Seadoo Service 4 Tec, 2 Stroke, Manual

2003
Shop Manual
GTI, GTI LE, GTI LE RFI, GTX DI,
XP DI, RX DI, LRV DI, GTX 4-TEC SERIES
Legal deposit:
National Library of Quebec
2
nd
trimester 2003
National Library of Canada
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
Bombardier Inc. 2003

Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
*Registered trademarks of Bombardier Inc.

Knights Spray-Nine

is a trademark of Korkay System Ltd
GTX
is a trademark of Castrol Ltd. Used under license

Loctite
is a trademark of Loctite Corporation

Snap-on
is a trademark of Snap-on Tools Corporation

Gelcote
is a trademark of Gelcote International Limited

The following trademarks are the property of Bombardier Inc. or its subsidiaries:
SEA-DOO
BOMBARDIER-ROTAX
BOMBARDIER LUBE
BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil

BOMBARDIER Formula XP-S DI Synthetic Injection Oil
BOMBARDIER-ROTAX Injection Oil
Sea-Doo Synthetic Grease
Sea-Doo LK
TM
DESS
TM
Rotax
O.P.A.S.
TM
TOPS
TM
SMR2003_001_00_00A2.FM I
SECTION SUBSECTION
PAGE
SAFETY NOTICE.................................................................................................................................. III
INTRODUCTION ................................................................................................................................... IV
01 SERVICE TOOLS
AND PRODUCTS
01 - Table of contents ...................................................................... 01-01-1
02 - Mandatory service tools............................................................ 01-02-1
03 - Optional service tools................................................................ 01-03-1
04 - Service products ....................................................................... 01-04-1
02 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-1
02 - Periodic inspection chart ........................................................... 02-02-1
03 - Flushing and lubrication............................................................. 02-03-1
04 - Water-flooded engine................................................................ 02-04-1
05 - Storage...................................................................................... 02-05-1
03 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-1
04 ENGINE (2-stroke) 01 - Table of contents ...................................................................... 04-01-1
02 - Leak test ................................................................................... 04-02-1
03 - Removal and installation ........................................................... 04-03-1
04 - Magneto system....................................................................... 04-04-1
05 - Top end ..................................................................................... 04-05-1
06 - Bottom end ............................................................................... 04-06-1
07 - Rotary valve............................................................................... 04-07-1
08 - Exhaust system......................................................................... 04-08-1
05 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 05-01-1
02 - Leak test ................................................................................... 05-02-1
03 - Intake system............................................................................ 05-03-1
04 - Exhaust system......................................................................... 05-04-1
06 - PTO housing/magneto .............................................................. 05-06-1
07 - Lubrication system.................................................................... 05-07-1
08 - Cylinder head and valves........................................................... 05-08-1
09 - Engine block.............................................................................. 05-09-1
06 ENGINE
MANAGEMENT (RFI)
02 - Overview................................................................................... 06-02-1
03 - Diagnostic procedures .............................................................. 06-03-1
04 - Component inspection.............................................................. 06-04-1
05 - Troubleshooting summary ........................................................ 06-05-1
06 - Adjustment................................................................................ 06-06-1
07 ENGINE
MANAGEMENT (DI)
02 - Overview................................................................................... 07-02-1
03 - Component inspection and adjustment .................................... 07-03-1
08 ENGINE
MANAGEMENT
(4-TEC)
02 - Overview................................................................................... 08-02-1
03 - Component inspection and adjustment .................................... 08-03-1
09 COOLING SYSTEM 01 - Table of contents ...................................................................... 09-01-1
02 - Circuit, components and care ................................................... 09-02-1
TABLE OF CONTENTS
II SMR2003_001_00_00A2.FM
SECTION SUBSECTION
PAGE
10 FUEL SYSTEM 01 - Table of contents...................................................................... 10-01-1
02 - Fuel circuit ................................................................................ 10-02-1
03 - Air intake (2-stroke)................................................................... 10-03-1
04 - Carburetor................................................................................. 10-04-1
11 LUBRICATION
SYSTEM (2-stroke)
01 - Table of contents...................................................................... 11-01-1
02 - Oil injection system.................................................................. 11-02-1
03 - Oil injection pump..................................................................... 11-03-1
12 ELECTRICAL
SYSTEM
02 - Ignition system (carbureted engines) ....................................... 12-02-1
03 - Charging system....................................................................... 12-03-1
04 - Starting system......................................................................... 12-04-1
05 - Instruments and accessories.................................................... 12-05-1
06 - DESS (carbureted and RFI engines).......................................... 12-06-1
13 PROPULSION
SYSTEM
02 - Jet pump................................................................................... 13-02-1
03 - Drive system............................................................................. 13-03-1
04 - Reverse system........................................................................ 13-04-1
05 - Variable trim system................................................................. 13-05-1
14 STEERING SYSTEM 01 - Table of contents...................................................................... 14-01-1
02 - Steering system........................................................................ 14-02-1
03 - Alignment ................................................................................. 14-03-1
15 SUSPENSION 01 - Table of contents...................................................................... 15-01-1
02 - Direct action suspension .......................................................... 15-02-1
16 HULL/BODY 01 - Table of contents...................................................................... 16-01-1
02 - Adjustment and repair .............................................................. 16-02-1
17 TECHNICAL DATA 01 - GTI and GTI LE models............................................................. 17-01-1
02 - GTI LE RFI models.................................................................... 17-02-1
03 - GTX DI, RX DI and XP DI models.............................................. 17-03-1
04 - LRV DI models.......................................................................... 17-04-1
05 - GTX 4-TEC models.................................................................... 17-05-1
18 WIRING DIAGRAMS 01 - Wiring diagrams........................................................................ 18-01-1
TABLE OF CONTENTS
SMR2003_001_00_00A2.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair all 2003 SEA-DOO watercraft.
See model list below.
This edition was primarily published to be used by watercraft mechanical technicians who are already
familiar with all service procedures relating to Bombardier made watercraft. Mechanical technicians should
attend training courses given by Bombardier Training Dept.
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 Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. 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.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
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.
Bombardier Inc. 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
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
SAFETY NOTICE
IV SMR2003_001_00_00A2.FM
INTRODUCTION 0
Thi s Shop Manual cover s t he f ol l owi ng
BOMBARDIER made SEA-DOO
2003 watercraft
models.
HULL IDENTIFICATION NUMBER
(H.I.N.)
It is located on footboard at the rear of watercraft.
1. Hull Identification Number (H.I.N.)
TYPICAL
1. Hull Identification Number (H.I.N.)
MODELS
ENGINE
TYPE
MODEL
NUMBER
XP DI 947 DI 6131
XP DI International 947 DI 6130
GTI (blue) International 717 5568
GTI (ultraviolet) 717 5598
GTI California
(ultraviolet)
717 5567
GTI International
(ultraviolet)
717 5597
GTI LE (earthen clay) 717 6102
GTI LE International
(earthen clay)
717 6101
GTI LE RFI 787 RFI 6104
GTI LE RFI International 787 RFI 6103
GTX DI 947 DI 6119
GTX DI International 947 DI 6118
RX DI 947 DI 6123
RX DI International 947 DI 6122
LRV DI 947 DI 5771
GTX 4-TEC 1503 6112
GTX 4-TEC International 1503 6111
GTX 4-TEC Vans Triple
Crown Edition
1503 6126
GTX 4-TEC Vans Triple
Crown Edition
International
1503 6125
GTX 4-TEC Supercharged
(viper red)
1503 6129
International (viper red)
1503 6128
(yellow)
1503 6106
International (yellow)
1503 6105
Limited
1503 6108
Limited International
1503 6107
F00L2EA 1
F08L0QA 1
INTRODUCTION
SMR2003_001_00_00A2.FM V
All Models
The Hull Identification Number is composed of 12
digits:
ENGINE IDENTIFICATION
NUMBER (E.I.N.)
717 Engines
The Engine Identification Number is located on the
upper side of the magneto housing.
TYPICAL
1. Engine Identification Number (E.I.N.)
787 RFI Engines
upper crankcase on PTO side.
947 DI Engines
upper crankcase on MAGNETO side.
ARRANGEMENT OF THIS
MANUAL
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Several sections are divided in various subsections.
There is a table of contents at the beginning of
many sections.
Z Z N 1 2 3 4 5 L 4 9 5
Model year
Serial
number*
F00A0CB
Month of production
Year of production
*A letter may also be used as a digit.
Manufacturer
1
F01D01A
F01D87A 1
F06D15A 1
INTRODUCTION
VI SMR2003_001_00_00A2.FM
Subsection 04 (MAGNETO SYSTEM)
03-04-1
F01D4WS
Loctite
243
Loctite
243
Loctite
243
Loctite
243
Loctite
243
Loctite
648
145 Nm
(107 lbfft)
Anti-seize
lubricant
Page heading
indicates section
and subsection
detailed.
Exploded view assits
you in identifying
parts and related
positions.
TYPICAL PAGE
F01A0CS
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Dotted box
contains parts of
a particular
model or an
exploded view.
Page numbering system:
03: ENGINE section
04: MAGNETO SYSTEM subsection
1: First page of this subsection
Italic sub-title
above exploded
view indicate
pertaining models.
Drop represents
a liquid product
to be applied to a
surface. In this case
Loctite 243 to
screw threads.
Bold face number
indicates special
procedure
concerning this part.
INTRODUCTION
SMR2003_001_00_00A2.FM VII
1
2
Section 06 FUEL SYSTEM
Subsection 03 (CARBURETORS)
06-03-4
Diaphragm
XP Model Only
CARBURETOR REMOVAL
Inspect parts for corrosion dammage (shaft, butterfly,
spring screw, check valve housing, etc.).
PUMP DIAPHRAGM LEAK TEST
TYPICAL
To remove carburetors from engine, proceed as fol-
lows:
Remove air vent tube support.
Unlock retaining slides holding air intake silencer base.
Remove air intake silencer base from watercraft.
Remove screws holding flame arrester base support
to cylinder head cover.
Unscrew base retaining screws then remove base from
carburetors and move to front of watercraft.
Turn the valve to OFF position.
NOTE: For fuel line removal, use pliers (P/N 295
000 054).
Disconnect pulse line from fuel pump.
Disconnect fuel fuel supply line from fuel pump.
Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable and
choke cable.
Remove screws no. 6 and lock washers no. 7 retaining
carburetors.
All Others Models
Remove 4 bolts no. 8 and lock washers no. 12 from
rotary valve cover then move carburetors and rotary
valve cover on top of engine.
NOTE: When removing rotary valve cover , pay
attention that the rotary valve stay in place, other-wise
it must be timed.
Remove carburetors from intake manifold.
Disconnect fuel bypass line between carburetors (twin
carburetors).
Remove carburetor(s) from rotary valve cover.
DISASSEMBLY AND INSPECTION
Using a suitable pump gauge tester, perform the fol-
lowing test proceeding as follows:
- Install pump gauge tester (P/N 295 000 083) on pulse
nipple.
- Pump tester until it reaches 28 kPa (4 PSI).
Diaphragm must stand pressure for 10 seconds. If
pressure drops, replace diaphragm.
F01F0XB
A
2
1
1 2
TYPICAL PAGE
Sub-title with part
name(s) from
exploded view.
TYPICAL mention
indicates a general
view which does not
represent full detail.
Sub-sub-title in this
case indicates that
particular procedure
for XP is finished, so
from this point, all
others models are
concerned.
Title in italic indicates a
particular procedure
concerning a model.
Service tool to be
used to perform a
certain procedure.
Title indicates main
procedure to be
carried-out.
Sub-sub-title in
capital indicates a
particular testing,
adjustment or
repair procedure.
Illustration
always follows
text it is
pertained to.
Numbers in a frame
are used to give a
sequence to be
perfomed.
Numbers are used
for description of
components.
Letters are used for
any measures.
Bold numbers in the
text refer to the parts
shown in the exploded
view at the beginning
of the subsection.
F01A0BS
INTRODUCTION
VIII SMR2003_001_00_00A2.FM
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
GENERAL INFORMATION
The use of RIGHT (starboard) and LEFT (port) indi-
cations in the text, always refers to driving position
(when sitting on watercraft).
Besides, in the marine industry, FRONT is called
BOW and REAR is called STERN.
1. Left (port)
2. Right (starboard)
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. Bombardier Inc. however, maintains a
policy of continuous improvement of its products
without imposing upon itself any obligation to in-
stall them on products previously manufactured.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
This Shop 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.
ILLUSTRATIONS AND
PROCEDURES
The illustrations 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.
CAUTION: These watercraft are designed with
parts dimensioned mostly in the metric system.
However some components may be from the impe-
rial system. When replacing fasteners, make sure to
use only those recommended by Bombardier.
DESCRIPTION
ADC Analog to Digital Conversion
AC Alternate Current
APS Air Pressure Sensor
ATS Air Temperature Sensor
B.U.D.S.
Bombardier Utility and Diagnostic
Software
CDI Capacitor Discharge Ignition
CPS Crankshaft Position Sensor
CSI Cooling System Indicator
DC Direct Current
DESS Digitally Encoded Security System
DI Direct Injection
E.I.N. Engine Identification Number
ECM Engine Control Module
ECU Electronic Control Unit
EPA Environmental Protection Agency (USA)
HP Horse Power
LED Light Emitting Diode
MAG Magneto
MPEM Multi-Purpose Electronic Module
MPH Mile Per Hour
MPI Multi Protocol Interface
N.A. Not Applicable
OPT Optional
P/N Part Number
PFD Personal Flotation Device
PSI Pound Per Square Inch
PTO Power Take Off
RAVE Rotax Adjustable Variable Exhaust
RFI Rotax Fuel Injection
RPM Revolution Per Minute
STD Standard
TBD To Be Determined
TDC Top Dead Center
TPS Throttle Position Sensor
VDC Volt Direct Current
VCK Vehicle Communication Kit
VDC Volt Direct Current
VTS Variable Trim System
WTS Water Temperature Sensor
F01L45B
1 2
INTRODUCTION
SMR2003_001_00_00A2.FM IX
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before undertaking
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
ENGINE EMISSIONS
INFORMATION
Manufacturers Responsibility
Beginning with 1999 model year engines, PWC
manufacturers of marine engines must determine
the exhaust emission levels for each engine horse-
power family and certify these engines with the
United States of America Environmental Protec-
tion Agency (EPA). An emissions control informa-
tion 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 re-
cent 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 com-
ponent must be executed in a manner that main-
tains emission levels within the prescribed certifi-
cation standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturers prescribed
changes, such as altitude adjustments for exam-
ple.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission lev-
els within prescribed certification standards.
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 spec-
ifications.
EPA Emission Regulations
All new 1999 and more recent Sea-Doo watercrafts
manufactured by Bombardier are certified to the
EPA as conforming to the requirements of the reg-
ulations for the control of air pollution from new wa-
tercraft 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, whenev-
er 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 emis-
sions for marine products. For more detailed informa-
tion on this subject, you may contact the following
locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3
rd
St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww
SELF-LOCKING FASTENERS
PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a screwtap to clean the hole
properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
utilization is to ensure the adhesive works properly.
INTRODUCTION
X SMR2003_001_00_00A2.FM
LOCTITE APPLICATION
PROCEDURE
The following describes the most common appli-
cation procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
THREADLOCKER
Uncovered Holes (bolts and nuts)
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
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.
Blind Holes
1. On threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
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.
Stud in Blind Holes
1. On threads
2. On threads and in the hole
3. Onto nut threads
A00A3LA
1
2
A00A3MA
1
2
A00A5RA
2
1 3
INTRODUCTION
SMR2003_001_00_00A2.FM XI
1. Clean threads (stud and hole) with solvent.
threads and allow to dry.
3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
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 un-
covered threads.
8. Tighten nuts as required.
Preassembled Parts
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.
Adjusting Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.
2. Apply drops of proper strength Loctite thread-
locker 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)).
STRIPPED THREAD REPAIR
Stripped Threads
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
A00A3OA
1
2
A00A3PA
1
2
A00A3QA
5
8
6
7
1
2
3
4
INTRODUCTION
XII SMR2003_001_00_00A2.FM
Standard Thread Repair
1. Follow instructions on Loctite FORM-A-THREAD
81668 package.
2. If a plate is used to align bolt:
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfaces.
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 Stan-
dard 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.
GASKET COMPOUND
All Parts
1. Proper strength Loctite
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 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 GASKET ELIMINATOR 518 (P/N 293 800
038) on both sides of gasket, using a clean ap-
plicator.
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.
MOUNTING ON SHAFT
Mounting with a Press
1. Bearing
3. Shaft
Standard
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 anti-seize Loctite or any similar
product.
4. No curing period is required.
A00A3SA
2 1
1
3
1
A00A3UA
1
2
3
INTRODUCTION
INTRODUCTION
SMR2003_001_00_00A2.FM XIII
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
CASE-IN COMPONENTS
Metallic Gaskets
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 lead-
ing 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.
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and text. When they are not specified
refer to following table.The table also gives the
metric conversion.
A00A3VA 1
Nm FASTENER SIZE (8.8) Lbfin
1 9
2 M4 18
3 27
4 M5 35
5 44
6 53
7 62
8 71
9 80
10 M6 89
11 97
12 106
13 115
14 124
15 133
16 142
17 150
18 159
19 168
Nm FASTENER SIZE (8.8) Lbfft
20 15
21 15
22 16
23 M8 17
24 18
25 18
26 19
27 20
28 21
29 21
30 22
31 23
32 24
33 24
34 25
35 26
36 27
37 27
INTRODUCTION
XIV SMR2003_001_00_00A2.FM
38 28
39 29
40 30
41 30
42 31
43 32
44 32
45 33
46 34
47 35
48 M10 35
49 36
50 37
51 38
52 38
53 39
54 40
55 41
56 41
57 42
58 43
59 44
60 44
61 45
62 46
63 46
64 47
65 48
66 49
67 49
68 50
69 51
70 52
71 52
72 53
73 54
74 55
75 55
76 56
77 57
78 58
79 58
80 M12 59
81 60
82 60
Nm FASTENER SIZE (8.8) Lbfft Nm FASTENER SIZE (8.8) Lbfft
83 61
84 62
85 63
86 63
87 64
88 65
89 66
90 66
91 67
92 68
93 69
94 69
95 70
96 71
97 72
98 72
99 73
100 74
101 74
102 75
103 76
104 77
105 77
106 78
107 79
108 80
109 80
110 81
111 82
112 83
113 83
114 84
115 85
116 86
117 86
118 87
119 88
120 89
121 89
122 90
123 91
124 91
125 92
126 93
127 94
INTRODUCTION
SMR2003_001_00_00A2.FM XV
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
Technical Publications
Bombardier Inc.
Valcourt (Quebec), Canada
Nm FASTENER SIZE (8.8) Lbfft
128 94
129 95
130 96
131 97
132 97
133 98
134 99
135 M14 100
136 100
137 101
138 102
139 103
140 103
141 104
142 105
143 105
144 106
145 107
146 108
147 108
148 109
149 110
150 111
Section 01 SERVICE TOOLS AND PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
SMR2003-049_01_01ATOC.FM 01-01-1
TABLE OF CONTENTS 0
MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1
ENGINE .............................................................................................................................. 01-02-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-02-5
PROPULSION SYSTEM..................................................................................................... 01-02-7
STEERING SYSTEM.......................................................................................................... 01-02-9
OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1
ENGINE .............................................................................................................................. 01-03-1
COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-03-6
BODY.................................................................................................................................. 01-03-8
WATERCRAFT HANDLING................................................................................................ 01-03-9
SERVICE PRODUCTS............................................................................................................ 01-04-1
Subsection 02 (MANDATORY SERVICE TOOLS)
SMR2003-002_01_02A.FM 01-02-1
MANDATORY SERVICE TOOLS 0
ENGINE
Degree wheel
P/N 529 035 607
A00B334
APPLICATION
717 and 787 RFI engines.
Piston circlip installer
A) P/N 529 035 562
B) P/N 529 035 563
F06B014
C) P/N 529 035 765
V04B0B4
APPLICATION
A) 717 and 787 RFI engines.
B) 947 DI engines.
C) 4-TEC engines
360 350
340
330
3
2
0
3
1
0
3
0
0
2
9
0
2
8
0
2
7
0
2
6
0
2
5
0
2
4
0
2
3
0
2
2 0
2 1 0
2 0 0 1 9 0 1 8 0
1 7 0
1 6 0
1
5
0
1
4
0
1
3
0
1
2
0
1
1
0
1
0
0
9
0
8
0
7
0
6
0
5
0
40
30
20
10
10
20
30
4
0
5
0
6
0
7
0
8
0
9
0
1
0
0
1
1
0
1
2
0
1
3
0
1
4
0
1
5
0
1 6 0
1 7 0 1 8 0 1 9 0
2 0 0
2 1 0
2
2
0
2
3
0
2
4
0
2
5
0
2
6
0
2
7
0
2
8
0
2
9
0
3
0
0
3
1
0
3
2
0
3
30
340
350 360
Sleeve set
A) P/N 529 035 542
(20 mm sleeve)
B) P/N 529 035 543
(21 mm sleeve)
F00B0U4
APPLICATION
B) 947 DI engines.
Air compressor ring compressor
P/N 529 035 713
F12B0L4
APPLICATION
947 DI engines.
Carbon dam guide
P/N 529 035 715
F12B0M4
APPLICATION
947 DI engines.
Carbon dam compressor
P/N 529 035 716
F12B0N4
APPLICATION
947 DI engines.
Bearing pusher
P/N 420 876 501
F00B074
APPLICATION
PTO flywheel remover/installer
A) P/N 295 000 001
B) P/N 529 035 820
F01J0T4
APPLICATION
A) 717 engines.
B) 4-TEC engines.
NOTE: This tool is also used for
the impeller.
01-02-2 SMR2003-002_01_02A.FM
Starter drive bearing pusher
P/N 420 876 502
F06B054
APPLICATION
947 DI engines.
Piston pin puller
P/N 529 035 503
Expansion sleeve
P/N 295 000 117
(787 RFI engines)
F00B0T4
APPLICATION
All 2-stroke engines.
Puller
P/N 529 035 547
A00C1A4
Puller plate
P/N 520 035 533
A00C1R4
Extension handle
P/N 295 000 125
F01D164
Screw M8 x 35 (3)
P/N 420 841 591
F00A094
Sleeve (3)
P/N 290 847 220
F00A0A4
APPLICATION
717 engines.
Puller is also used for PTO fly-
wheel on 947 DI engines.
Pusher
P/N 420 876 605
A00C0Y4
APPLICATION
717 engines.
Puller assy
P/N 290 876 488
1) Screw P/N 290 240 860
2) Hexagonal nut P/N 290 242 210
F01B0I4
APPLICATION
Alignment support plate kit
P/N 529 035 506
1) Alignment plates
A) P/N 529 035 507
B) P/N 529 035 508
2) Support
P/N 529 035 511
3) Screw (2)
P/N 207 182 544
4) Lock washer (2)
P/N 234 181 601
5) Flat washer (2)
P/N 234 081 410
F00B0F4
APPLICATION
All models.
A) 155.6 mm jet pump.
B) 139.5 mm jet pump.
Alignment shaft
P/N 295 000 141
F00B0G4
APPLICATION
All models.
2 1
SMR2003-002_01_02A.FM 01-02-3
Adapter
P/N 529 035 590
F00B124
APPLICATION
XP DI models.
Alignment adaptor
P/N 529 035 719
F18B0C4
APPLICATION
GTX 4-TEC models.
VCK (Vehicle Communication Kit)
P/N 529 035 844
F12H0A4
APPLICATION
All models.
Flywheel extractor
P/N 295 000 156
F00B044
APPLICATION
787 RFI engines.
Engine leak tester kit
P/N 295 500 352
Pump only
P/N 529 021 800
F01B2Q5
APPLICATION
717, 787 RFI , 947 DI engines.
Supplementary engine leak test
kit
P/N 295 500 780
1a) 787 RFI Intake plate
P/N 296 000 024
1b) 947 DI Intake plate
P/N 296 000 025
2) 947 DI Rave plate
P/N 296 000 026
3) 947 DI Exhaust plate
P/N 296 000 027
APPLICATION
787 RFI and 947 DI engines.
NOTE: This kit is supplementary
to P/N 295 500 352.
Handle
P/N 420 877 650
A00C3V4
APPLICATION
Use with pushers (P/N 290 876
609 and 290 877 740).
Rotary valve shaft pusher
P/N 290 876 609
F01B2B4
APPLICATION
787 RFI engines.
Use with handle P/N 420 877 650.
2 1 3
01-02-4 SMR2003-002_01_02A.FM
Oil seal pusher
P/N 290 877 740
F01B2C4
APPLICATION
787 RFI engines.
Use with handle P/N 420 877 650
Ring gear puller tool
P/N 420 976 235 (puller assy)
P/N 529 035 549 (puller bolt)
F01B294
APPLICATION
787 RFI and 947 DI engines.
Crankshaft protective cap
A) P/N 420 876 557
B) P/N 290 877 414
F00B194
APPLICATION
B) 947 DI engines.
A B
Polygonal wrench
P/N 529 035 505
F00B0Y4
APPLICATION
Exhaust system of the 947 DI en-
gines.
Ring gear blocking tool kit
A) P/N 529 035 846
B) P/N 529 035 946
F15B014
APPLICATION
A) 787 RFI engines.
B) 947 DI engines.
Intake plug
P/N 529 035 708
F12B0O4
APPLICATION
947 DI engines.
Crankshaft looking tool
P/N 529 035 821
F18B064
APPLICATION
4-TEC engines.
NEW
Camshaft looking tool
P/N 529 035 839
F18B074
APPLICATION
4-TEC engines.
Drive shaft adaptor
P/N 529 035 892
F00B214
APPLICATION
4-TEC engines.
Torx adapter
P/N 529 035 938
F00B204
APPLICATION
4-TEC Supercharged engines.
NEW
NEW
SMR2003-002_01_02A.FM 01-02-5
COOLING/FUEL/OIL SYSTEMS
Gear holder
P/N 420 277 905
A00C164
APPLICATION
717 engines.
Pliers
P/N 295 000 070
Oetiker 1099
F01D174
APPLICATION
All models.
Pliers
P/N 295 000 054
Caillau
F01B1T4
APPLICATION
All models.
the propulsion system.
Fuel pressure gauge
P/N 529 035 591
F02B0B4
APPLICATION
787 RFI and 4-TEC engines.
Fuel line disconnect tool
P/N 529 035 714
F12B0G4
APPLICATION
947 DI engines.
1. Fuel pressure gauge
P/N 529 035 709
2. Fuel pressure gauge T-fitting
P/N 529 035 710
3. Fuel pressure gauge pressure
relief valve
P/N 529 035 711
4. Fuel pressure gauge air com-
pressor adapter
P/N 529 035 712
F12R014
APPLICATION
947 DI engines.
Oil pressure gauge (1 to 8 bars)
P/N 529 035 709
V00B064
APPLICATION
4-TEC engines.
1
3 2 4
01-02-6 SMR2003-002_01_02A.FM
Engine oil pressure adapter
P/N 529 035 652
V00B074
APPLICATION
4-TEC engines.
Oil seal guide
P/N 529 035 822
F18B094
APPLICATION
4-TEC engines.
Coolant pump seal pusher
P/N 529 035 823
F18B084
APPLICATION
4-TEC engines.
SMR2003-002_01_02A.FM 01-02-7
PROPULSION SYSTEM
Impeller remover/installer
A) P/N 295 000 001
B) P/N 529 035 820
F01J0T4
APPLICATION
A) All 2-stroke models.
B) 4-TEC engines.
the PTO flywheel (on some mod-
els).
Pliers
P/N 295 000 069
Oetiker 1090
F01D184
APPLICATION
All models.
Impeller shaft holder
P/N 295 000 082
F01B0W4
APPLICATION
All 2-stroke models.
Jet pump bearing remover
P/N 295 000 144
F01J114
APPLICATION
Bearing/seal installer
P/N 295 000 107
F01J4K4
APPLICATION
All 2-stroke models
Inner seal installer
P/N 529 035 609
F08B014
APPLICATION
155.6 mm (6-1/8 in) jet pump.
Impeller shaft guide
P/N 295 000 002
F01J1O4
APPLICATION
Pliers
P/N 295 000 054
Caillau
F01B1T4
APPLICATION
All models.
the fuel system.
VTS tool
P/N 295 000 133
F01B2P4
APPLICATION
XP DI models.
Drive shaft alignment tool
P/N 529 035 590
F08B024
APPLICATION
XP DI models.
01-02-8 SMR2003-002_01_02A.FM
PTO seal support
P/N 529 035 842
F18B0F4
APPLICATION
GTX 4-TEC models.
Drive shaft holder
P/N 529 035 871
F18B0G4
APPLICATION
GTX 4-TEC models.
Drive shaft/floating ring
P/N 529 035 841
F18B044
APPLICATION
GTX 4-TEC models.
Seal/bearing pusher
P/N 529 035 818
F18B0D4
APPLICATION
GTX 4-TEC models.
Shaft pusher
P/N 529 035 819
F18B0E4
APPLICATION
GTX 4-TEC models.
Pressure cap
P/N 529 035 843
F18B054
APPLICATION
GTX 4-TEC models.
SMR2003-002_01_02A.FM 01-02-9
STEERING SYSTEM
O.P.A.S. cylinder nut wrench
P/N 529 035 840
F18B0A4
APPLICATION
Models equipped with the O.P.A.S.
system
Subsection 03 (OPTIONAL SERVICE TOOLS)
SMR2003-002_01_03A.FM 01-03-1
OPTIONAL SERVICE TOOLS 0
ENGINE
Engine stand
Not sold by Bombardier
F00B1X4
APPLICATION
4-TEC engines.
Lifting ring
P/N 529 035 830
A33B0642
APPLICATION
NEW
Lifting tool
P/N 529 035 940
A00B6B4
APPLICATION
All models.
Coil centering tool
P/N 420 876 922
A01B1V4
APPLICATION
717 engines.
Cylinder aligning tool
P/N 420 876 904
A00B084
APPLICATION
717 engines.
NEW
Distance gauge
A) P/N 529 034 800,
14 mm (.551 in)
B) P/N 529 034 900,
15.4 mm (.606 in)
C) P/N 529 035 100,
11.5 mm (.453 in)
D) P/N 529 035 000,
7.5 mm (.295 in)
F01B0H4
APPLICATION
A) 717 engines.
B) 787 RFI engines.
C) 947 DI engines (MAG).
D) 947 DI engines (PTO).
Spring installer/remover
P/N 529 035 559
A00C3S4
APPLICATION
GTX 4-TEC models.
01-03-2 SMR2003-002_01_03A.FM
Valve spring compressor clamp
P/N 529 035 724
V00B044
APPLICATION
4-TEC engines.
Valve spring compressor cup
P/N 529 035 725
V04B094
APPLICATION
4-TEC engines.
Ring compressor
Snap-on RC980
V04B084
APPLICATION
4-TEC engines.
Special pliers for valve stem seal
removal
Snap-on YA 8230
V02B064
APPLICATION
4-TEC engines.
Valve stem seal installer
P/N 529 035 687
V04B0H4
APPLICATION
4-TEC engines.
Torque angle gauge
Snap-on TA362
V04B0I4
APPLICATION
4-TEC engines.
Leak test kit pump
P/N 529 021 800
V00B084
APPLICATION
4-TEC engines.
Oil VAC
P/N 529 035 880
F18B0B4
APPLICATION
4-TEC engines.
Stroboscopic timing light
P/N 529 031 900
A00B4F4
APPLICATION
A) Four-pin magneto harness
P/N 295 000 131
B) Six-pin magneto harness
P/N 295 000 136
F01B284
APPLICATION
A) 717 engines.
B) 787 RFI and 947 DI engines.
SMR2003-002_01_03A.FM 01-03-3
Dial indicator (TDC gauge)
P/N 295 000 143
A00B4E4
APPLICATION
Digital/induction type
tachometer
P/N 529 014 500
F01B1G4
APPLICATION
Timing mark pointer
P/N 295 000 130
F01B2O4
APPLICATION
717 engines.
Timing mark pointer
P/N 295 000 135
F01H544
APPLICATION
787 RFI, 947 DI engines.
Crimping tool
P/N 295 100 164 AMP crimping
tool and die (for MPEM)
P/N 529 035 905 EMS ECU
crimping tool and die
Crimping tool
F00B0E4
Die
P/N 529 035 906 individual die for
EMS ECU connector
A00B6942
APPLICATION
Contacts of AMP and EMS ECU
plug connectors.
NEW
NEW
Crimp pliers
(P/N 529 035 730)
A00B6A4
APPLICATION
Starter and battery cable terminals
Terminal (Packard) remover
Snap-on
TT 600-4
F01B1J4
APPLICATION
All models.
Joint connector tool
Deutsch
114010
F12B0C4
APPLICATION
DI models.
NEW
01-03-4 SMR2003-002_01_03A.FM
Safety lanyard switch tool
P/N 529 034 600
F01B244
APPLICATION
All models.
Slide hammer puller
Snap-on:
Handle: CJ93-1
Hammer: CJ125-6
Claws: CJ93-4
F01J0Z4
APPLICATION
NOTE: This tool is also used to
pull out impeller shaft seal.
Protective mat
P/N 295 000 128
F02B0A4
APPLICATION
All models.
Gear/bearing puller
P/N 290 877 665
F04B034
APPLICATION
787 RFI engines.
Exhaust outlet tool
P/N 295 000 132
F01B2A4
APPLICATION
All models.
Feeler gauge 45
Snap-on
FB 300 A
F01B1K4
APPLICATION
Steering cable tool
P/N 295 000 145
F01B2P4
APPLICATION
All models.
Rubber pad
P/N 295 000 101
F01B0J4
APPLICATION
Rubber pad
P/N 290 877 032
F06B064
APPLICATION
947 DI engines.
MPEM programmer
P/N 529 035 878
A01B5B4
APPLICATION
Piston ring compressor (2)
A) P/N 290 876 965 (88 mm)
B) P/N 290 876 979 (82 mm)
F01B1T4
APPLICATION
A) 947 DI engines.
B) 717 and 787 RFI engines.
SMR2003-002_01_03A.FM 01-03-5
Digital multimeter
P/N 529 035 868
V00B0H4
APPLICATION
All models.
F01D885
1) Puller assy
P/N 420 877 635
2) Protective cap
P/N 420 876 557
P/N 290 877 414
(947 DI engines)
3) Ring (both ends)
P/N 420 977 490
P/N 420 977 480
(947 DI engines)
4) Ring halves (PTO)
P/N 420 977 475 (2)
P/N 420 876 330
(947 DI engines)
5) Distance ring (MAG)
P/N 420 876 569
6) Ring halves (MAG)
P/N 420 276 025 (2)
7) Screw M8 x 40
P/N 420 840 681 (2)
8) Screw M8 x 70
P/N 420 841 201 (2)
9) Puller bolt
P/N 420 940 755
APPLICATION
All 2-stroke engines.
MAG side PTO side
8
1
5
2
3
4
4
6
8 7 7
9 9
01-03-6 SMR2003-002_01_03A.FM
COOLING/FUEL/OIL SYSTEMS
Pump gauge tester
P/N 295 000 114
F01B0X4
APPLICATION
717 engines.
Lighted adjustable mirror
Snap-on
50101
F01B1I4
APPLICATION
All models.
Hose pincher
P/N 529 032 500
F01B234
APPLICATION
All models.
Hose pincher
P/N 295 000 076
A01B2I4
APPLICATION
All models.
35 43
25
2
15
1 5
60
50
4 0
30
20
1 0
Flexible spout (oil)
P/N 414 837 300
F04B044
APPLICATION
All models.
Flushing adapter
P/N 295 500 473
F00B104
APPLICATION
All models.
Use with coupler hose (P/N 295
500 258).
Test radiator cap
P/N 529 021 400
F18E1P4
APPLICATION
4-TEC models.
P
A
S
O
U
V
RIR A
C
H
A
U
D
SMR2003-002_01_03A.FM 01-03-7
PROPULSION SYSTEM
Fitting
P/N 295 000 086
F01B0Z4
APPLICATION
All models.
Slide hammer puller
Snap-on:
Handle: CJ93-1
Hammer: CJ125-6
Claws: CJ93-4
F01J0Z4
APPLICATION
All models.
NOTE: This tool is also used to re-
move rotary valve shaft bearing.
Hacksaw
Snap-on
HS3
F01B1M4
APPLICATION
All models.
01-03-8 SMR2003-002_01_03A.FM
BODY
Spring compressor
P/N 529 035 504
A01B4O4
APPLICATION
XP DI models.
Suspension adjustment wrench
P/N 529 012 200
A25A014
APPLICATION
XP DI models.
Suction cup
P/N 295 000 163
F00B1Y4
APPLICATION
4-TEC models.
NEW
SMR2003-002_01_03A.FM 01-03-9
WATERCRAFT HANDLING
Dolly (with wheels)
P/N 295 000 126
F01B014
Beach wheels (set of 2 wheels)
P/N 295 000 005
F01B074
APPLICATION
Dolly.
Tie-down
1.50 m (5 ft) long
P/N 295 100 103
F00B014
APPLICATION
All models.
Lift kit
A) P/N 295 100 206
B) P/N 295 100 205
C) P/N 295 100 204
F00B1Z4
APPLICATION
A) 2-stroke models except LRV DI.
B) 4-TEC models.
B) LRV DI models.
NEW
Subsection 04 (SERVICE PRODUCTS)
SMR2003-002_01_04A.FM 01-04-1
SERVICE PRODUCTS 0
Loctite
is a trademark of Loctite Corporation.

Permatex
is a trademark of Loctite Corporation.

Dow Corning
is a trademark of Dow Corning Corporation.

Medium strength threadlocker
P/N 293 800 060
Loctite 243 (blue)
(10 mL)
F00A0O4
High strength threadlocker
P/N 293 800 005
Loctite 271 (red)
(10 mL)
A00B2U4
High temperature threadlocker
P/N 420 899 788
Loctite 648 (green)
(5 g)
A00B3D4
High temperature retaining
compound
P/N 293 800 054
Loctite 642
(50 mL)
F00B024
Retaining compound
P/N 413 703 100
Loctite

RC/609 (green)
(10 mL)
A00B2S4
General purpose instant
adhesive
P/N 293 800 021
Loctite 495
A00B2V4
Gasket eliminator
P/N 293 800 038
Loctite 518
(50 mL)
F01B124
Flange sealant
P/N 293 800 081
Loctite 5910
(300 mL)
F00B1A4
01-04-2 SMR2003-002_01_04A.FM
Chisel gasket remover
P/N 413 708 500
(510 mL)
A00B574
RTV silicone sealant
P/N 293 800 066
Loctite 5900 (300 mL)
A02B0B4
Thread sealant
P/N 293 800 050
Loctite 577
(250 mL)
F00B0W4
Molykote 111
P/N 413 707 000
A00B3W4
NEW
1
1
1
Primer for gasket eliminator
P/N 293 800 041
Loctite 764
A00B3N4
Pipe sealant
A) P/N 293 800 018
B) P/N 293 800 013
A) Loctite 592 (50 mL)
B) Loctite 567 (250 mL)
A00B2W4
Hylomar sealant
P/N 293 800 001
PL-32
(100 g)
A00B3F4
Sealant
P/N 293 530 011
Sikaflex 221 (black)
(350 mL)
F01B1D4
Dielectric grease
P/N 293 550 004
Dow Corning
(150 g)
A00B1X4
High temperature RTV sealant
(P/N 293 800 090)
Ultra Copper (80 mL)
A00B5A4
Deoxit contact lubricant
P/N 293 550 034
(200 mL)
F00B0X4
SMR2003-002_01_04A.FM 01-04-3
Grease
P/N 293 550 005
(400 g)
A00B2L4
Synthetic grease
P/N 293 550 010
(400 g)
F01B154
Super Lube grease
P/N 293 550 030
V00B0I4
Anti-seize lubricant
P/N 293 800 070
Loctite 76764
454 g (16 oz)
A00B594
Grease Isoflex
(P/N 293 550 021)
(50 g)
A00B554
BOMBARDIER LUBE
P/N 293 600 016
(12 x 14 oz)
A00B624
BOMBARDIER storage oil
P/N 413 711 600 (CDN)
P/N 413 711 900 (U.S.)
(12 x 350 g)
A00B634
Sea-Doo fuel stabilizer
P/N 413 408 600
236 mL (8 oz)
A00B604
732 Multi-purpose sealant
P/N 293 800 033
Dow Corning (90 mL)
(clear)
F01B1C4
NEW
01-04-4 SMR2003-002_01_04A.FM
Premixed coolant 50/50
- 37C (- 35F)
P/N 293 600 038
(16 x 1 L)
A00B5X4
BOMBARDIER FORMULA XP-S II
synthetic injection oil
P/N 293 600 045
(12 x 1 liter)
A00B5T4
P/N 293 600 046
(3 x 4 liter)
A00B5U4
P/N 293 600 247
(205 liter)
Sealant adhesive
P/N 293 800 086
Loctite 5150
(29647)
A00B5S4
Instant gasket
P/N 293 800 088
(7 oz)
A02B0C4
Jet pump oil
P/N 293 600 011
Sea-Doo
synthetic jet pump oil
(12 x 6 oz)
F01B0P4
Jet pump bearing grease
P/N 293 550 032
(110g)
F18B0H4
Sea-Doo Cleaner
P/N 293 110 001 (400 g)
P/N 293 110 002 (4 L)
F01B2J4
Pulley flange cleaner
P/N 413 711 809
A00B5V4
Section 02 MAINTENANCE
SMR2003-049_02_01ATOC.FM 02-01-1
TABLE OF CONTENTS 0
PERIODIC INSPECTION CHART ........................................................................................... 02-02-1
FLUSHING AND LUBRICATION ........................................................................................... 02-03-1
GENERAL ........................................................................................................................... 02-03-1
PROCEDURE...................................................................................................................... 02-03-1
WATER-FLOODED ENGINE .................................................................................................. 02-04-1
GENERAL ........................................................................................................................... 02-04-1
PROCEDURE...................................................................................................................... 02-04-1
STORAGE............................................................................................................................... 02-05-1
ENGINE DRAINING ........................................................................................................... 02-05-1
FUEL SYSTEM................................................................................................................... 02-05-3
ENGINE OIL CHANGE AND FILTER ................................................................................. 02-05-4
COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION.................... 02-05-4
ENGINE LUBRICATION..................................................................................................... 02-05-4
BATTERY............................................................................................................................ 02-05-5
WATERCRAFT CLEANING................................................................................................ 02-05-5
ADDITIONAL RECOMMENDED PROTECTION................................................................ 02-05-5
ANTICORROSION TREATMENT....................................................................................... 02-05-14
CHECKLIST ........................................................................................................................ 02-05-14
Subsection 02 (PERIODIC INSPECTION CHART)
SMR2003-003_02_02A.FM 02-02-1
PERIODIC INSPECTION CHART 0
The schedule should be adjusted according to operating conditions and use.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenance
operation to whatever time comes first.
IMPORTANT: Schedule for watercraft rental operations or higher number of hour use, will require greater
frequency of inspection and maintenance.
2-Stroke Models
DESCRIPTION FREQUENCY
I: Inspect, verify, clean, adjust, lubricate, replace if necessary
C: Clean
L: Lubricate
R: Replace
F
I
R
S
T

1
0
H
O
U
R
S
E
V
E
R
Y

2
5
H
O
U
R
S

O
R
3

M
O
N
T
H
S
E
V
E
R
Y

5
0
H
O
U
R
S

O
R
6

M
O
N
T
H
S
E
V
E
R
Y

1
0
0
H
O
U
R
S
O
R

1

Y
E
A
R
GENERAL
Lubrication/corrosion protection C
ENGINE
Support and rubber mount I I
Exhaust system fasteners I I
RAVE valve (if so equipped) C C
Top end (leak test, piston and ring clearance) (DI models only)
Counterbalance shaft oil level (if so equipped) I I
Spark plug I R
Ignition timing (all models except DI) I
TDC setting (DI models only)
COOLING SYSTEM
Flushing C
Hose and fasteners I I
Engine drain tubes I
Water flow regulator valve (if so equipped) I
FUEL SYSTEM
Carburetor including choke/throttle cable (carburetor-equipped models) I I
Throttle/choke cables (carburetor-equipped models) I
Fuel filter (except RFI models) and lines I I
Fuel filter (except DI and RFI models) R
Fuel filter (DI models only)
Oil leakage between cylinder head and injector (DI models) I I
Fuel injection system sensors (except throttle body), (RFI and DI models) I I
Throttle body and their sensors (DI models) I I
Fuel vent line pressure relief valve I
Fuel lines, connections (DI models), check-valve and fuel system pressurization I I
Carburetors/throttle bodies, sensors, fuel lines, fuel rail and fittings
(if so equipped)
I I
Air intake silencer fit/tightness I I
Fuel tank straps I I
02-02-2 SMR2003-003_02_02A.FM
Every 10 hours in salt water use.
These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in
this chart.
Daily flushing in salt water or foul water use.
Except DI models.
Emission-related component.
In salt water use.
Replace at 150 hours.
Replace at 250 hours.
Check at 350 hours or 5 years.
LUBRICATION SYSTEM
Oil injection pump I I
Oil filter and lines I I
Oil filter R
Oil reservoir straps I
ELECTRICAL SYSTEM
Electrical connections and fastening (ignition system, electrical box(es), starting
system, fuel injectors (RFI and DI models), etc.)
I I
MPEM mounting brackets/fasteners I
Digitally Encoded Security System I I
Monitoring beeper I I
Battery and strap(s)/fasteners I I
STEERING SYSTEM
Steering cable I I
O.P.A.S. SYSTEM
O.P.A.S. system I I
PROPULSION SYSTEM
Drive shaft boot and splines (if so equipped) I
Drive shaft protection hose I
PTO flywheel L L
Shifter system/cable I I
VTS (Variable Trim System) (if so equipped) I I
Jet pump reservoir oil and oil level R I R
Jet pump cover pusher (if so equipped) I
Impeller shaft seal
Impeller and impeller/wear ring clearance R
Water intake grate I
HULL/BODY
Bailer pick-ups, check for obstructions I I
Hull I I
C: Clean
L: Lubricate
R: Replace
F
I
R
S
T

1
0
H
O
U
R
S
E
V
E
R
Y

2
5
H
O
U
R
S

O
R
3

M
O
N
T
H
S
E
V
E
R
Y

5
0
H
O
U
R
S

O
R
6

M
O
N
T
H
S
E
V
E
R
Y

1
0
0
H
O
U
R
S
O
R

1

Y
E
A
R
SMR2003-003_02_02A.FM 02-02-3
4-TEC Models
C: Clean
L: Lubricate
R: Replace
F
I
R
S
T

1
0
H
O
U
R
S
E
V
E
R
Y

2
5
H
O
U
R
S

O
R
3

M
O
N
T
H
S
E
V
E
R
Y

5
0
H
O
U
R
S

O
R
6

M
O
N
T
H
S
E
V
E
R
Y

1
0
0
H
O
U
R
S
O
R

1

Y
E
A
R
GENERAL
Lubrication/corrosion protection L
ENGINE
Engine oil and filter (including covers O-rings) R R
Support and rubber mount I I
Seals and fasteners I I
Exhaust system fasteners I I
Spark plug R
Supercharger slipping moment I
Supercharger drive gear, shaft and lock washer I
COOLING SYSTEM
Flushing (exhaust system) C
Hose and fasteners I I
Coolant
Coolant expansion tank cap/cooling system pressure test
FUEL SYSTEM
Throttle cable I
Fuel injection system sensors I I
Throttle body. Fault code reading I
Fuel vent line pressure relief valve I
Fuel lines, connections and fuel system pressurization I I
Throttle body, sensors, fuel lines, fuel rail and fittings I I
Air intake silencer fit/tightness I I
Fuel tank straps I I
ELECTRICAL SYSTEM
Electrical connections and fastening
(ignition system, starting system, fuel injectors etc.)
I I
Check fault codes I I
MPEM and EMS ECU connectors I
MPEM mounting brackets/fasteners I
Digitally Encoded Security System and safety lanyard/post I I
Monitoring beeper I I
Battery and fasteners I I
STEERING SYSTEM
Steering cable I I
O.P.A.S. SYSTEM
O.P.A.S. system including filter I I I
02-02-4 SMR2003-003_02_02A.FM
In salt water use.
These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in
this chart.
Daily flushing in salt water or foul water use.
Perform every 200 hours or 2 years.
Emission-related component.
Replace after the vehicle completed 100 hours of use or 2 years.
Replace for storage period or after 100 hours of use whichever comes first.
Every 25 hours when riding in weed areas.
Every 200 hours of use, not every 2 years.
PROPULSION SYSTEM
Drive shaft protection boot I
Grease splines in jet pump L
Shifter system/cable I I
Impeller shaft seal, sleeve and O-ring
Impeller and impeller/wear ring clearance I
Water intake grate I
Ride plate including coolant leak I I
Drive shaft/hull sealing system I I
HULL/BODY
Bailer pick-ups, check for obstructions I I
Hull I I
Ski/wake board post and fasteners I I
C: Clean
L: Lubricate
R: Replace
F
I
R
S
T

1
0
H
O
U
R
S
E
V
E
R
Y

2
5
H
O
U
R
S

O
R
3

M
O
N
T
H
S
E
V
E
R
Y

5
0
H
O
U
R
S

O
R
6

M
O
N
T
H
S
E
V
E
R
Y

1
0
0
H
O
U
R
S
O
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1

Y
E
A
R
Subsection 03 (FLUSHING AND LUBRICATION)
SMR2003-003_02_03A.FM 02-03-1
FLUSHING AND LUBRICATION 0
GENERAL
Flushing the cooling system 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 water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Cooling system flushing and engine internal lubri-
cation 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.
CAUTION: Failure to flush cooling system, when
necessary, will severely damage engine and/or
exhaust system. Never flush a hot engine. Make
sure engine operates during entire procedure.
PROCEDURE
Clean jet pump by spraying water in its inlet and
outlet and then spray BOMBARDIER LUBE lubri-
cant.
Install flushing adapter (P/N 295 500 473) to the
water outlet located at the rear of the watercraft.
1. Install flushing adaptor
Connect a garden hose to the flushing adaptor.
NOTE: A quick connect adapter can be used to
ease garden hose installation.
1. Quick connect adapter
2. Flushing adaptor (P/N 295 500 473)
1. Garden hose installed
2. Quick connector adaptor
WARNING
Perform this operation in a well ventilated area.
Do not touch any electrical parts or jet pump
area when engine is running.
WARNING
Always remove safety lanyard cap from post to
prevent accidental engine starting before
cleaning the jet pump area. Engine must not be
running for this operation.
F06E01A
1
1 F00E05A 2
F07E01B 1 2
02-03-2 SMR2003-003_02_03A.FM
All Models except 4-TEC Models
Start the engine then immediately open the water
tap.
CAUTION: Never flush a hot engine. Always start
the engine before opening the water tap. Open
water tap immediately after engine is started to
prevent overheating.
Run the engine about 3 minutes at a fast idle around
3500 RPM.
Spray BOMBARDIER LUBE lubricant through air
intake silencer keeping engine at fast idle for ap-
proximately one minute.
All Models except 947 DI and 4-TEC Models
717 AND 787 RFI ENGINES
1. Air intake silencer
2. Pull plug
3. Spray BOMBARDIER LUBE here
947 DI Models
Spray, through hole of air intake silencer.
NOTE: An increase of engine RPM may be noticed
while spraying the lubricant in the air intake silencer.
1. Partially pull tube out of air box to inject BOMBARDIER LUBE
lubricant or equivalent. Push tube in when finished
Close the water tap then stop the engine.
CAUTION: Always close the water tap before
stopping the engine.
Disconnect the garden hose.
CAUTION: Remove quick connect adapter after
flushing operation (if used).
Wipe up any residual water from the engine.
Remove spark plug cables and connect them on
the grounding device.
GTI AND GTI LE MODELS
1. Grounding device
WARNING
Do not touch any electrical parts or jet pump
F01F25A
1 3 2
WARNING
Always use spark plug cable grounding de-
vice when removing spark plugs.
F12F01A 1
1 F01H7CA
SMR2003-003_02_03A.FM 02-03-3
787 RFI AND 947 DI MODELS
1. Grounding device
Remove both spark plugs and spray BOMBARDIER
LUBE lubricant into each cylinder.
All Carburetor-Equipped Models
Connect safety lanyard cap to the post.
Fully depress the throttle lever then press the
start/stop button to crank the engine a few turns
to distribute the oil onto cylinder wall.
787 RFI Models
Fully depress throttle lever and connect the safety
lanyard to the switch.
Press the start/stop button to crank the engine a
few turns and distribute the lubricant onto cylinder
walls.
NOTE: Proceeding in this order, no fuel will be in-
jected into the engine.
947 DI Models
NOTE: Proceeding in this order, no fuel will be in-
jected and no ignition will occur in the engine.
While engine is stopped, fully depress throttle le-
ver and HOLD for cranking.
Wait 2 seconds then press the start/stop button
to crank the engine a few turns and distribute the
lubricant onto cylinder walls.
NOTE: A 1 second beep every second indicates the
drowned mode is active.
All Models except 4-TEC
Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover (if so
equipped, on 717 and 787 RFI engines).
NOTE: Engine fogging should be done wi th
BOMBARDIER LUBE lubricant whenever the water-
craft is to be stored for a few days or a long period.
CAUTION: Never leave rags or tools in the en-
gine compartment or in the bilge.
4-TEC Engines
Closed Loop Cooling System
4-TEC engines are equipped with a closed loop
cooling system which does not need to be flushed
even after salt water use.
Open Loop Cooling System
Flushing the exhaust cooling system with fresh wa-
ter is essential to neutralize corroding effects of salt
or other chemical products present in water. It will
help to remove sand, salt, shells or other particles in
water jackets and/or hoses.
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.
Proceed as follows:
Clean jet pump by spraying water in its inlet and
outlet and then apply a coating of BOMBARDIER
LUBE lubricant or equivalent.
1 F01H7DA
WARNING
Perform this operation in a well ventilated area.
Do not touch any electrical part or jet pump
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.
02-03-4 SMR2003-003_02_03A.FM
Models without a Flushing Connector in
Engine Compartment
Connect a garden hose to connector located at the rear
of watercraft on jet pump support. Do not open water
tap yet.
NOTE: An optional quick connect adapter can be
used. No hose pincher is required to flush engine.
1. Quick connect adapter
2. Flushing adaptor (P/N 295 500 473)
TYPICAL
1. Hose adapter
2. Quick connect adapter (optional, not mandatory)
3. Garden hose
Models with a Flushing Connector in Engine
Compartment
This flushing connector allows flushing while wa-
tercraft is on a lift or if you prefer to flush from this
location. Either flushing connector can be used to
flush the exhaust cooling system. The one at the
jet pump support (see above) or the one in the en-
gine compartment (see below).
Remove seat to gain access.
1. Flushing connector
2. Dust cap
Remove dust cap from flushing connector and at-
tach coupler hose (supplied in rear storage com-
partment). Make sure coupler hose is properly
locked to flushing connector.
WARNING
When operating the engine while the water-
craft 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.
1 F00E05A 2
F07E01C 3 2 1
1
2
F18E1TA
SMR2003-003_02_03A.FM 02-03-5
Install a hose pincher (supplied inside tool kit in
rear storage compartment) on water outlet hose.
NOTE: This prevents water from directly exiting
exhaust cooling system.
1. Coupler hose
2. Hose pincher
Attach other end of coupler hose to a garden hose.
Do not open water tap yet.
All 4-TEC Models
Flushing
To flush the exhaust cooling system, start the en-
gine then immediately open the water tap.
CAUTION: Never flush a hot engine. Always
start the engine before opening the water tap.
Open water tap immediately after engine is
started to prevent overheating.
Run the engine about 20 seconds at a fast idle
between 4000 - 5000 RPM.
CAUTION: Never run engine without supplying
water to the exhaust cooling system when wa-
tercraft is out of water.
Ensure water flows out of jet pump while flushing.
CAUTION: Never run engine longer than 5 min-
utes. Drive line seal has no cooling when water-
craft is out of water.
Close the water tap, then stop the engine.
CAUTION: Always close the water tap before
stopping the engine.
Disconnect the garden hose.
CAUTION: Remove quick connect adapter after
flushing operation (if used).
NOTE: Engine valves fogging should be done
whenever the watercraft is to be stored for a long
period. Refer to STORAGE section.
WARNING
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
1 2
F18E1UA
Subsection 04 (WATER-FLOODED ENGINE)
SMR2003-004_02_04A.FM 02-04-1
WATER-FLOODED ENGINE 0
GENERAL
If engine is water-flooded, it must be serviced
within a few hours after the event. Otherwise en-
gine will have to be overhauled.
CAUTION: A water-flooded engine must be prop-
erly lubricated, operated then lubricated again,
otherwise parts will be seriously damaged.
PROCEDURE
2-Stroke Models
Check fuel and oil reservoirs for water contamina-
tion. If necessary, siphon and refill with fresh fluids.
Turn fuel valve to OFF position (carburetor-
equipped models) then drain fuel filter bowl. Re-
fer to FUEL CIRCUIT.
Drain bilge if water is present.
GTI AND GTI LE MODELS
1. Grounding device
787 RFI AND 947 DI MODELS
1. Grounding device
Remove spark plugs and dry them with a clean
cloth. A contact cleaner spray can be used. It may
be preferable to replace spark plugs. Do NOT in-
stall spark plugs on engine yet.
Cover spark plug holes with a rag.
Carburetor-Equipped Models
Fully depress the throttle lever then crank the en-
gine to drain crankcase.
NOTE: Ensure choke lever is completely pushed in.
787 RFI Models
NOTE: Proceeding in the following order, no fuel
will be injected into the engine.
Remove safety lanyard from its post.
Depress and hold the throttle lever at full throttle
position. Wait 2 seconds then, reinstall the safety
lanyard cap.
Press the start/stop button to crank the engine to
allow water to escape from spark plug openings.
WARNING
Never crank engine with spark plugs removed
unless spark plug cables are connected to the
grounding device.
1 F01H7CA
WARNING
Be careful when cranking engine in the fol-
lowing procedure, water will spray out from
spark plug holes.
1 F01H7DA
02-04-2 SMR2003-004_02_04A.FM
947 DI Models
Remove the air pressure hose from the compres-
sor.
CAUTION: Failure to remove the air pressure
hose from the compressor will result in the
bending of the compressor connecting rod,
when cranking the engine.
1. Disconnect this hose
Remove the flywheel guard and turn the PTO fly-
wheel several times, by hand.
NOTE: Proceeding in the following order, no fuel
will be injected into the engine and ignition will be
cut.
While engine is stopped, fully depress throttle le-
ver and HOLD for cranking.
Crank engine several times to drain crankcase.
NOTE: A 1 second beep every second indicates
the drowned mode is active.
If water does not completely go out, it may be nec-
essary to remove the air intake silencer then to
lean the vehicle so that water can flow out from
throttle bodies.
Spray BOMBARDIER LUBE lubricant (P/N 293 600
016) into spark plug holes.
Crank engine again.
Reinstall spark plugs and spark plug cables.
787 RFI Engines
Remove the filler plug of the counterbalance shaft
on the engine crankcase.
787 RFI ENGINES
1. Remove filler plug
Insert a wire through oil filler hole to check oil con-
dition. A whitish oil indicates water contamination
and must be replaced.
In order to replace the oil, remove the drain plug
of the counterbalance shaft located on the PTO
side of the lower crankcase.
787 RFI ENGINES
1. Drain plug
Drain completely the crankcase oil of the counter-
balance shaft. Reinstall drain plug with Loctite 515.
Add 30 mL (1 oz) of SAE 30 motor oil.
Reinstall filler plug.
1
F18D1AA
F07D06A
1
F07D07A 1
SMR2003-004_02_04A.FM 02-04-3
Turn fuel valve to ON position.
Start engine. It may be necessary to use the
choke. If engine does not start, repeat previous
steps as necessary.
787 RFI and 947 DI Models
Start engine according to normal starting procedure.
CAUTION: To avoid starting motor overheating,
the cranking period should not exceed 5 - 10 sec-
onds and a rest period of 30 seconds should be
observed between cranking cycles.
NOTE: If engine does not start after several at-
tempts, check ignition system for spark occur-
rence. Refer to IGNITION SYSTEM for 717 and 787
RFI engines and refer to ENGINE MANAGEMENT
for 947 DI engines.
Check crankshaft if needed, it may be misaligned
or deflected. Refer to BOTTOM END.
After engine has started, spray BOMBARDIER
LUBE lubricant for one minute through air intake
silencer while engine is running.
All Models except 947 DI and 4-TEC Models
2. Pull plug
3. Spray BOMBARDIER LUBE here
947 DI Models
Spray, through hole of air intake silencer.
NOTE: An increase of engine RPM may be noticed
while spraying the lubricant in the air intake silencer.
1. Partially pull tube out of air box to inject BOMBARDIER LUBE
lubricant or equivalent. Push tube in when finished
Run engine until it reaches its normal operating
temperature.
CAUTION: Engine must be cooled using the flush
kit.
4-TEC Models
Check fuel reservoir for water contamination. If
necessary, siphon and refill with fresh fuel.
To limit damages to the engine, perform the fol-
lowing procedure as soon as possible.
Drain bilge if water is present.
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.
CAUTION: 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.
F01F25A
1 3 2
F12F01A 1
02-04-4 SMR2003-004_02_04A.FM
Whenever the engine is stopped, all the valves
close thus preventing water from being ingested
in the engine.
Supercharged 4-TEC Engines
Inlet duct should be disconnected from super-
charger inlet tube to validate presence of water.
1. Inlet duct
2. Inlet hose
3. Outlet hose
If water is suspected to be in the supercharger,
remove its outlet hose and siphon water out. En-
sure that siphon tube is inserted to the lowest
point in the supercharger.
If necessary, remove supercharger housing.
All 4-TEC Engines
If water is suspected to be in the intake and the
exhaust system, it must be drained as follows:
Remove the intake manifold and drain it. Then
suck out the water from the intake valve ports.
Refer to subsection INTAKE SYSTEM.
Remove the water from oil/air separator breather
hose.
Remove the exhaust pipe and drain it. Then either
remove the mufflers to drain them or siphon the
water out of them. Refer to subsection EXHAUST
SYSTEM.
If water gets in the oil (oil will be milky), change
the engine oil and filter as follows.
Oil Change Procedure
(water-contaminated oil)
1. Using the oil VAC (P/N529 035 880), siphon oil
from reservoir through dipstick hole.
CAUTION: Never crank or start engine when si-
phon tube is in dipstick hole. Never start engine
when there is no oil in engine.
2. Remove the oil vac tool from the dipstick hole.
3. While in drowned engine mode, crank the en-
gine for 5 seconds.
4. Remove the oil filter cap and the oil filter.
5. Again, siphon oil from the reservoir.
6. Put a rag under the scavenge oil pump cover.
7. Remove the scavenge oil pump cover drain plug
and install a fitting (P/N 293 710 037).
1. Scavenge oil pump cover drain plug
8. Connect the oil vac tool Bombardier (P/N 529
035 880) to the fitting.
9. The front of the engine must be tilted down ap-
proximately 15 degrees to facilitate the removal
of the oil. Raise the rear of the boat accordingly.
Siphon the oil from the fitting.
3 F18D2OA 2 1
1 F18D19A
F18D2PA
SMR2003-004_02_04A.FM 02-04-5
10. Level the engine.
11. Remove the oil vac tool and the fitting. Apply
Loctite 243 and reinstall the drain plug.
NOTE: If spillage occurs, clean immediately with
the Pulley flange cleaner (P/N 413 711 809) to pre-
vent oil stains.
12. Install a new oil filter and reinstall the oil filter
cap.
13. Fill up the reservoir with fresh oil.
14. Boil out the remaining water as follows:
a. Recommended procedure: BOIL OUT PRO-
CEDURE IN A TEST TANK OR TIED TO A
TRAILER WITH WATERCRAFT IN WATER.
b. Optional procedure: BOIL OUT PROCE-
DURE CONNECTED TO A FLUSH KIT.
Refer to instructions below.
Boil Out Procedure
Procedure in a Test Tank or Tied to a Trailer with
Watercraft in Water
1. Run the engine for 5 minutes at 3500 RPM.
2. With the engine still running at 3500 RPM, in-
stall a hose pincher to the coolant line going to
the oil cooler.
1. Oil cooler coolant inlet hose
3. Continue to run the engine at 3500 RPM for 15
more minutes (20 minutes total run time).
4. Shut the engine off.
5. Remove the hose pincher on the coolant line
going to the oil cooler.
CAUTION: Hose pincher must be removed pri-
or to operating the watercraft. Failure to do this
will result in damage to the engine.
6. Change the oil and filter again.
7. Procedure is now completed.
Procedure Connected to a Flush Kit
1. On drive shaft, remove the C-Clip then move
forward the ring seal carrier. Refer to DRIVE
SYSTEM section.
CAUTION: Make sure that the ring seal carrier
is not in contact with the PTO seal assembly,
neither with the carbon ring.
2. Connect a flush kit to the coolant line.
3. Run the engine for 5 minutes at 3000 RPM.
WARNING
Make sure to safely secure the watercraft.
WARNING
Certain components in the engine compart-
ment may be very hot. Direct contact may re-
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run-
ning.
1
F18E1QA
02-04-6 SMR2003-004_02_04A.FM
4. With the engine still running at 3000 RPM, in-
stall a hose pincher to the coolant line going to
the oil cooler.
1. Oil cooler coolant inlet hose
5. Continue to run the engine at 3000 RPM for 15
more minutes (20 minutes total run time).
6. Shut off the engine
7. Remove the hose pincher on the coolant line
going to the oil cooler
CAUTION: Hose pincher must be removed pri-
or to operating the watercraft. Failure to do this
will result in damage to the engine.
8. Change the oil and filter again.
9. Move rearward the Ring Seal Carrier and rein-
stall the C-Clip. Refer to DRIVE SYSTEM sec-
tion.
Water in Supercharger
Supercharged 4-TEC Engines
If there was water in Tthe oil and presence of wa-
ter is suspected in the shaft and bearing area of
the supercharger, it is recommended to take the
supercharger apart, dry all the components includ-
ing the slip clutch and replace both ball bearings.
Refer to INTAKE SYSTEM.
Finalizing the Procedure
All 4-TEC Engines
The watercraft should be ridden as soon as possi-
ble to dry it out.
WARNING
Certain components in the engine compart-
ment may be very hot. Direct contact may re-
sult in skin burn. Do not touch any electrical
parts or jet pump area when engine is run-
ning.
1
F18E1QA
Subsection 05 (STORAGE)
SMR2003-005_02_05A.FM 02-05-1
STORAGE 0
ENGINE DRAINING
All Carburetor-Equipped Engines
Check engine drain hose (lowest hose of engine).
Make sure there is no sand or other particles in it
and that it is not obstructed so that water can exit
the engine. Clean hose and fitting as necessary.
CAUTION: Water in engine drain hose must be
free to flow out, otherwise water could be trapped
in engine. Should water freeze in engine, severe
damage will occur. Check engine drain hose for
obstructions.
TYPICAL
1. Engine drain hose
RFI Models
Disconnect the water supply hose used to cool the
magneto. It features a quick connect fitting. Press
both tabs and pull fitting in order to disconnect
hose.
This hose is located at the bottom of the magneto
cover beside the engine support.
TYPICAL
1. Press tabs here and disconnect hose
Water should flow out of the fitting (magneto cooling
circuit) and hose (crankcase heat exchanger).
Push and hold hose against bilge so that draining
can take place.
1. Fitting
2. Hose
F07E0MA 1
F17E0AA
1
1
2
F17E0BA
02-05-2 SMR2003-005_02_05A.FM
CAUTION: Water in heat exchanger system must
be free to flow out. Should water freeze in engine,
severe damage will occur.
Reconnect hose when done.
DI Models
Disconnect the quick connect fitting. Press both
tabs and pull fitting.
RX DI MODELS DISCONNECT THIS HOSE
GTX DI MODELS DISCONNECT THIS HOSE
XP DI MODELS DISCONNECT THIS HOSE
1. Disconnect engine drain hose (crankcase cooling outlet)
2. Air compressor drain line
F07E0HA
F18E02A
F08E0FA
1
2
SMR2003-005_02_05A.FM 02-05-3
Lower hose as necessary so that draining can take
place.
Reconnect fitting when done.
Also ensure air compressor drain line is not ob-
structed. Clean as necessary.
PROPULSION SYSTEM
Jet Pump
Lubricant in impeller shaft reservoir should be
drained. Reservoir should be cleaned and refilled
with SEA-DOO synthetic 75W90 GL5 polyolester
oil. Refer to JET PUMP for proper procedure.
CAUTION: Use only SEA-DOO jet pump oil or
equivalent synthetic gear oil, otherwise compo-
nent service life could be reduced. Do not mix
oil brands or types.
PTO Flywheel
All 2-Stroke Models except XP DI
Remove PTO flywheel guard.
Lubricate PTO flywheel at grease fitting with syn-
thetic grease (P/N 293 550 010).
CAUTION: Do not lubricate excessively. Imme-
diately stop when a slight movement is noticed
on rubber boot.
1. Grease PTO flywheel
CAUTION: Never leave any clothing, tool or
other objects near PTO flywheel and drive shaft.
SEAL CARRIER
XP DI Models
Lubricate seal carrier of drive shaft support with
synthetic grease. Stop lubricating when grease is
just coming out of seal.
1. Grease seal carrier
FUEL SYSTEM
All Models
Verify fuel system. Check fuel hoses and carbure-
tor(s), if so equipped, for leaks. Replace damaged
hoses or clamps if necessary.
Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equiv-
alent should be added in fuel tank to prevent fuel
deterioration and, if so equipped, carburetor(s)
gumming. Follow manufacturers instructions for
proper use.
On RFI and DI models, fill up fuel tank completely.
Ensure there is no water inside fuel tank.
CAUTION: Should any water be trapped inside
fuel tank, severe internal damage will occur to
the fuel injection system (if so equipped).
F01I0BA 1
F08E0BA
1
02-05-4 SMR2003-005_02_05A.FM
CAUTION: Fuel stabilizer should be added prior
to engine lubrication to ensure fuel system com-
ponents protection against varnish deposits.
Always turn the fuel valve to OFF position when
storing the watercraft.
ENGINE OIL CHANGE AND FILTER
4-TEC Engines
Change engine oil and filter. Refer to LUBRICA-
TION in ENGINE section.
All Models
COOLING SYSTEM FLUSHING
AND ENGINE INTERNAL
LUBRICATION
Cooling system (exhaust cooling system on 4-TEC
models) has to be flushed with fresh water to
prevent salt, sand or dirt accumulation which will
clog water passages.
Engine must be lubricated to prevent corrosion on
internal parts.
For proper procedure, refer to FLUSHING AND
LUBRICATION.
ENGINE LUBRICATION
4-TEC Engines
Fogging 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 cyl-
inders and the exhaust valves.
To fog the engine intake valves, proceed as fol-
lows:
Remove the two bolts that hold the fuel rail on.
Remove the rail along with the three fuel injec-
tors.
Spray BOMBARDIER LUBE lubricant into the
intake ports.
Crank engine at wide open throttle to put it in
the drown engine mode. This will prevent fuel
injection and ignition.
Carefully inspect O-rings condition before rein-
stalling fuel injectors. Replace O-rings with new
ones if damaged. Lubricate O-rings with injec-
tion oil prior to installing.
Reinstall the injectors.
Apply Loctite 243 and torque the two bolts to
10 Nm (89 lbfin) that hold the fuel rail on.
Make sure there is no leak at injectors when
cranking the engine in the upcoming steps.
Pull engine cover upward to remove it.
Disconnect ignition coil connectors.
WARNING
Fuel is inflammable and explosive under cer-
tain conditions. Always work in a well ventilat-
ed area. Do not smoke or allow open flames or
sparks in the vicinity. Fuel tank may be pres-
surized, slowly turn cap when opening. Never
use an open flame to check fuel level. 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 in-
spect fuel system. Always turn the fuel tank
valve (if so equipped) to OFF position when
storing the watercraft.
WARNING
If a leak is present, immediately stop the en-
gine. Do not start engine until the leak is re-
paired.
WARNING
At preseason preparation, ensure to perform a
fuel pressure test and ensure there is no leak.
Also run engine and check for leaks. Refer to
ENGINE MANAGEMENT section.
WARNING
When disconnecting coil from spark plug, al-
ways 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.
SMR2003-005_02_05A.FM 02-05-5
IMPORTANT: Never cut the locking ties of coil
connectors. This would allow mixing the wires be-
tween cylinders.
Remove ignition coils.
CAUTION: Ensure there is no dirt in coil holes
prior to removing the spark plugs. Otherwise,
dirt would fall into cylinders and will damage
the internal components.
Remove the spark plugs.
Apply BOMBARDIER LUBE lubricant into the
cylinders.
Reinstall spark plugs and ignition coils.
Reconnect ignition coil connectors.
NOTE: Prior to inserting the ignition coil in its loca-
tion, apply some Molykote 111 grease (P/N 413
707 000) around the seal area that touches the
spark plug hole. After installation, ensure the seal
seats properly with the engine top surface.
To reinstall engine cover, push it downward until
it snaps.
Crank engine several times while keeping throt-
tle fully depressed to distribute lubricant on ex-
haust valves.
1. Engine intake ports
All Models
BATTERY
For battery removal, cleaning and storage, refer to
CHARGING SYSTEM.
WATERCRAFT 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. If any
repairs are needed to body or to the hull, touch up
paint and Gelcote
repair kit are available. Replace

