Upper Shaft
1. Unclip and remove both lateral rear panels.
SUSPENSION ARM SHAFTS

Removal of Front Suspension Arm
Shaft
1. Remove the FRONT SUSPENSION ARM, see
2. Remove and discard socket screws securing
supports to shaft.
3. Separate arm shaft supports from arm shaft.
Installation of Front Suspension Arm

Shaft
1. To reinstall the shaft, insert it in the suspension
arm.
2. Install a support on each end of shaft.
3. Secure the LH arm shaft support to suspension
base using NEW support screws.
NOTE: Make sure to insert the support pin into
suspension base hole.
4. Tighten the LH support screws to 25 Nm
(18 lbfft).
5. Apply a force on the RH support to move it on
the left side.
NOTICE Make sure arm shaft is fully inserted,
it must lean against the arm shaft support.
smr2009-041-073_a
1. RH lateral rear panel
2. Remove arm shaft support screws.
smr2009-041-077_a
1. Arm shaft support screws

supports to arm shaft.
4. Separate arm shaft support from arm shaft.
Installation of Rear Suspension Arm

Upper Shaft
smr2009-041-067_a
1. Arm shaft against its support
smr2009-041
1. To reinstall the shaft, insert it in the rear arm.

2. Install a support on each end of shaft.
3. Secure the LH support to rear arm holder using
NEW support screws.
NOTE: Make sure to insert the support pin into
holder hole.
463

smr2009-041-078_a
1. Support pin
2. Holder hole
4. Tighten the LH support screws to 25 Nm

(18 lbfft).
5. Apply a force on the RH support to move it on
the left side.
NOTE: A bar clamp can be used to compress both
supports together.
NOTICE Make sure arm shaft is fully inserted,
it must lean against the arm shaft support.
smr2009-041-067_a
smr2009-041-079_a
1. Bar clamp
2. New socket screws
Removal of Rear Suspension Arm

Lower Shaft
arm covers.
smr2009-041-072_a
1. Arm shaft against its support
1. Rear suspension arm cover
6. Install NEW support screws and tighten them

to 25 Nm (18 lbfft).
7. Secure both supports to shaft using NEW
socket screws. Tighten them to 12 Nm
(106 lbfin).
3. Mark position of rear suspension arm brackets for proper reinstallation.

smr2009-041-074_a
1. Rear suspension arm screws
464
smr2009-041


rear brackets to arm shaft ends.
smr2009-041-071_a
1. Bad installation
2. Good installation
smr2009-041-069_a
1. Socket screw
2. LH rear bracket
6. Press one rear bracket against the suspension

arm bushing and remove the circlip. Repeat for
the other side.
3. Lower the rear suspension arm on fixed deck.

4. Tighten NEW socket screws to 10 Nm
(89 lbfin).
5. Refer to REAR ARM for reinstallation.
smr2009-041-070_a
1. Circlip
Installation of Rear Suspension Arm

Lower Shaft
1. When reassembly the rear bracket on shaft
end, press bracket on bushing to install the
circlip.
2. When both brackets are installed on shaft, pull
brackets outside to position circlips against
brackets.
smr2009-041
465
466

Subsection 02 (BODY)
BODY
SERVICE TOOLS
Description
Part Number
Page
SUPERTITANIUM DRILL BIT 3/16"................................................ 529 031 800 ......................................... 485
SERVICE PRODUCTS
Description
Part Number
Page
BRP PLASTIC & VINYL CLEANER ................................................ 413 711 200 ................................. 481482
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................... 468, 476, 482
GENERAL
Verify hinges condition and latching mechanisms
condition and operation. Replace any damaged
components.
complete procedure.
NOTICE When applying threadlocker products (anaerobic products), pay attention so
that it does not come in contact with ABS plastic parts (painted parts). It could lead to plastic
cracks or other damage.
WARNING
etc.) must be replaced with new one.
smr2009-042-078_a
4. Move bellows downward.

5. Unscrew gas shock from its upper attachment.
6. Remove gas shock from vehicle.
7. Align boarding platform hinge openings with flat
sides of fixed hinges.

PROCEDURES
BOARDING PLATFORM
Boarding Platform Removal
1. Unlatch the boarding platform.
2. Open boarding platform completely.
3. Cut locking tie retaining the bellows of gas
shock.
smr2009-042-037_a
1. Boarding platform hinge

2. Fixed hinge
8. Remove boarding platform.
Boarding Platform Installation

1. Remove gas shock attachment from boarding
platform.
smr2009-042
467


threads of shock absorber body.
3. Tighten manually the attachment on gas shock.
4. Install the bellows and secure it using a locking
tie.
5. Install the gas shock on cover.
NOTE: The corrugated section of bellows must
pointed downward.
6. Align boarding platform hinge openings with flat
sides of fixed hinges.
7. Push in the boarding platform to assemble
hinges.
8. Position the bottom of the gas shock on cavity
opening.
NOTICE To avoid breaking the attachment,
do not force to insert it in cavity.
SPLASH DEFLECTOR
Splash Deflector Removal
sdd2009-001-052_a
1. To remove the splash deflector, drill out the 4

rivets securing the splash deflector to the fixed
deck.
2. Pull the deflector from the fixed deck.
NOTICE A molded location pin at each end
of the deflector are each inserted into the fixed
deck. Be careful not to break them when removing the deflector.
Splash Deflector Installation

smr2009-042-038_a
1. Lower attachment on cavity opening
NOTE: Make sure upper attachment is properly

inserted in its slots.
1. Position the splash deflector over the forward

end of the fixed deck and press the guide pins
into the holes provided in the deck.
2. Install four new rivets to secure the deflector to
the deck.
DECK EXTENSION
smr2009-042-039_a
1. Upper attachment
9. Close boarding platform to lock the bottom of

the gas shock.
10. Lock boarding platform.
smr2009-042-009_a
1. Deck extension
Deck Extension Removal

1. Open seat.
2. Remove vent box.
468
smr2009-042

Deck Extension Installation

1. Position the deck extension.
2. Install screws retaining deck extension and air
inlet.
3. Tighten these screws to 1.5 Nm (13 lbfin).
NOTICE Do not tighten screws over this
recommended torque. Otherwise, the rubber
grommet could turns and screw will be hard
to remove.
smr2009-016-001_a
1. Vent box
3. Remove screws securing air inlet to deck extension.
4. Install coolant reservoir screws and tighten

them to 5 Nm (44 lbfin).
5. Reposition moving deck. Refer to MOVING
DECK in this subsection.
MOVING DECK
smr2009-042-008_a
1. Moving deck
smr2009-042-020_a
1. Air inlet retaining screws
4. Remove coolant reservoir screws.
smr2009-042-021_a
1. Coolant reservoir screws
5. Remove all screws retaining deck extension to

fixed deck.
6. Close seat.
7. Tilt the MOVING DECK, see procedure in this
subsection.
8. Remove the deck extension.
smr2009-042
The moving deck is comprised of:

Front storage cover
Front body module
Steering
Seat
Foot wells.
The moving deck is attached to the intelligent suspension and moves as a single unit.
The moving deck does not comprise the boarding
platform and the rear storage bins.
It is possible to tilt the moving deck for servicing
the watercraft, such as:
Deck extension removal
Working on air intake system
Suspension position sensor replacement
Suspension hydraulic pump replacement.
The moving deck removal is also required for major repairs, such as:
Engine removal
Suspension component removal (except suspension position sensor)
Fuel tank removal.
469

Tilting Moving Deck for Servicing

Watercraft
5. Lift the rear suspension arm against seat handle

and attach it with locking tie or strap.
1. Remove the BOARDING PLATFORM, see procedure in this subsection.
smr2009-042-012_a
ssi2009-002-002_a
1. Seat handle
2. Ski/wakeboard attachment
3. Locking tie

arm covers.
6. Install two pieces of wood (4 x 4) under moving deck front area as shown to avoid potential
damage when lifting the moving deck.
smr2009-042-010_a
1. Cover screws

smr2009-042-022_a
1. Pieces of wood
7. Place steering in its lower position.

8. Using suitable lifting devices, raise the rear of
moving deck to 340 mm (13-1/2 in).
smr2009-042-011_a
1. Rear suspension arm

2. Reinstallation marks
3. Screws (discard)
470
smr2009-042

Removing the Moving Deck for

Servicing Watercraft
front basket.
2. Remove the BOARDING PLATFORM, see procedure in this subsection.
smr2009-042-066_a
1. Hoist
2. Lifting strap
ssi2009-002-002_a

arm covers.
smr2009-042-023_a
1. Use this rivet as reference point

A. 340 mm (13-1/2 in)
NOTICE Lifting the rear of moving deck more

than the recommended height can damaged
the steering cable.
Lowering Back Moving Deck
1. Carefully lower and secure the rear suspension
arm to the fixed deck.
1.1 Position the rear suspension arm brackets
in accordance with the reference marks
previously draw on fixed deck.
NOTICE If no mark was trace, refer to IS
SUSPENSION subsection for proper pro-
smr2009-042-010_a
1. Cover screws

cedure to install and align the rear suspension arm.

2. Detach lifting device.
3. Remove pieces of wood located under the front
of moving deck.
smr2009-042
471

smr2009-042-011_a
1. Rear suspension arm

2. Reinstallation marks
3. Screws (discard)
6. Lift and attach the rear suspension arm against

seat handle.
smr2009-042-014_a
RH SIDE SHOWN
1. Front carpet (discard)
2. Protective cap
8.2 Remove and discard screws securing

moving deck to lateral supports.
smr2009-042-015_a
smr2009-042-012_a
1. Seat handle
2. Ski/wakeboard attachment
3. Locking tie
7. Manually, tip up the front of moving deck and

install a piece of wood (2 x 4) between fixed
deck and each lateral supports.
RH SIDE SHOWN
1. Retaining screws (discard)
9. Open seat.
10. Remove and discard M8 hexagonal screws
securing the suspension mounting plate and
moving deck.
smr2009-042-013_a
smr2009-042-016_a
FROM THE FRONT OF VEHICLE

1. RH lateral support
2. Piece of wood
1. Moving deck central screws (discard)
8. Detach moving deck from lateral supports.

8.1 Remove front carpet of foot wells and protective caps on both sides of the moving
deck. Discard the front carpets.
11. Close seat.

subsection.
13. Disconnect the four connectors under moving
deck.
472
smr2009-042

15. Install lifting straps.

15.1 Using both mooring cleats under steering, install two lifting straps.
smr2009-042-005_a
1. Disconnect these connectors
14. Detach steering cable from steering column.

14.1 Remove bolt securing ball joint to steering column.
smr2009-042-079_a
1. Front lifting strap hooks into steering mooring cleats
15.2 Install another lifting strap on seat handle.

16. Attach all lifting straps to an lifting device to
lift the moving deck. Make sure lifting device
is located at the center of the vehicle to rise
moving deck horizontally.
17. Raise moving deck slowly and drive steering
cable out of steering column.
18. Place the moving deck on a level surface.
Moving Deck Installation

smr2009-042-006_a
1. Install 2 pieces of wood under lateral supports.
1. Steering cable ball joint

2. Steering column
14.2 Remove bolts retaining steering cable

clamp.
14.3 Unlatch steering cable clamp.
smr2009-042-071
smr2009-042-007_a
1.
2.
3.
4.
Steering
Steering
Steering
Steering
column
column clamp bolts
column clamp
cable adjusting nut
14.4 Place steering in its lower position.