damaged labels/decals.
Wash the body with soap and water solution (only
use mild detergent). Rinse thoroughly with fresh
water. Remove marine organisms from the hull.
Apply a nonabrasive wax.
CAUTION: Never clean fiberglass and plastic
parts with strong detergent, degreasing agent,
paint thinner, acetone, etc.
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.
CAUTION: The watercraft must never be Ieft in
water for storage. Never leave the watercraft
stored in direct sunlight.
ADDITIONAL RECOMMENDED
PROTECTION
All 2-Stroke Models
In cool regions (where freezing point may be en-
countered), cooling system should be filled with
water and antifreeze solution (40% water, 60%
antifreeze).
CAUTION: Remaining water in cooling system
will freeze. If antifreezing is not performed ade-
quately engine/exhaust system may freeze and
cause severe engine damage. Always use ethyl-
ene glycol antifreeze containing corrosion inhib-
itors specifically recommended for aluminum
engines.
NOTE: When available, it is recommended to use
biodegradable antifreeze compatible with internal
combustion aluminum engines. This will contrib-
ute to protect the environment.
NOTE: The engine will not have to run during this
operation.
All 2-Stroke Models except DI
NOTE: This procedure requires approximately 2.5 L
(2.6 U.S. qt) of antifreeze.
1
F18M01A
02-05-6 SMR2003-005_02_05A.FM
Hose Pinchers Installation
Some hoses have to be plugged to prevent drain-
ing, before filling cooling system jackets with the
antifreeze.
GTI AND GTI LE MODELS 717 ENGINES
1. Engine drain hose
RFI MODELS 787 ENGINES
1. Hose pincher installed on engine drain hose
NOTE: On RFI models, make sure the hose is
properly connected to the magneto cover.
1. Fitting properly connected
Install hose pincher on injection hose going to
tuned pipe.
GTI AND GTI LE MODELS 717 ENGINES
1. Hose pincher on injection hose going to tuned pipe
1
F17E05A
F15E01A 1
F17E0AB
1
F17E03A 1
SMR2003-005_02_05A.FM 02-05-7
1. Engine water outlet hose
Hose Disconnection
Some hoses have to be disconnected. Disconnect
hoses at the following location.
1. Disconnect engine water inlet hose
717 Engines
Temporarily install a short piece of hose to engine
water inlet at cylinder head.
Insert a funnel into hose and pour antifreeze mixed
with water (40% water, 60% antifreeze) in engine
until the colored solution appears at the cooling sys-
tem bleed outlet.
787 RFI Engines
Disconnect hose just above T-fitting as shown.
1. Hose connecting to cylinder head inlet fitting
2. Disconnect hose above T-fitting
787 RFI Engines
Install a hose pincher just below T-fitting.
F17E01A 1
F06E0EB 1
F07E0LA
F15E02A 2 1
02-05-8 SMR2003-005_02_05A.FM
1. Hose pincher below T-fitting
Pour approximately 300 mL (10 oz) of antifreeze in
the water regulator valve supply hose to allow an-
tifreeze flowing through the valve and into muffler
to protect them.
Reconnect hose to T-fitting and remove hose
pincher (if applicable).
Remove temporary hose on 717 engines and re-
connect engine water outlet hose.
Remove hose pinchers.
All DI Models except XP DI
antifreeze.
Install hose pinchers at the following location:
RX DI MODELS
1. Water outlet hose
GTX DI MODELS
LRV DI MODELS
F15E03A 1
F12E02A 1
F18E05A
1
F07E0NB
1
SMR2003-005_02_05A.FM 02-05-9
RX DI AND LRV DI MODELS
1. Crankcase cooling cover outlet hose
GTX DI MODELS
1. Crankcase cooling cover outlet hose
RX DI, GTX DI AND LRV DI MODELS
1. Engine cylinder drain hose
Hose Disconnection
Disconnect water INLET hose at engine between
T-fitting and cylinder head fitting.
1. Disconnect this side of the T-fitting
F12E0AA 1
F18E0FA
1
F07E0JA 1
F12E0BA 1
02-05-10 SMR2003-005_02_05A.FM
GTX DI MODELS
1. Disconnect this side of the T-fitting
Temporarily install a short piece of hose to replace
the one removed.
Antifreeze
Insert a funnel into the temporary hose and pour
antifreeze mix in engine until the colored solution
appears at cooling system bleed outlet.
At this point, install a hose pincher on bleed outlet
hose.
RX DI MODELS
1. Bleed outlet hose
GTX DI AND LRV DI MODELS
F18E0BA
1
F07E0LA
F07E0OA
1
F18E0EA 1
SMR2003-005_02_05A.FM 02-05-11
Continue to pour until antifreeze flows in air com-
pressor water outlet hose.
1. Air compressor water outlet hose
GTX DI MODELS
Remove pinchers in this order to allow proper flow
of antifreeze.
1. Bleed outlet hose.
2. Crankcase cooling cover outlet hose.
3. Engine cylinder drain hose.
4. Water outlet hose.
the water regulator valve supply hose to allow an-
tifreeze flowing through the valve and into muffler
to protect them.
Remove temporary hose and reconnect engine
water outlet hose.
All 2-Stroke Models except XP DI
Most of the antifreeze will drain out when removing
the hose pinchers. Use a container to recover it. DIS-
POSE ANTIFREEZE AS PER YOUR LOCAL LAWS
AND REGULATIONS.
NOTE: Although antifreeze will mainly drain out,
the antifreeze has mixed with the water that was
possibly trapped in the water jackets and thus pre-
venting freezing problems.
At preseason preparation, drain the remaining an-
tifreeze from cooling system prior to using the wa-
tercraft. Ensure no hose pincher was forgotten at
storage.
XP DI Models
NOTE: This procedure requires approximately 2.8 L
(3 U.S. qt) of antifreeze.
antifreeze.
Install hose pinchers at the following location:
XP DI MODELS
1. Water inlet hose
2. Engine cylinder drain hose (coming from underneath engine)
F07E0NC 1
1 F18E1VA
F08E0GA
2
1
02-05-12 SMR2003-005_02_05A.FM
XP DI MODELS
1. Water outlet hose underneath tuned pipe
Hose Disconnection
Disconnect the bottom hose at the water regulator
valve on muffler.
XP DI MODELS
1. Disconnect the bottom hose from water regulator valve
Temporarily install a hose of approximately 1 m
(3 ft) with an internal diameter of 12.7 mm (1/2 in)
over the previously disconnected hose.
Antifreeze
Insert a funnel into the temporary hose.
Ensure to hold the funnel approximately 1 m (3 ft)
above the deck when pouring the antifreeze to cre-
ate enough pressure so that it flows properly.
A. 1 m (3 ft) to ease antifreeze flow
Pour antifreeze mix in engine until the colored so-
lution appears at cooling system bleed outlet.
At this point, install a hose pincher on bleed outlet
hose.
F08E0PA
1
F08E0SA 1
F08E0TA
A
SMR2003-005_02_05A.FM 02-05-13
XP DI MODELS
Continue to pour until antifreeze appears at the en-
gine drain hose (crankcase cooling outlet). Then,
install a hose pincher on this hose.
1. Engine drain hose (crankcase cooling outlet)
Continue to pour until antifreeze flows in air com-
pressor water outlet hose.
XP DI MODELS
F08E0MA
1
F08E0JA
1
F08E0EA
1
02-05-14 SMR2003-005_02_05A.FM
The pouring operation is over.
Remove pinchers in this order to allow proper flow
of antifreeze.
NOTE: Most of the antifreeze will drain out when re-
moving the hose pinchers. Use a container to recover
it. DISPOSE ANTIFREEZE AS PER YOUR LOCAL
LAWS AND REGULATIONS.
1. Bleed outlet hose.
2. Engine drain hose (crankcase cooling cover out-
let).
3. Engine cylinder drain hose.
4. Water outlet hose.
5. Water inlet hose.
Install a temporary hose on the open fitting of the
water regulator valve.
the temporary hose to allow antifreeze flowing
through the water regulator valve and into muffler
to protect them.
Remove temporary hoses and reinstall the factory
hose to water regulator valve.
NOTE: Although antifreeze will mainly drain out,
the antifreeze has mixed with the water that was
possibly trapped in the water jackets and thus pre-
venting freezing problems.
At preseason preparation, drain the remaining an-
tifreeze from cooling system prior to using the wa-
tercraft. Ensure no hose pincher was forgotten at
storage.
4-TEC Engines
Refer to the COOLING SYSTEM section.
Antifreeze should be replaced for the storage pe-
riod to prevent antifreeze deterioration.
Make sure to perform an antifreeze density test.
CAUTION: Improper antifreeze mixture might
allow freezing of the liquid in the cooling system
if vehicle is stored in area where freezing point
is reached. This would seriously damage the en-
gine. Failure to replace the antifreeze for storage
may allow its degradation that could result in
poor cooling when engine will be used.
All Models
ANTICORROSION TREATMENT
Wipe off any residual water in the engine compart-
ment.
Spray BOMBARDIER LUBE lubricant over all me-
tallic components in engine compartment.
Lubricate the throttle cable with BOMBARDIER
LUBE lubricant.
The seat should be partially left opened during
storage (the engine cover for the XP DI models).
This will avoid engine compartment condensation
and possible corrosion.
CHECKLIST
OPERATION
Check engine drain hose(s).
Drain and clean impeller shaft reservoir
(except 4-TEC engines).
Lubricate PTO flywheel or seal carrier.
Verify fuel system.
Add Sea-Doo fuel stabilizer.
Flush the cooling system
Change engine oil and filter (4-TEC engines).
Flush the exhaust cooling system by running
the engine (4-TEC engines).
Lubricate the engine.
Remove, clean and store the battery.
Clean the bilge.
Wash the body.
Add antifreeze solution to the cooling system
(in cool regions)
Replace antifreeze. Check solution
concentration in the cooling system
(in cool regions) (4-TEC engines).
Spray BOMBARDIER LUBE over all metallic
components in engine compartment and in
throttle cable.
Spray BOMBARDIER LUBE in oil injection
pump cable (except 4-TEC engines).
Section 03 TROUBLESHOOTING
Subsection 01 (TROUBLESHOOTING CHART)
SMR2003-006_03_01A.FM 03-01-1
TROUBLESHOOTING CHART 0
The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should
not be assumed to show all causes for all problems.
NOTE: On fuel injection models, always check for fault codes recorded in the MPEM (DI models) or
EMS ECU (RFI and 4-TEC models) first using the VCK (vehicle communication kit (P/N 529 035 844). If
a fault code is detected, service the fault code and recheck operating conditions. Refer to DIAGNOSTIC
PROCEDURES in ENGINE MANAGEMENT section.
ENGINE WILL NOT START
OTHER OBSERVATION POSSIBLE CAUSE REMEDY
Engine does not turn over
Wrong safety lanyard Use one that has been programmed
for that watercraft
DESS operation non functional If 2 short beeps are not heard when
installing safety lanyard, refer to
ELECTRICAL SYSTEM and ENGINE
MANAGEMENT
Safety lanyard switch faulty or discon-
nected or harness damaged
Replace
Disconnected or faulty DESS auxil-
liary module
(if so equipped on 4-TEC models)
Refer to ENGINE MANAGEMENT
Burnt fuse on MPEM or in electrical
box: battery, starting system. Also
fuel pump on fuel injection models
Check wiring then replace fuse
Starting system fuse keeps on burning Check wiring, starting system solenoid
and MPEM
Discharged or disconnected battery Check/recharge
Defective or disconnected start/stop
switch
Check, refer to STARTING SYSTEM or
ENGINE MANAGEMENT
Battery connections Check/clean/tighten
Poor/bad or corroded ground contacts
(engine, starter etc.)
Check/clean/repair
Water/fuel hydrolock Check, refer to MAINTENANCE
Starter malfunction Check, refer to ELECTRICAL SYSTEM
Starter solenoid Check, refer to ELECTRICAL SYSTEM
Obstructed starter drive gear assy Check/repair, refer to PTO HOUSING/
MAGNETO
Seized or obstructed engine Check/repair, refer to ENGINE
Seized or obstructed supercharger
(4-TEC Supercharged models)
Check/repair, refer to INTAKE
Hydraulically locked air compressor
(DI models)
Check/repair as needed
Seized jet pump Check, refer to PROPULSION
SYSTEM
Faulty sensor, EMS ECU or MPEM
(fuel injection models)
Check faulty codes in MPEM or EMS
ECU memory,
refer to ENGINE MANAGEMENT
03-01-2 SMR2003-006_03_01A.FM
ENGINE WILL NOT START (contd)
Engine turns slowly
Loose battery cable connections Check/clean/tighten
Discharged/weak battery Check/charge/replace
Restriction in jet pump Check/clean pump
Partial seizure in jet pump Inspect, refer to PROPULSION SYS-
TEM
Partial engine hydrolock Check, refer to MAINTENANCE
Partial engine seizure Check compression, refer to ENGINE
Worn starter Check, refer to ELECTRICAL SYSTEM
Timing chain not guided by chain
guide (4-TEC models)
Check, refer to ENGINE BLOCK
Outside temperature too low Oil is too thick. Change oil viscosity
Battery capacity is not sufficient for
cold temperature
Engine turns over
Faulty component in the fuel injection
system (fuel injection models)
Check for fault codes with the VCK
(vehicle communication kit). Refer to
DIAGNOSTIC PROCEDURES in
ENGINE MANAGEMENT
Engine drowned mode is active
Release throttle lever
Low battery voltage Recharge or replace battery
Low or no fuel pressure
Check fuel pump operation
Check fuel pump pressure output
Check air/fuel rail
Check fuel pump fuse
Check wiring harness
Fuel injectors not working
Check fuel injector operation. Replace
as necessary
Check output signal from MPEM
Low or no air pressure (DI models) Check air/fuel rail
Check air compressor system
Check RAVE valve system for leaks
Direct injector not working
(DI models)
Check direct injector operation
Check output signal from MPEM
No spark at the spark plug Check spark plugs condition and
replace as necessary
Check ignition system and repair
Defective MPEM or EMS ECU Replace MPEM or EMS ECU
(as applicable)
Defective CPS
Check operation of CPS and replace if
necessary
Water-contaminated fuel Check/siphon and refill
Dirty fuel filter Clean/replace
Fouled or defective spark plug Replace
Water in engine Check, refer to MAINTENANCE
Carburetion (carburetor models) Check, refer to FUEL SYSTEM
Defective ignition circuit Check, refer to ELECTRICAL SYSTEM
SMR2003-006_03_01A.FM 03-01-3
ENGINE WILL NOT START (contd)
Engine turns over (contd)
Flooded engine
Carburetor needle valve stuck open
(carburetor models)
Check, refer to FUEL SYSTEM
Excessive rotary valve clearance
(if so equipped)
Check, refer to ENGINE
Incorrect rotary valve timing
(if so equipped)
Internal engine damage Check, refer to ENGINE
Defective encoder/trigger wheel
Check, refer to ENGINE MANAGE-
MENT
Incorrectly aligned flywheel and en-
coder/trigger wheel
Properly position flywheel and encoder/
trigger wheel, refer to PTO HOUSING/
MAGNETO
Insufficient engine compression Replace defective part(s)
Idle bypass valve stuck, not function-
ing or frozen (4-TEC models)
MANAGEMENT
No spark at spark plugs
Faulty rev limiter in MPEM
(carburetor models)
Replace MPEM
Spark plug faulty, fouled or worn out Check spark plug condition
Ignition Check, refer to ELECTRICAL SYSTEM
Faulty EMS ECU or MPEM
Replace EMS ECU or MPEM
(as applicable)
03-01-4 SMR2003-006_03_01A.FM
ENGINE HARD TO START
ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED
Defective idle bypass valve
(4-TEC models)
Wrong TPS zero setting
(4-TEC models)
Wrong throttle body mechanical ad-
justment of cable
Temperature too low for available
battery capacity
Battery capacity is not sufficient for cold
temperature
Air lock in fuel rail
(RFI and 4-TEC models)
Water in intake system (defective
MAP sensor) (4-TEC models)
Check and remove water
Refer to INTAKE SYSTEM in ENGINE
MANAGEMENT
Water in fuel reservoir or
contaminated fuel
Flush reservoir and refill with fresh gas
Mechanical engine failure Check cylinder compression
Check for cylinder head leaks
Check starting system
Spark plug faulty, fouled or worn out Check spark plug condition
Low fuel pressure
Check fuel pump operation. Refer to
ENGINE MANAGEMENT
Check fuel pressure regulator. Refer to
ENGINE MANAGEMENT
Low air pressure (DI models) Check air/fuel rail. Refer to ENGINE
MANAGEMENT
Check air compressor system. Refer to
ENGINE MANAGEMENT
Check RAVE valve for leaks
The system is in limp home mode
Refer to ENGINE and check the fault
codes in the EMS ECU
(4 TEC models) or MPEM or
(DI models)
Broken or loose throttle cable Change/readjust
SMR2003-006_03_01A.FM 03-01-5
ENGINE MISFIRES, RUNS IRREGULARLY
Weak spark
Fouled, defective, worn spark plugs Check/verify heat range/gap/replace
Faulty EMS ECU or MPEM
MANAGEMENT
MANAGEMENT
Too much oil supplied to engine
(2-stroke engines)
Adjust oil injection pump
Bad ignition coil wiring Check wiring condition and proper
grounding of ignition coil
Faulty ignition coil, or bad connector Check coil. Refer to ENGINE
MANAGEMENT
Poor engine ground Check/clean/repair
Lean fuel mixture
Dry spark plug (except
when water fouled)
Low fuel level (carburetor models) Check/refill
Carburetion dirty or out of adjust-
ment (carburetor models)
Check/clean/adjust, refer to
FUEL SYSTEM
Low fuel pressure
Check pump, regulator, injectors and
hose pinchers or if filter is plugged.
Replace if necessary
Leaking crankshaft seal(s) or intake
manifold (carburetor models)
Pressure check engine, to ENGINE
Restricted fuel valve
(carburetor models)
Check/replace
Loose carburetor
(carburetor models)
Tighten carburetor
Stale or water fouled fuel Check/siphon and refill
Fuel filter dirty or restricted
Check/clean/replace
Clogged fuel injectors
Remove and clean fuel injectors
Clogged direct injectors
(DI models)
(RFI and 4-TEC models)
Remove and clean direct injectors
Defective sensor or EMS
ECU/MPEM (fuel injection models)
Check faulty codes in EMS ECU or
MPEM (as applicable) memory, refer to
ENGINE MANAGEMENT
03-01-6 SMR2003-006_03_01A.FM
ENGINE MISFIRES, RUNS IRREGULARLY (contd)
Rich fuel mixture
Fouled spark plug
Flame arrester dirty or restricted
(if so equipped)
Check/replace
Partially closed choke
(carburetor models)
Check/adjust choke cable
Carburetor adjustment
(carburetor models)
Check/adjust, refer to FUEL SYSTEM
Loose main jet (carburetor models) Check, refer to FUEL SYSTEM
Faulty fuel injector(s)
Remove and replace fuel injector(s),
refer to ENGINE MANAGEMENT
Faulty direct injector(s) (DI models) Remove and replace direct
injector(s), refer to
ENGINE MANAGEMENT
Defective sensor or EMS ECU
/MPEM (fuel injection models)
Check faulty codes in EMS ECU or
MPEM (as applicable) memory, refer to
ENGINE MANAGEMENT
Rotary valve shaft seal leaking
(if so equipped)
Check/replace, refer to ENGINE
Damaged reed valve
(if so equipped)
Check, refer to BOTTOM END in EN-
GINE SECTION
Leaking crankshaft seal(s) or intake
manifold (DI models)
Pressure check engine, refer to
ENGINE
Leak in RAVE valve system
(DI models)
Check, refer to ENGINE MANAGEMENT
Oil injection pump adjustment
(2-stroke engines)
Check/adjust, refer to
LUBRICATION SYSTEM
Worn needles and seals
(carburetor models)
Check, refer to section FUEL SYSTEM
(if so equipped)
Fuel pressure fluctuating
Inspect fuel pressure regulators. Refer
to ENGINE MANAGEMENT
High fuel pressure
Check pump, regulator, injectors, hose
pinchers or if filter is plugged. Replace
if necessary
Starts, but runs poorly
Check spark plug condition, check
fault codes in the EMS ECU or
MPEM memory, check fuel pressure
(fuel injection models). Also check
RAVE valves operation
(2-stroke fuel injection models)
MANAGEMENT. If some work has
been performed on the unit, make sure
injector wire connectors were not
mixed. Refer to the wiring diagram for
wire colors and positions
Also fuel injection
misinjecting
Bent or missing tooth on encoder/
trigger wheel
MANAGEMENT
Injector wiring reversed
Check with wiring diagram
Damaged fuel injector
MANAGEMENT
Incorrect rotary valve timing
(if so equipped)
Check/adjust, refer to ENGINE
(if so equipped)
SMR2003-006_03_01A.FM 03-01-7
ENGINE CONTINUALLY BACKFIRES
ENGINE DETONATION OR PINGING
Weak spark Fouled, defective spark plugs Clean/replace
Spark plugs Ignition coil leads or wiring reversed Check with wiring diagram
Ignition timing/TDC setting
Incorrect setting Check/reset, refer to
ELECTRICAL SYSTEM
Check, refer to
ENGINE MANAGEMENT
Rotary valve
(if so equipped)
Incorrect timing Check/reset, refer to ENGINE
Carburetor
(if so equipped)
Carburetion too lean Check/adjust, refer to FUEL SYSTEM
Engine
Intake or exhaust valve(s) leak
(4-TEC models)
Pressure check engine, refer to
ENGINE
Ignition
Timing too far advanced Check/reset
Spark plug heat range too high Check/change to correct range
Engine/exhaust high
temperature
Engine overheats and exhaust over-
heats
Check, see engine overheats in this
section
Fuel octane too low of poor fuel quality Use good quality fuel
KS disconnected or faulty
Bad KS connection
Bad EMS ECU connection (on engine)
(4-TEC models)
03-01-8 SMR2003-006_03_01A.FM
ENGINE LACKS ACCELERATION OR POWER
Weak spark Check/replace, refer to
ELECTRICAL SYSTEM
Carburetion, jetting too rich/lean
(carburetor models)
Check/adjust, refer to FUEL SYSTEM
Throttle does not open fully Check/readjust, refer to
ENGINE MANAGEMENT
Low compression Check/repair, refer to ENGINE
Water in fuel Check/siphon/replace
Debris in carburetor needle valve
(carburetor models)
Check/clean, refer to FUEL SYSTEM
Impeller leading edge damaged Check/replace, refer to
PROPULSION SYSTEM
Too much engine oil (4-TEC models) Siphon or adjust level. Refer to LUBRI-
CATION
Twisted crankshaft (DI models) Check, refer to ENGINE
Poor fuel quality Siphon then refill with fresh fuel
Clogged direct injectors
(DI models)
Remove and clean direct injectors
Remove and clean fuel injectors
Low fuel pressure
Check fuel line and fuel pump pressure
Incorrect throttle position sensor
(TPS) adjustment
Check and adjust TPS, refer to ENGINE
MANAGEMENT
Improper timing chain alignment
(4-TEC models)
Refer to CYLINDER HEAD & VALVES
Defective supercharger
Overheated engine See ENGINE OVERHEATS in this chart
Engine revs lower than
its maximum operational
RPM
RAVE valve does not open
(if so equipped)
Limp home mode activated Refer to ENGINE MANAGEMENT
Peak performance is
delayed until higher
RPM range is reached
RAVE valve is stuck opened
(if so equipped)
SMR2003-006_03_01A.FM 03-01-9
ENGINE STOPS RUNNING
ENGINE CANNOT REACH MAXIMUM RPM
Engine dies during regular
operation (piston seizure)
Spark plug heat range too high Check/change to correct range
Improper ignition timing
(2-stroke engines)
Check/reset
Compression ratio is too high Install genuine parts
Poor injection oil quality
(2-stroke engines)
Use proper BOMBARDIER oil
Engine dies during regular
operation
Seized or obstructed supercharger
Engine was running below
2000 RPM.
No maintenance light
Electrical noise (DI models) Refer to ENGINE MANAGEMENT
Engine stalls at idle
Low air pressure (DI models)
Air in fuel rail (RFI and 4-TEC models)
Check air delivery circuit for leaks
Check air compressor
Refill fuel tank
Engine start but stops after
approximately 2 seconds
Engine running out of fuel
Air in fuel rail (RFI and 4-TEC models)
Check fuel delivery system for proper
fuel pressure and delivery
Refill fuel tank
Low air pressure (DI models) Check air system
(compressor, air/fuel rail etc.)
RAVE valve does not open
(if so equipped)
Check, refer to ENGINE and COOLING
SYSTEM
Faulty water regulator valve
(if so equipped)
Check, refer to COOLING SYSTEM
The system is in limp home mode.
MAINT is displayed on Information
Center
Refer to ENGINE and check the fault
codes in the EMS ECU
Low fuel pressure
Check fuel pump pressure output
Jet pump related problem Check propulsion components.
Refer to JET PUMP
Limp home mode activated
Exhaust system blockage/muffler
damage
Check and repair
Exhaust gases in bilge (leak) Check exhaust system for leaks
03-01-10 SMR2003-006_03_01A.FM
ENGINE RUNS TOO FAST (vehicle cannot reach its top speed)
ENGINE OVERHEATS
Engine RPM too high
Faulty rev limiter in EMS ECU/MPEM Check, refer to ENGINE
MANAGEMENT
Improper impeller pitch (too low) Check/replace, refer to
PROPULSION SYSTEM
Incorrect throttle position sensor
(TPS) adjustment (RFI models)
Check and adjust TPS, refer to ENGINE
MANAGEMENT
Damaged impeller Replace impeller. Refer to PROPULSION
Jet pump cavitation
Damaged leading or trailing edge of
impeller
Check/replace
NOTE: Leading edge damage contributes
to poor performance from start. Trailing
edge damage contributes to poor top per-
formance and stator vanes erosion.
Sealing of ride plate, jet pump support
or jet pump
Check/reseal, refer to section
PROPULSION SYSTEM or HULL/BODY
O.P.A.S.
TM
side vanes
do not go up while
watercraft is at speed.
Clogged filter, square rings damaged,
leakage in hoses or mechanical
malfunction.
Refer to STEERING SYSTEM
O.P.A.S. side vanes
do not go down while
engine is at idle.
Broken spring inside side vane
cylinder.
Coolant level too low
(4-TEC models)
Coolant level low Refill/check for leaks
Water leaking out of weep hole
(PTO housing)
Replace rotary seal
Hoses or clamps missing/defective Repair/replace
Cylinder head gasket leaks
(white exhaust gas)
Replace cylinder head gasket
Thermostat failure Replace
Coolant pump failure Replace
Internal passage blockage Inspect and clean
Monitoring beeper sounds
continuously
Temperature sensor defective
Check/replace. Refer to ENGINE
MANAGEMENT
Worn water pump impeller Check/replace
Cooling system restriction Check/flush, refer to MAINTENANCE
Damaged ride plate or hoses
(4-TEC models)
Check, refer to COOLING SYSTEM
and HULL/BODY
Grounded temperature sensor or
sensor wire (carburetor models)
Check/repair/replace
Thermostat defective
(4-TEC models)
Check/replace
SMR2003-006_03_01A.FM 03-01-11
O.P.A.S. SYSTEM FAULTS
ENGINE SMOKE IN THE EXHAUST (4-TEC SERIES)
LOW OR NO ENGINE OIL PRESSURE (4-TEC SERIES)
Watercraft is more
responsive than usual
while turning
Side vanes do not go up while
watercraft is at speed
Watercraft pulls on one
side
One side vane does not go up while
watercraft is at speed
O.P.A.S. side vanes do not
go up while watercraft is at
speed
Clogged filter, square rings damaged,
leakage in hoses or mechanical
malfunction
O.P.A.S. side vanes do not
go down while engine is at
idle
Broken spring inside side vane cylinder Refer to STEERING SYSTEM
White smoke
Coolant leak Check/repair. Refer to LEAK TEST
Damaged cylinder head gasket Check/replace cylinder head gasket
Water ingestion Inspect intake manifold for water infil-
ration
Blue smoke
Valve guide seals Check/replace valve guide seals, refer
to cylinder head and valves
PTO oil scavenge port blocked or
scavenge pump malfunction
Inspect and clean or replace pump
at engine starting Oil rings worn out Replace rings
with engine under load Oil rings Inspect/repair oil rings, refer to
ENGINE BLOCK
Oil level too high Siphon some oil from the oil tank
Oil level too low Refill. See TECHNICAL DATA for
specifications
Leaking gasket Replace
Oil leaking out of weep hole
(PTO housing)
Replace oil seal on pump shaft
Oil pressure sensor defective Check/replace
Oil pump malfunctioning Clean rotor and check wear limits
Oil regulator valve sticks open, or
spring load too small
Clean/replace
Heavy wear on plain bearings Replace
03-01-12 SMR2003-006_03_01A.FM
ENGINE OIL CONTAMINATION (MILKY) (4-TEC SERIES)
UNUSUAL ENGINE NOISE AND/OR VIBRATION (4-TEC SERIES)
Water and oil mixture
leaking out of weep hole
(PTO housing)
Oil seal and rotary seal on coolant
pump shaft leaking
Replace both seals. Refer to PTO
HOUSING. Change oil
Cylinder head gasket leaking Replace gasket. Refer to
CYLINDER HEAD. Change oil
Loose screws on cylinder head, PTO
housing or oil seperator
Retorque. Change oil
Oil contamination due to metal or
plastic particles
Replace possibly damaged parts.
Change oil
Water ingestion (intake manifold,
TOPS valve, dipstick)
Refer to MAINTENANCE
Water and oil mixture
without leaking out at
weep hole (PTO housing)
The same causes as above apply.
However, look at the following added
cause
Weep hole plugged Check/clean weep hole
Worn chain tensioner Replace
Worn chain guide Replace
Stretched chain and/or worn out
sprockets
Replace chain and sprockets
Sprocket screws got loose Retorque
Hydraulic element inside rocker
arm(s) is worn out (valve adjustment)
or lifter damaged
Replace faulty rocker arm(s) and/or
lifters
Rocker arm screws not tightened Retorque
Heavy wear on crankshaft and/or bal-
ancer shaft bearings
Replace
Crankshaft and balancer shaft not
aligned
Check marks and readjust shafts
Heavy wear on thrust washers, or
thrust washers missing
Check/replace
Missing/defective air intake hose Check/replace air intake hose or
clamps, refer to section INTAKE
SMR2003-006_03_01A.FM 03-01-13
ABNORMAL NOISE FROM PROPULSION SYSTEM
NOTE: Prior to replacing a EMS ECU or MPEM, refer to the appropriate EMS ECU/MPEM section or EMS
ECU/MPEM REPLACEMENT in the ENGINE MANAGEMENT section and read carefully the tests to do
before replacing a EMS ECU/MPEM that could otherwise be good.
Weeds/debris caught in intake grate
or impeller
Check/clean
Low oil level in jet pump
(if so equipped)
Check/troubleshoot source of leak/
refill supply, refer to
PROPULSION SYSTEM
Worn anti-rattle system
(if so equipped)
Check/replace pusher in cover, refer to
PROPULSION SYSTEM
Damaged or bent drive shaft Check/replace, refer to
PROPULSION SYSTEM
Idle speed too low Check fault codes
Broken engine mounts Check/replace, refer to ENGINE
Section 04 ENGINE (2-STROKE)
SMR2003-049_04_01ATOC.FM 04-01-1
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 04-02-1
GENERAL ........................................................................................................................... 04-02-1
PREPARATION................................................................................................................... 04-02-1
TESTING PROCEDURE ..................................................................................................... 04-02-1
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ 04-02-7
REMOVAL AND INSTALLATION.......................................................................................... 04-03-1
GENERAL ........................................................................................................................... 04-03-1
ENGINE REMOVAL............................................................................................................ 04-03-1
CLEANING ......................................................................................................................... 04-03-6
INSTALLATION.................................................................................................................. 04-03-6
MAGNETO SYSTEM............................................................................................................. 04-04-1
DISASSEMBLY .................................................................................................................. 04-04-4
CLEANING ......................................................................................................................... 04-04-10
ASSEMBLY......................................................................................................................... 04-04-10
TOP END................................................................................................................................ 04-05-1
GENERAL ........................................................................................................................... 04-05-4
DISASSEMBLY................................................................................................................... 04-05-6
CLEANING ......................................................................................................................... 04-05-14
INSPECTION ...................................................................................................................... 04-05-14
USED PISTON MEASUREMENT...................................................................................... 04-05-15
ASSEMBLY......................................................................................................................... 04-05-18
ADJUSTMENT................................................................................................................... 04-05-27
BOTTOM END........................................................................................................................ 04-06-1
DISASSEMBLY................................................................................................................... 04-06-4
CLEANING ......................................................................................................................... 04-06-11
INSPECTION ...................................................................................................................... 04-06-12
ASSEMBLY......................................................................................................................... 04-06-16
ROTARY VALVE..................................................................................................................... 04-07-1
GENERAL ........................................................................................................................... 04-07-2
INSPECTION ON WATERCRAFT....................................................................................... 04-07-2
DISASSEMBLY................................................................................................................... 04-07-3
CLEANING ......................................................................................................................... 04-07-5
INSPECTION ...................................................................................................................... 04-07-5
ASSEMBLY......................................................................................................................... 04-07-6
ROTARY VALVE TIMING ................................................................................................... 04-07-9
04-01-2 SMR2003-049_04_01ATOC.FM
EXHAUST SYSTEM............................................................................................................... 04-08-1
REMOVAL ........................................................................................................................... 04-08-6
TUNED PIPE REPAIR.......................................................................................................... 04-08-11
INSTALLATION................................................................................................................... 04-08-12
Subsection 02 (LEAK TEST)
SMR2003-007_04_02A.FM 04-02-1
LEAK TEST 0
GENERAL
A Sea-Doo Engine Leak Test Kit (P/N 295 500 352)
and Supplementary Engine Leak Test Kit (P/N 295
500 780) are available to help diagnose engine
problems such as engine seizure, poor perfor-
mance, oil leakage, etc.
Before disassembling any components of the en-
gine, it is important to perform a leakage test to
determine which part is defective.
It is also very important after servicing the engine,
even for a complete engine rebuilt, to perform an-
other leakage test; at this stage, it may avoid fur-
ther engine problems and minimizing the risk of
having to remove and reinstall the engine again.
Static bench testing is the most effective way to
conduct a leakage test. Inboard testing does not
allow complete access to, and observation of all
engine surfaces and should be avoided whenever
possible.
On the 717 engine, cylinders can not be verified
individually due to leakage from one cylinder to an-
other through a common intake manifold.
When installing hoses of the Engine Leak Test Kit
or Supplementary Engine Leak Test Kit, use the
collars provided in the kit to ensure a proper seal-
ing.
When pressurizing the engine, first confirm that
the components of the Engine Leak Test Kit or
Supplementary Engine Leak Test Kit are not leak-
ing by spraying a solution of soapy water on all
hoses, connections, fittings, plates, etc. If there is
a leak, bubbles will indicate leak location.
Three areas of the engine will be tested in se-
quence as per the diagnostic flow chart (see the
end of this subsection).
1. Engine Cooling System.
2. Bottom End and Top End.
3. Rotary Valve Shaft (except DI engine).
NOTE: If a leak is found, it is important to continue
testing as there is the possibility of having more
than one leak. Continue pumping to compensate
for the air lost to find another leak.
PREPARATION
Verify fuel system for leaks.
Disconnect battery BLACK negative cable.
Disconnect battery RED positive cable.
TESTING PROCEDURE
Engine Cooling System
Remove the tuned pipe. Refer to EXHAUST SYS-
TEM.
Remove the exhaust manifold gasket and ensure
the surface is clean.
Disconnect engine cooling hoses.
Install the appropriate exhaust manifold plate from
the Engine Leak Test Kit (P/N 295 500 352) or Sup-
plementary Engine Leak Test Kit (P/N 295 500 780).
Tighten plate using fasteners provided in the kit.
NOTE: Do not torque plate excessively.
Install a hose pincher on engine drain hose.
WARNING
If any fuel leak is found, do not start the en-
gine. Correct the leak and wipe off any fuel
spillage. Do not use electric powered tools
unless fuel system has passed pressure test.
WARNING
Always disconnect battery cables in the speci-
fied order, BLACK negative cable first.
04-02-2 SMR2003-007_04_02A.FM
Use hoses provided in the kit and install them on
the engine.
Install pump using reducer and appropriate tube(s)
as necessary.
717 ENGINES REAR VIEW
1. Engine drain hose blocked with a hose pincher
717 ENGINES FRONT VIEW
1. Loop hose and use clamps
2. Use two washers with exhaust manifold stud
3. Hose with adapter and nipple
787 RFI ENGINES REAR VIEW
1. Loop hose and use clamps
2. Hose with clamps. Install pump to the end
3. Block engine drain hose with a hose pincher
787 RFI ENGINES FRONT VIEW
1. Exhaust manifold plate
F01B2UB 1
F01B2VA
2
3
1
3
2 1
F02E0DA
F02D0WA 1
SMR2003-007_04_02A.FM 04-02-3
947 DI ENGINES SIDE VIEW
1. Block engine drain hose with a hose pincher
2. Install pump to water inlet hose
947 DI ENGINES FRONT VIEW
1. Exhaust manifold plate
NOTE: Water is not required for testing.
DI models, it is not necessary to pressurize the
bottom crankcase cover nor the magneto cover.
There is no possible water leak path toward the
internal components of the engine.
Activate pump and pressurize engine cooling sys-
tem to 34 kPa (5 PSI).
Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
If kit components are not leaking and pressure
drops, verify all external jointed surfaces, tem-
perature sensor and the O-ring between the
spark plug area and the engine cylinder head
cover. If none of these components are leaking,
there is an internal leak and it can be detected
with Bottom End and Top End testing.
Bottom End and Top End
Remove the carburetor(s) and gasket(s). Make
sure the surface of the intake manifold (717 en-
gines) or rotary valve cover (787 RFI engines) are
clean.
Install the intake plate(s) with fasteners from the
kit and tighten adequately.
NOTE: For the 787 RFI engines, use the intake
and exhaust plates included in the Supplementary
Engine Leak Test Kit (P/N 295 500 780).
DI Models
Remove throttle bodies on DI models.
Install intake manifold plugs (P/N 529 035 708).
1. Intake manifold plugs
All Models
On engines with the RAVE system, remove the
RAVE valves and gaskets.
Install the RAVE valve plates with fasteners from
the kit and tighten adequately.
F12E08A
2
1
F12E07A
1
1 F12D14A
04-02-4 SMR2003-007_04_02A.FM
NOTE: Engines with the RAVE system, the boot
(carburetor-equipped engines) and O-ring can
be checked for leakage with the valve in place.
Simply remove the cover to expose the parts.
Make sure the spark plugs (and the air/fuel rail on
DI engine) are installed and tightened.
Block pulse hose (carburetor-equipped engines)
using a hose pincher.
NOTE: Do not block the rotary valve shaft hoses
(if so equipped).
Install pump to the exhaust plate fitting.
717 ENGINES
1. Intake plates
2. Pulse hose blocked with a hose pincher
3. Exhaust plate
787 RFI ENGINES
1. Intake plates
2. RAVE valve plates
3. Pulse hose blocked with a hose pincher
4. Exhaust plate
947 DI ENGINES
1. Exhaust plate
2. Rave valve plates
3. Intake plates
Activate pump and pressurize engine to 34 kPa
(5 PSI).
CAUTION: Do not exceed this pressure.
Wait 3 minutes and check if pressure drops; if so,
verify all testing components.
If kit components are not leaking, verify engine
jointed surfaces as per following areas:
spark plugs
direct injector sealing (DI engines)
cylinder head gasket
cylinder base gasket
crankcase halves
rotary valve cover (except DI engines)
engine plugs
exhaust manifold
intake manifold (717 engines)
intake flanges (DI engines)
oil injection pump (717 engines).
F01B2ZA
2
3
1
F01B30A
2
4
1
3
3
1 2
F08D05A
SMR2003-007_04_02A.FM 04-02-5
Check also small oil injection pump lines and fit-
tings; check for air bubbles or oil column going to-
ward pump, which indicate a defective check valve.
Check for leak through counterbalancing shaft
seal toward air compressor (DI engines). Air bub-
bles in lowest fitting (oil return line) underneath
compressor indicates a seal leakage.
If the above mentioned components are not leak-
ing, block both oil hoses of the rotary valve shaft
(if so equipped) using hose pinchers.
NOTE: If leakage stops at this point, proceed with
ROTARY VALVE SHAFT testing (if so equipped).
If there is still some leakage, remove the PTO fly-
wheel to verify outer seal.
If no leak is found on the PTO side outer seal, re-
move magneto flywheel and verify crankshaft out-
er seals.
Proceed with the ROTARY VALVE SHAFT testing
(if so equipped) if the crankshaft outer seals are
not leaking.
Rotary Valve Shaft (if so equipped)
NOTE: It is mandatory to drain the injection oil
from the rotary valve shaft.
Block oil return hose of the rotary valve shaft with
a hose pincher.
717 ENGINES
1. Oil return hose blocked with hose pincher
787 RFI ENGINES
1. Oil return hose blocked with hose pincher
Install pump with reducer and nipple to the oil sup-
ply hose of the rotary valve shaft.
717 ENGINES
1. Pump with reducer and nipple
F01B31A 1
F01B33A 1
F01B32A
1
04-02-6 SMR2003-007_04_02A.FM
787 RFI ENGINES
1. Pump with reducer and nipple
Activate pump and pressurize to 34 kPa (5 PSI).
Check plug of the rotary valve shaft in crankcase.
Remove PTO side spark plug. If pressure drops, it
indicates a defective PTO side crankshaft inner seal
or crankcase is not sealed correctly.
Remove MAG side spark plug. If pressure drops, it
indicates a defective MAG side crankshaft inner
seal or crankcase is not sealed correctly.
If the above mentioned components are not leaking
and there is a pressure drops, remove the rotary
valve cover. Check the seal of the rotary valve shaft.
If the rotary valve shaft is not leaking, it could indi-
cates a defective engine casting. Disassemble en-
gine and carefully check for defects in castings. Pay
attention to tapped holes which may go through
sealed areas of engine and thus lead to leakage.
F01B34A
1
SMR2003-007_04_02A.FM 04-02-7
ENGINE LEAKAGE DIAGNOSTIC FLOW CHART
717 and 787 RFI Engines
F00D07S
PRESSURIZE ENGINE
IS ENGINE LEAKING?
CHECK ALL JOINTED SURFACES,
SCREW/STUD THREADS. MOUNTING
FLANGES ETC.
ANY LEAK FOUND?
CHECK SMALL OIL LINES OF
INJECTION PUMP
AIR BUBBLES FOUND
OR OIL MOVING
TOWARD PUMP?
BLOCK LARGE HOSES OF
ROTARY VALVE GEAR
LUBRICATION SYSTEM
IS ENGINE STILL LEAKING?
ARE SEALS LEAKING?
CHECK CRANKSHAFT OUTER
SEAL OF PTO AND
MAG SIDES
UNSEAL PTO CYLINDER AND MAG CYLINDER
SEPARATELY BY REMOVING THE
APPROPRIATE SPARK PLUG
IS RESERVOIR LEAKING?
CHECK FOR LEAKAGE AT ROTARY
VALVE SHAFT CRANKCASE PLUG
ANY LEAK FOUND?
REMOVE ROTARY VALVE COVER, CHECK
SEAL OF ROTARY VALVE SHAFT
IS SEAL LEAKING?
CAREFULLY INSPECT ENGINE CASTINGS,
PARTICULARLY THE THREADED HOLE AREAS
YES
YES
NO
PRESSURIZE ENGINE
COOLING SYSTEM
IS SYSTEMLEAKING?
CHECK TESTING KIT
REPLACE O-RING OF CYLINDER HEAD
AND/OR CYLINDER BASE GASKET
YES
YES
NO
CHECK TESTING KIT
PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
REPLACE GASKET OR O-RING,
RE-SEAL LEAKING AREA
REPLACE CHECK VALVE(S) / LINE(S)
PRESSURIZE ROTARY VALVE GEAR
RESERVOIR IN CRANKCASE
REPLACE DEFECTIVE SEAL(S)
REPLACE DEFECTIVE SEAL(S)
REPLACE OIL SEAL OF ROTARY
VALVE SHAFT END, OR
REPLACE CAP
REPLACE DEFECTIVE SEAL
REPLACE DEFECTIVE PARTS
NO
YES
YES
YES
YES
YES
NO
ANY LEAK FOUND?
ENGINE IS PERFECTLY SEALED
INTERNALLY
RECHECK ENGINE SEALING
CHECK TESTING KIT
RECHECK ENGINE SEALING
CHECK TESTING KIT
NO
NO
NO
YES
YES
NO
YES
NO
NO
NO
NO
04-02-8 SMR2003-007_04_02A.FM
947 DI Engines
F00D28T
Subsection 03 (REMOVAL AND INSTALLATION)
SMR2003-008_04_03A.FM 04-03-1
REMOVAL AND INSTALLATION 0
GENERAL
On some models, it is not necessary to remove
engine from watercraft to service TOP END, PTO
FLYWHEEL or MAGNETO. However, engine remov-
al is necessary to repair BOTTOM END.
ENGINE REMOVAL
DI Models
Use the VCK (Vehicle Communication Kit) (P/N 529
035 844) and release the fuel pressure in the fuel
system. Refer to ENGINE MANAGEMENT section.
All Models
In order to remove engine from watercraft proceed
as follows.
First, disconnect battery cables from battery.
Electrical Connections
It is recommended to disconnect electrical con-
nections prior to disconnecting fuel lines.
Disconnect temperature sensor wire and spark plug
cables.
Disconnect magneto wiring harness.
717 ENGINES
1. Unplug connector
787 RFI ENGINES
1. Unplug connector
947 DI ENGINES
1. Unplug connector
GTI LE RFI Models
Disconnect throttle position sensor (TPS), air pres-
sure sensor (APS) and air temperature sensor (ATS).
Disconnect crankshaft position sensor (CPS).
Disconnect connectors from fuel injectors.
Refer to FUEL INJECTION for location of sensors
and connectors.
DI Models
Disconnect both throttle position sensors (TPS),
manifold air pressure sensor (MAPS) and manifold
air temperature sensor (MATS).
WARNING
Always disconnect battery cables exactly in
the specified order, BLACK negative cable
first then the RED positive battery cable last.
F01D8RA
1
F06D0FA 1
F07D08A
1
04-03-2 SMR2003-008_04_03A.FM
Disconnect connectors from fuel injectors and di-
rect injectors.
Disconnect connector from knock sensor.
Disconnect RAVE valve hose where shown. Inspect
hose. If it has hardened or is slit, replace hose.
1. Disconnect hose here
Refer to ENGINE MANAGEMENT for location of sen-
sors and connectors.
Unplug air compressor lines (inlets and outlets):
cooling, oil (outlet only) and air (inlet only on throt-
tle body side).
Disconnect vent hose from balancing shaft gear
housing.
Jet Pump Removal
All Models
To withdraw jet pump, refer to JET PUMP.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
Drive System
To withdraw driveshaft(s), refer to DRIVE SYSTEM.
Cooling System
Disconnect the engine water supply hose.
Disconnect the engine water return hose.
NOTE: Engine will have to be raised inside bilge
to disconnect drain hose before removing from
bilge.
Refer to COOLING SYSTEM for proper water hose
location.
Tuned Pipe
To remove tuned pipe, refer to EXHAUST SYSTEM.
Air Intake Silencer
To remove air intake silencer, refer to AIR INTAKE.
Carburetor/Throttle Body
Turn fuel valve to OFF.
Disconnect fuel supply and fuel return hoses.
To remove carburetor(s), refer to CARBURETOR for
proper procedure.
GTI LE RFI Models
Disconnect fuel supply hose from fuel rail.
PRESS TABS AND PULL CONNECTOR
1. Fuel rail
DI Models
Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
1 F16D04A
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 the pressure. Wipe off any fuel spill-
age inside bilge.
F07F11A 1
SMR2003-008_04_03A.FM 04-03-3
All Models
Engine Support
NOTE: Be careful when removing engine sup-
port(s) or rubber mount adapters, shims could
have been installed underneath. Shims control
engine/jet pump alignment. Always note position
of shims for reinstallation, to avoid altering engine
alignment.
Remove engine support mount screws.
717 ENGINES
1. Remove screw of each engine support
TYPICAL 787 RFI AND 947 DI ENGINES FRONT SUPPORT
1. Remove screw
TYPICAL 787 RFI AND 947 DI ENGINES REAR SUPPORT
1. Remove screws
Lifting Engine
717 Engines
Engine can be easily lifted using lifting rings (P/N
529 035 830) and the engine lift tool (P/N 529 035
940).
LIFTING RING
Remove spark plugs and replace by lifting ring (P/N
529 035 830).
F02D08A
1
F06D35A 1
1 F07F12C
A33B06A
04-03-4 SMR2003-008_04_03A.FM
Hook engine lift tool (P/N 529 035 940) into lifting
ring holes.
ENGINE LIFT TOOL
Using a chain block, a hoist or other suitable equip-
ment, slightly lift engine to ease the remaining
component removal.
CAUTION: Take care not to damage cable or oil
injection hoses.
787 RFI and 947 DI Engines
Engine can be easily lifted by inserting a hook into
exhaust manifold eyelet.
TYPICAL
ment, slightly lift engine to ease the remaining com-
ponent removal.
CAUTION: Take care not to damage cable or oil
injection hoses.
Remove rear engine support.
TYPICAL
1. Rear support
Removal of Remaining Components
Lift up engine slowly until oil injection hoses can be
reached.
All Engines
Install a hose pincher to oil supply hoses of oil in-
jection pump and rotary valve shaft (except the
947 DI engines); then, disconnect hoses.
TYPICAL
1. Hose pincher (P/N 295 000 076)
A00B6BA
F01D7OA
1
F07F12A
A01B2JB
1
SMR2003-008_04_03A.FM 04-03-5
Install a hose pincher to oil return hose of rotary
valve shaft (except the 947 DI engines); then, dis-
connect hose.
TYPICAL 717 ENGINES
1. Rotary valve oil supply line
2. Hose pincher installed
TYPICAL 787 RFI ENGINES
1. Rotary valve oil supply line
2. Hose pincher installed
3. Disconnect RED positive cable
Disconnect RED positive cable from starter post.
TYPICAL
Disconnect BLACK negative cable from engine
crankcase.
1. Positive starter cable
2. Ground cable
Carry on engine lifting then tilt engine so that it can
be removed from the body opening.
CAUTION: Be careful not to scratch body or to
hit any component.
F01D3ZA
2
1
F04D10A 3 2 1
F01H1JB 1
F06H35A
2
1
04-03-6 SMR2003-008_04_03A.FM
TYPICAL
CLEANING
Wipe off any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
INSTALLATION
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
Rubber Mount, Shim and Screw
Check tightness and condition of rubber mounts.
If they have been removed, apply Loctite 243
(blue) on screw threads. Torque screws to 25 Nm
(18 lbfft).
CAUTION: Strict adherence to this torque is im-
portant to avoid damaging threads of alumi-
num insert in bilge.
Engine Support
717 Engines
Torque front and rear engine supports as shown in
the following illustration.
1. Torque screws to 22 Nm (16 lbfft)
2. Torque nuts to 39 Nm (29 lbfft)
787 RFI Engines
Apply Loctite 243 (blue) to rear engine support
screws and install them with flat washers and
torque to 24 Nm (17 lbfft).
TYPICAL
1. Torque engine support screws to 24 Nm (17 lbfft)
F01D7RA
F02D09B
1
2
1 Loctite
243
Loctite
243
Loctite
243
1
F07F12B
SMR2003-008_04_03A.FM 04-03-7
947 DI Engines
Install and torque the engine support screws to
24 Nm (17 lbfft) in the indicated order. Refer to
the following illustration.
TORQUE TO 24 Nm (17 lbfft) AS PER SEQUENCE
NOTE: Remember to install sleeves and flat washers.
1. Sleeves
2. Flats washers
Oil Injection Hoses
Make sure to reinstall hoses before completely low-
ering engine in bilge.
Positive Starter Cable
Torque nut of positive starter cable to 6 Nm
(53 lbfin). Apply dielectric grease on nut.
Engine/Jet Pump Alignment
Alignment is necessary to eliminate possible vi-
bration and/or damage to components. Check
alignment of engine using the following alignment
tools.
Support plate kit (P/N 529 035 506).
NOTE: Use plate (P/N 529 035 508) for the 139.5 mm
(5-1/2 in) jet pump and plate (P/N 529 035 507) for
the 155.6 mm (6-1/8 in) jet pump.
1. Plate
2. Support
Alignment shaft (P/N 295 000 141).
1. Alignment shaft
All Models except XP DI
To verify alignment proceed as follows:
Install the appropriate plate with the support to
hull with four nuts.
Carefully slide shaft through support.
3
F12D13A
1
4
2
5
F12D13B
2 1 2 1 2
F00B0FA 1 2
F00B0GA 1
F00B0HA
04-03-8 SMR2003-008_04_03A.FM
Insert shaft end into PTO flywheel.
NOTE: Ensure the protective hose and carbon
ring (or seal carrier) is removed to check engine
alignment. If the alignment is correct, the shaft will
slide easily without any deflection in PTO flywheel.
TYPICAL
1. Alignment shaft
2. PTO flywheel
If the alignment is incorrect loosen engine support
screws to enable to align PTO flywheel with shaft
end.
NOTE: Use shim(s) (P/N 270 000 024 or P/N 270
000 025) as necessary between engine supports
and rubber mounts to correct alignment.
TYPICAL
1. Shim
CAUTION: Whenever shims are used to correct
alignment, never install more than 1.3 mm
(0.051 in) shim thickness on the 947 DI engines
and 3 mm (0.12 in) on the 717 and 787 engines.
XP DI Models
Use:
plate (P/N 529 035 507)
1. Plate
2. Support
alignment shaft (P/N 295 000 141)
1. Alignment shaft
PTO flywheel adapter (P/N 529 035 590).
1. Adapter
Install support plate at rear of watercraft.
Install adapter on shaft.
NOTE: First ensure the mid bearing shaft support
has been properly aligned prior to performing en-
gine alignment. Refer to DRIVE SYSTEM. Then,
ensure the mid bearing is loosened to check en-
gine alignment.
F07D05A 2 1
F00D0CA
1
F00B0FA 1 2
F00B0GA 1
F00B11B 1
SMR2003-008_04_03A.FM 04-03-9
Carefully slide alignment shaft (P/N 295 000 141)
through shaft support and seal carrier.
TYPICAL
1. Alignment tool
2. Seal carrier
1. Alignment shaft
2. Adapter
Continue to slide the alignment shaft forward and
install PTO adapter (P/N 529 035 590) on shaft
end.
screws to enable to align PTO flywheel with shaft
end.
TYPICAL
1. Shim
alignment, never install more than 1.3 mm (0.051 in)
shim thickness.
Remove alignment shaft. Ensure the alignment
washers of mid bearing are still loose.
Reinstall drive shaft. Refer to DRIVE SYSTEM.
Ensure grease fitting of seal carrfier is located on
the top.
Apply Loctite 243 (blue) on studs and install nuts
no. 21.
Refer to following illustration for tightening se-
quence. Torque 1 to 6 at 3 Nm (27 lbfin) and
then 7 to 12 at 10 Nm (89 lbfin).
NOTE: It is very important to tighten nuts of seal
carrier in this sequence to maintain its alignment.
TIGHTENING SEQUENCE
F05I08A
1 2
1 F08I06A 2
F00D0CA
1
F00B25B
9
4
7
2
11
6
10
3
8
1
12
5
04-03-10 SMR2003-008_04_03A.FM
Engine Support Screws
All Models
Apply Loctite 243 (blue) on screw threads.
Torque engine support screws to 25 Nm (18 lbfft)
when procedure is completed.
717 ENGINES
1. Torque to 25 Nm (18 lbfft)
FRONT ENGINE SUPPORT 787 RFI AND 947 DI ENGINES
REAR ENGINE SUPPORT 787 RFI AND 947 DI ENGINES
Final Inspection
Check throttle cable condition and lubricate cable
with BOMBARDIER LUBE lubricant.
After its installation, properly adjust and bleed oil in-
jection pump as specified in OIL INJECTION PUMP
and adjust throttle cable as specified in ENGINE
MANAGEMENT (DI models).
Check hose condition and pressure test fuel sys-
tem, refer to FUEL CIRCUIT.
Verify all electrical connections.
Run engine and ensure there is no leakage.
CAUTION: If watercraft is out of water, engine
must be cooled using the flush kit.
F02D0KB
1
Loctite
243
1
Loctite
243
Loctite
243
1
F06D35A 1
WARNING
Whenever doing any type of repair on water-
craft or if any components of the fuel system
are disconnected, a pressure test must be done
before starting engine.
1 F07F12C
SMR2003-009_04_04A.FM 04-04-1
MAGNETO SYSTEM 0
717 Engines
24
Loctite
243
5
5 Nm
(44 lbfin)
9 Nm
(80 lbfin)
16
Loctite
243
4
6
7
Loctite
243
6 Nm
(53 lbfin)
23
6 Nm
(53 lbfin)
22
Loctite 243
3
6 Nm
(53 lbfin)
15
Loctite
243
14
13
150 Nm
(110 lbfft) Loctite
648
25
1
12
11
10 Nm (88 lbfin)
Anti-seize
lubricant
10 Nm
(88 lbfin)
11
Anti-seize
lubricant
10 Nm
(88 lbfin)
11
2.6 Nm
(23 lbfin)
2
F02D12S
04-04-2 SMR2003-009_04_04A.FM
787 RFI Engines
F06D3KS
Anti-seize
lubricant
9 Nm
(80 lbfin)
28
Molykote
111
24
Molykote
111
5
Dielectric
grease
Loctite
243
19
9 Nm
(80 lbfin)
8
17
10 Nm
(88 lbfin)
13
120 Nm
(89 lbfft)
Loctite
243
Loctite 243
14
3
4 Nm
(35 lbfin)
27
9 Nm
(80 lbfin)
9
Dielectric
grease
25
1
Molykote
111
11
Ground
cable
Dielectric
grease
Anti-seize
lubricant
6 Nm
(53 lbfin)
Anti-seize
lubricant
26
Anti-seize
lubricant
4 Nm
(35 lbfin)
20
9 Nm
(80 lbfin)
Anti-seize
lubricant
11
9 Nm
(80 lbfin)
Dielectric grease
Loctite
243
Anti-seize
lubricant
SMR2003-009_04_04A.FM 04-04-3
947 DI Engines
F18D2SS
Molykote
111
9 Nm
(80 lbfin)
Loctite
243
Molykote
111
Loctite
243
13 Nm
(115 lbfin)
9 Nm
(80 lbfin)
5 Nm
(44 lbfin)
Loctite
243
Loctite
243
Loctite
243
115 Nm
(85 lbfft)
3
8
14
21
20
16
29
9
25
1
11
13
17
13 Nm
(115 lbfin)
Loctite
648
30
04-04-4 SMR2003-009_04_04A.FM
DISASSEMBLY
717 Engines
NOTE: The magneto system can be disassembled
without removing the engine from the watercraft.
Magneto Cover
Remove screws no. 11 and wire support no. 12,
then withdraw magneto cover no. 1.
Magneto Flywheel and Ring Gear
Magneto flywheel no. 2 is locked with puller plate
(P/N 420 876 080), sleeves (P/N 290 847 220) and
extension handle (P/N 295 000 125).
1. Screw
2. Extension handle
3. Puller plate
4. Sleeve
Using three M8 x 35 screws (P/N 420 841 591),
install screws through puller plate and slide
sleeves on screws then secure puller plate on
magneto flywheel so that sleeves are against ring
gear no. 3.
Install extension handle on end of puller plate.
TYPICAL
1. Sleeves on opposite side
Using a suitable socket, unscrew retaining nut
no. 13 COUNTERCLOCKWISE when facing it.
NOTE: If socket is found too large to be inserted in
puller plate, machine or grind its outside diameter
as necessary.
TYPICAL
1. Extension handle locking crankshaft
Remove nut no. 13 and lock washer no. 14 from
magneto flywheel.
Magneto flywheel is easily freed from crankshaft
with puller (P/N 529 035 547).
Fully thread on puller in puller plate.
Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto fly-
wheel from its taper.
F01D47A
2
3
4
1
F01D48A
1
F01D4BA
1
A00C1AA
SMR2003-009_04_04A.FM 04-04-5
1. Puller plate
2. Puller
3. Extension handle
Lay magneto flywheel no. 2 on a steel plate. Tap
lightly on ring gear no. 3 using a hammer to re-
lease it from magneto flywheel.
1. Magneto flywheel
Armature Plate
Before removing, locate the manufacturers refer-
ence mark on the armature plate no. 4 and ensure
there is a corresponding indexing mark on the
crankcase housing.
NOTE: Since replacement crankcases do not have
timing mark for armature plate location, indexing
marks should be made on armature plate and crank-
case to ease reassembly and further ignition timing.
The following procedure is to find a common ref-
erence point on both crankcases (old and new) to
position armature plate.
Proceed as follows:
Before removing the armature plate, find a crank-
case locating lug (the top one in this example).
Place a cold chisel at the end of chosen lug, then
punch a mark on armature plate at this point.
1. Crankcase locating lug
2. Mark armature plate at the end of lug
At assembly, align armature plate mark (previ-
ously punched) with the end of the correspond-
ing locating lug on the new crankcase.
TYPICAL
1. Lug end of crankcase
2. Align mark and lug end here
Remove three retaining screws no. 15 and with-
draw armature plate.
Magneto Housing
To remove magneto housing no. 5, starter has to
be removed. Refer to STARTING SYSTEM.
Unscrew retaining screws, then withdraw housing.
Generating Coil
To replace generating coil no. 6:
Heat the armature plate to 93C (200F) around
the screw holes to break the threadlocker bond.
1
2
3
F01D4CA
1
F01D3AA
1
F01D4DA
2
1
F01D4EA
2
04-04-6 SMR2003-009_04_04A.FM
1. Heat the armature plate
CAUTION: Protect harness from flame.
Remove screws.
Uncrimp and unsolder BLACK/RED wire from coil.
1. Uncrimp and unsolder wire here
Battery Charging Coil
To replace battery charging coil no. 7:
Heat the armature plate to 93C (200F) around
the screw holes to break the threadlocker bond.
1. Heat the armature plate
CAUTION: Protect harness from flame.
Remove screws.
Uncrimp and unsolder YELLOW and YELLOW/
BLACK wires from coil.
Uncrimp and unsolder ground wire (BLACK) from
coil core.
1. Uncrimp and unsolder ground wire (BLACK)
2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires
787 RFI Engines
Magneto Housing Cover
Disconnect water hoses from heat exchanger cover.
Loosen screws no. 11. Remove engine magneto
cover no. 1.
787 RFI ENGINES
1. Disconnect water inlet hose
2. Heat exchanger cover
F00D08A
1
A25E0QA
1
F00D09A
1
A25E0SA
1
2
F07D0JA 1 2
SMR2003-009_04_04A.FM 04-04-7
Remove oil pump shaft from magneto rotor nut.
1. Oil pump shaft
Rotor and Ring Gear
Remove starter. Refer to STARTING SYSTEM.
NOTE: Crankshaft can also be locked by using the
PTO flywheel extractor tool. For procedure, refer to
BOTTOM END.
Lock ring gear using special tool (P/N 529 035 846).
SPECIAL TOOL (P/N 529 035 846)
1. Special tool (P/N 529 035 846)
Remove crankshaft position sensor no. 18 before
removing the ring gear.
Alternatively, you can lock ring gear using special
tool assembly (P/N 295 000 155).
1. Ring gear blocking tool (P/N 295 000 134)
2. Retaining plate (P/N 295 000 154)
1. Ring gear blocking tool with retaining plate
1 F07D0IA
F15B01A
1 F15D0AA
F01B26A
1 2
F01D85A 1
04-04-8 SMR2003-009_04_04A.FM
1. Crankshaft position sensor
Using a suitable socket, unscrew retaining nut
no. 13 of magneto rotor COUNTERCLOCKWISE
when facing it.
Ring gear is easily freed from crankshaft with pull-
er (P/N 420 976 235) and crankshaft protective cap
(P/N 420 876 557).
Remove special tool locking ring gear.
Insert crankshaft protector to outer end of crank-
shaft and fully thread puller in magneto rotor.
TYPICAL
1. Puller
Tighten puller screw and at the same time, tap on
screw head using a hammer to release magneto
rotor from its taper.
Magneto Housing
To remove magneto housing no. 5, starter has to be
removed. Refer to STARTING SYSTEM.
Unscrew retaining screws no. 19, then withdraw
housing.
REMOVE SCREWS
1. Magneto housing
Stator Assembly
787 RFI Engines
Remove holding plate and withdraw plug from cover.
Unscrew bolts no. 20 and remove stator no. 9 from
magneto cover.
787 RFI ENGINES
1. Holding plate
2. Stator assembly
3. Remove screws
F07D0KA
1
F01D7YA
1
F07D0LA 1
F07D0MA 2
1 3
SMR2003-009_04_04A.FM 04-04-9
947 DI Engines
Cover
Loosen screws no. 11. Remove engine magneto
cover no. 1.
TYPICAL
1. Cover
2. Screw
Remove oil pump shaft from magneto rotor nut.
TYPICAL
1. Remove oil pump shaft
Rotor and Ring Gear
To remove the rotor no. 8 or the ring gear no. 3,
the crankshaft must be locked. For procedure, re-
fer to BOTTOM END.
If necessary, the magneto rotor can be removed
without removing the ring gear and trigger wheel. Re-
move the six screws no. 17.
TYPICAL
1. Screw
To remove the ring gear/rotor assembly, unscrew
nut no. 13 counterclockwise when facing it.
TYPICAL
1. Nut
The magneto rotor is easily freed from crankshaft
with puller (P/N 420 976 235).
Install protective cap (P/N 290 877 414) to crank-
shaft.
Fully thread puller in magneto rotor.
CAUTION: Ensure to completely screw the puller
until it bottoms. Otherwise, not enough threads
would be engaged and damage may occur.
F06D1RA 1 2
F06D23A 1
F06D0LA 1
F06D0MA 1
04-04-10 SMR2003-009_04_04A.FM
TYPICAL
1. Puller
Tighten puller screw and at the same time, tap on
screw head using a hammer to release magneto
rotor from its taper.
CAUTION: Be careful after ring gear removal
not to bend the encoder wheel teeth. Also pay
attention when putting away. If you suspect a
bent tooth, refer to ENGINE MANAGEMENT for
inspection procedure.
Stator and Trigger Coil/CPS
(Crankshaft Position Sensor)
Loosen screws no. 20 and no. 21 to remove the
stator no. 9 and trigger coil no. 10 from the engine
magneto cover.
1. Remove screws
CLEANING
Clean all metal components in a solvent.
CAUTION: Clean coils and magnets using only
a clean cloth.
Clean crankshaft taper and threads using acetone.
Apply the acetone on a rag first then clean the crank-
shaft.
ASSEMBLY
717 Engines
Generating Coil
Strip end of old wire then crimp and solder on new
coil.
Apply Loctite 243 (blue) to screws no. 22 and in-
stall the new coil on armature plate.
Use magneto coil centering tool (P/N 420 876 922)
and install so that it fits around armature plate be-
fore tightening screws.
1. Magneto coil centering tool (P/N 420 876 922)
CAUTION: Before reinstalling the magneto, re-
move the loose epoxy from harness.
Position new coil, crimp and solder all wires.
Prior to assembly, apply Loctite 243 (blue).
Use magneto coil centering tool (P/N 420 876 922)
and install it so that it fits around armature plate
before tightening screws no. 23.
F06D0PA 1
F06D0NA 1
F00D0AA
1
SMR2003-009_04_04A.FM 04-04-11
1. Magneto coil centering tool (P/N 420 876 922)
Magneto Flywheel and Ring Gear
Apply Loctite 648 (green) to magneto flywheel
mating surface. Lay ring gear on a steel plate, then
heat with a propane torch in order to install it on
magneto flywheel.
Pay particular attention to position ring gear teeth
chamfer side as per following illustration.
1. Teeth chamfer
NOTE: Ensure that ring gear contacts magneto fly-
wheel flange.
Whenever replacing either ring gear or magneto
flywheel, Gun Kote must be applied to prevent
possible corrosion.
CAUTION: Always assemble magneto flywheel
and ring gear prior to apply Gun Kote. If not done
correctly, ring gear wont contact magneto fly-
wheel flange.
To apply Gun Kote proceed as follows:
1. Clean thoroughly and degrease replacement part
using a non oil base solvent.
2. Apply coating in light thin coats using a spray gun.
NOTE: Do not spray Gun Kote into magneto fly-
wheel threaded holes.
3. Bake parts in oven at 175C (350F) for 1 hour
to cure Gun Kote.
CAUTION: Do not eliminate Gun Kote heat cur-
ing time because it will lose all its resistance
and it will not give any protection.
Magneto Housing
Install gasket no. 24 between magneto housing
no. 5 and engine crankcase.
Install magneto housing and torque screws no. 16
to 9 Nm (80 lbfin).
Armature Plate
Position the armature plate on the crankcase, align-
ing the marks on both parts.
When reinstalling armature plate on a new crank-
case housing, proceed as follows.
Find manufacturers mark on armature plate. In
line with this mark, punch another mark on adja-
cent crankcase lug.
TYPICAL
1. Manufacturers mark on armature plate
2. Punch a mark on crankcase lug aligned with plate mark
The new mark on crankcase will be used for fur-
ther assembly positioning as a pre-timing position.
F00D0AA
1
F01D3BA 1
F01D4FA
2 1
04-04-12 SMR2003-009_04_04A.FM
TYPICAL
1. For further assembly, use these marks
Apply a drop of Loctite 243 (blue) on threads of
screws no. 15 and torque to 6 Nm (53 lbfin).
Magneto Flywheel
Apply Loctite 243 (blue) on crankshaft taper.
Position Woodruff key and magneto flywheel. Ap-
ply Loctite 243 (blue) on nut no. 13. Install nut with
lock washer and torque to 145 Nm (107 lbfft).
CAUTION: Never use any type of impact wrench
at magneto installation.
Ignition Timing
For ignition timing procedures of the 717 engine,
refer to IGNITION SYSTEM.
Magneto Housing Cover
Properly install O-ring no. 25 in magneto housing. Ap-
ply Loctite 767 anti-seize on screws no. 11, install
cover and wire support no. 12. Torque screws no. 11
in a criss-cross sequence to 9 Nm (80 lbfin).
787 RFI Engines
Stator
Install the stator no. 9 in magneto housing cover
no. 1 and torque screws no. 20 to 9 Nm (80 lbfin).
Install wiring harness bracket no. 26 of stator and
torque screws no. 27 to 4 Nm (35 lbfin).
1. Stator screws
2. Bracket
Magneto Housing
To install oil seal no. 28 of magneto housing no. 5,
use pusher (P/N 290 877 740) and handle (P/N 420
877 650).
1. Pusher
2. Handle
F01D4GA
1
F06D0CA
1 2
F01B2NA
1
2
SMR2003-009_04_04A.FM 04-04-13
Install gasket no. 24 between magneto housing
and engine crankcase.
Install magneto housing and torque screws no. 19
to 9 Nm (80 lbfin).
Rotor and Ring Gear
Install ring gear on crankshaft.
Apply Loctite 243 (blue) on nut no. 13. Install nut
with lock washer no. 14 and torque to 120 Nm
(89 lbfft).
CAUTION: Never use any type of impact wrench
at magneto installation.
Crankshaft Position Sensor
Install crankshaft position sensor no. 18 on mag-
neto housing. Torque screw to 9 Nm (80 lbfin).
NOTE: The crankshaft position sensor is not ad-
justable.
Cover
Before installing cover, make sure oil pump shaft
is properly positioned.
Before installation, properly install O-ring no. 25 in
engine magneto cover no. 1.
Apply Loctite 767 anti-seize compound on screws
no. 11. Torque screws in a criss-cross sequence
to 9 Nm (80 lbfin).
947 DI Engines
Stator and Trigger Coil/CPS
(Crankshaft Position Sensor)
Install the stator no. 9 and trigger no. 10 coil in
engine magneto cover. Torque screws to 9 Nm
(80 lbfin).
Reinstall wiring harness bracket no. 29 using tap-
tite screws no. 16.
Torque trigger coil screws no. 21 to 9 Nm (80 lbfin).
Torque stator screws no. 20 to 13 Nm (115 lbfin).
NOTE: The trigger coil is not adjustable.
1. Torque to 9 Nm (80 lbfin)
2. Taptite screws
3. Torque to 13 Nm (115 lbfin)
Cover
Before installing cover, make sure oil pump shaft
is properly positioned.
to 9 Nm (80 lbfin).
F04D0CA
F06D0NB 1 2 3
04-04-14 SMR2003-009_04_04A.FM
Rotor and Ring Gear
Install trigger wheel no. 30 on ring gear no. 3.
1. Ring gear
2. Trigger wheel
Apply Loctite 648 (green) on mating surface of the
rotor no. 8.
Apply Loctite 648 (green) on screws no. 17 retain-
ing rotor to ring gear and torque screws in a criss-
cross sequence to 13 Nm (115 lbfin).
ASSEMBLED FLYWHEEL
1. Loctite 243 (blue) on crankshaft taper
Install flywheel and make sure to align keyway
with the crankshaft Woodruff key.
Apply Loctite 243 (blue) on nut no. 13. Install nut
with lock washer and torque to 115 Nm (85 lbfft).
CAUTION: Never use any type of impact wrench.
Unlock crankshaft. Reinstall pulse fitting with wash-
er and torque to 19 Nm (14 lbfft).
Cover
to 9 Nm (80 lbfin).
If heat exchanger cover has been removed, en-
sure to align its notch with the emboss in casing.
1. Align notch with the emboss
1
F18D2TA
2
F18D2UA
F06D24A 1
1
F12R0EA
Subsection 05 (TOP END)
SMR2003-010_04_05A.FM 04-05-1
TOP END 0
717 Engines
F17D02S
10
11
12
12
14
6
2
13
9
13
5
3
4
3
4
5
6
24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
24 Nm
(17 lbfft)
Loctite 243
Loctite 243
Loctite 243
Engine
oil
Molykote 111
Molykote 111
Molykote 111
Engine
oil
8
7
04-05-2 SMR2003-010_04_05A.FM
787 RFI Engines
F07D0US
27 Nm
(17 lbfft)
7
8
3
5
4
5
6
(34 rollers)
Engine oil
Loctite
243
Molykote
111
14
1
11
12
12
2
13
Loctite 243
Molykote
111
40 Nm
(30 lbfft)
9
10
30
Molykote 111
10 Nm
(89 lbfin)
15
16 17 19
18
20
Molykote
111
3 Nm
(27 lbfin)
21
29 27
8
26
25
24 23 22
Molykote 111
SMR2003-010_04_05A.FM 04-05-3
947 DI Engines
40 Nm
(30 lbfft)
7
8
3
4
5
6
Engine oil
Loctite
243
Molykote 111
14
13
Loctite
243
Molykote
111
40 Nm
(30 lbfft)
9
10
34
2
10 Nm
(89 lbfin)
15
16 17 19
18
3 Nm
(27 lbfin)
26
24 23 22
Molykote 111
20
25
F12D0TS
Loctite 243
Engine oil
04-05-4 SMR2003-010_04_05A.FM
GENERAL
The 2-stroke ROTAX engine rotates counterclock-
wise seen from the rear (PTO flywheel).
The 717 and 787 RFI engines have a rotary valve
to control opening and closing of the intake. The
947 DI engines uses reed valves in the crankcase.
The 787 RFI and 947 DI engines are also equipped
with the RAVE system (Rotax Adjustable Variable
Exhaust).
CAUTION: No engine components can be inter-
changed between engines.
RAVE System
(Rotax Adjustable Variable Exhaust)
BASIC OPERATION
The RAVE valves change the height of the exhaust
port. The RAVE valve solenoid, which is controlled
by the MPEM, allows either positive crankcase
pressure (787 RFI engines) or a pressure from the
air compressor (947 DI engines) to inflate the bel-
lows and open the RAVE valves.
Carburetor-Equipped Engines
On top of the RAVE, there is a red plastic adjust-
ment knob. Turning the adjustment in or out
changes the preload on the return spring which, in
turn, will change the RPM at which the RAVE valve
opens and closes. On 947 DI engines, the spring
preload does not have a significant effect on the
valve operation.
787 RFI Engines
On these engines, the RAVE valves are controlled
by the Multi-Purpose Electronic Module (MPEM).
To open the RAVE valves, the MPEM activates a
solenoid which directs the positive pressure from
engine crankcase to the valves.
1. Solenoid
2. Pressure hose from crankcase
3. To atmospheric pressure
NOTE: A check valve on the pressure line elimi-
nates the negative pressure from the crankcase.
To close the RAVE valves, the MPEM deactivates
the solenoid which blocks the crankcase positive
pressure. The RAVE valves are opened to the at-
mosphere.
RAVE VALVE OPENED
1. Pulse from crankcase
2. Check valve
3. Positive pressure to solenoid
4. Solenoid activated
5. Positive crankcase pressure to RAVE valves
2
F06D3BA
1 3
3
F06D16A
2
1
4
5
SMR2003-010_04_05A.FM 04-05-5
RAVE VALVE CLOSED
1. Pulse from crankcase
2. Check valve
3. Positive pressure blocked by the solenoid
4. Solenoid deactivated
5. RAVE valves are opened to atmosphere
947 DI Engines
To open the RAVE valves, the MPEM activates a
solenoid which directs the pressure from air com-
pressor to the valves.
1. Pressure from solenoid
1. Solenoid
2. Pressure from air compressor
3. Pressure to RAVE valves
4. Vent to air intake silencer
5. Check valve
6. Vent from counterbalancing shaft oil cavity
To close the RAVE valves, the MPEM deactivates the
solenoid which blocks the air compressor pressure.
The RAVE valves are opened to the atmosphere.
The vent on couterbalancing shaft oil cavity is nec-
essary to prevent pressure buildup in the cavity by
the air compressor piston movement. The check
valve allows pressure to escape from the cavity
but does not allow liquid to enter into the cavity.
3
F06D16B
2
1
4
5
1
F12D02A
1
6
F12D15A
5 4
2 3
04-05-6 SMR2003-010_04_05A.FM
RAVE VALVE OPENED
2. Solenoid activated
3. Pressure to solenoid
4. Pressure to RAVE valves
RAVE VALVE CLOSED
2. Solenoid deactivated
3. Pressure to solenoid
4. Pressure to RAVE valves blocked by the solenoid
5. Vent to air intake silencer
6. Check valve
7. Counterbalancing shaft oil cavity vent
MAINTENANCE
There are no wear parts anywhere in the system
and there are no adjustments to be periodically
checked. The only possible maintenance required
would be cleaning of carbon deposits from the
guillotine slide. Cleaning intervals would depend
upon the users riding style and the quality of the
oil used. We suggest annual cleaning of the valve.
If a customer uses a lower than recommended
quality oil, more frequent cleaning may be re-
quired.
No special solvents or cleaners are required when
cleaning the valve.
BORING PRECAUTION
In its stock configuration the RAVE valve guillotine
has a minimum of 0.5 mm (.020 in) clearance to the
cylinder bore measured at the center line of the cyl-
inder. This is the minimum production clearance.
There is only a first oversize piston available for the
787 RFI and 947 DI engines. That piston is 0.25
mm (.010 in) larger in diameter than the stock pis-
ton. When the oversize is installed, the guillotine
will have a minimum clearance of 0.375 mm (.015
in) with the cylinder bore. This is the minimum op-
erating clearance the guillotine should be used
with. Clearance less than 0.375 mm (.015 in) will
require reworking of the guillotine to achieve the
proper clearance and radius.
DISASSEMBLY
RAVE Valve
787 RFI Engines
Loosen Allen screws no. 26 each side of RAVE valve.
1. Remove screws
3
2
1
F12D04A
4
3
2
1
F12D05A
4
5
6
7
F06D0QA 1
SMR2003-010_04_05A.FM 04-05-7
Remove RAVE valve no. 15.
Remove the cover no. 18 of the valve by releasing
the spring no. 16.
1. Spring
Remove the compression spring no. 19.
1. Remove spring
787 RFI engines
Remove spring no. 30 retaining bellows no. 21 to
valve piston no. 20.
1. Spring
Free bellows no. 21 from valve piston no. 20.
1. Bellows removed from piston
WARNING
Firmly hold cover to valve base. The com-
pression spring inside the valve is applying
pressure against the cover.
F06D0RA 1
F06D25A 1
F06D0SA 1
F06D0TA 1
04-05-8 SMR2003-010_04_05A.FM
Unscrew valve piston no. 20 from sliding valve
no. 22.
NOTE: Hold the sliding valve to prevent it from
turning.
1. Unscrew piston
2. Hold sliding valve
Remove compression spring no. 29.
1. Remove spring
Remove supporting ring no. 28.
1. Remove supporting ring
Remove O-ring no. 23.
1. Remove O-ring
F06D0TB 2 1
A06D26A 1
F06D27A
1
F06D28A
1
SMR2003-010_04_05A.FM 04-05-9
Remove sliding valve no. 22.
1. Remove sliding valve
Remove bellows no. 21.
1. Remove bellows
947 DI Engines
Loosen Allen screws no. 26 each side of RAVE valve.
1. Remove screws
Remove RAVE valve no. 15.
the spring no. 16.
1. Spring
F06D0UA 1
F06D0VA
1
WARNING
Firmly hold cover to valve base. The com-
pression spring inside the valve is applying
pressure against the cover.
1 F12D0UA 1
1 F12D0VA
04-05-10 SMR2003-010_04_05A.FM
Remove the compression spring no. 19.
1. Remove spring
Unscrew valve piston no. 20 from sliding valve
no. 22.
NOTE: Hold the sliding valve to prevent it from
turning.
1. Unscrew piston
2. Hold sliding valve
Remove sliding valve from valve housing.
1. Valve piston
2. Valve housing
3. Sliding valve
Cylinder Head Cover and Cylinder Head
Disconnect temperature sensor wire and spark
plug cables.
Connect spark plug cables on grounding device.
717 Engines
Remove air intake silencer and support, refer to
AIR INTAKE.
Remove screws no. 14.
Remove cylinder head cover no. 1.
If shells, sand, salt or any other particles are present
in cylinder head, clean with a vacuum cleaner.
Remove cylinder head no. 2.
If shells, sand, salt water or any other particles are
present in cylinder cooling jacket, clean with a vac-
uum cleaner.
947 DI Engines
Disconnect hose of RAVE valves.
Remove air/fuel rail. Refer to ENGINE MANAGE-
MENT.
1 F12D0WA
2
1 F12D0XA
1 F12D0YA 2 3
SMR2003-010_04_05A.FM 04-05-11
Use Snap-On Torx socket E12 and unscrew cylin-
der head screws no. 14 following the sequence
shown in the next illustration.
Remove cylinder head no. 2 and gasket no. 34.
Cylinder
NOTE: When removing cylinder, make sure con-
necting rods do not hit crankcase edge.
787 RFI Engines
Remove air intake silencer and support, refer to
AIR INTAKE.
Remove tuned pipe and exhaust manifold, refer to
EXHAUST SYSTEM.
Remove cylinders no. 9, while making sure con-
necting rods do not hit crankcase edge.
NOTE: Even if only 1 cylinder needs repair, both
cylinders should be lifted to allow 1-piece cylinder
base gasket replacement.
947 DI Engines
Remove cylinders screws then cylinders no. 9.
Piston
NOTE: All engines feature cageless piston pin
bearings.
Bring piston to Top Dead Center and install rubber
pad (P/N 295 000 101) over crankcase opening.
Secure with screws. Lower piston until it sits on
pad.
1. Rubber pad (P/N 295 000 101)
If the other cylinder has been removed, complete-
ly cover its opening with a clean rag.
1. Openings covered with rag and rubber pad
WARNING
If screws need to be heated for removal when
engine is in watercraft, fuel system pressuriza-
tion must be done first. Do not use open flame;
use a heat gun.
F12D08B
2
6
1
5
11
10 8
4
3
7
12
9
F01B0JA
1
F01D43A
1
04-05-12 SMR2003-010_04_05A.FM
947 DI Engines
Install rubber pad (P/N 290 877 032) on crankcase.
Secure with screws. Lower piston to be removed
until it sits on pad.
1. Rubber pad (P/N 290 877 032)
All Engines
To remove circlip no. 5, insert a pointed tool in pis-
ton notch then pry it out and discard.
TYPICAL
1. Piston notch
To extract piston pin no. 4, use piston pin puller
(P/N 529 035 503) with the appropriate set of
sleeves.
1. Puller
2. Shoulder sleeve
3. Sleeve
Fully thread on puller handle.
Insert extractor spindle into the piston pin.
Slide the sleeve and shoulder sleeve onto the
spindle.
Screw in extracting nut with the movable ex-
tracting ring toward spindle.
1. Puller
2. Sleeve
3. Shoulder sleeve
4. Extracting nut
WARNING
Always wear safety glasses when removing
piston circlips.
F06B06B 1
F01D0PA
1
ENGINE SLEEVE SET
717/787 RFI P/N 529 035 542
947 DI P/N 529 035 543
F00B0IA
2 3 1
F00B0JA
1 2 3 4
SMR2003-010_04_05A.FM 04-05-13
NOTE: The tool cutout must be positioned toward
the bottom of the piston.
1. Tool cut-out toward bottom of piston
Firmly hold puller and rotate handle to pull pis-
ton pin no. 4.
Rotate spindle until the shoulder sleeve is
flushed with the piston recess.
1. Shoulder sleeve flush with piston recess
Loosen the extracting nut and remove puller.
Remove the shoulder sleeve from piston.
1. Remove shoulder sleeve
Carefully remove the piston no. 3.
The needles, thrust washers and the sleeve re-
main in the connecting rod bore and may be
used again.
1. Needles and thrust washer
2. Sleeve
F00B0KA 1
F00B0LA
1
F00B0MA
1
1 2
F00B0NA
04-05-14 SMR2003-010_04_05A.FM
CLEANING
Discard all gaskets and O-rings.
Clean water passages and make sure they are not
clogged.
Remove carbon deposits from cylinder exhaust
port, RAVE valve (787 RFI and 947 DI engines),
cylinder head and piston dome.
Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
INSPECTION
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE: When repairing a seized engine, connect-
ing rods should be checked for straightness and
crankshaft for deflection/misalignment. Refer to
BOTTOM END for procedures.
Inspect plane surfaces for warpage. Small defor-
mation 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.
The inspection of engine top end should include
the following measurements.
N.A.: Not Applicable
NOTE: Replacement cylinder sleeves are avail-
able if necessary. Also, oversize pistons of 0.25
mm (.010 in) are available for all engines and over-
size pistons of 0.5 mm (.020 in) are available for
the 717 engine.
ENGINE
MEASUREMENT
TOLERANCES
NEW PARTS
(min.) (max.)
WEAR
LIMIT
Cylinder taper N.A.
0.05 mm
(.002 in)
0.1 mm
(.004 in)
Cylinder out of round N.A.
0.008 mm
(.0003 in)
0.08 mm
(.003 in)
Piston/cylinder wall
clearance for the
717 engine
0.10 mm
(.0039 in)
N.A.
0.20 mm
(.008 in)
clearance for the
787 RFI engine
0.13 mm
(.005 in)
N.A.
0.22 mm
(.009 in)
clearance for the
947 DI engine
0.12 mm
(.0047 in)
N.A.
0.20 mm
(.008 in)
Ring/piston groove
clearance for the
717 engine
0.025 mm
(.001 in)
0.070 mm
(.0027 in)
0.20 mm
(.008 in)
Ring/piston groove
clearance for the
787 RFI engine
0.025 mm
(.001 in)
0.070 mm
(.0027 in)
0.24 mm
(.009 in)
Ring/piston groove
clearance for the
947 DI engine
0.044 mm
(.002 in)
0.089 mm
(.003 in)
0.20 mm
(.008 in)
Ring end gap for the
717 engine
0.25 mm
(.010 in)
0.40 mm
(.016 in)
1.0 mm
(.039 in)
787 RFI engine
0.40 mm
(.016 in)
0.55 mm
(.022 in)
1.0 mm
(.039 in)
947 DI engine
0.55 mm
(.022 in)
0.7 mm
(.028 in)
1.1 mm
(.043 in)
SMR2003-010_04_05A.FM 04-05-15
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diam-
eter at 16 mm (5/8 in) from top of cylinder just below
auxiliary transfer port, facing exhaust port and just be-
low the auxiliary transfer port facing the exhaust port.
Compare readings. If the difference between read-
ings exceed specification, cylinder should be rebored
and honed or replaced.
1. Measuring perpendicularly (90) to piston pin axis
2. Auxiliary transfer port
A. 16 mm (5/8 in)
Cylinder Out of Round
Using a cylinder bore gauge, measure cylinder di-
ameter at 16 mm (5/8 in) from top of cylinder. Mea-
sure diameter in piston pin axis direction then per-
pendicularly (90) to it. If the difference between
readings exceed specification, cylinder should be
rebored and honed or replaced.
1. Measuring in piston pin axis
A. 16 mm (5/8 in)
USED PISTON MEASUREMENT
Note the measurement on the piston dome.
1. Piston dome
2. Piston measurement
A
F01D8AA
1
2
A
F01D8BA
A
1
2
F00D0EA 2 1
04-05-16 SMR2003-010_04_05A.FM
Using a micrometer, measure piston skirt perpen-
dicularly (90) to piston pin according to the follow-
ing table.
A. See previous table
The measured dimension must not be less than
0.12 mm (.005 in) of the one scribed on piston
dome. Otherwise, install a new piston.
Piston/Cylinder Wall Clearance
Used and New Pistons
IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
SUREMENT above.
To determine the piston dimension, take the mea-
surement on the piston dome.
1. Piston dome
2. Piston measurement
Adjust and lock a micrometer to the specified val-
ue on the piston dome.
1. Micrometer set to the piston dimension
With the micrometer set to the piston dimension,
adjust a cylinder bore gauge to the micrometer di-
mension and set the indicator to zero.
ENGINE TYPE
MAXIMUM A
mm (in)
717 29 (1.142)
787 RFI 28 (1.102)
947 DI 24 (0.945)
ENGINE TYPE
MAXIMUM PISTON SKIRT
WEAR
mm (in)
All 0.12 (.005)
F01D0NA
1
A
F00D0EA 2 1
F00B08A
1
SMR2003-010_04_05A.FM 04-05-17
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
1. Indicator set to zero
Position the dial bore gauge at 16 mm (5/8 in) be-
low cylinder top edge.
A. 16 mm (5/8 in)
Read the measurement on the cylinder bore gauge.
The result is the exact piston/cylinder wall clearance.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Ring/Piston Groove Clearance
Using a feeler gauge, check clearance between
rectangular ring and groove. If clearance exceeds
specified tolerance, replace piston.
NOTE: Ring/piston groove clearance can be cor-
rectly measured only on rectangular ring which is
bottom ring.
1. Feeler gauge
2. Rectangular ring (bottom)
947 DI Engines
Due to the semi-trapez rings, it is not possible to
accurately measure ring/piston groove clearance.
Ring End Gap
Position ring halfway between exhaust port and
top of cylinder.
NOTE: In order to correctly position ring in cylin-
der, use piston as a pusher.
F00B09A
1
2
F00B0AA
1
F01D0KA
1
A
F01D0XA
1
2
04-05-18 SMR2003-010_04_05A.FM
Using a feeler gauge, check ring end gap. If gap
exceeds specified tolerance, rings should be re-
placed.
1. Top of cylinder
2. Ring end gap
Cylinder Base Gasket
NOTE: The general procedure is to install a new
gasket of the same thickness. However, if you do
not know the gasket thickness that was installed
or if a crank repair has involved replacement of
connecting rods, refer to the COMBUSTION CHAM-
BER VOLUME MEASUREMENT to properly deter-
mine the required gasket thickness.
Different thicknesses of cylinder base gaskets are
used for a precise adjustment of the combustion
chamber volume.
To identify gasket thickness, refer to the identifi-
cation holes on the gasket.
TYPICAL
1. Identification holes
All Engines
RAVE Valve
Check RAVE valve bellows no. 21 for cracks.
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
RAVE Valve
787 RFI Engines
Make sure to insert O-ring no. 23 onto rod of slid-
ing valve no. 22.
The TOP position of the sliding valve no. 22 is in-
dicated on one side.
1. Sliding valve
2. O-ring
3. TOP
Install a new gasket no. 24. It must be installed at
the same time as the sliding valve no. 22.
F01D0OA 1
2
F01D67A
1
GASKET
THICKNESS
IDENTIFICATION
HOLES
0.3 mm (.012 in) 3
0.4 mm (.016 in) 4
0.5 mm (.020 in) 5
0.6 mm (.024 in) 6
0.8 mm (.031 in) 8
F01D8KA 1 3 2
SMR2003-010_04_05A.FM 04-05-19
Position the valve housing no. 25 onto the cylinder
so that its opening is toward the bottom.
1. Bottom of valve housing
When the valve is mounted onto the cylinder,
move the valve piston no. 20 to ensure the sliding
valve no. 22 moves easily and does not stick.
947 DI Engines
Check the piston valve O-ring. Replace if neces-
sary.
1. Piston valve O-ring
Check the sliding valve O-ring. Replace if neces-
sary.
1. Sliding valve O-ring
F01D8JB 1
F01D8LA
F12D0ZA 1
1 F12D10A
04-05-20 SMR2003-010_04_05A.FM
Check the O-ring under valve housing. Replace if
necessary.
1. Valve housing O-ring
All RAVE-Equipped Engines
There is only one way to insert the sliding valve
no. 22 in valve housing no. 25.
1. Sliding valve ridge toward housing groove
Piston
At assembly, place the pistons no. 3 with the let-
ters AUS (over an arrow on the piston dome)
facing in direction of the exhaust port.
1. Exhaust side
NOTE: On the 787 RFI and 947 DI engines, the
exhaust ports are located on the same side as the
intake.
Carefully cover crankcase opening as for disas-
sembly.
Piston Pin and Roller Bearing
To install roller bearing no. 4 and piston pin no. 6
use, piston pin puller (P/N 529 035 503) with the
appropriate set of sleeves as for disassembly.
Replacement bearings are held in place by a lo-
cating sleeve outside and 2 plastic cage halves
inside.
Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
Replace the inner halves by the appropriate
sleeve tool in the connecting rod bore.
Insert piston pin into piston until it comes flush
with inward edge of piston hub.
Warm piston to approximately 50 - 60C (122 -
140F) and install it over connecting rod.
NOTE: Make sure thrust washers are present each
side of needles.
1 F12D11A
F06D12A
1
A01C01A
AUS
1
SMR2003-010_04_05A.FM 04-05-21
Install the shoulder sleeve tool on the opposite
side of the piston pin.
1. Piston pin
2. Shoulder sleeve
Insert extractor spindle into the piston pin,
screw on extracting nut.
1. Puller installed on the opposite side of the piston pin
2. Tighten extracting nut
Rotate handle to pull piston pin carefully into the
piston.
Plastic Mounting Device Method
This is an alternate method when no service tool
is available.
Replacement roller bearings are delivered in a con-
venient plastic mounting device. For installation,
proceed as follows:
Align replacement roller bearing with connect-
ing rod bore.
Carefully push inner plastic sleeve into connect-
ing rod bore; outer plastic ring will release rollers.
1. Outer ring removal after inner sleeve insertion into bore
Make sure thrust washers are present each
side of rollers.
1. Thrust washer each side
F00B0OA
2 1
F00B0PA
1 2
F01D0QA
1
F01D0VA
1
04-05-22 SMR2003-010_04_05A.FM
Insert piston pin into piston until it comes flush
with inward edge of piston hub.
1. Piston pin flush here
2. Thrust washers
Place piston over connecting rod and align
bores, then gently tap piston pin with a fiber
hammer to push out inner plastic ring on oppo-
site side. Support piston from opposite side.
As necessary, pull halves of inner sleeve with
long nose pliers.
1. Pulling inner sleeve half
Circlip
Always use new circlips.
CAUTION: Always use new circlips. At installa-
tion, take care not to deform them. Circlips
must not move freely after installation.
Secure circlip with its opening located at the bot-
tom of the piston.
CAUTION: To minimize the stress on the cir-
clips, it is important to install them as described.
1. Circlip opening at 6 oclock (at bottom)
F01D0RA
1
2
F01D0SA
WARNING
Always wear safety glasses when installing
piston circlips.
F01D0TA
1
F06D18A 1
SMR2003-010_04_05A.FM 04-05-23
947 DI Engines
Secure circlip in piston groove with its bent end in
piston notch as shown.
1. Circlip end in piston notch
All Engines
To easily insert circlip into piston, use circlip installer.
1. Circlip installer
Remove sleeve from pusher then insert circlip
into its bore.
Reinstall sleeve onto pusher and push until cir-
clip comes in end of tool.
TYPICAL
1. Circlip near end of tool
Position end of tool against piston pin opening.
Firmly hold piston against tool and tap tool with
a hammer to insert circlip into its groove.
CAUTION: The hand retaining the piston should
absorb the energy to protect the connecting rod.
Cylinder Base Gasket
Install new base gasket.
NOTE: The general procedure is to install a new
gasket of the same thickness. However, if you do
not know the gasket thickness that was installed
or if a crankshaft and/or crankcase repair or re-
placement was involved, refer to the COMBUS-
TION CHAMBER VOLUME MEASUREMENT to
properly determine the required gasket thickness.
Five thicknesses of cylinder base gaskets are
available for a precise adjustment of the squish
gap.
To identify gasket thickness, refer to the identifi-
cation holes on the gasket.
Cylinder
To easily slide cylinder no. 9 over piston, use pis-
ton ring compressor (P/N 290 876 979).
1. Slide this edge
ENGINE TOOL P/N
717 and 787 RFI 529 035 562
947 DI 529 035 563
1
F07D0AB
F06B01A
1
F00B0QA
1
F00B0RA
A01B1TA
1
04-05-24 SMR2003-010_04_05A.FM
NOTE: Ring compressor will not fit on oversize
parts.
Make sure to align ring end gap with piston locat-
ing pin. Slide tool over rings.
1. Ring end gap aligned with piston locating pin
Slide cylinder over piston.
When reassembling cylinders to crankcase, it is
important to have them properly aligned so that
exhaust flanges properly match up with exhaust
manifold.
717 Engines
The aligning tool (P/N 420 876 904) or the exhaust
manifold can be used to align cylinders.
717 ENGINES
1. Exhaust flange aligning tool
717 ENGINES
1. Aligning cylinders using exhaust manifold
F01D0ZA
1
F01D10A
F01D44A 1
F01D45A
1
SMR2003-010_04_05A.FM 04-05-25
787 RFI Engines
The exhaust manifold is used to align cylinders.
787 RFI ENGINES
1. Aligning cylinders using exhaust manifold
Cylinder Block
947 DI Engines
Install cylinder base gasket no. 10. There is only
one way to install gasket.
The cylinder block is positioned with locating dowels.
Line up dowels with corresponding holes in cylin-
der block.
1. Dowels
To easily slide cylinder block over pistons, use ring
compressor (P/N 290 876 965).
1. Slide this edge
NOTE: For each ring, make sure to align ring end
gap with piston locating pin.
Install cylinder block.
Apply Molykote 111 on O-ring no. 31 and install it.
CAUTION: The O-rings must be installed and
properly positioned in the cylinder block. The
O-rings are meant to dampen stud vibration.
Cylinder Screw
717 Engines
Apply Molykote 111 below the screw head.
Apply also Loctite 243 (blue) on screw threads.
Install and torque screws no. 13 in a criss-cross se-
quence for each cylinder to 24 Nm (17 lbfft). Refer
to the following illustration.
F00D0FA 1
1
F02D0UA 1
A01B1TA
1
F01D35A
1 4 1 4
3 2 3 2
04-05-26 SMR2003-010_04_05A.FM
787 RFI Engines
Prior installation, apply Molykote 111 below screw
head and Loctite 243 (blue) on screw threads.
Install M10 x 105 screws on exhaust side and the
M10 x 73.5 on opposite side.
Torque screws in a criss-cross sequence for each
cylinder to 20 Nm (15 lbfft). Repeat the proce-
dure, retightening all cylinder screws to 40 Nm
(30 lbfft).
947 DI Engines
Apply Molykote 111 below the screw head.
The blue coating underneath the cylinder screw
head can be only used once. Either replace with
new bolts or remove blue coating and apply
Molykote 111 below the screw heads.
Install and torque screws to 40 Nm (30 lbfft) in the
indicated order. Refer to the following illustration.
All Engines
Cylinder Head
Install cylinder head gasket.
Make sure to install O-rings no. 12 around spark
plug holes and O-ring no. 11 of cylinder head as
shown in the following illustration.
1. O-rings
Apply Loctite 518 in O-ring groove of cylinder
sleeves.
947 DI Engines
Apply Loctite 243 (blue) below head of cylinder
head bolts no. 14.
Apply Molykote 111 on threads of cylinder head
bolts no. 14.
Torque bolts to 20 Nm (15 lbfft) as per following
sequence in the next illustration. Repeat the torqu-
ing sequence by retightening to 40 Nm (30 lbfft).
F01D7FA
3 3 2
4 1 1 4
2
F12D07A
7
2
3
5
8
1 4 6
F01D5AA 1
1
F12D08A
12
11
7
4
8
2
3
1
6
10
9
5
SMR2003-010_04_05A.FM 04-05-27
Cylinder Head Cover
Install cylinder head cover no. 1.
Apply Loctite 243 (blue) below head of screws no. 14.
Apply also Molykote 111 on threads of screws no. 14.
Torque cylinder head screws no. 14 to 12 Nm
(9 lbfft) as per following illustrated sequence. Re-
peat the procedure, retightening all screws to 24
Nm (17 lbfft).
TORQUING SEQUENCE
ADJUSTMENT
RAVE Valve
787 RFI Engines
Turn the red plastic knob no. 17 until it is flush to
the valve cover.
1. Knob flush with the cover
Combustion Chamber Volume
Measurement
All Engines
NOTE: This procedure is required to determine
the thickness of the cylinder base gasket to be in-
stalled if a crank repair has involved replacement
of connecting rods or if you are experiencing re-
petitive engine seizure.
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head in-
stalled on the engine.
1. Combustion chamber
NOTE: When checking the combustion chamber
volume, engine must be cold, piston must be free
of carbon deposit and cylinder head must be lev-
eled.
All Engines except 947 DI
1. Remove both spark plugs and bring one piston
to Top Dead Center a using a TDC gauge.
1. Bring piston to TDC
F01D46A
10 8 2 4 6 12
11 3 1 5 9 7
F00D0GA
1
F01D5VA
1
1
F01D2IA
04-05-28 SMR2003-010_04_05A.FM
947 DI Engines
1. Remove both direct injectors and bring one pis-
ton to Top Dead Center using a TDC gauge.
Keep spark plugs in their holes.
All Engines
2. Obtain a graduated burette (capacity 0 - 50 cc)
and fill with an equal part (50/50) of gasoline and
injection oil.
1. Graduated burette (0 - 50 cc)
3. Open burette valve to fill its tip. Add liquid in
burette until level reaches 0 cc.
4. Inject the burette content through the spark
plug hole on all engines except 947 DI and
through direct injector hole on DI engines until
liquid touches the top hole.
1. Top of spark plug hole
NOTE: The liquid level in cylinder must not drop
for a few seconds after filling. If so, there is a leak
between piston and cylinder. The recorded vol-
ume would be false.
5. Let burette stand upward for about 10 minutes,
until liquid level is stabilized.
6. Read the burette scale to obtain the quantity of
liquid injected in the combustion chamber.
Compare the obtained value with the table below.
The volume should be within the allowable range.
If the volume of the combustion chamber is not
within specifications, change cylinder base gasket
thickness as follow.
A higher volume dictates a thinner gasket.
A lower volume dictates a thicker gasket.
All Engines except DI
NOTE: When the combustion chamber is filled to
top of spark plug hole, it includes an amount of
2.39 cc corresponding to the spark plug tip. The
following table of combustion chamber volume in-
cludes this value.
All Engines
7. Repeat the procedure for the other cylinder(s).
F00B0BA
1
F00D0HA 1
ENGINE
COMBUSTION CHAMBER
VOLUME
717 31.2 - 34.0 cc
787 RFI 34.7 - 37.9 cc
947 DI 45.7 - 48.4 cc
Subsection 06 (BOTTOM END)
SMR2003-011_04_06A.FM 04-06-1
BOTTOM END 0
717 Engines
24 Nm
(17 lbfft)
2
Loctite
518
11
Molykote
111
4
Anti-seize
lubricant
12
3
110 Nm
(81 lbfft)
1
6
5
6
Anti-seize
lubricant
Loctite
642
12
4
Anti-seize
lubricant
Loctite
243
6
6
4
5
Loctite
5910
2
11
7
24 Nm
(17 lbfft)
10
10 Nm
(88 lbfin)
Loctite
518
Loctite
518
8
40 Nm
(30 lbfft)
4
9
F00D0YU
Molykote
111
Molykote
111
Molykote
111
04-06-2 SMR2003-011_04_06A.FM
787 RFI Engines
Loctite
518
Anti-seize
lubricant
13
Anti-seize
lubricant
110 Nm
(81 lbfft)
1
Molykote
111
2
Anti-seize
lubricant
Anti-seize
lubricant
4
Loctite
243
Loctite
642
Anti-seize
lubricant
Loctite
5910
Loctite
518
40 Nm
(30 lbfft)
Loctite
518
Loctite
518
24 Nm
(17 lbfft)
30 mL (1 oz)
SAE 30
motor oil
5
6
12
6
15
16
6
4
6
2
7
11
12
18
11
4
3
4
19
15
14
F07D0VS
9 Nm
(80 lbfin)
Anti-seize
lubricant
Molykote
111
Molykote
111
Molykote
111
Molykote 111
Molykote 111
Molykote
111
8
40 Nm
(30 lbfft)
8
7
24 Nm
(17 lbfft)
SMR2003-011_04_06A.FM 04-06-3
947 DI Engines
F18D2QS
Loctite 243
Loctite
243
Loctite 243
Loctite 648
23 Nm
(17 lbfft)
Synthetic
grease
Loctite
243
Molykote
111
Molykote
111
Molykote 111
Molykote
111
Molykote
111
Loctite
518
27 Nm
(20 lbfft)
Loctite
5910
6.5 Nm
(58 lbfin)
9 Nm
(80 lbfin)
7 Nm
(62 lbfin)
Anti-seize
lubricant
Anti-seize
lubricant
1.5 Nm
(13 lbfin)
Loctite 243
Molykote
111
115 Nm
(85 lbfft)
6.5 Nm
(58 lbfin)
Engine
oil
27 Nm
(20 lbfft)
40 Nm
(30 lbfft)
20 Nm
(15 lbfft)
Anti-seize
lubricant
28
5
4
6
16
15
17
29
30
14
13
2
24
25
9
27
23
3
2
4
4
6
6
5
1
22
20
21
7
8
7
7
31
32
15
13
8
XP DI
only
Loctite 243
23 Nm
(17 lbfft)
21
04-06-4 SMR2003-011_04_06A.FM
DISASSEMBLY
Engine has to be removed from watercraft and top
end has to be disassembled to open bottom end.
Refer to REMOVAL AND INSTALLATION and TOP
END.
PTO Flywheel
717 Engines
To remove PTO flywheel no. 1, the crankshaft
must be locked. Refer to MAGNETO SYSTEM and
follow the procedure to lock the magneto fly-
wheel.
PTO flywheel is loosen using PTO flywheel remov-
er (P/N 295 000 001).
Insert special tool in PTO flywheel splines.
TYPICAL
1. PTO flywheel remover (P/N 295 000 001)
Using a suitable wrench or socket with a breaker
bar, unscrew PTO flywheel COUNTERCLOCK-
WISE when facing it and hold extension handle
locking the magneto flywheel.
TYPICAL
NOTE: When splines of PTO flywheel are worn
out and special tool cannot be used, proceed with
the following alternate method.
Use a pipe wrench and install it on PTO flywheel
as illustrated.
TYPICAL
787 RFI Engines
PTO flywheel is loosened using PTO flywheel ex-
tractor (P/N 295 000 156).
F01J0TA
F01D1AA
1
F00D0ZA
1
F00D10A
1
F00B04A
SMR2003-011_04_06A.FM 04-06-5
Install special tool.
1. PTO flywheel extractor
Install the extension handle (P/N 295 000 125) on
the PTO flywheel extractor. Loosen PTO flywheel
COUNTERCLOCKWISE when facing it.
947 DI Engines except XP DI
Use PTO flywheel remover (P/N 295 000 001) to
hold flywheel and remove Allen screws no. 21 re-
taining coupler no. 20 to PTO flywheel.
PTO FLYWHEEL REMOVER TOOL
1. Loosen Allen screws
2. Breaker bar locking crankshaft
Remove the coupler no. 20.
XP DI Models
Remove Allen screws no. 21.
1. PTO flywheel
2. Coupler
3. Loosen Allen screw
Remove coupler no. 20.
F06I02A
1
F01J0TA
F06D37A 2 1
2
F08D02A
3 1
04-06-6 SMR2003-011_04_06A.FM
947 DI Engines
Install puller plate (P/N 529 035 533) and extension
handle (P/N 295 000 125) to PTO flywheel.
NOTE: Puller plate can be used without the exten-
sion handle.
Loosen bolt no. 22 retaining the PTO flywheel to the
crankshaft using a suitable socket and breaker bar.
1. Puller plate
2. Extension handle
3. Loosen bolt with socket and breaker bar
Remove the PTO flywheel using puller plate (P/N
529 035 533) and puller (P/N 529 035 547) and bolt
(P/N 529 035 549).
1. Puller plate
2. Puller
3. Bolt
4. Extension handle
Starter Drive Assembly
947 DI Engines Only
Loosen 2 Allen screws no. 24 retaining starter
drive cover no. 25.
1. Cover
2. Allen screw
Remove starter drive cover no. 25 and spring no. 9.
Remove starter drive assembly no. 27.
TYPICAL 947 DI ENGINES
1. Starter drive assembly
Reed Valve
947 DI Engines Only
Remove reed valves no. 28 from crankcase.
F06D38A
3
1 2
F06D39A 2 4 3 1
F06D1CA 1 2
F06D1DA 1
SMR2003-011_04_06A.FM 04-06-7
Crankcase
Before opening the bottom end, remove the fol-
lowing parts:
engine supports (717 engines)
magneto flywheel, refer to MAGNETO SYSTEM
magneto housing (except 947 DI engines)
starter
rotary valve cover and valve
(except 947 DI engines)
starter drive assembly (947 DI engines)
reed valves (947 DI engines)
air compressor cover (947 DI engines).
Put engine on a stand. Loosen crankcase screws.
717 ENGINES
1. M10 x 73.5 flanged screws
3. M8 x 45 socket head screws
787 RFI ENGINES
947 DI Engines
Place engine upright on crankcase magneto side.
Loosen crankcase screws.
947 DI ENGINES
1. M8 x 45 flanged screws
All Engines
Put engine back on a support. Insert a pry bar be-
tween crankcase lugs to separate halves.
CAUTION: Be careful to precision machined sur-
faces.
TYPICAL
1. Separate halves by prying at provided lugs
F01D20C
2
3
1
3
2
F15D05A 2
1 1 1
F07D09D
1
1
2
F01D1KA
1
04-06-8 SMR2003-011_04_06A.FM
TYPICAL
1. Separate halves by prying at provided lugs
Remove crankshaft and counterbalance shaft (787
RFI and 947 DI engines).
947 DI Engines
Open air compressor and disconnect the piston as
described in ENGINE MANAGEMENT.
Crankshaft Bearing and Seal
All Engines
If a crankshaft end seal no. 5 has to be replaced,
bottom end must be opened (except for the MAG
side seal on the 787 RFI engines, which is mount-
ed on the magneto housing).
NOTE: Do not needlessly remove crankshaft bear-
ings.
Remove end seal(s).
TYPICAL
1. End seal
717 Engines
To remove end bearings no. 4 from crankshaft,
use the following tools.
717 ENGINES
1. Puller (P/N 420 877 635)
2. Protective cap (P/N 420 876 557)
3. Distance ring, MAG side only (P/N 420 876 569)
4. Ring (both sides) (P/N 420 977 490)
5. MAG side ring halves (P/N 420 276 025)
6. PTO side ring halves (P/N 420 977 475)
7. Screw M8 x 40 (P/N 420 840 681)
8. Screw M8 x 70 (P/N 420 841 201)
NOTE: To facilitate ring or distance ring installa-
tion, lubricate their inside diameters.
787 RFI Engines
To remove end bearings no. 4 from crankshaft,
use the following tools.
NOTE: The outer PTO bearing and crankshaft gear
can be removed in one step using another puller.
See CRANKSHAFT GEAR no. 18.
787 RFI ENGINES
1. Puller (P/N 420 877 635)
3. Distance ring (P/N 420 876 569)
4. Ring (P/N 420 977 490)
5. Ring halves (P/N 420 977 475)
6. Screw M8 x 40 (P/N 420 840 681)
7. Screw M8 x 70 (P/N 420 841 201)
NOTE: To facilitate ring or distance ring installa-
tion, lubricate their inside diameters.
F01D1LA
1
F06D1GA 1
1 5 3 2
7
8
F01B09A
4 6
F01B2MA
1 2 3 5
7
6
4
SMR2003-011_04_06A.FM 04-06-9
947 DI Engines
To remove end bearings from crankshaft, use the
following tools.
947 DI ENGINES
1. Puller (P/N 420 877 635)
3. Distance ring (P/N 420 876 569)
4. Ring (P/N 420 977 480)
5. Ring halves (P/N 420 876 330)
6. Screw (P/N 420 841 201)
All Engines
TYPICAL
1. Removing crankshaft bearing
Or, use a bearing extractor such as Proto no. 4332
and a press to remove two bearings at a time (ex-
cept on PTO side for the 787 RFI engines).
1. Press bearings out
2. Bearing extractor
Crankshaft Gear
787 RFI Engines
The crankshaft gear no. 18 and bearing no. 5 can
be removed in one step using the following puller.
1. Puller (P/N 290 877 665)
F06B03A
5 4 3
2
1 6
6
F01D1OA
1
F01D1PA
1
2
F04B03A
1
04-06-10 SMR2003-011_04_06A.FM
Install the puller as per following illustration.
1. Puller
2. Protective cap
Secure puller in a vise and remove gear and bearing.
NOTE: If the inner PTO bearing needs to be re-
placed, remove the Woodruff key on the crank-
shaft.
Counterbalance Shaft
787 RFI Engines
Bearings no. 15 on counterbalance shaft no. 13
can be removed by using the following tools:
1. Puller (P/N 420 877 635)
3. Ring (P/N 420 977 480)
4. Ring halves (P/N 420 876 330)
5. Screw M8 x 40 (P/N 420 840 681)
1. Tool installed
To remove gear no. 14, first trace an index mark
on the gear and counterbalance shaft.
NOTE: There is no Woodruff key to position the
gear on the counterbalance shaft. An index mark
must be traced to ease assembly procedure.
1. Index mark
F00D0IA 2 1
F00D0JA
F00B0CA
1 2 3 4
5
F00D0KA 1
F00D0SA 1
SMR2003-011_04_06A.FM 04-06-11
Use a press to remove the gear no. 14 from the
counterbalance shaft.
947 DI Engines
Use a press to remove counterweights no. 16 and
bearings no. 15.
CAUTION: There is no woodruff key to position
the counterweights. An index mark must be traced
to retain the proper position of the counterweight.
1. Trace an index mark
Remove seals no. 17.
Remove bearing no. 31 and washer no. 32.
Use a press to remove gear no. 14.
CLEANING
All Models
Discard all oil seals, gaskets, O-rings and sealing
rings.
Clean oil passages and make sure they are not
clogged.
Crankcase mating surfaces are best cleaned using
a combination of the chisel gasket remover (P/N
413 708 500) and a brass brush. Brush a first pass
in one direction then make the final brushing per-
pendicularly (90) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new clean
hand towel only.
FIRST PASS
F00D0TA
F06D1HA 1
F00D2BA
F00D2CA
04-06-12 SMR2003-011_04_06A.FM
SECOND PASS
Finish the cleaning with acetone.
CAUTION: Ensure to clean compressor lubrica-
tion nipple.
CAUTION: Be careful not to spray cleaner on
the painted surface of the engine.
CAUTION: Never use a sharp object to scrape
away old sealant as score marks incurred are
detrimental to crankcase sealing.
INSPECTION
Assembled Engine
The following checks can be performed with en-
gine in watercraft without overhauling engine.
Crankshaft Alignment at Center Main
Journal
Since it is an assembled crankshaft it can become
misaligned or deflected. Crankshaft can be twist-
ed on center main journal, changing timing of one
cylinder in relation with the other.
1. Main journal alignment here
To accurately check if crankshaft is twisted on cen-
ter main journal, proceed as follows:
Remove magneto housing cover.
Remove flywheel nut (and magneto rotor for
the 787 RFI and 947 DI engines). Refer to
MAGNETO SYSTEM for procedures.
Install Bombardier degree wheel (P/N 529 035
607) on crankshaft end. Hand-tighten nut only.
Remove both spark plugs.
Install a TDC gauge in spark plug hole on MAG
side.
Bring MAG piston at Top Dead Center.
As a needle pointer, secure a wire with a cover
screw and a washer.
Rotate degree wheel (NOT crankshaft) so that
needle pointer reads 360.
F00D2DA
F01D1NA
1
SMR2003-011_04_06A.FM 04-06-13
TYPICAL
1. TDC gauge
2. Degree wheel
3. Hand tighten nut
4. Needle pointer
Remove TDC gauge and install on PTO side.
Bring PTO piston at Top Dead Center.
Interval between cylinders must be exactly 180
therefore, needle pointer must indicate 180 on
degree wheel (360 - 180 = 180).
Any other reading indicates a misaligned crank-
shaft.
Crankshaft Alignment at Connecting
Rod Journal
Counterweights can also be twisted on connect-
ing rod journal on any or both cylinder(s).
1. Connecting rod journal alignment here
Such misalignment may make it difficult to manu-
ally turne the crankshaft. Verification can be done
by measuring deflection each end of crankshaft.
If deflection is found greater than specified toler-
ance, this indicates worn bearing(s), bent and/or
disaligned crankshaft. Proceed with the disassem-
bly of the engine.
Disassembled Engine
The following verifications can be performed with
the engine disassembled.
Crankcase
Inspect plane surfaces for warpage. Small defor-
mation can be corrected by grinding surface with
a fine sandpaper. Install sandpaper on a surface
plate and rub part against oiled sand paper.
Bearing
Inspect crankshaft bearings no. 4. Check for cor-
rosion, scoring, pitting, chipping or other evidence
of wear. Make sure plastic cage is not melted. Ro-
tate and make sure they turn smoothly.
Crankshaft
NOTE: If crankshaft and/or components are found
defective, it must be repaired by a specialized
shop or replaced.
Connecting Rod Straightness
Align a steel ruler on edge of small end connecting
rod bore. Check if ruler is perfectly aligned with
edge of big end.
1. Ruler must be aligned with edge of connecting rod here
2. Align ruler here
1
F01D4IA
3
2
4
F01D1NB
1
F01D1QA
1
2
04-06-14 SMR2003-011_04_06A.FM
Crankshaft Deflection
All Models
Crankshaft deflection is measured each end with
a dial indicator.
First, check deflection with crankshaft in crank-
case. If deflection exceeds the specified toler-
ance, it can be either ball bearings wear, bent or
twisted crankshaft at connecting rod journal.
1. Measuring PTO side deflection in crankcase
1. Measuring MAG side deflection in crankcase
Remove crankshaft bearings and check deflection
again on V-shaped blocks as illustrated.
1. Measuring MAG side deflection on V-shaped blocks
1. Measuring PTO side deflection on V-shaped blocks
NOTE: Crankshaft deflection cannot be correctly
measured between centers of a lathe.
Connecting Rod Big End Axial Play
MEASUREMENT MAG SIDE PTO SIDE
Crankshaft
deflection (max.)
0.050 mm
(.002 in)
0.030 mm
(.001 in)
F01D1SA
1
F01D1TA
1
CONNECTING ROD BIG END AXIAL PLAY
MODEL
NEW PARTS WEAR
LIMIT (min.) (max.)
947 DI engines
0.390 mm
(.015 in)
0.737 mm
(.029 in)
1.2 mm
(.047 in)
787 RFI engines
0.230 mm
(.008 in)
0.617 mm
(.024 in)
1.2 mm
(.047 in)
717 engines
0.311 mm
(.012 in)
0.677 mm
(.026 in)
1.2 mm
(.047 in)
1
F01D97A
F01D98A
1
SMR2003-011_04_06A.FM 04-06-15
Using a feeler gauge, measure distance between
thrust washer and crankshaft counterweight.
1. Measuring big end axial play
2. Feeler gauge
Starter Drive Bearing
947 DI Engines Only
Check bearing no. 23 of starter drive assembly
no. 27 in crankcase.
1. Bearing of starter drive assembly
Removal
Starter drive bearing can be easily removed from
lower crankcase half using the following suggest-
ed tool or equivalent:
Snap-on hammer puller including:
handle CJ93-1
hammer CJ125-6
claws CJ93-4.
Close puller claws so that they can be inserted in
end bearing. Holding claws, turn puller shaft clock-
wise 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.
For installation, see below in this section.
Reed Valve
947 DI Engines Only
Check reed valve petals no. 29 for cracks or other
defects. The reed petals must lie completely flat
against the reed valve body no. 30. To check, hold
against light.
1. No play
In case of a play, turn reed petals upside down and
recheck. If there is still a play, replace petals.
Check perfect condition of rubber coating on reed
valve body.
F01D1WA
1
2
F06D1IA 1
F01J0ZA
F06D1JA 1
04-06-16 SMR2003-011_04_06A.FM
Check stopper distance from center of reed valve
block.
A. 13 0.25 mm (.512 .010 in)
NOTE: Distance should be the same on both sides.
Bent stopper as required to obtain the proper dis-
tance.
Air Compressor
Refer to ENGINE MANAGEMENT for compo-
nents inspection. However, if you find aluminum
dust or debris in this area, they may have flowed
toward the injection oil reservoir. In this case, the
oil reservoir and lines must be flushed and the fil-
ter replaced.
CAUTION: Failure to properly clean the oil sys-
tem will result in serious engine damage.
ASSEMBLY
to the following.
NOTE: It is recommended to spray BOMBARDIER-
ROTAX injection oil on all moving parts when re-
assembling the engine.
Crankshaft and Bearing
Apply Loctite 767 anti-seize on part of crankshaft
where bearing fits.
Prior to installation, place bearings no. 4 into a
container filled with oil, previously heated to 75C
(167F). This will expand bearing and ease instal-
lation.
To properly position the outer bearing(s), a dis-
tance gauge must be temporarily installed against
the inner bearing. Slide the outer bearing until
stopped by the distance gauge, then remove it.
1. Distance gauge
TYPICAL
1. Distance gauge
2. Outer bearing
Distance Ring
When installing the distance ring no. 12, make
sure to position it with its chamfer toward the
counterweight of the crankshaft.
F06D1EA
A
ENGINE DISTANCE GAUGE
717 P/N 529 034 800 (PTO)
787 RFI P/N 529 034 900 (MAG)
947DI
P/N 529 035 100 (MAG)
P/N 529 035 000 (PTO)
F01B0HA
1
F01D1YA
1
2
SMR2003-011_04_06A.FM 04-06-17
Crankshaft Gear
787 RFI Engines
Position the long flange of the gear no. 18 toward
the counterweight of the crankshaft. Also, make
sure to align the gear keyway with the Woodruff
key on the crankshaft.
1. Woodruff key on the crankshaft
1. Keyway
2. Long flange toward the crankshaft counterweight
Crankshaft Seal
All Models
When installing seal assembly no. 5, apply a light
coat of lithium grease on seal lips.
787 RFI Engines
Position PTO seal against the retaining shim; the
gap between the seal no. 5 and bearing no. 4 will
ensure proper lubrication of the bearing.
1. Seal against the retaining shim
947 DI Engines
Seals are positioned with the outer lip in the crank-
case recess.
1. Seal lip in crankcase recess
Drive Pin
Make sure drive pins no. 6 of bearings are proper-
ly installed in crankcase recesses at assembly.
F00D0LA 1
F00D0MA
1
2
F00D0NA
1
F06D1LA
1
04-06-18 SMR2003-011_04_06A.FM
1. Drive pins
Counterbalance Shaft
787 RFI Engines
Press gear no. 14 onto counterbalance shaft no. 13
taking care to align both marks previously traced.
CAUTION: Counterbalance shaft must be prop-
erly assembled, otherwise engine will vibrate
and premature wear will occur.
Proceed as follows to check if the gear no. 14 is
properly positioned on the counterbalance shaft:
Temporarily install the counterbalance shaft in
the crankcase.
Rotate the counterbalance shaft to align the
notch of the gear with the crankcase.
1. Gear notch aligned with the crankcase
The notch of the couterweight on the opposite
end of the counterbalance shaft must also be
aligned with the cranckcase.
1. Counterweight notch aligned with the crankcase
If notches are not aligned with the crankcase, re-
move the gear and repeat the procedure until the
notches are properly aligned.
947 DI Engines
Install bearing no. 31 and washer no. 32.
When installing seals no. 17, apply a light coat of
Molykote 111 on seal lips.
Prior to installation, place bearings no. 15 into a
container filled with oil, previously heated to 75C
(167F). This will expand bearings and ease their
installation.
Reinstall counterweights no. 16 using a press and
take care to align index marks previously traced.
Crankshaft and Counterbalance Shaft
Install crankshaft no. 3 first in crankcase.
After crankshaft installation, install counterbal-
ance shaft no. 13. Make sure to properly index
crankshaft and counterbalance shaft by gear align-
ing marks.
CAUTION: Marks on the crankshaft and coun-
terbalance shaft must be aligned, otherwise en-
gine will vibrate and premature wear will occur.
F00D0OA
1
F00D0UA
1
F00D0VA
1
SMR2003-011_04_06A.FM 04-06-19
787 RFI ENGINES
1. Marks must be aligned
947 DI ENGINES
1. Marks must be aligned
Turn by hand the crankshaft and counterbalance
shaft. Make sure they do not interfere with the
crankcase.
947 DI Engines
Properly position bearing no. 31 and washer
no. 32. Ensure to position lubrication hole on top
(if so equipped).
1. Bearing
2. Washer in crankcase groove
3. Lubrication hole on top (if so equipped)
Place seals no. 17 in their respective positions.
1. Seal in place
Air Compressor
947 DI Engines
Refer to ENGINE MANAGEMENT for procedures.
Crankcase
All Engines
Crankcase halves are factory matched and there-
fore, are not interchangeable or available as single
halves.
F00D0PA 1
F06D1MA 1
3 F12R16A 2 1
F06D1OA 1
04-06-20 SMR2003-011_04_06A.FM
Rotary valve shaft must be installed in crankcase
before closing halves.
CAUTION: Before joining crankcase halves, make
sure that crankshaft gear is well engaged with ro-
tary valve shaft gear.
717 Engines
Temporarily install armature plate to align crank-
case halves with each other.
CAUTION: Using different types of oil may re-
duce engine component life.
All Models
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 appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (unlike the Drei Bond sealing
compound, using a finger will not affect the adhe-
sion).
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
NOTE: The sealant curing time is similar to the
Loctite 518 without using the Primer N.
CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non silicone-
based sealant over a previously sealed crankcase
with Loctite 5910 will lead to poor adhesion and
possibly a leaking crankcase. These products are
chemically incompatibles. Even after cleaning, the
Loctite 5910 would leave incompatible microscos-
pic particules.
Use a plexyglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
Do not apply in excess as it will spread out inside
crankcase.
CAUTION: If sealant spreads out inside air
compressor area, it could plug the compressor
lubrication nipple and serious compressor
damage may occur.
NOTE: Do not use Loctite Primer N with this seal-
ant. The sealant curing time is similar to the Loc-
tite 518 without using the Primer N, which is 4 to
24 hours.
F12R17A
F12R18A
SMR2003-011_04_06A.FM 04-06-21
947 DI Engines
Make sure all locating dowels are in place.
1. Dowel
Counterbalance Shaft Bearing Cover
787 RFI Engines
Install the bearing cover no. 19 with its hollow
side toward the bearing.
1. Hollow side facing bearing
Crankcase Screws
717 Engines
Apply Loctite 518 on screw threads and Molykote
111 below head screws.
Torque crankcase screws to 24 Nm (17 lbfft) as
per following illustrated sequence.
Torque 2 M10 crankcase screws to 40 Nm (30 lbfft).
787 RFI Engines
Apply Loctite 518 on screw threads and Molykote
111 below head screws.
Torque crankcase screws to 12 Nm (106 lbfin)
as per following sequence. Repeat procedure, re-
tightening all screws to 24 Nm (17 lbfft).
F06D1PA 1
F00D0QA
1
F01D20D
12
7 1 11 3 9 5 13
14 6 10 2 4 8
F01D20B
1
11
F15D05B
7 21 1 3 22 5 9
8 19 12 17 13 15 4 2 16 14 18 6 20 10
04-06-22 SMR2003-011_04_06A.FM
As a final step, torque only M10 screws no. 8 of
crankcase to 40 Nm (30 lbfft) as per following se-
quence.
947 DI Engines
Apply Molykote 111 below head of screws and
Loctite 518 on threads.
Torque crankcase screws to 12 Nm (106 lbfin)
as per following sequence. Repeat procedure, re-
tightening all screws to 27 Nm (20 lbfft).
As a final step, torque only the M10 x 73.5 bolts
to 40 Nm (30 lbfft) as per following sequence.
Oil Fittings
If inlet and outlet oil fittings no. 11 of rotary valve
shaft have been removed from crankcase, rein-
stall them with their end pointing toward ignition
housing. Apply Loctite 518 on threads of fittings.
Stud
717 Engines
At assembly in crankcase, apply Loctite 518 on
threads of studs no. 10. Torque to 10 Nm (89 lbfin).
947 DI Engines
To install bearing no. 23 of starter drive assembly,
use pusher (P/N 420 876 502) and handle (P/N 420
877 650).
1. Handle
2. Pusher
F15D05C
11 7 1 3 5 9
8 12 4 6 10 2
F07D09E
7
3
1
16
5
19
22
11
10
8
24
21
15
4
13
2
18
6
23
12
14
9
20
17
F07D09C
9
7
3
1
5
11
10
8
4
2
6
12
F06D32A
1
2
SMR2003-011_04_06A.FM 04-06-23
PTO Flywheel
787 RFI Engines
Install O-ring onto crankshaft.
1. O-ring
717 and 787 Engines
Apply Loctite anti-seize lubricant (P/N 293 800 070)
to crankshaft threads.
Using the same tools as for disassembly proce-
dure, torque PTO flywheel to 110 Nm (81 lbfft).
947 DI Engines
Apply Loctite 243 (blue) on bolt no. 22.
Using the same tools as for disassembly proce-
dure, torque bolt no. 22 to 115 Nm (85 lbfft).
Apply Loctite 648 on mating surface of PTO fly-
wheel and coupler.
Apply Loctite 243 (blue) to Allen screws no. 21 of
coupler and torque to 23 Nm (17 lbfft).
Final Assembly
For rotary valve timing and assembly procedures,
refer to ROTARY VALVE.
787 RFI Engines
When engine assembly is completed, add 30 mL
(1 oz) of motor oil SAE 30 to the counterbalance
shaft gear through the crankcase filler plug.
1. Remove plug and add SAE 30 motor oil
947 DI Engines
Add 40 mL (1.35 oz) of Sea-Doo synthetic jet
pump oil (P/N 293 600 011) or standard gear oil
through crankcase ventilation nipple.
1. Crankcase ventilation nipple
Add approximately 10 mL (.3 oz) of injection oil in
bottom of crankcase for each cylinder. This will
give an additional lubrication for the first engine
startup.
F01D84A
1
F07D06A
1
1 F18D2RA
Subsection 07 (ROTARY VALVE)
SMR2003-012_04_07A.FM 04-07-1
ROTARY VALVE 0
F00D26T
8
2
20 Nm
(15 lbfft)
Molykote
111
7
10
6
9
5
11
3
4
14
15
717 engines
13
12
1
20 Nm
(15 lbfft)
9 Nm
(80 lbfin)
2
1
12
787 RFI engines
Anti-seize
lubricant
Engine
oil
Loctite
243
04-07-2 SMR2003-012_04_07A.FM
GENERAL
The following verification procedures such as clear-
ance of rotary valve cover or rotary valve shaft gear
backlash can be performed without removing en-
gine from watercraft.
However engine must be removed from water-
craft to work on rotary valve shaft/components.
Refer to REMOVAL AND INSTALLATION for en-
gine removal procedure.
Bottom end must be opened to remove rotary
valve shaft. Refer to BOTTOM END.
INSPECTION ON WATERCRAFT
Remove carburetor(s). Refer to CARBURETOR.
Rotary Valve Cover
Unscrew 4 screws no. 2 and withdraw rotary valve
cover no. 1.
Remove rotary valve no. 13.
Rotary Valve/Cover Clearance
The clearance between the rotary valve and the
cover must be 0.30 0.05 mm (.012 .002 in).
NOTE: If the clearance is below 0.25 mm (.010 in)
this could create an overheating situation and if
the clearance is over 0.35 mm (.014 in) this could
create a hard starting situation.
There are 2 methods to verify rotary valve/cover
clearance:
the 45 feeler gauge method
the soldering wire method.
45 FEELER GAUGE METHOD
Remove O-ring no. 12 from rotary valve cover no. 1.
Remove intake manifold from rotary valve cover
(except 787 RFI engines).
Reinstall cover no. 1 in place WITHOUT its O-ring
and torque screws to 20 Nm (15 lbfft).
Insert feeler gauge blade through cover inlet ports
to verify clearance. At least verify clearance at two
different places in each port.
Feeler gauge blade from 0.25 mm (.010 in) to
0.35 mm (.014 in) thickness should fit between ro-
tary valve and cover.
1. 45 feeler gauge
If rotary valve cover clearance is out of specifica-
tions, machine rotary valve cover seating surface
or replace the cover.
SOLDERING WIRE METHOD
Remove O-ring from rotary valve cover.
Use the following type of solder:
resin core
diameter: 0.8 mm (.032 in)
electronic application
(available at electronic stores).
Install 2 soldering wire pieces of 13 mm (1/2 in)
long directly on rotary valve, one above and one
below rotary valve gear. Apply grease to hold sol-
der in position.
Refer to the following illustration for proper posi-
tion or rotary valve and pieces of soldering wire.
TYPICAL
1. Soldering wire
Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 Nm (15 lbfft).
F01D53A
1
F01D3PA
1
SMR2003-012_04_07A.FM 04-07-3
Remove cover then clean and measure compressed
soldering wire thickness, it must be within the spec-
ified tolerance 0.30 0.05 mm (.012 .002 in).
If rotary valve cover clearance is over specified tol-
erances, machine rotary valve cover seating sur-
face or replace the cover.
MACHINING INFORMATION
The amount of material over tolerance must be
removed from the rotary valve cover seating sur-
face.
Also cut the O-ring groove the same amount to
keep the 1.00 0.03 mm (.039 .001 in) depth
between the bottom of the groove and the seating
surface.
Remove burrs on the edges of the seating surface
and O-ring groove.
SAME AMOUNT REMOVED FROM COVER SEATING SURFACE
AND O-RING GROOVE BASE
1. Cover seating surface
A. O-ring groove depth must be 1.00 0.03 mm (.039 .001 in)
Reverify the clearance.
At assembly the rotary valve timing must remain
as per original setting.
NOTE: If rotary valve crankcase surface is worn,
it is possible to have it reworked at the factory.
Contact your dealer or distributor.
Rotary Valve Shaft Gear Backlash
Remove spark plugs, rotary valve cover and valve.
Manually feel backlash at one position, then turn
crankshaft about 1/8 turn and recheck. Continue
this way to complete one revolution.
Backlash must be even at all positions. Otherwise
overhaul engine to find which part is faulty (gear,
rotary valve shaft or crankshaft with excessive de-
flection).
DISASSEMBLY
Rotary Valve Cover
Unscrew 4 retaining screws and withdraw rotary
valve cover no. 1 and rotary valve no. 13.
Rotary Valve Shaft
To remove the rotary valve shaft assembly, the en-
gine must be removed from watercraft (refer to
ENGINE).
Open bottom end and remove crankshaft (refer to
BOTTOM END).
First remove snap ring no. 4 from crankcase.
1. Removing snap ring
To remove rotary valve shaft assembly, use the
appropriate puller (P/N 290 876 488).
PULLER (P/N 290 876 488)
1
A
F01D3OA
F01D22A
1
F01D23B
04-07-4 SMR2003-012_04_07A.FM
Place puller over rotary valve shaft end and screw
on puller bolt into shaft. While retaining bolt with
a wrench, turn puller nut CLOCKWISE until shaft
comes out.
1. Hold bolt
Circlip and Spring Seat
If it is necessary to disassemble components of
rotary valve shaft assembly, use seat no. 6 to
compress spring and remove circlips no. 5.
1. Compress seat
2. Remove circlips
Shaft Bearing
To remove bearing no. 8 use a bearing extractor
such as Snap-on no. CJ-950 (or equivalent) as illus-
trated. Slide off distance sleeve no. 14, remove
snap ring no. 7 and washer no. 15 then press
shaft out.
1. Bearing
2. Bearing extractor Snap-on CJ-950
CAUTION: Ensure that rotary valve shaft is per-
fectly perpendicular with press tip.
End Bearing
CAUTION: Do not remove plug against bearing
in upper crankcase half.
1. Do not remove this plug
F01D61A 1
F01D27A
F01D25A
1
2
F01D4NA
1
2
F01D4OA
1
SMR2003-012_04_07A.FM 04-07-5
End bearing no. 9 can be easily removed from up-
per crankcase half using the following suggested
tool (or equivalent):
handle CJ93-1
hammer CJ125-6
claws CJ93-4.
against bearing.
1. End bearing
CLEANING
Discard all seals and O-rings.
clogged.
Clean rotary valve shaft and inside of distance
sleeve no. 14.
INSPECTION
Rotary Valve Cover
Inspect rotary valve cover no. 1 for warpage. Small
deformation can be corrected by surfacing with
fine sand paper on a surface plate. Surface part
against oiled sand paper.
Bearings
Inspect bearings no. 8 and no. 9. Check for scor-
ing, pitting, chipping or other evidence of wear.
Make sure plastic cage (on bigger bearing) is not
melted. Rotate them and make sure they turn
smoothly.
Gear
Visually check gear wear pattern. It should be even
on tooth length all around. Otherwise it could indi-
cate a bent shaft, check deflection. Replace gear
if damaged.
Check for presence of brass filings in gear housing.
Rotary Valve Shaft Deflection
Deflection is measured with a dial gauge. Install
rotary valve shaft in crankcase half, without its
gear.
NOTE: End bearing must be in crankcase half.
Measure shaft deflection next to gear splines.
1. Rotary valve shaft
2. End bearing in place
Deflection must not exceed 0.08 mm (.003 in). Re-
place shaft as necessary.
F01J0ZA
F01D28A
1
F01D2CA
2
1
04-07-6 SMR2003-012_04_07A.FM
ASSEMBLY
to the following.
Bearing
To install end bearing no. 9 in crankcase, use push-
er (P/N 420 876 501).
1. Pusher (P/N 420 876 501)
Position ball bearing shielded side towards rotary
valve.
1. Shield side (toward gear)
Push bearing until it stops on its seat.
Seal
Apply Molykote 111 on seal lips. Position seal no. 11
with shielded portion against shaft splines.
Bearing
Install ball bearing as illustrated.
1. Seal
2. Ball bearing
3. Bearing extractor Snap-on CJ-950
Install washer no. 15, snap ring no. 7 and slide dis-
tance sleeve no. 14 on shaft.
1. Seal
2. Ball bearing
3. Snap ring
4. Distance sleeve
5. Washer 0.5 mm (.020 in)
Rotary Valve Shaft Assembly
CAUTION: Crankcase halves must be separat-
ed and crankshaft must not be present to install
rotary valve shaft assembly in crankcase.
F00B07A 1
F01D2DA 1
F01D99A
2
1
3
A13C0FB
1 2 3 4
6 5
F01D2FA
SMR2003-012_04_07A.FM 04-07-7
717 Engines
To install rotary valve shaft in crankcase, use a
pusher (P/N 420 876 605).
1. Pusher
Push shaft until its stops on bearing seat.
2. Push shaft until it stops
787 RFI Engines
To install rotary valve shaft in crankcase, use a
pusher (P/N 290 876 609) and handle (P/N 420 877
650).
1. Pusher
2. Handle
Push shaft until it stops on bearing seat.
Snap Ring
Position snap ring no. 4 so that its sharp edge faces
outwards.
Rotary Valve
The rotary valve no. 13 controls the opening and
closing of the inlet ports. Therefore its efficiency
will depend on the precision of its installation.
IDENTIFICATION OF THE ROTARY VALVE
A00C0YA
1
F01D34A
1
2
F01B2FA
2
1
ENGINE
ROTARY
VALVE P/N
VALVE
DURATION
717/787 RFI 420 924 502 159
F01D8OA
04-07-8 SMR2003-012_04_07A.FM
There is no identification code on the valve. To find out the duration, place an angle finder on the valve
and measure the valve cut-out angle or use the following template.
F01D73W
159
SMR2003-012_04_07A.FM 04-07-9
ROTARY VALVE TIMING
CAUTION: Never use the ridge molded in crank-
case as a timing mark.
The following tools are required to measure rotary
valve opening and closing angles in relation with
MAG side piston.
Rotary valve must be set so that timing occurs as
follows:
Timing Procedure
The following specifications are used in this pro-
cedure:
OPENING: 147 BTDC
CLOSING: 65 ATDC
Proceed as follows:
Turning crankshaft, bring MAG side piston to
Top Dead Center using a TDC gauge.
1. Bring piston to TDC
For opening mark, first align 360 line of degree
wheel with BOTTOM of MAG side inlet port.
Then, find 147 line on inner scale of degree
wheel and mark crankcase at this point.
OPENING MARK
Step : Bottom of MAG inlet port.
Align 360 line of degree wheel
Step : Find 147 on inner scale of degree wheel and mark here
NOTE: Do not rotate the crankshaft.
ENGINE
TIMING
OPENING
BTDC
CLOSING
ATDC
717 147 5 65.5 5
787 RFI 147 5 63.5 5
360 350 340
330
320
3
1
0
3
0
0
2
9
0
2
8
0
2
7
0
2
6
0
2
5
0
2
4
0
2 3 0
2 2 0
2 1 0
2 0 0 1 9 0 1 8 0 1 7 0
1 6 0
1 5 0
1
4
0
1
3
0
1
2
0
1
1
0
1
0
0
9
0
8
0
7
0
6
0
50
40
30
20 10
10
20
30
40
5
0
6
0
7
0
8
0
9
0
1
0
0
1
1
0
1
2
0
1
3
0
1
4 0
1 5 0
1 6 0
1 7 0 1 8 0 1 9 0 2 0 0
2 1 0
2 2 0
2
3
0
2
4
0
2
5
0
2
6
0
2
7
0
2
8
0
2
9
0
3
0
0
3
1
0
320
330
340
350 360
F00B0DB
529 035 607
295 000 143
1
F01D2IA
F01D3DC
147
2
1
1
2
04-07-10 SMR2003-012_04_07A.FM
For closing mark, first align 360 line of degree
wheel with TOP of MAG side inlet port. Then,
find 65 line on outer scale of degree wheel and
mark crankcase at this point.
CLOSING MARK
Step : Top of MAG inlet port.
Align 360 line of degree wheel
Step : Find 65 on outer scale of degree wheel and mark here
Remove degree wheel.
Position rotary valve on shaft splines to have
edges as close as possible to these marks with
the MAG piston at TDC.
NOTE: Rotary valve is asymmetrical. Therefore,
try flipping it over then reinstall on splines to obtain
best installation position.
Apply BOMBARDIER injection oil on rotary valve
before reassembling rotary valve cover.
Remove TDC gauge.
Rotary Valve Cover
Install O-ring no. 12 and rotary valve cover no. 1 then
torque screws no. 2 to 20 Nm (15 lbfft) in a criss-
cross sequence.
F01D3EB
65
1
2
1
2
Subsection 08 (EXHAUST SYSTEM)
SMR2003-013_04_08A.FM 04-08-1
EXHAUST SYSTEM 0
717 Engines (GTI and GTI LE Models)
F17D04S
24 Nm
(17 lbfft)
4 Nm
(35 lbfin)
12
Loctite 243
9
18
19
16
14
5
10
25 Nm
(18 lbfft)
8
19
Loctite
243
6
4
15
Loctite
30542
1
Loctite 29647
11
2
1
3
4 Nm
(35 lbfin)
04-08-2 SMR2003-013_04_08A.FM
787 RFI Engines (GTI LE RFI Models)
F15D0BS
Loctite 518
7
9
16
48 Nm
(35 lbfft)
Loctite
243
14
19
18
19
6
3
10
19
18
19
25 Nm
(18 lbfft)
13
12
4 Nm
(35 lbfin)
1
20
25 Nm
(18 lbfft)
Loctite 243
2
Silicone sealant
5150
40 Nm
(30 lbfft)
Loctite
243
25 Nm
(18 lbfft)
1
25
Loctite sealant
1
24
1
Loctite
sealant
20
SMR2003-013_04_08A.FM 04-08-3
947 DI Engines (XP DI Models)
F08D0CS
8
Loctite 243
9
25 Nm
(18 lbfft)
18
19
40 Nm
(30 lbfft)
10
4
14 Nm
(124 lbfin)
16 22 21
47 Nm
(35 lbfft)
25 Nm
(18 lbfft)
18
19
6
40 Nm
(30 lbfft)
5
2
3
4 Nm
(35 lbfin)
1
11
Silicone
sealant
23 Nm
(17 lbfft)
1
48 Nm
(35 lbfft)
20
14 12-13
7 9
48 Nm
(35 lbfft)
15
Loctite
243
Loctite 82046
Loctite 82046
04-08-4 SMR2003-013_04_08A.FM
947 DI Engines (RX DI Models)
8
Loctite 243
9
25 Nm
(18 lbfft)
18
19
40 Nm
(30 lbfft)
7 9
10
4
14 Nm
(124 lbfin)
16 22 21
47 Nm
(35 lbfft)
Loctite 243
25 Nm
(18 lbfft)
18
19
Loctite
243
2
4 Nm
(35 lbfin)
11
1
48 Nm
(35 lbfft)
20
14 12-13
48 Nm
(35 lbfft)
15
1
3
1
6
5
Loctite
82046
40 Nm
(30 lbfft)
Loctite
82046
Loctite
243
Silicone
sealant
F16D06S
SMR2003-013_04_08A.FM 04-08-5
947 DI Engines (GTX DI Models)
F12D16S
48 Nm
(35 lbfft)
7
9
14 Nm
(124 lbfin)
4
15
5
Loctite
82046
25 Nm
(18 lbfft)
19
18
6
40 Nm
(30 lbfft)
8 9
48 Nm
(35 lbfft)
16
22
21
14
12-13
25 Nm
(18 lbfft)
40 Nm
(30 lbfft)
19
18
20
1
3
2 1
1
11
Silicone
sealant
5150
Body
Loctite 243
Loctite
30542
Loctite 30542 Loctite 82046
10
4 Nm
(35 lbfin)
Loctite 243
04-08-6 SMR2003-013_04_08A.FM
REMOVAL
Remove seat(s).
Remove rear vent hose support from body opening.
Remove seat support (all models except RX DI and
XP DI).
TYPICAL
1. Seat support
2. Remove screws
XP DI Models
Open engine compartment cover.
Remove storage basket.
Tuned Pipe
717 Engines
Disconnect water supply hose and water injection
hose.
Disconnect tuned pipe bleed hose.
TYPICAL
1. Bleed hose removed
2. Injection hose removed
3. Supply hose removed
Loosen exhaust hose collar no. 1 at tuned pipe
outlet.
Disconnect strap no. 2 retaining muffler no. 11.
Remove exhaust hose no. 3 from tuned pipe by
pulling muffler.
Remove clamp no. 4 from tuned pipe.
Remove tuned pipe cone no. 5.
Remove tuned pipe retaining screw no. 6 from ex-
haust manifold side.
Remove screws no. 12, nut no. 8 and flat wash-
ers no. 9 from tuned pipe flange.
NOTE: Slightly lift tuned pipe to release nut as
necessary. Be carful not to drop nut and flat wash-
er.
Withdraw tuned pipe head no. 10 in a forward and
rotating movement.
F07L1KA
2
2 1
F01D8NA
1
2
3
SMR2003-013_04_08A.FM 04-08-7
787 RFI Engines
Remove air intake silencer.
Disconnect water supply hose and water injection
hose at tuned pipe.
Loosen hose clamp no. 1 retaining exhaust hose
no. 3 to tuned pipe cone.
1. Loosen clamp
Remove screws no. 7 and washers no. 9 at tuned
pipe head flange.
Remove screw no. 6 and screw no. 20 retaining
tuned pipe to engine.
Remove tuned pipe from watercraft.
947 DI Engines
To remove this tuned pipe, there are 2 possible
ways to proceed.
The first procedure separates the tuned pipe head
from the tuned pipe cone, using the following pro-
cedure. The second procedure removes the tuned
pipe without tuned pipe head and tuned pipe cone
separation. This procedure is explained further.
Tuned Pipe Removal with Separation from
Tuned Pipe Head and Tuned Pipe Cone
1. Disconnect water return hose at tuned pipe
head no. 10.
1. Water return hose
2. Disconnect small hose from water outlet fitting
at the tuned pipe head no. 10.
1. Disconnect hose from outlet fitting
3. Disconnect the water injection hose at tuned
pipe head no. 10.
1. Water injection hose
1
F06D14A
1 F18E1WA
1 F06E09A
1 F06E0AA
04-08-8 SMR2003-013_04_08A.FM
4. Disconnect the water bleed hose.
1. Water bleed hose
5. Loosen clamp no. 1 retaining exhaust hose no. 3
to tuned pipe cone no. 5.
TYPICAL
1. Loosen clamp
6. Loosen and remove clamp no. 4 retaining tuned
pipe head no. 10 to tuned pipe cone no. 5.
1. Loosen and remove clamp
7. Loosen Allen screw retaining carburetor brack-
et to tuned pipe head.
8. Remove external seal.
1 F06E0BA
1
F06D14A
1
F06D1SA
1 F06D3JA
SMR2003-013_04_08A.FM 04-08-9
9. Loosen Allen screws no. 7 and nut no. 8 at tuned
pipe flange.
NOTE: To loosen nut, use polygonal wrench (P/N
529 035 505).
1. Tuned pipe flange
10. Loosen bolt no. 20 of tuned pipe head above
the engine magneto then remove bolts retain-
ing bracket to engine.
1. Remove bolt
11. Remove tuned pipe head no. 10.
12. Loosen bolt no. 6 of tuned pipe cone beside
the engine water return hose.
1. Loosen bolt
13. Remove tuned pipe cone no. 5.
14. Block exhaust opening in the manifold to keep
debris from entering cylinder during threads
cleaning procedure.
15. Remove the stud no. 21 from Y manifold.
16. Use a M10 x 1.5 screw/tap to clean the 4
threaded holes on the Y manifold and the 2
threaded holes on tuned pipe. Clean out the
debris with a spray cleaner and air pressure.
CAUTION: It is very important that the threads
are free of debris before installing new self-
locking fasteners.
Tuned Pipe Removal without Separation from
Tuned Pipe Head and Tuned Pipe Cone
Execute the above procedures 1 through 5.
Then proceed as follows:
Remove the strap no. 2 retaining the muffler then
remove the exhaust hose no. 3 from tuned pipe
cone no. 5.
1
F06D1TA
F06D1UA 1
1
F06D1VA
04-08-10 SMR2003-013_04_08A.FM
Loosen Allen screw retaining carburetor bracket
to tuned pipe head.
Loosen Allen screws no. 7 and nut no. 8 at tuned
pipe flange.
NOTE: To loosen nut, use polygonal wrench (P/N
529 035 505).
1. Tuned pipe flange
Loosen bolt no. 20 of tuned pipe head above the
engine magneto then remove bolts retaining
bracket to engine.
1. Remove bolt
Remove tuned pipe assembly.
Block exhaust opening in the manifold to keep de-
bris from entering cylinder during threads cleaning
procedure.
Remove the stud no. 21 from Y manifold.
Use a M10 x 1.5 screw/tap to clean the 4 threaded
holes on the Y manifold and the 2 threaded
holes on tuned pipe. Clean out the debris with a
spray cleaner and air pressure.
locking fasteners.
Exhaust Manifold
Remove 8 Allen screws no. 12 and lock washers
no. 13 then withdraw exhaust manifold.
Resonators
GTI and GTI LE Models
Remove vent tube support.
Upper Type Resonators
Detach resonator from body.
F06D2DA 1
1
F06D1TA
F06D1UA 1
SMR2003-013_04_08A.FM 04-08-11
Loosen clamps and disconnect hoses. Withdraw
resonator from watercraft.
TYPICAL
1. Loosen hose clamps
2. Upper type resonator
3. Muffler holding strap
Footwell Type Resonators
NOTE: Some models are equipped with both types
of resonators (GTI LE RFI).
TYPICAL
1. Footwell type resonator
2. Upper type resonator
Loosen clamps retaining exhaust hose going from
resonator to muffler.
Loosen clamps retaining exhaust hose to exhaust
outlet.
Detach holding strap retaining resonator inside
bilge.
Pull resonator out of bilge.
Muffler
On DI models, disconnect the EGT (exhaust gas
temperature) sensor.
Disconnect hoses from muffler no. 11.
Disconnect hoses of the water flow regulator
valve (except 717 engines).
TYPICAL
1. Water supply hose
2. To injection fitting on tuned pipe
Disconnect retaining strap no. 2 of muffler.
Pull muffler no. 11 out of bilge.
NOTE: On RX DI and XP DI models, remove the
VTS motor. Refer to VARIABLE TRIM SYSTEM.
TUNED PIPE REPAIR
This procedure is given to repair tuned pipe cracks
using T.I.G. welding process.
Procedure
Sand the cracked area to obtain bare metal.
Perform a 1.50 mm (1/16 in) depth chamfer over
crack.
Use pure argon gas with 5.55 mm (3/32 in) tungsten
electrode (puretung green, zirtung brown) and
AC current.
Use a 5.55 mm (3/32 in) aluminum welding rod
(no. 4043), to fill crack.
Sand welding slightly to remove material sur-
plus.
2
1 3 F07L1DA
F07L1EA
2
1
F01E1FD 1 2
04-08-12 SMR2003-013_04_08A.FM
Test
Use compressed air at 124 kPa (18 PSI) to pres-
surize tuned pipe.
CAUTION: Always ensure water passages are
not blocked partially or completely while weld-
ing tuned pipe.
NOTE: Prior to verify leaks, plug all holes and pres-
surize tuned pipe while immerging it in water.
INSTALLATION
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
Exhaust Manifold
Make sure gasket(s) no. 16 are properly posi-
tioned prior to finalizing manifold installation.
717 Engines
Apply Molykote 111 on threads of screws no. 12.
Install exhaust manifold no. 14 and torque screws
no. 12 to 24 Nm (17 lbfft) as per following illus-
trated sequence.
787 RFI Engines
Apply Loctite 518 on 2 screws no. 12. On the oth-
er screws no. 12, apply Molykote 111 on threads.
Install screws. Refer to the following illustration
for proper position of screws.
1. Screw with Loctite 518
2. Screw with Molykote 111
Torque exhaust manifold screws to 24 Nm
(17 lbfft) as per following illustrated sequence. Re-
peat the procedure, retightening screws to 40 Nm
(30 lbfft).
F01D59A
1 3
5
8
2
4
7
6
F01D82B
2
2 2
1 2 1
F01D82A
3
1
7 6
4
8
2
5
SMR2003-013_04_08A.FM 04-08-13
947 DI Engines
Apply Molykote 111 on threads of Allen screws
no. 12.
Install and hand tighten Allen screws no. 12 as per
following picture.
1. M10 x 60 Allen screws
2. M10 x 110 Allen screws
Torque Allen screws to 24 Nm (17 lbfft) as per fol-
lowing illustrated sequence. Repeat the procedure,
retightening Allen screws to 40 Nm (30 lbfft).
Tuned Pipe
717 Engines
CAUTION: Torque wrench tightening specifica-
tions must be strictly adhered to. Locking de-
vices (ex.: locking tabs, elastic stop nuts, self-
locking fasteners, etc.) must be installed or re-
placed with new ones where specified. If the
effiency of a locking device is impaired, it must
be renewed.
Ensure rubber bushings no. 19 and sleeve no. 18
are not damaged and are properly installed into
tune pipe support(s).
CAUTION: Damage to bushings and/or sleeve
will eventually cause stress to tuned pipe and
may cause cracking.
Make sure that gasket no. 16 is properly located
on exhaust manifold prior to finalizing pipe instal-
lation.
Apply Loctite 243 (blue) on nut no. 8 and screws
no. 6 and no. 12.
NOTE: Hand tighten all fasteners before torquing
any of them. For torquing sequence, see the fol-
lowing illustrations.
Install tuned pipe cone no. 5 with sealing ring
no. 15 and clamp no. 4.
F06D1YA 1 2 1
F06D1YB
7 4 1 5
8 2 3 6
25 Nm
(18 lbfft)
F00D29B
25 Nm
(18 lbfft)
5
1
2
3
4
8
7
50 Nm
(37 lbfft)
6
50 Nm
(37 lbfft)
9
50 Nm
(37 lbfft)
24 Nm
(17 lbfft)
12 Nm
(9 lbfft)
04-08-14 SMR2003-013_04_08A.FM
Position clamp no. 4 as illustrated. Do not tighten
clamp yet.
1. Clamp
2. Exhaust collar
With hose removed, align cone outlet with muffler
inlet.
NOTE: Due to exhaust cone angle, it may have to
be rotated to obtain alignment.
Push cone no. 5 until it touches tuned pipe, then
tighten exhaust clamp no. 4 and torque to 4 Nm
(35 lbfin).
CAUTION: There must be no gap between tuned
pipe cone and tuned pipe head.
NOTE: Exhaust clamp nuts should be tightened
alternately to assure no leakage and to obtain
specified torque.
787 RFI Engines
be renewed.
NOTE: Loosen all pipe supports from engine be-
fore installing tuned pipe.
Ensure rubber bushings no. 19 and sleeve no. 18
are not damaged and are properly installed into
tune pipe support(s).
may cause cracking.
Make sure that gasket no. 16 is properly located
on exhaust manifold prior to finalizing pipe instal-
lation.
Install the tuned pipe end into exhaust hose no. 3.
Do not toque yet.
Torquing Sequence:
CAUTION: Torque the tuned pipe in accordance
with the following sequence, otherwise serious
engine damage may occur.
F01D41A
1
2
SMR2003-013_04_08A.FM 04-08-15
F15D06S
25 Nm (18 lbfft)
NOTE: Press the pipe support on the engine
before torquing the pipe support bolt.
25 Nm
(18 lbfft)
1 Nm
(9 lbfin)
40 Nm
(30 lbfft)
40 Nm
(30 lbfft)
6 Nm
(53 lbfin)
48 Nm
(35 lbfft)
7
3
9
5
6 Nm
(53 lbfin)
48 Nm
(35 lbfft)
4
8
2
6
25 Nm
(18 lbfft)
25 Nm
(18 lbfft)
13
12
10
11
1
15
14
04-08-16 SMR2003-013_04_08A.FM
947 Engines
be renewed.
NOTE: Loosen all pipe supports from engine be-
fore installing tuned pipe.
Make sure to install the sealing ring no. 15 on
tuned pipe cone if it was removed.
TYPICAL
1. Sealing ring
Apply a thin layer of Loctite 30542 heat resistant
sealant (P/N 293 800 090) all around sealing ring
no. 15.
may cause cracking.
locking fasteners. Refer to removal procedure
for the proper thread cleaning procedure.
Clean the Y manifold and tuned pipe surfaces.
Screw stud no. 21 into the Y manifold. Torque
to 47 Nm (35 lbfft).
Install the new bushing no. 18.
Torquing Sequence
CAUTION: Torque the tuned pipe in accordance
with the following sequence, otherwise serious
engine damage may occur.
NOTE: Apply Loctite 243 (P/N 293 800 060) on
stud nut before tightening to 2.5 Nm (22 lbfin).
Use special tool (P/N 529 035 505).
Install external seal no. 22 and secure with a lock-
ing tie.
F07D0RA
1
SMR2003-013_04_08A.FM 04-08-17
6 Nm
(53 lbfin)
40 Nm
(30 lbfft)
F07D0ST
14 Nm
(124 lbfin)
25 Nm
(18 lbfft)
25 Nm
(18 lbfft)
3 Nm
(26 lbfin)
48 Nm
(35 lbfft)
3 Nm
(26 lbfin)
48 Nm
(35 lbfft)
3 Nm
(26 lbfin)
48 Nm
(35 lbfft)
3 Nm
(26 lbfin)
48 Nm
(35 lbfft)
5
15
6
40 Nm
(30 lbfft)
13
7
3
10
1
2
9
8
6 Nm
(53 lbfft)
12
14
4
11
04-08-18 SMR2003-013_04_08A.FM
Install exhaust hose.
1. Torque clamp to 4 Nm (35 lbfin)
1
F06D14A
Section 05 ENGINE (4-TEC)
SMR2003-049_05_01ATOC.FM 05-01-1
TABLE OF CONTENTS 0
LEAK TEST............................................................................................................................. 05-02-1
LEAK TEST PROCEDURE.................................................................................................. 05-02-1
PREPARATION................................................................................................................... 05-02-1
PROCEDURE...................................................................................................................... 05-02-2
INSTALLATION.................................................................................................................. 05-02-3
INTAKE SYSTEM................................................................................................................... 05-03-1
INSPECTION...................................................................................................................... 05-03-4
REMOVAL........................................................................................................................... 05-03-6
ASSEMBLY......................................................................................................................... 05-03-15
EXHAUST SYSTEM............................................................................................................... 05-04-1
EXHAUST PIPE.................................................................................................................. 05-04-2
EXHAUST MANIFOLD ...................................................................................................... 05-04-5
MUFFLER (LH) ................................................................................................................... 05-04-6
MUFFLER (RH) ................................................................................................................... 05-04-7
EXHAUST OUTLET ........................................................................................................... 05-04-8
GENERAL ........................................................................................................................... 05-05-1
ENGINE REMOVAL............................................................................................................ 05-05-1
CLEANING ......................................................................................................................... 05-05-3
INSTALLATION.................................................................................................................. 05-05-3
PTO HOUSING/MAGNETO.................................................................................................. 05-06-1
GENERAL ........................................................................................................................... 05-06-2
PTO HOUSING................................................................................................................... 05-06-2
PTO SEAL........................................................................................................................... 05-06-5
COUPLING......................................................................................................................... 05-06-5
STATOR ............................................................................................................................. 05-06-6
ROTOR AND ENCODER WHEEL....................................................................................... 05-06-7
RING GEAR........................................................................................................................ 05-06-8
STARTER DRIVE ASSY .................................................................................................... 05-06-9
OIL SPRAY NOZZLE.......................................................................................................... 05-06-10
05-01-2 SMR2003-049_05_01ATOC.FM
LUBRICATION SYSTEM......................................................................................................... 05-07-1
GENERAL............................................................................................................................ 05-07-3
OIL LEVEL VERIFICATION................................................................................................. 05-07-3
ENGINE OIL PRESSURE TEST.......................................................................................... 05-07-4
OIL FILTER.......................................................................................................................... 05-07-5
OIL STRAINERS.................................................................................................................. 05-07-6
ENGINE OIL PRESSURE REGULATOR............................................................................. 05-07-9
OIL PRESSURE PUMP ....................................................................................................... 05-07-10
OIL SUCTION PUMP.......................................................................................................... 05-07-13
OIL COOLER ....................................................................................................................... 05-07-15
OIL SEPARATOR................................................................................................................ 05-07-16
CYLINDER HEAD AND VALVES ........................................................................................... 05-08-1
GENERAL............................................................................................................................ 05-08-2
SPARK PLUG...................................................................................................................... 05-08-2
VALVE COVER .................................................................................................................... 05-08-2
ROCKER ARM..................................................................................................................... 05-08-3
CAMSHAFT TIMING GEAR................................................................................................ 05-08-7
TIMING CHAIN................................................................................................................... 05-08-8
CYLINDER HEAD................................................................................................................ 05-08-8
CAMSHAFT......................................................................................................................... 05-08-10
VALVE SPRING................................................................................................................... 05-08-11
VALVE................................................................................................................................. 05-08-12
ENGINE BLOCK...................................................................................................................... 05-09-1
GENERAL............................................................................................................................ 05-09-3
CRANKSHAFT LOCKING................................................................................................... 05-09-3
CRANKSHAFT .................................................................................................................... 05-09-3
TIMING CHAIN................................................................................................................... 05-09-8
CHAIN TENSIONER............................................................................................................ 05-09-8
BALANCER SHAFT............................................................................................................. 05-09-9
ENGINE BLOCK.................................................................................................................. 05-09-11
PISTON/CONNECTING ROD ............................................................................................. 05-09-17
PISTON RINGS................................................................................................................... 05-09-22
SMR2003-014_05_02A.FM 05-02-1
LEAK TEST 0
LEAK TEST PROCEDURE
The procedure has to be done when engine operat-
ing temperature of approx. 70C (158F) is reached.
PREPARATION
Remove:
seat and vent tube support
safety lanyard.
jet pump
(refer to JET PUMP in PROPULSION SYSTEM)
coolant tank cap
oil dipstick
1. Oil dipstick
unplug ignition coil and pull it out
spark plug from cylinder head.
NOTE: Ignition coil may be used as an extractor.
1. Ignition coil
2. Spark plug
Remove valve cover cowl.
Unscrew and remove valve cover.
1. Valve cover
2. Valve cover screw
WARNING
Prevent burning yourself due to handling on
the hot engine.
WARNING
Safety lanyard must be removed to prevent
engine to be cranked while fuel rail is re-
moved to prevent fuel to be sprayed out.
Fuel is flammable.
WARNING
To prevent burning yourself only remove the
coolant tank cap by wearing the appropriate
safety equipment.
1
R1503motr153A
1
R1503motr154A
2
2
R1503motr155A
1
05-02-2 SMR2003-014_05_02A.FM
PROCEDURE
The following procedure has to be performed for
each cylinder separately, because of the 120 off-
set between the TDCs.
Rotate crankshaft counterclockwise using drive
shaft adaptor (P/N 529 035 892) until the cylinder
no. 3 is at top dead center (TDC) compression
stroke.
NOTE: Cylinder numbers are molded on valve cover.
DRIVE SHAFT ADAPTOR (P/N 529 035 892)
1. Intake rocker arms
As the engine is turned over, observe the move-
ment of intake rocker arm of the cylinder no. 3.
After it completes the cycle and the intake valve
closes, observe the piston. When it reaches its up-
permost position that is TDC compression stroke.
Then perform the leak test on cylinder no. 3 as men-
tioned below.
To perform the leak test on cylinder no.1, rotate the
crankshaft counterclockwise to 240 so that the
cylinder no.1 is at TDC compression stroke. Fol-
low the instructions mentioned below to check
the leakage.
Rotate crankshaft counterclockwise to 240 so
that the cylinder no. 2 is at top dead center (TDC)
compression stroke. Follow the below given pro-
cedure to check the leakage.
The following procedure should be done for each
cylinder separately after positioning them at TDC
compression stroke, as per the procedure given
above.
Hold the crankshaft in this position by using drive
shaft adaptor (P/N 529 035 892).
Install gauge adapter into previously cleaned spark
plug hole.
Connect to adequate air supply.
NOTE: Each tester will have specific instruction
on the gauge operation and required pressure.
Set needle of measuring gauge to zero.
Supply combustion chamber with air.
1. Measuring gauge
2. Adequate adapter for spark plug hole
3. Air supply
F00B21A
1
R1503motr156A
1
R1503motr157A
2
3
SMR2003-014_05_02A.FM 05-02-3
Note the amount of leaking or percentage (de-
pending on tester).
Diagnose
Pressurize area to be tested, spray soap/water so-
lution at the indicated location and look and/or lis-
ten for air bubbles.
air escaping on intake port means leaking intake
valve(s)
air escaping on exhaust port means leaking ex-
haust valve(s)
air bubbles out of coolant tank means leaking
cylinder head gasket
air escaping into crankcase area means exces-
sively worn and/or broken piston rings.
INSTALLATION
NOTE: For installation use the torque values and
Loctite products from the exploded views (refer to
proper engine subsection).
For installation, reverse the preparation proce-
dure.
NOTE: Prior to inserting the ignition coil in its lo-
cation, apply some Molykote 111 (P/N 413 707
000) around the seal area that touches the spark
plug hole. After installation, ensure the seal seats
properly with the engine top surface.
General Engine Leakage
Spray soap/water solution at the indicated location
and look and/or listen for air bubbles.
Paying attention to the following checkpoints:
clamp(s) tightened
coolant hoses
air/oil escaping from crankcase means damaged
gasket(s) and/or loosened screws
(refer to ENGINE BLOCK)
air/water escaping from cylinder/head means
damaged gasket(s) and/or loosened screws
(refer to CYLINDER HEAD AND VALVES)
oily contamination on weep hole (speed sensor
area) means a damaged oil seal on coolant
pump shaft
coolant escaping from weep hole means a dam-
aged rotary seal on coolant pump shaft
(refer to COOLING SYSTEM)
1. Weep hole
coolant escaping from coolant pump housing
means damaged gasket(s) and/or loosened
screws (refer to COOLING SYSTEM).
NOTE: For all the checkpoints mentioned above
see the appropriate engine section to diagnose
and repair the engine.
LEAKAGE
PERCENTAGE
ENGINE
CONDITION
0% to 7% Excellent condition.
8% to 15%
Fair condition; proceed
with tuned up or adjust-
ment.
16% to 30%
Poor condition; engine will
r un and perf or mance
might be down in some
cases.
30% and higher
Very poor condition, diag-
nose and repair engine.
1 R1503motr158A
Subsection 03 (INTAKE SYSTEM)
SMR2003-015_05_03A.FM 05-03-1
INTAKE SYSTEM 0
4-TEC Engines
TYPICAL
R1503motr63S
10 Nm
(89 lbfin)
Loctite 243
10 Nm
(89 lbfin)
6 Nm
(53 lbfin)
10 Nm
(89 lbfin)
Loctite 243
6 Nm
(53 lbfin)
18 Nm
(159 lbfin)
10 Nm
(89 lbfin)
Loctite 243
Loctite 243
Oil
Loctite 243
05-03-2 SMR2003-015_05_03A.FM
4-TEC Supercharged Engines
R1503motr221S
30 Nm
(22 lbfft)
10 Nm
(88 lbfin)
Loctite 243
Loctite 5910
30 Nm
(22 lbfft)
Loctite 243
Oil
Loctite 243
Loctite 243
30 Nm
(22 lbfft)
Oil
Klueber isoflex
30 Nm
(22 lbfft)
SMR2003-015_05_03A.FM 05-03-3
R1503motr251A
10 Nm
(88 lbfin)
Loctite 243
Oil
Loctite 243
6 Nm
(53 lbfin)
18 Nm
(159 lbfin)
Loctite
243
6 Nm
(53 lbfin)
10 Nm
(88 lbfin)
10 Nm
(88 lbfin)
Oil
05-03-4 SMR2003-015_05_03A.FM
INSPECTION
Slipping moment Inspection
Remove seat, storage basket, vent tube and its
support. Refer to REMOVAL below.
Refer to EXHAUST SYSTEM section and remove
the following components.
Cross-over hose from LH muffler.
Resonator duct connected on LH muffler.
Detach exhaust pipe from exhaust manifold but
keep exhaust pipe coupled with LH muffler.
This will eliminate the need to realign the ex-
haust pipe and muffler at reinstallation.
LH muffler strap and slide LH muffler and ex-
haust pipe altogether rearwards as far as possi-
ble.
Remove air intake hose from supercharger assy.
1. Supercharger assy
2. Air intake hose
Remove valve cover and install camshaft locking
tool (P/N 529 035 839) to prevent camshaft rota-
tion while checking slipping moment of super-
charger. Refer to CYLINDER HEAD AND VALVES.
NOTE: Rotate supercharger nut to align camshaft
holes and to allow insertion of the locking tool.
1. Camshaft locking tool
Check slipping moment counterclockwise by us-
ing a torque wrench with actual torque viewer. A
mirror is useful to see the viewer.
1. Torque wrench
Supercharger should start to turn at a torque be-
tween 6 to 9 Nm (53 to 80 lbfin).
If the torque is less, remove supercharger assy
from engine (refer to SUPERCHARGER REMOV-
AL elsewhere in this section).
CAUTION: When removing the drive gear with
the needle pins, be careful not to lose one of
the 40 pins.
Loosen nut on supercharger shaft engine side.
Remove L-ring, spring washers, lock washer, drive
gear and needle pins by turning the supercharger
assy upside down.
1 R1503motr224A 2
R1503motr111A
1
1
R1503motr244A
SMR2003-015_05_03A.FM 05-03-5
1. L-Ring
2. Spring washers
3. Lock washer
4. Drive gear
5. Needle pins
Check the wear limit on drive gear, lock washer
and driven plate on supercharger shaft.
A. Driven plate thickness
B. Drive gear thickness
C. Lock washer thickness
Replace worn parts by new ones. If all parts are
within specifications, replace spring washer pack-
age on supercharger shaft.
For assembly, refer to SUPERCHARGER ASSEM-
BLY elsewhere in this section.
Spring Washer Height
Remove supercharger assy from engine.
Loosen nut on supercharger shaft engine side.
Remove L-ring and spring washers from shaft.
Put spring washer package together as it is assa-
mbled on the supercharger shaft. Measure the
height of the unloaded spring washer package.
A. Spring washer package height
For reassembly of the superchager refer to SU-
PERCHARGER ASSEMBLY elsewhere in this sec-
tion.
Properly reinstall removed parts.
DRIVEN PLATE JOURNAL DEPTH
mm (in)
NEW MINIMUM 9.960 mm (.3921 in)
NEW MAXIMUM 10.000 mm (.3937 in)
SERVICE LIMIT 9.700 mm (.3819 in)
DRIVE GEAR THICKNESS
mm (in)
5
R1503motr232A
4
3
2
1
A
R1503motr237A
B C
LOCK WASHER THICKNESS
mm (in)
SPRING WASHER PACKAGE HEIGHT
mm (in)
NEW 10.500 mm (.4134 in)
A R1503motr248A
05-03-6 SMR2003-015_05_03A.FM
REMOVAL
All 4-TEC Engines
Air Intake Manifold
Remove seat and storage basket.
Disconnect vent tube as follows.
Lift lock tab and holding the tab, pull the tube to
release it.
1. Lift lock tab
Then proceed with the tab under the tube. Refer
to the following illustration to see it.
1. Other lock tab under tube
Unlock coolant expansion tank, pull out then move
away.
Step : Push tab (each side) to release
Step : Pull tank out
NOTE: Pay attention not to drop the nuts under
support when removing screws.
1. Vent tube support
2. Remove retaining screws
3. Pay attention to nuts underneath
Remove oil dipstick.
Pull fuel rail cover out.
Disconnect battery cables from battery.
F18E0PA
1
1 F18E0QA
2
F18E1MA
1
1
2
2
1
F18L1GA
2
3
SMR2003-015_05_03A.FM 05-03-7
Release the fuel pressure in the system, refer to
ENGINE MANAGEMENT section.
Disconnect fuel hose connector at fuel rail.
Step : Squeese
Step : Pull out
1. Supporting tabs
2. Squeeze in middle of supporting tabs, hold and pull out
Cut locking ties where shown.
4-TEC NA (NORMALLY ASPIRATED) ENGINES
1. Cut locking ties to release harness coming from vehicle
4-TEC SUPERCHARGED ENGINES
1. Cut locking ties to release harness coming from vehicle
4-TEC NA (Normally Aspirated) Engines
Unplug connectors from ignition coils, TOPS valve,
OSPS, TPS, idle bypass valve, engine connector,
CTS, CAPS, KS, CPS, magneto, OPS and EGT.
4-TEC NA ENGINES
1. Ignition coils
2. TOPS
3. TPS (hidden behind throttle body)
4. Idle bypass valve
5. Engine connector
6. KS
7. CPS
8. Magneto
9. B Kostal connector
10. OSPS
WARNING
R1503motr78A
1
2
1
1
1
2
1
2
1
F18D0CA
1
1
R1503motr222A
5
1
R1503motr60A
9
8
7
6
2 3 10
4
05-03-8 SMR2003-015_05_03A.FM
Unplug connectors from ignition coils, idle bypass
valve, engine connector, CTS, CAPS, KS, CPS, mag-
neto, OPS and EGT.
1. Ignition coils
3. KS
4. CPS
5. Magneto
4-TEC NA Engines
For the TOPS valve connector, refer to the follow-
ing illustration.
1. Push here and hold while pulling connector out
4-TEC NA Engines
NOTE: The TPS connector is hidden behind the
TOPS hose. Disconnect hose from TOPS valve
then move away to access the TPS connector.
Slightly pry locking tab of connector to unlock.
1. TOPS hose disconnected and moved away
2. TPS connector
3. Slightly pry tab to unlock
All 4-TEC Engines
TYPICAL
1. CTS connector
2
1
R1503motr223A 5 4 3
1
R1503motr69A
R1503motr75A
1
3
2
1 R1503motr64A
SMR2003-015_05_03A.FM 05-03-9
TYPICAL
1. CAPS connector
TYPICAL
1. EGT connector
NOTE: On Supercharged models, a long screw-
driver may be used to unlock the connector from
the sensor.
1. Oil filter housing
2. OPS
Unplug the B connector from the Engine ECU.
1. Push this end to unlock
1. Pull here to release
Pull the connectors for KS, CPS and magneto out
of the ECU support. Refer to WIRING DIAGRAMS
section. Disconnect KS and CPS connectors.
1 R1503motr65A
1 R1503motr66A
1 F18D0BA 2
1 R1503motr70A
1
R1503motr71A
05-03-10 SMR2003-015_05_03A.FM
Pull wiring harness away from intake manifold.
4-TEC NA Engines
Slacken air intake silencer collar.
Unlock throttle cable housing from throttle body.
Cable is to be detached later on.
1. Air intake silencer collar
2. Unlock throttle cable housing
Remove inlet hose from throttle body.
Disconnect throttle cable from throttle body.
1. Detach hose
2. Disconnect cable
All 4-TEC Engines
Remove manifold retaining screws and push the
oil dipstick tube out of the manifold slot.
Lift intake manifold up to pull it out of the mount-
ing brackets just enough to reach throttle cable
end.
1. Mounting brackets
R1503motr72A
1
2
R1503motr252A 2 1
R1503motr59A
1 R1503motr61A
SMR2003-015_05_03A.FM 05-03-11
4-TEC NA Engines
Detach throttle cable end from throttle body.
1. Detach cable end from throttle body
All 4-TEC Engines
Pull intake manifold out.
TYPICAL
NOTE: The flame arrester in intake manifold is
maintenance free.
Supercharger
CAUTION: Be scrupulous when working on su-
percharger parts. Supercharger rotation reach-
es 40 000 rpm. Any modification, improper re-
pair/assembly or damage on the parts, may
result in damage of the supercharger. Strictly
follow the described procedures.
Remove seat, storage basket, vent tube and its
support. Refer to REMOVAL above.
Refer to EXHAUST SYSTEM section and remove
the following components.
Cross-over hose from LH muffler.
Resonator duct connected on LH muffler.
Detach exhaust pipe from exhaust manifold but
keep exhaust pipe coupled with LH muffler.
This will eliminate the need to realign the ex-
haust pipe and muffler at reinstallation.
LH muffler strap and slide LH muffler and ex-
haust pipe altogether rearwards as far as possi-
ble.
Remove hoses from supercharger ports.
1. Inlet hose
2. Outlet hose
1 R1503motr76A
R1503motr77A
1 R1503motr224A 2
05-03-12 SMR2003-015_05_03A.FM
Remove retaining screws and pull out the super-
charger assy.
1. Retaining screws
To remove the upper screw, use the Torx adapter
(P/N 529 035 938).
1. Upper retaining screws
Mount supercharger assy on support plate (P/N
529 035 947).
1. Supercharger mounting plate
Remove supercharger housing from supercharger
ground plate.
1. Retaining screws
2. Supercharger housing
3. Supercharger ground plate
R1503motr225A 1
F00B20A
1
R1503motr250A
F00B27A 1
1
F00B28A 3
2 1
1 1
SMR2003-015_05_03A.FM 05-03-13
PLASTIC HAMMER
NOTE: The cap nut on the supercharger shaft has
LH threads.
Loosen cap nut (turn clockwise) on supercharger
shaft impeller side while holding shaft with a re-
taining key (P/N 529 035 949).
1. Cap nut
Remove washer, supercharger impeller, O-ring
and step collar from supercharger shaft.
1. Washer
2. Supercharger impeller
3. O-ring
4. Step collar
Loosen nut on supercharger shaft engine side
while holding shaft with a retaining key (P/N 529
035 949).
1. Nut
2. Retaining key
F00B29A
1
R1503motr228A
1
R1503motr229A
2
3
4
2
F00B2BA 1
05-03-14 SMR2003-015_05_03A.FM
CAUTION: When removing the drive gear with
the needle pins, be careful not to lose one of
the 40 pins.
Remove L-ring, spring washers, lock washer, drive
gear and needle pins by turning the supercharger
assy upside down.
1. L-ring
2. Spring washers
3. Lock washer
4. Drive gear
5. Needle pins
Carefully push out supercharger shaft towards en-
gine side by using a press.
1. Supercharger shaft
CAUTION: Every time when removing the su-
percharger shaft, both ball bearings have to be
replaced.
Remove ball bearing from supercharger shaft by
using a press and retaining key (P/N 529 035 949).
2. Ball bearing
3. Retaining key
Screw out retaining disc with seal by using the 4-
pin socket (P/N 529 035 948).
NOTE: It may be necessary to heat the housing
with a heat gun to release the retaining disc.
1. 4-pin socket
5
R1503motr232A
4
3
2
1
1
F00B2CA
1
F00B2DA 2 3
F00B2AA 1
SMR2003-015_05_03A.FM 05-03-15
Remove ball bearing from supercharger ground
plate by using a press and a suitable bearing pusher.
1. Supercharger ground plate
2. Bearing pusher
ASSEMBLY
All 4-TEC Engines
Assembly is essentially the reverse of removal
procedures. However pay particular attention to
the following.
CAUTION: Do not modify air intake system,
otherwise calibration will be affected.
Supercharger
CAUTION: Every time when supercharger shaft
has been removed, both ball bearings have to
be replaced.
CAUTION: Both ball bearings have to be in-
stalled with cages facing supercharger impel-
ler side.
Apply enough engine oil on ball bearing. Install ball
bearing on supercharger shaft by using support
plate (P/N 529 035 947) to hold bearing.
CAUTION: Ensure to position ball bearing
against protrusion of support plate for the in-
stallation. 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.
2. Ball bearing
3. Bearing support plate
4. Protrusion of support plate on this side (underneath inner race)
Apply enough engine oil on ball bearing. Press in
the ball bearing in supercharger ground plate, by
using ball bearing support/pusher (P/N 529 035
950).
1. Bearing support/pusher
Mount supercharger assy on support plate (P/N
529 035 947).
1
R1503motr236A
2
4
3
1
F00B2FA 2
1
F00B2EA
05-03-16 SMR2003-015_05_03A.FM
Apply Loctite 243 on retaining disc and install it in
supercharger ground plate by using the 4-pin sock-
et (P/N 529 035 948). Torque to 30 Nm (22 lbfft).
1. Retaining disc
2. 4-pin socket
NOTE: Always use a new oil seal when assam-
bling the supercharger.
To properly support inner race of bearing in super-
charger, use support plate (529 035 947) and bear-
ing support/pusher (P/N 529 035 950) under super-
charger ground plate.
1. Support plate
2. Bearing support/pusher
3. Protrusion here
CAUTION: Before pressing in the supercharger
shaft, be sure to properly support the inner race
of ball bearing in supercharger ground plate
with the recommended tool. This way, the in-
stallation pressure will be applied to the inner
race and will not be transmitted to the bearing
balls which would otherwise shorten the bear-
ing life.
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 prior to
heating.
Apply engine oil on supercharger shaft. Press
shaft with distance sleeve together in supercharg-
er ground plate.
2. Distance sleeve
Apply engine oil on seal and push into retaining
disc by hand.
1. Oil seal
IMPORTANT: Grease drive gear before assam-
bling on the inner diameter as well as on the flanks
with Klueber Isoflex grease (P/N 293 550 021) or
an equivalent high quality bearing grease. Spring
washers have to be greased with engine oil.
Pre-assamble drive gear, needle pins and lock
washer on supercharger shaft.
Fix the lock washer by using retaining key (P/N 529
035 949).
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.
1
F00B2IA
2
3
F00B2GA 1
2
1
F00B2HA
2
1
R1503motr242A
SMR2003-015_05_03A.FM 05-03-17
Install step collar, O-ring, supercharger impeller
and washer on supercharger shaft impeller side
and tighten with cap nut. Apply Loctite 243 on cap
nut and torque to 30 Nm (22 lbfft) cap nut.
1. Step collar
2. O-ring
3. Supercharger impeller
4. Washer
5. Cap nut
CAUTION: When installing the spring washers,
take care of the exact installation direction of
the washers.
1. Spring washers
Complete installation on supercharger shaft en-
gine side. Install spring washers and L-Ring and
tighten with nut. Apply Loctite 243 on cap nut and
torque to 30 Nm (22 lbfft) cap nut.
1. Drive gear
2. Needle pins
3. Lock washer
4. Spring washers
5. L-ring
6. Nut
Apply Loctite 5910 on supercharger housing seal-
ing surface. For correct procedure refer to EN-
GINE BLOCK INSTALLATION in ENGINE section.
1. Apply Loctite 5910 on sealing surface
4
R1503motr229B
3
2
1
5
1
R1503motr249A
1
R1503motr241A
2
3
4
5
6
1
R1503motr246A
05-03-18 SMR2003-015_05_03A.FM
Install supercharger housing on supercharger
ground plate. Apply Loctite 243 on retaining
screws and torque to 10 Nm (88 lbfin) according
to the following sequence.
SUPERCHARGER TIGHTENING SEQUENCE
Sealing surface between supercharger and PTO
housing has to be greased with Loctite Antiseize.
1. Apply Loctite Antiseize
Install supercharger assy on PTO housing. Apply
Loctite 243 (blue) on the retaining screws.
Torque screws to 10 Nm (88 lbfin).
To tighten and torque the upper screw, use the
Torx adapter (P/N 529 035 938).
Ensure to install the tool perpendicularly (90) to
torque wrench to apply the proper torque to the
screw.
1. Tool perpendicular (90) to torque wrench
A. 90
CAUTION: Not installing the tool as shown will
change the torque applied to the screw. Proper
torque and tightening sequence are important.
After complete installation of the supercherger
assy the slipping moment has to be rechecked.
Refer to SLIPPING MOMENT INSPECTION above
in this section.
When reinstalling exhaust system components,
validate LH muffler/exhaust pipe alignment with
exhaust manifold. Refer to EXHAUST SYSTEM.
Air Intake Manifold
All 4-TEC Engines
Ensure that all gaskets are properly installed and
in a good condition.
INTAKE MANIFOLD
1. Gaskets
R1503motr227B
4 6
8
9
1
3
5
7
2
1 R1503motr247A
F00B20A
A
F00B1UA 1
1 R1503motr62A
SMR2003-015_05_03A.FM 05-03-19
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 man-
ifold.
1. Oil dipstick tube
Apply Loctite 243 (blue) on the intake manifold
screws. Torque them to 10 Nm (88 lbfin) follow-
ing the tightening sequence shown.
Ensure to properly route and resecure wiring har-
ness with locking ties.
Readjust throttle cable and reset the TPS using the
VCK. Refer to ENGINE MANAGEMENT section.
WARNING
Always check O-ring for damage such as defor-
mation at reinstallation. Replace the O-ring if it is
damaged.
R1503motr59B
1
5
R1503motr210A
3 1
2
6
7 4
SMR2003-016_05_04A.FM 05-04-1
EXHAUST SYSTEM 0
9
Loctite 296
11 Nm
(97 lbfin)
8
3
11
2
4
1
5
15
16
6
14
17
15
15
12
7
10
8 Nm
(71 lbfin)
16 Nm
(142 lbfin)
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
Loctite 5150
13
F18D0HT
05-04-2 SMR2003-016_05_04A.FM
EXHAUST PIPE
Removal
Remove seat and seat extension.
Remove seat support.
1. Seat support
2. Remove screws
Supercharged Models
Remove plastic resonator.
1. Plastic resonator
2. Disconnect here
All 4-TEC Engines
Disconnect the 3 cooling hoses from exhaust pipe
no. 1.
1. Exhaust pipe
2. Gear clamp
3. Exhaust clamp
Loosen the exhaust hose clamp no. 5 to the top
portion of the hose between muffler (LH) no. 6
and the exhaust pipe no. 1.
1. Exhaust hose clamp
2. Exhaust pipe
WARNING
Certain components in the engine compartment
may be very hot. Direct contact may result in skin
burn. Let exhaust system cool down prior to re-
moving parts.
1
2
F18L2GA 2
1
F18D2VA
2 2
2
3
F18D0IA
1
1 F18D0RA 2
SMR2003-016_05_04A.FM 05-04-3
Loosen both exhaust hose clamps no. 15 and re-
move the exhaust hose no. 16 between the muf-
fler (LH) and the muffler (RH).
1. Hose clamp
2. Exhaust hose
Detach the strap no. 11 from the muffler (LH) using
the spring installer/remover (P/N 529 035 559).
1. Muffler (LH)
2. Strap
3. Spring installer/remover
Slowly unscrew exhaust clamp nut no. 4 and re-
move it.
NOTE: Unscrewing the nut too fast generates heat
that will make it harder to unscrew.
1. Exhaust clamp
2. Exhaust pipe
Move muffler (LH) no. 6 backward enough to allow
the exhaust pipe to be pulled out.
Squeeze the exhaust hose no. 7 going to the exhaust
outlet with one hand, and withdraw the exhaust pipe
no. 1 from the exhaust manifold.
1. Exhaust pipe
2. Squeeze this hose to ease removal of pipe
1 F18D0QA 2
A00C3SA
2 F18D0JA 1 3
1
F18D0SA
2
1
F18D0KA
2
05-04-4 SMR2003-016_05_04A.FM
Inspection
Inspect exhaust pipe condition paying attention for
cracks or other damage. Check joints, coupling areas,
heat shield and hoses. Replace any defective part.
Installation
Installation is essentially the reverse of the remov-
al procedures. However, pay particular attention to
the following:
Apply sealant (P/N 293 800 090) on the welds of the
exhaust tube, while the exhaust pipe is removed from
the muffler (LH).
1. Sealant (P/N 293 800 090)
2. Exhaust pipe
Insert the exhaust pipe end in the exhaust hose.
Align the exhaust pipe flange to the engine manifold.
To achieve a good fit, it could be necessary to push
the exhaust pipe further down into the hose over its
step. Note distance if pushed over step, then cut hose
by obtained measure.
Add a second clamp no. 5 to the top portion of the
hose. The two clamps must be separated by 3 - 5 mm
(1/8 - 3/16 in) and the screws must be at least 25 mm
(1 in) apart.
1. Exhaust pipe step
2. Exhaust hose
3. Exhaust hose clamp
Pre-align the exhaust pipe no. 1 by rotating (axially)
and moving (longitudinally) the muffler (LH) so that
the exhaust pipe flange makes perfect contact with
the engine manifold.
1. Engine manifold
2. Exhaust pipe flange
CAUTION: Exhaust pipe alignment with the man-
ifold is critical to the bellows life. Any constraint
on the flexible joint will result in the bellows fail-
ure. Gap between the exhaust pipe flange and
the engine manifold should not exceed 1 mm
(3/64 in).
1 F18D0TA 2
1 F18D0VA 2 3
1
F18D0UA
2
SMR2003-016_05_04A.FM 05-04-5
Reinstall the exhaust clamp no. 4 to the exhaust
pipe flange and tighten enough to maintain the ex-
haust pipe in the proper position.
1. Exhaust pipe flange
2. Exhaust clamp
3. Engine manifold
Rotate (axially) and move (longitudinally) the muf-
fler (LH) so that the exhaust pipe flange makes
perfect contact with the engine manifold. A maxi-
mum gap of 1 mm (3/64 in) is allowed.
Torque the exhaust clamp no. 4 to 11 Nm
(97 lbfin) while maintaining the exhaust pipe in
the proper position.
Reinstall the muffler (LH) strap no. 11 using the
spring installer/remover (P/N 529 035 559). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube.
Torque the two clamps located in the upper part
of the muffler (LH) hose to 8 Nm (71 lbfin). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube.
Reconnect the water lines to the exhaust pipe and
torque to 8 Nm (71 lbfin).
water to the exhaust cooling system when water-
After installation, ensure there is no water or exhaust
gas leak when engine is running. Test run the engine
while supplying water to the flushing connector.
EXHAUST MANIFOLD
Removal
Supercharged Models
Remove plastic resonator.
1. Plastic resonator
2. Disconnect here
All 4-TEC Engines
Disconnect the cooling hoses no. 2 and no. 3
from the exhaust pipe no. 1.
Remove the exhaust clamp no. 4 and detach the
muffler (LH) from its support. Move the muffler
(LH) no. 6 rearwards to separate the exhaust pipe
from the manifold. See above in EXHAUST PIPE.
Disconnect the cooling system supply hose no. 8
underneath the front part of the exhaust manifold.
1. Exhaust manifold
2. Cooling system supply hose location
1 F18D0XA 2 3
1
F18D2VA
2 2
1 R1503motr151A 2
05-04-6 SMR2003-016_05_04A.FM
Unscrew the exhaust manifold no. 9 beginning
with the bottom screws. This will help holding the
manifold while you remove the screws.
Remove the manifold and move it out toward the
front of the watercraft to withdraw.
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 deforma-
tion 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.
Installation
procedures. However, pay particular attention to
the following:
NOTE: There is no gasket between engine block
and exhaust manifold.
Apply Loctite 518 on threads of screws.
To help holding the manifold while installing
screws, first insert the exhaust manifold into the
exhaust pipe no. 1 then, install the upper front
screw. Continue with the remaining screws.
Torque screws to 10 Nm (88 lbfin) as per follow-
ing illustrated sequence. Repeat the procedure,
torquing screws again to 10 Nm (88 lbfin).
water to the exhaust cooling system when water-
After installation, ensure there is no coolant or ex-
haust gas leak when the engine is running. Test run
the engine while supplying water to the flushing con-
nector.
MUFFLER (LH)
Removal
Remove the exhaust pipe no. 1. See above.
Disconnect the temperature sensor connector.
Disconnect the outlet hose.
1. Temperature sensor connector
2. Outlet hose
F18D0LA
R1503motr152A
7 5 1 3 9 11
8 6 4 2 10 12
1 F18D0MA 2
SMR2003-016_05_04A.FM 05-04-7
Detach the strap no. 11 from the muffler (LH) using
1. Muffler (LH)
2. Strap
Carefully pull out the muffler (LH) no. 6.
Inspection
Inspect parts condition paying attention for cracks or
other damage. Check hoses. Replace any defective
part.
Installation
Installation is the reverse of the removal procedures.
nector.
MUFFLER (RH)
Removal
Supercharged Models
Disconnect plastic resonator from muffler.
All 4-TEC Engines
Loosen both exhaust hose clamps no. 15 and discon-
nect the exhaust hoses no. 7 and no. 16 from the
muffler (RH) no. 10.
1. Disconnect inlet and outlet hoses from muffler (RH)
Detach the strap no. 12 from the muffler (RH) using
1. Muffler (RH)
2. Strap
Carefully pull out the muffler (RH) no. 10.
A00C3SA
2 F18D0JA 1 3
1 F18D0NA
A00C3SA
3 F18D0OA
2 1
05-04-8 SMR2003-016_05_04A.FM
Inspection
Inspect parts condition paying attention for cracks
or other damage. Check hoses. Replace any defec-
tive part.
Installation
Installation is the reverse of the removal procedures.
nector.
EXHAUST OUTLET
Removal
Remove the muffler (LH) no. 6. See above.
Remove the jet pump as an assembly from pump
support. Refer to PROPULSION SYSTEM.
From outside of hull, unscrew nut no. 13 with the
exhaust outlet tool (P/N 295 000 132).
TYPICAL
1. Exhaust outlet nut
2. Tool
From inside the bilge, pull out the exhaust hose
no. 7 and the adapter no. 14 together.
Detach the adapter no. 14 from the exhaust hose
no. 7.
Inspection
Inspect parts condition paying attention for cracks or
other damage. Check hose. Replace any defective
part.
Installation
Installation is essentially the reverse of the removal
procedures. However, pay particular attention to the
following:
Apply Loctite silicone sealant (P/N 293 800 086)
on the adapter flange to seal the bilge.
Test the bilge for water leaks.
F01B2AA
1
F18D0PA 2
SMR2003-017_05_05A.FM 05-05-1
GENERAL
Engine removal is necessary to repair BOTTOM
END.
ENGINE REMOVAL
035 844) and release the fuel pressure in the fuel sys-
tem. Refer to ENGINE MANAGEMENT section.
In order to remove engine from watercraft proceed
as follows.
First, disconnect battery cables from battery.
It is recommended to disconnect electrical con-
nections prior to disconnecting fuel lines.
Disconnect magneto wiring harness.
Disconnect the throttle position sensor (TPS),
manifold air pressure sensor (MAPS) and manifold
air temperature sensor (MATS) (refer to INTAKE
section).
Refer to ENGINE MANAGEMENT for location of sen-
sors and connectors.
O.P.A.S.
To disconnect O.P.A.S., refer to STEERING section.
Jet Pump Removal
To withdraw jet pump, refer to PROPULSION
section.
CAUTION: Whenever removing engine from
watercraft, engine/jet pump alignment must be
performed at reinstallation.
Drive System
To withdraw drive shaft, refer to PROPULSION
section.
Cooling System
To remove cooling system hoses, refer to COOL-
ING SYSTEM section
Exhaust Pipe
To remove exhaust pipe, refer to EXHAUST SYS-
TEM in ENGINE section.
Intake Manifold
To remove intake manifold, refer to INTAKE sec-
tion.
On Supercharged models, remove inlet tube
from supercharger and air duct.
Engine Support
NOTE: Be careful when removing engine sup-
port(s) or rubber mount adapters, shims could
have been installed underneath. Shims control
engine/jet pump alignment. Always note position
of shims for reinstallation, to avoid altering engine
alignment.
Remove engine support mount screws.
FRONT SUPPORT
1. Remove screw
WARNING
1 F18D13A
05-05-2 SMR2003-017_05_05A.FM
REAR SUPPORT
1. Remove screws
Lifting Engine
ment, slightly lift engine to ease the remaining com-
ponent removal.
CAUTION: Take care not to damage cables.
TYPICAL
1. Transport brackets
Removal of Remaining Components
Disconnect RED positive cable from starter post.
TYPICAL
Carry on engine lifting to remove from the body
opening.
CAUTION: Be careful not to scratch body or to
hit any component.
NOTE: An engine stand may be used to hold en-
gine.
1 F18D14A
1
F18D11A
1
1 F18D12A
F00B1XA
SMR2003-017_05_05A.FM 05-05-3
CLEANING
Wipe off any spillage in bilge. Clean with a bilge
cleaner.
Clean external parts of engine.
INSTALLATION
Installation of engine in watercraft is essentially
the reverse of removal procedures. However pay
particular attention to the following.
Rubber Mount, Shim and Screw
Check tightness and condition of rubber mounts.
If they have been removed, apply Loctite 243 (blue)
on screw threads. Torque screws to 25 Nm
(18 lbfft).
CAUTION: Strict adherence to this torque is im-
portant to avoid damaging threads of alumi-
num insert in bilge.
Engine Support
Positive Starter Cable
Torque nut of positive starter cable to 7 Nm
(62 lbfin). Apply dielectric grease on nut.
Engine/Jet Pump Alignment
Alignment is necessary to eliminate possible vi-
bration and/or damage to components. Check
alignment of engine using the following alignment
tools.
Support plate kit (P/N 529 035 506) and plate (P/N
529 035 507).
1. Plate
2. Support
Alignment shaft (P/N 295 000 141).
1. Alignment shaft
Engine alignment adapter (P/N 529 035 719).
1. Engine alignment adapter
1
1
1
Loctite 243
Loctite
243
Loctite
243
F18D10A
F00B0FA 1 2
F00B0GA 1
1 F18D16A
05-05-4 SMR2003-017_05_05A.FM
To verify alignment proceed as follows:
Secure plate and support to hull with four nuts.
TYPICAL
Install adapter (P/N 529 035 719) on drive shaft.
Carefully slide shaft through support.
Insert shaft end into engine alignment adapter.
NOTE: Ensure the protective hose and carbon
ring (or seal carrier) is removed to check engine
alignment. If the alignment is correct, the shaft will
slide easily without any deflection in engine align-
ment adapter.
TYPICAL
2. Alignment shaft
screws to enable to align engine alignment adapt-
er with shaft end.
TYPICAL
1. Shim
alignment, never install more than 5 mm (0.196 in)
shim thickness.
F00B0HA
1 F18D18A
1 F18D17A 2
1 F18D15A
SMR2003-017_05_05A.FM 05-05-5
Engine Support Screws
Apply Loctite 243 (blue) (P/N 293 800 060) on
screw threads.
Torque engine support screws to 25 Nm (18 lbfft)
when procedure is completed.
Properly align exhaust pipe. Refer to EXHAUST
SYSTEM in ENGINE section.
Final Inspection
Check throttle cable condition and lubricate it with
BOMBARDIER LUBE lubricant.
After its installation, properly adjust throttle cable as
specified in ENGINE MANAGEMENT.
Check hose condition and pressure test fuel sys-
tem, refer to FUEL SYSTEM section.
Verify all electrical connections.
Run engine and ensure there is no leakage.
1
1
1
Loctite 243
Loctite
243
Loctite
243
F18D10A
1 F18D13A
WARNING
are disconnected, a pressure test must be done
before starting engine.
1 F18D14A
Subsection 06 (PTO HOUSING/MAGNETO)
SMR2003-018_05-06A.FM 05-06-1
PTO HOUSING/MAGNETO 0
R1503motr262S
Loctite
243
10 Nm
(88 lbfin)
1
10 Nm
(88 lbfin)
Oil
22
11
Oil
3
10 Nm
(88 lbfin)
Loctite
243
Multi-purpose
grease
23
4-TEC
Supercharged
only
Loctite 648
10
3 Nm
(26 lbfin)
Left handed
thread
Oil
4
10 Nm
(88 lbfin)
Loctite
243
Oil
5
18 Nm
(159 lbfin)
Loctite
243
12 Nm
(106 lbfin)
Oil
Loctite
243
10 Nm
(88 lbfin)
Loctite
5910
21
20
19
13
12
17
9
15 18
14
10 Nm
(88 lbfin)
Loctite 243
24 Nm
(21 lbfft)
7
6
8
Oil
Loctite
243
16
Oil
250 Nm
(184 lbfft)
Loctite
anti-seize
2
05-06-2 SMR2003-018_05-06A.FM
GENERAL
Always perform the electric tests before removing
or installing any components.
Clean threads before using Loctite when installing
the screws.
PTO HOUSING
Removal
NOTE: When drive shaft will be removed, some oil
will flow out. To prevent it, start engine, run at 4000
RPM for 10 seconds and stop engine at this RPM.
This will move oil out of PTO housing into oil tank.
Drain engine oil. Refer to LUBRICATION in ENGINE
section.
If engine cannot be started, up to 1 L (34 oz) could
flow out at PTO housing removal. To prevent this,
follow instructions REMOVING OIL IN PTO HOUS-
ING WHEN ENGINE CANNOT BE STARTED be-
low. Otherwise, skip to instructions PTO HOUSING
REMOVAL below.
Removing Oil in PTO Housing when Engine
cannot be Started
1. Remove the scavenge oil pump cover drain plug
and install a fitting (P/N 293 710 037).
1. Scavenge oil pump cover drain plug
2. Connect the oil vac tool Bombardier (P/N 529 035
880) to the fitting.
3. The front of the engine must be tilted down ap-
proximately 15 degrees to facilitate the removal
of the oil. Raise the rear of the watercraft ac-
cordingly. Siphon the oil from the fitting.
4. When done, remove the oil vac tool and the fit-
ting. Apply Loctite 243 and reinstall the drain plug.
NOTE: If spillage occurs, clean immediately with
the pulley flange cleaner (P/N 413 711 809) to pre-
vent oil stains.
PTO Housing Removal
Place rags under PTO housing to prevent spillage.
Up to 250 mL (8 oz) of oil could flow out when re-
moving PTO housing. If spillage occurs, clean imme-
diately with the pulley flange cleaner (P/N 413 711
809) to prevent oil stains.
Disconnect CPS and magneto generator from wir-
ing harness.
1 F18D19A
WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK nega-
tive cable first. Disconnect electrical connec-
tions prior to disconnecting fuel lines.
F18D2PA
SMR2003-018_05-06A.FM 05-06-3
Remove:
jet pump
(refer to JET PUMP in PROPULSION SYSTEM)
drive shaft (refer to DRIVE SYSTEM in PROPUL-
SION SYSTEM)
slightly lift rear part of engine and safely block in
this position. Remove rear LH side engine support
no. 1.
TYPICAL
1. Engine support
Remove:
thru-hull fitting boot
1. Thru-hull fitting boot
2. Remove this collar
coolant pump housing no. 2
(refer to COOLING SYSTEM)
screws nos. 3 and 4
NOTE: Carefully separate the PTO housing from
the engine using two flat screwdrivers prying
equally at the same time. Proceed slowly so that
starter gear disc springs no. 6 and washer no. 7
do not fall down.
PTO housing no. 5
CAUTION: Ensure to use prying lugs to sepa-
rate PTO housing to prevent damaging contact
surface.
1. Disc springs
2. Washer
3. Flange washer
4. Starter drive gear
gasket no. 9.
Inspection
Check PTO housing for cracks or other damages.
Replace if necessary.
Installation
NOTE: Clean all metal component in a non-ferrous
metal cleaner.
For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: Turn the oil/coolant pump shaft in the right
position to fit into the balance shaft.
1
R1503motr50A
1 F18J0BA
2
WARNING
Wear safety glasses and work in a well venti-
lated area when working with strong chemical
products. Also wear suitable non-absorbent
gloves to protect your hands.
R1503motr263A
2 1
3
4
05-06-4 SMR2003-018_05-06A.FM
Position the disc springs no. 6 and washer no. 7
as per the following illustration.
1. Washer
2. Disc spring
3. Flange washer
4. Starter drive assy
CAUTION: Ensure the starter drive gear shaft is
well engaged in its bore.
Gently install PTO housing.
CAUTION: While installing housing, pay partic-
ular attention that gasket does not get pinched
or slide out of its contact surface in the area
shown in the following illustration. Never force
to install cover. If there is a strong resistance,
remove housing and check oil/coolant pump
alignment and starter gear alignment.
1. Pay attention that gasket remains properly positioned on this
surface
Refer to the following illustration for proper installa-
tion of screws.
1. Screws M6 x 35
2. Screws M6 x 85
Tightening sequence for screws on PTO housing is
as per following illustration.
Reinstall LH engine support. Apply Loctite 243 (blue)
on screw threads then torque to 24 Nm (17 lbfft).
Remove block under engine.
Properly reinstall chain tensioner. Refer to ENGINE
BLOCK subsection.
Properly reinstall valve cover. Refer to CYLINDER-
HEAD AND VALVES subsection.
Refill engine with oil and cooling system with cool-
ant. Refer to ENGINE and COOLING SYSTEM sec-
tions. Check engine alignment. Refer to REMOVAL
AND INSTALLATION in ENGINE section.
R1503motr46A
1 2 3 4
1
F18D2LA
R1503motr15A
1
1
1
2
2
2
2
2
R1503motr15B
14 15
16
17
18
19
20
21
2 3 4
5
6
7
8
9
10 11 1 12 13
SMR2003-018_05-06A.FM 05-06-5
PTO SEAL
Inspection
Check the PTO seal no. 22 and O-rings no. 10 on
the PTO housing. If brittle, hard or damaged, or if
you see a sign of oil leakage, replace it.
Removal
NOTE: When drive shaft will be removed, some
oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank.
If spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent oil
stains.
Remove:
Oetiker clamp no. 11 located close to the PTO
housing
jet pump (refer to JET PUMP in PROPULSION
SYSTEM)
drive shaft (refer to DRIVE SYSTEM in PROPUL-
SION SYSTEM)
PTO seal no. 22.
TYPICAL
1. Oetiker clamps
2. PTO seal
Installation
Reinstall removed parts in the reverse order.
COUPLING
Removal
Lock crankshaft with locking tool (P/N 529 035 821).
Refer to CRANKSHAFT LOCKING in ENGINE BLOCK
subsection.
Remove:
jet pump
drive shaft
PTO seal as described above
coupling no. 12 using impeller remover/installer
(P/N 529 035 820).
CAUTION: Apply some oil on the tool to protect
the seal located in the PTO coupling.
TYPICAL
Inspection
Check if seal no. 13 is brittle, cracked or hard. Check
coupling for worn splines.
If damaged, replace faulty part.
1 R1503motr47A
2
R1503motr48A
R1503motr49A
05-06-6 SMR2003-018_05-06A.FM
Installation
Torque PTO coupling to 250 Nm (184 lbfft). Ap-
ply Loctite anti-seize on threads.
STATOR
Removal
Remove:
PTO housing (refer to PTO HOUSING REMOVAL
elsewhere in this section)
holding plate no. 14 with CPS no. 15
TYPICAL
1. CPS screws
2. Holding plate
3. CPS
screws no. 16
stator no. 17.
TYPICAL
1. Stator screws
2. Stator
Inspection
Check stator and CPS condition. If damaged re-
place the faulty part.
For electrical inspection, refer to CHARGING SYS-
TEM for the stator and to ENGINE MANAGEMENT
for the CPS.
Installation
NOTE: There is only one position for the stator
(notch in the magneto housing cover).
TYPICAL
1. Notch for stator
1
R1503motr21A
2
3
1
R1503motr26A
2
1 R1503motr51A
SMR2003-018_05-06A.FM 05-06-7
Place the rubber grommets on both cables in the
proper notches at the PTO housing.
TYPICAL
1. Grommet on CPS cable
2. Grommet on stator cable
Apply Loctite 243 on threads.Torque stator and
CPS screws to 10Nm (88 lbfin).
ROTOR AND ENCODER WHEEL
Removal
subsection.
Remove:
PTO housing
hexagonal screws no. 18 retaining rotor.
Withdraw rotor no. 19 with encoder wheel no. 20.
TYPICAL
1. Hexagonal screws
2. Rotor
3. Encoder wheel
Inspection
Check rotor, bent teeth and encoder wheel condi-
tion. If damaged, replace faulty part.
Installation
Encoder wheel position has to be located with the
location pin on the crankshaft gear.
IMPORTANT: If rotor has balancing holes, never
install it so that they are inside the large gap be-
tween encoder wheel teeth. This would create a
non-starting condition of the engine.
1
R1503motr52A
2
1
R1503motr53A
2
3
1
05-06-8 SMR2003-018_05-06A.FM
WRONG INSTALLATION
1. Rotor
2. Balancing holes
3. Encoder wheel
4. Large gap
Apply Loctite 243 on threads.Torque rotor screws
RING GEAR
Removal
subsection.
Remove:
PTO housing cover
hexagonal screws no. 18.
Withdraw rotor no. 19, encoder wheel no. 20 and
starter ring no. 21.
TYPICAL
1. Hexagonal screws
2. Rotor
3. Encoder wheel
4. Ring gear
Inspection
Check ring gear condition, especially teeth condi-
tion. If damaged, replace faulty part.
Installation
Ring gear and encoder wheel position has to be lo-
cated with the location pin on the crankshaft gear.
TYPICAL
1. Location pin
2. Location pin holes
Apply Loctite 243 on threads.Torque rotor screws
1 F18D0AA 2 3
4
1
R1503motr54A
2
3
4
1
R1503motr54B
2
SMR2003-018_05-06A.FM 05-06-9
STARTER DRIVE ASSY
Removal
Remove:
PTO housing and ring gear as described above
starter drive assy no. 8.
1. Starter drive assy
CAUTION: Be careful not to lose the distance
washer, disc springs no. 6 and washer no. 7 lo-
cated on the starter drive shaft.
1. Disc springs
2. Washer
3. Flange washer
4. Starter drive gear
Inspection
Check condition of the teeth, shaft, etc. and if the
sprag clutch operates well. If damaged, replace faulty
part.
Installation
Apply some Isoflex Topas NB52 grease (P/N 293
550 021) on the starter drive bearing located in the
engine block and on the starter drive support in the
PTO housing cover.
1. Starter drive bearing
TYPICAL
1. Starter drive support
CAUTION: Be sure not to forget the distance
washer, disc springs and washer on the starter
drive shaft when assembling.
1
R1503motr55A
R1503motr263A
2 1
3
4
1
R1503motr56A
R1503motr45A
1
05-06-10 SMR2003-018_05-06A.FM
4-TEC Supercharged Models
OIL SPRAY NOZZLE
Removal
Remove the PTO housing as described above:
Turn oil spray nozzle no. 23 by using a grip plier
to crack the Loctite.
CAUTION: Do not try to pull out the oil spray
nozzle with a plier. This may damage the force
fit in the PTO housing.
Fix supercharger spray nozzle remover tight on
oil spray nozzle.
1. Oil spray nozzle
2. Spray nozzle remover
Remove oil spray nozzle carefully by using a slide
hammer puller.
Installation
Apply Loctite 648 on oil spray nozzle fitting surface.
CAUTION: The oil spray nozzle must be in ex-
act position to supply enough oil to the super-
charger. Any other installation will lead to a su-
percharger damage.
Only use supercharger spray nozzle installer to
push in the nozzle no. 23. Use retaining screw
hole to ensure the exact position.
1. Spray nozzle installer
2. Screw hole for positioning
1
R1503motr264A
2 1
R1503motr265A
2
Subsection 07 (LUBRICATION SYSTEM)
SMR2003-019_05_07A.FM 05-07-1
LUBRICATION SYSTEM 0
Multi-purpose
grease
Engine
oil
10 Nm
(89 lbfin)
3 Nm (27 lbfin)
Left handed threads
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
24 Nm
(18 lbfft)
Engine oil
Engine oil
Loctite
243
Engine oil
Loctite
243
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
12 Nm
(106 lbfin)
Loctite 243
10 Nm (89 lbfin)
1
2
3
4
19
18
17
16
15
39
23
24
22
21
6
Loctite
243
Loctite
5910
Loctite
243
5
Loctite 243
25
26
25
20
Loctite
243
18 Nm
(159 lbfin)
Engine oil
4-TEC Supercharged
only
R1503motr273S
05-07-2 SMR2003-019_05_07A.FM
34
35
37
Loctite 243
18 Nm
(159 lbfin)
10 Nm
(89 lbfin)
36
38
40
27
28
42
12
Loctite 243
10 Nm
(89 lbfin)
18 Nm
(159 lbfin)
Loctite 243
10 Nm
(89 lbfin)
Loctite 243
10 Nm
(89 lbfin) 11
10
10 Nm
(89 lbfin)
5-25 Nm
(44-221 lbfin)
Horizontal
to exhaust side
9
Loctite 243
Loctite 243
10 Nm
(89 lbfin) Loctite 243
8
Loctite
243
10 Nm
(89 lbfin)
Loctite 243
13
14
Loctite 243
10 Nm
(89 lbfin)
18 Nm
(159 lbfin)
R1503motr113S
Oil
Oil
Oil
Oil
Oil
Oil
Oil
29
30
7
SMR2003-019_05_07A.FM 05-07-3
GENERAL
Prior to changing the oil, ensure vehicle is on a
level surface.
Oil and oil filter must be replaced at the same time.
Oil change and oil filter replacement should be done
with a warm engine.
Dispose oil and filter as per your local environmen-
tal regulations.
OIL LEVEL VERIFICATION
CAUTION: Check level frequently and refill if
necessary. Do not overfill - it would make the
engine smoke and reduce its power. Operating
the engine with an improper level may severely
damage engine. Wipe off any spillage.
1. Dipstick
Check the oil level as follows:
NOTE: Before checking the oil level on this en-
gine, it is necessary to let it idle for 30 seconds
before shutting it off. Thereafter it is necessary to
wait 30 seconds. Then, the oil can be checked.
This is required to allow the oil to properly level in
the different oil chambers. Otherwise, you will
have a false oil level reading.
1. Watercraft must be level. Check oil level either
with watercraft in water or out of water. Engine
should be warm.
2. If out of water, raise trailer tongue and block in
position when bumper rail is level. Link a garden
hose to the flushing connector. Refer to FLUSH-
ING in MAINTENANCE and follow the proce-
dures.
CAUTION: Failure to flush exhaust cooling sys-
tem, when watercraft is out of water, may se-
verely damage engine and/or exhaust system.
3. Warm-up engine then let idle for 30 seconds
before stopping.
4. Stop engine.
5. Wait at least 30 seconds then pull dipstick out
and wipe clean.
utes. Drive line seal has no cooling when water-
6. Reinstall dipstick, push in completely.
WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.
F18D04A
1
WARNING
Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
rect contact may result in skin burn.
05-07-4 SMR2003-019_05_07A.FM
7. Remove dipstick and read oil level. It should be
between marks.
1. Full
2. Add
3. Operating range
8. Otherwise, add oil until its level is between
marks as required.
9. To add oil, unscrew oil cap. Place a funnel into
the opening and add the recommended oil to
the proper level. Do not overfill.
NOTE: Before checking the oil level on this en-
gine, it is necessary to let it idle for 30 seconds
before shutting it off. Thereafter it is necessary to
wait 30 seconds. Then, the oil can be checked.
This is required to allow the oil to properly level in
the different oil chambers. Otherwise, you will
have a false oil level reading.
ENGINE OIL PRESSURE TEST
NOTE: The engine pressure test should be done
with a warm engine and the recommended oil.
Remove plug below oil filter housing.
Use oil pressure gauge (P/N 529 035 709) and hose
adaptor (P/N 529 035 652) and install where shown.
Start engine and read pressure at different RPM
as per following table.
1. Oil filter housing
2. Pressure test plug
NOTE: Oil pressure switch works between 180 kPa
(26 PSI) and 220 kPa (32 PSI).
The engine oil pressure should be within the follow-
ing values.
If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
ING section.
Reinstall plug.
Oil Change
Engine in Vehicle
NOTE: If water is found in oil (oil will be milky),
refer to submerged engine in MAINTAINANCE
section and follow the procedure to flush it.
Bring engine to its normal operating temperature.
F18D2MA
1
2
3
OIL PRESSURE TEST
ENGINE RPM PRESSURE kPa (PSI)
Idle (cold) 300 - 400 (44 - 58)
Idle (at 80C (176F) min. 160 (23)
4000 - 7500 300 - 400 (44 - 58)
1 F18G03A 2
SMR2003-019_05_07A.FM 05-07-5
CAUTION: Failure to flush exhaust cooling sys-
tem, when engine is out of water, may severely
damage engine and/or exhaust system.
utes. Drive line seal has no cooling when wa-
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.
Using the Oil VAC (P/N529 035 880), siphon oil
through dipstick hole.
CAUTION: Never crank or start engine when si-
phon tube is in dipstick hole. Never start engine
when there is no oil in engine.
NOTE: So that siphon tube is located at the proper
height to siphon oil, it is suggested to put some
electrical tape on siphon tube at 475 mm (18.7 in)
from its end. Then, insert siphon tube until you
reach the tape.
1. Oil VAC
2. Siphon tube in dipstick hole
Pull siphon 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. Re-
peat the crank-siphon cycle 2 - 3 times.
Inspection
Oil condition gives information about the engine
condition. See TROUBLESHOOTING section.
Installation
Reinstall removed parts and fill in the new engine oil.
Oil Type and System Capacity
Refer to TECHNICAL DATA. For refilling procedure,
refer to OIL LEVEL VERIFICATION above.
OIL FILTER
Removal
Remove:
engine oil (refer to OIL CHANGE)
oil filter screw no. 1
oil filter cover no. 2
oil filter no. 3.
TYPICAL
1. Oil filter screw
2. Oil filter cover
3. Oil filter
WARNING
Engine oil may be hot. Certain components in
the engine compartment may be very hot. Di-
rect contact may result in skin burn.
2
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05-07-6 SMR2003-019_05_07A.FM
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.
Inspection
Check oil filter cover O-ring no. 4 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. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system
Installation
For installation, reverse the removal procedure. Pay
attention to the following details.
Install a new oil filter.
Install O-ring on oil filter cover.
TYPICAL
Torque oil filter screw to 9 Nm (80 lbfin).
OIL STRAINERS
The oil strainers do not need to be cleaned at every
oil change. Clean them during other inspections,
especially when the engine is disassembled.
PTO Oil Strainer
Removal
Remove:
PTO cover no. 5
(refer to PTO COVER/MAGNETO section)
oil strainer no. 6.
1. Oil strainer
WARNING
1 R1503motr115A 2
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1
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SMR2003-019_05_07A.FM 05-07-7
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 oth-
er contaminations.
1. Oil inlet to the oil pump
Installation
Refill engine at the proper level with the recom-
mended oil. Refer to TECHNICAL DATA for capacity
and OIL LEVEL VERIFICATION above for procedure.
Suction Pump Oil Strainer
Removal
Remove TOPS ventilation hose no. 7.
TYPICAL
1. TOPS ventilation hose
Disconnect wiring harness from TOPS valve
no. 8 and OSPS no. 9.
Detach air silencer from throttle body.
Disconnect battery cables and vent tube then re-
move battery. Refer to BATTERY in CHARGING
SYSTEM section for proper procedures.
Remove retaining screws no. 10 and no. 11.
Place rags under cover to prevent spillage. If
spillage occurs, clean immediately with the pul-
ley flange cleaner (P/N 413 711 809) to prevent
stains.
WARNING
Always wear eye protector. Chemicals can
cause a rash break out in and an injury to your
eyes.
1 R1503motr118A
WARNING
1
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05-07-8 SMR2003-019_05_07A.FM
Remove suction pump cover with oil separator.
Remove oil strainer no. 12.
1. Oil strainer
Cleaning and Inspection
Clean oil strainer with a part cleaner then use an
air gun to dry it.
Inspect rubber rings no. 13 and no. 14.
1. O-ring
2. Rubber ring gasket
If rubber rings are brittle, cracked or hard, replace
them.
Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
1. Oil inlet to the oil pump
Installation
Position screws according to their length as shown.
1. Screws M6 x 25
2. Screws M6 x 85
WARNING
Always wear eye protector. Chemicals can
cause a rash break out in and an injury to your
eyes.
1 R1503motr120A
1
R1503motr121A
2
1 R1503motr122A
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SMR2003-019_05_07A.FM 05-07-9
Torque suction pump cover screws to 10 Nm
(88 lbfin) as per sequence illustrated below. Ap-
ply Loctite 243 on threads.
ENGINE OIL PRESSURE
REGULATOR
The oil pressure regulator is located on the bottom
of the PTO housing.
1. Oil pressure regulator
NOTE: The oil pressure regulator system opens
when the oil pressure exceeds 400 kPa (58 PSI).
Removal
Remove:
oil pressure regulator plug no. 15, compression
spring no. 16, valve piston no. 17 and valve pis-
ton guide no. 18.
1. Valve piston guide
2. Valve piston
3. Compression spring
4. Oil pressure regulator plug
Inspection
Inspect valve piston and valve piston guide for scor-
ing or other damages.
Check compression spring for free length.
Replace parts if important wear or damage are
present.
Clean bore and threads in the PTO housing from
metal shavings and other contaminations.
Installation
Pay attention to the following details.
Be careful that the O-ring on plug screw is in place.
Torque plug screw to 12 Nm (106 lbfin) maxi-
mum. Apply Loctite 243 on threads.
1
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3
4
6
2
5
1
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WARNING
Oil pressure regulator plug on oil pump housing
is spring loaded.
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 60 mm (2.362 in)
SERVICE LIMIT 50.3 mm (1.980 in)
1 R1503motr124A 2 3 4
05-07-10 SMR2003-019_05_07A.FM
OIL PRESSURE PUMP
The oil pressure pump is located in the PTO hous-
ing and is driven by the balance shaft.
Removal
Remove:
PTO housing
(refer to PTO HOUSING/MAGNETO section)
coolant pump housing no. 19 and impeller no. 20
(refer to COOLING SYSTEM section)
screws no. 21
oil pump cover no. 22
1. Screws
2. Oil pump cover
outer oil pump rotor no. 23
1. Outer oil pump rotor
extract the coolant/oil pump shaft no. 24 from
outside PTO housing with a pusher
remove rotary seal no. 25 with a screwdriver
TYPICAL
CAUTION: Be careful not to damage the surface
of the rotary seal bore in PTO housing cover.
oil seal no. 26.
1. Oil seal
Inspection
Inspect oil pump shaft assembly, housing and cov-
er for marks or other damages.
Check inner rotor for corrosion pin-holes or other
damages. If so, replace oil pump shaft assembly.
Ensure to also check oil pump housing and cover
and replace if damaged.
1 R1503motr125A
2
1
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1
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SMR2003-019_05_07A.FM 05-07-11
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-
tween inner and outer rotors.
1. Outer rotor
2. Inner rotor
If clearance between inner and outer rotors ex-
ceeds the tolerance, replace coolant/oil pump shaft
assembly. 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.
1. PTO housing surface
2. Vernier depth gauge
1. Oil pump outer rotor surface
2. Vernier depth gage
Difference between pump housing and outer rotor
should not exceed 0.1 mm (.004 in). If so, replace
replace the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.
OUTER AND INNER ROTOR CLEARANCE
mm (in)
SERVICE LIMIT
A
0.25 mm (.009 in) B
C
1 R1503motr129A
2 R1503motr130A 1
C
A
B
1 R1503motr131A 2
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05-07-12 SMR2003-019_05_07A.FM
Installation
NOTE: Never use oil in the press fit area of the ro-
tary seal.
Push coolant/oil pump shaft seal in place by using
thumb.
1. Oil seal
Install the new rotary seal by using the rotary seal
pusher (P/N 529 035 823).
CAUTION: Never use a hammer for the rotary
seal or coolant/oil pump shaft installation. Only
use a press to avoid damaging the ceramic com-
ponent.
TYPICAL
1. Rotary seal
2. Rotary seal pusher
Install the coolant/oil pump shaft using the rotary
seal pusher (P/N 529 035 823) on the opposite
side to support the rotary seal. Use the oil seal
guide (P/N 529 035 822) with a press.
1. Oil seal guide
2. Coolant/oil pump shaft
1. Coolant/oil pump shaft with oil seal guide
2. Rotary seal pusher
Tighten oil pump cover screws and torque to 10 Nm
(88 lbfin). Apply Loctite 243 on threads.
Final Test
After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations.
1
R1503motr128A
1 R1503motr141A 2
1 R1503motr142A 2
2 R1503motr143A
1
SMR2003-019_05_07A.FM 05-07-13
OIL SUCTION PUMP
The oil suction pump is located on the front side
of the engine at the bottom of the oil separator.
Removal
TYPICAL
Disconnect wiring harness from OSPS no. 9
and TOPS valve no. 8.
Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
ING SYSTEM section for proper procedures.
Remove retaining screws no. 42.
stains.
Remove oil suction pump housing with oil sep-
arator.
Remove oil pump screws no. 27 and cover no. 28.
1. Oil pump cover
Remove oil pump shaft assy no. 29.
Remove outer rotor no. 30.
1. Oil pump shaft assy
2. Outer rotor
WARNING
1
R1503motr133A
1 R1503motr135A
1 R1503motr136A 2
05-07-14 SMR2003-019_05_07A.FM
Inspection
Inspect oil pump shaft assembly, housing and cov-
er for marks or other damages.
Check inner rotor for corrosion, pin-holes or other
damages. If so, replace oil pump shaft assembly.
Ensure to also check oil pump housing and cover
and replace if damaged.
1. Pittings on the teeth
Using a feeler gauge, measure the clearance be-
tween inner and outer rotors.
1. Outer rotor
2. Inner rotor
If clearance between inner and outer rotors ex-
ceeds the tolerance, replace oil pump shaft as-
sembly. 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 com-
plete oil pump and the PTO housing.
Using a vernier depth gage, measure side wear as
shown.
1. Oil pump housing surface
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 de-
creases.
Check the inside of oil pump housing and its cover
for scoring or other damages and replace if dam-
aged.
OUTER AND INNER ROTOR CLEARANCE
mm (in)
SERVICE LIMIT
A
0.25 mm (.009 in) B
C
1
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C
B
A
2 R1503motr139A 1
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SMR2003-019_05_07A.FM 05-07-15
Installation
1. Screws M6 x 85
2. Screws M6 x 25
Torque oil pump cover screws to 10 Nm (88 lbfin).
Tighten suction pump screws as per following se-
quence and torque to 10 Nm (88 lbfin). Apply
Loctite 243 (blue) on threads.
OIL COOLER
The oil cooler is located below the air intake man-
ifold.
TYPICAL
1. Oil cooler
Removal
Remove:
cooling hoses no. 34 and no. 35
retaining screws no. 36
oil cooler no. 37
1. Screws
2. Oil cooler
2
1
R1503motr134A 2
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1
4
5
8
6
7
3
2
1
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1
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2
05-07-16 SMR2003-019_05_07A.FM
O-rings no. 38.
1. O-rings
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.
Installation
Apply grease on O-rings.
Torque oil pump cover screws to 10 Nm (88 lbfin).
Apply Loctite 243 (blue) on threads.
OIL SEPARATOR
Pressure Test
Refer to ENGINE MANAGEMENT section.
Removal
TYPICAL
Disconnect wiring harness from TOPS valve
no. 8 and OSPS no. 9.
Disconnect battery cables and vent tube then
remove battery. Refer to BATTERY in CHARG-
ING SYSTEM section for proper procedures.
Remove retaining screws no. 42.
stains.
Remove suction pump cover with oil separator
assy.
Remove TOPS valve no. 8 from oil separator
assy. Refer to TOPS VALVE in ENGINE MAN-
AGEMENT section.
Completely disassemble oil separator assy.
1 R1503motr148A
WARNING
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SMR2003-019_05_07A.FM 05-07-17
Inspection
If O-rings and rubber rings are brittle, cracked or
hard, replace them.
Clean all contact surfaces of oil separator.
Check and clean the oil and blow-by channels for
dirt and other contaminations.
Installation
1. Screws M6 x 25
2. Screws M6 x 85
Apply grease on O-rings and rubber rings.
Torque screws to 10 Nm (88 lbfin). Apply Loctite
243 (blue) on threads.
1 R1503motr119A 2
Subsection 08 (CYLINDER HEAD AND VALVES)
SMR2003-020_05_08A.FM 05-08-1
CYLINDER HEAD AND VALVES 0
NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle.
Engine
oil
R1503motr245S
3
40 Nm (29.5 lbfft)
+ 120 + 90
10 Nm
(88 lbfin)
Loctite
243
Engine oil
4
5
10
11
10
1
6
8
Loctite
243
10 Nm
(88 lbfin)
Engine
oil
17
18
19
Loctite 243
10 Nm (88 lbfin)
26
27
Engine oil
20
Loctite
243
10 Nm
(88 lbfin)
9
18 Nm
(159 lbfin)
24
23
16
2
10 Nm
(88 lbfin)
18 Nm
(159 lbfin)
6 Nm
(53 lbfin)
21
Engine oil
15
13
10 Nm
(88 lbfin)
6 Nm
(53 lbfin)
Grease Klueber
Isoflex Topas NB52
7
Loctite 243
14
12
25
22
20 Nm (14.5 lbfft) + 90
05-08-2 SMR2003-020_05_08A.FM
GENERAL
NOTE: When diagnosing an engine problem, al-
ways perform a cylinder leak test. This will help
pin-point a problem. Refer to the instructions in-
cluded with your leak tester and LEAK TEST for
procedures.
Always place the vehicle on level surface.
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine from vehicle.
Always disconnect the negative wire from the bat-
tery before working on the engine.
Even if the removal of many parts is not necessary
to reach another part, it is recommended to re-
move these parts in order to check them.
For installation, use the torque values and Loctite
products as mentioned. Clean threads before us-
ing Loctite product when installing screws.
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.
SPARK PLUG
Removal
Remove fuel rail cover from engine.
Unplug the single-spark ignition coil connector on
the spark plug you need to remove.
Remove the single-spark ignition coil no. 1.
Clean spark plug and single-spark ignition coil area
before disassembly.
Unscrew spark plug no. 2 then use the single-
spark ignition coil to take spark plug out of spark
plug hole.
1. Single-spark ignition coil
2. Spark plug
Inspection
Check spark plug and single-spark ignition coil con-
dition (refer to ENGINE MANAGEMENT SYSTEM).
Installation
Check spark plug gap.
Place spark plug into single-spark ignition coil,
screw spark plug then remove the single-spark ig-
nition coil. Torque spark plug. Reinstall the single-
spark ignition coil.
NOTE: Prior to inserting the ignition coil in its lo-
cation, apply some BOMBARDIER LUBE lubricant
around the seal area that touches the spark plug
hole. After installation, ensure the seal seats prop-
erly with the engine top surface.
VALVE COVER
Removal
Remove:
valve cover shield no. 3
valve cover screws no. 4
1
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2
SMR2003-020_05_08A.FM 05-08-3
1. Valve cover screws
valve cover no. 5 and profile sealing ring no. 6.
1. Valve cover
2. Profile sealing ring
Inspection
Check if the profile sealing ring on the valve cover
and the rubber bushing on the valve cover screws
are brittle, cracked or hard. If so, replace the profile
sealing ring or the valve cover screw accordingly.
Installation
Check valve cover gasket. If there is a rubber tab
on chain guide side, cut it out.
CAUTION: Never assemble the cover on a gas-
ket having this tab. The tab must be cut out.
1. Cut this tab
NOTE: Install the valve cover screws according to
following sequence.
ROCKER ARM
Removal
Lock crankshaft with crankshaft locking tool
(P/N 529 035 821), refer to CRANKSHAFT LOCK-
ING in ENGINE BLOCK section.
1
R1503motr81A
1
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2
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3
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1 5
7
8 2 4 6
05-08-4 SMR2003-020_05_08A.FM
Remove:
spark plug
valve cover
spark plug tube no. 7
1. Spark plug tube
rocker arm shaft screws no. 8. Discard screws.
1. Rocker arm shaft screws
rocker arm shaft no. 9 with rocker arm assem-
bly (exhaust side no. 10 and intake side no. 11).
1. Rocker arm shaft
2. Rocker arms (exhaust side)
3. Rocker arm (intake side)
1. Oil supply from the camshaft to the rocker arm shaft, then to the
rocker arms and finally to the valve adjustment
Inspection
Spark Plug Tube
Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.
1. Spark plug tube
2. Seal to the valve cover
3. Seal to the cylinder head
1
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1
1
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2
3
1
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SMR2003-020_05_08A.FM 05-08-5
Rocker Arm
Inspect each rocker arm for cracks and scored fric-
tion 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.
1. Rocker arm (intake side)
2. Roller
A. Bore for rocker arm shaft
1. Rocker arm (exhaust side)
2. Roller
A. Bore for rocker arm shaft
Measure rocker arm bore diameter. If diameter is
out of specification, change the rocker arm assem-
bly.
Press the hydraulic lifter with your thumb. If the
hydraulic lifter groove disappears inside rocker
arm casting, replace rocker arm assembly. Lifter
must turn freely in rocker arm bore. Otherwise,
replace.
1. Hydraulic lifter groove
Rocker Arm Shaft
Check for scored friction surfaces, if so, replace parts.
Measure rocker arm shaft diameter.
A. Measure rocker arm shaft diameter here
Any area worn excessively will require parts replace-
ment.
ROCKER ARM BORE DIAMETER
A
1
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2
A
1
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ROCKER ARM SHAFT DIAMETER
1
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A
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05-08-6 SMR2003-020_05_08A.FM
Installation
Apply engine oil on rocker arm shaft.
IMPORTANT: The rocker arm shaft can only be
installed in one specific position. Therefore crank-
shaft as well as camshaft has to be positioned
with their locking pins when the piston of cylinder
no. 3 is on ignition TDC. Refer to CRANKSHAFT
LOCKING in ENGINE BLOCK section for crank-
shaft and the following for the camshaft locking.
Use camshaft locking tool (P/N 529 035 839). Ro-
tate camshaft so that tool can be pushed in cam-
shaft hole and lock camshaft in place.
Then, the camshaft sprocket lines should be lined
up as shown in the following illustration.
1. Position lines
Position the rocker arm shaft with the notches on
top.
1. Rocker arm shaft
2. Rocker arm shaft notches
Install NEW rocker arm shaft screws no. 8. Torque
as per following procedure:
CAUTION: 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 proce-
dure may cause screws to loosen and lead to
engine damage.
Torque screws at first to 10 Nm (88 lbfin) ac-
cording to following sequence.
Finish tightening screws turning an additional
90 rotation with a torque angle gauge.
R1503motr111A
1
1
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1
1
R1503motr91A
2
R1503motr93A
2
1 3 4
5
6
SMR2003-020_05_08A.FM 05-08-7
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 ap-
propriate.
Removal
Remove:
valve cover
chain tensioner
(refer to CHAIN TENSIONER REMOVAL in EN-
GINE BLOCK section)
chain guide no. 12
Allen screws no. 13
camshaft timing gear no. 14.
NOTE: Secure timing chain no. 15 with a retaining
wire.
Inspection
Check camshaft timing gear for wear or deteriora-
tion.
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft timing gear, refer to ENGINE BLOCK
section.
Installation
Using the camshaft locking tool (P/N 529 035 839),
lock camshaft on TDC position.
2. Camshaft on TDC position
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.
1. Good (with 1503 aligned)
2. Never
1
R1503motr92A
2
1
R1503motr94A
2
1
R1503motr97A
2
A
05-08-8 SMR2003-020_05_08A.FM
Install timing chain. Refer to ENGINE BLOCK sec-
tion.
Ensure chain guides are in place.
Loosely install 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 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.
Tighten screws and torque to 10 Nm (88 lbfin).
Remove locking tools.
CAUTION: Crankshaft and camshaft must be
locked on TDC position to place camshaft tim-
ing gear and timing chain in the proper posi-
tion. To double check, take a look at the timing
gear lines. They must be parallel to the cylinder
head surface.
1. Position lines
CAUTION: Ensure to remove locking tools when
finished.
TIMING CHAIN
Refer to ENGINE BLOCK section.
CYLINDER HEAD
Removal
Drain coolant (refer to COOLING SYSTEM).
Disconnect coolant temperature and camshaft po-
sition sensors (CTS and CAPS).
Remove:
exhaust manifold (refer to EXHAUST MANI-
FOLD REMOVAL elsewhere in this section)
engine hoses
TYPICAL
1. Coolant hose
chain tensioner
(refer to CHAIN TENSIONER REMOVAL in EN-
GINE BLOCK section)
valve cover shield
valve cover and profile sealing ring
(see VALVE COVER REMOVAL above)
camshaft timing gear
cylinder head screws M6 no. 16
1
R1503motr95A
1
1
R1503motr253A
2
SMR2003-020_05_08A.FM 05-08-9
1. Cylinder head screws M6
cylinder head screws M11 no. 17 retaining cyl-
inder head to engine block.
1. Cylinder head screws M11
Pull up cylinder head no. 18.
Remove gasket no. 19.
Cleaning
Remove carbon deposits from combustion cham-
ber, exhaust port and piston top.
Inspection
Check for cracks between valve seats, if so, replace
cylinder head.
Check mating surface between cylinder and cylin-
der head for contamination. If so, clean both sur-
faces.
Installation
Ensure dowel pins are in place.
Install new cylinder head gasket.
CAUTION: 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.
Install cylinder screws M11 no. 17. Torque screws
as per following procedure.
CAUTION: This assembly uses stretch screws.
As the screws have been stretched from the
previous installation, it is very important to
measure each screw at assembly. If screw is
out of specification, replace by a new. Failure
to replace screws and to strictly follow the
torque procedure may cause screws to loosen
and lead to engine damage.
Torque screws according to following sequence.
First torque to 40 Nm (30 lbfft).
Then tighten screws turning an additional 120 ro-
tation with a torque angle gauge and finish tight-
ening with a 90 rotation. Torque screws no. 16 to
10 Nm (88 lbfin).
1. Cylinder screws M11
2. Angle torque wrench
Remove crankshaft locking tool then install plug
with sealing ring.
1
R1503motr98A
1
R1503motr99A
CYLINDER SCREW M11
1
R1503motr100A
2
05-08-10 SMR2003-020_05_08A.FM
CAMSHAFT
Removal
Remove:
valve cover
rocker arms
chain tensioner (refer to CHAIN TENSIONER
REMOVAL in ENGINE BLOCK section)
camshaft timing gear
camshaft lock no. 20
camshaft no. 21.
1. Camshaft lock
2. Camshaft
Inspection
Check each lobe and bearing journal of camshaft
for scoring, scuffing, cracks or other signs of wear.
Measure camshaft bearing journal diameter and
lobe height using a micrometer.
Measure clearance between both ends of cam-
shaft and cylinder head.
A. Camshaft lobe (exhaust valves)
B. Camshaft lobe (intake valves)
C. Camshaft bearing journal
D. Camshaft bearing journal engine front
Replace parts that are not within specifications.
1
2
R1503motr101A
A
R1503motr102A
B C D A C A B C A C A B C A
CAMSHAFT LOBE - EXHAUST VALVE
NEW MINIMUM 31.699 mm (1.248 in)
NEW MAXIMUM 31.809 mm (1.252 in)
CAMSHAFT LOBE - INTAKE VALVE
CAMSHAFT BEARING JOURNAL
CAMSHAFT BEARING JOURNAL - ENGINE FRONT
CAMSHAFT BORE
MEASURED IN DIAMETER
CAMSHAFT BORE - ENGINE FRONT
MEASURED IN DIAMETER
SMR2003-020_05_08A.FM 05-08-11
Installation
Grease the camshaft bearing journals well by us-
ing the grease Klueber Isoflex (P/N 293 550 021)
or a similar product.
Install camshaft then place the camshaft lock no. 20
in the slot.
1. Camshaft lock position
For other parts, refer to proper installation proce-
dure.
VALVE SPRING
Removal
Remove:
rocker arms
cylinder head.
Compress valve springs no. 22 and no. 23. Use
valve spring compressor clamp (P/N 529 035 724)
and valve spring compressor cup (P/N 529 035
725).
1. Valve spring compressor clamp
2. Valve spring compressor cup
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF
THE VALVE
Remove valve cotters no. 24.
WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload.
1
R1503motr101B
2
1
R1503motr103A
R1503motr104A
05-08-12 SMR2003-020_05_08A.FM
Withdraw valve spring compressor, valve spring
retainer no. 25 and valve springs.
1. Valve spring retainer
2. Inner valve spring
3. Outer valve spring
Inspection
Check valve springs for rust, corrosion or other vis-
ible damages. If so, replace faulty valve springs.
Check valve springs for free length and straight-
ness.
Replace valve springs if not within specifications.
A. Valve spring length
Installation
Colored area of the valve spring must be placed on
top.
NOTE: Valve cotters must be properly engaged in
valve stem grooves.
1. Position of the valve spring
VALVE
Removal
Remove valve spring.
Push valve stem then pull valves no. 26 and
no. 27 out of valve guides.
1. Intake valve 38 mm
2. Exhaust valve 31 mm
OUTER VALVE SPRING FREE LENGTH
NEW NOMINAL 45.45 mm (1.789 in)
SERVICE LIMIT 43 mm (1.693 in)
INNER VALVE SPRING FREE LENGTH
NEW NOMINAL 41.02 mm (1.615 in)
1
R1503motr105A
2
3
R610motr122A
A
1
R1503motr105B
R1503motr106A
1
2
SMR2003-020_05_08A.FM 05-08-13
Remove valve stem seal no. 28 with special pliers
such as Snap-on YA 8230.
Inspection
Valve Stem Seal
Inspection of valve stem seals is not needed be-
cause new seals should always be installed when-
ever 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 depos-
its before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.
A. Valve stem diameter
R610motr125A
VALVE STEM DIAMETER mm (in)
NEW MINIMUM
Exhaust 5.946 mm (.2341 in)
Intake 5.961 mm (.2347 in)
NEW MAXIMUM
Exhaust 5.960 mm (.2346 in)
Intake 5.975 mm (.2352 in)
SERVICE LIMIT
Exhaust
5.93 mm (.233 in)
Intake
A
R610motr126A
05-08-14 SMR2003-020_05_08A.FM
Replace valve guide if it is out of specification or
has other damages such as wear or friction sur-
face. Refer to valve guide replacement below.
Valve guide replacement
CAUTION: Do not heat cylinder head for this pro-
cedure.
CAUTION: 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.
TYPICAL
1. Special reamer
2. Notch
Chase valve guide out of the cylinder head to-
wards combustion chamber by using a suitable
punch.
TYPICAL
1. Punch
VALVE GUIDE DIAMETER mm (in)
NEW MINIMUM
Exhaust
5.994 mm (.2359 in)
Intake
NEW MAXIMUM
Exhaust
6.018 mm (.2369 in)
Intake
SERVICE LIMIT
Exhaust
6.060 mm (.2386 in)
Intake
1
R1503motr258A
2
1
R1503motr255A
SMR2003-020_05_08A.FM 05-08-15
Check valve guide bore for abreased material.
NOTE: If valve guide has caused scoring during
extraction, replace the cylinder head.
The inlet and exhaust valve guides have the same
length and are interchangeable.
Grease the bore in cylinder head and the leading
end of valve guide with Molykote G-N slide paste.
TYPICAL
1. Valve guide leading end
2. Cylinder head bore
3. Jig
With a suitable jig press the valve guide into the
cold cylinder head as shown.
TYPICAL
A. Protrusion
NOTE: For lubrication of the reamer use only cut-
ting oil. Turn the reamer only forward, in cutting
direction, never backward. Clean the reamer at
short intervals from swarf, moving the reamer
only while turning in cutting direction.
Ream the new valve guide with a reamer 6 mm
diameter.
Clean cylinder head carefully. Check that the valve
seat is concentric with the new guide axis (check
contact surface with engineers blue).
3
R1503motr256A
1
2
VALVE GUIDE PROTRUSION mm (in)
MINIMUM 12.4 mm (.4882 in)
MAXIMUM 12.8 mm (.5039 in)
A
R1503motr257A
05-08-16 SMR2003-020_05_08A.FM
Valve Face and Seat
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 lap-
ping 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.
If valve seat contact width is too wide or has dark
spots, replace the cylinder head.
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.
Grind the valve seat at 45. Remove no more
material than absolutely necessary to clean the
seat up.
Using a 35 stone, narrow the valve seat until
the appropriate outer diameter is obtained
A. Valve Seat Outer Diameter EXHAUST
VALVE SEAT CONTACT WIDTH mm (in)
NEW
Exhaust
1.25 to 1.55 mm
(.049 to .061 in)
Intake
1.10 to 1.30 mm
(.043 to .051 in)
SERVICE LIMIT
Exhaust 2 mm (.078 in)
Intake 1.8 mm (.07 in)
1
2
R1503motr107A
3
V01C1HA
B
A
A
EXHAUST
80
45
35
80
45
35
R1503motr259A
SMR2003-020_05_08A.FM 05-08-17
A. Valve Seat Outer Diameter INTAKE
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.
Finally, coat the valve head sealing seating sur-
face with a fine paste of valve grinding com-
pound using a manual valve grinding mandrel.
Lightly grind the valves until a smooth, even,
uniform sealing surface of the appropriate in-
side and outside diameter is obtained on both
the valve and the seat. Use only a hand held
valve grinding mandrel with a suction cup, rotat-
ing the valve back and forth through about 45,
and then advancing the valve 45 before repeat-
ing this operation.
Installation
Install valve stem seal no. 28.
1. Valve stem seal
Apply engine oil on valve stem and install it.
CAUTION: Be careful when valve stem is passed
through sealing lips of valve stem seal.
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 releas-
ing the spring.
After spring is installed, ensure it is properly locked
by tapping on valve stem end with a soft hammer
so that valve opens and closes a few times.
CAUTION: An improperly locked valve spring will
cause engine damage.
VALVE SEAT OUTER DIAMETER mm (in)
Intake 37.35 mm (1.4705 in)
Exhaust 30.3 mm (1.1929 in)
R1503motr260A
A
INTAKE
55
45
55
45
35
35
1
R1503motr254A
R1503motr254B
1
Subsection 09 (ENGINE BLOCK)
SMR2003-021_05_09A.FM 05-09-1
ENGINE BLOCK 0
R1503motr01S
Loctite 243
10 Nm
(89 lbfin)
Klueber Isoflex Topas NB52 Grease
Engine
oil
Engine
oil
Engine
oil
Loctite 243
Loctite 243
Loctite 243
Loctite 243
Loctite 243
Loctite 243
Loctite 243
Engine
oil
Engine
oil
24 Nm
(18 lbfft)
18 Nm
(159 lbfin)
24 Nm
(18 lbfft)
24 Nm
(18 lbfft)
10 Nm
(89 lbfin)
24 Nm
(18 lbfft)
10 Nm
(89 lbfin)
18 Nm
(159 lbfin)
18 Nm
(159 lbfin)
24 Nm
(18 lbfft)
24 Nm
(18 lbfft)
21
22
20
18
3
2
1
7
17
16
19
40 Nm
(30 lbfft)
55 Nm
(41 lbfft)
+
Grease
05-09-2 SMR2003-021_05_09A.FM
R1503motr02S
8
9
10
8
12
11
13
5
14
15
15
6
4
4
Engine
oil
45 Nm
(33 lbfft)
+ 90
260 Nm
(191 lbfft)
Loctite
anti-seize
Engine
oil
Engine
oil
Engine
oil
Engine
oil
6
Engine
oil
Engine
oil
Engine
oil
Engine
oil
Engine
oil Engine
oil
Engine
oil
Engine
oil
Engine
oil
Engine
oil
23
SMR2003-021_05_09A.FM 05-09-3
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 (e.g.: you found a worn valve
guide. A bent spring could be the cause and it will
be easy to know which one among the springs is
the cause to replace it if you grouped them at dis-
assembly). Besides, since used parts have
matched together during the engine operation,
they will keep their matched fit when you reas-
semble them together within their group.
CRANKSHAFT LOCKING
Remove:
seat and vent tube support
air intake manifold (refer to AIR INTAKE MANI-
FOLD REMOVAL in ENGINE section)
fuel rail cover
spark plugs
plug screw.
1. Plug screw
2. Gasket ring
Put a screwdriver or similar tool into the spark plug
hole of cylinder no. 3 and feel when the piston
reaches TDC.
1. Screwdriver
In this position, the crankshaft can be locked by
using crankshaft locking tool (P/N 529 035 821).
When finished, reinstall all removed parts.
CRANKSHAFT
Removal
Remove:
engine oil
(refer to OIL CHANGE in LUBRICATION section)
engine from vehicle
(refer to REMOVAL AND INSTALLATION)
cylinder head
(refer to CYLINDER HEAD REMOVAL in CYLIN-
DER HEAD AND VALVES section)
PTO housing
(refer to PTO HOUSING REMOVAL in PTO
HOUSING/MAGNETO section)
starter gear
(refer to STARTER GEAR REMOVAL in PTO
HOUSING/MAGNETO section)
starter drive assy
oil suction pump with oil separator assy
(refer to SUCTION PUMP REMOVAL in LUBRI-
CATION section)
engine mounting brackets
2
R1503motr04A
1
1
R1503motr03A
05-09-4 SMR2003-021_05_09A.FM
oil tank plug screws no. 1 with O-ring no. 2
ENGINE UPSIDE DOWN
1. Oil tank plug screw with O-ring
engine block screws no. 3 and no. 7
BOTTOM VIEW OF ENGINE
1. Screws
bottom engine block half
connecting rod screws
1. Connecting rod screws
NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
tion when reassembling.
1. Mark on connecting rod
thrust washers no. 4
1. Thrust washer
1
R1503motr05A
1
R1503motr109A
1
R1503motr08A
R1503motr07A 1
R1503motr09A
1
SMR2003-021_05_09A.FM 05-09-5
crankshaft no. 5.
1. Crankshaft
Inspection
Replace crankshaft if the gears are worn or other-
wise damaged.
1. Balancer gear
2. Crankshaft timing gear
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. Crankshaft
2. Feeler gauge
Crankshaft Radial Play
Measure all crankshaft journals. Compare to inside
diameter of crankshaft bushings (elsewhere in this
section).
1. Micrometer
2. Crankshaft area for bushing
1
R1503motr10A
R1503motr11A
1
2
CONNECTING ROD BIG END
mm (in)
1
R1503motr12A
2
1
R1503motr13A
2
05-09-6 SMR2003-021_05_09A.FM
Crankshaft Pin
Measure all crankshaft pin diameters. Compare to
inside diameter of connecting rod bushings (else-
where in this section).
1. Micrometer
2. Crankshaft pin area for bushing
Installation
Pay attention to following details.
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.
CAUTION: Crankshaft and balancer shaft marks
have to be aligned.
1. Mark on balancer shaft
2. Mark on crankshaft
For correct installation of the connecting rods refer
to CONNECTING ROD INSTALLATION elsewhere
in this section.
CAUTION: It is absolutely necessary to follow
this procedure. Otherwise severe engine dam-
age can occur.
CAUTION: Never forget thrust washers no. 4
on center of crankshaft to control axial adjust-
ment.
CRANKSHAFT JOURNAL DIAMETER
mm (in)
CRANKSHAFT JOURNAL RADIAL CLEARANCE
mm (in)
CRANKSHAFT PIN DIAMETER
mm (in)
CRANKSHAFT PIN RADIAL CLEARANCE
mm (in)
R1503motr14A
1 2
R1503motr17A 1 2
SMR2003-021_05_09A.FM 05-09-7
Insert thrust washers as soon as crankshaft is in
place as per following illustration.
THRUST WASHER INSERT DIRECTION
1. Thrust washer
CAUTION: Thrust washers have to be flush with
the engine block sealing surface.
1. Thrust washer
2. Sealing surface
Install lower engine block half. Refer to ENGINE
BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence.
Install the crankshaft cover before mounting the
engine bracket. Apply oil on O-ring and press cover
in. Crankshaft cover has to be flush with engine
block surface.
1. O-ring
2. Crankshaft cover
CAUTION: Install crankshaft locking tool (P/N 529
035 821) right away to position crankshaft at
TDC before installing the camshaft and rockers
(refer to CYLINDER HEAD AND VALVES).
1. Crankshaft locking tool
R1503motr09A
1
1
R1503motr16A
2
1
R1503motr19A 2
1
R1503motr18A
05-09-8 SMR2003-021_05_09A.FM
TIMING CHAIN
Inspection
Check timing chain on camshaft gear for excessive
radial play.
Check chain condition for wear and rollers condition.
1. Timing chain
If chain is excessively worn or damaged, replace
it as a set (camshaft timing gear and timing chain).
Removal
Remove:
engine oil
engine from vehicle
(refer to REMOVAL AND INSTALLATION)
cylinder head (refer to CYLINDER HEAD REMOV-
AL in CYLINDER HEAD AND VALVES section)
PTO housing (refer to PTO HOUSING REMOV-
AL in PTO HOUSING/MAGNETO section)
crankshaft (refer to CRANKSHAFT REMOVAL
timing chain.
Installation
The installation is essentially the reverse of the re-
moval procedure but, pay attention to the follow-
ing details.
Ensure to perform proper valve timing. Lock crank-
shaft and camshaft at TDC (refer to CYLINDER
HEAD AND VALVES).
Install chain then, install chain tensioner.
CAUTION: Improper valve timing will damage
engine components.
CHAIN TENSIONER
Removal
NOTE: Removal of the air intake manifold allows
easier access to the chain tensioner, but is not
necessary. Refer to AIR INTAKE MANIFOLD RE-
MOVAL in INTAKE section.
Remove:
chain tensioner plug screw no. 18 with gasket
ring no. 19
chain tensioner no. 20.
1. Plug screw
2. Gasket ring
3. Chain tensioner
Inspection
Check chain tensioner for excessive wear or
cracks. Also check free movement of the chain ten-
sioner piston.
Installation
The installation is essentially the reverse of the re-
moval procedure but, pay attention to the follow-
ing details.
Torque chain tensioner plug screw to 18 Nm
(160 lbfin).
1
R610motr201A
3
R1503motr39A 1
2
SMR2003-021_05_09A.FM 05-09-9
BALANCER SHAFT
Removal
Remove:
engine oil
engine from vehicle (refer to REMOVAL AND
INSTALLATION)
in PTO HOUSING/MAGNETO section)
starter gear (refer to STARTER GEAR REMOV-
starter drive assy
oil suction pump with oil separator assy (refer
to SUCTION PUMP REMOVAL in LUBRICA-
TION section)
engine mounting brackets
oil reservoir plug screws no. 1 with O-ring no. 2
ENGINE UPSIDE DOWN
1. Oil reservoir plug screw with O-ring
engine block screws no. 3
1. Screws
bottom engine block half
thrust washers no. 6
1. Thrust washer
balancer shaft.
1
R1503motr05A
1
R1503motr109A
1
R1503motr20A
05-09-10 SMR2003-021_05_09A.FM
Inspection
Check balancer shaft and replace if damaged.
If the gear on the balancer shaft is damaged, re-
place balancer shaft.
Check gear on the crankshaft at the same time and
replace crankshaft if necessary (refer to CRANK-
SHAFT above).
Balancer Shaft Bushing Seat Play
Measure all balancer shaft bushing seats. Com-
pare to inside diameter of balancer shaft bushings
(elsewhere in this section).
1. Micrometer
2. Balancer shaft area for bushing
Installation
Pay attention to following detail.
CAUTION: Balancer shaft and crankshaft marks
have to be aligned.
1. Mark on balancer shaft
2. Mark on crankshaft
CAUTION: Never forget thrust washers no. 6
on PTO side to control axial adjustment on bal-
ancer.
Insert thrust washers as soon as balancer shaft is
in place as per following illustration.
THRUST WASHER INSERT DIRECTION
1. Thrust washer
BALANCER SHAFT SEAT DIAMETER
mm (in)
BALANCER SHAFT SEAT RADIAL CLEARANCE
mm (in)
1
R1503motr23A
2
R1503motr17A 1 2
1
R1503motr20B
SMR2003-021_05_09A.FM 05-09-11
CAUTION: Thrust washers have to be flush
with the engine block sealing surface.
1. Thrust washer
2. Sealing surface
Install lower engine block half. Refer to ENGINE
BLOCK ASSEMBLY elsewhere in this section for
proper procedure to clean surfaces, apply Loctite
5910 and proper torquing sequence.
block surface.
1. O-ring
2. Crankshaft cover
CAUTION: Install crankshaft locking tool (P/N
529 035 821) right away to position crankshaft at
ENGINE BLOCK
Removal
Remove:
engine oil
engine from vehicle (refer to REMOVAL AND
INSTALLATION)
in PTO HOUSING/MAGNETO section)
starter gear (refer to STARTER GEAR REMOV-
starter drive assy
oil suction pump with oil separator assy (refer
to SUCTION PUMP REMOVAL in LUBRICA-
TION section)
balancer shaft (refer to BALANCER SHAFT RE-
MOVAL elsewhere in this section)
crankshaft (refer to CRANKSHAFT REMOVAL
piston with connecting rod (refer to PISTON RE-
MOVAL elsewhere in this section).
2
R1503motr22A
1
1
R1503motr19A 2
1
R1503motr18A
05-09-12 SMR2003-021_05_09A.FM
Bushings
When bushings need to be removed from the en-
gine block, mark them to identify the correct posi-
tion at installation. See the following illustration for
an example:
1. Mark on balancer shaft bushings
2. Mark on crankshaft bushings
Check bearing no. 21 of starter drive assembly
no. 22 in engine block and replace it if damaged.
1. Bearing of starter drive assembly
Starter drive bearing can be easily removed from
lower crankcase half using the following suggest-
ed tool or equivalent:
handle CJ93-1
hammer CJ125-6
claws CJ93-4.
against bearing.
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 specifica-
tions, rehone cylinder sleeve and replace piston
assy 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 posi-
tions. See the following illustration.
1. First measuring diameter
2. Second measuring diameter
3. Third measuring diameter
A. 60 mm (2.362 in)
B. 110 mm (4.331 in)
1
R1503motr37A 2
R1503motr40A 1
F01J0ZA
R1503motr24A
3
1
2
B
A
SMR2003-021_05_09A.FM 05-09-13
Distance between measurements should not ex-
ceed the service limit mentioned above.
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 de-
scribed in CYLINDER TAPER above.
A. Perpendicular to crankshaft axis
B. Parallel to crankshaft axis
Bushings
To measure the wear of the crankshaft bushings
no. 13 and no. 14 and balancer shaft bushings
no. 15, both engine block halves with OLD bush-
ings have to be screwed together as per tighten-
ing procedure described below.
Measure the inside diameter of the bushings with
a bore gauge.
ENGINE UPSIDE DOWN
1. Bore gauge
ENGINE UPSIDE DOWN
1. Bore gauge
Replace bushings if they are out of specifications.
CYLINDER TAPER IN DIAMETER
mm (in)
CYLINDER OUT OF ROUND
mm (in)
A
R1503motr25A
B
CRANKSHAFT BUSHING INSIDE DIAMETER
mm (in)
BALANCER SHAFT BUSHING INSIDE DIAMETER
mm (in)
1
R1503motr33A
R1503motr34A 1
05-09-14 SMR2003-021_05_09A.FM
Oil Spray Nozzles
Remove oil spray nozzle no. 16 and banjo screw
no. 17 from engine block.
1. Banjo screw
2. Oil spray nozzle
Check if ball inside moves freely in the banjo
screw. Clean Nozzle and banjo screw from dirt and
debris.
Installation
Torque oil spray nozzle to 18 Nm (160 lbfin).
To install starter drive bearing no. 21 of starter
drive assembly, use pusher (P/N 290 876 502) and
handle (P/N 420 877 650).
1. Handle
2. Pusher
Use NEW bushings when diameters are out of
specification.
If OLD bushings can be used again, make sure
they are at the same position as they were before.
Correctly install bushings. Top crankshaft bushing
halves have a bore which has to be placed in the
upper engine block.
1. Upper engine block half
2. Oil bore in engine block
3. Oil bore in bushing
Bushings have to be flush with the engine block
split surface and their protrusions have to fit in the
notched areas in the engine block seat.
1. Bushing protrusion in engine block notch
Apply engine oil on all bushings, 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 PISTON
INSTALLATION elsewhere in this section.
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.
1
R1503motr38A
2
F06D32A
1
2
R1503motr35A
3
2
1
1
R1503motr36A
SMR2003-021_05_09A.FM 05-09-15
clogged.
Engine block mating surfaces are best cleaned us-
ing a combination of the 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).
CAUTION: 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 sug-
gested 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 appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (unlike the Drei Bond sealing
compound, using a finger will not affect the adhe-
sion).
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non sili-
cone-based sealant over a previously sealed
crankcase with Loctite 5910 will lead to poor ad-
hesion and possibly a leaking crankcase. These
products are chemically incompatibles. Even af-
ter cleaning, the Loctite 5910 would leave incom-
patible microscopic particles.
Use a plexiglas plate and apply some sealant on it.
Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
Do not apply in excess as it will spread out inside
crankcase.
NOTE: Do not use Loctite Primer N with this seal-
ant. The sealant curing time is similar to the Loc-
tite 518 without using the Primer N, which is 4 to
24 hours.
Tighten engine block screws as per following se-
quence.
Apply Loctite 243 (blue) on threads. Torque engine
block screws no. 3 at first to 40 Nm (29 lbfft)
and in a second sequence to 55 Nm (41 lbfft).
Torque engine block screws no. 7 to 22 Nm
(17 lbfft).
F12R17A
3 1 7
R1503motr06B
23 5 21 17 18 19 20 22
16 15 14 9 2 10 11 12 13 6 8 4
05-09-16 SMR2003-021_05_09A.FM
Before continuing the installation process, the ax-
ial clearance of balancer shaft and crankshaft has
to be checked.
1. Dial gauge
2. Crankshaft
1. Dial gauge
2. Balancer shaft
block surface.
1. O-ring
2. Crankshaft cover
CAUTION: Install crankshaft locking tool (P/N 529
035 821) right away to position crankshaft at
Install cylinder head, PTO housing and the other
parts in accordance with the proper installation
procedures.
CRANKSHAFT AXIAL CLEARANCE mm (in)
BALANCER SHAFT AXIAL CLEARANCE mm (in)
1
R1503motr41A 2
1
R1503motr42A 2
1
R1503motr19A 2
1
R1503motr18A
SMR2003-021_05_09A.FM 05-09-17
PISTON/CONNECTING ROD
Removal
Disassemble engine block as per ENGINE BLOCK
REMOVAL above.
Remove connecting rod screws.
1. Connecting rod screws
NOTE: Before removing the connecting rod bear-
ing caps, mark them to remember the right posi-
tion when reassembling.
Pull piston with connecting rod out of the cylin-
ders.
Remove one piston circlip no. 8 and discard it.
1. Piston circlip
NOTE: The removal of both piston circlips is not
necessary to remove piston pin.
Push piston pin no. 9 out of piston.
1. Piston
2. Piston pin
3. Circlip
Detach piston no. 10 from connecting rod.
Inspection
Connecting Rod/Piston Pin Clearance
Measure piston pin. Compare to inside diameter
of connecting rod no. 5.
1. Bore gauge
2. Connecting rod
1
R1503motr08A
1 R610motr134A
1
R1503motr27A
3 2
1
R610motr73A
2
05-09-18 SMR2003-021_05_09A.FM
A. Piston pin diameter in the area of the bushing
If the connecting rod small end diameter is out of
specification, replace connecting rod.
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 bushings no. 12 as they were
mounted initially.
Do the torque procedure as described below.
A. Connecting rod big end bushing
Use NEW bushings no. 12, when connecting rod
big end diameter is out of specification.
CONNECTING ROD SMALL END DIAMETER
mm (in)
PISTON PIN DIAMETER
mm (in)
PISTON PIN BORE CLEARANCE
mm (in)
A R610motr137A
CONNECTING ROD BIG END DIAMETER
mm (in)
CONNECTING ROD BIG END CLEARANCE
mm (in)
R610motr76A
A
SMR2003-021_05_09A.FM 05-09-19
Piston
Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 18 mm
(.709 in) perpendicularly (90) to piston pin axis.
A. 18 mm (.709 in)
The measured dimension should be as described
in the subsequent table. If not, replace piston.
Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.
1. Micrometer set to the piston dimension
With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
TYPICAL
1. Indicator set to 0 (zero)
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 clear-
ance.
NOTE: Make sure used piston is not worn. See PIS-
TON MEASUREMENT above.
PISTON MEASUREMENT
mm (in)
NEW NOMINAL
99.951 to 99.969 mm
(3.935 to 3.936 in)
1 R610motr136A
A
F00B08A
1
PISTON/CYLINDER CLEARANCE mm (in)
NEW NOMINAL
0.024 to 0.056 mm
(.0009 to .0022 in)
F00B09A
1
2
F00B0AA
1
05-09-20 SMR2003-021_05_09A.FM
If clearance exceeds specified tolerance, rehone
cylinder sleeve and replace piston assy by an
oversize one.
NOTE: It is not necessary to have all pistons re-
placed with an oversize if they are not all out of
specification. Mixed standard size and oversize
piston are allowed.
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Piston Pin
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other dam-
ages.
Measure piston pin. See the following illustration
for the proper measurement positions.
Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod.
1. Bore gauge
2. Connecting rod
Replace connecting rod if diameter of connecting
rod small end is out of specifications. Refer to
CRANKSHAFT AND BALANCER SHAFT for removal
procedure of connecting rod.
Installation
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.
CAUTION: Secure piston pin with new piston cir-
clips.
NOTE: Take care that the hook of the piston circlip
is positioned properly.
1. Sleeve with piston circlip inside
2. Assembly jig from piston clip installer
CORRECT POSITION OF THE PISTON CIRCLIP
CONNECTING ROD SMALL END DIAMETER
mm (in)
1
R610motr73A
2
1
R1503motr28A
2
R610motr134B
SMR2003-021_05_09A.FM 05-09-21
Using a piston ring compressor plier, such Snap-
ON RC-980, slide piston into cylinder.
CAUTION: Install piston with punched arrow
toward exhaust side.
1. Arrow toward exhaust side
Correctly install bushings and carefully clean split
surface on both sides (cracked area).
1. Half bushing of connecting rod big end
2. Split surface of the connecting rod
3. Protrusion of bushing in line with connecting rod groove
Torque NEW connecting rod screws no. 11 as per
following procedure:
Install screws and torque to 45 Nm (33 lbfft).
Do not apply any thread locker product.
Finish tightening the screws with an additional
90 turn using an angle torque wrench.
CAUTION: Failure to strictly follow this proce-
dure may cause screw to loosen and lead to en-
gine damage. Knowing that the screws have
been stretched from the previous installation, it
is very important to use new screws at assem-
bly.
1. Angle torque wrench
R1503motr29A
1
R1503motr30A
3
R610motr79A
1 2
R1503motr31A
1
05-09-22 SMR2003-021_05_09A.FM
PISTON RINGS
Removal
Remove piston assy as described above.
Remove rings.
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.
1. Piston
2. Filler gauge
Ring End Gap
Measure position for ring end gap in the area of 8
to 16 mm (.315 to .630 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 tol-
erance.
Installation
Install the oil scraper ring first, then the taper-face
ring with the word TO facing up, then the rectan-
gular ring with the word T facing up.
1. Rectangular ring
2. Taper-face ring
3. Oil scraper ring
RING/PISTON GROOVE CLEARANCE
mm (in)
NEW MINIMUM
RECTANGULAR 0.025 mm (.001 in)
TAPER-FACE 0.015 mm (.0006 in)
OIL SCRAPER RING 0.020 mm (.0008 in)
NEW MAXIMUM
SERVICE LIMIT
ALL 0.15 mm (.006 in)
2
R1503motr32A 1
RING END GAP
mm (in)
NEW MINIMUM
NEW MAXIMUM
SERVICE LIMIT
ALL 1 mm (.04 in)
A31C2NA
1
2
3
SMR2003-021_05_09A.FM 05-09-23
CAUTION: Ensure that top and second rings are
not interchanged.
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.
1. DO NOT align ring gap with piston trust side axis
2. DO NOT align ring gap with piston pin bore axis
A. 120
A31C2OA
1
2
A A
A
Section 06 ENGINE MANAGEMENT (RFI)
SMR2003-049_06_01ATOC.FM 06-01-1
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 06-02-1
AIR INDUCTION................................................................................................................. 06-02-2
FUEL DELIVERY................................................................................................................. 06-02-2
FUEL PUMP ....................................................................................................................... 06-02-2
FUEL PRESSURE REGULATOR........................................................................................ 06-02-2
FUEL FILTERS.................................................................................................................... 06-02-3
FUEL PUMP MODULE....................................................................................................... 06-02-3
FUEL INJECTORS.............................................................................................................. 06-02-3
ELECTRONIC MANAGEMENT.......................................................................................... 06-02-4
ELECTRONIC CONTROL UNIT (ECU)............................................................................... 06-02-4
MPEM (Multi-Purpose Electronic Module)...................................................................... 06-02-4
DIAGNOSTIC PROCEDURES................................................................................................ 06-03-1
VCK (Vehicle Communication Kit)................................................................................... 06-03-1
DIAGNOSTIC OPTION EXAMPLE USING MPEM PROGRAMMER................................ 06-03-1
FAULT CODE TABLES....................................................................................................... 06-03-3
ECU FAULTS...................................................................................................................... 06-03-3
INPUT SIGNAL FAULTS ................................................................................................... 06-03-3
OUTPUT SIGNAL FAULTS ............................................................................................... 06-03-4
COMPONENT INSPECTION.................................................................................................. 06-04-1
GENERAL ........................................................................................................................... 06-04-1
AIR INDUCTION SYSTEM................................................................................................. 06-04-3
THROTTLE BODY .............................................................................................................. 06-04-3
FUEL DELIVERY................................................................................................................. 06-04-3
FUEL FILTER ...................................................................................................................... 06-04-3
FUEL PUMP ....................................................................................................................... 06-04-3
REGULATOR...................................................................................................................... 06-04-3
FUEL INJECTOR ................................................................................................................ 06-04-4
LEAK TEST (SUPPLY AND VENTILATION CIRCUITS) .................................................... 06-04-5
HIGH PRESSURE TEST (fuel pump circuit) ..................................................................... 06-04-5
THROTTLE POSITION SENSOR (TPS) ............................................................................. 06-04-6
CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 06-04-7
AIR TEMPERATURE SENSOR (ATS) ................................................................................ 06-04-8
WATER TEMPERATURE SENSOR (WTS) ........................................................................ 06-04-8
AIR PRESSURE SENSOR (APS) ....................................................................................... 06-04-9
RAVE SOLENOID............................................................................................................... 06-04-10
RFI SENSORS RESISTANCE VALUES.............................................................................. 06-04-11
06-01-2 SMR2003-049_06_01ATOC.FM
TROUBLESHOOTING SUMMARY........................................................................................ 06-05-1
ENGINE DOES NOT START .............................................................................................. 06-05-1
FLOODED ENGINE FEATURE............................................................................................ 06-05-1
SPARK PLUG INSPECTION............................................................................................... 06-05-1
ECU FAULT CODES ........................................................................................................... 06-05-1
ENGINE STARTS BUT RUNS POORLY ............................................................................ 06-05-1
ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS ..................... 06-05-1
ENGINE CANNOT REACH MAXIMUM REVOLUTIONS.................................................. 06-05-1
ADJUSTMENT ....................................................................................................................... 06-06-1
THROTTLE CABLE ADJUSTMENT ................................................................................... 06-06-1
THROTTLE POSITION SENSOR (TPS).............................................................................. 06-06-1
CLOSED TPS....................................................................................................................... 06-06-1
IDLE SPEED ........................................................................................................................ 06-06-1
MPEM.................................................................................................................................. 06-07-1
THROTTLE POSITION SENSOR (TPS).............................................................................. 06-07-1
AIR TEMPERATURE SENSOR (ATS) ................................................................................ 06-07-1
AIR PRESSURE SENSOR (APS) ........................................................................................ 06-07-1
CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 06-07-1
FUEL PUMP ASSEMBLY ................................................................................................... 06-07-1
REGULATOR....................................................................................................................... 06-07-2
FUEL FILTER....................................................................................................................... 06-07-2
FUEL INJECTORS............................................................................................................... 06-07-2
Subsection 02 (OVERVIEW)
SMR2003-022_06_02A.FM 06-02-1
OVERVIEW 0
DESCRIPTION OF THE FUEL INJECTION SYSTEM
1. Fuel tank