14.5 Free steering cable from fixed clamp.
smr2009-042
2. Slowly, lower the moving deck just enough to

able to insert the end of steering cable in steering column.
NOTICE Make sure not to pinch electrical harness while lowering the moving deck.
473

smr2009-042-074_a
1. Steering cable
2. Steering column
3. Install steering cable clamp and its bolts. Do

not tighten bolts yet.
smr2009-042-015_a
RH SIDE SHOWN
1. Retaining screws (new)
6. Remove pieces of wood located under lateral

supports and reposition one under moving deck
front area.
smr2009-042-007_a
1.
2.
3.
4.
Steering
Steering
Steering
Steering
column
column clamp bolts
column clamp
cable adjusting nut
4. Connect the four electrical connectors under

moving deck.
smr2009-042-090_a
1. Install piece of wood here
7. Remove the front lifting straps.

8. Open seat.
9. Raise rear of moving deck until suspension is
clear of moving deck.
NOTICE Make sure not to raise the rear of
moving deck more than 340 mm (13-1/2 in).
smr2009-042-005_a
1. Connect these connectors
5. Lower the front of moving deck and secure it

on both lateral supports using NEW screws.
smr2009-042-023_a
1. Use this rivet as reference point

A. 340 mm (13-1/2 in)
474
smr2009-042

10. Install two homemade alignment pins on suspension mounting plate.

10.1 Take two M8 x 50 bolts and cut their
heads.
10.2 Make into a round shape the cut ends.
16. Carefully lower and secure the rear suspension arm to the fixed deck.
16.1 Position the rear suspension arm brackets in accordance with the reference
marks previously draw on fixed deck.
NOTICE If no mark was trace, refer to iS
SUSPENSION subsection for proper procedure to install and align the rear suspension arm.
smr2009-042-073_a
10.3 Install alignment pins into the 2 rear outside positions of suspension mounting
plate.

17. Remove rear lifting strap.
18. Attach steering cable to steering column.
19. Install gauge support. Refer to GAUGE subsection.
20. Install NEW front carpets on foot wells and
protective caps on moving deck.
21. Check steering alignment then tighten steering clamp bolts. Refer to STEERING subsection.
CARPETS
Carpet Cleaning
To clean the carpets, use 3M Citrus Base
Cleaner or the equivalent. See the manufacturer's instructions.
Carpet Removal
smr2009-042-072_a
1. Alignment pins
11. Position the moving deck so that alignment

pins are aligned with suspension reinforcement plate holes.
12. Lower the moving deck over alignment pins.
13. Install NEW M8 hexagonal screws to secure
the moving deck to suspension mounting
plate.
NOTE: Remove the alignment pins only when 2
screws are engaged in mounting plate.
14. Tighten screws to 25 Nm (18 lbfft).
15. Close seat.
smr2009-042
Unstick a carpet corner.

Pull carpet vigorously to remove the carpet and its
glue from body.
To remove the remaining glue from body, use a
plastic or rubber spatula. Scrape remaining glue
with spatula.
NOTE: Do not use any products (alcohol, acetone, thinner, etc.) or heat the remaining carpet
glue. Chemical reactions make glue very hard to
remove.
Carpet Installation
Clean body surface with isopropyl alcohol and dry
thoroughly.
Install new carpet.
475

STORAGE COMPARTMENT
COVER
smr2009-042-029_a
1. Cover hinge key

2. Front body module slot
smr2009-042-024_a
1. Storage compartment cover
Storage Compartment Cover Removal

1. Open cover.
2. Cut locking tie retaining the bellows of gas
shock.
Storage Compartment Cover

Installation
Remove gas shock attachment from cover.
threads of shock absorber body.
Tighten manually the attachment on gas shock.
Install the bellows and secure it using a locking tie.
Install the gas shock on cover.
NOTE: The corrugated section of bellows must
pointed downward.
smr2009-042-028_a
3. Move bellows downward.

4. Unscrew gas shock from its upper attachment.
5. Remove gas shock from vehicle.
6. Open cover completely.
7. Align cover hinge keys with front body module
slots.
8. Pull up cover to remove it.
smr2009-042-030_a
1. Corrugated section
Install cover on vehicle.

NOTICE Make sure to insert cover hinges
completely. A click must be heard to indicate
complete insertion.
Position the gas shock lower attachment on cavity
opening.
NOTICE To avoid breaking the attachment,
do not force to insert it in cavity.
476
smr2009-042

3. Install the new mirror and tighten wing nut.

3.1 The mirror adjustment is correct
when the spring length is between
10 mm and 12 mm (13/32 in and 15/32 in).
smr2009-042-031_a
1. Lower attachment in its cavity
Close cover to lock the bottom of the gas shock.
MIRRORS
Mirror Replacement
1. Remove the mirror trim.
1.1 Using a small screwdriver, unlock both
front tabs securing the front of mirror
trim.
1.2 Tilt the trim forward and remove it.
smr2009-042-041_a
A. 10 mm to 12 mm (13/32 in to 15/32 in)
4. Install the mirror trim.

4.1 Install the front locating tabs.
smr2009-042-043_a
1. Front locating tabs

smr2009-042-042_a
1. Front retaining tabs

2. Side retaining tabs
3. Locating tabs
4.2 Down the rear part of trim. Lift up the rear

edge and press the center of trim to position retainers over front retaining tabs.
2. Unscrew wing nut and spring securing mirror.
smr2009-042-044_a
smr2009-042-040_a
1. Wing nut
2. Spring
3. Mirror
smr2009-042
1. Trim retainers
2. Retaining tabs
477

GLOVE BOX COVER
FRONT GRILLE
smr2009-042-055_a
1. Glove box cover
Glove Box Cover Removal

1. Move steering in its upper position.
2. Open glove box cover until cover hinges are
aligned with front body module openings.
smr2009-042-056_a
LOCATED UNDER STORAGE COMPARTMENT COVER

1. Front grille
Front Grille Removal

1. Remove the STORAGE COMPARTMENT
COVER, see procedure in this subsection.
2. Press on both tabs securing front grille to front
body module.
smr2009-042-025_a
1. Glove box cover hinge

2. Front body module opening
3. Pull the bottom of cover gently to release

hinges.
Glove Box Cover Installation

Reverse the removal procedure.
smr2009-042-054_a
1. Front grille
2. Retaining tabs
3. Remove grille.
Front Grille Installation

478
smr2009-042

BODY COVER
ssi2009-003-004_a
LH SIDE SHOWN
1. Remove this plastic push-in clip
smr2009-042-057_a
1. Body covers
Body Cover Removal
6. Open seat and using a 3/16" drill bit, drill the

rivets securing the seat trims.
1. Remove the STORAGE COMPARTMENT

COVER, see procedure in this subsection.
2. Remove the FRONT GRILLE, see procedure in
this subsection.
3. Remove the plastic push-in clip securing the upper trim.
ssi2009-003-008_b
LH SIDE SHOWN
1. Remove these rivets
ssi2009-003-002_a
LH SIDE SHOWN
7. Remove seat trim and drill the front rivet securing the body cover.
8. At the front of front body module, remove
screws or rivets retaining both body cover.
9. Unlock rear and center retaining tabs.
4. Move both upper trims rearward and remove

them.
smr2009-042-058_a
ssi2009-003-003_a
LH SIDE SHOWN
1. LH upper trim
RH SIDE SHOWN
1. Rear retaining tabs
5. Remove the plastic push-in clips retaining the

LH and RH trims.
smr2009-042
479

Storage bin
Glove box cover
Body covers and front grille
Steering and steering lock
Speed-Tie unit (if equipped).
2. Remove both screws and washers located between seat and glove box.
smr2009-042-059_a
RH SIDE SHOWN
1. Center retaining tab
10. Unlock the four retaining tabs securing the

front of body cover.
smr2009-042-061_a
1. Rear retaining screws
3. On each side of front body module, remove

both retaining screws.
smr2009-042-060_a
RH SIDE SHOWN
1. Front retaining tab
11. Remove body covers.
Body Cover Installation

FRONT BODY MODULE
smr2009-042-062_a
1. LH side retaining screws
4. At the front of body module, remove screws.
smr2009-042-065_a
1. Front body module
Front Body Module Removal

1. Refer to appropriate procedures and remove
the following parts:
Storage compartment cover
480
smr2009-042-063_a
1. Front retaining screws
5. Unlock retaining tabs.

smr2009-042

smr2009-042-064_a
1. Front body module retaining tabs
6. Remove front body module.
Front Body Module Installation

SEAT
Seat Removal
1. Open seat.
2. Attach the seat to support it during removal.
3. Remove Allen socket screw retaining the lateral
arm to moving deck (one each side).
smr2009-042-027_a
1. Central arm
2. Retaining bolts
5. Remove seat from vehicle.
Seat Installation
Install seat to central arm. Tighten bolts to 4 Nm
(35 lbfin).
Secure lateral arms to moving deck. Install parts
as shown.
smr2009-042-032_a
smr2009-042-026_a
1. Allen socket screw

2. RH lateral arm
4. Remove bolts securing the central arm to seat.
1.
2.
3.
4.
5.
Allen socket screw

Stainless steel flat washers
Sleeve
RH lateral arm
Rubber grommet in moving deck
Tighten screws to 1.5 Nm (13 lbfin).

NOTICE Do not tighten screws over this
recommended torque. Otherwise, the rubber
grommet could turns and screw will be hard
to remove.
Seat Cleaning
For general purpose cleaning, use BRP PLASTIC &
VINYL CLEANER (P/N 413 711 200), Vinyl Finish Vinyl
Cleaner, Fantastik or warm water with a mild dish
soap such as Dawn or Ivory. Gently scrub with a
small soft bristle brush.
smr2009-042
481

For dirt build-up, use BRP PLASTIC & VINYL

CLEANER (P/N 413 711 200), Vinyl Finish Vinyl
Cleaner or an equivalent. Let soak for approximately 10 minutes, then gently scrub with a soft
bristle brush. For specific stain removal, refer to
your cleaning and care card.
Do not use any silicone-based protectants. They
will extract the plasticizers, leaving the vinyl hard
and brittle, and eventually cracking will occur.
RECOMMENDED PRODUCTS
SEAT LATCH
BRP Plastic and Vinyl Cleaner

(P/N 413 711 200)
1.
Seat Latch Adjustment
2. Dish Soap (Dawn or Ivory)