2. Fuel filter
3. Fuel pump
4. Regulator
5. Fuel rail
6. Fuel injector
7. Electronic Control Unit (ECU)
8. Multi-Purpose Electronic Module (MPEM)
9. Throttle plate
10. Throttle Position Sensor (TPS)
11. Air Pressure Sensor (APS)
12. Air Temperature Sensor (ATS)
13. Crankshaft Position Sensor (CPS)
14. Water Temperature Sensor (WTS)
15. Battery
16. Ignition coil
F07F18S
1
3
2
4
5
6
15
7
8
9
11
12
10
14
13
16
06-02-2 SMR2003-022_06_02A.FM
The Rotax Fuel Injection (RFI) is a semi-direct elec-
tronic fuel injection system.
Fuel is injected into each cylinder through the rear
transfer port. With this design, the injector is not
exposed to high combustion pressure, tempera-
ture and contaminants.
This system delivers the following benefits:
easier cold engine starting (no choke)
easier hot engine starting
improved idling
better throttle response
better fuel economy
no fuel valve.
This system has the advantage of optimizing the
engine power, fuel economy and emission con-
trols under all engine operating conditions by man-
aging both the fuel injection duration and ignition
timing.
The Rotax Fuel Injection (RFI) is composed of the
3 following basic systems:
1. air induction
2. fuel delivery
3. electronic management.
AIR INDUCTION
A single throttle body (56 mm) breath through the
air intake silencer to provide a sufficient amount
of air for the engine operation.
THROTTLE BODY
FUEL DELIVERY
FUEL PUMP
An electric fuel pump provides fuel pressure and
flow rate to the system.
FUEL PUMP
FUEL PRESSURE REGULATOR
A regulator maintains a constant fuel pressure of
386 - 414 kPa (56 - 60 PSI).
REGULATOR
F07F08A
F07F0JA
F07F0IA
SMR2003-022_06_02A.FM 06-02-3
FUEL FILTERS
A dual piece fuel filter protects the fuel pump, reg-
ulator and injectors.
1. Fuel pump assembly
2. External fuel filter
1. End cap of fuel pump assembly removed
2. Internal fuel filter
FUEL PUMP MODULE
All these components are comprised in a single
module mounted in the fuel tank. The fuel gauge
sender is also mounted on this module.
FUEL PUMP ASSEMBLY
FUEL INJECTORS
The injectors inject a metered quantity of fuel from
the fuel rail into the cylinder rear transfer port in
accordance with the signal from the Electronic
Control Unit (ECU).
INJECTOR
F07F0KA
1
2
F07F0LA
2 1
F07F09A
F07F0AA
06-02-4 SMR2003-022_06_02A.FM
ELECTRONIC MANAGEMENT
ELECTRONIC CONTROL UNIT
(ECU)
The electronic fuel injection is equipped with a
Bosch Electronic Control Unit (ECU).
ELECTRONIC CONTROL UNIT (ECU)
The ECU is mounted behind the MPEM in the
front of the watercraft, in a watertight box.
The ECU controls the following functions:
Basic Operating Function
Electronic Fuel Injection
The ECU receives the signals from 5 sensors which
indicate engine operating conditions at millisecond
intervals.
Throttle Position Sensor (TPS)
Crankshaft Position Sensor (CPS)
Air Temperature Sensor (ATS)
Water Temperature Sensor (WTS)
Air Pressure Sensor (APS).
These signals are used by the ECU to determine
the injection duration required for optimum air-fuel
ratio.
Ignition Timing
The ECU is programmed with data for optimum
ignition timing under all operating conditions. Us-
ing data provided by the sensors, the ECU controls
the ignition timing for optimum engine operation.
Maximum Engine Speed
The ECU limits the maximum allowable engine
speed. The RPM rev limiter is set at 7200 50
RPM.
Fail-Safe Function
In the event of a sensor malfunction, the ECU will
use a default operating mode to ensure driveability
to shore. A message may be displayed on the Info
Center to inform the operator.
Diagnostic Mode
The ECU is able to detect malfunctions in the sen-
sor network. The malfunction is recorded in the
memory of the ECU. The memory of the ECU can
be checked using VCK (Vehicle Communication
Kit) (P/N 529 035 844) or MPEM programmer tool.
MPEM
(Multi-Purpose Electronic Module)
The MPEM is also used with the Rotax Fuel Injec-
tion system.
MPEM
It is responsible of the following electrical func-
tions:
interpreting information
distributing information
start/stop function
timer
vehicle hours
Digitally Encoded Security System (DESS).
The MPEM has a special safety feature to limit
engine revolutions when the battery voltage is too
low.
For example, when the battery voltage reaches
8.9 volts for at least 30 seconds, engine revolu-
tions are limited to 4480 RPM.
When voltage reaches 7 volts for at least 30 seconds,
the engine is automatically shut off by the MPEM.
F07F0BA
F07H0BA
SMR2003-022_06_02A.FM 06-02-5
SIGNAL MANAGEMENT
Intake air
pressure
Crankshaft
Position
Sensor (CPS)
Crankshaft
position and
engine speed
Throttle valve
position (Idle to
wide open throttle)
Engine
temperature
Intake air
temperature
Battery
voltage
Start/stop
signal
Air Pressure
Sensor
(APS)
Water
Temperature
Sensor (WTS)
Air
Temperature
Sensor (ATS)
Fuel tank
Fuel filter
Fuel pump
Regulator
Injectors
Multi-Purpose Electronic Module
(MPEM)
Electronic Control Unit
(ECU)
PARAMETERS SENSORS FUEL
DELIVERY
Throttle
Position
Sensor (TPS)
To engine
F07F0NS
Subsection 03 (DIAGNOSTIC PROCEDURES)
SMR2003-022_06_03A.FM 06-03-1
DIAGNOSTIC PROCEDURES 0
VCK
(Vehicle Communication Kit)
The VCK (Vehicle Communication Kit) (P/N 529
035 844) is the primary tool to diagnose fuel injec-
tion related problems.
B.U.D.S. is designed to allow sensor inspection,
diagnostic options and adjustment such as the
Throttle Position Sensor (TPS) and the TDC set-
ting.
For more information pertaining to the use of the
software B.U.D.S., use its help which contains de-
tailed information on its functions.
DESS Post Connection Through the 4-Pin
Connector
1. 6-pin adapter
2. RFI 4-pin adapter
3. Connector under opening of front storage area
After all connections are done, connect the safety
lanyard to the DESS post to activate the commu-
nication.
IMPORTANT: When using the software B.U.D.S.,
ensure that the protocol matching the connection
used i s properl y sel ected i n MPI under
Choose protocol as per the following chart.
MPEM PROGRAMMER
The MPEM programmer is the alternative tool to
diagnose fuel injection related problems.
The latest software designed for the RFI model
allows sensor inspection, diagnostic options and
adjustment such as the Throttle Position Sensor
(TPS).
NOTE: Make sure your MPEM programmer is up-
dated with the latest software version. For a com-
plete overview of the programmer, refer to the
MPEM Programmer Guide (P/N 219 700 090).
DIAGNOSTIC OPTION EXAMPLE
USING MPEM PROGRAMMER
Turn on the programmer and enter your password.
Select VEHICLE INFO from the main menu and
press ENTER.
1. CHECK KEYS
2. PROGRAM KEY
3. VEHICLE INFO
4. START VEH.
5. OTHERS
WARNING
If the computer you are using is connected to
the 110 Vac power outlet, there is a potential
risk of electrocution when working in contact
with water. Be careful not to touch water
while working with the VCK.
2 F12H0CA 1 3
TYPE OF
CONNECTION
ADAPTER
TO USE
PROTOCOL
TO CHOOSE
RFI models through
the 4-pin connector
6-pin and
RFI 4-pin
DESS
06-03-2 SMR2003-022_06_03A.FM
By selecting the VEHICLE INFO you will access a
9-line sub-menu. Select BOSCH SYSTEM from
the sub-menu and press ENTER.
1. CUSTOMER NAME
2. DELIVERY DATE
3. VEH. SERIAL #
4. ENGINE PARAM.
5. PROGRAM KEY
6. HOUR INFO
7. MPEM INFO
8. BOSCH SYSTEM
9. SAVE + QUIT
By selecting BOSCH MENU you will enter a sec-
ond sub-menu. Select DIAGNOSIS and press EN-
TER.
1. DIAGNOSIS
2. START VEHICLE
By selecting DIAGNOSIS the following message
INITIALIZING IN PROCESS will be displayed a
few seconds, then a new menu will appear on the
screen.
Select READ FAULT and press ENTER.
1. BOSCH INFO
2. READ FAULT
3. ERASE FAULT
4. ADJUSTMENT
5. REAL TIME
6. END DIAGNOSIS
NOTE: Line no. 1 BOSCH INFO will display the iden-
tification of the watercraft and the MPEM/ECU.
By selecting READ FAULT, the MPEM program-
mer will display the number of faults in the ECU
memory and the codes related with the fault(s).
The programmer will offer PRESS ANY KEY. If
there is more than 1 fault in the ECU memory, the
next fault code will be displayed.
NOTE: On this model, there is always at least the
04 FC fault code. Ignore this fault code. Also,
when the engine is NOT operating, the fault code
02 01 03 will be displayed for the CPS (crankshaft
position sensor). It should not be considered as a
fault in the static mode.
Refer to the tables on next page for the explana-
tion of the fault codes.
After reading the fault codes in the memory of the
ECU, PRESS ANY KEY will return the program-
mer to the latest menu.
By selecting ERASE FAULT in the menu, it will
allows you to erase the faults in the ECU memory.
NOTE: The programmer will not allow fault code
erasing without first viewing in the READ FAULT.
SMR2003-022_06_03A.FM 06-03-3
FAULT CODE TABLES
ECU FAULTS
INPUT SIGNAL FAULTS
FAULT DETECTION
FAULT CODE
TYPE OF FAULT
MPEM
programmer
B.U.D.S.
No fault detected FF FF 88 N.A. No defect
Electronic Control Unit Internal
memory
FF FF 00 P 0604 Internal defect
FF FF 1B P 0605 Not plausible = EEPROM defect
EEPROM
FF FE 2B P 1600 EEPROM not programmed
EEPROM Data Setting
FF FD 10 P 1601 Data in EEPROM out of range (1 of 3 bytes)
FF FD 25 P 1602 Data in EEPROM out of range
(all 3 bytes different)
FAULT DETECTION
FAULT CODE
TYPE OF FAULT
MPEM
programmer
B.U.D.S.
Supply voltage to ECU
02 14 07 P 0562 Voltage from the battery too low
02 14 06 P 0563 Voltage from the battery too high
Engine Water Temperature
Sensor (WTS)
02 0A 1D P 0117 Sensor circuit shorted to ground
02 0A 1E P 0118 Signal interruption or short circuit to battery
02 0A 1B P 0116 Non plausible signal
02 06 1F P 0122 Sensor circuit shorted to ground
02 06 1C P 0123 Sensor circuit shorted to battery
(CPS)
02 1F 06
02 1F 23
P 0219 Signal exceeding RPM limits
(CPS)
02 01 03 P 0335 No signal detected (fault code active when
engine is not running and ignition is on)
02 01 1B P 0336 Synchronization error (sensor/toothed wheel)
Air Intake Temperature Sensor
(ATS)
02 0F 1D P 0112 Sensor circuit shorted to ground
02 0F 1E P 0113 Signal interruption or short circuit to battery
Air Pressure Sensor (APS)
02 10 1D P 0107 Sensor circuit shorted to ground
02 10 1E P 0108 Signal interruption or short circuit to battery
06-03-4 SMR2003-022_06_03A.FM
OUTPUT SIGNAL FAULTS
FAULT DETECTION
FAULT CODE
TYPE OF FAULT
MPEM
programmer
B.U.D.S.
Injector 1
04 E1 1C P 0262 Short circuit to battery
04 E1 1D P 0261 Short circuit to ground
04 E1 1E P 1200 Interruption or open circuit
Injector 2
04 E2 1C P 0265 Short circuit to battery
04 E2 1D P 0264 Short circuit to ground
04 E2 1E P 1201 Interruption or open circuit
Fuel pump 04 EB 1C P 0230 Short circuit to battery
Not applicable 04 FC N.A. Not applicable
RAVE vacuum solenoid
04 DB 1C P 0478 Short circuit to battery
04 DB 1D P 0477 Short circuit to ground
04 DB 1E P 0479 Interruption or open circuit
Subsection 04 (COMPONENT INSPECTION)
SMR2003-022_06_04A.FM 06-04-1
COMPONENT INSPECTION 0
GENERAL
Always disconnect battery properly prior to
working on the fuel system.
When the job is done, ensure that hoses from fuel
rail going to fuel pump are properly secured in their
support. Then, pressurize the fuel system. Per-
form the high pressure test as explained in this
section and pressurize the fuel tank and fuel lines
as explained in FUEL SYSTEM section.
Properly reconnect the battery.
CAUTION: Never use injector cleaning products.
They may contain additive that could damage in-
jector components. A copper wire brush may be
used to clean the tip of the direct injectors if nec-
essary.
Engine problems are not necessarily related to the
electronic fuel injection system.
It is important to check that the electrical system
is functioning properly:
battery
fuses
DESS
ignition (spark)
ground connections
wiring connectors.
If all of the above mentioned items are functioning
correctly, the following verifications can be per-
formed to detect any faulty components.
NOTE: Troubleshooting should be performed us-
ing the VCK or MPEM programmer tool. See
TROUBLESHOOTING in this subsection.
It is possible that a component seems to operate
in static condition but in fact, it is defective. In this
case, the best way to solve this problem is to re-
move the original part and replace it with one
which is in good condition.
Never use a battery charger to replace temporarily
the battery, as it may cause the MPEM to work
erratically or not to work at all. Check related-circuit
fuse solidity and condition with an ohmmeter. Vi-
sual inspection could lead to false results.
To perform verifications, a good quality multimeter
such as Fluke 111 (P/N 529 035 868) should be
used.
WARNING
The fuel system of a fuel injection system holds
much more pressure than on a carbureted wa-
tercraft. Prior to disconnecting a hose or to re-
moving a component from the fuel system, fol-
low the recommendation described here.
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appropriate
safety equipment when working on pressur-
ized fuel system. Wear safety glasses and 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 dis-
connecting fuel line connections. 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 ar-
ea. Always disconnect battery prior to work on
the fuel system. After performing a pressure
test, use the valve on the fuel pressure gauge to
release the pressure (if so equipped).
WARNING
Ensure to verify fuel line connections for dam-
age and that NO fuel line is disconnected prior
to installing the safety lanyard on the DESS
post. A pressure test must be done before con-
necting the safety lanyard. The fuel pump is
started each time the safety lanyard is installed
and it builds pressure very quickly.
WARNING
All electrical actuators (injectors, fuel pump,
RAVE solenoid, ignition coil and starter sole-
noid) are permanently connected to the bat-
tery positive terminal, even when the safety
lanyard is removed. Always disconnect the
battery prior to disconnecting any electric or
electronic parts.
06-04-2 SMR2003-022_06_04A.FM
Pay particular attention to ensure that pins are not
out of their connectors or out of shape. The trou-
bleshooting procedures cover problems not re-
sulting from one of these causes.
Before replacing a MPEM, always check electrical
connections. Make sure that they are very tight and
they make good contact and that they are corrosion-
free. A defective module could possibly be re-
paired simply by unplugging and replugging the
MPEM. The voltage and current might be too
weak to go through dirty wire pins. Check carefully
if posts show signs of moisture, corrosion or if
they look dull. Clean pins properly and then coat
them with silicon-based dielectric grease or other
appropriate lubricant (except if otherwise speci-
fied) when reassembling them. If the newly re-
placed MPEM is working, try the old one and re-
check if it works.
Ensure that all electronic components are genuine
particularly in the ignition system. Installing re-
sistive caps, non-resistive spark plug cables (or
modified length) or non-resistive spark plugs may
lead to generate fault codes or bad operation.
NOTE: Use the VCK to diagnose fault codes. See
TOUBLESHOOTING section.
After a problem has been solved, ensure to clear
the fault(s) in the MPEM using the VCK. Refer to
DIAGNOSTIC PROCEDURES.
Resistance Measurement
When measuring the resistance with an ohmmeter,
all values are given for a temperature of 20C
(69F). The resistance value of a resistance varies
with the temperature. The resistance value for
usual resistor or windings (such as injectors) in-
creases as the temperature increases. However,
our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite
which means that the resistance value decreases
as the temperature increases. Take it into account
when measuring at temperatures different from
20C (69F). Use this table for resistance variation
relative to temperature for temperature sensors.
CONVERSION CHART FOR TEMPERATURE SENSORS
The resistance value of a temperature sensor may
test good at a certain temperature but it might be
defective at other temperatures. If in doubt, try a
new sensor.
WARNING
Ensure all terminals are properly crimped on
wires and connector housings are properly
fastened.
TEMPERATURE RESISTANCE (ohms)
C F NOMINAL LOW HIGH
- 30 - 22 12600 11800 13400
- 20 - 4 11400 11000 11800
- 10 14 9500 8000 11000
0 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
70 158 440 370 510
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
SMR2003-022_06_04A.FM 06-04-3
Also remember this validates the operation of the
sensor at ambient temperature. It does not vali-
date the over temperature functionality. To test it,
the sensor could be removed from the engine/
muffler and heated with a heat gun while it is still
connected to the harness to see if the MPEM will
detect the high temperature condition and gener-
ate a fault code.
When working with injectors, the resistance value
might test good while the complete current would
not flow through the wire when pulsating current
is supplied to the injector in its normal operation.
A solution would be to use a jumper wire to direct-
ly supply the injector from the MPEM. If it now
works, replace the defective wire. A Noid light
(available from after-market tool/equipment sup-
pliers) may also be used to validate the injector
operation.
AIR INDUCTION SYSTEM
THROTTLE BODY
Check that the throttle plate moves freely and
smoothly when depressing throttle lever.
FUEL DELIVERY
FUEL FILTER
To inspect the fuel filter, the fuel pump assembly has
to be removed from the fuel tank. See REMOVAL in
this subsection for the procedure.
FUEL PUMP
The fuel pump operation can be checked as fol-
lows.
Install the safety lanyard cap on the switch. The
fuel pump should run for approximately 1 second
and then shut off.
If not, check the electrical circuit and the 10 A fuse
on the MPEM module.
REGULATOR
The regulator is mounted on top of the fuel pump
assembly.
1. Regulator
To inspect the regulator, a fuel pressure test must
be done.
Check that battery voltage is above 12 volts.
Place a suitable container below the quick connect
fitting of the fuel rail.
Cover the quick connect fitting with a shop towel.
Press on both tabs and disconnect the quick con-
nect fitting.
1. Fuel rail
WARNING
Fuel is under pressure. Wipe off any fuel spillage
in the bilge.
1
F07F0DA
F07F11A 1
06-04-4 SMR2003-022_06_04A.FM
Install a fuel pressure gauge (P/N 529 035 591) to
the quick connect fitting of the fuel hose.
FUEL PRESSURE GAUGE (P/N 529 035 591)
Install the safety lanyard cap on the switch to ac-
tivate the fuel pump. The fuel pressure should be
between 386 - 414 kPa (56 - 60 PSI).
If the pressure is too high, replace the fuel pump
module.
If the pressure is too low, check the following com-
ponents:
fuel hoses and connections
fuel filter
fuel pump
regulator
voltage at fuel pump (minimum 8 Vdc).
FUEL INJECTOR
1. Inlet side
2. Filter
3. Wiring terminal
4. Coil
5. Plunger
6. Needle valve
7. Injection side
Touch the injector while cranking the engine to
feel the operation of the injector.
If there is no signal detected from the injector, dis-
connect the plug connector from the injector and
check the signal from the MPEM.
To check the signal, verify voltage at the plug con-
nector. There should be at least 6 Vdc while crank-
ing engine.
F02B0BA
1
F07F0CA
2
3
4
5
6
7
SMR2003-022_06_04A.FM 06-04-5
Check the resistance of the fuel injector circuits.
Disconnect the AMP plug connector #4 on the
MPEM.
Using a multimeter, check resistance value be-
tween terminal as follows.
The resistance should be between 2.3 and
2.5 at temperature of 20C (68F).
If resistance value is incorrect, check wiring har-
ness between AMP plug connector and fuel injec-
tors for damaged wires or bad connections. Repair
if necessary.
Recheck resistance value at AMP plug connector #4.
If not within specification, replace the fuel injector.
Leakage Test (fuel injectors)
To perform a leakage test, the injectors and fuel rail
have to be removed from engine. See REMOVAL
in this subsection for the procedure.
NOTE: Do not detach injectors from fuel rail.
Reconnect the wire connector of the injector.
Place each injector in a clean bowl.
Install the safety lanyard cap on the switch to ac-
tivate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop of fuel per minute.
1. Fuel injectors
2. Fuel rail
3. Injector nozzles
If not within specification, replace the fuel injector(s).
LEAK TEST
(supply and ventilation circuits)
Refer to FUEL SYSTEM.
HIGH PRESSURE TEST
(fuel pump circuit)
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
CONTACT LOCATION
Injector no. 1 18 and 20
Injector no. 2 19 and 21
F07F15A
18 19 20 21
WARNING
age inside bilge.
2 1 F07F16A
3
06-04-6 SMR2003-022_06_04A.FM
Press on both tabs and pull quick connect fitting
to disconnect the fuel hose from fuel rail.
1. Quick connect fitting
2. Fuel rail
Install fuel pressure gauge (P/N 529 035 591) be-
tween fuel rail and fuel hose from fuel tank.
Install the safety lanyard cap on the switch to activate
the fuel pump.
The fuel pump should run for approximately 1 sec-
ond and the fuel pressure should be between 386 -
414 kPa (56 - 60 PSI).
Check hose connections at fuel pump and at fuel
rail.
THROTTLE POSITION SENSOR
(TPS)
Check the resistance value of the throttle position
sensor.
1. Throttle position sensor (TPS)
Disconnect the AMP plug connector #4 on the
MPEM.
Using a multimeter, check the resistance between
terminal 3 (PURPLE/BROWN wire) and terminal 4
(BLACK/BROWN wire) on the AMP plug connector.
The resistance should be between 1.6 k and
2.4 k.
Check also the resistance between terminal 4
(BLACK/BROWN wire) and terminal 11 (WHITE/
BROWN wire) with the throttle plate in idle posi-
tion.
2 F02F1XA 1
F02B0BA
F07F0EA 1
SMR2003-022_06_04A.FM 06-04-7
The resistance should be between 710 and
1380 .
If resistance is below specifications, replace the
throttle position sensor (TPS).
If resistance is above specifications, disconnect
the connector of the throttle position sensor and
check resistance of wiring harness and terminals
between AMP plug connector and TPS sensor
connector.
If there is an open circuit, repair or replace the defec-
tive wire or terminal.
Reconnect the throttle position sensor connector
and recheck resistance values at AMP plug con-
nector #4.
If not within specification, replace the throttle po-
sition sensor.
NOTE: Whenever the TPS is replaced, removed
or adjusted, the TPS closed position must be re-
adjusted.
Voltage Test
If the sensor resistance value is good, check the volt-
age output from MPEM to throttle position sensor.
Disconnect plug connector from throttle position
sensor and connect a voltmeter between the
PURPLE/BROWN wire and the BLACK/BROWN
wire in the wiring harness.
Depress the start/stop button with the safety lan-
yard removed to activate the timer. There should
be 5 Vdc.
CRANKSHAFT POSITION
SENSOR (CPS)
Check the resistance of the crankshaft position
sensor.
1. Crankshaft position sensor (CPS)
Disconnect the AMP plug connector #4 from the
MPEM module.
terminal 7 (GREY/YELLOW wire) and terminal 14
(GREY/RED wire) on the plug connector.
946 at temperature above 20C (68F).
If not within specification, replace the crankshaft
position sensor.
11 3
F07F15B
4
F07H0CA
1
7
F07F15C
14
06-04-8 SMR2003-022_06_04A.FM
AIR TEMPERATURE SENSOR
(ATS)
NOTE: When testing the resistance of the air tem-
perature sensor (ATS), it is important to check the
ambient temperature. The resistance values for
the sensor will be different according to the tem-
perature.
Check the air temperature sensor resistance.
1. Air temperature sensor (ATS)
MPEM module.
terminal 6 (BLACK/WHITE wire) and terminal 13
(WHITE/GREY wire) on the plug connector.
2.736 k at temperature of 19C to 21C (66F to
70F).
If resistance is below specifications, replace air
temperature sensor (ATS).
If resistance is above specifications, disconnect
the connector of the air temperature sensor and
check resistance of wiring harness and terminals
between AMP plug connector and ATS sensor
connector.
If there is an open circuit, repair or replace the de-
fective wire or terminal.
Reconnect the air temperature sensor connector
and recheck the resistance between terminal 6
and terminal 13 in the AMP plug connector #4.
If not within specification, replace the air temper-
ature sensor.
WATER TEMPERATURE SENSOR
(WTS)
Resistance Test
Check the water temperature sensor resistance.
1. Water temperature sensor (WTS)
MPEM module.
terminal 5 (BLACK/ORANGE wire) and terminal 12
(TAN/ORANGE wire) on the plug connector.
F07F0FA 1
6
F07F15D
13
F07F0GA
1
SMR2003-022_06_04A.FM 06-04-9
2.736 k at temperature of 19C to 21C (66F to
70F).
If not within specification, continue with the fol-
lowing tests.
Operation Test
Remove WTS from engine and keep it connected.
Place the WTS in a metal container filled with wa-
ter and heat with a heat gun. Use a thermometer
to monitor the temperature. Keep the container
outside and away from bilge as much as possible.
Heat up above 94C (201F) then start engine.
CAUTION: Do not run the engine longer than 1
minute. However, if this necessary, plug the WTS
hole and use the flush kit to cool the engine.
At this temperature, the overheat beeper should
sound. Otherwise, check the following.
Stop engine.
Disconnect the WTS.
Remove safety lanyard and press the start/stop
button to power up the system and check for 5 V
on the TAN/ORANGE wire.
If there is not 5 V, check the wiring harness and
pin #12 on the #4 AMP plug connector.
Remove the TAN/ORANGE wire from the #12 po-
sition on the AMP plug connector, install a test
connector (a female connector with about 25 mm
(1 in) of wire) then reconnect the AMP plug con-
nector. Press the start/stop button, and check for
5 V on the test wire. If none is present, replace the
MPEM.
On the WTS connector, check for continuity to
ground on the BLACK/ORANGE wire when the
system is not powered up, and within 5 - 12 ohms
when the system is powered up. Otherwise,
check the wiring harness and pin #5 on the #4 AMP
plug connector. Remove the BLACK/ORANGE
wire from the #5 position on the AMP plug connec-
tor, install a test connector (as described above)
then reconnect the AMP plug connector. Repeat
the same tests as above, if the tests are not within
specs, replace the MPEM.
AIR PRESSURE SENSOR (APS)
1. Air pressure sensor (APS)
Check the air pressure sensor resistance.
MPEM module.
WARNING
Do not use an open flame in the bilge area.
Fuel vapors may be present and this may lead
to an explosion.
F07F15E
12 5
F07F0HA
1
06-04-10 SMR2003-022_06_04A.FM
terminal 9 (WHITE/BLUE wire) and terminal 2
(BLACK/BLUE wire) on the plug connector.
8.2 k.
Check also the resistance between terminal 2
(BLACK/BLUE wire) and terminal 1 (PURPLE/
BLUE wire) of the plug connector.
8.2 k.
If not within specification, disconnect the connec-
tor of the water temperature sensor and check re-
sistance of wiring harness and terminals between
AMP plug connector and APS sensor connector.
Reconnect the air pressure sensor connector and
recheck the resistance value between terminals in
the AMP plug connector #4.
If not within specification, replace the air temper-
ature sensor.
Voltage Test
If the sensor resistance value is within specifications,
disconnect the plug connector from the APS sensor
and check the voltage between the PURPLE/BLUE
wire and the BLACK/BLUE wire in the wiring harness
from the MPEM.
Install safety lanyard. There should be 5 Vdc.
RAVE SOLENOID
RAVE SOLENOID
MPEM module.
Check resistance value between terminal 16 and
terminal 23 on the plug connector.
The resistance value should be 30 .
2
F07F15F
1 2 9
F07D0GA
F07F15G
23 16
SMR2003-022_06_04A.FM 06-04-11
RFI SENSORS RESISTANCE VALUES
COMPONENT
TERMINAL
NUMBER
WIRE COLOR
RESISTANCE
VALUE
VOLTS
Air pressure sensor
1 and 2 PU/BL and BK/BL 2.4 k - 8.2 k ohms
5 Vdc between
PU/BL and BK/BL
9 and 2 WH/BL and BK/BL 3.4 k - 8.2 k ohms
Throttle position sensor
3 and 4 PU/BW and BK/BW 1.6 k - 2.4 k ohms 5 Vdc between
PU/BW and
BK/BW
4 and 11 BK/BW and WH/BW 710 - 1380 ohms
Water temperature sensor 5 and 12 BK/OR and TA/OR 2280 - 2736 ohms N.A.
Air temperature sensor 6 and 13 BK/WH and WH/GY 2280 - 2736 ohms N.A.
Crankshaft position sensor 7 and 14 GY/YL and GY/RE 774 - 946 ohms N.A.
Rave solenoid 16 and 23 PU/GY and BK/GY 30 ohms N.A.
Injector no. 1 18 and 20 BL/PU and BL/BK 2.3 - 2.5 ohms
6 Vdc at the plug
connector
Injector no. 2 19 and 21 GR/PU and BK/GR 2.3 - 2.5 ohms
Subsection 05 (TROUBLESHOOTING SUMMARY)
SMR2003-022_06_05A.FM 06-05-1
TROUBLESHOOTING SUMMARY 0
ENGINE DOES NOT START
If the engine does not start, the following items
should be verified in this order:
fuses
ignition (spark)
fuel pump
check fault codes in the ECU memory.
FLOODED ENGINE FEATURE
If the engine does not start and it is flooded, pro-
ceed as follows:
Remove spark plugs and dry them using a rag.
Depress and hold the throttle lever at full throttle
position.
Install the safety lanyard cap on the switch. Press
the start/stop button wait 2 seconds then crank
the engine for approximately 10 seconds.
NOTE: Proceeding in this order, no fuel is injected
and the accumulated fuel in the engine will be ex-
pelled.
Reinstall spark plugs and connect cables.
Start engine normally without applying the throt-
tle.
SPARK PLUG INSPECTION
Whenever replacing the spark plugs, always use
NGK BR8ES with the resistor feature. The spark
plug gap is set to 0.5 - 0.6 mm (.02 - .024 in).
To check for ignition, attach an inductive timing
light to the high tension lead while turning the en-
gine with the starter.
Reversed high tension cables will not allow the RFI
to run. Unlike other Sea-Doo models, the spark plugs
spark independently on each piston stroke. Re-
versed high tension cables will cause backfires.
ECU FAULT CODES
Fault codes in the ECU memory will identify poten-
tial problems with the RFI system. When checking
fault codes without engine in operation, the CPS
fault code will always appear. Also, the 04 FC fault
code will always appear.
Disconnecting the battery will erase the fault codes
in the ECU memory.
ENGINE STARTS BUT RUNS
POORLY
If the engine starts but runs poorly, the following
items should be verified in this order:
Check spark plug condition.
Check fault codes in the ECU memory.
Check fuel pressure.
Check TPS adjustment.
If some work has been performed on the unit,
make sure injector wire connectors were not
mixed. It is also possible that the RAVE solenoid
connector be mixed with one of the injector con-
nector. Refer to the wiring diagram for wire colors
and positions.
ENGINE STARTS BUT STALLS
AFTER APPROXIMATELY
30 SECONDS
The RPM signal (GREY wire) is short circuit to the
ground. Check wire condition. If the wire test
good, either the tachometer or Info Center is de-
fective.
ENGINE CANNOT REACH
MAXIMUM REVOLUTIONS
Check battery voltage. When voltage is too low,
the MPEM limits the engine revolutions.
Recharge or replace battery.
The RAVE system is not functioning properly. The
sliding valves do not open. Check pressure hoses
and check valve from crankcase to RAVE solenoid.
Check RAVE solenoid.
Subsection 06 (ADJUSTMENT)
SMR2003-022_06_06A.FM 06-06-1
ADJUSTMENT 0
THROTTLE CABLE
ADJUSTMENT
Fully depress throttle lever. Lever must touch han-
dlebar grip.
1. Must touch handlebar grip
Ensure throttle plate is fully open.
Adjust cable to obtain a gap of 0.75 mm (.030 in)
between throttle lever stopper and bracket on
throttle body.
(TPS)
This adjustment is very important. The setting of
the TPS will determine the basic parameters for all
fuel mapping.
NOTE: Adjustment must be done each time the
throttle position sensor (TPS) is loosened or re-
moved.
CAUTION: An improperly adjusted TPS may
lead to serious engine damage.
The adjustment of the TPS is performed using the
MPEM programmer.
CLOSED TPS
To perform this adjustment, proceed as follows:
Using VCK
035 844) with B.U.D.S. software. Look under the
SETTING section to perform the Closed TPS ad-
justment.
Using MPEM Programmer
Access the BOSCH SYSTEM in the MPEM pro-
grammer. Then, select ADJUSTMENT in the sub-
menu.
Choose CLOSE TPS in the ADJUSTMENT menu.
The screen will display the actual adjustment of
the TPS in degrees and it will also offer to adjust it.
CAUTION: Do not select YES until the idle
speed screw is loosened to allow the throttle
plate to close.
Loosen the lock nut of the idle speed screw.
Loosen the idle speed screw until it does not con-
tact the throttle plate stopper.
Loosen the adjustment of the throttle cable.
1. Idle speed screw
Depress throttle lever a few times and ensure
throttle plate is completely closed.
Selecting YES will instantly readjust the close
throttle position adjustment to the new setting.
NOTE: If the ECU is replaced, the TPS closed po-
sition must be readjusted.
IDLE SPEED
grammer. Then, select REAL TIME in the sub-menu.
Turn idle speed screw approximately 3 turns from
the point when the screw end touches the lever,
or until the TPS idle position reads 6 - 7.
For a precise adjustment of the idle speed, it should
be finalized in water.
Idle speed in water is 1500 100 RPM.
F01K08A
1
F07F17A
1
SMR2003-022_06_07A.FM 06-07-1
MPEM
IMPORTANT: When MPEM is replaced, the safe-
ty lanyard(s), the TPS closed position and the TDC
setting must be reprogrammed/reset. Refer to
their specific section for adjustment.
(TPS)
Remove the air intake silencer.
Remove the flame arrester.
Remove the air temperature sensor to ease removal
of the TPS.
Disconnect the connector of the TPS.
Loosen 2 Allen screws retaining the TPS.
Remove TPS.
AIR TEMPERATURE SENSOR
(ATS)
Remove the flame arrester.
Disconnect the connector of the ATS.
Pull the ATS from the grommet retaining it.
AIR PRESSURE SENSOR (APS)
Disconnect the connector of the APS.
Loosen Allen screw retaining the APS.
Remove the APS.
At installation, apply Loctite 243 (blue) on screw
threads.
WATER TEMPERATURE
SENSOR (WTS)
Disconnect the connector of the WTS.
Loosen the WTS from the cylinder head.
At installation, apply Loctite 518 on threads of the
WTS.
CRANKSHAFT POSITION
SENSOR (CPS)
Disconnect the connector of the CPS.
Loosen Allen screw retaining the CPS.
Remove the CPS.
At installation, apply Loctite 243 (blue) on the Allen
screw.
NOTE: Clean threads prior installing screw.
FUEL PUMP ASSEMBLY
Open the front storage compartment cover.
Remove the storage basket.
Remove the glove box.
Disconnect the wire connector from the fuel pump
assembly.
Disconnect fuel vent hose from fuel pump assem-
bly.
Cover the quick connect fitting with a shop towel.
nect fitting.
Loosen nuts retaining the fuel pump assembly to
the fuel tank.
1. Loosen nuts
WARNING
Fuel is under pressure. Wipe off any fuel spill-
age in the bilge. Fuel is flammable and explo-
sive under certain conditions. Always work in
a well ventilated area.
1
F07F0DB
06-07-2 SMR2003-022_06_07A.FM
Remove fuel pump assembly from fuel tank.
REGULATOR
The regulator is not serviceable. Replace the fuel
pump assembly if the regulator is defective.
FUEL FILTER
The fuel filter is not serviceable. Replace the fuel
pump assembly if the fuel filter must be replaced.
FUEL INJECTORS
Place a suitable container below the quick connect
fitting of the fuel rail.
Cover the quick connect fitting of the fuel rail with
a shop towel.
nect fitting.
Disconnect the wire connectors of both fuel injec-
tors.
1. Press retaining clip to unlock the connector
Loosen both screws retaining the fuel rail to the
cylinders.
1. Loosen screws retaining the fuel rail
Remove the fuel rail with both fuel injectors.
To remove the fuel injector from the fuel rail, pry
off the retaining clip.
1. Pry the clip
Carefully inspect O-rings condition before rein-
stalling fuel injectors. Replace O-rings with new
ones if damaged.
When reinstalling the fuel injector, install the re-
taining clip to the injector, then insert the injector
into the fuel rail.
Apply a thin layer of injection oil to O-rings of fuel
injectors to ease fuel rail installation.
Check injectors to ensure there is no leak.
F07F0RA
1
WARNING
If a leak is present, immediately stop the en-
gine. Do not use engine until the leak is re-
paired.
F07F0SA 1
F07F0TA 1
Section 07 ENGINE MANAGEMENT (DI)
SMR2003-049_07_01ATOC.FM 07-01-1
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 07-02-1
OPERATING PRINCIPLE.................................................................................................... 07-02-2
AIR INDUCTION................................................................................................................. 07-02-2
AIR COMPRESSOR SYSTEM............................................................................................ 07-02-2
FUEL DELIVERY SYSTEM................................................................................................. 07-02-2
BASIC OPERATION........................................................................................................... 07-02-2
AIR/FUEL RAIL ASSEMBLY .............................................................................................. 07-02-2
FUEL PUMP MODULE....................................................................................................... 07-02-3
MPEM (Multi-Purpose Electronic Module)...................................................................... 07-02-4
IGNITION SYSTEM............................................................................................................ 07-02-8
COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 07-03-1
GENERAL ........................................................................................................................... 07-03-1
FUEL SYSTEM................................................................................................................... 07-03-1
ELECTRICAL SYSTEM....................................................................................................... 07-03-2
AMP CONNECTOR PIN-OUT............................................................................................ 07-03-3
QUICK FUEL PRESSURE TEST ........................................................................................ 07-03-4
THROTTLE BODY .............................................................................................................. 07-03-5
AIR COMPRESSOR............................................................................................................ 07-03-9
PRESSURE TEST............................................................................................................... 07-03-9
REPAIR ............................................................................................................................... 07-03-10
FUEL DELIVERY................................................................................................................. 07-03-13
FUEL PRESSURE REGULATOR........................................................................................ 07-03-13
FUEL INJECTOR ................................................................................................................ 07-03-14
AIR/FUEL RAIL ................................................................................................................... 07-03-15
DIRECT INJECTOR ............................................................................................................ 07-03-17
FUEL PUMP ....................................................................................................................... 07-03-18
MPEM REPLACEMENT ..................................................................................................... 07-03-23
MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 07-03-28
MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 07-03-29
EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 07-03-30
KNOCK SENSOR (KS) ....................................................................................................... 07-03-30
RAVE SOLENOID............................................................................................................... 07-03-31
IGNITION COIL .................................................................................................................. 07-03-32
07-01-2 SMR2003-049_07_01ATOC.FM
TDC SETTING..................................................................................................................... 07-03-34
SPARK PLUGS.................................................................................................................... 07-03-38
CRANKING SYSTEM.......................................................................................................... 07-03-39
DI SYSTEM TEST SUMMARY........................................................................................... 07-03-39
DIAGNOSTIC PROCEDURES................................................................................................. 07-04-1
GENERAL............................................................................................................................ 07-04-1
FAULT DETECTION AND COMPENSATORY ACTIONS.................................................. 07-04-2
COMPONENT FAILURE WARNING SYSTEM.................................................................. 07-04-2
VCK (Vehicle Communication Kit) ................................................................................... 07-04-4
DI SYSTEM FAULT CODES............................................................................................... 07-04-5
SMR2003-023_07-02A.FM 07-02-1
OVERVIEW 0
F12F03T
07-02-2 SMR2003-023_07-02A.FM
OPERATING PRINCIPLE
The Orbital Combustion Process (OCP) provides a
stratified combustion process resulting from the
direct injection of a finely atomized fuel spray (less
than 10 microns). This is achieved by using a pneu-
matically assisted direct injection system, a
unique combustion chamber geometry and a pre-
cise control of the combustion process by the
MPEM (Multi-Purpose Electronic Module).
AIR INDUCTION
Air for combustion is drawn directly at the base of
the engine through two 46 mm throttle bodies.
The air flow is controlled by two throttle plates.
The air continues through the reed valves into the
crankcase.
TWIN 46 mm THROTTLE BODIES
AIR COMPRESSOR SYSTEM
The air compressor supplies the compressed air
required for fuel atomization in the air injector. It is
integrated with the engine and mechanically driv-
en by the counterbalance shaft. It also supplies the
air pressure required to operate the RAVE valves.
FUEL DELIVERY SYSTEM
BASIC OPERATION
When the piston reaches the correct position, the
MPEM opens the fuel injector and fuel is dis-
charged into a cavity inside the direct injector.
Next, the direct injector opens and the fuel is dis-
charged into the combustion chamber by the com-
pressed air which breaks the fuel up into a very
fine mist in the process. This air/fuel mixture is
then ignited by the spark plug.
AIR/FUEL RAIL ASSEMBLY
TYPICAL
1. Air/fuel rail
2. Fuel injector
3. Fuel pressure regulator
4. Air pressure regulator
5. Air inlet hose
6. Fuel inlet
7. Air return
8. Fuel return
1 F12F05A 1
F12D01A
2
5 F12F06A
4 3 2 6
7 8 1
SMR2003-023_07-02A.FM 07-02-3
The air/fuel rail assembly is mounted on top of the
cylinder head. It provides support for the air/fuel
injectors and both air and fuel regulators. It also
contains passages for the air and the fuel. The rail
is a small reservoir for the injectors that keeps
enough fluid at the proper pressure to supply the
injectors demand.
Fuel Injector
Fuel injectors are used to provide fuel from the
fuel rail to the direct injector.
Fuel Pressure Regulator
A fuel pressure regulator controls the pressure in-
side the fuel rail, and allows the excess of fuel to
return to the fuel tank. The fuel pressure regulator
regulates the fuel pressure at approximately
185 kPa (27 PSI) higher than the air pressure in the
fuel rail. The back side of the diaphragm is ex-
posed to the air rail pressure. As the air pressure
increases in the fuel rail, the fuel pressure needed
to open the regulator will increase equally.
The differential pressure regulation utilizes the air
pressure reference signal to maintain constant
pressure drop across fuel injector orifice.
The initial operating pressure of the regulator is
preset by the manufacturer and is not adjustable.
Direct Injector
Also called air injector, two direct injectors (one
per cylinder) are used to inject air/fuel mixture into
the combustion chamber.
Air Pressure Regulator
An air pressure regulator regulates the pressure of
air delivered by the air compressor.
It regulates the pressure developed inside the air
passage to approximately 550 kPa (80 PSI).
The initial operating pressure of the regulator is
preset by the manufacturer and is not adjustable.
FUEL PUMP MODULE
The fuel pump module is located inside the fuel
tank. The module includes the fuel pump and the
fuel level sensor.
Fuel Pump
It operates at a nominal pressure of approximately
735 kPa (107 PSI).
Fuel Filter
A mesh filter is located at the bottom of the fuel
pump module inside the fuel tank. An inline fuel
filter is also installed on the fuel line going to the
fuel rail.
F12D0AA
07-02-4 SMR2003-023_07-02A.FM
MPEM
(Multi-Purpose Electronic Module)
The electronic fuel injection is equipped with a
MPEM. It is also called ECU (Electronic Control
Unit). It is the brain of the electrical system/fuel
injection system.
TYPICAL
1. Multi-purpose electronic module (MPEM)
The MPEM is mounted in the front of the water-
craft.
The MPEM is directly powered by the battery. It is
responsible for the following engine management/
electrical functions:
start/stop function
DESS (Digitally Encoded Security System)
ignition timing maps
injection maps (fuel injector and direct injector)
MPEM contains a total of 34 maps (injection
and ignition) for optimum engine operation in all
conditions
engine RPM limiter
etc.
The MPEM features a permanent memory that
will keep the programmed safety lanyard(s) active,
fault codes and other vehicle information, even
when the battery is removed from the watercraft.
MPEM General Functions
Safety Lanyard Reminder
If engine is not started within 5 seconds after in-
stalling the safety lanyard on its post, 4 short
beeps every 3 second interval will sound for ap-
proximately 2 hours to remind you to start the en-
gine or to remove safety lanyard. Afterwards, the
beeps will stop. The same will occur when safety
lanyard is left on its post 5 seconds after engine is
stopped.
Always ensure safety lanyard is not left on its post
after engine is stopped.
IMPORTANT: Leaving the safety lanyard on its
post when engine is not running will slowly dis-
charge the battery.
Antistart Feature
This system allows starting the vehicle only with
safety lanyard(s) that has been programmed to op-
erate a specific watercraft. This functionality is the
DESS system. See below for details.
Digitally Encoded Security System (DESS)
The following components are specially designed
for this system: Multi-Purpose Electronic Module
(MPEM), safety lanyard cap and safety lanyard
post.
The safety lanyard cap contains a magnet and a
ROM chip. The magnet actually closes the reed
switch inside the post which is the equivalent of a
mechanical ON/OFF switch. The chip has a unique
digital code.
F12D0EA
1
SMR2003-023_07-02A.FM 07-02-5
The DESS circuitry in the watercraft MPEM is ac-
tivated at the factory. Therefore, a safety lanyard
must be programmed to start the engine.
NOTE: Actually, it is the memory of the MPEM
which is programmed to recognize the digital code
of the safety lanyard cap. This is achieved with the
MPEM programmer (P/N 529 035 878) or the VCK
(Vehicle Communication Kit) (P/N 529 035 844).
Refer to their operation manual or help system to
program a safety lanyard.
The system is quite flexible. Up to 8 safety lan-
yards may be programmed in the memory of the
watercraft MPEM. They can also be erased indi-
vidually.
The MPEM also offers a special safety lanyard the
Sea-Doo LK (learning key) which can be pro-
grammed so that the vehicle can be run only at a
limited speed approximately 48 km/h (30 MPH).
Such feature is ideal for first time riders or renters.
NOTE: If desired, a safety lanyard can be used on
other watercraft equipped with the DESS. It only
needs to be programmed for that watercraft.
When connecting a safety lanyard cap on the post,
the DESS is activated and will emit audible signals:
2 short beeps indicate a working safety lanyard.
Engine starting can take place.
1 long beep indicates a wrong safety lanyard is
being used or that something is defective. En-
gine starting is not allowed.
The MPEM features a self-diagnostic mode. Refer
to DIAGNOSTIC PROCEDURES subsection for
more information.
The memory of the MPEM is permanent. If the
battery is disconnected, no information is lost.
When ordering a new MPEM from the regular
parts channel, the DESS circuitry will be activated.
Gauges Current Supply
When installing the safety lanyard it activates the
reading of gauges without the engine running. It
will give access to most functions of the informa-
tion center gauge without starting the engine.
NOTE: The fuel pump will be activated for 2 sec-
onds to build up pressure in the fuel injection sys-
tem, only when connecting the safety lanyard cap
to the post.
Engine Starting
If the MPEM recognizes a valid safety lanyard, it
allows engine to start when the start/stop button
is pressed.
If start/stop button is held after engine has started,
the MPEM automatically stops the starter when
the engine speed reaches 1000 RPM.
If start button is activated while the throttle lever
is depressed more than 70%, the engine will not
be allowed to start.
Engine RPM Limiter
The MPEM will limit the maximum engine speed.
Engine Stopping
There are 2 ways to stop the engine.
Press start/stop button or remove the safety lan-
yard cap from its post.
Low-Fuel and Low-Oil Level Warning Device
When the fuel level in the reservoir is low, the fuel
level sensor transmits a signal to the MPEM. The
MPEM sends out signals to the beeper and to the
information center gauge.
When the oil level is low in the reservoir, the
MPEM sends out a signal to the information center
gauge and the pilot lamp on the gauge will turn on.
Power Distribution
A power supply cut-off relay isolates the battery
from the electrical system to prevent battery
drain. When the safety lanyard is installed, the re-
lay then supplies current to the MPEM.
The relay is located in electrical box cover.
The MPEM distributes power from battery to all
accessories (except bilge pump which is connect-
ed to battery power on XP DI models). Accesso-
ries are protected by fuses integrated in the
MPEM, in fuse holder(s) close to MPEM or in the
electrical box. Fuses are identified besides their
holder.
IMPORTANT: The sensors and injectors are con-
tinuously powered with the supply from the bat-
tery. The MPEM switches the ground to com-
plete the electrical circuits it controls. Take this
into account when troubleshooting the electrical
system.
WARNING
When programming a Sea-Doo LK (learning
key), use only a lanyard that is identified for
that purpose. Otherwise, a customer could use
a vehicle with a greater speed than he was ex-
pecting.
07-02-6 SMR2003-023_07-02A.FM
MPEM Engine Management Functions
F12D0CS
SMR2003-023_07-02A.FM 07-02-7
This engine management system controls both
the fuel injection and the ignition timing.
As shown in the DI CONTROL SYSTEM illustra-
tion, the MPEM is the central point of the fuel in-
jection system. It reads the inputs, makes compu-
tations, uses pre-determined parameters and
sends the proper signals to the outputs for proper
engine management.
The MPEM also stores the fault codes and general
information such as: operating conditions, vehicle
hours, serial numbers, customer and maintenance
information.
The MPEM reads the signals from different sen-
sors which indicate engine operating conditions at
milli-second intervals.
Signals from sensors are used by the MPEM to
determine the injection parameters (fuel maps) re-
quired for optimum air-fuel ratio.
The CPS and both TPS are the primary sensors
used to control the injection and ignition timing.
Other sensors are used for secondary input.
NOTE: The EGT sensor does not provide control
inputs to the MPEM. Its sole purpose is to protect
the exhaust system components by emitting a
warning signal in the event of overheating.
Ignition Timing
The MPEM is programmed with data (it contains
ignition mappings) for optimum ignition timing un-
der all operating conditions. Using engine operat-
ing conditions provided by the sensors, the MPEM
controls the ignition timing for optimum engine
operation.
Knock Sensor
A knock sensor is mounted on top of the cylinder
head. It detects specific vibration that would be
typically generated by engine detonation. If deto-
nation occurs, the knock sensor detects it and the
MPEM retards the ignition advance temporarily (it
goes in a specific mode) until detonation stops.
Engine Modes of Operation
The MPEM controls different operation modes of
the engine to allow proper operation for all possi-
ble conditions: Cranking, start up, idle, warm up,
normal operation, Sea-Doo LK (learning key)
(limited vehicle speed), engine speed limiter,
flooded engine and limp home (see below).
Flooded Engine (drowned mode)
If the engine does not start and it is flooded, pro-
ceed as follows:
Remove spark plugs and dry them using a rag.
While engine is stopped, depress and HOLD the
throttle lever at full throttle position for cranking.
Crank the engine several times.
A 1 second beep every second indicates the drowned
mode is active.
NOTE: Proceeding in this order, no fuel is injected,
no ignition occurs and the accumulated fuel in the
engine will be expelled.
In case of water-flooded engine, if water does not
completely go out, it may be necessary to remove
the air intake silencer then to lean the vehicle so
that water can flow out from throttle bodies.
Reinstall spark plugs and connect cables.
Start engine normally without applying the throttle.
Monitoring System
The MPEM monitors the electronic components
of the fuel injection system and some compo-
nents of the electrical system. When a fault oc-
curs, it sends visual messages through the infor-
mation center and/or audible signals through a
beeper to inform you of a particular condition. Re-
fer to the DIAGNOSTIC PROCEDURES subsec-
tion for the displayed messages and the beeper
coded signals chart.
Limp Home Modes
Besides the signals as seen above, the MPEM
may automatically use default parameters for the
engine management to ensure the adequate op-
eration of the watercraft if a component of the fuel
injection system is not operating properly.
Depending on the severity of the malfunction, the
watercraft speed may be reduced and not allowed
to reach its usual top speed.
The engine RPM may be limited to idle if some
critical components fail. In this case, removing and
reinstalling the safety lanyard on its post may al-
low retrieving normal operation.
07-02-8 SMR2003-023_07-02A.FM
These performance-reduced modes allow the rid-
er to go back home which would not be possible
without this advanced system. Refer to the DIAG-
NOSTIC PROCEDURES for a complete chart.
If a fault occurs and involves a limp home mode
operation, the DI system will reduce engine RPM
gradually to the proper level.
Diagnostic Mode
The malfunctions are recorded in the memory of
the MPEM. The memory of the MPEM can be
checked using the VCK (Vehicle Communication
Kit) (P/N 529 035 844) to see the fault codes. Refer
to the DIAGNOSTIC PROCEDURES subsection.
IGNITION SYSTEM
The ignition system consist of different sub-systems
where some are interrelated.
Unregulated AC current is produced by the mag-
neto. Part of the AC current is rectified and regu-
lated for the charging system.
A 12 volts battery supplies the Multi-Purpose Elec-
tronic Module (MPEM) with DC current.
Refer to CHARGING SYSTEM.
The following type of ignition system is used:
Digital Inductive System.
Magneto System
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric
current (AC).
The magneto has a 3 phase-delta wound stator on
18 poles. Capacity is 270 watts.
Ignition Coil
Ignition coil induces voltage to a high level in the
secondary windings to produce a spark at the
spark plug.
Two separate ignition coils receive input from the
MPEM. Each coil provides high voltage to its cor-
responding spark plug.
This ignition system allows spark plugs to spark
independently.
CAUTION: Do not interchange spark plug ca-
bles. The white tape on the ignition coil should
match the white tape on the high tension cable.
Both coils are located inside the electrical box.
TYPICAL
1. PTO side ignition coil
2. MAG side ignition coil
F12R0UC
1 2
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
SMR2003_024 _07_03A.FM 07-03-1
COMPONENT INSPECTION AND
ADJUSTMENT 0
GENERAL
It is important to ensure that the mechanical integrity
of the engine/propulsion system is present:
good jet pump/drive system operation
good engine compression and properly operat-
ing mechanical components, no leaks etc.
fuel pump connection and fuel lines without leaks.
Check the chart in TROUBLESHOOTING section
to have an overview of problems and suggested
solutions.
When replacing a component, always check its
operation after installation.
FUEL SYSTEM
035 844) to release the fuel pressure in the sys-
tem. Look in the ACTIVATION section of the
B.U.D.S. software.
Always disconnect battery properly prior to
working on the fuel system.
support. Then, pressurize the fuel system. Perform
the high pressure test as explained in this section
and pressurize the fuel tank and fuel lines as ex-
plained in FUEL SYSTEM section.
WARNING
Air compressor hose may be hot. Use a rag
or gloves or let hose cool down.
WARNING
low the recommendation described here. Note
that some hoses may have more than one clamp
at their ends. Ensure to reinstall the same quan-
tity of clamps at assembly.
WARNING
Fuel lines remain under pressure at all times. Al-
ways proceed with care and use appropriate
safety equipment when working on pressurized
fuel system. Wear safety glasses and 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 the VCK (Vehicle Com-
munication Kit) 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 bat-
tery prior to working on the fuel system. After
performing a pressure test, use the valve on the
fuel pressure gauge to release the pressure (if so
equipped).
WARNING
age and that NO fuel line is disconnected prior to
installing the safety lanyard on the DESS post.
Always perform the high pressure test if any
component has been removed. A pressure test
must be done before connecting the safety lan-
yard. The fuel pump is started each time the safe-
ty lanyard is installed and it builds pressure very
quickly.
07-03-2 SMR2003_024 _07_03A.FM
CAUTION: Never use injector cleaning products.
They may contain additive that could damage in-
jector components. A copper wire brush may be
used to clean the tip of the direct injectors if nec-
essary.
To check air/fuel rail for leaks, first pressurize the
system then spray soapy water on all hose con-
nections, regulators and injectors. Air bubbles will
show the leaking area. Check also for leaking fuel
or fuel odor.
ELECTRICAL SYSTEM
It is important to check that the following electrical
system components are functioning properly:
battery
fuses
DESS
ignition (spark)
ground connections
wiring connectors.
Never use a battery charger to replace temporarily
the battery, as it may cause the MPEM to work
erratically or not to work at all. Check related-circuit
fuse solidity and condition with an ohmmeter. Vi-
sual inspection could lead to false results.
used.
Pay particular attention to ensure that terminals
are not out of their connectors or out of shape. The
troubleshooting procedures cover problems not
resulting from one of these causes.
Before replacing a MPEM, always check electrical
connections. Make sure that they are very tight and
they make good contact and that they are corrosion-
free. A defective module could possibly be re-
paired simply by unplugging and replugging the
MPEM. The voltage and current might be too
weak to go through dirty wire terminals. Check
carefully if posts show signs of moisture, corro-
sion or if they look dull. Clean terminals properly
and then coat them with silicon-based dielectric
grease or other appropriate lubricant (except if oth-
erwise specified) when reassembling them. If the
newly replaced MPEM is working, try the old one
and recheck if it works.
Ensure that all electronic components are genu-
ine particularly in the ignition system. Installing
resistive caps, non-resistive spark plug cables (or
modified length) or non-resistive spark plugs may
NOTE: Diagnostic can be done through the VCK.
See DIAGNOSTIC PROCEDURES section.
the fault(s) in the MPEM using the VCK. Refer to
DIAGNOSTIC PROCEDURES section.
WARNING
If any gasoline leak and/or odor are present,
do not start the engine. Repair the leak.
WARNING
Never use a hose pincher on high pressure
hoses.
WARNING
All electrical actuators (injectors, fuel pump,
RAVE solenoid, ignition coil and starter sole-
noid) are permanently connected to the bat-
tery positive terminal, even when the safety
lanyard is removed. Always disconnect the
battery prior to disconnecting any electric or
electronic parts.
WARNING
wires and connector housings are properly
fastened.
SMR2003_024 _07_03A.FM 07-03-3
(69F). The value of a resistance varies with the
temperature. The resistance value for usual resis-
tor or windings (such as injectors) increases as
the temperature increases. However, our temper-
ature sensors are NTC types (Negative Tempera-
ture Coefficient) and work the opposite which
means that the resistance value decreases as the
temperature increases. Take it into account when
measuring at temperatures different from 20C
(69F). Use this table for resistance variation rela-
tive to temperature for temperature sensors.
new sensor.
connected to the harness to see if the MPEM will
detect the high temperature condition and gener-
ate a fault code.
When working with injectors, the resistance value
might test good while the complete current would
not flow through the wire when pulsating current
is supplied to the injector in its normal operation.
A solution would be to use a jumper wire to direct-
ly supply the injector from the MPEM. If it now
works, replace the defective wire. A Noid light
(available from after-market tool/equipment sup-
pliers) may also be used to validate the injector
operation.
AMP CONNECTOR PIN-OUT
Use this diagram to locate the terminal numbers
on the AMP connector no. 3 and no. 4 of the wir-
ing harness when performing tests.
AMP CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
- 30 - 22 12600 11800 13400
- 20 - 4 11400 11000 11800
- 10 14 9500 8000 11,000
0 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
70 158 440 370 510
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
F07F15A
18 19 20 21
07-03-4 SMR2003_024 _07_03A.FM
QUICK FUEL PRESSURE TEST
Disconnect outlet hose (the one with the fuel fil-
ter) from fuel pump using tool (P/N 529 035 714).
Connect adapter to pressure gauge as shown.
NOTE: On XP DI models, remove seat and rub-
ber plug underneath to gain access to fuel pump
and hoses.
1. Pressure gauge (P/N 529 035 709)
2. T-adapter (P/N 529 035 710)
Install pressure gauge between disconnected hose
(inline installation).
TYPICAL
1. Fuel filter
2. Fuel line going to air/fuel rail
3. Pressure gauge between disconnected hose (inline installation)
Install safety lanyard and observe fuel pressure.
Do not crank engine.
If pressure is within limits, air/fuel rail is working
adequately. Proceed with the fuel pressure test
below.
If pressure is out of limits, refer to FUEL DELIV-
ERY below and proceed with the tests described
there.
Crank or start engine and observe fuel pressure.
If pressure is within limits, fuel and air systems are
working adequately. No subsequent tests are nec-
essary for the air/fuel system.
Remove pressure gauge and reinstall fuel hose. At
installation apply engine oil on O-ring.
If pressure is out of limits, proceed with all the tests.
WARNING
Read PRESSURE TEST under AIR/FUEL RAIL
further in this section for precautions and
setup to take care of, before performing this
test. The procedure here is a quick summary.
F12R08A
1
2
FUEL REGULATOR PRESSURE
(when installing safety lanyard)
185 14 kPa (27 2 PSI)
FUEL PRESSURE
(when cranking engine
or when engine is running)
738 14 kPa (107 2 PSI)
2
3
1
F12R09A
SMR2003_024 _07_03A.FM 07-03-5
THROTTLE BODY
Mechanical Inspection
Check that the throttle plates moves freely and
smoothly when depressing throttle lever. Take this
opportunity to lubricate the throttle cable.
IMPORTANT: The throttle bodies are designed to
be tamper proof. Changing the idle stop or modi-
fying them in any way will not increase perfor-
mance or change the idle speed.
Before replacing any parts, check the following as
these could be causing the fault. Perform the test
while the engine is not running.
Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
Throttle body idle set screw is loose or worn.
Throttle linkage between the two throttles has
moved.
TPS is loose.
Corroded or damaged wiring or connectors.
Throttle body has been replaced and the closed
TPS reset has not been performed.
MPEM has been replaced and the closed TPS
reset has not been performed.
Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS) in
ELECTRONIC MANAGEMENT below.
Replacement
Removal
To remove throttle bodies from engine, proceed
as follows:
Remove air intake silencer. Refer to AIR INTAKE
section.
Disconnect TPS connectors.
Disconnect throttle cable and oil injection pump
cable.
Detach hoses and remove fasteners retaining
throttle bodies and pull out together.
If only one throttle body replacement is required,
detach them and remove the sealant on idle set
screw head. Gently remove the plastic cap from
the synchronization screw.
Remove TPS, throttle lever, spring and guide from
the old throttle body.
Installation
Reinstall removed parts on the new throttle body.
For TPS replacement procedures, refer to THROT-
TLE POSITION SENSOR (TPS) in ELECTRONIC
MANAGEMENT below.
Properly attach throttle bodies together if previ-
ously detached.
Adjustment
Throttle Body Synchronization
NOTE: If both throttle bodies are replaced togeth-
er with new ones, no synchronization is required
as it has already been set at the factory. However,
proceed with throttle cable and closed TPS adjust-
ments as described below. If only one throttle body
is replaced, proceed with the complete following
adjustments. Ensure to perform all the adjust-
ments prior to starting the engine. Otherwise, en-
gine may run at a limited RPM in limp home mode.
IMPORTANT: The throttle body synchronization
is required only when replacing one throttle body.
Otherwise, do not tamper with it as this is NOT a
regular maintenance procedure.
The master throttle body is the one driven by the
throttle cable. The slave throttle body follows the
master and must be synchronized with the master.
1. Throttle cable attachment
2. Master throttle body
3. Master throttle plate
4. Slave throttle body
5. Slave throttle plate
6. Idle set screw
7. Lock nut
8. Synchronizing screw with its tamper proof cap
4
F12R0XA
5 8 6 2 3
7 1
07-03-6 SMR2003_024 _07_03A.FM
NOTE: In the following illustrations, the lower link
plate has been removed for clarity purposes only.
It does not have to be removed to perform the
adjustment.
Loosen lock nut of idle set screw.
Unscrew idle set screw so that master throttle
plate completely closes in the throttle body. En-
sure screw end clears the lever stopper.
1. Unscrew until master throttle plate is fully closed in throttle body
2. Unscrew here
3. Gap here
Remove synchronizing screw and spring between
levers.
NOTE: The 175 resistance mentioned below is
used to open the throttle plates the same amount
on each throttle body to obtain the proper synchro-
nization. It is the equivalent of using a drill bit in
the throttle bore to open throttle plate on carbure-
tors.
Master TPS
Snap throttle plate a few times to ensure it is com-
pletely closed.
Using an ohmmeter, measure resistance between
terminals 2 and 3. Note the resistance value. Add
175 to that value.
Turn idle set screw clockwise until ohmmeter
reading reaches the computed value above 20 .
1. Measure resistance between terminals 2 and 3
2. Turn screw clockwise to increase resistance
Tighten lock nut.
Recheck reading and readjust as necessary.
Slave TPS
Install a new synchronizing screw. Screw in and
ensure screw end clears the lever stopper. Ensure
also to keep slave throttle plate completely closed
in the throttle body.
2
F12R0YA
1
3
WARNING
Do not apply any threadlocker on the screw
threads. The threadlocker may leak off the
screw and onto the throttle mechanism and
cause the throttle to stick.
WARNING
Ensure to use a new screw which is coated
with the proper threadlocker to avoid further
loosening. Do not use the removed screw
even if you were applying any threadlocker.
The threadlocker may leak off the screw and
flow onto the throttle mechanism and cause
the throttle to stick.
F12R1BA 1 2
SMR2003_024 _07_03A.FM 07-03-7
1. Gap here
2. Spring removed
Snap throttle plate a few times to ensure it is com-
pletely closed.
Measure resistance between terminals 2 and 3.
Note the resistance value. Substract 175 from
that value.
Properly reinstall the spring. Ensure that master
throttle plate is still closed.
Turn synchronizing screw clockwise until read-
ing reaches the computed value above 20 .
1. Measure resistance between terminals 2 and 3
2. Turn screw clockwise to decrease resistance
Ensure spring is still well positioned on stoppers.
Properly reinstall the plastic cap on the synchroni-
zation screw.
Apply Loctite 5900 (P/N 293 800 066) RTV silicone
sealant on idle set screw head.
1. Plastic cap
2. Wider spaced tabs here
3. Loctite 5900 flange sealant
2
F12R1DA
1
1
2 F12R1CA
WARNING
Ensure no Loctite product protrudes screw head.
1
F12R10A
3
2
07-03-8 SMR2003_024 _07_03A.FM
Throttle Cable Adjustment
Mechanically adjust the throttle cable using the ad-
justing device as shown. Slacken lock nut to allow
adjuster rotation. Free-play on lever should be be-
tween 2 and 3.5 mm (1/16 and 1/8 in). When done,
tighten lock nut.
RX DI AND GTX DI MODELS
1. Slacken nut
2. Turn adjuster
XP DI MODELS
1. Slacken nut
2. Turn adjuster
NOTE: On GTX DI models, vent tube removal in
front storage compartment may be necessary to
reach the adjusting device.
CAUTION: Improper cable adjustment will cause
strain on cable and/or damage cable bracket or
throttle lever at handlebar.
Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment.
Choose the Monitoring tab.
Press throttle lever to reach full throttle.
Turn cable adjusting device until throttle opening
meter indicates between 95% and 99%.
F12R1GB
1
2
1 F08R01A 2
SMR2003_024 _07_03A.FM 07-03-9
Closed TPS Adjustment
Perform the CLOSED TPS ADJUSTMENT as de-
scribed in THROTTLE POSITION SENSOR (TPS)
in ELECTRONIC MANAGEMENT below.
Injection Oil Pump Cable Adjustment
As oil injection cable is throttle dependent, always
proceed with the oil injection pump cable adjust-
ment after throttle cable adjustment. Refer to LU-
BRICATION SYSTEM.
CAUTION: Improper oil injection pump synchro-
nization with throttle bodies can cause serious
engine damage.
AIR COMPRESSOR
PRESSURE TEST
The pressure test will show the available pressure
from the air compressor.
First ensure there is no leak from compressor gas-
kets, hoses and fittings. Soapy water can be sprayed
on components. Repair any leak.
Disconnect hose outlet from air compressor.
Connect adapters and pressure relief valve to pres-
sure gauge as shown.
2. Adapter for air compressor (P/N 529 035 712)
3. T-adapter (P/N 529 035 710)
4. Pressure relief valve (P/N 529 035 711)
CAUTION: Make sure to install pressure relief
valve to allow excess pressure to escape and to
point valve arrow as shown above. Note the ar-
row on the valve. Otherwise, air compressor
components might be damaged.
Install pressure gauge to air compressor.
NOTE: To prevent fuel from being injected and
from going out the disconnected hose, use the
drowned engine mode to crank engine. While en-
gine is stopped, depress and HOLD the throttle
lever at full throttle position to crank engine.
Ensure the battery is in good condition to get the
normal cranking speed.
Crank engine and observe air pressure.
NOTE: A 1 second beep every second indicates
the drowned mode is active.
F12R02A
WARNING
Be careful with pressure relief valve outlet as
compressed air may flow out from it.
MINIMUM AIR PRESSURE (at cranking)
621 14 kPa (90 2 PSI)
2 3 4
1
F12R03A
07-03-10 SMR2003_024 _07_03A.FM
If pressure is within limits, air compressor is work-
ing adequately.
If pressure is below limits, ensure inlet hose is not
obstructed, bent or kinked. Otherwise, repair the
air compressor.
Remove pressure gauge and reinstall air compres-
sor hose.
REPAIR
Top End
Remove retaining screws.
Lift cover then remove compressor head.
Clean all parts in a solvent and visually inspect for
corrosion damage.
Check reed valve plates for cracks, deformation,
dirt or other defects. The reed plates must lie com-
pletely flat against the reed valve body.
Inspect plane surfaces for warpage.
If reed valve is found defective, it is suggested to
replace it then to temporarily reassemble the com-
pressor to then make a pressure test. If it fails,
check bottom end.
When changing reed valve, ensure to position ring
plate opening so that 2 holes align inside the open-
ing. Holes must not be obstructed by the opening
edges.
1. Reed valve opening
2. Rotate opening to align 2 holes inside without obstructing the
holes
Ensure to position O-ring, around top of cylinder
sleeve.
1. O-ring on top of cylinder sleeve
Ensure to position screw from the bottom up as
show. Torque nut to 2.7 Nm (24 lbfin).
1. Screw from bottom up
CAUTION: Failure to properly position screw
head will lead piston to hit it.
If pressure is still low then continue with BOTTOM
END. Otherwise, remove components again. In-
stall a new gasket, new O-ring, compressor head
and cover. Apply synthetic grease below screw
head and Loctite 243 on threads. Install screws
and torque to 5 Nm (44 lbfin), then retorque to
11 Nm (97 lbfin).
1 2
F12R04A
1 F12R05A
F12D0BA
2.7 Nm
(24 lbfin)
1
SMR2003_024 _07_03A.FM 07-03-11
Bottom End
To gain access to piston, rings and connecting rod,
engine PTO flywheel must be removed. Refer to
ENGINE section.
Remove engine support and slightly lift engine to
allow access. Block engine in this position.
Remove top end as explained above.
Remove access plug of air compressor connect-
ing rod.
Remove connecting rod retaining screw.
As a puller, use a M7 x 1.0 x 50 mm screw to re-
lease connecting rod crankpin.
1. Use a M7 x 1.0 x 50 mm screw as a puller
Push piston upward with or without the cylinder
sleeve.
Remove rubber plug then push piston pin end to
remove from connecting rod.
Inspection
Clean all parts in a solvent and visually inspect for
corrosion damage.
Clean piston ring grooves with a groove cleaner
tool, or a piece of broken ring.
Check bearings and terminals for wear and heat
discoloration. Check connecting rod for straight-
ness. Replace damaged components.
Inspect piston for damage. Light scratches can be
sanded with a fine sandpaper.
If you find aluminum dust or debris in this area,
some may have traveled toward the injection oil
reservoir. In this case, the oil reservoir and lines
must be flushed and the filter replaced.
CAUTION: Failure to properly clean the oil sys-
tem will result in serious engine damage.
The inspection of top end should include the fol-
lowing measurements.
Piston/Cylinder Wall Clearance
Clearance can be quickly checked with a feeler
gauge. Insert feeler gauge in cylinder then slide
piston (without piston rings installed). If clearance
exceeds tolerance, check cylinder top area with
your finger to feel if there is a ridge. If so, the cyl-
inder sleeve is worn and needs replacement. Oth-
erwise, replace piston.
Ring End Gap
Position ring close to top of cylinder top.
NOTE: In order to correctly position ring in cylin-
der, use piston as a pusher.
Using a feeler gauge, check ring end gap. If gap
exceeds specified tolerance, rings should be re-
placed.
1. Top of cylinder
2. Ring end gap
1
F12R06A
ENGINE
MEASUREMENT
TOLERANCES
NEW PARTS WEAR
LIMIT (min.) (max.)
clearance
0.12 mm
(.005 in)
N.A.
0.2 mm
(.008 in)
Ring end gap
0.1 mm
(.004 in)
0.25 mm
(.010 in)
0.5 mm
(.020 in)
2 1 F12R07A
07-03-12 SMR2003_024 _07_03A.FM
Assembly
Apply injection oil in cylinder and on rings prior to
installing.
Install the oil ring with the TOP marking on top.
Identify the correct position by looking at beveled
edge of oil ring and while installation, make sure
that the beveled edge is towards the top of the
piston.
1. Beveled edge
Position ring openings 180 apart.
1. Ring openings 180 apart
2. TOP marking on this side
Use ring compressor (P/N 529 035 713) and insert
piston in cylinder.
NOTE: Cylinder may be removed from crankcase
to install piston more easily from the bottom.
When attaching connecting rod to crankpin, strict-
ly follow this procedure:
1. Block counterbalance shaft to prevent any rota-
tion.
2. Install the crankpin (bushing) so that its
grooved end is on the screw head side.
1. Groove here
3. Install a NEW screw and torque to 6.5 Nm
(58 lbfin). Do not apply any thread locker product.
4. Turn the screw clockwise an additional 80 de-
grees 5 degrees.
CAUTION: Failure to strictly follow this proce-
dure may cause screw to loosen and lead to
engine damage. The bushing grooved end
must be against the counterweight. Besides, as
the crankpin screw has been stretched from
the previous installation, it is very important to
use a new screw at assembly. Also, the new
screw will have the proper threadlocking coat-
ing.
Ensure to correctly position O-ring on access cov-
er and install cover.
Reinstall remaining removed parts. Ensure to
check engine alignment.
1
F12R1OA
1
2 F12R15A
1
1
F18R0CA
SMR2003_024 _07_03A.FM 07-03-13
FUEL DELIVERY
FUEL PRESSURE REGULATOR
Pressure Test
at the air/fuel rail. It validates the pressure regula-
tor and leaks in the system.
IMPORTANT: Before checking air/fuel rail pres-
sure, make sure the fuel pressure from the fuel
pump and the air pressure from the air compres-
sor are within specifications. See the procedures
elsewhere in this section.
Also ensure there is no leak from hoses and fit-
tings. Repair any leak.
Ensure there is enough gas in fuel tank.
Release the fuel pressure in the system.
NOTE: On XP DI models, remove seat and rub-
ber plug underneath to gain access to fuel pump
and hoses.
Disconnect outlet hose (the one with the fuel fil-
ter) from fuel pump using tool (P/N 529 035 714).
Connect T-adapter to pressure gauge as shown.
2. T-adapter (P/N 529 035 710)
Install pressure gauge between disconnected ends
(inline installation).
1. Fuel filter
2. Fuel line going to air/fuel rail
3. Pressure gauge between disconnected ends (inline installation)
Do not crank engine.
If pressure is within limits, fuel pressure regulator
is working adequately.
A rapid pressure drop indicates leakage either
from the air/fuel rail or from the fuel pump check
valve. Check air/fuel rail for leaks. If it is not leaking
then replace fuel pump.
A slow pressure drop indicates leakage either from
the fuel injector or from the fuel pressure regulator.
Check fuel injector for leaks (see below). If it is not
leaking then replace fuel pressure regulator.
NOTE: Fuel in air compressor outlet line is an indica-
tion of a leaking fuel pressure regulator diaphragm.
F12R08A
1
2
FUEL REGULATOR PRESSURE
185 14 kPa (27 2 PSI)
2
3
1
F12R09A
07-03-14 SMR2003_024 _07_03A.FM
Fuel Pressure Regulator Replacement
Removal
Disconnect spark plug cables from spark plugs.
Disconnect the fuel injector wires, if necessary.
1. Push clip toward injector to release connector
Unscrew rail retaining screws.
1. Retaining screws
Gently pull rail up by hand, working each side slight-
ly at a time.
Pull rail out.
Unscrew retaining plate screws.
1. Retaining plate
2. Screws
3. Fuel injector
4. Fuel pressure regulator and cover
5. Air pressure regulator
NOTE: If needed, use a small screwdriver to lift
the fuel pressure regulator.
To remove fuel pressure regulator, pull the fuel
regulator and the cover out of rail.
Installation
For the installation, reverse the removal procedure
but pay attention to the following.
If the same regulator is reinstalled, it is recommend-
ed to change the O-rings.
Insert the fuel pressure regulator into the cover
then install both regulators together in place with
your hand. Do not use any tool.
NOTE: A thin film of injection oil may be applied
on O-ring to ease insertion in rail.
Apply Loctite 243 on rail retaining screws then
FUEL INJECTOR
Leakage Test
Testing the fuel injector operation can be per-
formed with the air/fuel rail installed.
The leakage test is validated when performing the
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section.
WARNING
Wipe off any fuel spillage in the bilge. Fuel is
flammable and explosive under certain con-
ditions. Always work in a well ventilated area.
1
F12R0DA
F12R19A
1 1
4
2 F12R1AA 3 1 3 2
2 5
SMR2003_024 _07_03A.FM 07-03-15
Electrical Test
Safety lanyard must be on DESS post.
Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the fuel injector
from the ACTIVATION section.
If the injector does not work, disconnect the con-
nector from the injector.
Install a temporary connector to the injector with
wires long enough to make the connection out-
side the bilge and apply voltage (12 V) to this test
harness.
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it.
Otherwise, check the resistance of the fuel injec-
tor circuit.
Reconnect the injector and disconnect the AMP
connector number 4 on the MPEM.
tween terminals as follows.
The resistance should be between 1.7 and 1.9 .
If resistance value is correct, try a new MPEM.
Refer to MPEM REPLACEMENT procedures else-
where in this section.
If resistance value is incorrect, repair the wiring
harness/connectors between AMP connector and
fuel injector.
Fuel Injector Replacement
When one fuel injector is defective, both have to
be replaced at the same time. Be sure to check
the other one. Also replace direct injectors.
Removal
See FUEL PRESSURE REGULATOR REPLACE-
MENT above for procedure. However, do not re-
move any regulator.
To remove fuel injector, pull it out of rail.
Installation
For the installation, reverse the removal proce-
dure. Paying attention to the following details.
If the same injector is reinstalled, carefully inspect
O-ring condition before reinstalling fuel injector.
Replace O-ring with a new one if damaged.
Insert the fuel injector in place with your hand. Do
not use any tool.
to O-ring to ease insertion in rail.
Apply Loctite 243 on rail retaining screws then torque
AIR/FUEL RAIL
Pressure test
If pressure is within limits, fuel and air systems are
working adequately. No subsequent tests are nec-
essary for the air/fuel system.
If pressure is out of limits, check air/fuel rail for
leaks. If it is not leaking then replace air pressure
regulator.
A higher pressure may be an indication of a
pinched or clogged air pressure regulator outlet
line.
Air Pressure Regulator Replacement
Removal
See FUEL PRESSURE REGULATOR REMOVAL
above for procedure.
Remove the fuel regulator then the air pressure
regulator.
Installation
For the installation, reverse the removal procedure
but pay attention to the following.
to O-ring to ease insertion in rail.
Apply Loctite 243 on rail retaining screws then
COMPONENT TERMINAL LOCATION
Fuel injector MAG 7 and 13
Fuel injector PTO 8 and 14
FUEL PRESSURE
(when cranking engine or when engine is running)
738 14 kPa (107 2 PSI)
07-03-16 SMR2003_024 _07_03A.FM
Air/Fuel Rail Replacement
Removal
Disconnect air compressor supply hose from rail.
Disconnect fuel hoses (supply and return) at their
inline connectors.
Temporarily connect these hose ends together to
prevent rail draining.
Disconnect spark plug cables from spark plugs
and fuel injector wires. Cut locking ties of wiring.
1. Air/fuel rail
2. Air supply hose
3. Fuel supply hose
4. Retaining screws
1. Push clip toward injector to release connector
ly at a time.
Pull rail out.
Disconnect hose ends at their inline connectors
and drain fuel rail.
Disconnect air and fuel hoses from rail.
1. Air and fuel return hoses
2. Fuel supply hose
3 1 4 2
F12R0CA
1
F12R0DA
1
2
F12R0FA
SMR2003_024 _07_03A.FM 07-03-17
NOTE: When lifting/removing air/fuel rail, we rec-
ommend replacing carbon dams on direct injec-
tors that have been running for 50 hours or more.
Remove fuel injectors, fuel pressure regulator and
air pressure regulator.
Installation
For installation, reverse the removal process but
pay attention to the following.
NOTE: A thin film of injection oil may be applied on
O-rings of fuel injectors to ease rail installation.
When connecting fuel or air hose fittings to the air/
fuel rail, use Loctite Krylox (no. 29-719).
DIRECT INJECTOR
When one direct injector is defective, both have
to be replaced at the same time. Be sure to check
the other one. Also replace fuel injectors.
The direct injectors can be replaced by lifting the
air/fuel rail.
Leakage Test
If direct injector leaks through its large top O-ring,
there will be an air/fuel leak between the injector
and the air/fuel rail. Replace O-ring of both injectors.
If there is an injector internal leak, the high tempera-
ture from the combustion chamber will make visible
overheated area. Replace damaged components.
Electrical Test
the B.U.D.S. software, energize the direct injector
in the ACTIVATION section.
Install a temporary connector on the injector with
harness.
This will validate its mechanical and electrical op-
eration.
If it does not work, replace the direct injector.
Otherwise, check the resistance of the direct in-
jector circuit.
Reconnect the injector and disconnect the AMP
The resistance should be between 1 and 1.6 .
If resistance value is correct, try a new MPEM.
Refer to MPEM REPLACEMENT procedures else-
direct injector.
Direct Injector Replacement
IMPORTANT: Do not remove direct injectors
needlessly. They are sealed with a carbon dam
that may expand when pulled out. A special tool is
required to compress it prior to reinstalling. Other-
wise, sealing efficiency might be affected.
Remove air/fuel rail retaining screws. Partially lift
rail to allow direct injector removal.
Disconnect direct injector connector then pull in-
jector out of cylinder head.
1. Air/fuel rail
2. Disconnect and pull injector out
Compress the carbon dam using tool (P/N 529 035
716).
Carefully install direct injector in cylinder head pay-
ing attention to carbon dam insertion. Ensure to
position connector pointing toward bottom of cyl-
inder head.
Direct injector MAG 5 and 15
Direct injector PTO 6 and 21
1
F12R0GA 2
07-03-18 SMR2003_024 _07_03A.FM
to carbon dam if necessary to ease insertion in cyl-
inder head.
Reconnect electrical connector.
1. Carefully insert direct injector
2. Connector pointing toward bottom of cylinder head
Reinstall air/fuel rail.
Carbon Dam Replacement
Remove direct injector. See procedure above.
NOTE: When replacing a carbon dam, it is recom-
mended to replace it on both injectors. It is also
recommended to replace all O-rings. When servic-
ing air/fuel rail or direct injectors, we recommend
replacing carbon dams that have been running for
50 hours or more.
CAUTION: Never reuse a carbon dam after it has
been removed from the injector. Always install
a new one.
Remove carbon dam and O-ring using a small pick.
Install seal guide (P/N 529 035 715) on end of injec-
tor. Carefully slide carbon dam in injector groove.
Use carbon dam compressor (P/N 529 035 716) to
compress carbon dam evenly.
FUEL PUMP
Pressure Test
from the fuel pump.
Ensure there is no leak from hoses and fittings.
Repair any leak.
Use the VCK (Vehicle Communication Kit) to re-
lease the fuel pressure in the system. Look in the
ACTIVATION section of the software B.U.D.S.
Disconnect inlet and outlet hoses from fuel pump
using tool (P/N 529 035 714).
Connect T-adapter and pressure relief valve to
pressure gauge as shown.
2. T-adapter (P/N 529 035 710)
3. Pressure relief valve (P/N 529 035 711)
CAUTION: Make sure to install pressure relief
valve to allow excess pressure to escape and to
point valve arrow as shown above. Note the ar-
row on the valve. Otherwise, air compressor
components might be damaged.
F12R0HA 1
2
3 2
1
F12R0AA
SMR2003_024 _07_03A.FM 07-03-19
Install pressure gauge between disconnected
hoses on fuel pump side (closed-loop installation
on fuel pump). Make sure the pressure-relief valve
is installed on the fuel pump return line side.
1. Fuel pump outlet hose (fuel filter side)
2. Fuel pump return line
3. Fuel relief valve on the return line side
4. Pressure gauge between disconnected hose (inline installation)
If pressure is within limits, fuel pump is working
adequately.
If pressure is below limits, ensure fuel filters are
not obstructed. There is one in-line fuel filter at the
fuel pump outlet hose and one filter at the inlet
underneath the pump. Otherwise, replace the fuel
pump.
Remove pressure gauge and reinstall fuel hoses.
At installation apply engine oil on O-ring.
Electrical Test
When connecting the safety lanyard to the DESS
post, the fuel pump should run for 2 seconds to
build up the pressure in the system.
If the pump does not work, disconnect the con-
nector from the fuel pump.
Install a temporary connector on the fuel pump
with wires long enough to make the connection
outside the bilge and apply voltage (12 V) to this
test harness.
If pump does not run, replace the fuel pump.
Otherwise, check the continuity of the fuel pump
circuit.
Disconnect the AMP connector number 4 on the
MPEM.
Using a multimeter, check continuity between ter-
minals of circuits 24 and 26.
If wiring harness is good, try a new MPEM. Refer
to MPEM REPLACEMENT procedures elsewhere
in this section.
Otherwise, repair the wiring harness/connectors
between AMP connector and fuel pump.
Fuel Pump Replacement
Ensure fuel pressure has been released in the sys-
tem using the VCK (Vehicle Communication Kit).
Removal
Open front storage compartment cover.
Remove the storage basket.
Remove glove box (see HULL/BODY section).
Remove front vent tubes.
MINIMUM FUEL PUMP PRESSURE
721 kPa (105 PSI)
1
2
3
4
F12R0BA
07-03-20 SMR2003_024 _07_03A.FM
RX DI Models
Remove tube Y-connector.
Remove tube bracket by unscrewing nuts from
bilge (front storage area).
1. Vent tube bracket
2. Nut
XP DI Models
Remove rear access panel.
Referring to DIRECT ACTION SUSPENSION de-
tach shock absorber to allow tilting of seat for-
ward.
Remove access plug.
From glove box opening, remove fuel pump retain-
ing nuts.
1. Fuel pump
2. Retaining screw
All Models
Disconnect electrical connector.
Disconnect vent tube from fuel pump.
Disconnect inlet and outlet hoses from fuel pump
using tool (P/N 529 035 714).
XP DI SHOWN
1 F12R0KA
2
F08R04A
1 F12R0IA 2
F08R05A
SMR2003_024 _07_03A.FM 07-03-21
RX DI Models
Compress springs of pump module to reduce its
height to allow pulling pump out.
Pull fuel pump toward front of vehicle. Wipe off
any fuel spillage in the bilge.
TYPICAL
1. Pull fuel pump toward front
XP DI Models
Pull fuel pump out. Wipe off any fuel spillage in the
bilge.
All Models
Installation
Install fuel pump on fuel tank and torque nuts to
2.5 Nm (1.8 lbfin).
Ensure to align the arrow with the dot on the gas-
ket towards the LH side of fuel tank.
TORQUE AS PER SEQUENCE
1 F12R0JA
F08R06A
F18F09A
10
11
9
2
12
5
1
6
7
3
8
07-03-22 SMR2003_024 _07_03A.FM
OK
no
F12A06S
Air pressure less
than 621 kPa
(90 PSI)
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
line
OK
Crank or start engine
Install pressure gauge on
fuel pressure line
Connect safety lanyard
Fuel pump runs
Fuel pressure less
than 185 kPa (27 PSI)
Fuel pressure
more than
185 kPa
(27 PSI)
Fuel pressure
is 185 kPa
(27 PSI)
System OK
Check fuel lines
for leaks
Check fuel filters
Repair or
replace
Perform fuel
pump test
Proceed to air
compressor
pressure test
Fuel pressure lower
Check for
blocked fuel
return line
Repair or replace
Line OK
yes
Replace
fuel pump
module
Fuel pressure
is 735 kPa
(107 PSI)
Fuel pressure
greater than
735 kPa
(107 PSI)
Check air
return
line for
blockage
Check
for air
leaks
Repair
leaks
Check direct
injector
yes
Perform fuel
pump test
Replace
fuel pump
module
pass
no
leaks
Check
RAVE
for air
leaks
Repair air
compressor
Air pressure more
than 621 kPa
(90 PSI)
OK
Replace
direct
injector
Connect safety lanyard Fuel pump does not run
Fuel pump runs
for 2 sec. then stops
Check fuses
Check lanyard connection
Check pump module operation
Repair or replace if necessary
test OK
OK
fails
Replace fuel
pressure
regulator
Replace air
pressure
regulator
Retest
Direct
injector
OK
Check air/fuel rail for leaks
Repair/replace air/fuel rail
OK
fails
fails
no
leaks
fails
Repair
leaks
Fast
pressure
drop
yes
no
Verify
fuel pump
check valve
fails
Replace
fuel pump
OK
Ensure
air/fuel
rail is not
leaking yes
Check fuel
injector
Repair/replace
air/fuel rail
OK
fails
Replace fuel
injector
Replace fuel
pressure
regulator
fails
NOTE: The tolerance for the pressure is 14 kPa (2 PSI).
SMR2003_024 _07_03A.FM 07-03-23
MPEM REPLACEMENT
General
Prior to replacing a suspected MPEM, ensure that
all the recommendations in the general introduc-
tion of this section have been followed.
IMPORTANT: When MPEM is replaced, the TPS
closed position and the TDC setting must be re-
programmed/reset. Refer to their specific section
for adjustment.
To allow transferring the previous recorded infor-
mation from the old MPEM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S.
software. Use MPEM Replace in the Module
menu. Follows instructions in its help system.
NOTE: If the old MPEM is working, it must be read
inside B.U.D.S. prior to removing it from the vehicle
to carry vehicle information and history to the new
MPEM. Besides, select the Setting tab and note
the Current Angle in the ignition offset area. When
installing the new MPEM, re-use this setting as a
preliminary setting. Then, proceed with the regular
procedure for the TDC setting.
If the old MPEM is not working, try to find a previous
saved file from B.U.D.S. Otherwise, perform the op-
erations described in IF THE PREVIOUS MPEM
WAS NOT READ WITH B.U.D.S. below.
Replacement
Disconnect battery cables.
Disconnect AMP connectors from MPEM.
Remove MPEM.
Install the new MPEM on the vehicle.
Reconnect AMP connectors to MPEM then bat-
tery cables.
If the previous MPEM was read with B.U.D.S.
Transfer the data from the previous MPEM to the
new one using B.U.D.S. then proceed with the re-
quired resets after following the procedure in VAL-
IDATING TPS SYNCHRONIZATION below.
If the previous MPEM was NOT read with
B.U.D.S.
Enter the vehicle and engine serial numbers in
the Vehicle tab.
Enter the old MPEM serial number in the Part
Replacement under History tab. Click on Add
part in History.
Reprogram safety lanyard(s).
NOTE: The MPEM serial number can be found on
the MPEM sticker that also shows the P/N.
Continue procedure as per VALIDATING TPS SYN-
CHRONIZATION below.
Validating TPS Synchronization
Select the Activation tab.
Point the mouse cursor over the PTO TPS. Check
the ADC reading. It must be between 23 and 45.
1. Activation tab
2. Point on PTO TPS
3. ADC reading
Point the mouse cursor over the MAG TPS. Check
the ADC reading. It must be between 37 and 59.
If either readings are not within those parameters,
they are out of range and the MPEM will be unable
to initialize. Proceed with THROTTLE BODY SYN-
CHRONIZATION as detailed in THROTTLE BODY.
If the ADCs are within range, proceed with the
required resets.
After performing the required resets, ensure to
clear all faults from the newly replaced MPEM.
Now, all faults must be inactive (except the Diag-
nostic Cap Missing fault).
WARNING
Battery BLACK negative cable must always
be disconnected first and connected last.
Activation
30
1
3 F12R1JA 2
07-03-24 SMR2003_024 _07_03A.FM
Start the engine and increase engine speed above
5000 RPM to be sure no fault appears.
(TPS)
General
The throttle position sensor (TPS) is a potentiom-
eter that sends a signal to the MPEM which is pro-
portional to the throttle shaft angle. On the DI sys-
tem, two sensors are used for redundancy purposes.
The MPEM compares the signals from both sensors
and determines if there is an error and uses the most
appropriate sensor to operate the system.
IMPORTANT: Prior to testing the TPS, ensure that
mechanical components/adjustments are adequate
according to THROTTLE BODY in AIR INDUCTION
SYSTEM above.
The MPEM may generate two types of fault codes
pertaining to the TPS. Refer to DI SYSTEM FAULT
CODES in DIAGNOSTIC PROCEDURES section
for more information.
Wear Test
While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.
Using the vehicle communication kit (VCK) with the
B.U.D.S. software, use the THROTTLE OPENING
display under Monitoring.
Slowly and regularly depress the throttle. Observe
the needle movement. It must change gradually
and regularly as you move the throttle. If the nee-
dle sticks, bounces, suddenly drops or if any dis-
crepancy between the throttle movement and the
needle movement is noticed, it indicates a worn
TPS that needs to be replaced.
NOTE: In this particular case, by comparing the
signals from both sensors, the MPEM will gener-
ate a fault code when the TPS is malfunctioning
due to specific spots.
To isolate the faulty TPS, disconnect one and test
the other.
Voltage Test Both TPS
Check the MPEM voltage output on the desired
throttle position sensor.
Disconnect connector from throttle position sensor
and connect a voltmeter to the wiring harness.
Check the voltage readings on the PTO side as
follows.
Check the voltage readings on the MAG side as
follows.
1 F12F05A 1
CONNECTION VOLTAGE
Terminal 1 with engine
ground
5 V
ground
0 V
ground
0 - 0.5 V
CONNECTION VOLTAGE
ground
5 V
ground
0 V
ground
4.75 - 5 V
SMR2003_024 _07_03A.FM 07-03-25
If voltage test is good, replace the TPS.
If voltage test is not good, check the resistance of
the TPS circuit.
Resistance Test
Reconnect the TPS.
NOTE: Resistance values are different at idle on
each TPS.
MAG Side
MPEM.
tween terminals 10 and 14.
The resistance should be 1600 - 2400 .
Check the resistance between terminals 5 and 14
with the throttle plate in idle position.
The resistance should be 2500 .
PTO Side
MPEM.
Test Results Both TPS
If resistance values are correct, try a new MPEM. Re-
fer to MPEM REPLACEMENT procedures else-
If resistance values are incorrect, disconnect the
TPS and perform the resistance measurement di-
rectly to the TPS terminals. If TPS is good, repair
the wiring harness/connectors between AMP
connector and the TPS.
Replacement
Remove the air duct.
Disconnect the TPS connector.
Loosen two Allen screws retaining the TPS.
Remove TPS.
MAG SIDE THROTTLE BODY
1. Allen screws
Apply Loctite 243 on screw threads, install the
new TPS.
NOTE: Both TPS do not need to be replaced at the
same time.
Reinstall remaining removed parts.
Proceed with the CLOSED TPS ADJUSTMENT.
See below.
Closed TPS Adjustment
NOTE: Although this operation is called adjust-
ment, it is not really an adjustment. Rather, it per-
forms a reset of the values in the MPEM.
This reset is very important. The setting of the TPS
will determine the basic parameters for all fuel
mappings and several MPEM calculations.
NOTE: Reset must be done each time the TPS is
loosened or removed or throttle body(ies) is(are)
replaced or MPEM is replaced.
2
F12R0LA
1
07-03-26 SMR2003_024 _07_03A.FM
CAUTION: An improperly adjusted TPS may
lead to poor engine performance and emission
compliance could possibly be affected.
Ensure the throttle body plate stop lever rests
against its stopper. Open throttle approximately one
quarter then quickly release. Repeat 2 - 3 times to
settle throttle plate. If stopper does not rest against
its stop lever, perform throttle cable adjustment. Re-
fer to THROTTLE BODY in AIR INDUCTION SYS-
TEM above.
Push the Reset button in the SETTING section of
B.U.D.S.
NOTE: There is no idle speed adjustment to per-
form. The MPEM takes care of that. If TPS are not
within the allowed range while resetting the
closed TPS, the MPEM will generate a fault code
and will not accept the setting. To solve that, per-
form the Validating TPS Synchronization in the
MPEM REPLACEMENT section above.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap-
pear, refer to DI SYSTEM FAULT CODES in DIAG-
NOSTIC PROCEDURES section for more informa-
tion.
CRANKSHAFT POSITION
SENSOR (CPS)
1. Magneto cover
2. CPS connector
Check for RPM display at the information center
while cranking engine (first ensure information
center is in tachometer mode). If it displays ap-
proximately 300 RPM, the CPS circuitry is properly
working.
Otherwise, validate the information center is
working by activating the tachometer using the
software B.U.D.S. under Activation (first ensure
information center is in tachometer mode). If it
does not display 3000 RPM, the information cen-
ter may be faulty and needs to be tested.
If the information center correctly displayed 3000
RPM, perform the following tests.
NOTE: Take into account that a CPS fault can be
triggered by bent or missing encoder wheel teeth.
Check the teeth condition. Also, bad connections
in magneto connector could generate electrical
noise that would make you wrongly think the CPS
is faulty. Check terminals and wires.
Encoder Wheel Inspection
To check the encoder wheel for bent teeth, pro-
ceed as follows.
Remove magneto cover. Refer to MAGNETO SYS-
Install a dial indicator on crankcase. Position the
gauge on a tooth and set it to zero (0). Rotate fly-
wheel and check needle movement. The maxi-
mum allowed difference between teeth is 0.15
mm (.006 in). Otherwise, straighten the tooth or
replace the encoder wheel.
1. Encoder wheel
2. Dial indicator
Properly reinstall cover.
2
F12R0OA
1
F12R1HA
2
1
SMR2003_024 _07_03A.FM 07-03-27
The encoder wheel can also be inspected for bent
teeth by the following alternative method.
Remove magneto cover. Refer to MAGNETO SYS-
Install a pointer wire on one of the threaded hole
of crankcase with the screw as shown in the fol-
lowing illustration.
1. Pointer wire
2. Screw in the threaded hole
Rotate the flywheel one time and adjust the point-
er so that it slightly touches the highest tooth. Us-
ing a feeler gauge, check and measure the clear-
ance between each tooth and pointer.
1. Pointer wire
2. Feeler gauge
The maximum allowed difference between teeth
is 0.15 mm (.006 in). Otherwise, straighten the
tooth or replace the encoder wheel.
Voltage Test
Unplug magneto connector.
Check connector terminals for corrosion or damage.
Check the voltage readings on the harness side as
follows:
If voltage tests good, the CPS is defective and
needs replacement.
If voltage does not test good, perform the follow-
ing tests.
Resistance Test
Check the continuity of the wiring harness.
MPEM.
Using a multimeter, check continuity of circuits 6,
7 and 14.
If wiring harness is good, it could be either the CPS
or the MPEM. Try a new part one at a time. When
trying a new MPEM, refer to MPEM REPLACE-
MENT procedures elsewhere in this section.
between AMP connector and the CPS.
Replacement
Remove tuned pipe.
Unscrew front engine support and slightly lift en-
gine to have access to magneto cover screws.
Block engine in this position.
Disconnect connector and remove magneto cover.
1
F12R1MA
2
2
F12R1NA
1
CONNECTION VOLTAGE
ground
0 V a small mV
tolerance
ground
12 V
ground
5 V
07-03-28 SMR2003_024 _07_03A.FM
Remove CPS.
1. CPS inside magneto cover
Apply Loctite 243 on screw threads then install the
new CPS.
MANIFOLD AIR TEMPERATURE
SENSOR (MATS)
PTO SIDE THROTTLE BODY
1. Manifold air temperature sensor (MATS)
Resistance Test
Disconnect the connector from the MATS and
check the resistance of the sensor itself.
2740 .
Otherwise, replace the MATS.
If resistance tests good, reconnect the MATS and
disconnect the AMP connector number 4 on the
MPEM.
Using a multimeter, recheck resistance value be-
If resistance value is correct, try a new MPEM. Re-
the MATS.
Replacement
Disconnect the connector of the MATS.
Pull MATS out while turning right and left.
Install the new MATS.
WATER TEMPERATURE SENSOR
(WTS)
1. Water temperature sensor (WTS)
Resistance Test
Disconnect the connector from the WTS and
2740 .
Otherwise, replace the WTS.
If resistance tests good, reconnect the WTS and
MPEM.
1
F12R0NA
1 F12R0MA
1 F12R0PA
SMR2003_024 _07_03A.FM 07-03-29
the WTS.
Replacement
Remove air/fuel rail retaining screws.
Cut locking ties as necessary to allow lifting of
air/fuel rail in order to give access to the tempera-
ture sensor.
Disconnect WTS connector and remove WTS.
Apply Loctite 518 on WTS threads then install it.
MANIFOLD AIR PRESSURE
SENSOR (MAPS)
MAG SIDE THROTTLE BODY
1. Manifold air pressure sensor (MAPS)
NOTE: This sensor is a dual function device. When
engine is started and it runs at idle speed, the sen-
sor takes the atmospheric pressure and stores it in
the MPEM. Thereafter, it takes the manifold air
pressure at operating RPMS.
Ensure sensor is correctly installed in elbow adap-
tor. Otherwise, the MAPS could generate a fault
code for an unexpected sensor range at idle when
it reads the atmospheric pressure. Ensure the cor-
rect connector is plugged and not mixed with the
MAG TPS. 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.
Voltage Test
Check the MPEM voltage output to the manifold air
pressure sensor (MAPS).
Disconnect connector from MAPS sensor and
connect a voltmeter between terminal 1 and 3 and
also between terminal 1 and 2 of wiring harness.
If voltage test is good, replace the MAPS.
If voltage test is not good, check the continuity of
the MAPS circuit.
Resistance Test
MPEM.
Using a multimeter, check continuity of circuits 3-3,
3-6 and 3-7.
in this section.
between AMP connector and the MAPS.
Replacement
Disconnect MAPS connector and remove the MPAS.
Install the new MAPS paying attention to index its
tab into the adaptor notch.
F12R0LB
1
07-03-30 SMR2003_024 _07_03A.FM
EXHAUST GAS TEMPERATURE
SENSOR (EGT)
1. Muffler
2. Exhaust gas temperature sensor (EGT)
Resistance Test
Disconnect the connector from the EGT and check
the resistance of the sensor itself.
2740 .
Otherwise, replace the EGT.
If resistance tests good, reconnect the EGT and
MPEM.
the EGT.
Replacement
Disconnect EGT connector and remove EGT.
Apply Loctite 518 on threads of the EGT then in-
stall.
Replug connector.
KNOCK SENSOR (KS)
1. Knock sensor (KS)
Dynamic Test
the B.U.D.S. software, monitor the knock sensor
using the FAULTS section.
Start the engine and bring engine RPM above
4500 RPM. If no fault code occurs, the knock sen-
sor 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.
Check the knock sensor resistance.
Disconnect the AMP connector number 4 from
the MPEM.
Static Resistance Test
terminals 2 and 17 on the connector.
The resistance should be approximately 5 M.
Otherwise, check the continuity of the knock sen-
sor circuit 4-2 and 4-17.
in this section.
between AMP connector and knock sensor.
2 F12R0SA
1
1
F12R0QA
SMR2003_024 _07_03A.FM 07-03-31
Replacement
Unscrew and remove knock sensor.
Clean contact surface, apply Loctite 243 in thread-
ed hole then install the new knock sensor.
Torque screw to 20 Nm (15 lbfft).
CAUTION: Improper torque might prevent sen-
sor to work properly and lead engine to severe
damage of internal components.
Re-plug connector.
RAVE SOLENOID
A quick check can be done as follows. When engine
is being stopped, the RAVE valves will open and
close. This can be heard or seen by carefully remov-
ing the caps and feeling the movement with a hand.
Another test can be done using the vehicle com-
munication kit (VCK) with the B.U.D.S. software,
using the MONITORING section. Start engine and
bring its RPM to approximately 6000 and look at
the RAVE solenoid LED. It should turn on, indicat-
ing the RAVE system is working on the electronic
side. However, pneumatic test still has to be per-
formed to validate the mechanical operation.
Leakage/Voltage Test
NOTE: The solenoid activates both RAVE valves
at the same time.
Unplug the RAVE solenoid supply hose from air
compressor.
1. Air compressor
2. Disconnect RAVE solenoid supply hose
Install leak test pump (P/N 529 021 800) on hose end
and pressurize air line to 69 - 103 kPa (10 - 15 PSI).
Wait some time to see if pressure drops. If so,
check line for leaks. Otherwise, the solenoid is de-
fective and needs to be replaced.
the B.U.D.S. software, energize the RAVE sole-
noid from the ACTIVATION section.
The pressure should drop when the solenoid is ac-
tivated. If the solenoid does not work, disconnect
the connector from the solenoid.
Install a temporary connector on the solenoid with
harness.
If it does not work, replace the solenoid. Other-
wise, proceed with the resistance test below.
Reconnect hose to compressor.
Unplug the outlet hose from RAVE solenoid.
1. RAVE solenoid
2. Supply hose from air compressor
3. Check valve
4. Outlet hose to RAVE valves
Install leak test pump on hose end and apply pres-
sure. If pressure can not be held, check hoses for
leaks. If hoses test good, connect pump directly
to each RAVE valve nipple and pressurize. If pres-
sure drops, replace the defective seal inside RAVE
valve.
Take into account that the RAVE may be mechani-
cally stuck in the cylinder slot. Open the RAVE
valve and check for free operation. Refer to EN-
GINE section and look in TOP END subsection.
F12R0RA
1 2
1 F12R0TA 2
4
3
07-03-32 SMR2003_024 _07_03A.FM
Pressure Relief Circuit
When RAVE valve is released, the pressure es-
cape from this vented hose. If the RAVE valves do
not return when the solenoid is released, ensure
the return spring is in good condition, this hose is
not kinked or plugged and that the solenoid allows
pressure to bleed there.
Although it is not related with RAVE valve opera-
tion, we suggest to verify the check valve opera-
tion which prevents the pressure from going
down into the crankcase. Install a hose pincher af-
ter the T-fitting to adequately pressurize the check
valve portion.
1. RAVE solenoid
2. Pressure relief hose
3. Install hose pincher here
Resistance Test
Reconnect the solenoid and disconnect the AMP
If resistance value is correct, try a new MPEM. Refer
to MPEM REPLACEMENT procedures elsewhere in
this section.
solenoid.
IGNITION COIL
NOTE: The MPEM energizes the primary side of
each ignition coil individually. It can detect open
and short circuit in the primary winding but it does
not check the secondary winding.
the B.U.D.S. software, energize the ignition coil
from the ACTIVATION section.
You should hear the spark occurring. In doubt, use an
inductive spark tester or a sealed tester available
from after-market tool/equipment suppliers to pre-
vent spark occurring in the bilge. Otherwise, perform
the following checks.
Primary Winding
Disconnect the connector from the ignition coil
and check the resistance of the primary circuit.
1. PTO side ignition coil
2. Mag side ignition coil
3. Primary winding connector
F12R0TB 1
3 2
WARNING
Never make a spark test with spark plug re-
moved. Flammable vapors may be present in
the bilge and ignited which could cause an
explosion.
3 F12R0UA 1
2
SMR2003_024 _07_03A.FM 07-03-33
The resistance should be between .45 - .55 at
20C (68F).
Otherwise, replace the ignition coil.
If resistance tests good, reconnect the ignition
coil connector and disconnect the AMP connector
number 3 on the MPEM.
tween terminals 21 and 22 for MAG side and ter-
minals 20 and 23 for PTO side.
the ignition coil.
Secondary Winding
Static Test
NOTE: An ignition coil with good resistance mea-
surement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter. A dynamic test is more effective.
Remove high tension lead from ignition coil.
the terminals C and the coil post.
10200 at 20C (68F).
If not within specification, replace the ignition coil.
Otherwise, perform the DYNAMIC TEST below.
Measure resistance of the high tension leads.
They must be as follows. Otherwise, replace the
lead.
NOTE: It is not necessary to remove the spark
plug cap.
IMPORTANT: Always replace leads with genuine
parts. Otherwise, fuel injection system operation
may be impaired.
Check continuity between ignition coil ground cir-
cuits and engine.
Dynamic Test
Use an ignition coil tester, available from after-market
tool/equipment suppliers.
1. With ignition coil removed from craft, hook high
tension leads from tester to ignition coil high
tension cable.
2. Connect 2 smaller tester leads to the primary
winding of ignition coil.
TYPICAL
1. Lead to high tension cable
2. Leads to primary winding
3. Turn power switch to 12 volts and you should
observe spark jumping at a predetermined gap
of 7 to 8 mm (.276 to .311 in).
If there is no spark, if it is weak or intermittent, the
coil is defective and should be replaced.
MODEL SIDE VALUE OHM
RX DI and
XP DI
MAG 5700
PTO 4300
GTX DI and
LRV DI
MAG 5700
PTO 4900
WARNING
Do NOT use coil tester on metal work bench.
Follow manufacturer instructions.
WARNING
Always reconnect spark plug cable to its original
spark splug. The cable coming out the edge of
the electrical box must be connected to the
MAG side spark plug. Otherwise, severe back-
fire may occur with possible damage to exhaust
system components. The white tape on the ig-
nition coil should match the white tape on the
high tension cable.
F12H0UA
1
2
07-03-34 SMR2003_024 _07_03A.FM
1. MAG side ignition coil at bottom
2. Mag side ignition coil wire on edge of electrical box
3. Edge of electrical box
NOTE: If PTO ignition coil is replaced, ensure to
reinstall the white tape on the new coil if it is not
present.
TDC SETTING
General
Before checking TDC setting with a stroboscopic
timing light (dynamic test), it is mandatory to
scribe a timing mark on the PTO flywheel (static
test) corresponding to the specific engine.
Also, the mark scribed on the PTO flywheel can
be used to troubleshoot a broken magneto woo-
druff key.
CAUTION: The relation between the PTO flywheel
mark position and crankshaft position may
change as the PTO flywheel might move on crank-
shaft when engine is ran. This will result in a false
ignition timing reading. Always verify PTO fly-
wheel mark position before checking ignition tim-
ing with an appropriate timing light. If mark does
not align with tool, repeat static test to ensure fly-
wheel has not moved before changing the ignition
timing.
NOTE: Do not use the factory mark found on the
PTO flywheel to check TDC setting or troubleshoot
any problems.
Normally TDC setting should not be required. It
has been set at factory and it should remain cor-
rectly set since every part is fixed and not adjust-
able. The only time the TDC setting might have to
be changed would be when replacing the crank-
shaft, the magneto rotor, the CPS, the encoder
wheel or the MPEM. If the TDC setting is found
to be incorrect, you should first check for proper
crankshaft alignment. This might be the indication
of a twisted crankshaft.
With this ignition system, the TDC setting can be
checked with either the engine hot or cold. Also,
the TDC setting is to be checked at any RPM with
the timing light. The TDC setting is best checked
at idle speed as it is more accurate and easier than
at higher speed, also it will keep the engine tem-
perature lower for a longer time. Ensure to prop-
erly cool the engine through the flushing fitting.
NOTE: When checking the TDC setting, the spark
advance has to be locked to allow proper verifica-
tion of the TDC marks. See TDC SETTING below.
Static Test
1. Disconnect MAG side spark plug wire and con-
nect wire to grounding device then remove spark
plug.
CAUTION: Never crank engine with spark plugs
removed unless spark plug cables are connect-
ed to the grounding device.
2. Remove PTO flywheel guard.
3. Remove middle screw securing the engine to
the rear engine mount. Reinstall screw with tim-
ing mark pointer tool.
1. Timing mark pointer tool (P/N 295 000 135)
F12R0UB
1 3 2
1
F12R1IA
SMR2003_024 _07_03A.FM 07-03-35
4. Install and adjust a TDC gauge (P/N 295 000 143)
in MAG side spark plug hole.
5. Ensure to install its roller to allow proper reading
of the gauge. Proceed as follows:
Rotate magneto flywheel clockwise until pis-
ton is just Before Top Dead Center.
1. Outer ring
2. Adaptor lock nut
3. Adaptor
4. Roller
5. Roller lock nut
Install roller on dial gauge end. Ensure to posi-
tion roller edge parallel with the dial gauge
face. Secure in this position by tightening roller
lock nut. This will keep the roller in the proper
axis for measurement accuracy.
Loosen adaptor lock nut then holding gauge
with dial face directed toward you when you
are in line with the crankshaft, screw adaptor
in spark plug hole.
Slide gauge far enough into adaptor to obtain
a reading then finger tighten adaptor lock nut.
Since we are working with an indirect mea-
surement, ensure that dial gauge face is po-
sitioned in the same direction as the connect-
ing rod.
Rotate magneto flywheel clockwise until pis-
ton is at Top Dead Center.
Unlock outer ring of dial and turn it until 0
(zero) on dial aligns with pointer.
Lock outer ring in position.
6. From this point, rotate magneto flywheel back 1/4
turn then rotate it clockwise to reach 7.87 mm
(.310 in).
NOTE: This specification is of the type indirect
measurement relative to the piston movement
since we are measuring at a 45 angle through the
spark plug hole.
7. Scribe a thin mark on PTO flywheel aligned with
timing mark pointer tool.
NOTE: This mark becomes the reference when
using the stroboscopic timing light.
CAUTION: The static test cannot be used as a
TDC setting procedure, therefore, always check
the TDC setting with a stroboscopic timing light.
8. Remove TDC gauge.
9. Reinstall spark plug and connect wire.
Dynamic Test
To check TDC setting, use Bombardier timing light
(P/N 529 031 900).
1
F12R0VA
2 3
4 5
A00B4FA
07-03-36 SMR2003_024 _07_03A.FM
10. Connect timing light pick-up to MAG side spark
plug wire.
TYPICAL
1. Timing light pick-up
IMPORTANT: To check the TDC setting, the spark
advance curve must be locked first. This allows to
perform TDC setting at any RPM by keeping the
ignition timing frozen so that it does not vary
with engine RPM. See TDC SETTING below for
more information.
CAUTION: If the spark advance curve is not
locked using B.U.D.S. then a wrong ignition tim-
ing will be seen as the ignition curve does not
match the locked ignition timing.
11. Start engine and check marks at idle speed.
Point beam of timing light straight in line with
timing mark pointer.
NOTE: Look at the mark at the same angle as it
was scribed so that parallax error is minimized.
1. Timing light straight in line with pointer
CAUTION: If engine is to be run more than a few
seconds, engine must be cooled using the flush
kit.
NOTE: If mark on PTO flywheel is perfectly align-
ed with timing mark pointer, no adjustment is re-
quired. If mark does not align with pointer, recheck
PTO flywheel mark before performing the TDC
setting to ensure PTO flywheel has not loosen or
tightened.
TDC Setting
General
To correct the TDC setting, the data of the MPEM
is changed using the VCK (Vehicle Communication
Kit) (P/N 295 035 844). Look in SETTING section
of the software B.U.D.S.
NOTE: For more information on the VCK, refer to
its online help. The MPEM programmer will not
work to perform this operation on the DI engines.
CAUTION: If the TDC setting is adjusted too ad-
vanced, this will cause serious damage to the
engine.
Adjustment
In this operation, the ignition timing light and
B.U.D.S. are used to synchronize the MPEM TDC
reference with the engine crankshaft. This timing
adjustment will affect the timing of ignition as well
as direct injector timings. The aim of the adjust-
ment is to align the mark on the flywheel with the
pointer at idle using the timing light and B.U.D.S.
When this is achieved, then the MPEM TDC refer-
ence is synchronized with the engine crankshaft.
1. Setting tab
2. Ignition section
3. Locked box
4. Current angle in MPEM
5. Arrows to change the angle
1
F00H1QA
F06H07A
1
F17H08A
1
2
3
4 5
SMR2003_024 _07_03A.FM 07-03-37
1. Choose the Setting tab and look under IGNI-
TION OFFSET.
2. Check the Locked box to freeze the timing at
the correct value.
3. The VCK displays the number that is stored in
the MPEM.
4. Now click the up or down arrow to change the
number of the current angle so that the TDC
setting marks align when checking with the tim-
ing light. Each step makes an adjustment of 1/4
degree.
NOTE: Each time the setting is changed on the
screen, the new value is also changed in the
MPEM, so there may be a slow response, do not
make changes too quickly.
5. When marks align, uncheck the Locked box to
finish.
NOTE: This will write the new value immediately
in the MPEM. There is no need to press the Write
data button to transfer the data to the MPEM un-
less other changes were made. However, we rec-
ommend to reset the service hours when you per-
form a service action such as the TDC setting.
NOTE: The MPEM features a permanent (non-vol-
atile) memory and keeps the TDC setting pro-
grammed even when the watercraft battery is dis-
connected.
Engine Start/Stop Switch Verification
A quick operation test can be done using the vehi-
cle communication kit (VCK) with the B.U.D.S. soft-
ware, using the MONITORING section. Press the
start button and look at the Start button LED. It
should turn on, indicating the starting system is
working on the input side (start button, MPEM and
wiring). You know now the problem is on the output
side (MPEM output signal to starting solenoid, wir-
ing harness going to the solenoid, starter motor. Re-
fer to STARTING SYSTEM for testing procedures).
Otherwise, check the input side as follows.
Disconnect the YELLOW/RED wire of the start/
stop switch. Using an ohmmeter, connect test
probes to YELLOW/RED wire and to ground.
Measure resistance, it must be an open circuit
(switch is normally open). Depress and hold switch,
the ohmmeter should read close to 0 ohm. Other-
wise, replace switch.
If the switch tests good, check continuity of cir-
cuits 2-8 and 2-12 using a multimeter.
If wiring harness tests good, it could be the MPEM.
Try a new MPEM referring to MPEM REPLACE-
MENT procedures elsewhere in this section.
Safety Lanyard Switch Verification
If 2 short beeps are not heard when installing the
safety lanyard, refer to DIAGNOSTIC PROCEDURES.
The following continuity tests can also be per-
formed using an ohmmeter:
Disconnect switch wires.
Safety Lanyard Removed
Connect test probes to switch BLACK and BLACK/
YELLOW wires. Measure resistance, there should
be NO continuity (open circuit).
Connect one test probe to the WHITE/GRAY wire
and the other test probe to the switch terminal.
Measure resistance, it must be close to 0 ohm.
Connect one test probe to the BLACK wire and the
other test probe to the switch ring. Measure resis-
tance, it must be close to 0 ohm.
Safety Lanyard on Switch
YELLOW wires. Measure resistance, it must be
close to 0 ohm.
As the DESS switch also controls the signal wire
to the power supply cut-off relay, it should be
checked as described below.
Power Supply Cut-Off Relay Verification
When the safety lanyard is on its post, the relay
allows current to be supplied from the battery to
the RED/PURPLE wire which supplies the MPEM
and all the electrical components (except bilge
pump which is connected to battery power on XP
DI models).
When the safety lanyard is NOT on its post, the
relay cuts the current supply from the battery to
the MPEM and the electrical components thus
preventing current drain that would slowly dis-
charge the battery.
Test the signal wire to the power supply cut-off
relay as follows:
Disconnect DESS switch wires.
PURPLE wires.
With safety lanyard NOT on its switch: Measure
resistance. There should be NO continuity (open cir-
cuit). Otherwise replace DESS switch.
07-03-38 SMR2003_024 _07_03A.FM
With safety lanyard INSTALLED on its switch:
Measure resistance. There should be continuity.
Otherwise replace DESS switch.
If switch tests good in both checks, do the follow-
ing.
Disconnect the connector on electrical box.
Using a voltmeter, perform the following tests:
Connect test probes to the small RED wire on the
starter solenoid and on the RED/PURPLE wire from
the cut-off relay. Reading should be 0 V. Otherwise,
replace the cut-off relay.
Keeping the test probes on the same wires, con-
nect a jumper wire between the BLACK/PURPLE
wire from the cut-off relay and the battery ground.
Measure voltage. Reading should be 12 V. Other-
wise, check wiring and if it is good, replace the cut-
off relay.
If there is no current supply to the electrical com-
ponents while the DESS switch and the cut-off re-
lay test good, check the wiring harness. If it tests
good, the MPEM could be suspected. Try a new
one.
SPARK PLUGS
Disassembly
First unscrew the spark plug one turn.
Clean the spark plug and cylinder head with com-
pressed air then completely unscrew.
Heat Range
The proper heat range of the spark plugs is deter-
mined by the spark plugs ability to dissipate the
heat generated by combustion.
The longer the heat path between the electrode tip
to the plug shell, the hotter the spark plug operat-
ing temperature will be and conversely, the
shorter the heat path, the colder the operating tem-
perature will be.
A cold type plug has a relatively short insulator
nose and transfers heat very rapidly into the cylin-
der head.
Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
The hot type plug has a longer insulator nose
and transfers heat more slowly away from its firing
end. It runs hotter and burns off combustion de-
posits which might tend to foul the plug during
prolonged idle or low speed operation.
1. Cold
2. Hot
CAUTION: Severe engine damage might occur
if a wrong heat range plug is used.
A too hot plug will result in overheating and pre-
ignition, etc.
A too cold plug will result in fouling or may cre-
ate carbon build up which can heat up red-hot and
cause pre-ignition or detonation.
Fouling
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss of
compression. Other possible causes are: pro-
longed idling, or running on a too rich mixture or
incorrect fuel. The plug face of a fouled spark plug
has either a dry coating of soot or an oily, glossy
coating given by an excess either of oil or of oil
with soot. Such coatings form a conductive con-
nection between the center electrode and ground.
Spark Plug Installation
Prior to installation make sure that contact surfac-
es of the cylinder head and spark plug are free of
grime.
1. Using a wire feeler gauge, set electrode gap ac-
cording to the following chart.
2. Apply anti-seize lubricant over the spark plug
threads to prevent possible seizure.
A00E09A
1 2
SMR2003_024 _07_03A.FM 07-03-39
3. Hand screw spark plug into cylinder head. Then,
tighten the spark plug clockwise an additional
1/4 turn with a proper socket.
1. Proper socket
2. Improper socket
CRANKING SYSTEM
See above for start/stop switch and the DESS post
testing. Refer to STARTING SYSTEM section for
other tests.
DI SYSTEM TEST SUMMARY
Pressure Tests
ENGINE
SPARK
PLUG
TORQUE
GAP
mm (in)
DI
NGK
ZFR4F-11
Hand tighten
+ 1/4 turn with
a socket
1.1
(.043)
COMPONENT
VALUE
kPa (PSI)
Air compressor 621 14 (90 2) at cranking
Fuel pressure
regulator
185 14 (27 2)
when installing safety lanyard
Fuel pressure
738 14 (107 2)
inline test at cranking or
when engine is running
Fuel pump 721 (105) minimum at cranking
A00E0BA
2
1
07-03-40 SMR2003_024 _07_03A.FM
Electrical Tests
COMPONENT CONNECTOR
TERMINAL
NUMBER
WIRE COLOR VALUE
Fuel pump AMP no. 4
26 and terminal B PU/PK
0 ohm (continuity)
24 and terminal D BK/PK
Fuel injector MAG
AMP no. 4
7 and 13 BL/PU and BL/BK
1.7 - 1.9 ohms
Fuel injector PTO 8 and 14 GY/PU and GY/BK
Direct injector MAG
AMP no. 4
5 and 15 BL/BW and BL/PK
1 - 1.6 ohms
Direct injector PTO 6 and 21 GY/BW and GY/PK
Throttle position
sensor MAG
(TPS)
TPS
1 and engine ground PU/BW 5 V
2 and engine ground BK/BW 0 - 0.5 V
3 and engine ground PU/BW 4.75 - 5 V
AMP no. 3
10 and 14 PU/BW and BK/BW 1600 - 2400 ohms
5 and 14 WH/BW and BK/BW 2500 ohms at idle
5 and 10 WH/BW and PU/BW 1200 ohms at idle
Throttle position
sensor PTO
(TPS)
TPS
1 and engine ground PU/RD 5 V
2 and engine ground BK/RD 0 - 0.5 V
3 and engine ground WH/RD 0 V
AMP no. 4
3 and 18 BK/RD and PU/RD 1600 - 2400 ohms
1 and 3 WH/RD and BK/RD 1000 ohms at idle
1 and 18 WH/RD and BK/RD 2500 ohms at idle
Crankshaft position
sensor
(CPS)
CPS
(Deutsche
connector)
Terminal 4 and
ground
BK
0 V (with a small mV
tolerance)
Terminal 5 and
ground
GY/RD 12 V
Terminal 6 and
ground
GY/YL 5 V
AMP no. 2
Terminal 7 and
terminal 6 of CPS
GY/YL
0 ohm (continuity)
Terminal 6 and
terminal 5 of CPS
GY/RD
Terminal 14 and
terminal 4 of CPS
BK
Manifold air
temperature sensor
(MATS)
AMP no. 4 16 and 19 WH/GY and BK/WH 2280 - 2740 ohms
Water temperature
sensor (WTS)
AMP no. 4 9 and 11 TA/OR and BK/OR 2280 - 2740 ohms
Manifold air
pressure sensor
(MAPS)
AMP no. 3
Terminal 3 and
terminal 1 of MAPS
PU/BL
0 ohm (continuity)
Terminal 6 and
terminal 3 of MAPS
WH/BL
Terminal 7 and
terminal 2 of MAPS
BK/BL
SMR2003_024 _07_03A.FM 07-03-41
Exhaust gas
temperature (EGT)
AMP no. 4 10 and 12 TA/GY and BK/TA 2280 - 2740 ohms
Knock sensor (KS) AMP no. 4 2 and 17 BK/BL and YL/BL 5 M ohms
Rave solenoid (RS) AMP no. 4 20 and 23 PU/GY and BK/GY 24 ohms
Ignition coil MAG
AMP no. 3 21 and 22 RE/GN and WH/GN
.45 - .55 ohms
primary winding
Coil terminal C
and coil post
6800 - 10200 ohms

secondary winding w/o
high tension leads
Ignition coil PTO
AMP no. 3 20 and 23 RE/BL and WH/BL
.45 - .55 ohms
primary winding
Coil terminal C
and coil post
6800 - 10200 ohms

secondary winding w/o
high tension leads
High tension leads
RX DI and XP DI
models
MAG 5700 ohms lead alone
PTO White tape 4300 ohms lead alone
High tension leads
GTX DI and LRV DI
models
MAG 5700 ohms lead alone
PTO White tape 4900 ohms lead alone
COMPONENT CONNECTOR
TERMINAL
NUMBER
WIRE COLOR VALUE
SMR2003-025_07_04A.FM 07-04-1
GENERAL
Here is the basic order suggested to diagnose a suspected fuel injection related problem:
Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested solutions.
Check if there is a MAINT signal reported by the vehicle information center. If so, use the VCK (Vehicle
Communication Kit) and look for fault codes to diagnose the trouble.
Check all fuses.
Check air/fuel rail pressure.
Check spark plugs condition.
Check if the RAVE valves are stuck.
Check fuel pump pressure.
Check air compressor pressure.
Self-Diagnostic Mode
It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate
monitoring. Refer to the following chart.
SIGNAL CAUSE REMEDY
2 short beeps
(when installing safety
lanyard on watercraft post).
Safety lanyard is recognized by the MPEM.
Good contact between safety lanyard cap and
DESS post.
Ignition is authorized, engine can be started nor-
mally.
1 long beep
(when installing safety
lanyard on watercraft
post or when pressing
start/stop button).
Bad connection between safety lanyard cap
and post.
Remove and replace the safety lanyard on the
post until 2 short beeps are heard to indicate the
system is ready to allow engine starting.
Unprogrammed or defective safety lanyard. Use the safety lanyard that has been programmed
for the watercraft. If it does not work, check safe-
ty lanyard condition with the programmer. Re-
place safety lanyard if reported defective.
Salt water or dirt in safety lanyard cap. Clean safety lanyard cap to remove dirt or salt
water.
1 second beep every
second intervals.
Engine drowned mode is active. Release throttle to cancel this mode.
4 short beeps every
3 seconds interval for
2 hours.
Safety lanyard has been left on its post without
starting engine or after engine was stopped.
To prevent battery discharge, remove the safety
lanyard from its post.
A 2 seconds beep every
2 seconds intervals.
Exhaust system overheat. Refer to COOLING SYSTEM.
minute intervals.
Fuel tank level is low. Refill as soon as possible.
Very low battery voltage. Refer to CHARGING SYSTEM.
Coolant and exhaust gas temperature sen-
sors or TPS (throttle position sensor) or CPS
(crankshaft position sensor) malfunction.
Refer to ENGINE MANAGEMENT.
MPEM malfunction. Refer to ENGINE MANAGEMENT.
15 minutes intervals.
Oil injection reservoir level is low. Refill.
07-04-2 SMR2003-025_07_04A.FM
FAULT DETECTION AND COMPENSATORY ACTIONS
For a basic overview of the monitoring system and the limp home modes, see OVERVIEW section.
COMPONENT FAILURE WARNING SYSTEM
Sensor Failures
Refers to open or short circuit failures on sensors, drivers, injectors or ignition.
PROBLEM INFO CENTER RED LED BUZZER
BUZZER
CODE
LIMP HOME MODE
Manifold air
pressure sensor
(MAPS)
MAINT ON OFF 7 Limited RPM
Manifold air
temperature sensor
(MATS)
Throttle position
sensor (single TPS)
MAINT ON ON 5
Limited RPM
(idle speed if both
TPSs fail)
Water temperature
sensor (WTS)
MAINT ON OFF/(ON) 7/(5)
Limited RPM
(code 5 if EGT also
fails)
Direct injector
(single injector)
Fuel injector
(single injector)
Ignition
(no firing on one
cylinder)
RAVE solenoid MAINT ON OFF 7 Limited RPM
Starter solenoid MAINT ON OFF 7 Engine may not start.
Fuel pump MAINT ON OFF 7 Limited RPM
Exhaust gas
temperature sensor
(EGT)
MAINT ON OFF/(ON) 7/(5)
Limited RPM
(code 5 if WTS
also fails)
Fuel level sensor MAINT ON OFF 7 None
Diagnostic cap fault MAINT ON OFF 7 None
Knock sensor MAINT ON OFF 7 Limited RPM
Engine drowned
mode activated
(it is not a fault)
None None ON 2
Engine will not run.
Release throttle.
SMR2003-025_07_04A.FM 07-04-3
System Failures
Refers to operating conditions outside normal and/or safe ranges such as demand system failures, ex-
treme voltages, over temperature conditions or low fuel/oil levels.
To see how the normal operation is recovered from the limp home mode, see the DI FAULT CODES
chart elsewhere in this section. Look in column Normal operation resumes if fault removed and....
PROBLEM INFO CENTER RED LED BUZZER
BUZZER
CODE
LIMP HOME MODE
Manifold air pressure