3. Fantastik
4. 3M Citrus Cleaner
5. 303 Protectant
Vinyl Cleaning Recommendations for Special

Stains
TYPE OF
STAIN
STEP STEP STEP

1
2
3
Ballpoint ink*
Chewing gum
Coffee, tea,
chocolate
Pen
Grease
Household soil
Ketchup
Latex paint
Lipstick
Mildew or wet
leaves*
Motor oil
Oil-based paint
Permanent
marker*
Spray paint
Suntan lotion
Tar/asphalt
Yellow mustard
All cleaning methods must be followed by a thorough rinse with warm water.
Certain household cleaners, powdered abrasives,
steel wool and industrial cleaners can cause damage and discoloration and are not recommended.
Dry cleaning fluids and lacquer solvents should
not be used as they will remove printed pattern
and gloss. Waxes should be used with caution
as many contain dyes or solvents that can permanently damage the protective coating.
ACTION
NOTE: Apply LOCTITE 243 (BLUE) (P/N 293 800 060)

on threads of lock pin when the adjustment is required or when the lock pin is removed. If a new
lock pin is used, it is already coat with a threadlocker.
1. Loosen adjustment nut.
2. Adjust lock pin height. Do not torque yet.
3. Close and latch seat.
4. Pull lock pin rearward and tighten adjustment
nut.
A. Medium-soft brush,
warm soapy water,
rinse/dry.
B. Vinyl Finish Cleaner,

rinse/dry.
C. One (1) tablespoon

of ammonia, one-fourth
(1/4) cup of hydrogen
peroxide, three-fourth
(3/4) cup of water,
rinse/dry.
smr2009-042-033_a
1. Lock pin
2. Adjustment nut. Torque to 8 Nm (71 lbfin)
A. 32.0 mm 0.5 mm (1.26 in .02 in)
BUMPERS
D. Wipe or scrape off
excess (chill gum with
ice before hand).
Bumper Removal
Front Bumper
1. Remove both protective caps.
E. Denatured alcohol,
rinse/dry.
* Suntan lotion, tree pollen, wet leaves and some other

products can contain dyes that stain permanently.
482
smr2009-042

smr2009-042-045_a
smr2009-042-048_a
1. Front bumper
2. Protective caps
1. Rear bumper
2. Protective cap
2. Remove side screws securing front bumper to

body.
2. Remove side screws securing rear bumper to

body.
smr2009-042-046_a
smr2009-042-049_a
FROM RH SIDE OF VEHICLE

1. Front bumper
2. Retaining screw
3. Side bumper
FROM RH SIDE OF VEHICLE

1. Rear bumper
2. Retaining screw
3. Side bumper
3. Remove screws located under front bumper.
3. Remove screws located under rear bumper.
smr2009-042-047_a
UNDERNEATH FRONT OF VEHICLE

1. Retaining screws
4. Remove front bumper from vehicle.

Rear Bumper
1. Remove both protective caps (one on each
side).
smr2009-042
smr2009-042-050_a
1. Retaining screws
4. Remove rear bumper from vehicle.

Side Bumpers
1. Remove front and rear bumpers.
2. Using a marker, trace a line at bumper end's.
These marks will be used during installation.
483

smr2009-042-053_a
smr2009-042-051_a
1. Protective skin
1. Trace a line here
3. Pull the top of bumper to unclip it from body.

NOTE: A heat gun can be used to soften side
bumper.
4. Insert bumper over body lip.

4.1 Insert lower section first.
4.2 Insert upper section last.
smr2009-042-052_b
smr2009-042-052_a
Bumper Installation
Front and Rear Bumper
Tighten bumper screws to 5 Nm (44 lbfin).
Side Bumpers
1. Remove all remaining residues of the mounting
tape.
2. Clean bumper area using isopropyl alcohol.
3. Remove the protective skin on mounting tape.
1. Make sure bumper is positioned correctly
NOTE: A heat gun can be used to soften side

bumper.
SPEED-TIE UNIT
Front Speed-Tie Unit Removal
1. Open the glove box.
2. Remove the plastic push-in clip securing the LH
upper trim.
ssi2009-003-002_a
3. Move upper trim rearward and remove it.
484
smr2009-042

ssi2009-003-003_a
1. Upper trim
smr2009-042-034_a
4. Remove the plastic push-in clip retaining the LH

trim.
1. Retaining tabs
7. Using a small screwdriver, release both retaining hooks securing the cam trim on locking
mechanism.
ssi2009-003-004_a

ssi2009-003-015_a
5. Open seat and using the SUPERTITANIUM DRILL

BIT 3/16" (P/N 529 031 800), drill the rivet securing
the LH body cover and the seat trim.
529031800
1. Retaining hooks
8. Remove the four screws retaining the SpeedTie unit.

9. Position the reel of Speed-Tie unit to the bottom
of its cavity.
10. Remove the locking mechanism from vehicle.
11. Open storage cover and unlock the front tab
securing the LH trim.
ssi2009-003-008_a
1. LH body cover
2. Remove this rivet
3. Seat trim
6. Remove front trim by releasing both retaining

tabs.
ssi2009-003-009_a
1. Front locking tab
12. Unlatch the rear tab.
smr2009-042
485

smr2009-042-036_a
1. Retaining screws
4. Remove the Speed-Tie unit from vehicle.

ssi2009-003-010_a
1. Rear locking tab
Front Speed-Tie Unit Installation
13. Lightly pull the top of LH trim and remove the

reel of the Speed-Tie unit from its location as
shown.
1. Ensure both double cage nuts are correctly inserted into Speed-Tie unit cavities.
ssi2009-003-007_a
1. Double cage nut

2. Positioning tab
ssi2009-003-011_a
1. Speed-Tie unit reel
NOTICE During Speed-Tie unit removal, be

careful not to damage the LH trim.
2. Insert the Speed-Tie unit in vehicle.

2.1 Unlock the front tab securing the LH trim.
Rear Speed-Tie Unit Removal

1. Remove screws securing the Speed-Tie unit to
the boarding platform.
2. Remove rear trim by releasing retaining tabs.
ssi2009-003-009_a
1. Front locking tab
2.2 Unlatch the rear tab.

smr2009-042-035_a
1. Retaining tabs
3. Remove screws securing the locking mechanism to the boarding platform.

486
smr2009-042

5. Lift the lever and insert the locking mechanism

so that the lever is pointing toward the front of
vehicle.
ssi2009-003-010_a
1. Rear locking tab
2.3 Lightly pull the top of LH trim and insert

the reel of the Speed-Tie unit in its location
as shown.
NOTE: Insert the unit with the marking outside.
ssi2009-003-013_a
1. Locking lever
2. Rope
6. Align the reel with the locking mechanism

and secure them using four M6 x 45 tapered
screws.
7. Tighten
screws
to
4 Nm 1 Nm
(35 lbfin 9 lbfin).
ssi2009-003-011_a
1. Speed-Tie unit reel
NOTICE During Speed-Tie unit insertion,

be careful not to damage the LH trim.
3. To facilitate the locking mechanism insertion,
temporarily pull approximately 200 mm (8 in) of
rope between reel and locking mechanism.
4. Position the reel to the bottom of its cavity.
ssi2009-003-014_a
1. M6 x 45 tapered screws
8. Install the cam trim.

8.1 Insert both cam trim retaining hooks into
locking mechanism openings.
ssi2009-003-015_a
1. Retaining hooks
ssi2009-003-012_a
1. Push in the reel
smr2009-042
8.2 Press down the cam trim until it snaps into

place.
487

9. Install the front trim.

9.1 Insert top tabs and align lower tabs with
openings.
ssi2009-003-102_a
1. Locking lever
2. Boarding platform slot
4. Position a double cage nut on the locking mechanism.

ssi2009-003-016_a
1. Tabs
9.2 Press trim in place.

10. Test Speed-Tie operation.
11. Reinstall all removed parts.
Rear Speed-Tie Unit Installation

1. Lift up the boarding platform.
2. To facilitate the locking mechanism insertion,
temporarily pull approximately 200 mm (8 in) of
rope.
ssi2009-003-103_a
1. Double cage nut
5. Secure it using two M6 x 45 tapered screws.
ssi2009-003-104_a
ssi2009-003-101_a
1. Locking mechanism
A. 200 mm (8 in)
3. Insert the locking mechanism in boarding platform opening. Position the locking lever toward
the slot.
488
1. M6 x 45 tapered screws
6. Install the second double cage nut.

7. Secure the reel of the Speed-Tie unit on boarding platform using four hexagonal plastite
screws #10 x 7/8".
8. Tighten
screws
to
5 Nm 1 Nm
(44 lbfin 9 lbfin).
smr2009-042

ssi2009-003-109_a
1. Tabs
2. Alignment pin
ssi2009-003-105_a
1. Speed-Tie unit
9. Close boarding platform.

10. Tighten tapered screws securing the locking mechanism to 2.5 Nm 0.5 Nm
(22 lbfin 4 lbfin).
12.2 Press trim in place.

13. Test Speed-Tie operation.
Speed-Tie Unit Cleaning

A minimum of maintenance is required to keep
the Speed-Tie unit and the rope in serviceable condition.
Clean the locking mechanism and rope with fresh
water to remove salt, sand or other deposits.
NOTICE Do not use a high pressure washer
to clean the Speed-Tie unit.
Let dry.
Speed-Tie Rope Replacement

ssi2009-003-106_a
1. Remove the Speed-Tie unit from the vehicle.

2. Using a small tool, remove the rope cap.
11. Install the cam trim.

11.1 Insert both cam trim retaining hooks into
locking mechanism openings.
ssi2009-003-017_a
1. cap
2. Small screwdriver
ssi2009-003-107_a
3. Untie the knot and remove the button.
1. Retaining hooks
11.2 Press down the cam trim against boarding platform.

12. Install the rear trim.
12.1 Align tabs and alignment pin with corresponding openings.
smr2009-042
489

ssi2009-003-018_a
1. Untie this knot

2.
4.
Remove the locking mechanism and let the

rope retracts into housing.
5. Remove the back cover.
ssi2009-003-021_a
1. Retaining screw
8. Split the rewind unit and remove damaged

rope.
ssi2009-003-019_a
1. Back cover
2. Retaining screws
6. Remove the rewind unit.
ssi2009-003-020_a
ssi2009-003-022_a
9. Before discarding rope, remove and keep the

inner stopper.
ssi2009-003-023_a
1. Rewind unit
1. Inner stopper
7. Turn the unit upside down and remove the retaining screw.
10. Insert the inner stopper on new rope and tie

a knot near the end of the line. Position the
inner stopper in order to its flat side leans
against the knot.
490
smr2009-042

ssi2009-003-025_a
1. Inner stopper
A. 106 mm 6 mm (4-1/8 in 15/64 in)
11. On rewind unit base, identify the short tongue.
ssi2009-003-028_a
1. Cover notch
13.2 Press in the cover until both parts are

completely pressed together.
ssi2009-003-026_a
1. Short tongue
12. Install the rope end (with the knot) over the
short tongue as shown.
ssi2009-003-029_a
13.3 Install the retaining screw.
ssi2009-003-021_a
1. Retaining screw
ssi2009-003-027_a
1. Short tongue
13. Install the rewind unit cover.

13.1 Align the cover notch and the rope.
smr2009-042
13.4 Tighten screw to 1.1 Nm 0.1 Nm

(10 lbfin 1 lbfin).
14. Turn rope clockwise. Check indications on inner side of rewind unit.
491

ssi2009-003-030
15. Lock the end of rope as shown.
ssi2009-003-033_a
18. Unlock the end of the rope and pull it out by

the housing opening.
NOTE: Be careful not to release the rope and the
spring. Otherwise you will need to remove drum
and repeat the cranking operation.
19. Install locking mechanism and rope.
19.1 Pull out rope end.
19.2 Insert end of rope through locking mechanism.
ssi2009-003-031
16. Install rewind unit into housing.