sensor (MAPS),
ATM fault (bad
atmospheric
pressure reading)
Throttle position
sensor (single TPS)
MAINT ON ON 3 Limited RPM
Throttle position
sensor (dual TPS)
MAINT ON ON 5 Idle RPM
Throttle position
sensor
(single adaption fault)
None OFF OFF 7 None
Throttle position
sensor
(dual adaption fault)
Sensor supply fault
(TPS and MAPS)
MAINT ON ON/OFF 5/(7)
Limited RPM
(code 7 and idle RPM
if both in fault)
Encoder (CPS) fault
(bad pattern)
Low battery
voltage
12 V LOW ON OFF 7 None
Very low battery
voltage
12 V LOW
MAINT
ON ON 5 Limited RPM
High battery
voltage
MAINT ON OFF 7 None
Very high battery
voltage
MAINT ON OFF 7 Idle RPM
High water
temperature
HI-TEMP ON ON 1 None
Exhaust
over temperature
HI-TEMP ON ON 3 None
Low oil level OIL-LOW ON ON 6 None
Low fuel level FUEL-LO ON ON 5 None
Setup fault
(TDC or TPS not set
on a new MPEM)
MAINT ON OFF 7 Idle RPM
MPEM fault MAINT ON OFF 7 Engine will not start.
07-04-4 SMR2003-025_07_04A.FM
Buzzer Code
VCK
035 844) is the primary tool to diagnose fuel injec-
tion related problems.
B.U.D.S. is designed to allow, among other things,
the programming of safety lanyard(s), entering
customer information, engine monitoring, sensor
inspection, diagnostic options and adjustment
such as the Throttle Position Sensor (TPS) and the
TDC setting.
Always OFF
2 second beep every 15 minutes
2 second beep every 58 seconds
2 second beep every 2 seconds
Always ON (continuously beep)
1 second beep every second
BUZZER PATTERN
BUZZER
CODE
5
3
4
2
1
NOTE
6
7
4 short beeps every 3 seconds
2 SEC. 15 MIN.
58 SEC.
ON
OFF
2 SEC.
2 SEC. 2 SEC.
1 SEC.
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
1 SEC.
3 SEC.
4 short beeps
ON
OFF
3 SEC.
F18R0BS
WARNING
SMR2003-025_07_04A.FM 07-04-5
DI Models Through the 6-Pin Connector
1. 6-pin adapter
2. Connector close to MPEM
nication.
used is properly selected in MPI under Choose
protocol as per the following chart.
with the DI engines, ensure that the protocol 947
DI is properly selected in MPI under Choose
protocol.
Refer to the tables below for the fault codes you will
find in the B.U.D.S.
DI SYSTEM FAULT CODES
General
The faults registered in the MPEM are kept when
the battery is disconnected.
Be aware that a red light blinking with the MAINT
message may not be for a fault code. It may be a
maintenance inspection reminder. Press and hold
the SET button of the information center for 2 sec-
onds. If the blinking continues, it is a fault code.
Use the VCK (Vehicle Communication Kit) to see
it. Otherwise, it was a maintenance reminder.
IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the MPEM using the
VCK. This will properly reset the appropriate
counter(s). This will also records that the problem
has been fixed in the MPEM memory.
Many fault codes at the same time is likely to be
burnt fuse(s).
For more information pertaining to the code faults
(state, count, first etc.) and report, refer to B.U.D.S.
online help.
Supplemental Information for Some
Specific Faults
ECU fault code P0606: This code may occur in
the following situations:
Electrical noise is picked up by the MPEM. Ensure
that all connections are in good condition, also
grounds (battery, MPEM, engine and ignition sys-
tem), they are clean and well tightened and that all
electronic components are genuine particularly
in the ignition system. Installing resistive caps,
non-resistive spark plug cables (or modified
length), non-resistive spark plugs or improper
knock sensor wiring/routing may lead to generate
this fault code.
Electrical noise might also lead engine to occa-
sional cutout without generating a fault code
when engine is restarted. When looking at the
fault code, pay attention to the count value in
the software B.U.D.S. A value between 1 and 9
confirms an electrical noise problem. A value of
10 and above will generate a fault code.
When installing a new MPEM. It is not properly
programmed from the factory. The MPEM must
be returned to be properly activated.
If everything is in good condition, replace the
MPEM.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
referred as 4-23 for instance. It means AMP con-
nector no. 4 and the circuit wire no. 23 as found in
the wiring diagram.
TPS (Throttle Position Sensor) Faults
Faults which are reported in B.U.D.S. fall into two
groups TPS faults and adaption faults. These are
displayed on the B.U.D.S. system as TPS OUT OF
RANGE and TPS ADAPTION FAILURE.
TYPE OF
CONNECTION
ADAPTER
TO USE
PROTOCOL
TO CHOOSE
DI models through
the 6-pin connector
6-pin 947-DI
F12H0DA
1 2
07-04-6 SMR2003-025_07_04A.FM
TPS OUT OF RANGE Fault
It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also show up a fault that is intermittent.
TPS ADAPTATION FAILURE Fault
It is caused by the idle position moving out of an acceptable range.
POSSIBLE CAUSES RESULT ACTION
Check if wrong connector is connected to TPS. Yes Fix.
Check if sensor is loose. Yes Fix and reset closed TPS.
Inspect sensor for damage or corrosion. Yes Replace and reset closed TPS.
Inspect wiring (voltage test). Failed Repair.
Inspect wiring and sensor (resistance test). Failed
If bad wiring, repair.
If bad TPS, replace and reset closed TPS.
Test sensor operation (wear test). Failed Replace and reset closed TPS.
Sensor has been replaced and TPS closed
position not reset.
Yes Reset closed TPS.
Throttle body has been replaced and TPS
closed position not reset.
MPEM has been replaced and TPS closed
position not reset.
Throttle cable too tight. Yes Fix and reset closed TPS.
Sensor is loose. Yes Fix and reset closed TPS.
Throttle bracket is loose. Yes Fix and reset closed TPS.
Idle screw or synchronization screw worn
or loose.
Yes Fix and reset closed TPS.
SMR2003-025_07_04A.FM 07-04-7
DI System Fault Code Chart
F
A
U
L
T

C
O
D
E
D
I
A
G
N
O
S
E
D
C
O
M
P
O
N
E
N
T
/
S
E
N
S
O
R
/
C
I
R
C
U
I
T
E
C
U

I
N
T
E
R
N
A
L
N
A
M
E
F
A
U
L
T
D
E
T
E
C
T
E
D
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
R
U
N
N
I
N
G
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
N
O
T

R
U
N
N
I
N
G
N
O
R
M
A
L

O
P
E
R
A
T
I
O
N
R
E
S
U
M
E
S

I
F

F
A
U
L
T
R
E
M
O
V
E
D

A
N
D
.
.
.
SERVICE ACTION
AND
POSSIBLE CAUSES
P1100
Direct
injector
MAG
AIR_INJ_1
Open or
short
circuit
Yes No
Return to
idle
Service action:
Check for 1 - 1.6 ohm resistance between system circuits 4-15
and 4-5. Check for + 12 volts on pin A of injector connector (color).
Possible causes:
Damaged injector, damaged circuit wires, damaged connector,
damaged ECU output pins. ECU failure.
P1101
Direct
injector PTO
AIR_INJ_2
Open or
short
circuit
Yes No
Return to
idle
Service action:
Check for 1 - 1.6 ohm resistance between system circuits 4-21
Possible causes:
P0201
Fuel injector
MAG
FUEL_INJ_1
Open or
short
circuit
Yes No
Return to
idle
Service action:
Check for 1.7 - 1.9 ohm resistance between system circuits 4-13
Possible causes:
P0202
Fuel injector
PTO
FUEL_INJ_2
Open or
short
circuit
Yes No
Return to
idle
Service action:
Check for 1.7 - 1.9 ohm resistance between 4-14 and 4-8. Check
for + 12 volts on pin A of injector connector (color).
Possible causes:
P0351
Ignition coil,
primary
winding
MAG
IGN_CYL_1
Open or
short
circuit on
ignition
primary
circuit
Yes No
Return to
idle
Service action:
Check for .45 - .55 ohm resistance between system circuits 3-21
and 3-22. Check for + 12 volts on pin A of coil connector (color).
Possible causes:
Damaged coil, damaged circuit wires, damaged connector, dam-
aged ECU output pins. ECU failure.
P0352
Ignition coil,
primary
winding PTO
IGN_CYL_2
Open or
short
circuit on
ignition
primary
circuit
Yes No
Return to
idle
Service action:
Check for .45 - .55 ohm resistance between system circuits 3-20
and 3-23. Check for + 12 volts on pin A of coil connector (color).
Possible causes:
Damaged coil, damaged circuit wires, damaged connector, dam-
aged ECU output pins. ECU failure.
P0335
Encoder
(CPS)
Encoder
Wrong
pattern
sensed
Yes No
Return to
idle
Service action:
Check for 12 volts on pin 5 and 5 volts on 6 and 0 volts on pin 4 of
encoder harness connector. Check system circuits 2-6, 2-7, 2-14.
Possible causes:
Damaged sensor, damaged circuit wires, damaged connector,
damaged ECU pins. ECU failure. Damaged tooth wheel. Check
correct rectifier regulator operation.
07-04-8 SMR2003-025_07_04A.FM
P0120 TPS, PTO TPI_1
Sensor out
of range
Yes No
Return to
idle
Service action:
Check for 5 volts on pin 1 and 0-0.5 volts on pin 3 and 0 volts on
pin 2. Check system circuits 4-1, 4-2, 4-18. Check with throttle
closed the resistance between 1 and 2 is 2000 ohms and between
2 and 3 is 1000 ohms and between 1 and 3 2500 ohms. Check for
linear resistance rise when opening throttles. Check physical stops
for wear.
Possible causes:
Damaged Sensor, damaged circuit wires, damaged connector,
damaged ECU pins, ECU failure, damaged or out of alignment
throttle bodies or sensor.
P0220 TPS, MAG TPI_2
Sensor out
of range
Yes No
Return to
idle
Service action:
Check for 5 volts on pin 1 and 4.75-5.0 volts on 3 and 0volts on pin
2. Check system circuits 3-5, 3-10, 3-14. Check with throttle closed
the resistance between 1 and 2 is 2500 ohms and between 2 and
3 is 2500 ohms and between 1 and 3 1200 ohms. Check for linear
resistance rise when opening throttles. Check physical stops for
wear.
Possible causes:
Damaged Sensor, damaged circuit wires, damaged connector,
damaged ECU pins, ECU failure, damaged or out of alignment
throttle bodies or sensor.
P1102 TPS, PTO TPI_1_ADAP
Throttle
position
adaption
failure
Yes No
Full reset.
Key off
and on
Service action:
Check cable adjustment. Check Idle stop for wear check throttle
angles at idle.
Possible causes:
No initialisation after throttle body or ECU changes throttle idle
stop drifted.
P1103 TPS, MAG TPI_2_ADAP
Throttle
position
adaption
failure
Yes No
Full reset.
Key off
and on
Service action:
Check cable adjustment. Check Idle stop for wear. Check throttle
angles at idle.
Possible causes:
No initialisation after throttle body or ECU changes throttle idle.
Stop drifted.
P0116 WTS COOL_SENS
Sensor out
of range
Yes No
Return to
idle
Service action:
Check for resistance approx. 2280 ohms to 2736 ohms at temper-
ature of 19 to 21C (66 to 70F) between system circuits 4-9 and
4-11.
Possible causes:
damaged ECU pins. ECU failure.
P0217 WTS COOL_RED
Overheat
warning
Yes No
As soon as
fault is not
present
Service action:
Check for debris or blockage in cooling system. Check for resis-
tance approx. 2280 ohms to 2736 ohms at temperature of 19 to
21C (66 to 70F) between system circuits 4-9 and 4-11.
Possible causes:
Engine overheated, damaged sensor.
P0110 MATS MCT_SENS
Sensor out
of range
Yes No
Return to
idle
Service action:
4-19.
Possible causes:
F
A
U
L
T

C
O
D
E
D
I
A
G
N
O
S
E
D
C
O
M
P
O
N
E
N
T
/
S
E
N
S
O
R
/
C
I
R
C
U
I
T
E
C
U

I
N
T
E
R
N
A
L
N
A
M
E
F
A
U
L
T
D
E
T
E
C
T
E
D
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
R
U
N
N
I
N
G
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
N
O
T

R
U
N
N
I
N
G
N
O
R
M
A
L

O
P
E
R
A
T
I
O
N
R
E
S
U
M
E
S

I
F

F
A
U
L
T
R
E
M
O
V
E
D

A
N
D
.
.
.
SERVICE ACTION
AND
POSSIBLE CAUSES
SMR2003-025_07_04A.FM 07-04-9
P0106 MAPS MAP
Sensor out
of range
Yes No
Return to
idle
Service action:
Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5
volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2. Check
Sensor housing is correctly inserted into manifold.
Possible causes:
Check sensing port for dirt or blockage. Sensor failure, unexpect-
ed reading at idle. Sensor fallen out of housing. Leaking Inlet
system, ECU failure.
P0105 MAPS MAP_ATM
Bad
atmospheric
reading
Yes No
Full reset.
Key off
and on
Service action:
Check system circuits 3-3, 3-6, 3-7. Check sensor connector for 5
volts on pin 1 and 0 volts on pin 3 and 0 volts on pin 2.
Possible causes:
Check sensing port for dirt or blockage, damaged sensor, dam-
aged circuit wires, damaged connector, damaged ECU pins. ECU
failure.
P1400 EGT EXH_SENS
Sensor out
of range
Yes No
Return to
idle
Service action:
4-12.
Possible causes:
P1401 EGT EXH_RED
Overheat
warning
Yes No
As soon as
fault is not
present
Service action:
Check for debris or blockage in cooling system. Check tune pipe
injection valve.
Possible causes:
Exhaust system overheated, damaged sensor damaged circuit
wires.
P0460
Fuel level
sensor
FUEL_SENS
Sensor out
of range
Yes No
As soon as
fault is not
present
Service action:
TBD.
Possible causes:
P0230 Fuel pump FUEL_PUMP
Open or
short
circuit
Yes,
short
circuit
Yes,
open
circuit
Return to
idle
Service action:
Check for resistance of 6-8 ohms between system circuits 4-24
and 4-26.
Possible causes:
Damaged pump, damaged circuit wires, damaged connector,
P0475
RAVE
solenoid
RAVE
Open or
short
circuit
Yes,
open
and
short
circuit
Yes,
open
circuit
Return to
idle
Service action:
Check for resistance of 30 ohms between system circuits 4-23
and 4-20.
Possible causes:
Damaged solenoid, damaged circuit wires, damaged connector,
P1300
Starting
system
solenoid
(winding)
CRANK
Open or
short
circuit
Yes,
open
and
short
circuit
Yes,
open
circuit
As soon as
fault is not
present
Service action:
Check for resistance of 6ohms between system circuits 3-19 and
3-15.
Possible causes:
Damaged solenoid, damaged circuit wires, damaged connector,
F
A
U
L
T

C
O
D
E
D
I
A
G
N
O
S
E
D
C
O
M
P
O
N
E
N
T
/
S
E
N
S
O
R
/
C
I
R
C
U
I
T
E
C
U

I
N
T
E
R
N
A
L
N
A
M
E
F
A
U
L
T
D
E
T
E
C
T
E
D
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
R
U
N
N
I
N
G
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
N
O
T

R
U
N
N
I
N
G
N
O
R
M
A
L

O
P
E
R
A
T
I
O
N
R
E
S
U
M
E
S

I
F

F
A
U
L
T
R
E
M
O
V
E
D

A
N
D
.
.
.
SERVICE ACTION
AND
POSSIBLE CAUSES
07-04-10 SMR2003-025_07_04A.FM
P0563
Battery
voltage
BV_HI_WARN
Battery
voltage
high
Yes Yes
As soon as
fault is not
present
Possible causes:
Battery failure, rectifier failure, battery terminal connection.
P1500
Battery
voltage
BV_HI_RED
Battery
voltage
very high
Yes Yes
Full reset.
Key off and
on
Possible causes:
Battery failure, rectifier failure, battery terminal connection.
P0562
Battery
voltage
BV_LO_WARN
Battery
voltage
low
Yes Yes
As soon as
fault is not
present
Service action:
Check fuse.
Check system circuits 3-25 to battery + terminal, 2-26 to regulator
2 pin connector pin A, 2-25 to regulator 2 pin connector pin B.
Possible causes:
Battery failure, rectifier failure, damaged circuit wires, battery
terminal connection, damaged magneto, damaged connectors.
P1501
Battery
voltage
BV_LO_RED
Battery
voltage
very low
Yes Yes
Return to
idle
Service action:
Check fuse, check system circuits 3-25 to battery + terminal, 2-26
to regulator 2 pin connector pin A, 2-25 to regulator 2 pin connec-
tor pin B.
Possible causes:
Battery failure, rectifier failure, damaged circuit wires, battery
terminal connection, damaged magneto, damaged connectors.
P0122
Sensor
supply (TPS,
MAG and
MAPS)
XDRP_1
Sensor
5 volt
supply
failure
Yes Yes
Return to
idle
Service action:
Check for shorts to ground or corrosion on the following system
circuits 3-10 or 3-3.
Possible causes:
Damaged circuit wires, associated sensor failure (TPI 2 or MAP),
ECU fault.
P0222
Sensor
supply (TPS,
PTO)
XDRP_2
Sensor
5 volt
supply
failure
Yes Yes
Return to
idle
Service action:
Check for shorts to ground or corrosion on system circuit 4-18.
Possible causes:
Damaged circuit wires, associated sensor failure (TPI 1), ECU
fault.
P1600 ECU SETUP
TDC and
ECU not
initialised
Yes Yes
Reinitialise
from
B.U.D.S.
Service action:
Initialize ECU.
Possible causes:
ECU not initialised, TDC not setup, throttle sensors not initalised.
P0606 ECU ECU_FAULT
Internal
ECU faults
Yes Yes
Full reset.
Key off
and on
Service action:
Check ignition leads, coils and correct spark plugs, replace ECU.
Possible causes:
Incorrect software, ignition noise causing errors, internal EE-
PROM failure.
P0325
Knock
sensor
KNOCK_SENS
Knock
sensor
failure
Yes,
over
4500
No
Return to
idle
Service action:
Bring engine to 4500 RPM. If fault code appears, check for resis-
tance approx. 4.8 ohms between system circuits 4-2 and 4-17.
Possible causes:
P1601
Diagnostic
cap
COMMS_CAP
Diagnostic
cap is not
installed
on wiring
harness
Yes Yes
As soon as
fault is not
present
Service action:
Reinstall cap on wiring harness.
Possible causes:
Cap is not installed on wiring harness.
F
A
U
L
T

C
O
D
E
D
I
A
G
N
O
S
E
D
C
O
M
P
O
N
E
N
T
/
S
E
N
S
O
R
/
C
I
R
C
U
I
T
E
C
U

I
N
T
E
R
N
A
L
N
A
M
E
F
A
U
L
T
D
E
T
E
C
T
E
D
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
R
U
N
N
I
N
G
F
A
U
L
T