16.1 Install the rewind unit with the retaining
screw downward. The end of rope must
be placed in front of the housing opening.
16.2 Insert spring in shaft notch.
ssi2009-003-034_a
19.3 Pass rope end through the rope button

and tie a knot on the rope end, see picture.
ssi2009-003-032_a
1. Spring in notch
NOTE: Ensure spring is properly inserted in

notch.
17. Using a screwdriver, crank rewind spring exactly 7 turns (clockwise).
ssi2009-003-035_a
1. Rope
A. 18 mm 6 mm (23/32 in 15/64 in)
19.4 Pull knot in the button and install the

button cap. Make sure cap is properly
snapped.
20. Install Speed-Tie cover. Tighten screws to
0.9 Nm 0.1 Nm (8 lbfin 1 lbfin).
492
smr2009-042

21. Check Speed-Tie operation.

22. Reinstall the Speed-Tie unit on vehicle.
DECALS
Decal Removal
Using a heat gun warm up one end of decal for a
few seconds until decal can roll off when rubbing
with your finger.
NOTE: When heating near light surfaces, duct
tape should be applied to protect the surface.
Otherwise the light color could become a yellowish color.
Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be
peeled off.
If decal tears while pulling off, it has to be heated
for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.
Decal Installation (With a Protective

Film on Back Side)
These decals usually contain written information
(e.g.: warning) and are used on gelcoat or metal.
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Using a pencil and the decal as a template, mark
the area where decal will be located.
Remove half of the decal back protective film and
align decal with marks. Start sticking it from center and remove the other half of the film to stick
it completely. Carefully squeegee decal beginning
at center and working outward using, firm, short,
overlapping strokes.
Decal Installation (With a Protective

Film on Both Sides)
These decals usually contain graphics and are
used on gelcoat or plastic.
Installation on Gelcoat
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Using a pencil and the decal as a template mark
For better adhesion a dry application is recommended, however, to ease decal installation a
mild solution of soapy water can be sprayed over
surface where decal will be installed.
smr2009-042
Remove back protective film from decal and align

decal with marks. When well aligned squeegee
decal beginning at center and working outward using firm, short, overlapping strokes.
Remove front protective film once decal has adhered to hull.
Installation on Plastic Surface (Storage Cover)
Clean surface with isopropyl alcohol and dry thoroughly.
Using a pencil and the decal as a template, mark
NOTICE Do not use soapy water to locate decal on plastic parts.
Remove back protective film from decal and carefully align decal with marks. When well aligned
squeegee decal beginning at center and working
outward using firm, short, overlapping strokes.
Remove front protective film once decal has adhered.
GELCOAT
The fixed deck of this Sea-Doo is constructed
of chopped fiberglass, saturated with resin. It is
sprayed on the layer of gelcoat along with pieces
of fiberglass mat, cloth and woven roving which
are added at required areas.
NOTE: For the hull, a different material is used.
Gelcoat Repair Information

NOTE: Fiberglass repair kit is available through
automotive or marine suppliers. Gelcoat repair
kits are available directly from Gelcote International Ltd.
Contact Information:
Gelcote International Ltd.
174 Colonnade Road Suite 29
Ottawa ON
Canada K2E 7J5
Phone: 613 225-2177
Toll Free: 877 435-2683
Email: [email protected]
493

WARNING
Protect skin, wear gloves when in contact
with resin, hardeners and gelcoat. A barrier
skin cream may also be used. Do not expose
area to open flame or lit cigarette. Some of
the materials are flammable. Protect eyes,
wear safety glasses when grinding, sanding
or spraying. Use a dust mask when sanding
or grinding. When spraying wear a respirator
or paint mask. Always read warning labels
on products.
TOOLS:
- Air mask
- Buffing pad
- Power sander
- Putty knife
- Cover sheets
- Heavy-duty polisher
- Safety glasses
Paint brush
Plastic container (mixing)
Plastic film
Plastic squeegee
- Sanding block
Scissors
Spray gun
Stirring stick
White cloths
MATERIALS:
- Acetone
- Cabosil
- Cardboard
- Fine compound
(white)
- Fiberglass cloth
- Epoxy filler
- Masking tape
- Liquid gelcoat
- Medium compound
(white)
- Polyester resin
- Fiberglass mat
- 24-grit sanding disks
- Gelcoat putty
- Wax
- Sandpaper
(100-grit, 220-grit, 320-grit, 400-grit, 600-grit, 1000-grit)
Air Bubbles Repair

Possible cause:
Air pocket trapped between layers of laminate
and gelcoat.
Preparation of Surface
Remove all of the damaged gelcoat surrounding
the air bubble with a putty knife or preferably a
carbide grinding tip. Make sure all loose and weak
areas are completely removed. Sand a small area
of the gelcoat surface with 220-grit sandpaper. If
needed, sand the cavity itself. These areas must
have a rough surface to allow the gelcoat putty to
bond properly.
494
Filling the Cavity

The prepared surface must be cleaned with acetone on a cloth. Use a gelcoat repair kit. Follow
the mixing instructions in the kit when preparing
the gelcoat putty.
Carefully mix the required amount while making
sure there are no air bubbles in the mixture. With
a putty knife, fill the repair area and cover with
plastic film. Curing time may depend on temperature, amount of putty and percentage of catalyst.
After 2 hours, press lightly on the surface with
fingers to test the hardness. When the area becomes hard, remove the plastic film.
Sanding
Begin block sanding the patch with 320-grit sandpaper until you come close to the original surface.
Remove dust with a water soaked cloth and continue sanding with a 400-grit wet paper. Finish
wet sanding with a 600-grit to remove deeper
scratches. If needed you can wet sand with finer
grit paper such as 1000-grit.
Buffing and Waxing
Buff the surface using a heavy duty polisher with
a buffing pad. Make sure the pad is free of dirt
or you may damage the gelcoat. Carefully begin
buffing with a white medium compound. Finish
off using a fine compound. While buffing, pay
close attention to avoid overheating the surface.
Blisters Repair
Possible causes:
Insert catalyst
Improper catalyst/gelcoat ratio.
A blister is a visible bump on the watercraft surface that may not necessarily come right through
the gelcoat layer. In the case of only a few blisters, follow the same repair procedure as for air
bubbles. If they are numerous and in close concentration, spray liquid gelcoat to achieve proper
repair. This procedure is covered in MINOR GELCOAT FRACTURES.
Minor Gelcoat Fractures Repair

Possible causes:
Flexing of fiberglass laminate
Gelcoat thickness
Direct result of impact.
In case of fractures which have not penetrated
past the gelcoat layer, the repair concerns the gelcoat only. If flex cracking or impact are evident,
smr2009-042

then additional reinforcement may be necessary.

This subject will be covered in COMPOUND
FRACTURES.
buffing with a white medium compound. Finish

off using a fine compound. While buffing, pay
close attention to avoid overheating the surface.
Preparing the Surface

Small Fractures: Open the cracks up with a
sharp triangular can opener or preferably a carbide tipped die grinder. The V groove will provide
a good bonding area for the gelcoat. With 220-grit
sandpaper, sand the sides of the notched out areas.
Numerous Fractures: Using a grinder with a
24-grit disk, remove the gelcoat. Sand the area
edge with 220-grit sandpaper.
Compound Fractures Repair
Filling the Repair Area

Small Fractures: Refer to the same procedure as
in the AIR BUBBLES.
Numerous Fractures Over Large Surface: Prepare the area for spray application of liquid gelcoat. Wipe down the surface with acetone. Mask
the area off to protect the watercraft from overspray.
Mix the needed quantity of gelcoat and catalyst
according to suppliers recommendations. The
gelcoat can be thinned with acetone up to 10%.
If it needs more consistency you can add cabosil.
Make sure that the air supply is free of oil, dirt and
water.
Test spray the gelcoat mixture on paper to verify
its consistency and pattern. You may have to apply 5 or 6 coats to cover the area properly. Overlap each coat further than the last, leaving at least
30 seconds between passes. Avoid trying to coat
the surface with only a few heavy coats, this will
not allow the gelcoat to dry properly.
Apply a coat of polyvinyl alcohol (PVA) to seal off
the air and protect the gelcoat surface from dust.
PVA speeds up the curing process because gelcoat will not cure properly when exposed to air.
Sanding
Wash the polyvinyl alcohol off with water. Depending on the size of the area repaired, you
can either block sand as per previous procedure
or you may use an air sander. Sand the surface
down with progressively finer grits of sandpaper
until the desired finish is achieved.
Buffing and Waxing
Buff the surface using a heavy duty polisher with
a buffing pad. Make sure the pad is free of dirt
or you may damage the gelcoat. Carefully begin
smr2009-042
Possible causes:
Thickness of fiberglass laminate
Direct result of impact.
Compound fractures are those that have gone
past the gelcoated surface and in through the layers of fiberglass laminate. Two types of repairs
have to be performed. The first is to restore the
structural integrity of the damaged area. Fracture
types can vary from a simple crack to a large
hole. Usually, fiberglass reinforcement becomes
necessary, especially if the fracture can be attributed to weakness. The final part of the repair
is the gelcoating, which cannot be done until the
interior and exterior laminate surfaces have been
repaired.
Outside: Remove the damaged gelcoat and fiberglass with a 24-grit disk using a power sander.
Grind outward at least 2 inches from the fracture
to allow the patch to bond to strong material.
Cut enough pieces of fiberglass mat necessary
to build up the area. The pieces should be cut
so they overlap each other by at least a half inch.
For a smoother finish, the last layer should be
fiberglass cloth. If the fracture is small enough all
you may have to do is fill the area with an epoxy
filler.
Inside: For the interior repair, you can grind more.
This will allow for more fiberglass material which
will strengthen the area. If the fracture opening is
too large after surface preparation, you may need
a backing support to cover the opening. Cut alternating pieces of fiberglass mat and cloth in overlapping sizes.
Patching the Repair Area
Outside: The outside should be done first. Wipe
clean the area with acetone on a cloth, then mask
off area. For a small crack use an epoxy filler in
the same way you would use gelcoat repair putty.
When laying up a larger area you will use mat,
cloth and fiberglass resin and catalyst. Use a clean
container to mix the resin, mix only what you will
need. Follow the recommended catalyst ratio.
Using a clean paintbrush, brush the mixed resin
on the surface. Place the smallest piece of mat
over the fracture and then wet out the mat. Follow with the remaining pieces of mat and final
layer of cloth. While wetting the pieces make sure
you work the air bubbles out and saturate all the
495

pieces evenly. Try to work quickly, you may only

have 15 or 20 minutes. You may clean the brush
with acetone.
Wait until the repair has hardened before moving
on to the interior repair. If the size of the opening
is too large for the pieces to maintain the proper
shape, you will have to use a backing support. It
is a shaped piece of cardboard that fits flush to the
interior surface and has a plastic layer on the repair
side. It is held in place by tape or a support.
Inside: Wipe down the area with acetone on a
cloth. Apply the same procedure as for outside
repair when laminating the alternating pieces
of fiberglass material. If a backing support was
used, remove it before starting the repair. After
the area has hardened, remove sharp edges of
material from surface. If required paint the surface.
Sanding
Outside: This surface will have to be prepared for
application of gelcoat. The size of the area will
determine the gelcoating procedure to be used.
Refer to the MINOR GELCOAT FRACTURES REPAIR.
Buffing and Waxing
Refer to the BUFFING AND WAXING in MINOR
GELCOAT FRACTURES REPAIR.
496
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Subsection 03 (HULL)
HULL
SERVICE PRODUCTS
Description
Part Number
BRP HEAVY DUTY CLEANER .......................................................

LOCTITE 5150 (SILICONE SEALANT) ...........................................
LOCTITE 577 (THREAD SEALANT) ...............................................
LOCTITE 5900 ...............................................................................
293
293
293
293
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110
800
800
800
001
086
050
066
Page
......................... 502503, 505

................................. 508509
......................................... 507
......................... 502503, 505
497

Hull
NEW
14.5 Nm
(128 lbfin)
Hull
Loctite 5150
(silicone
sealant)
NEW
14.5 Nm
(128 lbfin)
Loctite
5150
(silicone
sealant)
50 Nm
(37 lbfft)
25 Nm
(18 lbfft)
25 Nm DEVCON
(18 lbfft) HP250Q
DEVCON
HP250Q
DEVCON
HP250Q
25 Nm
(18 lbfft)
Loctite 577
(thread sealant)
16 Nm
(142 lbfin)
Loctite
5900
25 Nm
(18 lbfft)
Loctite 5150
(silicone
sealant)
10 Nm
(89 lbfin)
NEW
14.5 Nm
(128 lbfin)
GTX
Limited
iS
model
9 Nm
(80 lbfin)
DEVCON HP250Q
25 Nm (18 lbfft)
(inside hull)
DEVCON HP250Q
25 Nm (18 lbfft)
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498
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All Models
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
Loctite 5900
(300 ml)
7 Nm
(62 lbfin)
NEW
35 Nm
(25 lbfft)
NEW
35 Nm
(25 lbfft)
Loctite 5900
(300 ml)
NEW
35 Nm
(25 lbfft)
Loctite 567
pipe sealant
(250 ml)
8 Nm
(71 lbfin)
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499

GENERAL
Verify condition and operation of hinges and latching mechanisms. Replace any damaged components.
and service products as specified in the exploded
views.
complete procedure.
smr2009-043-013_a
NOTICE When applying threadlocker products (anaerobic products), pay attention to

prevent the product from coming into contact
with ABS plastic parts (painted parts). Plastic
parts may develop cracks or other damages,
and finished or painted surfaces may become
damaged.
WARNING
1. Inlet grate screws

2. Inlet grate
NOTICE An impact screwdriver should be

used to loosen screws.
Inlet Grate Installation

When installing inlet grate, install NEW screws
with Scotch Grip.

PROCEDURES
INLET GRATE
Inlet Grate Removal
1. Remove inlet grate retaining screws using an
impact tool and remove inlet grate. Discard the
retaining screws.
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1. M8 x 40 screw
2. M8 x 20 screws
Follow this sequence referring to the illustration:

1. Hand tighten inlet grate screws., then torque
screws to 35 Nm (26 lbfft) as per sequence in
2
3
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INLET GRATE TORQUE SEQUENCE
500
smr2009-042

RIDE PLATE
Ride Plate Removal
NOTE: The jet pump support and ride plate must
be removed as an assembly. The pump support
is fastened to the ride plate and the forward pump
support mounting screws cannot be accessed
when the ride plate is installed.
NOTICE If the ride plate is replaced, or
removed and installed, the engine/driveshaft/pump alignment must be checked. Refer
to ENGINE REMOVAL AND INSTALLATION.
1. Remove iBR gate and VTS trim ring, refer to iBR
AND VTS subsection.
2. Remove jet pump and nozzle, refer to JET
PUMP subsection.
3. Drain cooling system, refer to COOLING SYSTEM subsection.
4. Remove the battery from the watercraft, refer
to CHARGING SYSTEM subsection.
5. Move the electrical accessories support and
electrical harness above and to the right of the
resonator box for improved access to the ride
plate coolant hoses and fittings.
6. Reach in between the exhaust system resonator and hull to loosen the gear clamps and
disconnect both coolant hoses from the ride
plate.
smr2009-043-014_a
1. Hose fittings
NOTICE Removing the hose fittings from the

ride plate prior to removing the ride plate prevents the possibility of damaging or breaking
the fittings. If fittings cannot be removed before ride plate removal, carefully remove the
ride plate with the fittings still installed, while
paying particular attention to the hose fittings
at the forward end of the ride plate.
9. Remove INLET GRATE, see procedure in this
subsection.
10. Using an impact tool, remove and discard ride
plate retaining screws.
smr2008-036-008_a
TYPICAL
1. Ride plate screws
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11. Install a low height hydraulic bottle jack and 2

steel plates between ride plate and hull as per
1. Exhaust system resonator

2. Gear clamps
3. Coolant hoses
7. Remove excess sealant from around the

coolant hose fittings.
8. Unscrew both hose fittings from the ride plate.
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501

Ride Plate Installation

1. Install the jet pump support on the ride plate,
see procedure in this section.
NOTE: The jet pump support must be installed on
the ride plate before installation of the ride plate
on the watercraft.
2. Reinstall hose fittings on ride plate and torque
to 7 Nm (62 lbfin).
3. Apply LOCTITE 5900 (P/N 293 800 066) sealant on
ride plate and jet pump support circumference
as seen in the following illustration.
smr2009-043-036_a
TYPICAL
1. Hydraulic bottle jack
2. Steel plates
12. Heat edge of ride plate and the inside diameter of the pump support with a heat gun to
soften the sealer before prying the ride plate
and pump support off the watercraft.
smr2009-043-018
LOCTITE 5900 SEALANT APPLICATION
smr2009-043-017_a
APPLY HEAT HERE
13. Using a sharp knife, carefully cut the sealant

around the ride plate edges.
14. Pump the hydraulic jack slowly to pry the ride
plate from the hull.
NOTE: If the ride plate needs to be taken apart,
the jet pump support must be removed from the
ride plate to access the screws at the forward end
of ride plate.
4. Remove all excess sealant from ride plate

mounting holes. Pay particular attention to the
RH forward mounting hole.
5. Position ride plate on hull and engage NEW M8
screws with Scotch grip 5 turns by hand.
6. Position inlet grate and engage NEW retaining
screws 5 turns by hand. Refer to INLET GRATE
in this subsection.
7. Push ride plate completely forward and torque
ride plate screws to 35 Nm (26 lbfft) as per
following torque sequence.
502
17
Ride Plate Cleaning

1. Carefully scrape off all excess sealant from ride
plate and hull.
2. Clean hull surface with BRP HEAVY DUTY
CLEANER (P/N 293 110 001) to eliminate grease,
dust and sealant residue. Clean fitting threads.
28
4
smr2009-043-015_b
TYPICAL
8. Torque inlet grate screws. See INLET GRATE

INSTALLATION in this subsection.
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9. Reinstall coolant hoses on ride plate fittings,

pay attention to gear clamp positioning. See
3. Sealant is applied between the jet pump support and the ride plate. Using a heat gun, heat
the base of the pump support to soften the
sealant and carefully pry the pump support off
the ride plate.
smr2009-043-016_b
1. Gear clamp positioning
10. Install jet pump, refer to the JET PUMP subsection.

11. Install iBR gate and VTS trim ring, refer to the
IBR AND VTS subsection.
12. Install battery and electrical accessories support, refer to CHARGING SYSTEM subsection.
13. Refill cooling system and carry out a leak test.
Refer to COOLING SYSTEM subsection.
14. Install all remaining parts in the reverse order
of removal.
JET PUMP SUPPORT

Jet Pump Support Removal
1. Remove the inlet grate and ride plate, see procedures in this subsection.
2. Remove the four screws retaining the pump
support to the ride plate.
smr2009-043-019_b
APPLY HEAT HERE
Jet Pump Support Cleaning

1. Scrape off all excess sealant from jet pump support, ride plate, and hull.
2. Inspect pump support for cracks and other
damages. Replace as necessary.
3. Clean jet pump support and hull surface with
BRP HEAVY DUTY CLEANER (P/N 293 110 001) to
eliminate grease, dust, and sealant residue.
Jet Pump Support Installation

1. Ensure sealant contact areas are clean and dry.
2. Apply LOCTITE 5900 (P/N 293 800 066) on the ride
plate and pump support as seen in the following
illustrations.
smr2009-043-021_a
smr2009-043-019_a
1. Apply loctite 5900 here
TYPICAL - TOP VIEW RIDE PLATE AND PUMP SUPPORT

1. Pump support retaining screws
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503

Thru-Hull Fitting Removal

Inner Fitting Removal
1. Remove drive shaft, refer to DRIVE SHAFT subsection.
2. Using a heat gun, heat the glue at the joint between the hull and the inner thru-hull fitting to
soften the glue applied.
smr2009-043-020_a
1. Apply loctite 5900 here (underside of pump support)
3. Torque jet pump support screws as specified in

exploded view.
smr2009-043-022_a
1. Heat here
3. Carefully remove overlapping glue from around

the inner fitting.
smr2009-043-019_a
1. Torque pump support screws (4x)
4. Remove any excess sealant from the right hand

forward ride plate mounting hole.
5. Reinstall all removed parts in the reverse order
of removal. Refer to appropriate subsections
for procedures.
THRU-HULL FITTING
The thru-hull fitting is composed of 2 pieces, an
outer fitting, and an inner fitting that screws onto
the outer fitting after the outer fitting is inserted
in the hull.
smr2009-043-031_a
1. Inner thru-hull fitting (overlapping glue removed)
4. Unscrew the inner fitting from the outer fitting

using a 65 mm (2.56 in) socket.
Outer Fitting Removal
1. Carefully cut sealant around the edge of the
outer fitting (jet pump side).
smr2009-043-024_a
1. Outer fitting
2. Inner fitting
504
smr2009-042

2. Insert the outer fitting into the hull from the jet
pump side of the hull towards the inside. Ensure fitting is pushed in against the hull.
3. Continue with INNER FITTING INSTALLATION
procedure.
Inner Fitting Installation
1. Apply DEVCON HP 250 Q completely around
the joint where the outer fitting comes through
the hull.
smr2009-043-023_a
TYPICAL
1. Cut sealant around outer fitting here
2. Heat the inside of the outer fitting to soften the

sealant and help break the bond between the
hull and fitting.
3. Using a rubber mallet (or a hammer and a
wooden block), hammer the outer fitting from
the inside of the hull towards the outside, until
it is flush with the hull.
4. Reach in through the pump support and pull the
fitting out of the hull.
Hull Cleaning for Thru-Hull Fitting Installation
1. Scrape off all excess sealant from the hull on
the outer fitting side.
2. Remove excess glue from the hull on the inner
fitting side.
3. Clean hull surface with BRP HEAVY DUTY
CLEANER (P/N 293 110 001) to eliminate grease,
dust, and sealant residue.
NOTE: Use only a clean, dry, oil free filtered air
supply for dusting and drying parts or hull.
smr2009-043-030_a
1. Apply glue here
2. Screw the inner fitting onto the outer fitting and

torque as specified in the exploded view.
3. Using a tongue depressor (or popsicle stick),
smooth out glue over the hull and inner fitting
joint.
Outer Fitting Installation

1. Apply a bead of LOCTITE 5900 (P/N 293 800
066) sealant completely around the outer edge
of the fitting (pointed end), and another bead
across the top of the fitting.
smr2009-043-022_a
1. Smooth out glue here over edge of inner fitting
4. If the outer fitting was replaced, ensure it is

properly seated against the hull in the jet pump
area. Remove excess sealant at the joint between the outer fitting and hull.
smr2009-043-029_a
1. Apply Loctite 5900 here
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505

The bailer pick ups are connected through a hose

system to two syphon tubes mounted in the jet
pump venturi that draw the water out of the bilge
through the bailer pick ups. The bailers are also
connected to the bilge drain plugs in the stern.
Bailer Pick-Up Inspection
smr2009-043-023_a
TYPICAL
1. Fitting properly seated, excess sealant removed
1. Open boarding platform and remove the storage bins.

2. Inside hull, check holes in the bailer pick-ups to
see if they are obstructed. Clean if necessary.
NOTE: On the port side (LH), the bailer is located
below the iBR actuator.
SPONSON
NOTE: Removal and installation procedure for RH
and LH sponson is the same.
Sponson Removal
Unscrew sponson retaining screws, then remove
sponson.
smr2009-043-006_c
TYPICAL - LEFT SIDE SHOWN (IBR ACTUATOR REMOVED)

1. Bailer assembly
NOTE: On the starboard side (RH), the bailer is

located between the battery support base and the
hull (jet pump tunnel).
smr2005-024-014_a
TYPICAL
1. Sponson
2. Bolts
Sponson Installation
1. Install the spacers in the holes provided in the
sponson on the hull side of the sponson. See
exploded view.
2. Thread a screw with washer through each hole
and install sponson on watercraft. Torque sponson retaining screws as specified in exploded
view.
BAILER SYSTEM
smr2009-043-035_a
1. Starboard bailer
3. Check if the hole on each bailer hose elbow fitting is obstructed. Clean both elbow fittings if
necessary.
Two bailer pick ups (one each side), serve to drain

the bilge of the watercraft when it is in operation.
506
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smr2009-043-032_a
smr05-005-001_A
1. Elbow fitting holes
DRAIN PLUGS
NOTE: The two drain plugs on the stern are each
connected to a bailer. When watercraft is on dry
land, the drain plugs can be removed to manually
drain the bilge.
DRAIN PLUG REMOVAL

1. Drain plug
2. Drain neck
4. Using a ratchet handle and extension of appropriate size, unscrew the drain neck from the
hull.
Drain Plug Neck Removal

1. Open the boarding platform and remove the
rear storage bins (one each side).
2. Cut locking tie securing bailer hose to the drain
plug assembly.
smr2009-043-033
DRAIN NECK REMOVAL
Drain Plug Neck Installation
smr2009-043-034_a
LEFT SIDE SHOWN (IBR ACTUATOR REMOVED)

3. Unscrew the drain plug from the drain neck and

pull the drain plug out or the neck.
1. Apply LOCTITE 577 (THREAD SEALANT) (P/N 293

800 050) on the drain neck threads.
2. Install drain neck and torque to 16 Nm
(142 lbfin).
3. Secure bailer hose to drain neck using a NEW
locking tie.
4. Reinstall all removed parts in the reverse order
of removal.
BOW EYELET
Bow Eyelet Removal
To remove the retaining nuts on the bow mooring eyelet, an access hole must be cut in the fixed
deck. An etched line in the fixed deck located un-
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507

der the splash deflector indicates the exact location of the piece to cut out. Carry out the following
steps.
1. Remove splash deflector, refer to BODY subsection.
2. Using a drill bit 6 mm (1/4 in) in size MINIMUM,
drill a hole at each of the five corners of the
piece to cut out of the fixed deck as per following illustration.
smr2009-043-027_a
CUT HERE AT AN INWARD ANGLE
4. Unscrew and discard both elastic stop nuts

holding the bow eyelet in place.
smr2009-043-027_b
DRILL HOLES HERE
NOTICE Failure to drill holes as instructed

may lead to cracks in the fixed deck.
3. Using a small thin cutting wheel (such as used
on a Dremel rotary tool), make a precise clean
cut along the scribed line in the fixed deck.
NOTE: The cut should be made at an angle pointing in towards the center of the piece to be cut.
This will prevent the piece from falling through the
hole on installation and increase the contact area
for the repair.
NOTICE Do not cut hole opening larger than
etched line to prevent weakening of fixed deck
and to ensure proper sealing of splash deflector on installation.
508
smr2007-034-109_a
TYPICAL
1. Elastic stop nuts
5. Pull bow eyelet to remove it from watercraft.

6. Clean any residue of silicone sealant on hull.
Bow Eyelet Installation

1. The installation is the reverse of the removal
procedure. However, pay attention to the following.
2. Inside hull, apply LOCTITE 5150 (SILICONE
SEALANT) (P/N 293 800 086) around eyelet
mounting holes.
3. Install small washers and nylon washers on
bow eyelet and insert it through hull holes.
4. Inside hull, install rubber washers, large washers and NEW elastic stop nuts.
5. Torque nuts to 14.5 Nm (128 lbfin).
smr2009-042

4. Clean any residue of silicone sealant from the

hull.
Stern Eyelet Installation
smr2007-034-110_a
1.
2.
3.
4.
5.
6.
7.
1. Install small washers and nylon washers to

stern eyelet and insert it through the hull.
2. Inside hull, apply LOCTITE 5150 (SILICONE
SEALANT) (P/N 293 800 086) all around holes.
3. Install eyelet and other parts using NEW elastic
stop nuts as per following illustration.
Bow eyelet
Small washer
Nylon washer
Loctite 5150 (silicone sealant) here
Rubber washer
Large washer
Elastic stop nut
6. Repair the hole cut in the fixed deck using

the piece cut out during removal. Refer to the
BODY subsection for fiberglass repair procedure.
NOTE: The previous step is not mandatory if
splash deflector is properly sealed as detailed in
following step.
7. Apply a bead of LOCTITE 5150 (SILICONE
SEALANT) (P/N 293 800 086) to the inside of
the splash deflector as in following illustration.
smr2007-034-112_a
1.
2.
3.
4.
5.
6.
7.
Stern eyelet
Small washer
Nylon washer
Loctite 5150 (silicone sealant) here
Rubber washers
Large washers
Elastic stop nuts
4. Torque retaining nuts to 14.5 Nm (128 lbfin).
HULL INSERTS
smr2009-043-028_a
Metal inserts (brass) of various types and sizes

are screwed into the hull at various locations. A
threaded hole in the insert is used for fastening
various parts and equipment onto the hull (engine
mounts, battery mounts, ride plate, sponsons,
etc).
Some inserts pass completely through the hull,
while others do not (blind hole inserts). Some are
designed to accept an M6 screw while others an
M8 screw.
APPLY SILICONE HERE
8. Reinstall the splash deflector on the fixed deck.
STERN EYELETS
Stern Eyelet Removal
1. Open boarding platform and remove the applicable storage tray.
2. Inside hull, unscrew and discard elastic stop
nuts securing the stern eyelet to hull.
3. Pull stern eyelet to remove it from watercraft.
smr2009-042
509

smr2009-043-025_a
1. Passe thru insert
smr2009-043-026_b
BLIND HOLE INSERT

1. Excess glue on head
3. Use a six pan socket of appropriate size and a

ratchet wrench to unscrew the insert from the
hull.
NOTE: An impact tool may be used to facilitate
removal of the insert.
Insert Installation
1. Clean the insert hole in the hull to remove any
dirt or loose glue using clean, dry, oil free filtered air.
smr2009-043-026_a
1. Blind hole insert
All type inserts may be replaced if the inner screw

threads are damaged beyond use.
NOTE: Inserts should only be replaced as a last
resort. First try passing a tap, cleaning the hole,
and using a NEW screw with Scotch Grip threadlocker. If fastener can be tightened to the specified torque, do not change insert. If torque cannot
be applied, drill and tap insert one size larger before trying to change an insert.
Insert Removal
1. Heat the insert using a heat gun to soften the
glue securing the insert into the hull.
2. Remove any excess glue from around the head
of the insert that would prevent proper insertion
of the socket used to remove the insert.
510
NOTICE Do not use a metal tool to clean or

remove the glue inside the hull insert hole to
prevent damaging the threads in the hull material. The glue that is properly bonded to the
hull does not need to be removed.
2. If the insert passes completely through the hull,
screw a stud of appropriate size into the insert
(M6 or M8) to prevent any glue from seeping
into the fastener threads in the insert. Apply
DEVCON HP 250 Q glue to the outer threads
of the insert.
NOTE: Apply a sufficient amount of glue thru the
full length of the insert threads to ensure excess
glue will come out of the hole as the insert is
screwed into the hull.
3. If the insert screws into a blind hole, apply DEVCON HP 250 Q glue to the threads in the hull.
4. Screw the insert in the hull boss and torque to
25 Nm (18 lbfft). Ensure the flanged portion
of the insert makes contact with the boss it is
being screwed into.
smr2009-042
Section 08 TECHNICAL SPECIFICATIONS

Subsection 01 (RXT iS 255/GTX LIMITED iS 255)
RXT iS 255/GTX LIMITED iS 255

MODEL
RXT iS 255
GTX LIMITED iS 255
ENGINE
Engine type
ROTAX 1503 4-TEC, 4-stroke, Single Over Head Camshaft (SOHC)
Induction
Supercharged intercooled
3
Number of cylinders
Number of valves
12 valves with hydraulic lifters (no adjustment)

Standard
Bore
1st
Oversize
Stroke
100 mm (3.9 in)

100.25 mm (3.95 in)
63.4 mm (2.5 in)
Displacement
1 493.8 cm (91 in)

8.4:1
Compression ratio
Maximum HP
8000 RPM
Type
Lubrication
Dry sump (2 oil pumps). Replaceable oil filter. Water-cooled oil cooler
Oil type
XPS summer grade oil (P/N 293 600 121). Refer to

LUBRICATION subsection
Capacity
3 L (3.2 qt (U.S. liq.)) oil change w/filter

4.5 L (4.8 qt (U.S. liq.)) total
Intake valve opening
0 BTDC
Intake valve closing
50 ABDC
Exhaust valve opening
50 BBDC
Exhaust valve closing
0 ATDC
Intake
Valve stem diameter

Exhaust
Wear limit
New
Wear limit
New
Valve guide diameter

Inner
Valve spring free
length
Outer
Intake
Valve seat contact
width
Exhaust
Rocker arm inner diameter
Rocker arm shaft diameter
Cylinder head maximum warpage
smr2009-044
New
5.961 mm to 5.975 mm (.2347 in to .2352 in)

5.930 mm (.233 in)
5.946 mm to 5.960 mm (.2341 in to .2346 in)
5.930 mm (.233 in)
5.990 mm to 6.010 mm (.2358 in to .2366 in)
Wear limit
6.060 mm (.2386 in)
New
41.02 mm (1.615 in)
Wear limit
38.80 mm (1.528 in)
New
45.45 mm (1.789 in)
Wear limit
New
Wear limit
New
Wear limit
New
Wear limit
New
Wear limit
Service limit
43.00 mm (1.693 in)

1.10 mm to 1.30 mm (.043 in to .051 in)
1.60 mm (.063 in)
1.25 mm to 1.55 mm (.049 in to .061 in)
1.80 mm (.071 in)
20.000 mm to 20.020 mm (.7874 in to .7882 in)
20.030 mm (.7886 in)
19.980 mm to 19.990 mm (.7866 in to .787 in)
19.960 mm (.7858 in)
0.15 mm (.006 in)
511

MODEL
RXT iS 255
GTX LIMITED iS 255
ENGINE (cont'd)
Piston ring type
Ring end gap
Ring/piston groove
clearance
1st
Upper compression ring, rectangular
2nd
Lower compression ring, tapered face
3rd
Oil scraper ring
Rectangular
New
0.30 mm to 0.50 mm (.012 in to .02 in)
Taper-face
New
0.30 mm to 0.50 mm (.012 in to .02 in)
Oil scraper
ring
New
0.30 mm to 0.50 mm (.012 in to .02 in)
All
Wear limit
Rectangular
New
0.20 mm to 0.70 mm (.008 in to .028 in)
Taper-face
New
0.20 mm to 0.60 mm (.008 in to .024 in)
Oil scraper
ring
New
0.20 mm to 0.55 mm (.008 in to .022 in)
All
Wear limit
Piston/cylinder wall clearance

Cylinder taper
New
Camshaft bearing
journal diameter
PTO and
center
Front
Camshaft bearing
inner diameter
PTO and
center
Intake
Cam lobe height

Exhaust
Crankshaft deflection
Crankshaft axial clearance
Crankshaft bearing journal diameter
0.15 mm (.006 in)

0.04 mm to 0.08 mm (.0016 in to .0031 in)
Wear limit
0.100 mm (.0039 in)
Wear limit
0.100 mm (.0039 in)
Cylinder out of round (maximum)

Front
1.50 mm (.059 in)
0.015 mm (.0006 in)

New
Wear limit
New
Wear limit
New
Wear limit
New
Wear limit
New
Wear limit
New
24.939 mm to 24.960 mm (.9819 in to .9827 in)

24.910 mm (.9807 in)
39.890 mm to 39.900 mm (1.5705 in to 1.5709 in)
39.880 mm (1.5701 in)
25.000 mm to 25.010 mm (.9843 in to .9846 in)
25.020 mm (.985 in)
40.000 mm to 40.010 mm (1.5748 in to 1.5752 in)
40.020 mm (1.5756 in)
31.690 mm to 31.800 mm (1.2476 in to 1.252 in)
31.650 mm (1.2461 in)
31.480 mm to 31.590 mm (1.2394 in to 1.2437 in)
Wear limit
31.430 mm (1.2374 in)
Maximum
0.05 mm (.002 in)
New
Wear limit
New
0.080 mm to 0.220 mm (.0031 in to .0087 in)

0.35 mm (.014 in)
49.991 mm to 50.000 mm (1.9681 in to 1.9685 in)
Wear limit
49.950 mm (1.9665 in)
Crankshaft radial clearance
Wear limit
0.07 mm (.0028 in)
Connecting rod big end diameter
Service limit
45.080 mm (1.7748 in)
Connecting rod big end radial play
Service limit
0.090 mm (.0035 in)
Connecting rod big end axial play

Connecting rod small end diameter
512
New
Wear limit
New
Wear limit
0.135 mm to 0.287 mm (.0053 in to .0113 in)

0.500 mm (.0197 in)
23.010 mm to 23.020 mm (.9059 in to .9063 in)
23.070 mm (.9083 in)
smr2009-044

MODEL
RXT iS 255
GTX LIMITED iS 255
ENGINE (cont'd)
Connecting rod small end radial play Wear limit
0.080 mm (.0031 in)
New
Piston pin diameter
22.996 mm to 23.000 mm (.9054 in to .9055 in)
Wear limit
Balance shaft journal diameter
22.990 mm (.9051 in)
New
31.980 mm to 32.000 mm (1.2591 in to 1.2598 in)
Wear limit
31.950 mm (1.2579 in)
Balance shaft radial clearance
Wear limit
0.070 mm (.0028 in)
Balance shaft axial clearance
New
0.020 mm to 0.250 mm (.0008 in to .0098 in)
Supercharger shaft driven plate

journal depth
New
14.460 mm to 14.500 mm (.5693 in to .5709 in)
Supercharger drive gear thickness

Supercharger lock washer thickness
Wear limit
14.600 mm (.5748 in)
New
11.000 mm to 11.050 mm (.4331 in to .435 in)
Wear limit
10.900 mm (.4291 in)
New
4.050 mm to 4.150 mm (.1594 in to .1634 in)
Wear limit
3.950 mm (.1555 in)
Supercharger spring washer package New

height (not compressed)
Wear limit
10.900 mm to 10.700 mm (.4291 in to .4213 in)

10.200 mm (.4016 in)
AIR INTAKE SYSTEM

Intake spark arrester
Tubular, wire screen
COOLING SYSTEM
Type
Closed loop cooling system

Ethylene-glycol and distilled water (50%/50%). Use premix coolant
from BRP or a coolant specially formulated for aluminum engines
Coolant
Cooling system capacity
5.5 L (5.8 qt (U.S. liq.)) total
Thermostat
87C (189F)
Monitoring beeper setting
100C (212F)
EXHAUST SYSTEM
D-Sea-Bel sound reduction system. Water cooled/water injected
(open loop). Direct flow from jet pump
Type
Water injection in muffler
3 x 3.5 mm (.138 in) on exhaust pipe and 1 x 3.5 mm (.138 in) on muffler
FUEL SYSTEM
Multipoint fuel injection with iTC (intelligent Throttle Control).
Single throttle body (60 mm) with an actuator
Fuel injection type

Fuel pressure
386 kPa to 414 kPa (56 PSI to 60 PSI)
Fuel injector
Fuel type
Quantity
Inside North America ((RON + MON)/2)
91 or higher
Outside North America (RON)
95 or higher
Fuel tank (including reserve)

Fuel tank reserve (from low level signal)
Idle speed
smr2009-044
70 L (18.5 U.S. gal.)

approx. 14 L (3.7 U.S. gal.)
1800 50 RPM (not adjustable)
513

MODEL
RXT iS 255
GTX LIMITED iS 255
ELECTRICAL SYSTEM
Fuse box #1
Fuses and relay
Fuse box #2
#1: Gauge
3 A
#2: CAPS
3 A
#3: Depth
sounder
3 A
#4: Starter
solenoid
5 A
#5: iBR control
5 A
#6: Fuel pump
6 A
#7: Inj/Ign
cyl 1
10 A
#8: Inj/Ign
cyl 2
10 A
#9: Inj/Ign
cyl 3
10 A
#10: OTAS
switch
3 A
#11: iS control
5 A
Relay
30 A
#15: Charging
syst
30 A
#16: iS power
30 A
#17: Batt
power
30 A
#18: iBR
power
30 A
#20: ECM
15 A
#21:
START/STOP
switch
3 A
#22: Diag
connector
15 A
#23: GPS
3 A
Magneto generator output
360 W @ 6000 RPM
Stator
0.1 to 1.0
Battery
12 V, 30 Ah
D.E.S.S. (Digitally Encoded Security System) with selectable max
vehicle speed settings for RK (rental key) and LK (learning key)
Anti-start system
Ignition system type
IDI (inductive discharge ignition)
Ignition timing
Variable (electronically controlled)
Spark plug
Ignition coil
Engine speed limiter setting
514
Make and type

Gap
NGK DCPR8E
0.7 mm to 0.8 mm (.028 in to .031 in)
Primary
0.85 to 1.15
Secondary
9.5 to 13.5 K
8300 RPM
smr2009-044

MODEL
RXT iS 255
GTX LIMITED iS 255
STEERING AND PROPULSION

Steering
Adjustable tilt
26
Steering nozzle pivoting angle

O.T.A.S. (Off-Throttle Assisted Steering)
Jet pump
Type
Grease type
Rotation (seen from rear)
Impeller
Impeller shaft
New
Wear limit
Counterclockwise
14/25
159 mm 0.06 mm (6.26 in .002 in)
0 mm to 0.23 mm (0 in to .009 in)
0.35 mm (.0138 in)
End play (new)
Side play
Coupling type
Drive shaft
Axial flow single stage

Jet pump bearing grease (P/N 293 550 032)
Pitch
Outside diameter
Impeller/wear ring clearance
Electronically-controlled. Achieved with the iBR gate and engine speed
Deflection
(max.)
Minimum required water level for propulsion system
Crowned splines, direct drive

0.75 mm (.03 in)
90 cm (3 ft) underneath the lowest rear portion of hull
iBR and VTS

Intelligent Brake and Reverse activated by a LH lever.
Electronically-controlled iBR gate to provide brake, reverse,
neutral and forward position
Description
Gate angle (from horizontal line of

watercraft)
Forward
Approx. from +8 to -5
Neutral
Approx. -54
Braking
Approx. -74
Reverse
Approx. from -54 to -74
VTS system
Actuator
Electronically-controlled with manual and 2 preset positioning.

VTS range angle: 8 up, 5 down
12 V, 80 A max. capacity (fused @ 30 A). Reversible PWM
(pulse-width modulation) motor
iS SUSPENSION
Description
Type
Intelligent suspension. Electronically-controlled suspension with auto

mode or manual mode with 9 presets and a dock mode
Direct action twin-rate suspension
Suspension stroke at seat

Hydraulic cylinder stroke (dock mode + preload
adjustment)
150 mm (6 in)
107 mm (4.2 in)
Preset sag (auto mode)
50 mm (2 in)
Motion ratio (damper stroke/seat stroke)
0.8175 : 1
Shock absorber
Spring rate (dual rate)
smr2009-044
Fox racing shock PS6

GTX LTD calibration type: Cruiser
RXT calibration type: Sport
36 N/m - 48 N/m
(2.5 lbf/ft - 3.3 lbf/ft)
30 N/m - 40 N/m
(2.1 lbf/ft - 2.7 lbf/ft)
515

MODEL
RXT iS 255
GTX LIMITED iS 255
iS SUSPENSION (cont'd)
Type
Oil type
Hydraulic pump
Oil quantity
Motor
Radial piston
Automatic transmission fluid (ATF) Dexron III
Reservoir is full when oil level reaches 130 mm 5 mm
(5-1/8 in 13/64 in) from bottom
12 V, 30 A. Reversible PWM (pulse-width modulation) motor
WEIGHT AND LOADING CAPACITY

Dry weight
446 kg (990 lb)
Number of passenger (driver incl.)

Load limit (passenger and 10 kg (22 lb) luggage)
441 kg (970 lb)

3
227 kg (500 lb)
DIMENSIONS
Overall length
354 cm (139 in)
Overall width
122 cm (48 in)
Overall height with keel horizontal, suspension

extended
128 cm (50 in)
Overall height with keel horizontal, suspension

collapsed
111 cm (44 in)
MATERIALS
Hull
Composite fiberglass
Inlet grate
Aluminum
Steering cover
Thermoplastic
Impeller material
Stainless steel
Impeller housing/stator
Aluminum/aluminum
Venturi
Aluminum
Nozzle
Aluminum
Fuel tank
Polyethylene
Seat
Polyurethane/foam
PERFORMANCE
Estimated pump power
Maximum fuel consumption at wide
open throttle
Cruising time at full
throttle
516
93 kW (125 HP)
73.8 L/h (19.5 U.S. gal/h)
Fuel tank without reserve
43 minutes
Fuel tank reserve (from low

level signal)
14 minutes
smr2009-044
Section 09 WIRING DIAGRAM

Subsection 01 (WIRING DIAGRAM INFORMATION)
WIRING DIAGRAM INFORMATION

GENERAL
WIRING DIAGRAM LOCATION
The wiring diagram is in the back cover pocket.
WIRING DIAGRAM CODES
Wire Color Codes
YL - BK
1
2
F04H6LA
smr05-026-002_a
1. Wire main color

2. Tracer (thin colored line)
TYPICAL
1. Wire identification numbers
General Wire Color Use

COLOR
USE
RED
Battery power (12 Vdc directly

connected to battery)
RED + tracer
Fused 12 Vdc power or switched

power from relay
YELLOW
Alternating current (AC)

from magneto
BLACK
Ground
BLACK + tracer
Switched ground (by ECM)
WHITE/RED
WHITE/BLACK
CAN HI wires
CAN LO wires
Terminal Identification on Wiring

Diagram
In-line connectors of wiring harness are given on
the wiring diagram with their approximate location
and the following information.
Terminal Identification on Connector

On the wiring diagram, a letter or a digit is used to
identify the terminal position in a connector.
smr2009-045-006_a
1. Connector location
2. Connector identification (reference number)
3. Number of pins
CAN Wire Circuit References

smr2009-045-005_a
1. Terminal position
On the wiring diagram, CAN linked components

use the following coding.
On a connector, a letter or a digit is usually molded

on the connector to identify the terminal position.
smr2009-044
517

Subsection 01 (WIRING DIAGRAM INFORMATION)
smr2009-045-007_a
1. CAN wire
2. Wire destination
FB2: Fuse box #2
C7: Terminal C7 in fuse box #2
On the wiring diagram, corresponding CAN links

are identified in fuse box #2 using the following
coding.
smr2009-045-008_a
1. CAN wire
2. Wire origin
3. Destination terminal (was referenced at ECM)
Fuse Box Terminal Reference

Refer to POWER DISTRIBUTION subsection.
518
smr2009-044

Subsection 02 (CONNECTOR INFORMATION)
CONNECTOR INFORMATION
SERVICE TOOLS
Description
Part Number
CRIMPING TOOL (HEAVY GAUGE WIRE) ....................................

ECM ADAPTER TOOL...................................................................
ECM TERMINAL REMOVER 2.25.................................................
ECM TERMINAL REMOVER 3.36.................................................
529
529
529
529
035
036
036
036
730
166
175
174
Page
......................................... 526
......................................... 523
......................................... 523
......................................... 523

Description
Part Number
AMP TERMINAL EXTRACTOR...................................................... 726503-1

DELPHI TERMINAL EXTRACTOR ................................................. 12094429
GM TERMINAL EXTRACTOR........................................................ 12094430
Page
......................................... 525
......................................... 524
......................................... 524
1
PROCEDURES
MAGNETO AND ENGINE
CONNECTOR (DEUTSCH)
Connector Removal from its Support
Magneto Connector
Insert a small flat screwdriver between the support and the Deutsch connectors. Pry while sliding out connectors in the direction shown.
F18Z0LA
TYPICAL
1. Flat screwdriver
2. Deutsch connectors
smr2009-045-009_a
MALE CONNECTOR REMOVED FOR CLARITY PURPOSE

To disconnect the Deutsch connectors, twist a

small flat screwdriver between each housing to
disengage, press the release button and disconnect them.
F18Z0MA
TYPICAL
1. Release
smr2009-044
519

Connector Disassembly
1
2
F18Z0NA
TYPICAL
2. Press release button
Engine Connector
Insert a small flat screwdriver between the support and the Deutsch connectors. Pry while sliding out connectors in the direction shown.
F00H1CA
1.
2.
3.
4.
Male connector
Female connector
Secondary lock
Sealing cap
NOTICE Do not apply dielectric grease on terminal inside connector.

To remove terminals from connector, proceed as
follows:
Using a long nose pliers, pull out the lock.
smr2009-045-010_a
MALE CONNECTOR REMOVED FOR CLARITY PURPOSE

V01G0OA
FEMALE CONNECTOR
1. Female lock
520
smr2009-044

6. After all required terminals have been inserted,

the lock must be installed.
V01G0PA
MALE CONNECTOR
1. Male lock
F04H6LA
1. Wire identification numbers
NOTE: Before extraction, push wire forward to relieve pressure on retaining tab.
1. Insert a 4.8 mm (.189 in) wide screwdriver
blade inside the front of the terminal cavity.
2. Pry back the retaining tab while gently pulling
wire back until terminal is removed.
ECM CONNECTOR (MOLEX)

There are 2 connectors on the ECM. The engine
wiring harness connector is connected on the
ECM connector A and the vehicle wiring harness
connector is connected to the ECM connector B.
Each ECM connector has 48 pins.
smr2009-027-005
ECM CONNECTORS
ECM Connector Removal
V01G0QA
To reach ECM connector, refer to ELECTRONIC

Push and hold the locking tab of the desired connector.
FEMALE CONNECTOR
1. Retaining tabs
To install:
3. For insertion of a terminal, make sure the lock
is removed.
4. Insert terminal into appropriate cavity and push
as far as it will go.
5. Pull back on the terminal wire to be sure the
retention fingers are holding the terminal.
smr2009-044
521

smr2009-045-013_b
smr2009-045-011_a
Rotate connector lock until it stops.
Install connector to ECM.

Rotate connector lock until it snaps locked.
smr2009-045-012_a
Pull out connector.
smr2009-045-011_b
1. Locked here
ECM Connector Inspection
smr2009-045-013_a
ECM Connector Installation

Fully open connector lock.
522
Before replacing an ECM, always check electrical

connections. Make sure that they are very tight
and they make good contact and that they are
corrosion-free. Check if wiring harness shows
any signs of scoring. Particularly check ECM
ground connections. Ensure that contacts are
good and clean. A defective module could
possibly be repaired simply by unplugging and
re-plugging the ECM. Or if a newly replaced ECM
is working, try the old one and recheck if it works.
The voltage and current might be too weak to go
through dirty wire terminals. Check carefully if
terminals show signs of moisture, corrosion or if
they look dull.
Do not apply any lubricant product to the pins of
the connector on the ECM.
smr2009-044

ECM Connector Probing

The most recommended and safest method to
probe ECM connector terminals is to use the ECM
ADAPTER TOOL (P/N 529 036 166). This tool will
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating
intermittent or permanent problems.
529036175
Remove rear protector from connector.

Pull out the connector lock.
529036166
Disconnect the desired ECM connector and reconnect on the probing tool. Probe required
terminals directly in the tool holes.
smr2009-045-025_a
Insert tool to unlock terminal.
vmr2008-139-016_a
TYPICAL
1. ECM connector
2. ECM adapter
NOTICE Never probe directly on ECM harness connector. This could change the shape
or enlarge the terminals and create intermittent or permanent contact problems.
ECM Terminal Removal (Harness

Connector)
smr2009-045-026_a
1. Unlock here
To remove a signal terminal from ECM harness

connector, use the ECM TERMINAL REMOVER 2.25
(P/N 529 036 175). To remove a power terminal,
use the ECM TERMINAL REMOVER 3.36 (P/N 529
036 174).
smr2009-044
523

smr2009-045-015_a
WARNING
smr2009-045-027_a
WARNING
Before terminal installation, ensure all terminals are properly crimped on wires. After
plugging connectors, ensure they are properly fastened.
BRLS, TAS AND STARTER

SOLENOID CONNECTORS
(DELPHI)
iBR AND iS POWER

CONNECTORS (DELPHI)
To remove a terminal from connector, use a special tool such as the GM TERMINAL EXTRACTOR
(P/N 12094430).
To remove a terminal from connector, use a special tool such as the DELPHI TERMINAL EXTRACTOR (P/N 12094429).
NOTE: Grinding the tool end to make it smaller is
required.
smr2009-045-016_a
1. Unlock terminal here
smr2009-045-014_a
smr2009-045-017_a
524
smr2009-044

WARNING
SPS CONNECTORS (BOSCH)

To remove a terminal from connector, use a special tool such as the AMP TERMINAL EXTRACTOR
(P/N 726503-1).
smr2009-045-020_a
1. Pry out locking cap
smr2009-045-018_a
smr2009-045-021_a
1. Unlock here
smr2009-045-019_a
WARNING
INFORMATION CENTER
CONNECTORS (DELPHI)
To remove a terminal from connector, first remove
the locking cap.
smr2009-045-022_a
WARNING
VTS, iS, MODE/SET

AND UP/DOWN SWITCH
CONNECTORS (DELPHI)
To remove a terminal from connector, first remove
the locking cap.
smr2009-044
525

A
A32E2QA
smr2009-045-023_a
A. 10 mm (3/8 in)
1. Pry out locking cap
NOTE: Make sure not to cut wire strands while

stripping the wire.
Install the appropriate terminal on the wire according to the requirement. Refer to appropriate
PARTS CATALOG.
smr2009-045-024_a
1. Unlock here
A32E2RA
INSTALLATION OF TERMINAL
Follow the instructions provided with the CRIMPING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper position of the tool.
529035730
NOTE: Different wires require different crimping

pliers settings, so make sure to follow the instruction supplied with the tool.
smr2009-045-028_a
WARNING
BATTERY CABLE TERMINAL

Crimping
Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.
526
smr2009-044

Install the protective heat shrink rubber tube on

the terminal. Heat the heat shrink rubber tube using the heat gun so that it grasps the wire and the
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.
2
A32E2SA
POSITIONING THE CRIMPING PLIERS

Step 1: Press
Step 2: Rotate
After positioning the crimping pliers, crimp the terminal already installed on wire.
A32E2TA
CRIMPING OF WIRE
A32E2UA
PROPERLY CRIMPED WIRE
To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
NOTICE Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
smr2009-044
527
NOTES
NOTES
2009 Sea-Doo 4-TEC iTC iS Series

RXT iS 255
GTX Limited iS 255
smr2009-045-001
STARTING SYSTEM
IGNITION SYSTEM
CHARGING SYSTEM
smr2009-045-002

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LIBRO

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2009

03 ELECTRONIC MANAGEMENT SYSTEMS

03 ELECTRONIC MANAGEMENT SYSTEMS (contd)

04 FUEL SYSTEM (contd)

05 ELECTRICAL SYSTEM (contd)

06 STEERING AND PROPULSION

06 STEERING AND PROPULSION (contd)

07 BODY AND HULL

07 BODY AND HULL (contd)

CAUTION Indicates a hazard situation

Topaz mist metallic

1503 HO (255 HP)

1503 HO (255 HP)

It is located on footboard at the rear of watercraft.

1. Engine Identification Number (E.I.N.)

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

NOTICE Using any other lifting strap kit than

EPA Emission Regulations

This manual uses technical terms which may be

Exploded view assists

Dotted box contains

NEW indicates that the

Magneto Flywheel Cleaning

CAUTION: Clean magneto flywheel using only

Magneto Flywheel Removal

muffler, refer to the EXHAUST SYSTEM

Italic bold face typesetting indicates a

Bold face number following part

2. Apply the half of the recommended torque

105 Nm (77 lbfft)

128 Nm (94 lbfft)

135 Nm (100 lbfft)

170 Nm (125 lbfft)

200 Nm (148 lbfft)

3. Choose proper strength Loctite threadlocker.

Threadlocker Application for Blind

TYPICAL SELF-LOCKING FASTENER

Threadlocker Application for

1. Clean threads (bolt and hole) with solvent.

Threadlocker Application for Stud in

1. Clean threads (bolt and nut) with solvent.

1. Clean threads (stud and hole) with solvent.

2. Apply LOCTITE PRIMER N (P/N 293 800 041) on

Threadlocker Application for Adjusting

Threadlocker Application for

1. Adjust screw to proper setting.

Application for Stripped Thread Repair

1. Clean bolts and nuts with solvent.

Standard Thread Repair

3. Twist bolt when inserting it to improve thread

5. Place gasket on mating surfaces and assemble

Threadlocker Application for Mounting

Gasket Compound Application

1. Proper strength Loctite

1. Remove old gasket and other contaminants

1. Clean shaft external part and element internal

Threadlocker Application for Case-In

1. Proper strength Loctite

1. Clean inner housing diameter and outer gasket

(1) Check level before each ride.