D
E
T
E
C
T
E
D
W
H
I
L
E

E
N
G
I
N
E
N
O
T

R
U
N
N
I
N
G
N
O
R
M
A
L

O
P
E
R
A
T
I
O
N
R
E
S
U
M
E
S

I
F

F
A
U
L
T
R
E
M
O
V
E
D

A
N
D
.
.
.
SERVICE ACTION
AND
POSSIBLE CAUSES
Section 08 ENGINE MANAGEMENT (4-TEC)
SMR2003-049_08_01ATOC.FM 08-01-1
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 08-02-1
COMPLETE ELECTRICAL SYSTEM OVERVIEW.............................................................. 08-02-1
MAGNETO SYSTEM AND POWER SUPPLY................................................................... 08-02-3
OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................... 08-02-3
AIR INDUCTION................................................................................................................. 08-02-3
FUEL DELIVERY SYSTEM................................................................................................. 08-02-4
BASIC OPERATION........................................................................................................... 08-02-4
INTAKE MANIFOLD........................................................................................................... 08-02-4
FUEL PUMP MODULE....................................................................................................... 08-02-5
EMS (ENGINE MANAGEMENT SYSTEM) ....................................................................... 08-02-5
EMS GENERAL FUNCTIONS ....................................................................................... 08-02-6
EMS ENGINE MANAGEMENT FUNCTIONS............................................................... 08-02-8
MPEM MULTI-PURPOSE ELECTRONIC MODULE...................................................... 08-02-11
COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 08-03-1
GENERAL ........................................................................................................................... 08-03-1
FUEL SYSTEM................................................................................................................... 08-03-1
ELECTRICAL SYSTEM....................................................................................................... 08-03-2
ENGINE CONNECTOR PIN-OUT ...................................................................................... 08-03-3
CONNECTORS ON ENGINE ............................................................................................. 08-03-4
THROTTLE BODY .............................................................................................................. 08-03-5
FUEL DELIVERY................................................................................................................. 08-03-8
FUEL PUMP ....................................................................................................................... 08-03-9
FUEL RAIL .......................................................................................................................... 08-03-11
FUEL INJECTOR ................................................................................................................ 08-03-11
EMS ECU AND MPEM REPLACEMENT........................................................................... 08-03-13
ENGINE WIRING HARNESS ............................................................................................. 08-03-15
IDLE BYPASS VALVE ........................................................................................................ 08-03-20
CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 08-03-22
MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 08-03-23
COOLANT TEMPERATURE SENSOR (CTS)..................................................................... 08-03-24
MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 08-03-24
EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 08-03-25
KNOCK SENSOR (KS) ....................................................................................................... 08-03-26
OIL PRESSURE SENSOR (OPS) ....................................................................................... 08-03-27
08-01-2 SMR2003-049_08_01ATOC.FM
OIL SEPARATOR PRESSURE SENSOR (OSPS) ............................................................... 08-03-27
TOPS VALVE (blow-by) ...................................................................................................... 08-03-29
IGNITION COILS................................................................................................................. 08-03-31
TDC SETTING (TOP DEAD CENTER)................................................................................. 08-03-32
ENGINE START/STOP SWITCH VERIFICATION............................................................... 08-03-32
SAFETY LANYARD SWITCH VERIFICATION.................................................................... 08-03-33
SPARK PLUGS.................................................................................................................... 08-03-33
CRANKING SYSTEM.......................................................................................................... 08-03-34
DIAGNOSTIC PROCEDURES................................................................................................. 08-04-1
GENERAL............................................................................................................................ 08-04-1
SELF-DIAGNOSTIC MODE ................................................................................................ 08-04-3
VCK (Vehicle Communication Kit) ................................................................................... 08-04-4
4-TEC SYSTEM FAULT CODES......................................................................................... 08-04-5
SMR2003-026_08-02A.FM 08-02-1
OVERVIEW 0
COMPLETE ELECTRICAL SYSTEM OVERVIEW
F18L1XS
COLOR CODE
WH = WHITE
BK = BLACK
RE = RED
These components are shared between the MPEM and the
EMS ECU. The MPEM supplies the power while the EMS ECU
controls and completes the circuit by switching it to the ground.
- COMPASS
- OUTSIDE AIR
TEMPERATURE
SENSOR
VCK
(COMMUNICATION
PORT)
COMMUNICATION LINK
COMMUNICATION LINK
- POWER TO
EMS ECU
- INFORMATION
CENTER
- SET AND MODE
SWITCHES
- SPEED SENSOR
- FUEL LEVEL
SENDER
- BEEPER
- DEPTH GAUGE
- START/STOP
SWITCH
- STARTING
SOLENOID
- FUEL PUMP
- FUEL INJECTORS
- IGNITION COILS
- TOPS VALVE
- TOPS SWITCH
- CAPS
INFORMATION
CENTER
EMS ECU MPEM
- TPS
- MAPS
- MATS
- CTS
- EGT
- KS
- OPS
- OSPS
- CPS
- DESS
- IDLE
BYPASS
VALVE
COMMUNICATION
LINK
WH/BK
WH/RE
WH/BK
WH/RE
WH/RE
WH/BK
EMS
08-02-2 SMR2003-026_08-02A.FM
The complete electrical system is managed by
micro-controllers working together. Overall, the
MPEM (multi-purpose electronic module) manag-
es the vehicle electrical system, the EMS (engine
management system) controls the engine man-
agement and the information center is used to dis-
play information that comes both from MPEM and
EMS.
A communication link is used between the elec-
tronic modules to communicate with each other.
It consists of a twisted pair of wires (WHITE/RED
and WHITE/BLACK).
For communication link troubleshooting, refer to
INSTRUMENTS AND ACCESSORIES in ELECTRI-
CAL section.
The communication link is also used to communi-
cate informative messages, monitoring and diag-
nostic codes to the information center and to the
VCK (vehicle communication kit) where B.U.D.S.
(Bombardier utility and diagnostic system) is used
for diagnosing and troubleshooting the system.
The fault code can be seen from either the infor-
mation center or B.U.D.S. Refer to DIAGNOSTIC
PROCEDURES section.
R1503motr266S
ENGINE MANAGEMENT SYSTEM - OVERVIEW
ROTAX 1503 4-TEC SUPERCHARGED
EMS
ECU
KS
CPS
OPS
CTS
CAPS
INJECTOR 1,2,3
MAPS
MATS
IDLE
BYPASS VALVE
TPS
IGNITION COIL
OSPS
TOPS VALVE
EGT
MPEM
REGULATOR /
RECTIFIER
MUFFLER
Cyl.1 Cyl.2 Cyl.3
MAGNETO
ENGINE POWER SUPPLY
EMS ECU Engine Management System
MPEM Multi-Purpose Electronic Module
KS Knock Sensor
CPS Cranshaft Position Sensor
OPS Oil Pressure Sensor
OSPS Oil Separator Pressure Sensor
CTS Coolant Temperature Sensor
CAPS Camshaft Position Sensor
EGT Exhaust Gas Temperature
MAPS Manifold Air Pressure Sensor
MATS Manifold Air Temperature Sensor
TOPS Tip-Over Protection System
Con.A Connector for Engine Wiring Harness
Con.B Connector for MPEM Connection
BATTERY
Con. A
Con. B
SMR2003-026_08-02A.FM 08-02-3
MAGNETO SYSTEM AND
POWER SUPPLY
current (AC).
The magneto has a 3 phase-delta wound stator on
18 poles. Capacity is 380 watts.
It supplies DC current to battery after being trans-
formed by the voltage regulator/rectifier. Refer to
CHARGING SYSTEM.
The battery then supplies all the electrical system
with regulated 12 Vdc.
OPERATING PRINCIPLE OF
ENGINE MANAGEMENT
A highly advanced EMS has been used to ensure
a high power output with cleanest combustion.
The EMS calculates the proper air/fuel mixture and
ignition timing for each cylinder separately. The
fuel is injected into the intake port of each cylinder.
NOTE: On the 1503, PTO and magneto (MAG) are
on the same engine side (rear). Each cylinder is
referenced as 1, 2 and 3 instead of PTO, CENTRE
and MAG. The numbers are stamped on the valve
cover.
1. Cylinder 1
2. Cylinder 2
3. Cylinder 3
NOTE: The EMS includes an ECU (electronic con-
trol unit), sensors, injectors, electromagnetic valves
and ignition system.
AIR INDUCTION
4-TEC Normally-Aspirated Models
Air for combustion is drawn directly at the front of
the engine through one 52 mm throttle body. The
air flow is controlled by a throttle plate and an idle
bypass valve. The air continues through the intake
manifold, which contains the flame arrester and
goes into the cylinder head.
52 mm THROTTLE BODY
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Air for combustion is drawn at the back of the en-
gine by a mechanical driven supercharger. The
compressed air flows through one 52 mm throttle
body and is controlled by a throttle plate and an
idle bypass valve. The air continues through the
intake manifold, which contains the flame arrester
and goes into the cylinder head.
1. Supercharger
2. Throttle body
FUEL DELIVERY SYSTEM
BASIC OPERATION
When the intake valve reaches the correct posi-
tion, the EMS ECU (Electronic Control Unit) opens
the fuel injector and fuel is discharged into the in-
take port at the air intake manifold by the high fuel
pressure inside the fuel rail. The air/fuel mixture
enters then the combustion chamber through the
open intake valve. This mixture is then ignited by
the spark plug.
INTAKE MANIFOLD
INTAKE MANIFOLD
1. Electronic Control Unit (EMS ECU)
2. Fuel rail
3. Injector
4. Throttle body
5. Ignition coil
INTAKE MANIFOLD (SUPERCHARGED)
1. Electronic Control Unit (EMS ECU)
2. Fuel rail
3. Injector
4. Throttle body
5. Ignition coil
2
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SMR2003-026_08-02A.FM 08-02-5
The intake manifold is mounted on the R.H. side of
the engine block. It provides support for the fuel
injectors, the fuel rail, the EMS ECU, the flame ar-
rester and the throttle body. The air intake manifold
is a resonator between the throttle body and the
cylinder head.
Fuel Rail
The fuel rail is a small tube on which the three
injectors are mounted. It ensures all the time, that
enough fuel at the right pressure can be delivered
to the fuel injectors. The fuel rail is fed by the fuel
pump with a fuel pressure of approximately
303 kPa (44 PSI).
Fuel Injector
Three fuel injectors (one per cylinder) are used to
inject fuel into the intake ports of the cylinder
head.
Flame Arrester
The flame arrester is a tube inside the air intake
manifold. It prevents flames leaving through the
intake system if the engine backfires.
Throttle Body
It is a 52 mm throttle body mounted on intake
manifold. Fitted on the throttle body, the TPS and
the idle bypass valve allow the EMS ECU to con-
trol the RPM while the throttle plate is closed.
FUEL PUMP MODULE
The fuel pump module is located inside the fuel
tank. The module includes fuel pump, fuel pres-
sure regulator and fuel level sensor.
Fuel Pump
It provides fuel pressure and flow rate to the system.
Fuel Pressure Regulator
A fuel pressure regulator controls the pressure in
the system and allows the excess of fuel to return
to the fuel tank. The fuel pressure regulator regu-
lates the fuel pressure at approximately 303 kPa
(44 PSI).
Fuel Filter
A mesh filter is located at the bottom of the fuel
pump module inside the fuel tank.
EMS
(Engine Management System)
The EMS is controlled by its ECU.
1. EMS ECU
EMS ECU
The EMS ECU is mounted on the intake manifold.
It controls all engine management functions, by
processing the information given by various sen-
sors.
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TYPICAL
1. EMS ECU on intake manifold
The EMS ECU gets its power by the MPEM which
is directly powered by the battery. It is responsible
for the following engine management/electrical
functions:
start/stop function
DESS (Digitally Encoded Security System)
ignition timing control
injection control
The EMS ECU applies the proper map (injection
and ignition) for optimum engine operation in all
conditions.
engine RPM limiter
etc.
The EMS ECU features a permanent memory that
will keep the programmed safety lanyard(s) active,
fault codes and other engine information, even
when the battery is removed from the watercraft.
EMS GENERAL FUNCTIONS
stalling the safety lanyard on its post, 4 very short
stopped.
charge the battery.
Antistart Feature
This system allows starting the vehicle only with
safety lanyard(s) that has been programmed to op-
erate a specific watercraft. This functionality is the
DESS system. See below for details.
Digitally Encoded Security System
(DESS)
(MPEM), EMS ECU, safety lanyard cap and safety
lanyard post.
The safety lanyard cap contains a magnet and a
ROM chip. The magnet actually closes the reed
switch inside the post which is the equivalent of a
mechanical ON/OFF switch. The chip has a unique
digital code.
The DESS circuitry in the EMS ECU is activated at
the factory. Therefore, a safety lanyard must be
programmed to start the engine.
NOTE: Actually, it is the memory of the EMS ECU
VCK (Vehicle Communication Kit) P/N 529 035
844. Refer to B.U.D.S. help system to program a
safety lanyard.
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The system is quite flexible. Up to 8 safety lan-
watercraft EMS ECU. They can also be erased in-
dividually.
The EMS ECU also offers a special safety lanyard
the Sea-Doo LK (learning key) which can
be programmed so that the vehicle can be run only
at a limited speed approximately 55 km/h
(35 MPH). Such feature is ideal for first time riders
or renters.
other watercraft equipped with the DESS. It only
needs to be programmed for that watercraft.
When connecting a safety lanyard cap on the post,
the DESS is activated and will emit audible signals:
2 short beeps indicate a working safety lanyard.
Engine starting can take place.
being used or that something is defective. En-
gine starting is not allowed.
The EMS ECU features a self-diagnostic mode.
Refer to DIAGNOSTIC PROCEDURES section for
more information.
The memory of the EMS ECU is permanent. If the
When ordering a new EMS ECU from the regular
Engine Starting
If the EMS ECU recognizes a valid safety lanyard,
it allows engine to start when the start/stop button
is pressed.
the EMS ECU automatically stops the starter
when the engine speed reaches 1600 RPM.
If start button is activated while the throttle lever
is depressed more than 65%, the engine will not
be allowed to start.
Engine RPM Limiter
The EMS ECU will limit the maximum engine
speed.
Engine Stopping
There are 2 ways to stop the engine.
Press and hold start/stop button or remove the
safety lanyard cap from its post.
Low-Oil Pressure Warning Device
When the oil pressure falls under a certain level,
the EMS ECU sends out signals to the beeper and
to the information center gauge. Additionally the
engine goes in limp home mode.
High Coolant Temperature and EGT
Warning Device
When the coolant temperature or the exhaust gas
temperature is getting to high, the EMS ECU
sends out signals to the beeper.
WARNING
When programming a Sea-Doo LK (learning
key), use only a lanyard that is identified for
that purpose. Otherwise, a customer could
use a vehicle with a greater speed than he was
expecting.
08-02-8 SMR2003-026_08-02A.FM
EMS ENGINE MANAGEMENT FUNCTIONS
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This engine management system controls both
the fuel injection and the ignition timing.
As shown in the 1503 4-TEC CONTROL SYSTEM
illustration, the EMS ECU is the central point of the
fuel injection system. It reads the inputs, makes
computations, uses pre-determined parameters
and sends the proper signals to the outputs for
proper engine management.
The EMS ECU also stores the fault codes and gen-
eral information such as: operating conditions, ve-
hicle hours, serial numbers, customer and mainte-
nance information.
The EMS ECU reads the signals from different sen-
sors which indicate engine operating conditions at
milli-second intervals.
Signals from sensors are used by the EMS ECU to
determine the injection parameters (fuel maps) re-
quired for optimum air-fuel ratio.
The CPS, the MATS, the MAPS and the TPS are
the primary sensors used to control the injection
and ignition timing. Other sensors (like tempera-
ture sensors, etc.) are used for secondary input.
NOTE: The EGT, OPS and OSPS sensors do not
provide control inputs to the EMS ECU. Their sole
purpose is to protect the engine components by
emitting a warning signal and/or a fault code in the
event of overheating or low oil pressure or TOPS
valve fault.
Ignition System
The ignition system is a digital inductive type. The
EMS ECU controls the ignition system parame-
ters, such as spark timing, duration and firing order
to achieve the proper engine requirements.
Ignition Coils
Three separate ignition coils induce voltage to a
high level in the secondary windings to produce a
spark at the spark plug.
The ignition coils receive input from the EMS ECU.
Each coil provides high voltage to its correspond-
ing spark plug.
This ignition system allows spark plugs to spark
independently.
NOTE: Ignition coil wires are not interchangeable
due to different lengths.
All three ignition coils are located on the cylinder
head directly on the spark plugs.
1. Ignition coils
Ignition Timing
The EMS ECU is programmed with data (it con-
tains ignition mappings) for optimum ignition tim-
ing under all operating conditions. Using engine
operating conditions provided by the sensors, the
EMS ECU controls the ignition timing for optimum
engine operation.There is no mechanical adjust-
ment to perform.
Knock Sensor
A knock sensor is mounted on the engine block
behind the air intake manifold. It detects specific
vibration that would be typically generated by en-
gine detonation. If detonation occurs, the knock
sensor detects it and the EMS ECU retards the
ignition advance temporarily (it goes in a specific
mode) until detonation stops. The EMS ECU is
able to evaluate the knocking cylinder and modi-
fies the ignition advance just on the detonating
one.
Engine Modes of Operation
The EMS ECU controls different operation modes
of the engine to allow proper operation for all pos-
sible conditions: Cranking, start-up, idle, warm up,
part load, full load, Sea-Doo LK (learning key, lim-
ited vehicle speed), engine speed limiter, drowned
engine and limp home (see below).
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Flooded Engine (drowned mode)
If engine is fuel-flooded and does not start, this
special mode can be activated to prevent fuel in-
jection and ignition while cranking. Proceed as fol-
lows 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 nor-
mal 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 COMPONENT IN-
SPECTION AND ADJUSTMENT subsection.
If engine is water-flooded, refer to WATER
FLOODED ENGINE in MAINTENANCE section.
Limp Home Modes
Besides the signals as seen above, the EMS ECU
may automatically uses default parameters for the
engine management to ensure the adequate op-
eration of the watercraft if a component of the fuel
injection system is not operating properly.
The following components failure will trigger a
limp home mode: CTS, EGT, OPS, OSPS and
TOPS.
When minor fault occurs, the fault and message/
beeper will disappear automatically, if the condi-
tion does not exist anymore.
Releasing throttle and letting the engine returning
at idle speed may allow normal operation to come
back. If it does not work, try removing and rein-
stalling the safety lanyard on its post.
Depending on the malfunction, the watercraft
speed may be reduced and not allowed to reach
its usual top speed. The engine speed will be lim-
ited to 2500 or 5000 RPM.
These performance-reduced modes allow the rid-
er to go back home which would not be possible
without this advanced system. Refer to the DIAG-
NOSTIC PROCEDURES for a complete chart.
If a fault occurs and involves a limp home mode
operation, the engine management system will re-
duce engine RPM gradually to the proper level.
Diagnostic Mode
The malfunctions are recorded in the memory of
the EMS ECU. The memory of the EMS ECU can
be checked using the VCK (Vehicle Communication
Kit) (P/N 529 035 844) to see the fault codes. The
EMS ECU and the VCK are able to communicate
through a connector on the vehicle. Refer to the
DIAGNOSTIC PROCEDURES section. B.U.D.S.
Version 2 and up must be used for this system.
WARNING
to ignite.
SMR2003-026_08-02A.FM 08-02-11
MPEM MULTI-PURPOSE ELECTRONIC MODULE
Power Distribution
The MPEM distributes power from battery to all accessories and the EMS ECU. Accessories are protected
by fuses integrated in the MPEM. Fuse ratings is identified besides their holder.
IMPORTANT: Some components are continuous-
ly powered with the supply from the battery
through MPEM. The EMS ECU switches the
ground to complete the electrical circuits it con-
trols. Take this into account when troubleshooting
the electrical system. Refer to the illustration at
the beginning of this section.
When installing the safety lanyard, it activates the
reading of gauges without the engine running. It
will give access to most functions of the informa-
tion center gauge without starting the engine.
Gauges are supplied with current whenever the
safety lanyard cap is installed on its post.
NOTE: The fuel pump will be activated for 2 sec-
onds to build up pressure in the fuel injection sys-
tem, only when connecting the safety lanyard cap
to the post.
Low-Fuel Level Warning Device
MPEM sends out signals to the beeper and to the
information center gauge.
Monitoring System
The EMS ECU monitors the electronic compo-
nents of the fuel injection system and also the en-
gine components of the electrical system.The
MPEM monitors the vehicle electrical system and
the accessories. When a fault occurs, it sends vi-
sual messages through the information center
and/or audible signals through a beeper to inform
you of a particular condition. Refer to the DIAG-
NOSTIC PROCEDURES section for the displayed
messages and the beeper coded signals chart.
Addition of Accessories
Every time an accessory is added such as an elec-
tric bilge pump or a VTS for instance, it must be
registered using B.U.D.S. to activate it in the
MPEM. Otherwise, the accessory will not work.
Use the Options area in the Setting tab in B.U.D.S.
10A
2A
10A
1A
10A
10A
3A
5A
10A
2A
7.5A
5A
F18H07T
10A
2A
10A
1A
10A
10A
3A
5A
10A
2A
7.5A
5A
Depth gauge
(if so equipped)
or spare fuse
T.O.P.S.
Cylinder 3
ignition coil
and injection
Information
center
EMS
start/stop circuit
VTS
(optional)
MPEM
Electric starter,
fuel pump
Bilge pump
(optional)
Beeper
diagnostic,
connector
Cylinder 2
ignition coil
and injection
Cylinder 1
ignition coil
and injection
Spare fuse
SMR2003_027 _08_03A.FM 08-03-1
COMPONENT INSPECTION AND
ADJUSTMENT 0
GENERAL
It is important to ensure that the mechanical integ-
rity of the engine/propulsion system is present:
good jet pump/drive system operation
good engine compression and properly operat-
ing mechanical components, no leaks etc.
fuel pump connection and fuel lines without leaks.
Check the chart in TROUBLESHOOTING section
to have an overview of problems and suggested
solutions.
When replacing a component, always check its
operation after installation.
Whenever watercraft is out of water and engine is
running, ensure to supply water through the con-
nector on jet pump support to cool down exhaust
system.
FUEL SYSTEM
035 844) to release the fuel pressure in the system.
Look in the Activation section of the B.U.D.S. soft-
ware.
Always disconnect battery properly prior to work-
ing on the fuel system. Refer to BATTERY section.
supports. Then, pressurize the fuel system. Per-
form the high pressure test as explained in this
section and pressurize the fuel tank and fuel lines
as explained in FUEL SYSTEM section.
WARNING
low the recommendation described here. Note
that some hoses may have more than one
clamp at their ends. Ensure to reinstall the
same quantity of clamps at assembly.
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 elec-
trical connectors. Proceed with care when re-
moving/installing high pressure test equipment
or disconnecting fuel line connections. Use the
VCK (Vehicle Communication Kit) 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 mini-
mize spilling. Wipe off any fuel spillage in the
bilge. Fuel is flammable and explosive under
certain conditions. Always work in a well venti-
lated area. Always disconnect battery prior to
working on the fuel system. After performing a
pressure test, use the valve on the fuel pressure
gauge to release the pressure (if so equipped).
WARNING
age and that NO fuel line is disconnected prior
to installing the safety lanyard on the DESS
post. Always perform the high pressure test if
any component has been removed. A pressure
test must be done before connecting the safety
lanyard. The fuel pump is started each time the
safety lanyard is installed and it builds pressure
very quickly.
08-03-2 SMR2003_027 _08_03A.FM
To check fuel rail for leaks, first pressurize the sys-
tem then spray soapy water on all hose connec-
tions, regulators and injectors. Air bubbles will
show the leaking area. Check also for leaking fuel
or fuel odor.
On some 4-TEC models, there is a valve on fuel
inlet hose connected to the fuel rail. This valve is
for manufacturing purpose only.
ELECTRICAL SYSTEM
It is important to check that the following electrical
system components are functioning properly:
battery
fuses
DESS
ignition (spark)
ground connections
wiring connectors.
Never use a battery charger to substitute tempo-
rarily the battery, as it may cause the MPEM/EMS
ECU 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 re-
sults.
used.
Pay particular attention to ensure that terminals
are not out of their connectors or out of shape. The
troubleshooting procedures cover problems not
resulting from one of these causes.
Before replacing a MPEM or EMS ECU, always
check electrical connections. Make sure that they are
very tight and they make good contact and that they
are corrosion-free. Particularly check MPEM and
EMS ECU ground connections. Ensure that con-
tacts are good and clean. A defective module
could possibly be repaired simply by unplugging
and replugging the MPEM or EMS ECU. The volt-
age 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. Clean terminals properly and then coat them
prior to assembling as follows:
AMP connectors, EMS ECU connectors, OPS
and OSPS connectors: Apply a thin coat of DEOX-
IT contact lubricant (P/N 293 550 034)
Other connectors: Apply a silicon-based dielectric
grease or other appropriate lubricant. If the newly
replaced MPEM or EMS ECU is working, try the
old one and recheck if it works.
Ensure that all electronic components are genuine
any modification on the wiring harness may
WARNING
If any gasoline leak and/or odor are present,
do not start the engine. Repair the leak.
WARNING
Never use a hose pincher on high pressure
hoses.
WARNING
PRESSURIZED FUEL
Do not unscrew protective cap.
Do not operate the watercraft without cap
properly installed.
WARNING
All electrical actuators (idle bypass valve,
TOPS valve, injectors, fuel pump, ignition coils
and starter solenoid) are permanently sup-
plied by the battery when the safety lanyard is
installed. Always disconnect the battery prior
to disconnecting any electric or electronic
parts.
WARNING
wires and connector are properly fastened.
SMR2003_027 _08_03A.FM 08-03-3
NOTE: For diagnostics purposes, use Vehicle
Communication Kit (VCK). See DIAGNOSTIC
PROCEDURES subsection.
the fault(s) in the EMS ECU using the VCK. Refer
to DIAGNOSTIC PROCEDURES subsection.
(69F). The value of a resistance varies with the
temperature. The resistance value for usual resis-
tor or windings (such as injectors) increases as
the temperature increases. However, our temper-
ature sensors are NTC types (Negative Tempera-
ture Coefficient) and work the opposite which
means that the resistance value decreases as the
temperature increases. Take it into account when
measuring at temperatures different from 20C
(69F). Use this table for resistance variation rela-
tive to temperature for temperature sensors.
new sensor.
connected to the harness to see if the EMS ECU
will detect the high temperature condition and
generate a fault code.
NOTE: In case of overheating, EGT and CTS do
not generate fault codes. A message will be dis-
played on the information center, the beeper will
be activated and the EMS will be set in limp home
mode.
ENGINE CONNECTOR PIN-OUT
Connector Position
TYPICAL
1. EMS ECU connector A
2. Engine connector
- 30 - 22 12600 11800 13400
- 20 - 4 11400 11000 11800
- 10 14 9500 8000 11,000
0 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
70 158 440 370 510
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
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08-03-4 SMR2003_027 _08_03A.FM
EMS ECU Connector
on the EMS ECU connector A of the wiring har-
ness when performing tests.
EMS ECU CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
CAUTION: Probe on top of terminal only. Do
not try to probe inside terminal or to use a pa-
per clip to probe inside terminal, it can damage
the square-shaped terminal.
CAUTION: Do not disconnect the EMS ECU
connector needlessly. They are not designed to
be disconnected/reconnected repeatedly.
Engine Connector
on the Engine connector of the wiring harness
when performing tests.
CAUTION: Before unplugging engine connec-
tor, always remove safety lanyard first then wait
15 seconds. Otherwise, damage to CAPS may
occur.
ENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
CONNECTORS ON ENGINE
Removal
To remove connectors from engine connector
bracket, slide a flat screwdriver between the con-
nector bracket and the connectors and remove
connectors.
1. Engine connector bracket
2. Connectors
2. Deutsch connector
3. Flat screwdriver
To disconnect two connectors slide a flat screw-
driver between each other to disengage, press the
release button and disconnect them.
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28
41
29
14
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SMR2003_027 _08_03A.FM 08-03-5
1. Flat screwdriver
2. Connectors
1. Release button
2. Connectors
1. Connectors
2. Press release button
THROTTLE BODY
IMPORTANT: Never mix up throttle bodies of nor-
mally-aspirated and supercharged 4-TEC engines.
Doing so will automatically lead to a misfunction of
the EMS and will cause a bad engine calibration.
1. Throttle body
2. Throttle cable attachment
3. Throttle plate
4. TPS
5. Idle bypass channel
Mechanical Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever. Take this
opportunity to lubricate the throttle cable.
IMPORTANT: The throttle body is designed to be
tamper proof. Changing the idle stop or modifying it
in any way will not increase performance or change
the idle speed but may cause poor startability and
erratic idling.
Before replacing any part, check the following as
these could be causing the fault. Perform the test
while the engine is not running.
Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
Throttle body idle set screw is loose or worn.
TPS is loose.
Idle bypass valve is loose.
Corroded or damaged wiring or connectors.
Throttle body has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
1
F18Z0LA 2
2
F18Z0MA 2 1
F18Z0NA 1 2
6
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08-03-6 SMR2003_027 _08_03A.FM
EMS ECU has been replaced and the Closed
Throttle and Idle Actuator reset has not been
performed.
Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS) and
IDLE BYPASS VALVE in ELECTRONIC MANAGE-
MENT below.
Replacement
Removal
To remove the throttle body from engine, proceed
as follows:
Disconnect air intake silencer from throttle body.
Move boot away.
Remove retaining screws of throttle body.
4-TEC NORMALLY-ASPIRATED MODELS
1. Throttle body
2. Screws
Disconnect air intake hose from throttle body.
Move boot away.
Remove retaining screws of throttle body.
4-TEC SUPERCHARGED MODELS
1. Throttle body
2. Screws
Slightly pull throttle body out.
Disconnect connectors from idle bypass valve,
and TPS.
Disconnect throttle cable.
Installation
Installation of the new throttle body is the reverse
of the removal procedure.
For TPS and idle bypass valve replacement proce-
dures, refer to the respective paragraph in ELEC-
TRONIC MANAGEMENT below.
Adjustment
THROTTLE BODY
1. Idle stop screw
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1
2
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SMR2003_027 _08_03A.FM 08-03-7
CAUTION: It is not allowed to perform any
change on the idle stop screw.
The adjustment of the idle stop screw is optimized
by the throttle body manufacturer and locked to
prevent any modification.
CAUTION: Never attempt to adjust the idle
speed through the throttle body tamper proof
screw. If so, it would impair the idle speed sta-
bility. Besides, no adjustment could be per-
formed by the dealer or the factory to correct
the idle speed. The throttle body would need to
be replaced. Also take into account that it might
change the engine emission level and the en-
gine might not meet the EPA/CARB require-
ments.
CAUTION: Do not alter or tamper with throttle
cable adjustment or routing. It may cause poor
startability and erratic idling.
When the throttle body has been replaced, per-
form throttle cable adjustment (see below) and
then the Closed Throttle and Idle Actuator reset.
Refer to THROTTLE POSITION SENSOR (TPS) in
ELECTRONIC MANAGEMENT below.
Mechanically adjust the throttle cable.
Lubricate cable with BOMBARDIER LUBE lubricant.
When throttle is released, cable must have a free
play of 0.5 - 4 mm (1/64 - 5/32 in).
Besides, throttle lever must reach handlebar grip
without causing strain to cable or brackets. Ensure
throttle lever fully closes on its stopper.
Ensure throttle body is fully open at full throttle po-
sition. At this position, throttle lever stopper is al-
most in contact with throttle body.
NOTE: Apply a light pressure on the throttle plate, a
slight play should be obtained.
CAUTION: If there is no free-play at idle posi-
tion, it may cause poor idling and startability.
Improper cable adjustment will cause strain on
cable and/or damage cable bracket or throttle
lever at handlebar.
To adjust, loosen jam nut then turn adjustment nut
as necessary.
1. Adjustment nut
2. Jam nut
3. Throttle lever stopper
Tighten jam nut and recheck adjustment.
Closed Throttle and Idle Actuator Reset
Perform the Closed Throttle and Idle Actuator re-
set as described in THROTTLE POSITION SENSOR
(TPS) in ELECTRONIC MANAGEMENT below.
F01K08A
1
WARNING
Make sure idle speed stopper contacts throt-
tle cam when throttle lever is fully released at
handlebar.
1
F18F07A
2 3
08-03-8 SMR2003_027 _08_03A.FM
FUEL DELIVERY
4-TEC FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART
Repair or
replace
Replace fuel
pump module
FUEL SYSTEM OK
Retest
Replace fuel
pump module
R1503motr209S
Fuel pump does not run
Fuel pump runs
for 2 sec. then stops
Install fuel pressure gauge
on fuel pressure line
Check fuses.
Check safety lanyard connection.
Check fuel pump operation.
Repair or replace if necessary.
Fuel pressure is
303 kPa (44 PSI)
Fuel pressure more
Fuel pressure less
Perform fuel pump test
Check fuel line/
rail for leaks
Crank or start
engine
Fuel pressure less
Fuel pressure more
Check fuel
injector
Fails
Fuel pump runs
Fuel pressure is
303 kPa (44 PSI)
OK
OK
Yes
No
Check
fuel line/
rail for leaks
Repair or
replace
OK
Fails
Perform fuel
pump test
OK
Fast
pressure drop
Verify fuel
pump check
valve
OK
Fails
Fails
OK
Fails
SMR2003_027 _08_03A.FM 08-03-9
FUEL PUMP
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
Release the fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and leaks in the system.
Remove glove box to have access to fuel pump.
Refer to HULL/BODY section.
Remove air vent tube from front storage area.
Ensure there is no leak from hoses and fittings.
Repair any leak.
Disconnect outlet hose from fuel pump.
Install fuel pressure gauge (P/N 529 035 591) be-
tween disconnected hose (inline installation).
1. Hose disconnected from fuel pump
2. In-line installation of fuel pressure gauge
Install safety lanyard and observe fuel pressure. Do
not crank engine. Repeat twice. Release pressure
using B.U.D.S. between tests so that the gauge is
reset to zero (0).
The fuel pressure should be the same as above.
If pressure is within limits, fuel pump and pressure
regulator are working adequately.
A rapid pressure drop indicates leakage either from
the fuel rail or from the fuel pump check valve.
Check fuel rail for leaks. If it is not leaking then re-
place fuel pump.
A slow pressure drop indicates leakage either from
the fuel injector or from the fuel pressure regulator.
Check fuel injector for leaks (see below). If it is not
leaking then replace fuel pump module.
Release fuel pressure in the system using B.U.D.S.
Look in the Activation tab.
Remove pressure gauge and reinstall fuel hose.
Reinstall removed parts.
WARNING
age inside bilge.
F02B0BA
FUEL PRESSURE
303 kPa (44 PSI)
WARNING
Wipe off any fuel spillage in the bilge. Fuel is
1 F18R08A 2
08-03-10 SMR2003_027 _08_03A.FM
Electrical Test
When connecting the safety lanyard to the DESS
post, the fuel pump should run for 2 seconds to
build up the pressure in the system.
If the pump does not work, disconnect the con-
nector from the fuel pump.
Install a temporary connector on the fuel pump
with wires long enough to make the connection
outside the bilge and apply voltage (12 V) to this
test harness.
If pump does not run, replace the fuel pump module.
Otherwise, probe terminals A and D of fuel pump
connector on vehicle harness side. When installing
safety lanyard, you should read battery voltage for
approximately 2 seconds (then voltage will drop to
approximately 11 V). If battery voltage is read, the
problem can be in fuel pump or in harness connec-
tor. Repair or replace appropriate part.
If battery voltage is not read, probe terminal A and
battery ground.
a. If battery voltage is read, check continuity of cir-
cuit B-29 going towards EMS ECU. If it is good,
try a new EMS ECU.
b. If battery voltage is not read, check continuity
of circuit 1-26 going towards MPEM. If it is
good, try a new MPEM.
Fuel Pump Replacement
Removal
Open front storage compartment cover.
Remove the storage basket (if so equipped).
Remove front access panel (see HULL/BODY sec-
tion).
Remove front vent tubes.
Remove glove box (see HULL/BODY section).
Disconnect electrical connector.
Disconnect vent tube from fuel pump.
Disconnect inlet hose from fuel pump.
From glove box opening, remove fuel pump retain-
ing nuts.
Pull fuel pump out from glove box opening.
Installation
Align tab of gasket with tank neck and then align
arrow of fuel pump with tab of gasket.
quence. Torque 1 to 4 at 1 Nm (9 lbfin) and then
5 to 13 at 2 Nm (18 lbfin).
TIGHTENING SEQUENCE
1. Fuel tank neck
2. Align
Perform a pressure test on fuel tank. Refer to FUEL
SYSTEM section.
F18R09A
1
F18R0AA
1 5
6
3 7
8
2 9
10
11
13
12
2
4
SMR2003_027 _08_03A.FM 08-03-11
FUEL RAIL
Pressure at fuel rail is supplied and controlled by
the fuel pump module. Refer to FUEL PUMP for
pressure test.
Fuel Rail Replacement
Removal
Remove fuel rail cover from the engine.
Insert pointed tools each side of fuel hose connec-
tor.
Disconnect wiring harness from the three fuel in-
jectors.
1. Fuel injector connectors
Disconnect fuel hose.
1. Insert pointed tools each side
Wrap a rag around the hose end to prevent rail drain-
ing.
Cut tie raps and remove the wiring harness from
the fuel rail.
ly at a time.
Pull rail out with fuel injectors.
If necessary remove fuel injectors as described be-
low.
Installation
A thin film of injection oil should be applied to
O-rings of fuel injectors to ease installation in in-
take manifold.
to 10 Nm (89 lbfin).
When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.
FUEL INJECTOR
IMPORTANT: Never mix up fuel injectors of nor-
mally-aspirated and supercharged 4-TEC engines.
Doing so will automatically lead to a misfunction of
the EMS and will cause a bad engine calibration.
Leakage Test
To perform a leakage test, the injectors and fuel
rail have to be removed from the engine. Refer to
REMOVAL in FUEL RAIL REPLACEMENT for the
procedure.
NOTE: Do not detach injectors from the fuel rail.
Reconnect the fuel line and the wiring harness.
Place each injector in a clean bowl.
Install the safety lanyard cap on the DESS post to
activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.
If not within specification, replace the fuel injector(s).
1 R1503motr163A
1
R1503motr162A
WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
08-03-12 SMR2003_027 _08_03A.FM
The leakage test is validated when performing the
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section.
Electrical Test
Voltage Test
Safety lanyard must be on DESS post.
the B.U.D.S. software, energize the fuel injector
from the Activation section.
Install a temporary connector on the injector with
harness.
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it. If it works, continue
procedure.
Using B.U.D.S., activate injector while probing ter-
minal 2 (of injector on harness side) and battery
ground.
a. If 12 V is read, check continuity of circuit as
per following table. If it is good, try a new
EMS ECU.
b. If it does not read 12 V, check continuity of
circuit as per following table. If it is good, try
a new MPEM.
Resistance Test
Reconnect the injector and disconnect the EMS
ECU connector A.
Remove safety lanyard and wait 15 seconds. Dis-
connect engine connector.
CAUTION: Before unplugging engine connec-
tor, always remove safety lanyard and wait 15
seconds. Otherwise, damage to CAPS may oc-
cur.
ENGINE CONNECTOR
EMS ECU CONNECTOR
CIRCUIT NUMBER
(EMS ECU connector A)
INJECTOR
NUMBER
A-15 1
A-33 2
A-14 3
CIRCUIT NUMBER
(AMP connector #2)
INJECTOR
NUMBER
2-16 1
2-17 2
2-18 3
Fuel injector cylinder 1
1 (engine connector) and
A-15 (EMS ECU
connector)
A-33 (EMS ECU
connector)
A-14 (EMS ECU
connector)
4
R1503motr192A
1
2 3
R1503motr193A
15
33
14
SMR2003_027 _08_03A.FM 08-03-13
4-TEC Models
The resistance should be between 11.4 and 12.6 .
If resistance value is correct, try a new EMS ECU.
Refer to EMS ECU REPLACEMENT procedures
harness/connectors or replace the wiring harness
between EMS ECU connector and fuel injector.
The resistance should be between 14 and 15 .
harness/connectors or replace the wiring harness
between EMS ECU connector and fuel injector.
Fuel Injector Replacement
Removal
Before removing the injectors, the fuel rail has to
be removed from the engine. Refer to REMOVAL
in FUEL RAIL REPLACEMENT for the procedure.
FUEL RAIL ASSY
1. Fuel injector
2. Injector clip
3. O-ring
Then remove the injector clip. Now the fuel injec-
tor can be easily pulled out of the fuel rail.
Installation
For the installation, reverse the removal proce-
dure. Paying attention to the following details.
If you reinstall a used injector, carefully inspect O-
ring condition before reinstalling fuel injector. Re-
place O-ring with a new one if damaged. Insert the
fuel injector in place with your hand.
NOTE: A thin film of engine oil should be applied
to O-rings to ease insertion in rail.
EMS ECU AND MPEM
REPLACEMENT
General
Prior to replacing a suspected EMS ECU or MPEM,
ensure that all the recommendations in the general
introduction of this section have been followed.
IMPORTANT: When the EMS ECU is replaced,
the Closed Throttle and Idle Actuator must be
reprogrammed/reset. Refer to its specific section
for adjustment.
To allow transferring the previous recorded informa-
tion from the old EMS ECU or MPEM to the new
one, use the vehicle communication kit (VCK) with
the B.U.D.S. software. Use Replace ECM or MPEM
in the Module menu. Follows instructions in its help
system.
NOTE: If the old EMS ECU or MPEM is working, it
must be read inside B.U.D.S. prior to removing it
from the vehicle to carry vehicle information and his-
tory to the new EMS ECU or MPEM. Otherwise,
perform the operations described in IF THE PREVI-
OUS MPEM WAS NOT READ WITH B.U.D.S. be-
low.
EMS ECU Replacement
CAUTION: Never try to use a 4-TEC Super-
charged EMS ECU on a normally-aspirated en-
gine. Doing so will automatically lead to a mis-
function of the EMS and will cause irregular
combustion which will damage the engine.
1
2
R1503motr164A
3
WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.
WARNING
08-03-14 SMR2003_027 _08_03A.FM
Disconnect both EMS ECU connectors from EMS
ECU.
TYPICAL
1. EMS ECU
2. Retaining screws
Unscrew all retaining screws and remove the en-
gine EMS ECU from intake manifold.
Install the new EMS ECU to the engine.
Reconnect EMS ECU connectors to EMS ECU then
battery cables.
If the previous EMS ECU was read with
B.U.D.S.
Transfer the data from the previous EMS ECU to
the new one using B.U.D.S. then proceed with the
required resets.
Continue procedure as per FINALIZING EMS ECU
REPLACEMENT below.
If the previous EMS ECU was NOT read with
B.U.D.S.
Enter the old EMS ECU (named ECM in
B.U.D.S.) serial number in the Part Replace-
ment under History tab. Click on Add part in
History.
Reprogram safety lanyard(s).
NOTE: The EMS ECU serial number can be found
on the EMS ECU sticker that also shows the P/N.
Continue procedure as per FINALIZING EMS ECU
REPLACEMENT below.
Finalizing EMS ECU Replacement
After performing the required resets, ensure to
clear all faults from the newly replaced EMS ECU.
Start the engine and increase engine speed above
5000 RPM to be sure no fault appears.
MPEM Replacement
Disconnect AMP connectors from MPEM. Re-
move retaining nuts on top.
Pull MPEM out.
Install the new MPEM in vehicle. Reconnect AMP
connectors to MPEM.
If the previous MPEM was read with B.U.D.S.
Transfer the data from the previous MPEM to the
new one using B.U.D.S.
Continue procedure as per FINALIZING MPEM
REPLACEMENT below.
If the previous MPEM was NOT read with
B.U.D.S.
Enter the vehicle and engine serial numbers in
the Vehicle tab.
Enter the old MPEM and the actual EMS ECU
(named ECM in B.U.D.S.) serial numbers in the
Part Replacement under History tab. Click on
Add part in History.
Manually activate the options installed on vehi-
cle under the Setting tab.
NOTE: The MPEM serial number can be found on
the MPEM sticker that also shows the P/N.
NOTE: If an option is installed but not checked in
B.U.D.S., the information center will not display
that option. If an option is checked in B.U.D.S. but
not installed in vehicle, a fault code will be gener-
ated.
Continue procedure as per FINALIZING MPEM
REPLACEMENT below.
Finalizing MPEM Replacement
Ensure to clear all faults from the newly replaced
MPEM.
Start engine and ensure no fault is active.
2
2
R1503motr180A
1
WARNING
SMR2003_027 _08_03A.FM 08-03-15
ENGINE WIRING HARNESS
4-TEC ENGINES
1.EMS ECU connector
2.CTS connector
3.EGT connector
4.CAPS connector
5.Fuel injector connector (cylinder 1)
6.Ignition coil connector (cylinder 1)
10. Ignition coil connector (cylinder 3)
11. TOPS valve connector
12. OSPS connector
13. TPS connector
14. Idle bypass valve connector
15. MATS connector
16. Engine connector
17. MAPS connector
18. OPS connector
19. KS connector
20. CPS connector
1.EMS ECU connector
2.CTS connector
3.EGT connector
4.CAPS connector
10. Ignition coil connector (cylinder 3)
11. TOPS valve connector
12. OSPS connector
13. TPS connector
14. Idle bypass valve connector
15. MATS connector
16. Engine connector
17. MAPS connector
18. OPS connector
19. KS connector
20. CPS connector
Resistance Test
Check continuity of the circuits according to the
wiring diagram in the WIRING DIAGRAMS section
of this manual.
If wiring harness is good, check the respective
sensor/actuator as described in this section.
Otherwise, repair the connectors, replace the wir-
ing harness or the EMS ECU/MPEM as diagnosed.
4
R1503motr199A
5 6 7 8
10
9
11
12
3
2
1
19
20
18
17
14
13
15
16
13
4
R1503motr270A
3
2
5
6
7
8
9
10
11 12
14
18
19 20 1
16
15
17
08-03-16 SMR2003_027 _08_03A.FM
Removal
Remove fuel rail cover.
Disconnect the wiring harness from all sensors/
actuators.
Disconnect the EMS ECU connector from the EMS
ECU.
Cut all tie raps which are holding the wiring harness
in position.
TYPICAL
1. Wiring harness
Remove complete wiring harness.
Installation
First connect the EMS ECU connector A to the
EMS ECU and fix the harness on the wiring sup-
port with a locking tie.
1. Locking tie
Lead the cable bundle with the injector and igni-
tion coil connectors to the fuel rail and fix it also by
using 4 locking ties.
1. Locking ties
Connect the fuel injectors, ignition coils, CAPS, CTS
and EGT to the wiring harness.
Install the engine connector on the appropriate
bracket on the wiring support.
Then fix the other bundle on the appropriate sup-
ports on the wiring support and the EMS ECU brack-
et with locking ties.
TYPICAL
1. Locking ties
1
R1503motr200A
1 R1503motr201A
WARNING
Pay attention not to mix injectors or ignition
coils wires between cylinders. The location of
the splice connectors indicate which cylinder
wires belong to.
1
R1503motr202A
1
1
R1503motr203A
SMR2003_027 _08_03A.FM 08-03-17
Connect the CPS, KS, OPS, and the MAPS to the
wiring harness.
Also connect now the MATS, TPS, OSPS, idle by-
pass and TOPS valve to the wiring harness.
Fix the wiring for the MATS with a locking tie to
support the cables.
1. Locking tie
Install all remaining parts, which has been removed.
(TPS)
General
The throttle position sensor (TPS) is a potentiom-
eter that sends a signal to the EMS ECU which is
proportional to the throttle shaft angle.
4-TEC ENGINES
IMPORTANT: Prior to testing the TPS, ensure that
mechanical components/adjustments are adequate
according to THROTTLE BODY in AIR INDUCTION
SYSTEM above.
The EMS may generate several fault codes pertain-
ing to the TPS. Refer to SYSTEM FAULT CODES in
DIAGNOSTIC PROCEDURES section for more in-
formation.
Wear Test
While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.
the B.U.D.S. software, use the Throttle Opening
display under Monitoring.
Slowly and regularly depress the throttle. Observe
the needle movement. It must change gradually
and regularly as you move the throttle. If the nee-
dle sticks, bounces, suddenly drops or if any dis-
crepancy between the throttle movement and the
needle movement is noticed, it indicates a worn
TPS that needs to be replaced.
1 R1503motr204A
1
R1503motr165A
1 R1503motr271A
08-03-18 SMR2003_027 _08_03A.FM
Voltage Test
Check the EMS ECU voltage output from to the throt-
tle position sensor.
TPS
Disconnect connector from throttle position sen-
sor. To unlock connector, insert a small screwdriv-
er between the folded tab.
NOTE: On the Supercharged Models, a mirror is
useful to see under throttle body.
To see the connector pin-out, temporarily remove
the connector shield joining the harness, to ex-
pose the terminal numbers. Connect a voltmeter
to the terminals of the wiring harness as per the
following table.
Remove and reinstall the safety lanyard to activate
the EMS ECU.
Check the voltage readings as follows.
If voltage test is good, replace the TPS.
If voltage test is not good, check the resistance of
the TPS circuit.
Resistance Test
Reconnect the TPS.
Disconnect the EMS ECU connector A on the EMS
ECU.
tween terminal A-25 and A-39.
Check the resistance between terminal A-24 and
terminal A-39 with the throttle plate in idle posi-
tion.
The resistance should be approximately 2500 .
terminal A-39 with the throttle plate in wide open
position.
A-25 with throttle plate in idle position.
Now check the resistance with the throttle plate
in wide open position.
NOTE: When measuring between terminals A-24
and A-39, resistance value decreases while de-
pressing throttle lever. when measuring between
terminals A-24 and A-25, resistance value in-
creases while depressing throttle lever. The resis-
tance value should change smoothly and propor-
tionally to throttle movement. Otherwise, replace
TPS.
If resistance values are correct, try a new EMS ECU.
CONNECTION VOLTAGE
terminal 1 with engine ground 0 V
terminal 3 with engine ground 4.5 - 5 V
R1503motr167A
3
2
1
R1503motr191A
24
39
25
SMR2003_027 _08_03A.FM 08-03-19
If resistance values are incorrect, repair connector
or replace the wiring harness between EMS ECU
connector and the TPS. If wiring harness and con-
nector test good, replace TPS.
Replacement
Remove the throttle body as described above.
Loosen two screws retaining the TPS.
Remove TPS.
THROTTLE BODY
2. Screws
Apply Loctite 243 on screw threads, install the new
TPS.
Proceed with the Closed Throttle and Idle Actu-
ator Reset. See below.
Closed Throttle and Idle Actuator Reset
NOTE: This operation performs a reset of the val-
ues in the EMS ECU.
This reset is very important. The setting of the TPS
will determine the basic parameters for all fuel
mapping and several EMS ECU calculations and
the setting of the idle bypass valve will determine
the basic parameters for the idle speed control of
the engine.
NOTE: Reset must be done each time the throttle
position sensor (TPS) or the idle bypass valve is
loosened or removed or throttle body is replaced
or EMS ECU is replaced.
CAUTION: An improperly set TPS or idle by-
pass valve may lead to poor engine perfor-
mance and emission compliance could possi-
bly be affected. In addition, improper idle
bypass valve reset may lead to poor engine
starting, improper idle (too low or way too
high) and engine stop on deceleration.
Ensure the throttle body plate stop lever rest
against its stopper. Open throttle approximately
one quarter then quickly release. Repeat 2 - 3 times
to settle throttle plate. If stopper does not rest
against its stop lever, perform throttle cable ad-
justment. Refer to THROTTLE BODY in AIR IN-
DUCTION SYSTEM above.
To properly reset valve, first install safety lanyard
then remove it and then wait 5 seconds. Repeat
this cycle 2-3 times.
Push the Reset button in the Setting section of
B.U.D.S.
NOTE: No message will be displayed if operation
is good. If operation is wrong, an error message
will be displayed.
NOTE: There is no idle speed adjustment to per-
form. The EMS ECU takes care of that. If TPS is
not within the allowed range while resetting the
Closed Throttle and Idle Actuator, the EMS ECU
will generate a fault code and will not accept the
setting.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes ap-
pear, refer to SYSTEM FAULT CODES in DIAGNOS-
TIC PROCEDURES section for more information.
2
1
R1503motr168A
08-03-20 SMR2003_027 _08_03A.FM
IDLE BYPASS VALVE
An idle bypass valve with good resistance mea-
surement can still be faulty. It is also possible that
a mechanical failure occurs which is not detect-
able without measuring the air flow. Replacing the
idle bypass valve may be necessary as a test.
Resistance Test
Disconnect idle bypass valve from the wiring har-
ness.
Using a multimeter, check the resistance in both
windings.
Check the resistance between terminals A and D
and also between terminals C and B of the idle
bypass valve.
The resistance in each winding should be approx-
imately 50 at 23C (73F).
If the resistance of one or both windings is not
good, replace the idle bypass valve.
If resistance test of valve windings is good, check
continuity of circuits A-35, A-36, A-37, A-38.
Visual Inspection
Remove idle bypass valve from throttle body.
Check the piston and bypass channel for dirt/de-
posits which can cause a sticking piston.
CAUTION: Do not try to operate the piston of
the idle bypass valve when it is dismounted.
Also do not move the piston by hand. The
screw drive is very sensitive and will be de-
stroyed.
Clean the parts and install the idle bypass valve on
the throttle body.
Proceed with the Closed Throttle and Idle Actu-
ator Reset. See above.
CRANKSHAFT POSITION
SENSOR (CPS)
TYPICAL
1. CPS connector
Ensure that information center works. Needles
will sweep, LED and LCD segments will turn on
when the safety lanyard is installed. Check for
RPM display at the information center while crank-
ing in engine drowned mode. Press and HOLD
throttle lever then press start/stop button. 800-
1000 RPM should display. Otherwise perform the
following tests.
NOTE: Take into account that a CPS fault can be
triggered by bent or missing encoder wheel teeth.
First check fault codes then check the teeth con-
dition if necessary. See below.
Disconnect CPS wiring harness connector. Probe
terminals coming from CPS while cranking en-
gine. Voltage should be within 1-2 Vac. Otherwise,
inspect wiring and replace CPS if wiring is good.
Resistance Test
Disconnect the CPS connector from the wiring
harness and check the resistance of the sensor
itself.
The resistance should be between 190 and 290 .
Otherwise, replace the CPS.
1
R1503motr169A
SMR2003_027 _08_03A.FM 08-03-21
If resistance tests good, reconnect the CPS and
disconnect the EMS ECU connector A on the EMS
ECU.
If resistance value is incorrect, repair the connec-
tors or replace the wiring harness between EMS
ECU connector and the CPS.
Replacement
Disconnect connectors and remove the PTO cov-
er. Refer to PTO HOUSING/MAGNETO in ENGINE
section.
Remove CPS.
1. CPS inside PTO cover
Apply Loctite 243 on screw threads then install the
new CPS. Torque to 10 Nm (89 lbfin).
Encoder Wheel Inspection
To check the encoder wheel for bent teeth, pro-
ceed as follows.
Remove PTO cover. Refer to PTO HOUSING/
MAGNETO in ENGINE section.
Install a dial indicator on crankcase casting. Posi-
tion the gauge on a tooth and set it to zero (0).
Rotate flywheel and check needle movement. The
maximum allowed difference between teeth is
0.15 mm (.006 in). Otherwise, straighten the tooth
or replace the encoder wheel.
1. Encoder wheel
2. Dial indicator
R1503motr182A
5
19
1
R1503motr170A
2
R1503motr177A 1
08-03-22 SMR2003_027 _08_03A.FM
CAMSHAFT POSITION SENSOR
(CAPS)
1. CAPS
Voltage Test (harness)
Disconnect the connector from the wiring harness.
To see the connector pin-out, temporarily remove
the connector shield joining the harness, to ex-
pose the terminal numbers.
Remove and reinstall safety lanyard to activate the
system.
Probe terminal 3 of CAPS connector (wiring har-
ness side) and battery ground.
a. If 12 V is read, check continuity of circuits A-20
and A-34. If they test good, perform the CAPS
voltage test as explained below. If CAPS tests
good, try a new EMS ECU.
EMS ECU CONNECTOR
b. If 12 V is not read, check continuity of circuit 2-19
from MPEM to the CAPS. If it tests good, try a
new MPEM. Otherwise, repair wiring harness.
Remove the CAPS from the cylinder head.
Set up the following electric circuit to perform the
voltage test.
CAPS PIN-OUT
Touch the CAPS with a conductor (ex.: screwdriv-
er) and look if the voltage at the multimeter
switches from 12 V to less than 1 V.
1 R1503motr178A
R1503motr183A
20
34
R1503motr184A
1 2 3
CAPS
1200 W
1 2 3
12 V
+
-
V
R1503motr208A
Voltmeter
SMR2003_027 _08_03A.FM 08-03-23
1. CAPS
2. Conductor
If the voltage is not good, replace the CAPS.
Replacement
Unscrew the retaining screw and replace the
CAPS. Ensure to reinstall O-ring.
Apply Loctite 243 (blue) on thread and torque to
6 Nm (53 lbfin).
MANIFOLD AIR TEMPERATURE
SENSOR (MATS)
TYPICAL INTAKE MANIFOLD
Resistance Test
Disconnect the connector from the MATS and
2740 at 20C (68F).
Otherwise, replace the MATS.
If resistance tests good, reconnect the MATS and
ECU.
ECU connector and the MATS.
Replacement
Disconnect the connector of the MATS.
Screw MATS out and install the new one. Torque
2
R1503motr207A
1 Pin 1 Pin 2
1200 W resistor
Pin 3
V
1 R1503motr171A
R1503motr186A
7
21
08-03-24 SMR2003_027 _08_03A.FM
COOLANT TEMPERATURE
SENSOR (CTS)
1. Coolant temperature sensor (CTS)
Resistance Test
Disconnect the connector from the CTS and check
2740 at 20C (68F).
Otherwise, replace the CTS.
If resistance tests good, reconnect the CTS and
ECU.
ECU connector and the CTS.
Replacement
Unlock expansion tank and temporarily move
away to gain access.
Remove the fuel rail cover.
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 18 Nm
(159 lbfin).
MANIFOLD AIR PRESSURE
SENSOR (MAPS)
IMPORTANT: Never mix up MAPS of normally-as-
pirated and supercharged 4-TEC engines. Doing so
will automatically lead to a misfunction of the EMS
ECU and will cause a bad engine calibration.
TYPICAL
NOTE: This sensor is a dual function device. When
engine is started and it runs at idle speed, the sen-
sor takes the atmospheric pressure and stores it in
the EMS ECU. Thereafter, it takes the manifold air
pressure at operating RPMs.
Ensure sensor is correctly installed on intake man-
ifold. 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.
1 R1503motr172A
R1503motr187A
11
27
1 R1503motr173A
SMR2003_027 _08_03A.FM 08-03-25
Voltage Test
Check the voltage output from EMS ECU to the man-
ifold air pressure sensor (MAPS).
Disconnect connector from MAPS and connect a
voltmeter to the terminals of the wiring harness
as per the following table.
Remove and reinstall the safety lanyard to activate
the EMS ECU.
If voltage test is good, replace the MAPS.
If voltage test is not good, check the continuity of
the MAPS circuit.
Resistance Test
Disconnect the EMS ECU connector A on the EMS
ECU.
Using a multimeter, check continuity of circuits 12,
28 and 40.
If wiring harness is good, try a new EMS ECU.
Otherwise, repair the connectors or replace the
wiring harness between EMS ECU connector and
the MAPS.
Replacement
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 (EGT)
1. Muffler
2. Exhaust gas temperature sensor (EGT)
Resistance Test
Disconnect the connector from the EGT and check
2740 at 20C (68F).
Otherwise, replace the EGT.
If resistance tests good, reconnect the EGT and
ECU.
tor or replace the wiring harness between EMS
ECU connector and the EGT.
Replacement
Disconnect EGT connector and remove EGT.
Apply Loctite 518 on threads of the EGT then in-
stall.
Replug connector.
CONNECTION VOLTAGE
2
F18D2IA
1
08-03-26 SMR2003_027 _08_03A.FM
KNOCK SENSOR (KS)
1. Knock sensor (KS)
Dynamic Test
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 sen-
sor 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 SYS-
TEM section.
Check the knock sensor resistance.
Disconnect the connector from knock sensor har-
ness.
Static Resistance Test
both terminals on the knock sensor harness side.
The resistance should be approximately 5 M.
If resistance is not good, replace knock sensor.
If resistance is good, reconnect the knock sensor
connector and disconnect the EMS ECU connec-
tor A from the EMS ECU.
If wiring harness is good, try a new EMS ECU. Re-
fer to EMS ECU REPLACEMENT procedures else-
Otherwise, repair the connector or replace the wir-
ing harness between EMS ECU connector and
knock sensor.
Replacement
Remove the intake manifold. Refer to INTAKE
MANIFOLD REPLACEMENT in INTAKE section.
Unscrew and remove knock sensor.
Clean contact surface, apply Loctite 243 in thread-
ed hole then install the new knock sensor.
Torque screw to 24 Nm (18 lbfft).
CAUTION: Improper torque might prevent sen-
sor to work properly and lead engine to severe
damage of internal components.
Replug connector.
1 R1503motr174A
R1503motr188A
9
23
SMR2003_027 _08_03A.FM 08-03-27
OIL PRESSURE SENSOR (OPS)
TYPICAL
1. OPS
Oil Pressure Test
First, carefully check the condition of the connec-
tor terminals. Clean to remove dirt and corrosion
that coud affect proper operation of the sensor.
IMPORTANT: Do not apply grease on terminal.
To check the function of the oil pressure sensor,
an ,oil pressure test has to be performed. Refer to
OIL PRESSURE TEST in LUBRICATION SYSTEM
section.
If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOT-
ING section.
If the engine oil pressure is good, check the resis-
tance of the OPS while engine is off and while
engine is running.
Resistance Test
Disconnect the connector from the OPS and use
a multimeter to check the resistance between
OPS terminal and engine ground while engine is
stopped (without oil pressure) and while engine is
running (with oil pressure).
When engine is stopped the resistance is infinitely
high (normally open switch).
When engine is running and the oil pressure reach-
es 180 - 220 kPa (26 - 32 PSI), the resistance of
the OPS is close to 0 .
If resistance values are incorrect, replace OPS.
If the values are correct, check the continuity of
the wiring harness.
Disconnect the EMS ECU connector A from the
EMS ECU and check continuity of circuit 6.
OPS.
OIL SEPARATOR PRESSURE
SENSOR (OSPS)
1. OSPS
1 R1503motr194A R1503motr195A
6
1
R1503motr189A
08-03-28 SMR2003_027 _08_03A.FM
TOPS Pressure Test
To check the function of the OSPS (oil separator
pressure sensor), disconnect the TOPS valve and
perform a TOPS pressure test as follows.
Remove oil dipstick from engine.
Using appropriate tubes, install the engine leak
test pump (P/N 529 021 800) on dipstick tube. En-
sure to have a tight fit.
Start engine. Spray soapy water on the tubes from
the pump to the dipstick tube to ensure there is
no leak. If so, correct the leak before measuring
the pressure.
If the engine blow-by pressure does not reach
40 kPa (6 PSI), check the points described in the
following flow chart.
Stop engine and wait 30 seconds to let pressure
drop before removing tubes and pump from dip-
stick tube.
Otherwise, check the resistance of the OSPS
while engine is off and while engine is running.
Resistance Test
Disconnect the connector from the OSPS and use
a multimeter to check the resistance between
OSPS terminal and engine ground while engine is
stopped (without blow-by pressure) and while en-
gine is running (with blow-by pressure).
When engine is stopped and the blow-by pressure
is released, the resistance of the OSPS is close to
0 (normally closed switch).
When engine is running and the blow-by pressure
exceeds 40 kPa (6 PSI), the resistance is infinitely
high.
If resistance values are incorrect, replace OSPS.
If the values are correct, check the continuity of
the wiring harness.
Disconnect the EMS ECU connector A from the
EMS ECU and check continuity of circuit 31.
OSPS.
WARNING
The TOPS system might be pressurized.
When the TOPS valve is disconnected from
the wiring harness, never open the oil filler
cap. Stop the engine and wait at least 30 sec-
onds before opening it, to release the pres-
sure.
WARNING
Stop the engine and wait at least 30 seconds
before removing the pump and tubes, so that
pressure drops.
R1503motr198A
31
SMR2003_027 _08_03A.FM 08-03-29
TOPS VALVE (blow-by)
Pressure stays below
40 kPa (5.8 PSI) for 10 min.
(TOPS valve is open)
R1503motr206T
TOPS DIAGNOSTIC FLOW CHART
Connect safety
lanyard
TOPS valve opens
(short knocking noise)
Check
TOPS switch
Check output voltage
on wiring harness
Replace
TOPS valve
Lower than 8 V
Greater than 8 V
No
OK
Fails
Repair or
replace
Install engine leak test pump
gauge on oil dipstick tube
Start engine
Yes
No
Pressure drops
down directly after
reaching 40 kPa (5.8 PSI)
(TOPS valve opens again)
TOPS OK
Yes
Check
OSPS
Fails
OK
Fails
Yes
No
OK
Fails
Replace
OSPS
Retest Retest
OK
Try a new MPEM
Check
wiring harness
Retest
Working?
No
Yes
Try a new
EMS ECU
08-03-30 SMR2003_027 _08_03A.FM
The valve is turned on as soon as safety lanyard is
installed on its post. The valve opening allows ven-
tilation of crankcase.
The OSPS monitors the pressure to detect a mal-
function of this valve. If pressure rises above a pre-
set threshold, the valve is re-energized again and
if it fails, a fault code is generated.
The TOPS switch (mercury type), located besides
the MPEM (on MPEM bracket), monitors the wa-
tercraft position. If the watercraft rolls above a pre-
set threshold (or tips over) the switch opens and
the EMS ECU closes the valve to prevent oil in
engine crankcase to flow towards intake manifold.
Besides, the engine RPM will be gradually re-
duced then engine will be stopped.
1. TOPS valve
Resistance Test
Disconnect the connector from the TOPS valve and
check the resistance of the solenoid itself.
The resistance should be between 1.27 and
2.47 .
Otherwise, replace the TOPS valve.
Dynamic Test
Activate the TOPS valve by installing the safety
lanyard on the DESS post.
If you can hear the movement of the piston (knock-
ing), the valve works fine, otherwise follow the pro-
cedure shown in the following chart.
NOTE: Take into account that you could hear the
piston movement and the valve might not be
working properly. The retaining washer could be
unlocked from the piston shaft. Disassembly will
reveal its condition.
TOPS Valve Replacement
Disconnect the wiring harness from the TOPS
valve.
Remove the oil separator cover. Refer to OIL SEP-
ARATOR REPLACEMENT in the LUBRICATION
SYSTEM section.
1. Solenoid valve
2. Spring
3. Valve disc
4. Retaining washer
Remove the valve disc and the spring on the bot-
tom of the TOPS valve after removing the retain-
ing washer.
Unscrew and remove the TOPS valve.
Install the new valve with new gasket. Apply Loc-
tite 243 (blue) on threads and torque to 10 Nm
(89 lbfin).
TOPS Switch
Disconnect TOPS switch and remove from MPEM
bracket.
Using and ohmmeter, measure resistance between
terminals.
1
R1503motr179A
WARNING
The spring on the TOPS valve is tensioned and
can shoot away the valve disc. Hold the valve
disc with fingers while removing the washer.
1
R1503motr181A
2
3
4
SMR2003_027 _08_03A.FM 08-03-31
Position switch as it is located in vehicle. Resistance
should be close to 0 .
Rotate switch as it would do in vehicle. Switch
should remain closed up to approximately 120
(from the vertical axis) in either direction. Other-
wise, replace switch.
NOTE: Since this is a mercury switch, dispose it
properly according to the environmental regula-
tions in your area.
Farther than 120 and when switch is upside
down, switch should be open and resistance will
be infinite.
IGNITION COILS
1. Ignition coil
NOTE: The MPEM energizes the primary side of
each ignition coil individually. It can detect open
and short circuit in the primary winding but it does
not check the secondary winding.
the B.U.D.S. software, energize the ignition coil
from the Activation section.
You should hear the spark occurring. In doubt, use an
inductive spark tester or a sealed tester available
from after-market tool/equipment suppliers to pre-
vent spark occurring in the bilge. Otherwise, perform
the following checks.
An ignition coil with good resistance measure-
ment can still be faulty. Voltage leak can occur at
high voltage level which is not detectable with an
ohmmeter. Replacing the ignition coil may be nec-
essary as a test.
Voltage Test
Disconnect the connector from the ignition coil
and check the voltage supplied by the MPEM.
Install safety lanyard on the DESS post.
Check voltage between terminal 2 of ignition coil
connector on the wiring harness and battery
ground.
The voltage should be 12 V.
If 12 V is NOT read, check continuity of appropri-
ate circuit 2-16 (cylinder 1), 2-17 (cylinder 2) or 2-18
(cylinder 3). If it tests good, try a new MPEM.
1
R1503motr175A
WARNING
Never make a spark test with spark plug re-
moved. Flammable vapors may be present in
the bilge and ignited which could cause an ex-
plosion.
WARNING
to ignite.
R1503motr196A
2
1
08-03-32 SMR2003_027 _08_03A.FM
If 12 V is read, disconnect the EMS ECU connector
A from the EMS ECU and check the continuity of
appropriate circuit 41 (cylinder 1), 1 (cylinder 2) or
29 (cylinder 3).
EMS ECU CONNECTOR
If wiring harness is defective, repair the connector
or replace the wiring harness between EMS ECU
connector and the ignition coil.
If wiring harness is good, test resistance of prima-
ry and secondary winding of ignition coil.
Resistance Test
CAUTION: Do not remove the ignition coil be-
fore disconnecting the connector, or the wires
will be damaged. Do not pry up ignition coil
with a screwdriver to avoid damage.
Remove ignition coil from spark plug.
1. Spark plug terminal
Using a multimeter, check the resistance in both
primary and secondary windings.
For primary winding check the resistance between
terminals 1 and 2 of the ignition coil.
The resistance should be between 0.85 and 1.15
at 20C (68F).
For secondary winding check the resistance be-
tween terminal 1 and spark plug terminal.
The resistance should be between 9.5 and 13.5 k
at 20C (68F).
If the resistance of one of both windings is not
good, replace the defective ignition coil.
If the windings test good, try a new engine EMS
ECU.
NOTE: Prior to inserting the ignition coil to its lo-
cation, apply some silicone lubricant (P/N 293 600
041) around the seal area that touches the spark
plug hole. After installation, ensure the seal seats
properly with engine top surface.
TDC SETTING (Top Dead Center)
The EMS is able to determine the exact position
of camshaft and crankshaft. That means that no
TDC setting has to be performed. It is used for
both injection and ignition timings.
ENGINE START/STOP SWITCH
VERIFICATION
A quick operation test can be done using the vehi-
cle communication kit (VCK) with the B.U.D.S. soft-
ware, using the Monitoring section. Press the
start button and look at the start button LED. It
should turn on, indicating the starting system is
working on the input side of the starting system
(start button, MPEM, EMS ECU and wiring). You
know now the problem is on the output side of the
starting system (MPEM output signal to starting so-
lenoid, wiring harness going to the solenoid and
starter motor. Refer to STARTING SYSTEM for test-
ing procedures). Otherwise, check the input side as
follows.
Disconnect the start/stop switch connector. Using
an ohmmeter, connect test probes to YELLOW/RED
and PURPLE wires.
the ohmmeter should read lower than 200 ohms.
Otherwise, replace switch. Reconnect connector.
R1503motr190A
1
41 29
1
R1503motr197A
2
1
WARNING
Always reconnect ignition coil cables at the
same spark plugs where they come from.
Otherwise, severe backfire may occur with
possible damage to exhaust system compo-
nents. The genuine wiring harness is de-
signed to prevent a cable mixing by using dif-
ferent cable lengths.
SMR2003_027 _08_03A.FM 08-03-33
If the switch tests good, temporarily disconnect
the inline DESS auxiliary module (if so equipped)
(see safety lanyard switch verification below for
more information). Connect the 6-pin connector to
bypass the auxiliary module. Try the start/stop
switch.
If it works, try a new auxiliary module. Otherwise,
continue testing procedure.
Test continuity of circuit 2-23. If it is good, try a new
MPEM. Otherwise, repair harness/connectors.
Test continuity of circuit B-19. If it is good, try a new
EMS ECU. Otherwise, repair harness/connectors.
SAFETY LANYARD SWITCH
VERIFICATION
safety lanyard, refer to DIAGNOSTIC PROCEDURES.
formed using an ohmmeter.
be NO continuity (open circuit).
and the other test probe to the switch top termi-
nal. Measure resistance, it must be close to
0 ohm.
DESS Auxiliary Module (if so equipped)
This module enhances safety lanyard recognition
at the EMS ECU. It is located under steering sup-
port. It is an inline connection of the DESS post
harness.
If a safety lanyard cannot be programmed or it fails
to be recognized, first refer to the basic self diagnos-
tic mode in DIAGNOSTIC PROCEDURES section.
If it still does not work, disconnect the DESS aux-
iliary module and connect the regular 6-pin DESS
harness.
a. Try pushing down and turning the lanyard on its
post. If it is working now, check module harness/
connections and if they are in good condition, try
a new module.
b. If it is now working, check module harness/
connections. Ensure wires from MPEM and
EMS ECU are properly positioned in connector
and match those on auxiliary module side. Refer
to WIRING DIAGRAMS. If harness/connector
are correct, try a new module.
Reconnect module.
If the above procedures did not work, refer to elec-
trical troubleshooting in TROUBLESHOOTING
and ENGINE MANAGEMENT sections.
close to 0 ohm.
SPARK PLUGS
Disassembly
Disconnect the wiring harness from the ignition
coil.
Remove the ignition coil.
Clean the spark plug and cylinder head with pres-
surize air then completely unscrew.
WARNING
Never remove ignition coil from the spark
plug without disconnecting it from the wiring
harness. Flammable vapors may be present
in the bilge and ignited by a spark which
could cause an explosion.
08-03-34 SMR2003_027 _08_03A.FM
grime.
3. Hand screw spark plug into cylinder head. Then,
tighten the spark plug clockwise an additional
1/4 turn with a proper socket.
1. Proper socket
2. Improper socket
CRANKING SYSTEM
See above for start/stop switch and the DESS post
testing. Refer to STARTING SYSTEM section for
other tests.
ENGINE
SPARK
PLUG
TORQUE
GAP
mm (in)
1503
4-TEC
NGK
DCPR8-ES
Hand tighten
+ 1/4 turn with
a socket
0.6
(.024)
A00E0BA
2
1
SMR2003-028 _08-04A.FM 08-04-1
GENERAL
Here is the basic order suggested to diagnose a
suspected engine management or fuel injection
related problem:
Check the chart in TROUBLESHOOTING sec-
tion to have an overview of problems and sug-
gested solutions.
Check if there is a message displayed by the
vehicle information center. If so, use the VCK
(Vehicle Communication Kit) and look for fault
codes to diagnose the trouble.
NOTE: Fault codes, the letter P - followed by 4 digits
(P-1234), can be displayed in the information center
for troubleshooting. With safety lanyard on its post,
press 5 times the SET button to start the display of
P-codes (onboard diagnostic). Press MODE to scroll
codes if more than one is present. When list is
over, END will appear. When END appears, press
MODE to exit.
1. Press 5 times to activate display of P-codes (onboard diagnostic)
1. Press to scroll if more than one P-code
1. When END appears, press MODE to exit
Check all fuses.
Check fuel rail pressure.
Check spark plugs condition.
Check fuel pump pressure.
Check all connections of the wiring harness.
Refer to COMPONENT INSPECTION AND AD-
JUSTMENT section for procedures.
F18L09D 1
F18L09C 1
F18L09C 1
08-04-2 SMR2003-028 _08-04A.FM
Terminology
Some documents or softwares use technical terms
that may be different from the one used in this man-
ual. The following table will help to find the equiva-
lence.
TERMS USED
IN THIS MANUAL
TERMS USED IN OTHER
DOCUMENTS/
SOFTWARES
EMS ECU
(Engine Control Unit of
Engine Management
System)
ECM
(Engine control module)
MAPS
(Manifold Air Pressure
Sensor)
APS
(Air Pressure Sensor)
or
(Atmospheric Pressure
Sensor)
MATS
(Manifold Air
Temperature Sensor)
ATS
(Air Temperature Sensor)
or
(Intake manifold
Temperature Sensor)
Communication link CAN
CTS
(Coolant Temperature
Sensor)
WTS
(Water Temperature
Sensor)
EGT
(Exhaust Gas
Temperature)
ETS
(Exhaust Temperature
Sensor)
TOPS valve
(Tip-Over Protection
System)
Blow-by valve
Idle bypass valve - DLA
(Digital Linear Actuator)
- Idle actuator
- Idle valve
OSPS
(Oil Separator Pressure
Switch)
OTPS
(Oil Tank Pressure Switch)
DESS auxiliary module DESS ECU
Safety lanyard Key
Information center Cluster
SMR2003-028 _08-04A.FM 08-04-3
SELF-DIAGNOSTIC MODE
Refer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUSTMENT
section.
CODED SIGNALS POSSIBLE CAUSE REMEDY
2 short beeps
(while installing safety
lanyard on post).
Confirms safety lanyard signal operation. Engine can be started.
Safety lanyard is recognized by the EMS ECU.
Good contact between safety lanyard and DESS
post.
1 long beep
post).
Bad DESS system connection. Reinstall safety lanyard cap correctly over post.
Wrong safety lanyard. Use a safety lanyard that has been
programmed for the watercraft. If it does not
work, check safety lanyard condition with
BUDS. Replace safety lanyard if reported
defective.
Defective safety lanyard. Use another programmed safety lanyard.
Dried salt water or dirt in safety lanyard cap. Clean safety lanyard cap to remove salt water.
Defective DESS post. Refer to ENGINE MANAGEMENT section.
Improper operation of EMS ECU or defective wir-
ing harness.
1 short beep followed
by 1 long beep.
EMS ECU has been set to onboard diagnostic
mode.
Remove and reinstall safety lanyard or press
MODE button twice to exit that mode.
2 very short beeps
every 3 seconds
interval for 4 hours.
Safety lanyard has been left on its post without
starting engine or after engine was stopped.
To prevent battery discharge, remove the
safety lanyard from its post.
A 2 seconds beep
every minute interval.
High pressure in oil separator tank. Refer to LUBRICATION SYSTEM section.
Low fuel level. Refer to INSTRUMENTS AND ACCESSORIES
section.
Fuel tank level sensor or circuit malfunction. Refer to INSTRUMENTS AND ACCESSORIES
section.
A 2 seconds beep
every 15 minutes
interval.
Watercraft is upside down. Turn watercraft upright. If it does not work,
check the TOPS switch. Refer to ENGINE
MANAGEMENT section.
Engine coolant temperature sensor or circuit mal-
function.
Fuel tank sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
Exhaust temperature sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
Engine oil pressure sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
Low pressure in oil separator tank (engine oil leak). Refer to ENGINE MANAGEMENT section.
TOPS sensor or circuit malfunction. Refer to ENGINE MANAGEMENT section.
TOPS valve solenoid or circuit malfunction. Refer to ENGINE MANAGEMENT section.
EMS ECU failure. Refer to ENGINE MANAGEMENT section.
Bilge pump circuit low or high voltage
(if so equipped).
Starter solenoid circuit malfunction. Refer to ENGINE MANAGEMENT section.
Communication link fault detected by MPEM. Refer to ENGINE MANAGEMENT section.
EMS ECU communication link message missing
(detected by MPEM).
Information center communication link message
missing (detected by MPEM).
Continuously beeps. High engine coolant temperature. Refer to COOLING SYSTEM.
High exhaust temperature. Refer to COOLING SYSTEM.
08-04-4 SMR2003-028 _08-04A.FM
VCK
035 844) is the primary tool to diagnose engine
management and fuel injection related problems.
NOTE: The MPEM programmer does not work on
4-TEC models.
The 4-TEC requires B.U.D.S. version 2.
B.U.D.S. (Bombardier utility and diagnostic soft-
ware) is designed to allow among other things, the
programming of safety lanyard(s), entering cus-
tomer information, engine monitoring, allowing
actuators, sensors and electronic equipments in-
spection, diagnostic options and reset such as the
closed throttle and idle actuator.
4-TEC Models Through the 6-Pin Connector
TYPICAL
1. 6-pin adapter
2. Connector close to MPEM
nication.
with the 4-TEC engines, ensure that the protocol
KW2000 is properly selected in MPI under
Choose protocol.
When B.U.D.S. is connected with MPEM and
EMS ECU, the status bar shows the protocol
(KW2000) and a number 1 or 2 to the right. To work
with the watercraft, number 2 must be displayed.
Number 2 means that 2 ECUs are connected
(MPEM and EMS ECU).
MPEM AND EMS ECU ARE CONNECTED
Number 1 means that 1 ECU is connected (ei-
ther MPEM or EMS ECU). Therefore, there is a
problem. Check fuses and connections.
ONLY ONE ECU IS WORKING. THERE IS A PROBLEM
If an X is shown, the safety lanyard is not in-
stalled on its post or there is a problem with both
ECUs. Ensure VCK is working properly and
check connections on VCK and watercraft.
VCK Supply
The VCK (MPI box) can use the watercraft power
for its supply.
The safety lanyard must be connected in order to
use the watercraft as a power source.
If watercraft power is used, every time the safety
lanyard is taken off the DESS post, the KW2000
protocol will have to be re-activated.
Changes in EMS ECU
Anytime a change is brought in EMS ECU through
B.U.D.S., there will be an EMS Tracking mes-
sage that will say Remove key from vehicle.
When this occurs, remove the safety lanyard from
its post and wait until the message disappears (it
lasts approximately 15 seconds after lanyard re-
moval).
WARNING
F12H0DA
1 2
F18H0XA
kW2000
F18H0WA
kW2000
SMR2003-028 _08-04A.FM 08-04-5
4-TEC SYSTEM FAULT CODES
General
The faults registered in the MPEM/EMS ECU are
kept when the battery is disconnected.
IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the MPEM/EMS ECU
using the VCK. This will properly reset the appro-
priate counter(s). This will also records that the
problem has been fixed in the MPEM/EMS ECU
memory.
Many fault codes at the same time is likely to be
burnt fuse(s).
For more information pertaining to the code faults
(state, count, first, etc.) and report, refer to B.U.D.S.
online help.
Supplemental Information for Some
Specific Faults
Communication link fault code 1681: Sometimes
the information center does not synchronize fast
enough for the MPEM. That brings this fault code.
Simply clear the fault and try again.
EMS ECU fault codes P0601, P0602, P0604 and
P605: These codes may occur in the following sit-
uations:
Electrical noise is picked up by the EMS ECU.
Ensure that all connections are in good condi-
tion, also grounds (battery, EMS ECU, engine
and ignition system), they are clean and well
tightened and that all electronic components
are genuine particularly in the ignition sys-
tem. Installing resistive caps, non-resistive
spark plugs or improper knock sensor wir-
ing/routing may lead to generate this fault code.
Electrical noise might also lead engine to occa-
sional cutout without generating a fault code
when engine is restarted. When looking at the
fault code, pay attention to the count value in
the software B.U.D.S. A value between 1 and 9
confirms an electrical noise problem. A value of
10 and above will generate a fault code.
When installing a new EMS ECU. It is not proper-
ly programmed from the factory. The EMS ECU
must be returned to be properly activated.
If everything is in good condition, try a new EMS
ECU.
When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
referred as 4-23 for instance. It means Amp con-
nector no. 4 and the circuit wire no. 23 as found in
the wiring diagram.
When they are referred as A-41, it means connec-
tor A on the EMS ECU and the circuit 41.
TPS (Throttle Position Sensor) Faults
Faults which are reported in B.U.D.S. fall into two
groups TPS faults and adaption faults. These are
displayed on the B.U.D.S. system as TPS OUT OF
RANGE and TPS ADAPTION FAILURE.
08-04-6 SMR2003-028 _08-04A.FM
TPS OUT OF RANGE Fault
It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also show up a fault that is intermittent.
TPS ADAPTATION FAILURE Fault
It is caused by the idle position moving out of an acceptable range.
Following failures can be effected by a TPS Adaption Failure:
Idle speed is out of range.
Engine stops, when throttle is released quickly.
Engine runs inconsistent in low partload or low RPM.
Check if connector is disconnected from TPS Yes Fix.
Check if sensor is loose Yes
Fix and reset Closed Throttle and
Idle Actuator.
Inspect sensor for damage or corrosion Yes
Replace and reset Closed Throttle and
Idle Actuator.
Inspect wiring (voltage test) Failed Repair.
Inspect wiring and sensor (resistance test)
Failed
If bad wiring, repair.
If bad TPS, replace and
reset Closed Throttle and Idle Actuator.
Test sensor operation (wear test)
Replace and reset Closed Throttle and
Idle Actuator.
Sensor has been replaced and TPS closed
position not reset
Yes Reset Closed Throttle and Idle Actuator.
Throttle body has been replaced and TPS
closed position not reset
EMS ECU has been replaced and TPS closed
position not reset
Throttle cable too tight Yes
Idle Actuator.
Sensor is loose Yes
Idle Actuator.
Throttle bracket is loose Yes
Idle Actuator.
Adjustment screw worn or loose Yes Change throttle body.
Section 09 COOLING SYSTEM
SMR2003-049_09_01ATOC.FM 09-01-1
TABLE OF CONTENTS 0
CIRCUIT, COMPONENTS AND CARE................................................................................... 09-02-1
CIRCUIT.............................................................................................................................. 09-02-11
COMPONENTS.................................................................................................................. 09-02-15
CARE .................................................................................................................................. 09-02-18
CIRCUIT.............................................................................................................................. 09-02-20
COOLING SYSTEM LEAK TEST........................................................................................ 09-02-21
INSPECTION...................................................................................................................... 09-02-22
DRAINING THE SYSTEM.................................................................................................. 09-02-23
COOLANT REPLACEMENT............................................................................................... 09-02-23
COOLANT PUMP HOUSING............................................................................................. 09-02-24
THERMOSTAT................................................................................................................... 09-02-25
COOLANT PUMP IMPELLER ............................................................................................ 09-02-26
ROTARY SEAL ................................................................................................................... 09-02-27
CARE .................................................................................................................................. 09-02-29
Subsection 02 (CIRCUIT, COMPONENTS AND CARE)
SMR2003-029_09_02A.FM 09-02-1
CIRCUIT, COMPONENTS AND CARE 0
717 Engines
F17E04T
Loctite
567
Loctite
567
Bleed
hose
Water
injection
hose
Tuned pipe
water
inlet hose
Loctite
567
Engine
drain hose
Engine water
supply hose
Engine
water
return
hose
1.2 Nm
(11 lbfin)
Pump support
Loctite
567
09-02-2 SMR2003-029_09_02A.FM
787 RFI Engines
F15E04T
1
Loctite 592
Loctite
592
1.2 Nm
(11 lbfin)
Water
injection
hose
Tuned
pipe
water
inlet
hose
1.2 Nm
(11 lbfin)
Regulator
valve water
supply hose
2
Loctite
592
Engine
drain hose
Inlet
Outlet
4
3
7
8
6
0.6 Nm
(5 lbfin)
5
5 Nm
(44 lbfin)
0.11 Nm
(1 lbfin)
Inlet
Outlet
Loctite 567
Loctite 567
SMR2003-029_09_02A.FM 09-02-3
947 DI Engines
TYPICAL
F12E0XS
Loctite 567
1
Loctite 567
2
Body
Loctite 243
Loctite 518
4
7
0.11 Nm
(1 lbfin)
8
6
0.6 Nm
(5 lbfin)
5
5 Nm
(44 lbfin)
3
Loctite
567
Loctite
567
Loctite
567
Loctite
296
Silicone
sealant
Loctite
primer N
Loctite
567
Loctite 567
Loctite
567
Loctite
567
09-02-4 SMR2003-029_09_02A.FM
4-TEC Engines Closed Loop System
F18E0ZS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
SMR2003-029_09_02A.FM 09-02-5
4-TEC Engines Open Loop System
F18E1DS
09-02-6 SMR2003-029_09_02A.FM
717 Engines
Temperature sensor activates
monitoring beeper when temperature
exceeds 96 - 99C (205 - 210F)
Uppermost point
of circuit (tuned pipe)
allows bleeding
Calibrated
cylinder
head limits
water flow
Fresh water
enters engine
head for
additional
combustion
chamber cooling
Calibrated
outlet fitting
limits
water flow.
ALSO used
as flushing
connector
Cooling System
Indicator (CSI):
Small stream of
water flows out
of bleed outlet located
under bumper
line on front
port side
Engine water
hose outlet
Pressure
zone
Calibrated outlet
fitting limits
water flow
Tuned pipe bleed
hose injects
water into
muffler to cool
exhaust
components
Lowest point of
circuit allows
draining
whenever
engine is
stopped
Water injected
directly into
exhaust gases for
noise reduction
and performance
improvement
Water flows
through
tuned pipe
and manifold
water jackets
F17E06S
SMR2003-029_09_02A.FM 09-02-7
787 RFI Engines
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F15E08S
09-02-8 SMR2003-029_09_02A.FM
947 DI Engines All Models except XP DI
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SMR2003-029_09_02A.FM 09-02-9
947 DI Engines XP DI
C
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F08E0US
09-02-10 SMR2003-029_09_02A.FM
4-TEC Engines
F18E0WS
Ride plate
(operates as heat
exhanger)
Coolant flows
to ride plate
Coolant housing
including thermostat
opens at 87C (188F)
and coolant pump
impeller
Bleed hose from
cylinder head to
expansion coolant tank
Expansion
coolant tank
Coolant temperature
sensor (CTS)
activates when
temperature exceeds
100C (212F)
Coolant flows
to oil cooler
Oil
cooler
Coolant returns
from oil cooler
Coolant returns
from ride plate
SMR2003-029_09_02A.FM 09-02-11
CIRCUIT
CAUTION: All hoses and fittings of the cooling
system have calibrated inside diameters to as-
sure proper cooling of the engine. Always replace
using appropriate Bombardier part number.
717 Engines
A Serial Cooling System is utilized on the 717 en-
gines, which offers an efficient cooling of the
combustion chamber to prevent the possibilities
of detonation.
The water supply is taken from a pressurized area
in the jet pump between the impeller and venturi.
Water enters the cylinder head, cooling the com-
bustion chamber to prevent detonations. Then,
water exits cylinder head toward tuned pipe.
1. Cylinder head cover
2. Fresh water from jet pump
3. Water exiting head assembly to tuned pipe, exhaust manifold and
cylinders
4. Water from cylinder water jackets exiting engine
The tuned pipe and exhaust manifold are designed
with a double wall to allow water circulation.
Water is pre-heated by the exhaust system before
entering the cylinder cooling jackets.
Water enters cylinder cooling jacket through pas-
sages located below exhaust ports from tuned
pipe.
1. Water passages
No water enters crankcase.
When engine is running, water must flow from
bleed outlet indicating that water circulates.
CAUTION: When investigating for no water flow
in the cooling system, check all elbows and
straight fittings as well as all hoses for blockage.
For a minimum back pressure in the exhaust, en-
gine water outlet hose is not connected to the ex-
haust. It has its own outlet at the rear of the hull.
Draining of the cooling system is accomplished by
a drain hose located at the lowest point of the cir-
cuit.
717 ENGINES
1. Drain hose
F01E1LA
2 3
1 4
F01D7HB
1
F01E0FB
1
09-02-12 SMR2003-029_09_02A.FM
787 RFI Engines
The 787 RFI engines features a heat exchanger sys-
tem. This system allows water coming out of the
cylinder head to circulate through a magneto heat
exchanger and the crankcase heat exchanger.
1. Quick connect hose fitting
2. Engine heat exchanger water supply hose
3. Engine drain hose from cylinder heat exchanger
4. Water outlet hose to exhaust outlet
The engine heat exchanger supply hose has a quick
connect hose fitting to facilitate engine draining.
1. Heat exchanger water supply hose
2. Quick connect hose fitting
The water coming out of the engine heat exchang-
er is evacuated at the exhaust outlet for noise re-
duction.
DI Engines
The water supply is provided by a pressurized area
The water flow is controlled by a reducer located
between the jet pump support and the jet pump
on the inlet side. The reducer is blue on the DI
models.
The water is entering the engine by the water inlet
fitting at the cylinder head.
1. Water supply hose
Water from inlet hose also supplies the water reg-
ulator on muffler and magneto cover and crank-
case cover.
Water then is expulsed through the pump support
drain.
Water circulates through the one piece cylinder
head which features improved combustion cham-
ber and better spark plug cooling.
F15E09A 3 2
1
4
F02E0BA 1 2
F08E05A
1
F06D21A
SMR2003-029_09_02A.FM 09-02-13
Water enters cylinder block water jackets and is
directed to the water jackets of the exhaust man-
ifold and tuned pipe head through passages locat-
ed above and below exhaust ports.
1. Water passages
Water exits tuned pipe water jackets through an
outlet fitting.
1. Engine water outlet
Water circulates in the water outlet hose and is
expelled out of the cooling system through a fit-
ting located in the jet pump support on the tran-
som of the watercraft.
Water flows out of tuned pipe water jacket from
upper fitting of tuned pipe and is directed to the
air compressor, then to the air silencer at the tran-
som.
Water continues to flow in the crankcase water
jacket to cool the crankcase area to then be ex-
pulsed to the transom area.
Draining of the cooling system is accomplished by
the drain hose connected to a fitting at the bottom
of the cylinder-block, on tuned pipe side.
1. Drain hose
Bleeding of the cooling system is accomplished by
the bleed hose located at the uppermost point of
the circuit at the tuned pipe. The bleed hose also
serves as the Cooling System Indicator (CSI).
1. Bleed hose
F06D20A 1
1 F06E08A
F06E0IA 1
1 F06E0BA
09-02-14 SMR2003-029_09_02A.FM
The water supply to the water flow regulator is
provided by the water supply hose coming from
the pump.
1. Water flow going to CSI
The lower hose of the valve is the water supply
and the upper hose is the regulated injection water
for the tuned pipe.
1. Water from engine water supply hose
2. Regulated injection water to the tuned pipe
3. Muffler
Regulated water is injected in the tuned pipe by a
calibrated fitting.
1. Injection fitting
All 2-Stroke Engines
CAUTION: Never modify cooling system arrange-
ment, otherwise serious engine damage could
occur.
1 F06E09A
F06E0CA
2
1
3
TECHNICAL DATA
TYPE:
TLCS (Total Loss Cooling System).
COOLANT FLOW:
Pressure build-up at impeller housing
(no water pump).
TEMPERATURE CONTROL:
Calibrated outlet fittings (no thermostat).
SYSTEM BLEEDING:
Self-bleed type (hose at uppermost point of circuit).
SYSTEM DRAINING:
Self-drain type (hose at lowest point of circuit).
SYSTEM FLUSHING:
Fitting hose adapter.
MONITORING BEEPER:
Turns on at 86 - 94C (187 - 201F).
1 F06E0AA
SMR2003-029_09_02A.FM 09-02-15
COMPONENTS
Clamp
To cut or secure non-reusable Oetiker clamps of
cooling system hoses, use pliers (P/N 295 000 070).
1. Cutting clamp
2. Securing clamp
Elbow Fitting
Water injection used on exhaust system cools the
exhaust gases to obtain maximum performance
from the tuned pipe. The elbow fitting no. 1 has a
calibrated inside diameter to optimize water flow
in tuned pipe.
The water injection also helps in reducing noise lev-
el and cools components of the exhaust system.
CAUTION: The elbow fittings are calibrated and
can not be interchanged with one of a different
size as severe engine damage could result.
The elbow fitting can be identified by using the
number stamped onto the fitting or by measuring
its inside diameter. Refer to the following illustra-
tion and chart.
1. Stamped number
A. Outlet diameter = 4.6 mm (.181 in)
B. Inlet diameter = 5.5 mm (.219 in)
Water Flow Regulator Valve
A water flow regulator valve is mounted on mod-
els with the 787 RFI and 947 DI engines so that
they can produce the maximum horsepower out-
put and yet maintain the necessary diameter of
the injection fitting at the tuned pipe head for un-
obstructed water flow.
1
F01B2KA
2
STAMPED
NUMBER
ON
FITTING
FITTING
P/N
INLET
DIAMETER
OUTLET
DIAMETER
16 293 700 016
5.5 mm
(.219 in)
4.6 mm
(.181 in)
48 293 710 048
4.0 mm
(.157 in)
3.5 mm
(.139 in)
16
A
1
B
F00E04A
09-02-16 SMR2003-029_09_02A.FM
The water flow regulator valve no. 2 is mounted
directly onto the muffler.
TYPICAL
1. Water supply hose of regulator valve
2. Regulated water to injection fitting
3. Water injected into the muffler
NOTE: The water injected into the muffler is not
regulated by the tapered needle of the valve. In-
stead, a calibrated water injection fitting controls
water flow into the muffler. Refer to the following
chart.
The water flow regulator valve has a calibrated
spring and a tapered needle which regulate the
injected water in the tuned pipe.
CAUTION: Do not change anything on the wa-
ter flow regulator valve, otherwise serious en-
gine damage can occur. In many countries it is
illegal to tamper with this valve as this will af-
fect the EPA certification.
At low speed, water pressure in the supply hose
of the regulator valve is not sufficient to overcome
the spring of the regulator valve; more water is
being delivered to the injection fitting at the tuned
pipe.
LOW SPEED OPERATION
1. Water entering regulator valve
2. Water exiting regulator valve (less restriction)
3. Water injected in the muffler
At higher speed, water pressure increases in the
supply hose of the regulator valve and gradually
overcomes the return spring of the regulator valve.
Less water is being delivered to the injection fitting
at the tuned pipe.
HIGH SPEED OPERATION
1. Water entering regulator valve
2. Water exiting regulator valve (more restriction)
3. Water injected in the muffler
MODEL
INJECTION FITTING
INSIDE DIAMETER
mm (in)
RX DI, GTX DI, XP DI 3 (.118)
GTI LE RFI 4.5 (.177)
F01E1FA
1 2 3
1
F15E0AA 3
2
1
F15E0BA 3
2
SMR2003-029_09_02A.FM 09-02-17
Adjustment
The water flow regulator valve has been calibrated
at the factory and should not be modified.
NOTE: Water flow regulator valves ordered from
the parts channel are also calibrated. The valve cap
on the DI models is sealed and it is not adjustable.
If the maximum engine speed cannot be attained
or if the engine has poor performance, the water
flow regulator valve should be considered in the
troubleshooting of the problem.
Disassembly
the spring no. 3.
1. Spring
2. Cover
Remove fitting no. 5 from valve housing.
1. Fitting
Unscrew the tapered needle no. 6.
NOTE: Hold the valve to prevent it from turning.
1. Tapered needle
Remove the tapered needle from valve housing.
1. Remove tapered needle
WARNING
Firmly hold cover to valve base. The spring
inside the valve is applying a pressure against
the cover.
F01E1RA
1
2
F01E1SA
1
F01E1TA
1
F01E20A
1
09-02-18 SMR2003-029_09_02A.FM
Pull the valve slightly. Using pliers, release the clamp
which retains the bellows no. 8.
Remove valve no. 7 and bellows no. 8.
Loosen clamp to separate valve from bellows.
1. Clamp
Inspection
Inspect parts for damage. Verify especially bellows
for cracks.
Assembly
Assembly is essentially the reverse of disassembly
procedures.
CARE
For flushing purposes, the cooling system is equipped
with either a fitting spigot or a hose adapter de-
pending upon the model.
For flushing operation, a coupler hose is available
(unnecessary for models with the hose adapter) to
connect to the fitting spigot. A garden hose is
used to flush the whole system by backwash. For
flushing procedure, refer to FLUSHING AND LU-
BRICATION.
For winterization of cooling system, refer to STOR-
AGE.
717 Engines
When servicing the hull, always rotate watercraft
counterclockwise (seen from the rear). Rotating
watercraft on the opposite side could allow resid-
ual water in tuned pipe to enter the engine and
cause damage.
Other Engines
When servicing the hull, always rotate watercraft
clockwise (seen from the rear). Rotating water-
craft on the opposite side could allow residual wa-
ter in tuned pipe to enter the engine and cause
damage.
TYPICAL
F01E21A
F01E24A 1
F01L45C
Max. 90
F06L0GA
max. 90
SMR2003-029_09_02A.FM 09-02-19
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).
When towing your watercraft in water, pinch the
water supply hose from the jet pump housing to the
engine with a large Hose Pincher (P/N 529 032 500).
This will prevent the cooling system from filling
which may lead to water being injected into and
filling the exhaust system. Without the engine run-
ning there isnt any exhaust pressure to carry the
water out the exhaust outlet.
CAUTION: Failure to do this may result in dam-
age to the engine. If you must tow a stranded wa-
tercraft in water and do not have a hose pincher
be sure to stay well below the maximum towing
speed of 24 km/h (15 MPH).
Snugly install the hose pincher on the water sup-
ply hose as shown in the following illustrations.
717 ENGINES GTI AND GTI LE MODELS
1. Hose pincher on water supply hose
787 RFI ENGINES GTI LE RFI MODELS
1. Hose pincher
947 DI ENGINES RX DI AND LRV DI MODELS
1. Hose pincher on water supply hose on this side of the T-fitting
947 DI ENGINES GTX DI MODELS
1. Hose pincher on water supply hose on this side of the T-fitting
F01B23A
F02E04A 1
F02E04A 1
F12E01A 1
1 F18E01A
09-02-20 SMR2003-029_09_02A.FM
947 DI ENGINES XP DI MODELS
1. Hose pincher on water supply hose
CAUTION: When finished towing the watercraft,
the hose pincher must be removed before oper-
ating it.
1503 Engines
CIRCUIT
Closed Loop System
A closed loop cooling system is utilized on the
1503 4-TEC engines, which offers an efficient en-
gine cooling while keeping dirt and salt water out
of the cooling system. This system keeps the tem-
perature 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 coolant pump
impeller into the engine block. It goes around the
cylinders and straight up to the cylinder head. A
smaller quantity of engine coolant enters the en-
gine 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 ride plate which operates as a heat exchanger.
A smaller quantity of engine coolant is also direct-
ed towards the oil cooler, which is located under
the air intake manifold, to increase cooling effi-
ciency.
Coolant temperature sensor and bleed nipple are
located on the cylinder head.
1. Bleed nipple
2. Coolant temperature sensor (CTS)
CAUTION: Never modify cooling system ar-
rangement, otherwise serious engine damage
could occur.
Pressure Cap
Check if cap pressurize the system. if not, install
a new 90 kPa (13 PSI) cap (do not exceed this pres-
sure).
1
F08E08A
1
F18E0XA
2
SMR2003-029_09_02A.FM 09-02-21
COOLING SYSTEM LEAK TEST
Install test radiator cap (P/N 529 021 400) and hose
pincher (P/N 295 000 076) on overflow hose. Pres-
surize all system through coolant expansion tank
to 90 kPa (13 PSI).
1. Hose pincher
2. Pressure pump (P/N 529 021 800)
Check all hoses, ride plate, engine and oil cooler
for coolant leaks. Spray a soap/water solution and
look for air bubbles.
Remove hose pincher and test pressure cap.
Open Loop System
The water supply is provided by a pressurized area
The water flow is controlled by a reducer located
between the jet pump support and the jet pump
on the inlet side. The reducer is black on the 4-TEC
models.
Water is directed to the exhaust manifold fitting
located at front of manifold.
1. Exhaust manifold
2. Water inlet
3. Water outlet
Water enters the manifold end and is directed to
water jackets of exhaust manifold.
Water exits exhaust manifold through 2 hoses at
rear manifold.
1. Water coming from exhaust manifold
2. Exhaust pipe
3. Bleed hose
WARNING
To prevent burning yourself, do not remove
the expansion tank cap or loosen the ride-
plate drain plug if the engine is hot.
1
2
F18E1IA
2
3
F18E1FA
1
1
F18E1EA
2 3
09-02-22 SMR2003-029_09_02A.FM
Water enters exhaust pipe and flows in the water
jacket of pipe.
1. Exhaust pipe
2. Outlet holes of exhaust pipe
3. Muffler
Bleeding of the exhaust system is accomplished
by the bleed hose located at the upper most point
of the circuit of the exhaust pipe.
Water exits exhaust pipe through holes at the end
of the water packet and mixes with exhaust gas
in the muffler.
Water is expulsed from mufflers then through the
exhaust outlet in transom area.
Clamp
To cut or secure non-reusable Oetiker clamps of
cooling system hoses, use pliers (P/N 295 000
070).
1. Cutting clamp
2. Securing clamp
INSPECTION
Check general condition of hoses and clamp tight-
ness.
Check the weep hole if there is oil or coolant.
1. Weep hole
NOTE: Flowing coolant indicates a damaged rota-
ry seal. Oil out of the weep hole indicates a non
working oil seal.
2
F18E1GA
1 3
1
F01B2KA
2
1 F18E1CA
SMR2003-029_09_02A.FM 09-02-23
DRAINING THE SYSTEM
Remove expansion tank cap.
To drain cooling system, unscrew cooling system
drain plug at the rear of ride plate.
1. Cooling drain plug
Use an appropriate container to collect coolant.
Dispose coolant as per local regulations.
Do not reinstall drain plug at this time.
COOLANT REPLACEMENT
Recommended Coolant
Use a blend of 50% antifreeze with 50% water.
Premixed antifreeze/water is available (P/N 293
600 038).
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands un-
less cooling system is completely flushed and re-
filled.
Do not reinstall pressure cap.
CAUTION: To prevent rust formation or freez-
ing condition in cold areas, always replenish
the system with 50% antifreeze and 50% water.
Pure antifreeze will freeze at a higher tempera-
ture than the optimal water/antifreeze mix. Al-
ways use ethylene glycol antifreeze containing
corrosion inhibitors specifically recommended
for aluminum engines.
System Capacity
Refer to TECHNICAL DATA.
Coolant Replacement Procedure
Drain the system completely as described above.
Watercraft should be level, engine cold and drain
plug removed for refilling.
Place a container under drain plug to collect anti-
freeze.
Ask someone to pour antifreeze in expansion tank
while watching antifreeze and air bubble flowing
out through drain hole. When no air bubbles es-
cape, reinstall drain plug. Torque to 8.3 Nm
(73 lbfin).
1. Pour antifreeze/water mix in expansion tank
1. Watch air bubbles flowing here
WARNING
Never drain or refill cooling system when en-
gine is hot.
1 F18E1JA
WARNING
To prevent burning yourself do not remove
the expansion tank cap or loosen the ride
plate drain plug if the engine is hot.
1
F18E1LA
1
F18E1KA
09-02-24 SMR2003-029_09_02A.FM
Continue to pour and fill expansion tank between
marks.
1. Level between marks when engine is cold
Do not install pressure cap at this time.
Properly cool exhaust system by installing a gar-
den hose. Refer to flushing in MAINTENANCE
section.
Start engine and let run for 2 minutes. Stop engine
and wait 15 minutes to cool down. Refill tank as
necessary.
Repeat this run-stop cycle 2-3 times until thermo-
stat opens and stop engine.
Last, refill expansion tank and install cap.
When engine has completely cooled down, re-
check coolant level in radiator and coolant tank and
top up if necessary.
Test the density of the coolant using an antifreeze
hydrometer.
NOTE: Follow hydrometer manufacturer instruc-
tions for proper use.
The reading should be some degrees below the
coldest temperature you expect in the area where
the watercraft is to be used. Add water or anti-
freeze accordingly. Refill to the proper level.
CAUTION: Pure antifreeze will freeze at a high-
er temperature than the optimal water/anti-
freeze mix.
COOLANT PUMP HOUSING
1. Coolant pump housing
Removal
Remove air compressor inlet and outlet hoses to
make room.
1. Air compressor
2. Inlet hose
3. Outlet hose
Drain cooling system and engine oil, refer to LU-
BRICATION SYSTEM.
Remove from housing:
ride plate inlet and outlet hoses
cylinder head outlet hose no. 1
oil cooler inlet hose no. 2
oil cooler outlet hose no. 3
screws no. 4 and no. 5 retaining coolant pump
housing no. 6
coolant pump housing no. 6.
F18E0NA
1
1
F18E0YA
1 F18F0CA 2 3
SMR2003-029_09_02A.FM 09-02-25
Inspection
Check if gasket no. 7 is brittle, hard or damaged
and replace as necessary.
1. Weep hole pump housing gasket
Check if thermostat is in good condition. Refer to
THERMOSTAT elsewhere in this section.
Installation
The installation is the opposite of the removal pro-
cedure. Install screws as per the following illustra-
tion.
1. Screws M6 x 25
2. Screws M6 x 105
CAUTION: To prevent leaking, take care that
the gaskets are exactly in groove when you re-
install the coolant pump housing.
Apply Loctite 243 on screw threads and torque to
10 Nm (88 lbfin).
Tightening sequence for screws on coolant pump
housing is as per following illustration.
THERMOSTAT
The thermostat is a single action type.
Removal
Remove the coolant pump housing from the PTO
cover. Refer to COOLANT PUMP HOUSING RE-
MOVAL elsewhere in this section.
NOTE: The thermostat is located inside the cool-
ant pump housing.
1
F18E11A
1
2
F18E10A 1
1
1
1
2 1
F18E10B
3 2
4
5
1 88 7
6
09-02-26 SMR2003-029_09_02A.FM
Leak Test
Plug the connections of the oil cooler return hose,
coolant tank hose, ride plate return hose and cyl-
inder head return hose with a rag.
1. Oil cooler return connection
2. Coolant tank hose connection
3. Ride plate return hose connection
4. Cylinder head return hose connection
Fill the coolant pump housing with water.
If a bigger quantity of coolant leaks out at the ride
plate outlet connection, replace the coolant pump
housing. Refer to COOLANT PUMP HOUSING in
this section.
If there is no leak, check the operation of the ther-
mostat.
Dynamic 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 move-
ment of the thermostat. Thermostat should open
when water temperature reaches 87C (188F).
If there is no operation, replace coolant pump
housing and thermostat.
Installation
For installation, reverse the removal procedure,
paying attention to the following details.
Refer to COOLANT PUMP HOUSING REPLACE-
MENT in this section.
COOLANT PUMP IMPELLER
Removal
Remove:
unscrew the impeller no. 8 clockwise.
1. Impeller
CAUTION: Coolant/Oil pump shaft no. 9 and
impeller no. 8 have left-hand threads. Remove
by turning clockwise and install by turning
counterclockwise.
Inspection
Check impeller for cracks or other damage. Re-
place impeller if damaged.
Installation
cedure. Pay attention to the following details.
CAUTION: Be careful not to damage impeller
wings during installation.
Torque impeller to 3 Nm (26 lbfin).
1 F18E12A 3
2
4
1
F18E13A
SMR2003-029_09_02A.FM 09-02-27
ROTARY SEAL
Inspection
Check weep hole for oil or coolant leak.
1. Weep hole
Coolant leaking out of the hole indicates a defec-
tive rotary seal. Leaking oil indicates a faulty oil
seal.
However, if seal is disassembled both parts have
to be replaced together.
Removal
Remove:
CAUTION: Always unscrew the impeller clock-
wise otherwise you can damage the compo-
nents.
unscrew the impeller no. 8 clockwise
remove PTO cover no. 10
(refer to PTO HOUSING/MAGNETO section)
remove screws no. 11 retaining oil pump cover
1. Retaining screws
2. Oil pump cover
remove oil pump cover no. 12
remove outer oil pump rotor no. 13
1. Outer oil pump rotor
1 F18E1CA
1
2
F18E14A
1
F18E15A
09-02-28 SMR2003-029_09_02A.FM
extract the coolant/oil pump shaft no. 9 from
outside PTO housing cover with a pusher
1. Pusher
remove Rotary Seal no. 14 with a screwdriver
CAUTION: Be careful not to damage the sur-
face of the rotary seal bore in magneto housing
cover.
always replace also the oil seal no. 15 behind
the rotary seal.
1. Oil seal
Installation
cedure. Pay attention to the following details.
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 the rotary seal in-
staller (P/N 529 035 823).
CAUTION: Never use a hammer for the rotary
seal or water/oil pump shaft installation. Only
use a press to avoid damaging the ceramic
component.
1. Rotary seal
2. Rotary seal installer
Install the coolant/oil pump shaft using the rotary
seal installer (P/N 529 035 823) on the opposite
side to the rotary seal and the oil seal protector
(P/N 529 035 822) with a press.
1. Oil seal protector
1
F18E16A
2
F18E17A
1
F18E18A
1
F18E19A
2
1
F18E1AA
2
SMR2003-029_09_02A.FM 09-02-29
1. Coolant/oil pump shaft with oil seal protector
2. Rotary seal installer
CARE
For flushing purposes, the exhaust cooling system
is equipped with a hose adapter.
To connect to the fitting spigot. A garden hose is
used to flush the whole system by backwash. For
flushing procedure, refer to FLUSHING AND LU-
BRICATION.
For winterization of cooling system, refer to
STORAGE.
When servicing the hull, rotate watercraft either
way (seen from the rear) maximum to 90.
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).
When towing your watercraft in water, pinch the
water supply hose from the jet pump housing to
the engine with a large Hose Pincher (P/N 529 032
500).
This will prevent the exhaust cooling system from
filling which may lead to water being injected into
and filling the exhaust system and the engine.
Without the engine running there isnt any ex-
haust pressure to carry the water out the exhaust
outlet.
CAUTION: Failure to do this may result in dam-
age to the engine. If you must tow a stranded
watercraft in water and do not have a hose
pincher be sure to stay well below the maxi-
mum towing speed of 24 km/h (15 MPH).
Snugly install the hose pincher on the water sup-
ply hose as shown in the following illustrations.
NOTE: Pinch the hose with the red tape (if so
equipped).
1. Hose pincher
CAUTION: When finished towing the water-
craft, the hose pincher must be removed before
operating it.
1
F18E1BA
2
F01B23A
F18E0RA
1
09-02-30 SMR2003-029_09_02A.FM
TECHNICAL DATA
TYPE:
Closed and open loop cooling system.
COOLANT FLOW:
Pressure build-up at coolant pump.
TEMPERATURE CONTROL:
Thermostat.
SYSTEM BLEEDING:
Self-bleed type through expansion tank
(hose at uppermost point of circuit).
SYSTEM DRAINING:
Self-drain type on the exhaust cooling system
(hose at lowest point of circuit).
SYSTEM FLUSHING:
Required only for exhaust cooling system
(open loop system).
MONITORING BEEPER:
Turns on at 100C (212F).
COOLANT LIFE CYCLE
100 hours or 1 year. Should be replaced before
storage.
SMR2003-049_10_01ATOC.FM 10-01-1
TABLE OF CONTENTS 0
FUEL CIRCUIT........................................................................................................................ 10-02-1
GENERAL ........................................................................................................................... 10-02-6
REMOVAL........................................................................................................................... 10-02-6
INSPECTION ...................................................................................................................... 10-02-9
ASSEMBLY......................................................................................................................... 10-02-10
FUEL SYSTEM PRESSURIZATION................................................................................... 10-02-10
AIR INTAKE (2-STROKE) ....................................................................................................... 10-03-1
REMOVAL........................................................................................................................... 10-03-4
ASSEMBLY......................................................................................................................... 10-03-6
CARBURETOR ....................................................................................................................... 10-04-1
GENERAL ........................................................................................................................... 10-04-2
REMOVAL........................................................................................................................... 10-04-2
CLEANING ......................................................................................................................... 10-04-3
DISASSEMBLY AND INSPECTION................................................................................... 10-04-3
ASSEMBLY......................................................................................................................... 10-04-5
INSTALLATION.................................................................................................................. 10-04-7
ADJUSTMENTS ................................................................................................................ 10-04-7
Subsection 02 (FUEL CIRCUIT)
SMR2003-030_10_02A.FM 10-02-1
FUEL CIRCUIT 0
22 Nm
(16 lbfft)
8
4 Nm
(35 lbfin)
4
4 Nm
(35 lbfin)
5
6
7
Body
2 Nm
(18 lbfin)
6 Nm
(53 lbfin)
1.2 Nm
(11 lbfin)
3 Nm
(27 lbfin)
2
1
3
1.2 Nm
(11 lbfin)
1.2 Nm
(11 lbfin) 4 Nm
(35 lbfin)
12
11
10
3 Nm
(27 lbfin)
9
13
1.2 Nm
(11 lbfin)
Engine
Dielectric
grease
4
F06F18S
14
10-02-2 SMR2003-030_10_02A.FM
XP DI Models
F08F0OS
6
7
16
8
18
17
14
4
5
4
22 Nm
(16 lbfft)
4 Nm
(35 lbfin)
13
SMR2003-030_10_02A.FM 10-02-3
GTI LE RFI Models
F02F27S
Body
6
7
10
11
8
22 Nm
(16 lbfft)
4 Nm
(35 lbfin)
5
4
4 Nm
(35 lbfin)
4
13
14
10-02-4 SMR2003-030_10_02A.FM
All DI Models except XP DI
F12F15S
6
7
16
5
4
4 Nm
(35 lbfin)
22 Nm
(16 lbfft)
4
4 Nm
(35 lbfin)
13
14
8
18
17
SMR2003-030_10_02A.FM 10-02-5
4-TEC Engines
F18F08S
2.5 Nm
(22.12 lbfin)
7
6
5
4
13
22 Nm
(16 lbfft)
4 Nm
(35 lbfin)
4
4 Nm
(35 lbfin)
14
8
10-02-6 SMR2003-030_10_02A.FM
GENERAL
When working with fuel, pay attention to the fol-
lowing warning.
To secure or cut Oetiker clamps on fuel lines, use
pliers (P/N 295 000 070).
1. Cutting clamp
1. Securing clamp
1. Securing clamp in limited access
When replacing the vent hose on all SEA-DOO
models be sure to use B1 hoses when replac-
ing the fuel supply line to the fuel rail on RFI and
4-TEC models use A1 hoses. These hoses are
available through the Bombardier parts depart-
ment. On DI models, use hoses assy available as
parts replacement only. This will ensure continued
proper and safe operation.
REMOVAL
Fuel Filter
Open storage compartment cover.
Remove basket.
XP DI Models
Open engine cover and remove basket.
GTI, GTI LE Models
Remove seat.
WARNING
DI Models: The fuel system of a fuel injection
system hold much more pressure than on a
carbureted watercraft. Prior to disconnecting
a hose or to removing a component from the
fuel system, follow the recommendations de-
scribed in ENGINE MANAGEMENT (DI) under
Fuel System.
WARNING
Whenever repairing the fuel system, always
verify for water infiltration in reservoir. Re-
place any damaged, leaking or deteriorated
fuel lines.
WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area. Always wipe off any fuel spillage
from the watercraft.
F01B03A
1
WARNING
Use of improper fuel lines could compromise
fuel system integrity.
F01B04A 1
F01B05A
1
SMR2003-030_10_02A.FM 10-02-7
Turn the fuel valve to OFF position.
Unscrew fuel filler cap to remove any fuel pres-
sure in system.
Unscrew the fuel filter bowl no. 2 counterclock-
wise then pull toward the bottom.
TYPICAL
Step : Loosen counterclockwise
Step : Pull
Pull fuel filter no. 1 toward the bottom.
TYPICAL
RFI Models
The fuel pump assembly has to be removed from
the fuel tank to have access to the fuel filter. Refer
to ENGINE MANAGEMENT (RFI).
Fuel filters are not replaceable on RFI models.
They are lifetime reliable under the normal condi-
tion of use.
4-TEC Models
Fuel filters are not replaceable on 4-TEC models.
They are lifetime reliable under the normal condi-
tion of use.
DI Models
A replaceable inline filter is located near the fuel
tank. Refer to ENGINE MANAGEMENT (DI) sec-
tion.
CAUTION: A pressure test needs to be com-
plete after replacement.
Fuel Baffle Pick Up
NOTE: The baffle pick up has an integrated fuel
sender for the fuel gauge.
1. Pick up tube
2. Fuel sensor
3. Baffle pick up
WARNING
The engine must not be running and fuel
valve must be set to OFF position. Gasoline is
F01F01A
2
1
1
2
F01F04A
WARNING
The inline filter needs to be replaced only with
4 Oetiker clamps (2 on each side).
F01F20A
1
2
3
10-02-8 SMR2003-030_10_02A.FM
Disconnect BLACK negative cable, then RED pos-
itive cable of battery.
Open storage compartment cover.
Remove storage basket from watercraft (if so
equipped).
Remove rear panel of storage compartment (if so
equipped).
Siphon fuel tank.
Remove steering assembly. Refer to STEERING
SYSTEM for procedure.
XP DI Models
Tilt seat. Refer to HULL/BODY for procedure.
Remove access plug on body.
Syphon fuel tank.
All Models except RFI, 4-TEC and DI Models
Disconnect fuel lines from baffle pick up and loos-
en lower clamp no. 10.
TYPICAL
1. Disconnect fuel hoses
2. Loosen lower clamp
Disconnect wiring harness of fuel sender.
Remove baffle from fuel tank.
Remove upper clamp no. 12 from adapter no. 11
and slide adapter from baffle.
Push inward on the 3 clips at the base of the baffle
in order to remove the filter. Pry base off using a
small slotted screwdriver (if necessary).
Electric Fuel Pump
RFI, 4-TEC and DI Models
Refer to appropriate ENGINE MANAGEMENT
section.
Fuel Tank
NOTE: On all models (except RFI and LRV DI), it
is necessary to remove the engine. Refer to RE-
MOVAL and INSTALLATION sub section.
Siphon fuel tank.
Remove fuel baffle pick up or electric fuel pump
on RFI and DI models. Refer to the above section.
Detach all fuel tank straps.
Pull out fuel tank.
4-TEC Series Models
NOTE: It is necessary to remove the engine. Re-
fer to REMOVAL AND INSTALLATION sub sec-
tion.
Siphon fuel tank.
Use pliers to pull out darts and remove front ac-
cess panel.
1. Dart
Disconnect MPEM connectors.
Detach MPEM assembly and support from bilge.
WARNING
the specified order, BLACK negative cable first.
F02F1OA
1
2
1
F18F0AA
SMR2003-030_10_02A.FM 10-02-9
Remove TOPS switch from electrical harness or
MPEM bracket.
Remove air box. (Refer to AIR INTAKE SYSTEM
sub section.
From storage compartment disconnect fuel pump
connections.
Remove fuel pump from fuel tank. Refer to EN-
GINE MANAGEMENT section.
Detach reverse system support.
1. Screws
Remove battery. Refer to CHARGING SYSTEM
sub section.
Disconnect fuel tank connections.
Cut locking ties as required to release wiring har-
ness.
Detach straps with hook tool (P/N 529 035 559).
Remove fuel tank from the vehicle.
INSPECTION
Fuel Filter
All Models except RFI, DI and 4-TEC Models
Inspect fuel filter condition. Carefully use low
pressure compressed air to clean fuel filter. Re-
place filter if permanently clogged or damaged.
Fuel Filter Bowl
Check filter bowl for water contamination.
Gasket
Inspect gasket condition. Make sure gasket no. 3
is well positioned into the filter bowl no. 2.
1. Gasket in bowl
RFI Models
The filter at fuel pump inlet is not replaceable indi-
vidually. The complete fuel pump unit has to be
replaced. Refer to ENGINE MANAGEMENT.
DI Models
Inspect inline filter condition. Carefully use low
pressure compressed air to clean. Replace if per-
manently clogged or damaged.
NOTE: The fuel filter needs to be replaced after
250 hours.
Fuel Filler Hose
All Models
Verify fuel filler hose no. 5 for damage. Always en-
sure that clamps no. 4 are well positioned and
tightened. Torque clamps to 4 Nm (35 lbfin).
WARNING
Check that fiberglass is not exposed.
1
F18F0BA
WARNING
Ensure that there is no leakage from the fuel
filter.
F01F02A
1
10-02-10 SMR2003-030_10_02A.FM
Pressure Relief Valve
This valve will eliminate fuel spillage when the wa-
tercraft is upside down. If pressure is built up in
fuel system the valve should open at 3.5 kPa (0.5
PSI) for DI, 4-TEC and RFI models and at 10 kPa
(1.5 PSI) for all other models to release the pres-
sure.
NOTE: It is a one-way valve with an arrow to indi-
cate the air flow.
Check Valve
Black side of the one-way check valve no. 7 is the
valve outlet. It allows air to get in reservoir.
Baffle Pick Up Filter
All Models except RFI, DI and 4-TEC
Inspect filter no. 9 of baffle pick up. Clean or re-
place as necessary.
Fuel Tank
All Models
Visually inspect the inside and outside of the fuel
tank necks for crack(s). If crack(s) are existing, re-
place fuel tank no. 14.
Check with your finger to feel the inside and out-
side surfaces of fuel tank. Flex fuel tank necks to
ensure there are no hidden cracks.
1. Tank upper surface
2. Inspect outside, above upper surface
3. Normal molding seam
4. Inspect inside, above upper surface
5. Base of the neck
A. Approx. 4 mm (5/32 in)
NOTE: A fuel tank is comprised of 3 components:
the tank, the fuel pick up neck 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 ap-
pear on the inner side of the necks at approximate-
ly 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.
ASSEMBLY
to the following.
Reinstall fuel pump. Refer to ENGINE MANAGE-
MENT section.
4-TEC Engines
Ensure rubber carpet is in place.
Insert tank, air box and straps.
Place straps in clips (bottom) and in guides of air-
box.
Insert strap ends in hoops. Use tape to hold in
place.
Properly secure harnesses.
Reinstall fuel pump. Refer to ENGINE MANAGE-
MENT section.
Baffle Pick Up
All Models except RFI, DI and 4-TEC
Slide adapter no. 11 onto baffle pick up no. 8 until
it stops on rib. Install clamp no. 12.
Install baffle pick up no. 8 into fuel tank and push it
until it sits on fuel tank neck. Install clamp no. 10
and torque both clamps to 3 Nm (27 lbfin).
FUEL SYSTEM PRESSURIZATION
WARNING
If pressure relief valve is stuck, the pressure
in fuel system will build up and it may cause
fuel leakage in engine compartment.
F07F06A
4 2
1
A 3 5
WARNING
are disconnected, a pressure test must be
done before starting engine. Ensure to verify
fuel line ends for damage. Always cut dam-
aged end before reinstallation.
SMR2003-030_10_02A.FM 10-02-11
Pressure Test (supply and vent circuits)
All Models
Proceed as follows:
Fill up fuel tank.
Disconnect air inlet hose of fuel tank from body.
Install a hose pincher (P/N 295 000 076) on fuel
tank vent hose.
TYPICAL
1. Disconnect air inlet hose
2. Install a hose pincher to vent hose
Connect pump gauge tester (P/N 529 021 800)
to air inlet hose.
NOTE: This pump is included in the ENGINE LEAK
TESTER KIT (P/N 295 500 352).
Turn fuel valve to OFF position (except RFI, DI
and 4-TEC).
Pressurize fuel system to 34 kPa (5 PSI).
If no leaks are found, turn fuel valve to ON po-
sition and pressurize once more.
If pressure is not maintained locate leak and
repair/replace component leaking. To ease leak
search spray a solution of soapy water on com-
ponents, bubbles will indicate leak location.
NOTE: The system must maintain a pressure of
34 kPa (5 PSI) during 10 minutes. Never pressurize
over 34 kPa (5 PSI).
Reconnect air inlet hose of fuel tank to body.
NOTE: Before removing the hose pincher, block
with your finger the outlet fitting to feel if air is
coming out when removing hose pincher. This will
indicate that pressure relief valve and the outlet
fitting are not blocked.
Remove hose pincher from fuel tank vent hose.
High Pressure Test (fuel pump circuit)
RFI, DI and 4-TEC Models
Refer to the appropriate ENGINE MANAGEMENT
section.
R
E
S
O
U
T
F01F0KA
2
1
WARNING
If any leak is found, do not start the engine
and wipe off any fuel leakage. Do not use
electric powered tools on watercraft unless
system has passed pressure test.
WARNING
Prior to installing the safety lanyard, refer to
the appropriate ENGINE MANAGEMENT sec-
tion for safety precautions to take.
Subsection 03 (AIR INTAKE (2-STROKE))
SMR2003-031_10_03A.FM 10-03-1
AIR INTAKE (2-STROKE) 0
717 Engines
F02F2CS
10 Nm
(89 lbfin)
3
4
2
10 Nm
(89 lbfin)
8
6
10 Nm
(89 lbfin)
Loctite 518
10
Loctite 518
5
9
1
7
Loctite
243
Loctite 243
15
Loctite 243
10-03-2 SMR2003-031_10_03A.FM
787 RFI Engines
F15F01T
2
1
4
9
3
10 Nm
(89 lbfin)
5
10
10 Nm
(89 lbfin)
6
7
10 Nm
(89 lbfin)
8
Loctite
243
Loctite
243
SMR2003-031_10_03A.FM 10-03-3
947 DI Engines
2
11
12
4
13
3
Super
Lube
14
Loctite
243
F18F0NS
Loctite 243
Loctite 243
XP DI only
Loctite 243
10-03-4 SMR2003-031_10_03A.FM
REMOVAL
Air Intake Silencer Cover
Unlock the 6 retaining slides holding air intake si-
lencer cover no. 1 and remove cover.
TYPICAL
1. Air intake silencer cover
2. Unlock
Air Intake Silencer Base
Remove screws no. 2 of retaining plate no. 3.
Pull out retaining plate no. 3 and air intake silencer
base no. 4.
1. Retaining plate
2. Remove screws
Flame Arrester Base
Remove flame arrester no. 5.
Remove screws no. 8 retaining support no. 6 of
flame arrester base to the cylinder head cover (717
engines) or to the exhaust manifold (787 engines).
TYPICAL
1. Remove support
Remove screws no. 10 from flame arrester base
then withdraw base.
NOTE: On GTI and GTI LE models, withdraw
both arrester supports no. 15.
947 DI Engines
Air Intake Silencer
Pull hair pin out to allow removal of clip no. 2.
2. Clip
3. Hair pin
F01F2OA
1 2
F00F02A
1
2
F00F03A
1
2
F00F0FA
3
1
SMR2003-031_10_03A.FM 10-03-5
Unlock the clip no. 2 on top of air intake silencer.
Remove bolts retaining both air ducts to engine (both
sides).
1. Remove bolts
Pull air ducts out.
1. Air duct
NOTE: Do not disconnect oil lines.
Push the air intake silencer out of the carburetor
adapter no. 3 and throttle body.
RX DI Models
Pull the air intake silencer rearward to remove it
from the lower bracket no. 4 and remove it in a
rotating movement.
XP DI Models
Detach 2 straps from the oil reservoir using spring
remover tool (P/N 529 035 559).
Unclip oil filter. Pull oil reservoir out.
Remove foam under the fuel tank.
Remove air ducts and protector pads of air silencer.
Pull the air silencer forward to remove it from the
lower bracket no. 4 and remove it in a rotating move-
ment.
XP DI MODELS
The air intake silencer is a molded piece and it can
not be opened. It has an integrated flame arrester.
F08F08A 1 1
1
F08F09A
529 035 559
F12F16A
F08F0AA
10-03-6 SMR2003-031_10_03A.FM
ASSEMBLY
Assembly is essentially the reverse of removal pro-
cedures. However pay particular attention to the fol-
lowing.
CAUTION: Do not modify air intake system,
otherwise calibration will be affected.
717 Engines
Flame Arrester Base
Apply Loctite 518 on mating surfaces of flame ar-
rester base no. 7.
Apply Loctite 243 (blue) on screws no. 10 and
Flame Arrester
Inspect condition of flame arrester no. 5. Replace
or clean as necessary.
Gasket
Inspect condition of gasket no. 9. Make sure to prop-
erly install gasket.
947 DI Engines
Air Intake Silencer
Ensure that support plate edges no. 14 are prop-
erly crimped to air intake silencer. Use pliers as
necessary.
Make sure that gaskets no. 11 are installed into
throttle bodies.
Check O-rings no. 12 on throttle bodies and change
them if necessary.
NOTE: Apply Super Lube grease (P/N 293 550 014)
to mating surface of air intake silencer no. 1.
Install air intake silencer on throttle bodies and
latch in place.
Clip air intake silencer back in place.
Properly reinstall hair pin to secure clip no. 2.
Ensure the elbow adaptor is well inserted and that
it has not pushed the gasket inside the air intake
silencer.
NOTE: Make sure the air intake silencer is retained
by the lower bracket no. 4.
Place protector pads on duct supports. Use slot in
rubber to insert pad on bracket eyelet. Side tongue
of protector pad should be toward outside of vehi-
cle and bent downward toward the exhaust flange.
Put air ducts in intake adapters and secure them
on duct supports with hexagonal screws no. 13,
wide washers, narrow washers and elastic stop
nuts. A slight lift will be required to make the bolts
line up with brackets.
TYPICAL 947 DI ENGINES
1. Hexagonal screw M6
2. Wide flat washer
3. Insulator
4. Air duct
5. Protector pad
6. Duct support eyelet
7. Narrow flat washer
8. Hexagonal stop nut M6
WARNING
Do not operate watercraft without flame ar-
rester.
WARNING
While doing so, ensure that the clip snaps
firmly, securing the air intake silencer in a
tight fit; if not, bend the clip using pliers until
you feel that the clip is tight enough.
1
F06F0VA
2 3 7 8
4 6 5
Subsection 04 (CARBURETOR)
SMR2003-032_10_04A.FM 10-04-1
CARBURETOR 0
For fuel system on RFI, DI and 4-TEC models, refer to appropriate ENGINE MANAGEMENT section.
Mikuni BN-40i
F17F01S
Loctite
243
11
9
12
20
21 13
14
6
7
4
19
5
15
2
13
8
3
18
17
16
1
20 Nm
(15 lbfft)
Anti-seize
lubricant
Synthetic
grease
Loctite 243
Synthetic
grease
20
10-04-2 SMR2003-032_10_04A.FM
GENERAL
The following illustration shows which part of the
carburetor begins to function at different throttle
plate openings.
VIEW FROM AIR INTAKE OPENING
1. Throttle plate openings
2. Throttle plate closed
3. Throttle plate wide opened
4. Low-speed screw
5. Pilot jet
6. Main jet and high-speed screw
The carburetor is equipped with a fuel accelerator
pump.
The fuel accelerator pump is linked to the throttle
valve via a linkage.
A metering jet in the fuel inlet hose controls fuel
flow to the pump.
A check valve on the fuel outlet hose helps to
prime the system.
REMOVAL
To remove carburetor from engine, proceed as fol-
lows:
Remove air vent tube support (GTI and GTI LE
models).
Remove air intake silencer. Refer to AIR INTAKE.
Turn fuel valve to OFF position.
Disconnect pulse line.
TYPICAL
1. Pulse line
2. Loosen gear clamp
Disconnect fuel supply line from fuel pump.
Disconnect fuel return line.
Disconnect oil injection pump cable, throttle cable
and choke cable.
Remove screws no. 20 and lock washers no. 21
retaining carburetor.
TYPICAL
1. Remove screws
Remove carburetor.
1
F01F13A
2
3
4
5
6
F06F0LA
1
2
F07F03A
1 1
1 1
SMR2003-032_10_04A.FM 10-04-3
CLEANING
The carburetor exterior surfaces should be cleaned
with a general solvent and dried with compressed
air before disassembly.
CAUTION: Be careful at carburetor cleaning not
to remove paint. Paint removal will cause carbu-
retor to rust very rapidly. Repaint if necessary.
Carburetor body and jets should be cleaned with
a carburetor cleaner. Follow manufacturers in-
structions.
CAUTION: Heavy duty carburetor cleaner may
be harmful to the rubber parts, O-rings, etc.
Therefore, it is recommended to remove these
parts prior to cleaning.
Inspect O-rings, diaphragms and gaskets.
DISASSEMBLY AND INSPECTION
Inspect parts for corrosion damage (shaft, throttle
plate, spring, screw, check valve housing, etc.).
Needle Valve
Inspect needle valve tip for a grooved condition. If
worn, needle and seat must be replaced as a
matched set.
Low Speed Screw
Check tip of low speed screw no. 2 for a grooved
condition. Replace if necessary.
Diaphragm
Pump Diaphragm Leak Test
Using a suitable pump gauge tester, perform the
following test proceeding as follows:
Install pump gauge tester (P/N 295 000 114) on
pulse nipple.
Pump tester until it reaches 28 kPa (4 PSI).
TYPICAL
1. Pump gauge tester
2. Install on pulse nipple
Diaphragm must stand pressure for 10 seconds.
If pressure drops, replace diaphragm no. 3.
Fuel Pump Valve
Check fuel pump valve operation as follows:
Connect a clean plastic tubing to the inlet nipple of the
fuel pump body no. 4 and alternately apply pressure
and vacuum with the mouth. The inlet valve should
release with pressure and hold under vacuum.
TYPICAL
1. Fuel outlet nipple
2. Pulse nipple
3. Inlet nipple
Repeat the same procedure at the outlet nipple of
the fuel pump body no. 4. This time the outlet
valve should hold with pressure and release under
vacuum.
Inspect valves. The pumping area should be free
of holes, tears or imperfections. Replace as needed.
WARNING
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as they are flammable and explosive.
WARNING
Some fuel may be present in fuel pump. Be
careful not to swallow fuel when under vacuum.
F01F0XA
1
2
F01F0WA
1
2
3
10-04-4 SMR2003-032_10_04A.FM
Internal Fuel Filter
To verify condition of filter no. 5, proceed as follows:
Remove pump cover no. 16, gasket no. 17, dia-
phragm no. 18 and then pump body no. 4 and di-
aphragm no. 19.
Remove filter no. 5 from carburetor body then
clean filter and blow carefully with compressed air
(low pressure).
Replace filter if damaged.
TYPICAL
1. Filter
Fuel Accelerator Pump
Disconnect inlet and outlet hoses from accelerator
pump nipples.
TYPICAL
1. Fuel inlet hose
2. Fuel outlet hose
Using a suitable pump gauge tester, perform the
following test proceeding as follows:
Install pump gauge tester (P/N 295 000 083) on
inlet nipple of accelerator pump no. 22.
Obstruct outlet nipple with a finger and hold
while pumping.
Pump tester until it reaches 28 kPa (4 PSI).
2. Hose installed to inlet nipple
3. Outlet nipple obstructed
Diaphragm must stand pressure for 10 seconds.
If pressure drops, replace accelerator pump dia-
phragm.
Verify accelerator pump check valves operation as
follows:
Connect a clean plastic tubing to the valve inlet
nipple and alternately apply pressure and vacuum.
The check valve should release with pressure and
hold under vacuum.
TYPICAL
1. Apply pressure and vacuum at inlet nipple
F01F0YA
1
F06F06A 1 2
WARNING
Some fuel may be present in fuel pump.
F06F07A
2 1 3
F06F08A 1
SMR2003-032_10_04A.FM 10-04-5
To check the injector, install pump gauge tester to
the injector hose.
NOTE: Injectors are also equipped with check
valves.
TYPICAL
1. Install pump gauge tester to injector hose
2. Injector
Pump tester. Injector check valve should open at
19.4 kPa 4.7 (2.8 .6 PSI).
NOTE: If the obtained pressure is too low, the
check valve is leaking. If it is too high, less fuel will
be delivered which may lead to engine hesitation
under acceleration.
ASSEMBLY
When assembling pump, ensure to properly posi-
tion components together. Refer to previous illus-
trations if necessary.
Choke Plate and Throttle Plate
When installing plate no. 6 onto shaft no. 7, close
plate so that it centers into carburetor bore. Firmly
tighten screws.
CAUTION: Always apply Loctite 243 (blue) on
screw threads prior to installing screws.
Needle Valve Lever
Rounded end of needle valve lever no. 8 must be
flush with surrounding metering chamber floor
and not with body assembly. Place the end of a
ruler over lever to check adjustment.
1. Metering chamber floor
2. Lever end
3. Flush
To adjust, bend lever very slightly to change its height.
CAUTION: When adjusting lever, do not pry it
so that it applies pressure on needle. This could
damage valve seat/needle.
HIGH LEVER
Step : Depress here
Step : Push tab down
F04F0JB
1
2
1
F01F0ZA
3
2
F01F0HA
2 1
1
2
10-04-6 SMR2003-032_10_04A.FM
LOW LEVER
Step : Depress here
Step : Pry up here
POP-OFF Pressure Test
Proceed as follows:
Install pump gauge tester on carburetor fuel in-
let nipple.
Obstruct fuel return nipple with a finger.
Pump tester until inlet release pressure is reached
(seen by a sudden pressure drop).
TYPICAL
2. Install on inlet nipple
3. Obstruct outlet nipple
Refer to the following table for pop-off pressure
specifications:
NOTE: Pressure test should be performed three
times to obtain a valid reading.
If pop-off pressure is not within specification,
check control lever adjustment. Replace spring as
necessary.
CAUTION: Do not stretch or cut spring.
LEAK TEST
Needle valve must stand a pressure of 69 kPa
(10 PSI) for 30 seconds. Otherwise, hold carbure-
tor upside down, pour oil over needle valve and
apply pressure.
Check for bubbles. If they come from seat or
O-ring, bubbles will exit around seat. Retighten as
necessary.
If it still leaks remove needle and seat and replace
O-ring.
If bubbles come from needle, replace needle and
seat.
Main Jet and Pilot Jet
Pilot jet no. 10 and main jet no. 9 are replaceable.
Different jet sizes are available to suit temperature
and altitude conditions. Always inspect spark plug
tip condition when dealing with pilot jet and main
jet. Spark plug tip condition gives a good indication
of carburetor mixture setting.
CAUTION: Adjustments vary with temperature
and altitude. Always observe spark plug condi-
tion for proper jetting.
NOTE: To have access to pilot jet no. 10 or main
jet no. 9, check valve housing must be removed.
TYPICAL
1. Pilot jet
2. Gasket
3. Main jet
4. Check valve housing removed
MODELS
POP OFF PRESSURE
min./max. (PSI)
GTI, GTI LE 36/40
F01F34A
2 1
1
2
F01F10A
1
2
3
1
F01F11A
2
3
4
SMR2003-032_10_04A.FM 10-04-7
Check Valve Assembly
The check valve is needed if a back pressure oc-
curs into carburetor. It will prevent fuel from flow-
ing back into carburetor lower portion.
Inspect check valve no. 11. It should be free of
holes, tears or imperfections. Replace as needed.
1. Check valve
NOTE: Prior to check valve assembly installation,
remember to set gasket.
Diaphragm and Cover
Install diaphragm no. 3 with its integrated O-ring
into carburetor groove. Make sure that the tab of
cover no. 12 is inserted into carburetor notch.
O-Ring
When installing O-rings no. 13 of low speed and
high speed screws, apply some BOMBARDIER
LUBE (P/N 293 600 016) to prevent sticking.
Lubricate pump plunger, roller and cam with syn-
thetic grease (P/N 293 550 010) and roller shaft
with BOMBARDIER LUBE (P/N 293 600 016).
TYPICAL
1. Apply synthetic grease to plunger
2. Apply BOMBARDIER LUBE on roller shaft
INSTALLATION
Carburetor
At installation, pay attention to the following:
Install carburetor with gasket to intake manifold
(rotary valve cover).
Apply synthetic grease on screws no. 20. Then,
install screws no. 20 with lock washers no. 21
and torque to 20 Nm (15 lbfft).
Fuel Lines and Hose Clamps
If fuel line ends are damaged, cut damaged end
before reinstallation.
Properly install clamps.
For fuel system pressurization, refer to FUEL CIR-
CUIT.
ADJUSTMENTS
Carburetor Adjustment
California Models
There is no mixture adjustment to be performed
by the dealer.
IMPORTANT: Trying to bypass the anti-tamper
screws could damage the carburetor. It could also
change the engine emission level and lead the en-
gine not to meet the California emission control reg-
ulations.
NOTE: Do not activate throttle lever unnecessari-
ly. Carburetor is equipped with fuel accelerator
pump. This pump is injecting fuel into carburetors
each time throttle lever is depressed.
Lubricate cable with BOMBARDIER LUBE lubricant.
Throttle lever must reach handlebar grip without
causing strain to cable or carburetor cable bracket.
F01F12A
1
F06F06B 1 2
WARNING
Make sure there is no leak in fuel system.
10-04-8 SMR2003-032_10_04A.FM
Ensure carburetor throttle plate(s) is (are) fully open
at full throttle position. At this position, throttle le-
ver stopper is almost in contact (0.5 mm (1/64 in))
with carburetor body.
NOTE: Apply a light pressure on the throttle plate(s),
a slight play should be obtained.
CAUTION: Improper cable adjustment will cause
strain on cable and/or damage cable bracket or
throttle lever at handlebar.
To adjust, loosen jam nut then turn adjustment nut
as necessary.
1. Adjustment nut
2. Jam nut
3. Throttle lever stopper
After throttle cable adjustment, always proceed
with the oil injection pump cable adjustment. Re-
fer to OIL INJECTION PUMP.
CAUTION: Improper oil injection pump synchro-
nization with carburetor can cause serious en-
gine damage.
All Models except California Models
Low Speed Screw Adjustment
1. Low speed screw
CAUTION: Do not attempt to set engine idle speed
with low-speed screw.
Tighten low speed screw until a slight resistance
is felt. Then, back it off to the specification as per
following chart.
NOTE: Turning screw clockwise leans mixture and
turning screw counterclockwise enriches mixture.
Start and warm up engine.
Check that engine idles and runs smoothly. Make
sure engine reacts quickly to throttle lever de-
pression. If necessary, readjust low speed screw
( 1/4 turn).
High Speed Screw
The high speed screw no. 14 is sealed with a plas-
tic cap that allows an adjustment of 1/4 turn.
NOTE: Turning screw 1/4 turn counterclockwise en-
riches mixture and turning screw clockwise leans
mixture.
CAUTION: Do not attempt to adjust high speed
screw by removing plastic cap.
WARNING
Make sure idle speed screw contacts stopper
when throttle lever is fully released at handle-
bar.
F01K08A
1
F01G0YC
1 2 3
ENGINE TYPE LOW SPEED SCREW
717 1.0 0.25 turns
F06F0GA
1
SMR2003-032_10_04A.FM 10-04-9
1. High speed screw
Idle Speed Screw
Turning screw no. 15 clockwise increases engine
idle speed and turning screw counterclockwise de-
creases engine idle speed.
1. Idle speed screw
Connect an induction-type tachometer (P/N 529
014 500) on spark plug cable of magneto side to
measure engine speed.
NOTE: To adjust idle speed, ensure flame arrester
and air intake silencer are installed.
Start engine and bring to normal operating temper-
ature.
Turn screw so that engine idles at 1500 RPM in
water or 3000 RPM out of water.
All Engines
Ensure throttle cable and idle speed are properly
adjusted.
With the engine not running, loosen adjustment
screw lock nut. Use a feeler gauge between lever
tab and pump plunger. Turn adjustment screw to
achieve approximately 0.05 - 0.15 mm (.002 - .005 in)
gap. Tighten adjustment screw lock nut.
TYPICAL
1. Adjustment screw
2. Small gap
NOTE: Turning the adjustment screw clockwise will
increase the gap.
Choke Cable
Ensure choke lever has a free-play of 0.5 to 2.0 mm
(1/64 to 5/64 in).
TYPICAL
1. Choke lever
A. Free play of 0.5 to 2.0 mm (1/64 to 5/64 in)
To adjust, loosen jam nut on carburetor bracket,
then turn adjustment nut as necessary.
F06F0IA 1
F01G0YD
1
F02F1QA
1
2
1
F07F02A A
Section 11 LUBRICATION SYSTEM (2-STROKE)
SMR2003-049_11_01ATOC.FM 11-01-1
TABLE OF CONTENTS 0
OIL INJECTION SYSTEM...................................................................................................... 11-02-1
GENERAL ........................................................................................................................... 11-02-4
OIL SYSTEM PRESSURIZATION...................................................................................... 11-02-4
OIL INJECTION PUMP .......................................................................................................... 11-03-1
OIL PUMP IDENTIFICATION ............................................................................................. 11-03-4
REMOVAL........................................................................................................................... 11-03-4
DISASSEMBLY .................................................................................................................. 11-03-4
CLEANING ......................................................................................................................... 11-03-4
ASSEMBLY ........................................................................................................................ 11-03-5
ADJUSTMENT................................................................................................................... 11-03-6
CHECKING OPERATION.................................................................................................... 11-03-9
Subsection 02 (OIL INJECTION SYSTEM)
SMR2003-033_11_02A.FM 11-02-1
OIL INJECTION SYSTEM 0
GTI Series
1
2
3
4
1
27 Nm
(20 lbfft)
3.5 Nm
(31 lbfin)
Dielectric
grease
1.2 Nm
(11 lbfin)
3.5 Nm
(31 lbfin)
F17G02S
11-02-2 SMR2003-033_11_02A.FM
XP DI Models
F08G05S
4
3
Oil pump
Under air
compressor
Steering harness
SMR2003-033_11_02A.FM 11-02-3
RX DI and GTX DI Models
Under air
compressor
F12G07S
3.5 Nm
(31 lbfin)
1
4
1
2
2
3
3.5 Nm
(31 lbfin)
27 Nm
(20 lbfft)
Dielectric
grease
11-02-4 SMR2003-033_11_02A.FM
GENERAL
Whenever repairing the oil injection system, al-
ways verify for water infiltration in reservoir.
Also pressure test the oil injection system.
All Models except the XP DI
Clamp and Hose
Verify oil filler neck hose no. 2 for damage. Always
ensure that clamps no. 1 are well positioned and
tightened. Torque clamps to 3.5 Nm (31 lbfin).
All Models
Check Valve
Black side of the one-way check valve no. 3 is the
valve outlet. It allows air to get in reservoir.
Oil Filter
Oil filter no. 4 should be replaced annually.
OIL SYSTEM PRESSURIZATION
Pressure Test
Proceed as follows:
Fill up oil reservoir.
Install a hose pincher to rotary valve shaft oil
supply hose (except 947 engines).
Install a hose pincher to rotary valve shaft oil
return hose (except 947 engines).
Install a hose pincher to oil injection pump sup-
ply hose.
DI Models
Install a hose pincher to compressor return line air.
Disconnect oil tank vent line on PTO side throttle
body.
Connect pump gauge tester (P/N 529 021 800) to
oil injection reservoir vent check valve.
DI Models
Connect pump gauge tester (P/N 529 021 800) to
disconnected tube at throttle body.
All Models
NOTE: Use the same pump included in the EN-
GINE LEAK TESTER KIT (P/N 295 500 352).
TYPICAL
1. Connect pump to check valve
Pressurize oil system to 21 kPa (3 PSI).
All Models
If pressure is not maintained, locate leak and
repair/replace component leaking. To ease leak
search spray a solution of soapy water on compo-
nents, bubbles will indicate leak location.
DI Models
Verify check valve inside filler neck (inside vent
adapter on XP DI) if pressure does not hold. Also
ensure air can enter through check valve in the
opposite direction.
All Models
NOTE: The system must maintain a pressure of
21 kPa (3 PSI) for at least 10 minutes. Never pres-
surize over 21 kPa (3 PSI).
CAUTION: If any leak is found, do not start the
engine and wipe off any oil leakage.
Disconnect pump gauge tester and remove hose
pinchers. On DI models, reconnect line at throttle
body.
WARNING
Whenever oil system components are dis-
connected or replaced, a pressure test must
be done before starting engine. Ensure to ver-
ify oil line ends for damage. Always cut dam-
aged end before reinstallation.
1
F01G0IA
Section 11 LUBRICATION SYSTEM (2 STROKE)
Subsection 03 (OIL INJECTION PUMP)
SMR2003-034_11_03A.FM 11-03-1
OIL INJECTION PUMP 0
717 Engines
F00G03T
Loctite
243
1
4.5 Nm
(40 lbfin)
8 Nm
(71 lbfin)
8 Nm
(71 lbfin)
2
3
10 Nm
(89 lbfin)
5
Loctite
243
6 Nm
(53 lbfin)
6
4
6 Nm
(53 lbfin)
Loctite
243
5 Nm
(44 lbfin)
Synthetic
grease
11-03-2 SMR2003-034_11_03A.FM
787 RFI Engines
F07G0DS
6
6 Nm
(53 lbfin)
4.5 Nm
(40 lbfin)
9
8
7
3 Nm
(27 lbfin)
1
4.5 Nm
(40 lbfin)
SMR2003-034_11_03A.FM 11-03-3
947 DI Engines
Throttle cable
Oil pump
1
6 Nm
(53 lbfft)
8
6 Nm
(53 lbfft)
4.5 Nm
(40 lbfft)
6
6
Molykote
111
Loctite
243
Loctite
243
F12G08S
11-03-4 SMR2003-034_11_03A.FM
OIL PUMP IDENTIFICATION
Pump Lever
Different engines need different pumps. See iden-
tification on lever.
CAUTION: Always mount proper pump on en-
gine.
NOTE: The following procedures can be done with-
out removing the engine from hull.
REMOVAL
Oil Injection Pump
717 Engines
Remove air intake silencer (refer to AIR INTAKE).
Remove carburetor (refer to CARBURETOR).
Remove rotary valve cover (refer to ROTARY VALVE).
Remove Allen screws no. 5 retaining intake man-
ifold no. 2 to rotary valve cover.
Separate intake manifold from rotary valve cover.
To separate oil pump from intake manifold no. 2,
remove oil pump gear no. 3 using gear holder (P/N
420 277 905) and unscrew lock nut no. 4.
1. Gear holder
Remove 2 Allen screws no. 6 with flat washers
retaining oil injection pump to intake manifold
no. 2.
Remove pump.
947 DI Engines
Remove tuned pipe head. Refer to EXHAUST SYS-
TEM.
The cable end has a slight press fit in the lever.
Using a small screwdriver, pry cable end out.
Disconnect oil injection pump cable no. 7.
Remove 2 Allen screws no. 6 with flat washers
retaining oil injection pump to magneto housing
cover.
Pull pump.
Disconnect oil hoses from fittings of oil injection
pump.
DISASSEMBLY
NOTE: Some oil pump parts are not available in
single parts. A gasket set is available for the pump.
Refer to parts catalog.
If the pump is found defective, it should be replaced
by a new one.
CLEANING
Discard all seals and O-rings. Clean metal compo-
nents in a solvent.
ENGINE TYPE
OIL PUMP
IDENTIFICATION
717 105Q-5
787 RFI 06
947 09
A00C17B
1
SMR2003-034_11_03A.FM 11-03-5
ASSEMBLY
717 Engines
Oil Injection Pump and Intake Manifold
Install oil injection pump no. 1 to intake manifold
no. 2. Torque screws no. 6 to 6 Nm (53 lbfin).
CAUTION: Whenever oil injection lines are re-
moved, always make the routing as shown.
TYPICAL
1. Small oil line
Oil Pump Gear
Install gear no. 3 to oil injection pump shaft. Torque
lock nut no. 4 to 6 Nm (53 lbfin).
NOTE: Make sure 1 washer is installed on each
side of gear.
Install intake manifold no. 2 to rotary valve cover
and torque screws no. 5 to 10 Nm (89 lbfin).
TYPICAL
A. 10 Nm (89 lbfin)
787 and 947 DI Engines
Oil Injection Pump and Shaft
Make sure shaft no. 8 is installed in crankshaft
end.
Install pump. Secure with flat washers and screws
no. 6. Torque to 6 Nm (53 lbfin).
Install oil injection pump cable.
947 DI Engines
F01D4SA
1
1
F01D4RC A
F12G02A
F12G03A
11-03-6 SMR2003-034_11_03A.FM
1. Cable end completely inserted
2. Cable end NOT seated on the steps
CAUTION: Ensure cable end is completely en-
tered in its housing. Ensure it is NOT seated on
the steps.
ADJUSTMENT
CAUTION: As oil injection pump adjustment is
dependent on throttle cable position, make
sure to perform throttle cable adjustment first
except if otherwise specified.
Preliminary Synchronization
NOTE: To check synchronization of pump as a rou-
tine maintenance, see Final Synchronization.
Make sure idle speed screw on carburetor is prop-
erly set on Carburetor-Equipped Engines.
Refer to CARBURETOR for throttle cable adjust-
ment procedure.
NOTE: On a twin carburetor engine, make sure
carburetors are properly synchronized.
Turn oil pump cable adjustment nut to align refer-
ence marks on pump.
NOTE: A mirror may be used to facilitate this ver-
ification.
717 Engines
TYPICAL
1. Jam nut
2. Adjustment nut
3. Aligned marks
787 RFI Engines
1. Aligned marks
F12G04A 2 1
F01D4RE
2
3
1
F07G02B
1
SMR2003-034_11_03A.FM 11-03-7
Loosen jam nut and turn cable adjustment nut to
obtain proper pump setting.
The adjustment nut and jam nut for the oil injection
pump cable are located at the cable support on the
throttle body.
1. Oil pump cable
2. Adjustment nut
947 DI Engines
Loosen jam nut and turn cable adjustment nut to
obtain pump mark alignment. Refer to following
photos.
The adjustment is located under the throttle body
bracket.
1. Oil pump cable adjustment
2. Throttle cable
Adjust the cable to the rich position. Use the long-
est mark.
1. Mark on pump must be facing longest mark on lever
All Engines
Start and bring engine to normal operating temper-
ature.
must be cooled using the flush kit. If air bubbles
are present in the oil injection system, bleed
system before operating engine.
Adjust idle speed to specification on Carburetor
Equipped Engines. Refer to CARBURETOR.
NOTE: On RFI engines, refer to FUEL INJECTION
for idle speed adjustment procedure.
NOTE: On DI engines, there is no idle speed ad-
justment to perform.
Stop engine.
Final Synchronization
Eliminate throttle cable free-play by depressing
throttle lever until a slight resistance is felt. In this
position, marks on pump body and lever must
align.
If necessary, turn cable adjustment nut to obtain
pump mark alignment. Refer to above illustrations.
Tighten jam nut and recheck alignment marks.
1 F07F0WB 2
1
F16F01A
2
F16G03B
1
11-03-8 SMR2003-034_11_03A.FM
CAUTION: Proper oil injection pump adjustment
is very important. Any delay in the opening of
pump can result in serious engine damage.
Bleeding
CAUTION: Oil injection system must be bled and
adjustment checked before operating engine.
Ensure oil injection reservoir is sufficiently filled.
Install a dry rag below oil injection pump.
Loosen bleed screw to allow oil to flow.
717 ENGINES
1. Bleed screw
787 RFI ENGINES
1. Bleed screw
947 DI ENGINES
1. Bleed screw
Keep bleeding until all air has escaped from line.
Make sure no air bubbles remain in oil supply line.
Tighten bleed screw.
Wipe any oil spillage.
Check small oil lines of the pump. They must be
full of oil.
1. Lines must be full of oil
2. Oil pump
If not, proceed as follows.
1
F01D4SC
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SMR2003-034_11_03A.FM 11-03-9
Run engine at idle speed while manually holding
pump lever in fully open position. Do not activate
throttle lever.
947 DI Engines
Use the VCK (Vehicle Communication Kit) (P/N
529 035 676). Look in the MONITORING sec-
tion of the B.U.D.S software.
Use the Oil lines bleeding function that al-
lows to lock the engine RPM in idle speed
while the throttle is fully depressed to ease the
bleeding operation.
Since oil cannot be seen through the small oil
lines, press and hold the vehicle throttle to wide
open position for 45 seconds.
All Engines
CHECKING OPERATION
On Watercraft
NOTE: Oil line supply must be full of oil. See
bleeding procedure above.
Start engine and run at idle while holding the pump
lever in fully open position.
Oil must advance into small oil lines.
All Engines
NOTE: The engine should have a rich mixture,
idling irregularly and emitting smoke at exhaust
outlet.
If not, remove pump assembly and check the
pump gear (717 engine) or shaft (787 RFI and 947
DI engines) for defects, replace as necessary. Test
pump as described below:
NOTE: Through normal use, oil level must not
drop in small tubes. If oil drops, verify check valve
operation. Replace as necessary.
Bench Test
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil con-
tainer. Using a counterclockwise (reverse position)
rotating drill, rotate pump shaft. Oil must drip from
fittings in parts of rotary valve cover while holding
lever in a fully open position.
TYPICAL
1. Supply oil line to an oil container
2. Hold lever in fully open position
3. Counterclockwise (reverse) rotating drill
4. Oil must drip here
For an accurate test, each port should be checked
separately to ensure equal delivery on both ports.
To obtain a precise result of the oil pump delivery
rate, rotate it counterclockwise at 1500 RPM for a
total time of 5 minutes.
NOTE: To ensure accuracy of test, oil lines should
be completely filled before starting test.
Compare the results with the chart below. If oil
pump is out of specification, replace it.
ENGINE
OIL PUMP DELIVERY AT
1500 RPM (pump speed)
FOR 5 MINUTES
717 9.9 - 12.1 mL (each port)
787 RFI 5.7 - 6.9 mL (each port)
947 DI 7.5 - 9.1 mL (each port)
F01G02A
1
2
3
4
Section 12 ELECTRICAL SYSTEM
SMR2003-049_12_01ATOC.FM 12-01-1
TABLE OF CONTENTS 0
IGNITION SYSTEM (CARBURETED ENGINES)................................................................... 12-02-1
GENERAL ........................................................................................................................... 12-02-1
MULTI-PURPOSE ELECTRONIC MODULE (MPEM)........................................................ 12-02-2
IGNITION TIMING ............................................................................................................. 12-02-2
IGNITION SYSTEM TESTING PROCEDURE.................................................................... 12-02-9
SPARK PLUGS................................................................................................................... 12-02-12
CHARGING SYSTEM............................................................................................................. 12-03-1
GENERAL ........................................................................................................................... 12-03-1
TESTING PROCEDURE ..................................................................................................... 12-03-2
BATTERY............................................................................................................................ 12-03-6
CABLE TERMINAL INSTALLATION.................................................................................... 12-03-12
STARTING SYSTEM.............................................................................................................. 12-04-1
GENERAL ........................................................................................................................... 12-04-4
STARTING SYSTEM TROUBLESHOOTING..................................................................... 12-04-5
STARTER REMOVAL.......................................................................................................... 12-04-6
STARTER DISASSEMBLY.................................................................................................. 12-04-7
CLEANING ......................................................................................................................... 12-04-10
PARTS INSPECTION.......................................................................................................... 12-04-11
STARTER ASSEMBLY........................................................................................................ 12-04-12
STARTER INSTALLATION................................................................................................. 12-04-13
STARTER SPECIFICATION................................................................................................ 12-04-16
INSTRUMENTS AND ACCESSORIES .................................................................................. 12-05-1
GENERAL ........................................................................................................................... 12-05-1
POWER SUPPLY CUT-OFF RELAY VERIFICATION ......................................................... 12-05-1
MULTI-PURPOSE ELECTRONIC MODULE (MPEM)........................................................ 12-05-1
INSPECTION ...................................................................................................................... 12-05-10
DESS (CARBURETED AND RFI ENGINES) .......................................................................... 12-06-1
GENERAL ........................................................................................................................... 12-06-1
VCK (Vehicle Communication Kit)................................................................................... 12-06-2
Subsection 02 (IGNITION SYSTEM (CARBURETED ENGINES))
SMR2003-035_12_02A.FM 12-02-1
IGNITION SYSTEM (CARBURETED
ENGINES) 0
GENERAL
NOTE: For DI and 4-TEC models, refer to ENGINE
MANAGEMENT section.
717 Engines
Unregulated AC current is produced in the magne-
to by the battery charging coil. This AC current is
rectified and regulated by the charging system.
The resulting regulated DC current is used to
charge the battery.
Unregulated AC current is produced in the magne-
to by the ignition generator coil for the ignition sys-
tem. This current is sent to the MPEM where it is
processed to then be sent to the ignition coil.
The ignition generator coil, MPEM and the ignition
coil work together in this Digital CDI ignition sys-
tem.
787 RFI Engines
Unregulated AC current is produced by the mag-
neto. This AC current is rectified and regulated by
the charging system. The resulting regulated DC
is used to charge the battery.
The CPS, MPEM, ECU and the ignition coil work
together in this Digital Inductive ignition system.
All Engines
A 12 volts battery supplies the Multi-Purpose Elec-
tronic Module (MPEM) with DC current.
Refer to CHARGING SYSTEM.
Magneto System
current (AC).
717 Engines
The flywheel contains 4 permanent magnets and
spins around the generating coil. This electric cur-
rent flows to the Multi-Purpose Electronic Module
(GTI and GTI LE models).
1. Flywheel
2. Generating coil
MAGNETO OUTPUT
MODEL WATT
GTI and GTI LE 160 @ 6000 RPM
GTI LE RFI 270 @ 6000 RPM
1
F00H0EA
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12-02-2 SMR2003-035_12_02A.FM
787 RFI Engines
Crankshaft Position Sensor (CPS)
The CPS is an inductive speed sensor located on
the magneto housing and is working in conjunc-
tion with a 60 teeth ring gear which has 2 teeth
missing on the gear. The inductive sensor regis-
ters the 58-tooth sequence.
An AC voltage is generated by the sensor and is
sent to the ECU to calculate the crankshaft posi-
tion and the engine speed.
1. Crankshaft position sensor (CPS)
Ignition Coil
Ignition coil induces voltage to a high level in sec-
ondary windings to produce a spark at spark plug.
The ignition coil steps up the voltage input from
the Multi-Purpose Electronic Module to high volt-
age current for both spark plugs.
The ignition coil is located in the rear electrical box-
located under air intake.
GTI LE RFI Models
The digital inductive ignition system on the RFI
models allows the spark plugs to spark indepen-
dently on each piston stroke.
CAUTION: Do not interchange spark plug ca-
bles. Reversed spark plug cables will not allow
the RFI to run and will cause backfires.
MULTI-PURPOSE ELECTRONIC
MODULE (MPEM)
The MPEM is responsible of the following electri-
cal functions related to the ignition system:
ignition timing curve
engine rev limiter.
For the other functions of the MPEM, refer to IN-
STRUMENTS AND ACCESSORIES section.
787 RFI Engines
The MPEM is also used with the Rotax Fuel Injec-
tion system.
The RFI models use a Digital Inductive Ignition
system. The Bosch ECU controls the ignition tim-
ing and dwell time. It receives input from the CPS
and signals the ignition coil when to fire.
IGNITION TIMING
Before checking ignition timing with a stroboscop-
ic timing light (dynamic test), it is mandatory to
scribe a timing mark on the PTO flywheel (static
test) corresponding to the specific engine.
Also, the timing mark scribed on the PTO flywheel
can be used to troubleshoot a broken magneto
woodruff key.
CAUTION: The relation between the PTO fly-
wheel mark position and crankshaft position may
change as the PTO flywheel might move/tighten/
loosen on the crankshaft. As an example on
threaded flywheels, when the engine is accel-
erated out of water, PTO flywheel may tighten
then loosen when the engine is decelerated.
This will result in a false ignition timing read-
ing. Always verify PTO flywheel mark position
before checking ignition timing with an appro-
priate timing light. If mark does not align with
tool, repeat static test to ensure flywheel has
not loosen or moved before changing the igni-
tion timing.
NOTE: Do not use the factory mark found on the
PTO flywheel to check ignition timing or trouble-
shoot any problems.
F07H0CA
1
SMR2003-035_12_02A.FM 12-02-3
787 RFI Engines
Normally ignition timing adjustment should not be
required. It has been set at factory and it should
remain correctly adjusted since every part is fixed
and not adjustable. The only time the ignition timing
might have to be changed would be when replacing
the crankshaft, the magneto rotor the CPS and the
MPEM or the ECU. If the ignition timing is found
incorrect, you should first check for proper crank-
shaft alignment. This might be the indication of a
twisted crankshaft.
RFI Models
The fixed timing mode must be activated before
checking ignition timing. See FIXED TIMING
FUNCTION paragraph.
Static Test
All Engines
1. Disconnect MAG side spark plug wire and con-
nect wire to grounding device then remove
spark plug.
CAUTION: Never crank engine with spark plugs
removed unless spark plug cables are connect-
ed to the grounding device.
2. Remove PTO flywheel guard.
717 Engines
3. Install timing mark pointer tool on engine using
wing nuts previously removed.
TYPICAL
787 RFI Engines
4. Remove middle screw securing the engine to
the rear engine mount. Reinstall screw with tim-
ing mark pointer tool.
All Engines
5. Install and adjust a TDC gauge (P/N 295 000 143)
in MAG side spark plug hole.
TYPICAL
1. TDC gauge on MAG side
F01H5SA 1
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F01H5TA
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12-02-4 SMR2003-035_12_02A.FM
6. Rotate PTO flywheel counterclockwise (when
facing it) until piston is at Top Dead Center.
TYPICAL
1. Adjust gauge dial at zero
7. From this point, rotate flywheel clockwise to reach
proper specification according to engine. Refer
to the following chart.
8. Scribe a thin mark on PTO flywheel in the mid-
dle of tool slot (717 engines) or aligned with
timing mark pointer tool (787 RFI engines).
TYPICAL
1. Tool slot
2. Flywheel mark
NOTE: This mark becomes the reference when
using the stroboscopic timing light.
CAUTION: The static test cannot be used as a
timing procedure, therefore, always check the
timing with a stroboscopic timing light.
9.Remove TDC gauge.
10.Reinstall spark plug and connect wire.
Dynamic Test
To check ignition timing, use Bombardier timing
light (P/N 529 031 900).
ENGINE
IGNITION TIMING
(BTDC)
717 2.59 mm (.102 in)
787 RFI 1.02 mm (.040 in)
9
0
8
0
7
0
6
0
5
0
4
0
3
0
2
0
1
0
0
1
F01H4LA
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A00B4FA
SMR2003-035_12_02A.FM 12-02-5
717 Engines
NOTE: To perform this procedure, make sure to
use a stroboscopic timing light rated up to 6000
RPM. Otherwise, an inaccurate reading will be ob-
tained.
The ignition components are affected by temper-
ature variation, therefore, timing must be checked
when engine is cold, after idling for a MAXIMUM
of 20 seconds.
1. Connect an induction-type tachometer (P/N 529
014 500) to spark plug wire.
1. Tachometer pick-up
plug wire.
3. Start engine and point timing light straight in line
with timing tool slot. Bring engine to 6000 RPM.
1. Timing light straight in line with tool slot
kit.
4. Check if PTO flywheel mark aligns with timing
tool slot.
NOTE: On this system, timing advance decreases
as engine speed increases.
If timing mark aligns with tool slot, timing is prop-
erly set. If mark does not align with tool slot, re-
check PTO flywheel mark before adjusting ignition
timing to ensure PTO flywheel has not loosen.
787 RFI Engines
1. Connect an induction-type tachometer (P/N 529
014 500) to spark plug wire.
1. Tachometer pick-up
F00H0GA 1
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12-02-6 SMR2003-035_12_02A.FM
plug wire.
IMPORTANT: To check the ignition timing, the tim-
ing advance curve must be locked first. This allows
to perform ignition timing at any RPM by keeping
the timing frozen so that it does not vary with
engine RPM. See FIXED TIMING FUNCTION for
more information.
NOTE: Fixed Timing function must be activated
before starting engine when using the MPEM pro-
grammer. When using B.U.D.S., it must be activat-
ed after starting the engine.
3. Start engine and point the beam of a timing light
on mark.
1. Timing light straight in line with tool slot
kit.
NOTE: If mark on PTO flywheel is perfectly align-
ed with timing mark pointer, no adjustment is re-
quired. If mark does not align with pointer, recheck
PTO flywheel mark before adjusting ignition timing
to ensure PTO flywheel has not loosen or moved.
Ignition Timing Adjustment
717 Engines
Remove magneto housing cover and wire support.
For removal of magneto, refer to MAGNETO SYS-
TEM.
Timing is performed by moving armature plate;
clockwise to retard spark occurrence or counter-
clockwise to advance.
TYPICAL
1. To retard
2. To advance
To adjust, loosen 3 armature plate retaining screws
and slightly rotate armature plate in proper direction.
NOTE: As a guideline, turn the armature plate the
same amount needed to align mark on PTO flywheel.
TYPICAL
1. Retaining screw
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SMR2003-035_12_02A.FM 12-02-7
Example 1
When PTO flywheel mark is on right side of timing
tool slot, it indicates advanced timing.
1. Too advanced timing
In this case, turn armature plate clockwise when
facing it.
Example 2
When PTO flywheel mark is on left side of timing
tool slot, it indicates retarded timing.
1. Retarded timing
In this case, turn armature plate counterclockwise
when facing it.
After adjustment, tighten armature plate retaining
screws.
CAUTION: Armature plate screws must have Loc-
tite 243 (blue) applied before tightening. Make
sure armature plate screws are well secured.
Reinstall removed parts. Refer to MAGNETO SYS-
TEM.
Recheck ignition timing (make sure engine is cold).
Repeat armature plate positioning procedure if
timing mark position is not adequate.
787 RFI Engines
CAUTION: If the ignition timing is adjusted too
advanced, this will cause serious damage to the
engine.
For the 787 RFI engines, use the VCK (Vehicle
Communication Kit) (P/N 295 035 676).
NOTE: For more information on the VCK, refer to
its online help.
B.U.D.S. (Bombardier Utility Diagnostic Software)
is designed, among other things, to allow adjust-
ing the ignition timing.
RFI Models Through the 4-Pin Connector
1. 6-pin adapter
nication.
F01H5UA
1
F01H5VA
1
WARNING
2 F12H0CA 1 3
12-02-8 SMR2003-035_12_02A.FM
used i s properl y sel ected in MPI under
MPEM Programmer
As an alternate method to correct the ignition tim-
ing, the data of the MPEM can be changed using
the MPEM programmer (P/N 529 035 878).
NOTE: For more information on the MPEM pro-
grammer, refer to the MPEM programmer guide
(P/N 219 700 138).
Refer to the timing correction charts, used per
MPEM Programmer, to find the number corre-
sponding to the timing correction needed.
The Fixed Timing function must be activated first.
This function allows to check ignition timing at any
RPM because it locks ignition timing at 12 degrees
BTDC .
NOTE: Fixed Timing function must be activated
before starting engine when using the MPEM pro-
grammer.
Fixed Timing Function
1. Connect the communication cable to the MPEM
programmer and the other end to the safety lan-
yard switch on the craft.
2. Press the ON/C button on programmer and
enter your password.
3. Press 3 to choose Vehicle info in programmer.
4. Press 8 to choose Bosch system.
5. Press 1 to choose Diagnosis.
6. Press 4 to choose Adjustment.
7. Press 4 to choose Fixed timing.
8. The programmer display Timing = 12.00 deg.
9. Press any key to continue. Programmer will go
back one level to Adjustment.
10. Press Menu to go back one level to Diagnosis.
11. Press Menu to go back one level to Bosch sys-
tem.
12. Programmer now ask Quit Bosch Diagnosis?
Choose yes to quit.
Press 2 to choose Start Vehicle, the program-
mer will then ask Modify Max RPM, press menu
then start engine with start/stop button.
NOTE: If engine fail to start and as soon engine
stops revving (start/stop button has been released),
Fixed Timing function is disabled. To reactivate
function, repeat complete procedure.
Timing Verification
With engine running, check timing.
kit.
If timing is correct stop engine. This will automat-
ically disable Fixed Timing function.
If further adjustment is required refer to following
procedure.
Timing Adjustment
Unlike the other models, the ignition timing correc-
tion can be made from 4.5 (advanced) to - 2.25 (re-
tarded).
The VCK will display directly the timing correction
under Offset angle. See illustration below.
1. Setting tab
2. Ignition offset section
3. Locked box
4. Current angle in MPEM
5. Arrows to change the angle
MPEM Programmer
The MPEM programmer will display correction
numbers from 1 to 8. Refer to the next timing cor-
rection chart.
TYPE OF
CONNECTION
ADAPTER
TO USE
PROTOCOL
TO CHOOSE
RFI models through
the 4-pin connector
6-pin and
RFI 4-pin
DESS
F17H08A
1
2
3
4 5
SMR2003-035_12_02A.FM 12-02-9
grammer, then select ADJUSTMENT in the sub-
menu.
Choose IGNITION in the ADJUSTMENT menu.
The screen will display the actual ignition timing
correction in degrees and it will also offer to adjust it.
Refer to the following chart to find the number cor-
responding to the timing correction needed.
Choose the Fixed Timing function, start the en-
gine and verify the timing again. Repeat the above
procedure if the timing is still incorrect.
Ignition timing is set at 12 BTDC at any RPM,
when the Fixed Timing function is active.
IGNITION SYSTEM TESTING
PROCEDURE
All Engines
When dealing with ignition problems, the follow-
ing items should be verified in this order:
1. Spark occurrence/spark plug condition.
2. Battery condition.
3. Electrical connections.
4. Engine start/stop switch.
5. Safety lanyard switch.
6. Power supply cut-off relay.
7. Multi-Purpose Electronic Module (MPEM).
8. Magneto output (717 engines).
9. Ignition coil output.
CAUTION: Whenever replacing a component
in ignition system, check ignition timing.
NOTE: To perform verification, a good quality mul-
timeter such as Fluke 111 (P/N 529 035 868)
should be used.
Engine Start/Stop Switch Verification
Disconnect the YELLOW/RED wire of the start/stop
switch. Using an ohmmeter, connect test probes
to YELLOW/RED wire and to ground.
the ohmmeter should read close to 0 ohm.
Safety Lanyard Switch Verification
NOTE: The safety lanyard also controls the power
supply cut-off relay. Refer to INSTRUMENTS AC-
CESSORIES for its testing procedure.
safety lanyard, refer to DIGITALLY ENCODED SE-
CURITY SYSTEM.
formed using an ohmmeter:
be no continuity (open circuit).
and the other test probe to the switch terminal.
Measure resistance, it must be close to 0 ohm.
close to 0 ohm.
Rev Limiter Verification
To check engine rev limiter, connect an induction
tachometer (P/N 529 014 500), start engine and
check its maximum speed.
TIMING CORRECTION CHART 787 RFI
MPEM PROGRAMMER
NUMBER
IGNITION TIMING
CORRECTION
1 4.50
2 3.75
3 3
4 2.25
5 .75
6 0
7 - 0.75
8 - 2.25
MODEL
RPM LIMITER
SETTING
GTI and GTI LE 7100 50
GTI LE RFI 7200 50
12-02-10 SMR2003-035_12_02A.FM
Multi-Purpose Electronic Module
(MPEM) Verification
It is not possible to accurately check the MPEM
condition without specialized tools. Therefore, re-
place MPEM with a good known unit to conduct
testing.
NOTE: Before replacing the MPEM, make sure all
connectors are properly secured and there is no
water in connectors. Check also the signal and
power contacts in the AMP plug connectors. See
WIRING DIAGRAMS.
Generating Coil Verification
717 Engines
STATIC TEST
Disconnect magneto wiring harness connector.
Install the 4-pin magneto harness adapter (P/N 295
000 131).
TYPICAL
Check resistance with a multimeter. Refer to the
following table for values and wire colors.
1. Multimeter
2. 4-pin magneto harness adapter
3. RED/BLACK wire
4. BLACK wire
DYNAMIC TEST
1. Connect spark plug cables to grounding device.
2. Disconnect magneto wiring harness connector.
3. Install the 4-pin magneto harness adapter (P/N 295
000 131).
4. Connect positive test probe of the multimeter
to the RED/BLACK wire of the 4-pin magneto
harness adapter.
5. Connect negative test probe of the multimeter
to BLACK wire of the 4-pin magneto harness
adapter.
6. Set multimeter to Vac scale.
7. Crank engine and note result. The obtained val-
ue should be between 18 and 25 Vac.
8. If the generating coil is out of specification, re-
place it.
NOTE: If the generating coil tests good, discon-
nect the primary wires of the ignition coil. Crank
engine and check voltage at primary wires. It should
be at least 20 Vac. If there is insufficient or no volt-
age, either the MPEM or wiring harness is defec-
tive.
PART NAME
ADAPTER
WIRE
RESISTANCE
Generating coil
BLACK with
RED/BLACK
40 - 76
F01B28A
F01H5WA
2 1
3 4
SMR2003-035_12_02A.FM 12-02-11
Ignition Coil Verification
STATIC TEST
NOTE: An ignition coil with good resistance mea-
surement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter.
717 Engines
Primary Winding
1. Primary side
2. Secondary side
3. Ground plate
Disconnect the wire connectors on primary side
of the ignition coil.
the primary side connectors of the coil.
The resistance should be 0.34 to 0.62 at 20C.
Secondary Winding
The spark plug caps must be removed from high
tension cables, because they are resistor caps.
The cap resistance is 4.48 K ohms.
1. Resistor cap
2. High-tension cable
the two high tension leads with the spark plug
caps removed.
The resistance should be 12 3 K at 20C.
NOTE: A short circuit will read 0 ohm (or close to)
on ohmmeter.
787 RFI Engines
Primary Winding
IGNITION COIL
1. Primary side
2. Secondary side
3. Ground wire
Disconnect the wire connector on the primary side
of the ignition coil.
the terminals 1 and 2. Repeat a resistance test be-
The resistance should be 0.3 to 0.6 at 20C.
If the ignition coil test good, check the power sup-
ply on the primary side.
Disconnect the ignition coil 3-pin connector. Check
to see if there is approximately 6 Vdc between the
RED wire and engine ground.
If there is no voltage, either the MPEM or the wir-
ing harness is defective.
Secondary Winding
Due to the integrated diode, it is not possible to
take any resistance measurement of the second-
ary winding on the GTI LE RFI models.
DYNAMIC TEST
All Models
Use an ignition coil tester, available from after-
market tool/equipment suppliers.
CAUTION: Do NOT use coil tester on metal work
bench. Follow manufacturer instructions.
3
1 F17H04A 2
3
A00E0QA
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F07H0EA
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12-02-12 SMR2003-035_12_02A.FM
1. With ignition coil removed from craft, discon-
nect spark plug caps from high tension cables.
2. Hook high tension leads from tester to ignition
coil high tension cables.
3. Connect 2 smaller tester leads to primary of ig-
nition coil.
TYPICAL
1. Leads to secondary
2. Leads to primary
4. Turn power switch to 12 volts and you should
observe spark jumping at a predetermined gap
of 7 to 8 mm (.276 to .311 in).
If there is no spark, if it is weak or intermittent, the
coil is defective and should be replaced.
SPARK PLUGS
Disassembly
Clean the spark plug and cylinder head with pres-
surize air then completely unscrew.
Heat Range
The proper heat range of the spark plugs is deter-
mined by the spark plugs ability to dissipate the
heat generated by combustion.
The longer the heat path between the electrode
tip to the plug shell, the hotter the spark plug op-
erating temperature will be and inversely, the
shorter the heat path, the colder the operating
temperature will be.
A cold type plug has a relatively short insulator
nose and transfers heat very rapidly into the cylin-
der head.
Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
The hot type plug has a longer insulator nose
and transfers heat more slowly away from its firing
end. It runs hotter and burns off combustion de-
posits which might tend to foul the plug during
prolonged idle or low speed operation.
1. Cold
2. Hot
CAUTION: Severe engine damage might occur
if a wrong heat range plug is used.
A too hot plug will result in overheating and pre-
ignition, etc.
A too cold plug will result in fouling or may create
carbon build up which can heat up red-hot and cause
pre-ignition or detonation.
F00H14A
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SMR2003-035_12_02A.FM 12-02-13
Fouling
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss of
compression. Other possible causes are: prolonged
idling, or running on a too rich mixture due to a
faulty carburetor adjustment or incorrect fuel. The
plug face of a fouled spark plug has either a dry
coating of soot or an oily, glossy coating given by
an excess either of oil or of oil with soot. Such
coatings form a conductive connection between
the center electrode and ground.
Spark Plug Analysis
1. Overheated (light grey)
2. Normal (brownish)
3. Fouled (black)
The plug face (and piston dome) reveals the con-
dition of the engine, operating condition, method
of driving and fuel mixture. For this reason it is
advisable to inspect the spark plug at regular inter-
vals, examining the plug face (i.e. the part of the
plug projecting into the combustion chamber) and
the piston dome.
grime.
3. Hand screw spark plug into cylinder head and
tighten with a torque wrench and a proper socket.
1. Proper socket
2. Improper socket
Spark Plug Chart
NOTE: Refer to next page for NGK SPARK PLUG
SYMBOL EXPLANATION.
A00E0AA 1 2 3
ENGINE
SPARK
PLUG
TORQUE
Nm (lbfft)
GAP
mm (inch)
717 and
787 RFI
engines
NGK
BR8ES
24 (17)
0.4 - 0.5
(.016 - .020)
A00E0BA
2
1
12-02-14 SMR2003-035_12_02A.FM
NGK Spark Plug Symbol Explanation
10: 1.0 mm (.040")
11: 1.1 mm (.044")
13: 1.3 mm (.050")
14: 1.4 mm (.055")
15: 1.5 mm (.060")
20: 2.0 mm (.080")
B R 8
E S
15
Thread
diameter
Heat rating
numbers
Reach
Firing end
construction
Construction
PREFIX SUFFIX
WIDE GAP
19 mm
(3/4")
Taper
Seat
12.7 mm
(1/2")
11.2 mm
(7/16")
21 mm
(53/54")
E:
F:
H:
L:
Z:
2 Hot
4
5
6
7
8
9
10 Cold
18 mm
14 mm
10 mm
12 mm
8 mm
12 mm x 19 mm
Reach
A:
B:
C:
D:
E:
J:
Special Design
Single Ground
Special Alloy
Dual Ground
Special Alloy
Racing Type
Racing Version
of V-Type
Half Heat Range
Standard Center
Electrode
Fine Wire Center
Electrode
Booster Gap
V-Grooved Center
Electrode
A:
GV:
B:
C:
G:
L:
S:
V:
X:
Y:
Blank
18 mm 12 mm
(31/64")
14 mm 9.5 mm
(3/8")
F02H0MS
Compact Type
Projected
Insulator Type
Resistor Type
Surface Discharge
Inductive
Suppressor Type
M:
P:
R:
U:
Z:
A01E1PS
Standard
Type
CROSSCUTS AND GAP STYLES OF SPARK PLUGS
Surface
Discharge Type
Projected
Insulator Type
Taper
Seat Type
V-Type
Subsection 03 (CHARGING SYSTEM)
SMR2003-036_12_03A.FM 12-03-1
CHARGING SYSTEM 0
GENERAL
Magneto
The purpose of the charging system is to keep the
battery at a full state of charge.
current.
717 Engines
The magneto has a three-pole coil. Capacity is 160
watts.
The magneto has a 3 phase, delta wound stator
on 18 poles. Capacity is 270 watts.
4-TEC Engines
The magneto has a 3 phase, delta wound stator
on 18 poles. Capacity is 380 watts.
Rectifier/Regulator
All Models
The rectifier receives AC current from the magne-
to and transforms it into direct current (DC).
The regulator, included in the same unit, limits
voltage at a maximum level (14.5 to 14.8 volts) to
prevent any damage to components.
717 Engines
A half-wave rectifier receives magneto current
and transforms it into regulated current to allow
battery charging.
The unit is using a 3 phase in series rectifier/regulator
which transforms (AC) from the magneto into (DC) to
allow battery charging.
Battery
The battery is the DC source for the electric start-
er, the Multi-Purpose Electronic Module and all ac-
cessories.
Fuse
If the battery is regularly discharged, check fuse
condition.
The rectifier/regulator could be the culprit of a blown
fuse. To check, simply disconnect the rectifier/
regulator from the circuit.
If the fuse still burns, check for a defective wire.
CAUTION: Do not use a higher rated fuse as this
cause severe damage.
GTI LE RFI Models
The main electric system fuse is 20 A and located
on the cut off relay. Also another 20 A fuse is mount-
ed on the MPEM bracket to protect the rectifier/reg-
ulator.
DI Models
The charging system is protected by 2 fuses.
A 25 A fuse is mounted on the MPEM and a 30 A
fuse is located in the rear electrical box on the cut-
off relay.
4-TEC Engines
The charging system is protected by 1 fuse (30 A).
All Other Models
Two 15 A fuses protect the charging system. The
first one is mounted on the MPEM and the other
one is located in the rear electrical box on the cut-
off relay.
12-03-2 SMR2003-036_12_03A.FM
TESTING PROCEDURE
NOTE: First, ensure that battery is in good condi-
tion prior to performing the following tests.
Rectifier/Regulator
STATIC TEST: CONTINUITY
Due to internal circuitry, there is no static test avail-
able.
DYNAMIC TEST
Current Test
Carburetor-Equipped Engines and 947 DI
Engines
Proceed as follows:
Start engine.
Lay an inductive ammeter on positive cable of
battery.
Bring engine to approximately 6000 RPM.
Current reading should be approximately 4 am-
peres for the 717 engine and 5 amperes for the 947
DI and 4-TEC engines . If not, check magneto out-
put prior to concluding that rectifier is faulty.
787 RFI Engines
Proceed as follows:
Remove the 20 A fuse from the holder with the
RED wire coming from the connector.
1. RED wire
Connect an ammeter across the fuse holder.
Start engine.
Note the reading. This is the current supplied by
the regulator.
Reinstall fuse.
Remove the 20 A fuse from the holder with the
RED/PURPLE wire coming from the connector.
1. Fuse holder
Connect an ammeter across the fuse holder.
Start engine.
Note the reading. This is the current actually
consumed.
Reinstall fuse.
Substract the consumed current from the regu-
lator current. This gives the actual charging cur-
rent. It should be within 3 - 4 A.
If charging current is below specification, check
magneto output. If the magneto output is good,
try another rectifier/regulator. Recheck charging
current. If still out of specification, the fuel pump
or the MPEM current draw is too high.
If charging current exceeds specification, replace
the rectifier/regulator.
1
F15F09A
Charging current = Current from regulator - Consumed current
1
F15F0AA
SMR2003-036_12_03A.FM 12-03-3
Voltage Test
All Models
Proceed as follows:
Start engine.
Connect a multimeter to battery posts. Set mul-
timeter to Vdc scale.
If multimeter reads over 15 volts, regulator is defec-
tive. Replace it.
NOTE: If it is continually necessary to add distilled
water to the battery, this indicates an over voltage
situation, requiring replacement of the rectifier/
regulator. If, on the other hand, the battery will not
stay charged, the problem can be any of the charg-
ing circuit components. If these all check good,
you would be accurate in assuming the problem
to be in the rectifier/regulator.
If there is no charging at the battery with the pre-
ceding voltage test, the following test can also be
performed.
Disconnect the connector housing of the rectifier/
regulator.
Using an appropriate terminal remover (Snap-on
TT600-4), remove the RED and BLACK wires from
the tab housing of the rectifier/regulator.
Reconnect the connector housing.
Connect the positive probe of a multimeter to the
RED wire and the negative probe to the BLACK wire.
Set multimeter to Vdc scale.
Start and rev engine to 3500 RPM. The obtained
value should be between 12 and 25 Vdc.
NOTE: If the rectifier/regulator is within the specifi-
cation, either the MPEM or wiring harness between
the rectifier and battery is defective. If the rectifier/
regulator is out of specification and the battery charg-
ing coil (or stator) test good, the rectifier/regulator is
defective.
717 Engines
1. Disconnect the magneto wiring harness connec-
tor.
000 131) to the magneto wiring harness. Leave
wiring harness side disconnected.
3. Check resistance between the YELLOW and
BLACK/YELLOW wires of the magneto harness
adapter. Refer to the following table.
NOTE: A short circuit will read 0 ohm (or close to)
on ohmmeter.
1. Multimeter
2. Magneto harness adapter
3. YELLOW and BLACK/YELLOW wires
PART NAME
ADAPTER
WIRE COLOR
RESISTANCE
()
Battery
charging coil
YELLOW with
BLACK/YELLOW
0.05 - 0.6
F02H0KA
1 2 3
12-03-4 SMR2003-036_12_03A.FM
STATIC TEST: INSULATION
tor.
3. Insert multimeter positive (+) probe to the YEL-
LOW wire of the 4-pin magneto harness adapt-
er.
4. Ground the multimeter negative (-) probe to the
engine or the stator iron core and note the read-
ing.
TYPICAL
1. Multimeter
3. Positive (+) probe to YELLOW wire
4. Negative (-) probe to ground
5. Repeat test with the other two YELLOW/ BLACK
wires of the 4-pin magneto harness adapter.
NOTE: There should be no continuity (infinity) be-
tween the stator insulated coils and ground. If
there is a reading, the stator coils and/or the wiring
from the coils is grounded and needs to be re-
placed or repaired.
DYNAMIC TEST
tor.
000 131) between connectors.
3. Connect test probes of the multimeter to the
YELLOW and BLACK/YELLOW wires of the 4-pin
magneto harness adapter.
4. Start and rev engine to 3500 RPM. The obtained
value should be between 25 and 40 Vac.
5. If the battery charging coil is out of specifica-
tion, replace it.
Stator
947 DI and 4-TEC Engines
tor.
000 136).
NOTE: On 4-TEC engines disconnect the stator
wiring harness connector and probe the three con-
nectors.
3. Check resistance between two of the YELLOW
wires. The resistance should be between 0.1 to
1.0 ohm.
TYPICAL
1. Multimeter
3. YELLOW wires
4. Place either meter lead into the remaining YEL-
LOW wire and note the resistance (same as
step no. 3). If the readings are out of specifica-
tion, the stator will need to be replaced.
F01H60A
1 3
2
4
F01H5ZA
1 3
3 2
SMR2003-036_12_03A.FM 12-03-5
tor.
3. Insert multimeter positive (+) probe to one of
the YELLOW wire of the 6-pin magneto harness
adapter.
ing.
TYPICAL
1. Multimeter
3. Positive (+) probe to YELLOW wire
4. Negative (-) probe to ground
5. Repeat test with the other two YELLOW wires of
the 6-pin magneto harness adapter.
there is a reading, the stator coils and/or the wiring
from the coils is grounded and needs to be re-
placed or repaired.
DYNAMIC TEST
tor.
NOTE: On 4-TEC engines disconnect the stator
wiring harness connector and probe the three con-
nectors.
3. Connect test probes of the multimeter to two
of the YELLOW wires of the 6-pin magneto har-
ness adapter.
value should be between 45 and 70 Vac, and 25
Vac on 4-TEC engines.
6. If the stator is out of specification, replace it.
Magneto
787 RFI Engines
tor.
000 131).
3. Check resistance between the BLACK/YELLOW
and the BLACK wires of the 4-pin magneto har-
ness adapter. The resistance should be between
0.1 to 1.0 ohm.
4. Place either meter lead into the RED/BLACK wire
and note the resistance (same as step no. 3). If the
readings are out of specification, the stator will
need to be replaced.
F01H60A
1 3
2
4
12-03-6 SMR2003-036_12_03A.FM
tor.
3. Insert multimeter positive (+) probe to the
BLACK/YELLOW wire of the 4-pin magneto har-
ness adapter.
ing.
5. Repeat test with the other BLACK and RED/
BLACK wires of the 4-pin magneto harness adapt-
er.
there is a reading, the stator coils and/or the wir-
ing from the coils is grounded and needs to be
replaced or repaired.
DYNAMIC TEST
tor.
3. Connect test probes of the multimeter to the
BLACK/YELLOW and RED/BLACK wires of the
4-pin magneto harness adapter.
value should be between 45 and 70 Vac.
6. Repeat test with the BLACK wire and either the
RED/BLACK or BLACK/YELLOW wires of the
4-pin magneto harness adapter.
7. If the stator is out of specification, replace it.
BATTERY
Troubleshooting
Removal
SYMPTOM: DISCHARGED OR WEAK BATTERY
CAUSE REMEDY
1. Battery posts and/or
cable terminal
oxidized.
Clean and coat with
dielectric grease.
2. Loose or bad
connections.
Check wiring and
connector cleanliness,
damaged or short circuit.
3. Faulty battery
(sulfated, doesnt
keep a full charge,
damaged casing,
loose post).
Replace.
4. 20 amp fuse(s) burnt
or faulty rectifier.
First check fuse.
If it is in good condition,
check rectifier/regulator.
5. Faulty battery charging
coil (or stator).
Replace.
WARNING
Never charge or boost battery while installed
in watercraft.
SMR2003-036_12_03A.FM 12-03-7
RX DI Models
Remove LH side bilge vent tube at rear.
1. LH side vent tube
All Models except GTI and GTI LE Models
Proceed as follows:
1. Disconnect the BLACK negative cable first.
2. Disconnect the RED positive cable last.
3. Remove the vent line from the battery.
4. Remove the holding strap(s).
5. Withdraw battery from watercraft being careful
not lean it so that electrolyte flows out of vent
elbow.
GTI, GTI LE and LRV DI Series
Remove 4 M6 bolts retaining seat support and re-
move upper section from watercraft.
1. Remove bolts
Pull lower section with vent tubes toward the front
of the watercraft.
Disconnect battery cables and vent tube from bat-
tery.
Remove battery straps.
Release battery from support and move it toward
the front of the watercraft.
Pull battery from under resonator and remove bat-
tery from watercraft.
All Models
CAUTION: Should any electrolyte spillage oc-
cur, immediately wash off with a solution of
baking soda and water.
Cleaning
Clean the battery casing, caps, cables and battery
posts using a solution of baking soda and water.
CAUTION: Do not allow cleaning solution to en-
ter battery.
Remove corrosion from battery cable terminals
and battery posts using a firm wire brush. Rinse
with clear water and dry well.
Inspection
Visually inspect battery casing for cracks or other
possible damage. If casing is damaged, replace
battery and thoroughly clean battery tray and close
area with water and baking soda.
Inspect battery posts for security of mounting.
Inspect for cracked or damaged battery caps, re-
place defective caps.
F12H01A 1
1
F07L18A
1
WARNING
Electrolyte is poisonous and dangerous. Avoid
contact with eyes, skin and clothing. Wear a
suitable pair of non-absorbent gloves when re-
moving the battery by hand.
12-03-8 SMR2003-036_12_03A.FM
4-TEC Models
NOTE: Hand tighten caps then tighten a additional
1/4 turn using a 20 mm (3/4 in) socket. Using other
tool could damage the plastic battery caps.
All Models
Electrolyte Level
Check electrolyte level in each cell, add distilled wa-
ter up to upper level line.
CAUTION: Add only distilled water in an activat-
ed battery.
Battery Testing
There are 2 types of battery tests: electrolyte read-
ing and load test. An electrolyte reading is made
on a battery without discharging current. It is the
simplest and commonly used. A loaded test gives
more accuracy of the battery condition.
Electrolyte Reading
Check charge condition using either a hydrometer
or multimeter.
With a multimeter, voltage readings appear in-
stantly to show the state of charge. Always re-
spect polarity. A fully charge battery will have a
reading of 12.6 Vdc.
A hydrometer measures the charge of a battery in
terms of specific gravity of the electrolyte. A fully
charge battery will have a specific gravity between
1.265 to 1.280.
Most hydrometers give a true reading at 21C (70F).
1. Specific gravity 1.265
In order to obtain correct readings, adjust the initial
reading by adding .004 points to the hydrometer
readings for each 5.5C (10F) above 21C (70F)
and by subtracting .004 point for every 5.5C
(10F) below 21C (70F).
This chart will be useful to find the correct reading.
WARNING
Battery electrolyte is caustic. To prevent spill-
age, battery cell cap should be sufficiently
tight to properly seal.
WARNING
Battery caps do not have vent holes. Make sure
that vent line is not obstructed.
ELECTROLYTE
TEMPERATURE OPERATION TO
PERFORM
C F
38
32
27
100
90
80
.012
.008
.004
Add
to the
reading
21 70 CORRECT READING
16
10
4
- 1
60
50
40
30
.004
.008
.012
.016
Subtract
from the
reading
EXAMPLE NO. 1
TEMPERATURE ABOVE 21C (70F):
Hydrometer reading: 1.250
Electrolyte temperature: - 1C (30F)
Subtract .016 Sp. Gr.
Corrected Sp. Gr. is 1.234
EXAMPLE NO. 2
TEMPERATURE ABOVE 21C (70F):
Hydrometer reading: 1.235
Electrolyte temperature: 38C (100F)
Add .012 Sp. Gr.
Corrected Sp. Gr. is 1.247
A17E0JA
1
SMR2003-036_12_03A.FM 12-03-9
Load Test
This is the best test of battery condition under a
starting load. Use a load testing device that has an
adjustable load.
Apply a load of 3 times the ampere-hour rating of
the battery. At 14 seconds into the test, check bat-
tery voltage; if battery is in good condition, it will
have at least 10.5 Vdc.
Battery Storage
CAUTION: Battery storage is critical for battery
life. Regularly charging the battery during stor-
age will prevent cell sulfation. Keeping the bat-
tery in vehicle for storage may lead to contacts
degradation/corrosion and case damage if freez-
ing occurs. A discharged battery will freeze and
break in area where freezing point is experi-
enced. Electrolyte leakage will damage sur-
rounding parts. Always remove battery from ve-
hicle for storage and regularly charge to keep
an optimal condition.
Disconnect and remove battery from watercraft
as explained in REMOVAL.
Check electrolyte level in each cell, add distilled
water up to upper level line.
CAUTION: Do not overfill.
The battery must always be stored in fully charged
condition. If required, charge until specific gravity
of 1.265 is obtained.
CAUTION: Battery electrolyte temperature must
not exceed 50C (122F). The casing should not
feel hot.
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.
CAUTION: Do not allow cleaning solution to en-
ter 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, keep the battery at its upper level line
and near full charge as possible (trickle charge).
Activation of a New Battery
A new battery is factory fresh dry charged. For
storage purposes, it is fitted with a temporary seal-
ing tube.
CAUTION: Do not remove the sealing tube or
loosen battery caps unless activation is desired.
NOTE: In case of accidental premature removal
of caps or sealing tube, battery should be given a
full charge.
Perform the following operations anytime a new
battery is to be installed.
1. Remove the sealing tube from the vent elbow.
2. Remove caps and fill battery to UPPER LEVEL
line with electrolyte (specific gravity: 1.265 at
21C (70F)).
SPECIFIC GRAVITY READING
USING A HYDROMETER
STATE OF
CHARGE
ELECTROLYTE
TEMPERATURE
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
WARNING
Never charge or boost battery while installed in
watercraft.
WARNING
Failure to remove the sealing tube could re-
sult in an explosion.
12-03-10 SMR2003-036_12_03A.FM
NOTE: This battery may fill slower than others
due to the anti-spill check ball design.
1. Sealing tube removed
2. Battery electrolyte
3. Upper level line
3. Allow the battery to stand for 30 minutes MIN-
IMUM so that electrolyte soak through battery
cells.
1. 30 minutes
4. Readjust the electrolyte level to the UPPER LEVEL
line.
1. Battery electrolyte
2. Upper level line
5. Connect a 2 A battery charger for 3 to 5 hours.
Step : Connect + lead to battery + post
Step : Connect - lead to battery - post
Step : Plug battery charger
CAUTION: If charging rate raises higher than
2.4 A reduce it immediately. If cell temperature
rises higher than 50C (122F) or if the casing
feels hot, discontinue charging temporarily or
reduce the charging rate.
6. Disconnect battery charger.
Step : Unplug battery charger
Step : Disconnect - lead
Step : Disconnect + lead
A17E0FB
2
1
3
A17E0GA
1
A17E0RB
1
2
WARNING
Gases given off by a battery being charged
are highly explosive. Always charge in a well
ventilated area. Keep battery away from cig-
arettes or open flames. Always turn battery
charger off prior to disconnecting cables. Oth-
erwise a spark will occur and battery might ex-
plode.
A17E0IA
- +
2 1
3
1
2
3
A17E0IB
- +
1
3 2
1
2
3
SMR2003-036_12_03A.FM 12-03-11
7. Test battery state of charge. Use a hydrometer.
1. Specific gravity 1.265
8. If electrolyte level has dropped after charging,
fill with distilled water to UPPER LEVEL line. Af-
ter water is added, continue charging for 1 to 2
hours to mix water with electrolyte.
9. Reinstall caps and clean any electrolyte spillage
using a solution of baking soda and water.
4-TEC Models
NOTE: Hand tighten caps then tighten a additional
1/4 turn using a 20 mm (3/4 in) socket. Using other
tool could damage the plastic battery caps.
All Models
Charging a Used Battery
For best results, battery should be charged when
the electrolyte and the plates are at room temper-
ature. A battery that is cold may not accept current
for several hours after charging begun.
Do not charge a frozen battery. If the battery charge
is very low, the battery may freeze. If it is suspected
to be frozen, keep it in a heated area for about 2 hours
before charging.
The time required to charge a battery will vary de-
pending on some factors such as:
Battery temperature: The charging time is in-
creased as the temperature goes down. The
current accepted by a cold battery will remain
low. As the battery warms up, it will accept a
higher rate of charge.
State of charge: Because the electrolyte is near-
ly pure water in a completely discharged battery,
it cannot accept current as well as electrolyte.
This is the reason the battery will not accept
current when the charging cycle first begins. As
the battery remains on the charger, the current
from the charger causes the electrolytic acid
content to rise which makes the electrolyte a
better conductor and then, the battery will ac-
cept a higher charging rate.
Type of charger: Battery chargers vary in the
amount of voltage and current that they can
supply. Therefore, the time required for the bat-
tery to begin accepting measurable current will
also vary.
Charging a Very Flat or Completely Discharged
Battery
The battery charger should have an adjustable
charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-
ments is acceptable.
The battery charger must be equipped with an am-
meter capable of accurately measuring current of
less than 1 ampere.
Unless this procedure is properly followed, a good
battery may be needlessly replaced.
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, in
term of milliamperes, because electrolyte is
nearly pure water as explained above. It could
be some time before the charging rate increas-
es. Such low current flow may not be detect-
able on some charger ammeters and the bat-
tery will seem not to accept any charge.
Exceptionally for this particular case, set the
charger to a high rate.
WARNING
Battery electrolyte is caustic. To prevent spill-
age, battery cell cap should be sufficiently
tight to properly seal.
WARNING
Never charge battery while installed in water-
craft.
WARNING
Always charge battery in a well ventilated area.
A17E0JA
1
12-03-12 SMR2003-036_12_03A.FM
NOTE: Some chargers have a polarity protection
feature which prevents charging unless the charg-
er leads are connected to the correct battery ter-
minals. 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 manufacturers instruc-
tion on how to bypass or override this circuitry
so that the charger will turn on and charge a low-
voltage battery.
Since the battery chargers vary in the amount
of voltage and current they provide, the time
required for the battery to accept measurable
charger current might be up to approximately
10 hours or more.
If the charging current is not up to a measurable
amount at the end of about 10 hours, the bat-
tery should be replaced.
If the charging current is measurable before the
end or at the end of about 10 hours, the battery
is good and charging should be completed in
the normal manner as specified in ACTIVATION
OF A NEW BATTERY.
It is recommended that any battery recharged
by this procedure be load tested prior to return-
ing it to service.
Battery Installation
Proceed as follows:
1. Install battery in its emplacement.
2. Secure vent line to the battery and support. En-
sure vent line is not kinked or obstructed.
3. First connect RED positive cable.
4. Connect BLACK negative cable last.
5. Apply dielectric grease on battery posts.
6. Verify cable routing and attachment.
RX Models
Reinstall bilge vent tube.
GTI, GTI LE and LRV DI Models
Reinstall seat support.
CABLE TERMINAL INSTALLATION
Carefully strip the wire approximately to 10 mm
(1/2 in) in length, using a wire stripping tool or
sharp blade/knife.
A. 10 mm (1/2 in)
NOTE: Make sure not to cut wire strands while
stripping the wire.
Install the appropriate terminal on the wire accord-
ing to the requirement. Refer to appropriate parts
catalog.
INSTALLATION OF TERMINAL
Follow the instructions provided with the crimp plier
(P/N 529 035 730) to select the proper position of
the tool.
WARNING
Always connect battery cables exactly in the
specified order, RED positive cable first BLACK
negative cable last.
WARNING
Vent line must be free and open. Avoid skin con-
tact with electrolyte.
A32E2QA
A
A32E2RA
SMR2003-036_12_03A.FM 12-03-13
NOTE: Different wires require different crimp plier
settings, so make sure to follow the instruction sup-
plied with the tool.
POSITIONING THE CRIMP PLIER
Step : Press
Step : Rotate
After positioning the crimp plier, crimp the termi-
nal already installed on wire.
CRIMPING OF WIRE
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.
CAUTION: Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
Install the protective heat shrink rubber tube (P/N
278 001 692) on the terminal. Heat the heat shrink
rubber tube using the heat gun so that it grasps
the wire and the terminal.
CAUTION: Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.
2
A32E2SA
1
1
2
A32E2TA
A32E2UA
Subsection 04 (STARTING SYSTEM)
SMR2003-037_12_04A.FM 12-04-1
STARTING SYSTEM 0
717 Engines
F00H1PS
16
Loctite 243
15
Loctite
271
14
Ground
cable
17
22 Nm
(16 lbfft)
Loctite
243
13
22 Nm
(16 lbfft)
22 Nm
(16 lbfft)
5 Nm
(44 lbfin)
Dielectric
grease
1
12
2
3
5
4
6
11
10
7
8
9
12-04-2 SMR2003-037_12_04A.FM
787 RFI Engines
F15H01S
Loctite
243
6
7
8
9
10
11
4
1
2
3
5
5 Nm
(44 lbfin)
12
22 Nm
(16 lbfft)
13
17
Dielectric
grease
Loctite
243
16
22 Nm
(16 lbfft)
SMR2003-037_12_04A.FM 12-04-3
947 DI Engines
F07H0TS
Dielectric
grease
17
Loctite
243
16
10 Nm
(89 lbfin)
Synthetic
grease
Synthetic
grease
18
10
11
19
Ground
cable
1
2
3
5
12-04-4 SMR2003-037_12_04A.FM
GENERAL
Causes of troubles are not necessarily related to
starter but may be due to a burnt fuse, faulty bat-
tery, start/stop switch, safety lanyard switch,
MPEM (or ECU or DESS auxiliary module on 4-
TEC engines), solenoid, electrical cables or con-
nections.
Check these components before removing start-
er. Consult also the starting system troubleshoot-
ing table on next page for a general view of possi-
ble problems.
Fuse
Make sure the following fuse(s) is in good condi-
tion.
5A fuse on the MPEM.
Fuse on the power supply cut-off relay.
947 DI Engines
25A BAT and 15A INJ fuses on the MPEM.
Fuse on the power supply cut-off relay.
4-TEC Engines
10A (#9 on wiring diagram) fuse on the MPEM and
the 30A main fuse (starting system) besides the
MPEM.
The solenoid may be the cause of a burnt fuse. If
the solenoid checks good, one of the accessory
may be defective.
Battery
To check battery condition, refer to CHARGING
SYSTEM.
MPEM (or EMS ECU on 4-TEC engines)
safety lanyard, refer to DIGITALLY ENCODED SE-
CURITY SYSTEM or ENGINE MANAGEMENT.
Engine Start/Stop Switch and Safety
Lanyard Switch
Refer to IGNITION SYSTEM or ENGINE MANAGE-
MENT or INSTRUMENTS AND ACCESSORIES.
Solenoid
NOTE: Solenoid is located in the electrical box or
above MPEM on 787 RFI engines and besides
MPEM on 4-TEC engines.
Inspect connections and clean as necessary.
Static Test: Continuity
With a multimeter, check primary winding resis-
tance.
It should be approximately 5 ohms.
There should be no continuity between the posi-
tive posts of the solenoid.
Dynamic Test
Depress start/stop button and measure the volt-
age on the solenoid positive posts with a multim-
eter.
If there is no voltage and battery is in good condi-
tion, replace the solenoid.
Electrical Cables or Connections
Check all connections, cables and wires. Tighten
any loose cables. Replace any chafed wires.
WARNING
Short circuiting electric starter is always a dan-
ger, therefore disconnect the battery ground
cable before carrying out any kind of mainte-
nance on starting system. Do not place tools
on battery.
SMR2003-037_12_04A.FM 12-04-5
STARTING SYSTEM TROUBLESHOOTING
SYMPTOM CAUSE REMEDY
STARTER DOES NOT TURN. Burnt fuse (see text above). Check wiring condition and replace fuse.
Poor contact of battery terminal(s). Clean and tighten terminal(s).
Poor battery ground cable connection. Clean and tighten.
Weak battery. Recharge or replace battery.
Poor contact of start/stop switch,
safety lanyard switch or solenoid.
Check connectors and clean contacts.
Check and replace defective parts.
Open circuit: start/stop switch or
solenoid.
Check and replace.
Safety lanyard or MPEM (or EMS ECU
on 4-TEC engines).
Refer to DIGITALLY ENCODED
SECURITY SYSTEM or ENGINE
MANAGEMENT.
DESS auxilliary module (if so
equipped on 4-TEC engines)
Refer to ENGINE MANAGEMENT.
STARTER ENGAGES;
BUT DOES NOT CRANK
THE ENGINE.
Poor battery cable connections. Clean battery cable connections.
Poor contact of brush. Straighten commutator and brush.
Burnt commutator. Turn commutator on a lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace brush holder or spring.
Weak magnet. Replace yoke assembly.
Worn bushings. Replace clutch.
Weak battery. Recharge or replace battery.
STARTER TURNS, BUT
OVERRUNNING CLUTCH
PINION DOES NOT MESH
WITH RING GEAR.
Worn clutch pinion gear. Replace clutch.
Defective clutch. Replace clutch.
Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn ring gear. Replace ring gear.
STARTER MOTOR KEEPS
RUNNING.
Shorted solenoid winding. Replace solenoid.
Melted solenoid contacts. Replace solenoid.
Sticking or defective starter clutch. Lubricate or replace.
Presence of salt water in the electrical
box (if so equipped) which gives
continuity.
Verify electrical box watertightness.
12-04-6 SMR2003-037_12_04A.FM
STARTER REMOVAL
Disconnect BLACK cable ground connection from
battery.
Disconnect RED cable connection from battery.
Remove the following parts:
cables from starter
screw no. 13 of starter rear support
starter mount screws no. 16.
947 DI Engines
Disconnect starter cables and loosen Allen screws
no. 16 retaining starter bracket to engine.
1. Positive starter cable
2. Negative starter cable
3. Allen screw
Remove bracket and starter.
NOTE: To remove the starter drive assembly, mag-
neto flywheel has to be removed. Refer to MAG-
NETO SYSTEM and BOTTOM END.
To check and replace the starter end bearing, refer
to BOTTOM END section.
4 -TEC Engines
Remove retaining screws no. 1 (refer to illustra-
tion above) from starter.
Pull starter no. 3 out. Lift starter enough to reach
starter cable then disconnect from starter (nut
no. 2).
1. Exhaust manifold
2. Starter
3. Retaining screws
4. Nut
WARNING
Always disconnect ground cable first and re-
connect last.
F06H35B
2
1
3
3
4
F18H0MA
5
3
2
1
Grease Klueber Isoflex
Topas NB 52
1
F18H0UA
2 4
3
SMR2003-037_12_04A.FM 12-04-7
STARTER DISASSEMBLY
Before disassembling, trace index marks on yoke
no. 1 and clutch housing no. 10 to ease further
assembly.
TYPICAL
1. Trace indexing marks
Remove starter support nuts no. 12 then through
bolts no. 5. Separate end frame no. 3 from yoke
assembly no. 1. Withdraw yoke assembly from ar-
mature no. 11.
Brush holder no. 2 can be removed from end frame
no. 3 by unscrewing nut retaining terminal.
Check that the radial play between the armature
shaft and end frame is not greater than 0.20 mm
(.008 in). Replace end frame if so.
Tap the pinion stop collar no. 7 using a screwdriv-
er. Remove circlip no. 6. Disassemble pinion stop
collar no. 7 and spring no. 8.
1. Pinion stop collar
Turn clutch assembly no. 9 clockwise to remove
it from armature assembly no. 11.
Pull housing from armature.
947 DI Engines
Locate index marks on yoke no. 1 and end covers
no. 3 and no. 10.
1. Index marks
Loosen through bolts no. 5.
1. Through bolts
Remove end cover no. 3 and gasket on armature
shaft side.
F01H0PA
1
A03E04A
1
F06H1FA
1
F06H1GA
1
12-04-8 SMR2003-037_12_04A.FM
Remove thrust washers no. 19 from armature shaft.
1. Thrust washers
Remove the other end cover no. 10 and gasket.
Remove the three washers no. 18 from armature
shaft.
1. Washers
Remove armature no. 11.
1. Pull armature shaft
Release brush wires of yoke from brush holder no. 2.
Remove brush holder no. 2.
1. Remove brush holder
To remove brushes from yoke no. 1, loosen nut
and remove washers.
1. Loosen nut and remove washers
F06H1HA 1
F06H1IA
1
F06H1JA 1
F06H1KA
1
F06H1LA
1
SMR2003-037_12_04A.FM 12-04-9
Remove brushes.
To remove bearing and seal in end cover, release
tabs of retainer.
1. Retainer
4-TEC Engines
Remove bendix retaining circlip no. 4 and starter
bendix no. 5.
1. Retaining circlip
2. Starter bendix
Locate index marks on yoke and end covers.
1. Index marks
Loosen through bolts.
1. Through bolts
Remove end cover.
F06H1MA 1
1 F18H0NA 2
1 F18H0OA
1
F18H0PA
12-04-10 SMR2003-037_12_04A.FM
Remove thrust washer from armature shaft.
TYPICAL
1. Thrust washers
Remove the other end cover with brushes and
brush holder assembly.
Remove armature.
TYPICAL
1. Pull armature shaft
Remove brushes from brush holder by loosening
retaining screws.
1. Brushes
2. Retaining screw
3. Brush holder
Remove springs.
CLEANING
All Engines
CAUTION: Yoke assy and drive unit assembly
must not be immersed in cleaning solvent.
Discard all O-rings.
Clean brushes and holders with a clean cloth soaked
in solvent. Brushes must be dried thoroughly with
a clean cloth.
Blow brush holders clean using compressed air.
Remove dirt, oil or grease from commutator using
a clean cloth soaked in suitable solvent. Dry well
using a clean, dry cloth.
Clean engine ring gear teeth and drive unit (clutch).
NOTE: Bushings or bearings must not be cleaned
with grease dissolving agents.
Immerse all metal components in cleaning solution.
Dry using a clean, dry cloth.
F06H1HA 1
F06H1JA 1
WARNING
Always wear safety glasses when using com-
pressed air.
1
F18H0QA
2 3
SMR2003-037_12_04A.FM 12-04-11
PARTS INSPECTION
Armature
NOTE: An ohmmeter may be used for the follow-
ing testing procedures, except for the one con-
cerning shorted windings in armature.
Check commutator for roughness, burnt or scored
surface. If necessary, turn commutator on a lathe,
enough to resurface only.
Check commutator for mica depth. If depth is less
than 0.20 mm (.008 in), undercut mica. Be sure
that no burrs are left and no copper dust remains
between segments after undercutting operation
is completed.
1. Commutator undercut 0.20 mm (.008 in)
Check commutator out of round condition with V-
shaped blocks and an indicator. If commutator out
of round is more than 0.40 mm (.016 in), commu-
tator should be turned on a lathe.
Check commutator outer diameter. If less than
27 mm (1.063 in), replace.
4-TEC Engines
Check commutator condition with an indicator. If
out of specification, replace the starter.
1. Commutator undercut 0.20 mm (.008 in)
All Engines
Brush Holder
Check brush holder for insulation using an ohm-
meter. Place one test probe on insulated brush
holder and the other test probe on brush holder
plate. If continuity is found, brush holder has to be
repaired or replaced.
Brush
Measure brush length. If less than 8.5 mm (.335 in),
replace them.
NOTE: New brush length is 12 mm (.472 in).
1. New
2. Wear limit, 8.5 mm (.335 in)
F01H0RA
1
A03E06A
1
F18H0RA
A03E05A
1
2
12-04-12 SMR2003-037_12_04A.FM
Overrunning Clutch
2-Stroke Engines
Pinion of overrunning clutch should turn smoothly
in clockwise direction, and should not slip in a
counterclockwise direction. If defective, replace.
Check pinion teeth for wear and damage. If defec-
tive, replace.
NOTE: Always check engine ring gear teeth for
wear and damage. If defective replace ring gear.
Refer to MAGNETO.
STARTER ASSEMBLY
All Engines
Reverse the order of disassembly to reassemble
starter. However, attention should be paid to the
following operations.
Prior to assembling, coat sliding surfaces on arma-
ture shaft splines, overrunning clutch and bushing
(717 engine) with G.E. Versilube G 341 M or ESSO
Beacon 325 lubricant or equivalent.
After placing pinion stop collar no. 7 on armature
shaft no. 11, fit circlip no. 6 into armature shaft,
then make sure that it is properly secured.
Slide stop collar no. 7 over circlip no. 6 and secure
in place by punching it at two or three places.
1. Armature shaft
2. Circlip
3. Pinion stop collar
4. Punch
Yoke Assembly and Clutch Housing
Align previously traced indexing marks.
TYPICAL
1. Align marks
Open brushes no. 4 and slide over commutator.
Align end frame locating notch with yoke locating
protrusion and properly sit brush holder no. 2 into
yoke no. 1.
1. Locating protrusion is the higher one
1. Brush holder locating notch
A03E0EA
1
2
4
3
F01H0QA
1
F01H0SA
1
F01H0TA
1
SMR2003-037_12_04A.FM 12-04-13
To ease end frame installation, retain brush holder
with a small screwdriver while installing end frame.
Step : Retaining brush holder with a screwdriver
Step : Align here
Align end frame notch with brush holder notch/
yoke protrusion.
CAUTION: Make sure end frame fits perfectly on
yoke.
947 DI Engines
Install new O-rings and gaskets.
Insert thrust washers no. 19 onto armature shaft.
1. Thrust washers
Install the three washers no. 8 onto armature shaft.
When installing end covers no. 3 and no. 10 to
yoke, align index marks.
Apply Loctite 271 (red) on through bolts no. 5 and
STARTER INSTALLATION
procedure. However, pay particular attention to
the following.
Make sure that starter and engine mating surfaces
are free of debris. Serious trouble may arise if
starter is not properly aligned.
Screw
Apply Loctite 243 (blue) on threads and torque start-
er screws no. 13 and no. 16 to 22 Nm (16 lbfft).
Nut
Connect the RED positive cable to the starter and
torque nut no. 17 to 6 Nm (53 lbfin). Apply di-
electric grease on terminal and nut.
F01H0UA
2
1
1
2
F06H1HA 1
12-04-14 SMR2003-037_12_04A.FM
Screw and Teeth Washer
Apply Loctite 271 (red) to screw.
Connect BLACK negative cable to starter using flat
washer, teeth washer no. 15 and screw no. 14.
Torque screw to 22 Nm (16 lbfft). Apply dielectric
grease on terminal and screw.
717 ENGINES SHOWN
Step : Torque nut to 6 Nm (53 lbfin)
Step : Apply Loctite 271 on screw
Step : Torque screw to 22 Nm (16 lbfft)
Step : Apply dielectric grease
947 DI Engines
Screw
Apply Loctite 243 (blue) to Allen screws no. 16 of
starter bracket and torque to 10 Nm (89 lbfin).
Nut
torque nut no. 17 to 6 Nm (53 lbfin). Apply di-
electric grease on terminal and nut.
947 DI ENGINES
1. Torque nut to 6 Nm (53 lbfin), apply dielectric grease and install
protection cover
2. Negative BLACK cable
3. Apply Loctite 243 to threads and torque screw to 10 Nm
(89 lbfin)
4-TEC Engines
Apply grease Isoflex Topas NB52 (P/N 293 550
021) on O-rings of starter.
Install Starter.
NOTE: If starter does not mesh properly, try to pull
it out and slightly rotate the starter gear; then re-
install starter. One could also temporarily remove
both O-rings, properly mesh gears then remove
starter to reinstall O-rings, being careful not to ro-
tate gear to keep its position, to finally reinstall
starter.
Apply Loctite 243 (blue) on retaining screws no. 1
and torque to 10 Nm (89 lbin).
WARNING
Always connect RED positive cable first then
BLACK negative cable last. Whenever con-
necting the RED positive cable to the starter
motor make sure the battery cables are dis-
connected to prevent electric shock.
F01H1JC
1 4
2
3
4
1
2
3
4
WARNING
F06H35B
2
1
3
3
SMR2003-037_12_04A.FM 12-04-15
Nut
torque nut to 7 Nm (62 lbfin). Apply dielectric
grease on terminal and nut.
Ensure to slide protector over nut to hide metallic
parts.
1. Grease on O-rings.
2. Torque nut to 7 Nm (62 lbfin) and apply dielectric grease and
install protection cover
3. Apply Loctite 243 to threads and torque screws to 10 Nm
(89 lbfin)
WARNING
3 2 1
F18H0UB
12-04-16 SMR2003-037_12_04A.FM
STARTER SPECIFICATION
947 DI Engines
4-TEC Engines
Nominal output 0.6 kW
Voltage 12 V
Rated time 30 seconds
Rotation Counterclockwise (viewed from pinion side)
Weight Approx. 2 kg (4.4 lb)
Performance specification at 20C (68F)
No load 11.5 V 20 A max. 5500 RPM
Load 8.5 V 170 A max. 2200 RPM
Stall 5 V 350 A max. 0 RPM
Battery 12 V, 19 Ah
Voltage 12 V
Weight 1.7 kg (3.7 lb)
Load 9 V 120 A max. 5350 RPM
Stall 2.25 V 390 A max. 0 RPM
Battery 12 V, 19 Ah
Voltage 12 V
Weight 2.5 kg (5.39 lb)
Load 8.5 V 140 A max. 5200 RPM
Stall 3.75 V 330 A max. 0 RPM
Battery 12 V, 30 Ah
Subsection 05 (INSTRUMENTS AND ACCESSORIES)
SMR2003-038_12_05A.FM 12-05-1
INSTRUMENTS AND ACCESSORIES 0
GENERAL
Install safety lanyard to activate MPEM to perform
testing procedures that requires the device to be
supplied with electricity.
POWER SUPPLY CUT-OFF RELAY
VERIFICATION
2-Stroke Models
When the safety lanyard is on its switch, the relay
allows current to be supplied from the battery to
the RED/PURPLE wire which supplies the MPEM
and all the electrical components (except bilge
pump which is connected to battery power on XP
DI models).
When the safety lanyard is NOT on its switch, the
relay cuts the current supply from the battery to
the MPEM and the electrical components thus
preventing current drain that would slowly dis-
charge the battery.
The relay is located in cover of electrical box (on
MPEM box on RFI models).
Test the signal wire to the power supply cut-off
relay as follows:
Disconnect DESS switch wires.
PURPLE wires.
With safety lanyard NOT on its switch: Measure
resistance. There should be NO continuity (open cir-
cuit). Otherwise replace DESS switch.
With safety lanyard INSTALLED on its switch:
Measure resistance. There should be continuity.
Otherwise replace DESS switch.
If switch tests good in both checks, do the following.
Disconnect the connector on electrical box.
Using a voltmeter, perform the following tests:
Connect test probes to the small RED wire on the
starter solenoid and on the RED/PURPLE wire from
the cut-off relay. Reading should be 0 V. Otherwise,
replace the cut-off relay.
Keeping the test probes on the same wires, con-
nect a jumper wire between the BLACK/PURPLE
wire from the cut-off relay to the battery ground.
Measure voltage. Reading should be 12 V. Other-
wise, check wiring and if it is good, replace the cut-
off relay.
If there is no current supply to the electrical com-
ponents while the DESS switch and the cut-off re-
lay test good, check the wiring harness. If it tests
good, the MPEM could be suspected. Try a new
one.
MULTI-PURPOSE ELECTRONIC
MODULE (MPEM)
Carburetor-Equipped and RFI Models
The MPEM is directly powered by the battery
through the cut-off relay. It has a micro-processor
inside of its sealed case.
All the electrical system is controlled by the MPEM.
It is in charge of the following electrical functions:
start/stop function
Digitally Encoded Security System
ignition timing curve
engine rev limiter.
Some fuses are directly mounted onto the MPEM.
The MPEM features a permanent memory that
will keep the programmed safety lanyard(s) active
and other vehicle information, even when the bat-
tery is removed from the watercraft.
MPEM Functions
stalling the safety lanyard on its post, 4 short
stopped.
12-05-2 SMR2003-038_12_05A.FM
charge the battery.
Antistart Feature
When connecting a safety lanyard cap on the switch
the DESS system inside the MPEM is activated
and will emit audible signals:
2 short beeps indicate a right safety lanyard is
being used and gauges are supplied with cur-
rent for 33 seconds. The MPEM will thus allow
the engines to start.
being used or that the antistart feature is defec-
tive. Current to gauges is cut after the audible sig-
nal is emitted and the engine cannot be started.
A wrong safety lanyard is a safety lanyard which is
defective or not programmed in the MPEM memory.
To better understand the antistart feature, refer to
DESS (DIGITALLY ENCODED SECURITY SYSTEM).
If the MPEM responds differently from what is
mentioned above, refer to the troubleshooting
section to find out why.
When the safety lanyard is installed, it activates
the reading of gauges without the engine running.
It will give access to most functions of the infor-
mation center gauge without starting the engine.
NOTE: On the RFI models, the fuel pump will be
activated for 1 second to build up pressure in the
fuel injection system, only when connecting the
safety lanyard cap to the switch.
Engine Starting
If the MPEM recognizes a valid safety lanyard, it
allows engine to start when the start/stop switch
is pressed.
the MPEM automatically stops the starter when
the engine speed reaches 1000 RPM.
Engine RPM Limiter
The MPEM will limit the maximum engine speed.
Engine Stopping
There are two ways to stop the engine.
Press start/stop switch or remove the safety lan-
yard cap from the switch.
Low-Fuel Level Warning Device
MPEM sends out signals for the beeper (RFI mod-
els only) and to the Information Center gauge.
When the oil level is low in the reservoir, the
MPEM sends out a signal to the Information Cen-
ter gauge and the pilot lamp on the gauge will turn
on.
Power Distribution
A power supply cut-off relay supplies the MPEM
from the battery.
The MPEM distributes power from the cut-off re-
lay to all accessories (except bilge pump which is
connected to battery power on XP DI models).
Accessories are protected by fuses integrated in
the MPEM, in fuse holder(s) close to MPEM or in
the electrical box. Fuses are identified besides
their holder. See below for fuses location and de-
scription.
Overheat Sensor
When the engine temperature reaches a threshold
value, the MPEM triggers a continuous beep to indi-
cate overheating.
Diagnostic Mode
In order to facilitate the use of the watercraft, a
system controls the digitally encoded security sys-
tem (DESS) and sends, through a buzzer, some
audible signals informing the operator of a specific
situation. The diagnostic mode is automatically ac-
tivated when connecting the safety lanyard cap to
the switch. Refer DIGITALLY ENCODED SECURI-
TY SYSTEM.
SMR2003-038_12_05A.FM 12-05-3
Information Center
2-Stroke Models with the Information Center
This is a LCD multifunction gauge. Different dis-
plays and functions can be activated using 2 but-
tons MODE and SET following specific se-
quences as described below.
1. To change display mode
2. To set or reset a function
NOTE: Some models have the MODE and SET but-
tons at a different location and differ in appearance.
However, the functionality is the same. The follow-
ing explanations apply to both types of buttons.
Resetting a Function
To reset a function (such as the chronometer, dis-
tance, etc.) press and hold the SET button for 2
seconds while in the appropriate mode.
The information center includes the following dis-
play areas.
1. General display
2. Message/units display
3. Warning light
4. Fuel level display
5. VTS position indicator (if so equipped)
General Display
Repeatedly pressing the MODE button scrolls the
following displays: Compass (if so equipped), Ta-
chometer, speedometer, average speed, trip
meter, hourmeter, water temperature, exterior
temperature (if so equipped) and chronometer.
1. Press to change display mode
When you are satisfied with your choice, stop press-
ing the button.The display you have chosen will re-
main until it is changed. When safety lanyard is in-
stalled, the last chosen display will come back.
Compass (if so equipped): Displays the cardinal
points to indicate the orientation of the watercraft.
F00L2BA 1 2
F18L09B 1 2
WARNING
Use the compass as a guide only. Not to be
used for navigation purposes.
F00L2CA
1 2
3 4
5
F00L2BB 1
12-05-4 SMR2003-038_12_05A.FM
Tachometer: Indicates the revolutions per minute
(RPM) of the engine.
Speedometer: Indicates the speed of watercraft
in kilometers per hour (KPH) or miles per hour
(MPH).
Average Speed: The information center approxi-
mately calculates and displays the average speed
(AV KPH or AV MPH) of the watercraft since the
last engine start.
Trip Meter: The information center approximately
calculates the distance based on the operation time
and the watercraft speed and displays the result in
kilometers (KM) or miles (MILES).
Hourmeter: Displays the time in hours of the wa-
tercraft usage.
Water Temperature: Displays the water tempera-
ture of the water surface (L TEMP) in degrees Cel-
sius (C) or Fahrenheit (F).
Exterior Temperature (if so equipped): Displays
the exterior air temperature (E TEMP) in degrees
Celsius (C) or Fahrenheit (F).
Chronometer: Allows to measure an interval of
time in hours and minutes (hh:mm).
Message Display
The information center features a display area that
blinks a message whenever one of the following
circumstances occurs:
fuel injection system sensors and major compo-
nents (MAINT) (DI models)
compass error (COMPAS) (if so equipped)
maintenance (MAINT)
engine overheating (H-TEMP)
low fuel (FUEL-LO)
low oil (OIL LOW)
low voltage (12 V LOW).
A buzzer will sound when one of the four last cir-
cumstances occurs.
Except for low fuel and low oil, which can be correct-
ed by refilling, it is recommended to see an autho-
rized SEA-DOO dealer when other messages occur.
The warning light will blink at the same time.
Warning Light
The red warning LED (Light-Emitting Diode) blinks
along with the message display to catch your at-
tention.
Fuel Level Display
Bar gauge continuously indicates the amount of
fuel in the fuel tank while riding. A low-fuel condi-
tion is also indicated when it occurs. See MES-
SAGE DISPLAY above.
VTS Position Indicator (if so equipped)
The VTS position indicator shows the riding angle
of the watercraft.
1. Position indicator
2. Bow up
3. Bow down
Display Priorities
As a self test, all LCD segments and the LED will
turn on for 3 seconds each time the information cen-
ter is activated (when safety lanyard is installed).
When the information center is activated, the last
function set will be displayed if it was the tachom-
eter, speedometer or chronometer. If another func-
tion was set, the compass will be displayed. On
models without the compass function, the word
SeaDoo will be displayed.
In the event of a warning message, the message
will blink and override the units display.
If more than one warning message occurs, the
blinking messages will scroll every 4 seconds.
F00L2DA
1 2 3
SMR2003-038_12_05A.FM 12-05-5
Other Functions
The following describes how to select other avail-
able functions.
Language Option
While in the compass mode (while SeaDoo is
displayed on models without compass):
1. Press and hold for 2 seconds
1. Repeatedly press
1. Press to end
English/Metric System
Allows to display the units in the metric system or
in the SAE English system.
1. Press TOGETHER and hold for 2 seconds
Chronometer
While in the chronometer mode:
1. Press to start or stop chronometer
1. Press and hold for 2 seconds to reset
Chronometer is reset every time engine is turned
off.
Maintenance Information
When the watercraft is due for a maintenance in-
spection, the message MAINT will blink.
To clear the warning message while it is blinking:
1. Press and hold for 2 seconds to reset
NOTE: If maintenance message (MAINT) contin-
ues to blink, it indicates a fault with the fuel injec-
tion system on Di models. Refer to DIAGNOSTIC
PROCEDURES section.
4-TEC Models
This is a multifunction gauge that supplies several
real time useful information to the driver.
F00L2BC 1
F00L2BB 1
F00L2BC 1
F00L2BD 1
F00L2BC 1
F00L2BC 1
F00L2BC 1
12-05-6 SMR2003-038_12_05A.FM
Components Description
1. Analog speedometer
2. Analog tachometer
3. Display area
1. Text and numerical area
1. Function buttons
Display Area
The display area comprises the following.
1. Fuel level indicator
2. Numerical section
3. Units and messages section
Fuel Level Display
Bar gauge continuously indicates the amount of
fuel in the fuel tank while riding. A low-fuel condi-
tion is also indicated in the information center
when only one bar is displayed. See MESSAGE
DISPLAY below.
Numerical Section
This section shows the digits of the function dis-
played such as the speedometer, trip hour meter
etc.
Units and Messages Section
This section shows the units related to the num-
bers displayed. Units such as KMH (MPH), HOUR
etc. are displayed.
This section also display navigational and system
fault informations.
See the gauge functions and message lists below
for more details.
Gauge Functions
Digital Tachometer: Indicates the revolution per
minute (RPM) of the engine.
Digital Speedometer: Indicates the speed of the
watercraft in miles per hour (MPH) and kilometers
per hour (km/h).
Depth Gauge (if so equipped): It continuously
display the water depth under the hull within 0 to
50 meters (0 to 166 feet).
F18H08A 3
1 2
F18H08B 1
F18L09A 1
WARNING
Never use the depth gauge as a warning de-
vice to ride in shallow water. Use it as a nav-
igation guide only. Not to be used for naviga-
tion purposes.
F18H08C 3 2 1
SMR2003-038_12_05A.FM 12-05-7
Compass: Displays the cardinal points to indicate
the orientation of the watercraft.
Average Speed: The information center approxi-
mately calculates and displays the average speed
(AV KM/H or AV MPH) of the watercraft since the
last engine start.
Distance (KM or MILES). The information center
approximately calculates the distance based on the
operation time and the watercraft speed and dis-
plays the result in kilometers (KM) or miles (MILES).
Hourmeter: Displays the time in hours of the wa-
tercraft usage (HOUR).
Water Temperature: Displays the water temper-
ature of the water surface (L TEMP) in degrees
Celsius (C) or Fahrenheit (F).
Exterior Temperature: Displays the exterior air
temperature (E TEMP) in degrees Celsius (C) or
Fahrenheit (F).
Trip Hour Meter: (TRIPMTR) Allows to measure an
interval of time in hours and minutes (hh:mm).
Function Buttons
Different displays and functions can be activated
using 2 buttons MODE and SET following
specific sequences as described below.
Resetting a Function
To reset a function (such as the trip hour meter, dis-
tance, etc.) press and hold the SET button for 2 sec-
onds while in the appropriate mode.
Display Selection
Repeatedly pressing the MODE button scrolls the
following displays: Compass, tachometer, speed-
ometer, average speed, distance, hourmeter, water
temperature, exterior temperature, depth gauge (if
so equipped), and trip hour meter.
1. Press to change display mode
When you are satisfied with your choice, stop press-
ing the button and it will become active. The display
you have chosen will remain until it is changed.
Display Priorities
As a self test at start-up, the needles of the speed-
ometer and tachometer will sweep to their maxi-
mum position, all LCD segments and the LED will
turn on for 3 seconds each time the information cen-
ter is activated (when safety lanyard is installed).
This allows the driver to validate they are all working
properly.
When the information center is activated, the last
function set will be displayed.
In the event of a warning message, the message
will blink and override the units display unless
MODE button is pressed. The display will then dis-
play the last function after 10 seconds.
If more than one warning message occurs, the
blinking messages will scroll every 4 seconds.
WARNING
Use the compass as a guide only. Not to be
used for navigation purposes.
F18L09B 1 2
F18L09C 1
12-05-8 SMR2003-038_12_05A.FM
Other Functions
The following describes how to select other avail-
able functions.
Language Option
While in the compass mode:
1. Press and hold for 2 seconds
1. Repeatedly press
1. Press to end
English/Metric System
Allows to display the units in the metric system or
in the SAE English system.
NOTE: This function is not available when informa-
tion center displays the compass, hourmeter or trip
hour meter.
1. Press TOGETHER and hold for 2 seconds
F18L09D 1
F18L09C 1
F18L09D 1
F18L09A 1
SMR2003-038_12_05A.FM 12-05-9
Trip Hour Meter
While in the trip hour meter mode:
1. Press to start or stop trip hour meter
1. Press and hold for 2 seconds to reset engine is turned off
Trip hour meter is reset every time engine is turned
off.
Message Display
The information center features a display area that
blinks a message whenever one of the following cir-
cumstances occurs. The abbreviations between pa-
renthesis here are the code displayed:
engine or exhaust system overheating
(H-TEMP)
low oil pressure (OIL)
low battery voltage (12 V LOW)
high battery voltage (12 V HI)
low fuel level (FUEL-LO)
maintenance reminder (MAINT)
check engine (CHK ENG)
sensor failure (vehicle electronic equipment)
(SENSOR)
invalid safety lanyard (KEY)
safety lanyard, learning key active
(L KEY)
end of faults (END).
A beeper will sound depending on the fault occur-
ring to catch the driver attention when necessary.
Except for low liquid levels, which can be corrected
by refilling, it is recommended to see an authorized
Sea-Doo dealer when other messages occur.
NOTE: If a fault occurs, this system generates num-
bered fault codes (P-XXXX) that can be displayed
through the information center using a special pro-
cedure. In case of a failure, refer to DIAGNOSTIC
PROCEDURES in ENGINE MANAGEMENT.
Warning Light
The red warning LED (Light-Emitting Diode) blinks
along with the beeper to catch your attention.
Maintenance Information
When the watercraft is due for a maintenance in-
spection, the message MAINT will blink. Afterwards,
it will blink at every start-up for 10 seconds. After ser-
vicing, ensure to clear it.
Addition of Electrical Accessories
Every time an electrical accessory is added such
as an electric bilge pump or a VTS for instance, it
must be registered using B.U.D.S. to activate it in
the MPEM.
If an option is installed but not checked in B.U.D.S.,
the information center will not display that option.
If an option is checked in B.U.D.S. but not installed
in vehicle, a fault code will be generated.
Use the OPTIONS area in the Setting tab in B.U.D.S.
F18L09D 1
F18L09D 1
12-05-10 SMR2003-038_12_05A.FM
INSPECTION
Information Center
Some 2-Stroke Models
The PURPLE wire is the 12 Vdc power source of
the Information Center.
The BLACK wire is the ground.
The accuracy of some features of the Information
Center can be checked with a potentiometer as
follows.
Fuel Level
Fuel Injection Models
Disconnect the AMP connector #1 from the
MPEM.
Using an appropriate terminal remover, remove
the PINK wire from the AMP connector.
Reconnect the connector housing.
Disconnect the 2-circuit connector housing (3-circuit
on GTX DI models) from the information center
which contains a PURPLE and BLACK wires.
Remove the BLACK wire from the receptacle hous-
ing.
Reconnect the connector housing and the BLACK
terminals together.
Connect potentiometer test probes to the PINK
and BLACK wires.
Adjust potentiometer to the resistance values as
per following chart to test the accuracy of the Infor-
mation Center.
GTI LE RFI Models
RX DI, GTX DI and XP DI Models
VTS Position Indicator
Some Models
MPEM.
the BROWN/ WHITE and BROWN/BLACK wires
from the AMP connector.
Connect potentiometer test probes to the BROWN/
WHITE and BROWN/BLACK wires.
mation Center.
RESISTANCE
()
DISPLAYED
SEGMENT ON
FUEL LEVEL
LCD
LOW FUEL
LEVEL RED
LIGHT
4.8 + 2.2 FULL OFF
17.8 2.2 7/8 OFF
27.8 2.2 6/8 OFF
37.8 2.2 5/8 OFF
47.8 2.2 4/8 OFF
57.8 2.4 3/8 OFF
67.8 2.8 2/8 OFF
77.8 3.6 1/8 ON
89.8 3.6 EMPTY ON
RESISTANCE
()
DISPLAYED
SEGMENT ON
FUEL LEVEL
LCD
LOW FUEL
LEVEL RED
LIGHT
4.8 2.2 FULL OFF
17.8 2.2 7/8 OFF
27.8 2.2 6/8 OFF
37.8 2.2 5/8 OFF
47.8 2.2 4/8 OFF
57.8 2.4 3/8 OFF
67.8 2.8 2/8 OFF
77.8 3.6 1/8 ON
89.8 3.6 EMPTY ON
RESISTANCE
()
VTS DISPLAYED
LCD SEGMENT
167.3 2.2 11/11 (UP)
153.0 2.2 10/11
138.7 2.2 9/11
124.4 2.2 8/11
110.1 2.2 7/11
95.8 2.2 6/11
81.5 2.2 5/11
67.2 2.2 4/11
52.9 2.2 3/11
38.6 2.2 2/11
24.3 2.2 1/11 (DOWN)
SMR2003-038_12_05A.FM 12-05-11
Water Temperature (L temp)
Some Models
The water temperature sensor is integrated with
the speed sensor located on the ride plate or tran-
som. As a result, that sensor has 3 wires.
MPEM.
the BLACK/ORANGE and TAN/ORANGE wires
from the AMP connector.
Connect potentiometer test probes to the BLACK/
ORANGE and TAN/ORANGE wires.
mation Center.
Exterior Temperature
Some Models
Disconnect the 2-circuit connector housing of the
Information Center which contains a TAN/WHITE
and BLACK/WHITE wires.
Connect potentiometer test probes to the TAN/
WHITE and BLACK/WHITE wires.
per following chart to test the accuracy of the In-
formation Center.
Information Center not Working
4-TEC Models
When there is no display at the information center,
perform the following:
B.U.D.S. can be used to check its operation.
Look in the Monitoring tab.
Check fuses.
Check supply wire (1-23) and ground wire (1-8)
from MPEM.
Check communication link wires (WHITE/RED
and WHITE/BLACK):
To quickly check if the communication link is
working, temporarily disconnect a sensor on
the engine to create a fault code. Start the
engine. The information should display a fault
code when in onboard diagnostic mode.
Check if wires are swapped, unconnected or
short circuit.
One faulty wire will cause a longer delay to
perform the self-test when safety lanyard is
installed.
If everything tests good, try a new information
center.
RESISTANCE
()
DISPLAY
TEMPERATURE (C)
25407.3 5 2
19911.1 10 2
15718.0 15 2
12495.0 20 2
10000.0 25 2
8054.9 30 2
6528.3 35 2
RESISTANCE
()
DISPLAY
TEMPERATURE (F)
22799.0 45 4
17262.0 55 4
13470.0 65 4
10496.3 75 4
8264.4 85 4
6528.3 95 4
RESISTANCE
()
DISPLAY
TEMPERATURE (C)
4712 5 2
3792 10 2
3069 15 2
2500 20 2
2057 25 2
1707 30 2
1412 35 2
RESISTANCE
()
DISPLAY
TEMPERATURE (F)
4316 45 4
3337 55 4
2712 65 4
2138 75 4
1771 85 4
1412 95 4
12-05-12 SMR2003-038_12_05A.FM
Fuel/Oil Gauge/Low Oil Warning Light
Some Models
The fuel gauge has a pointer which indicates fuel
level in the tank.
The low oil warning light is part of the gauge. It will
light when injection oil level is low.
TYPICAL
Fuel Baffle Pick-Up Sender
The baffle pick-up has an integrated fuel sender.
To verify fuel sender, a resistance test should be
performed with a multimeter allowing the float to
move up through a sequence.
1. Pick-up tube
2. Fuel sender
3. Baffle pick-up
The resistance measured between PINK/BLACK
and PINK wires must be in accordance with fuel
level (measured from under the flange) as speci-
fied in the following charts.
RFI, DI and 4-TEC Models
The fuel pick-up system is part of the fuel pump
module mounted inside the fuel reservoir.
The fuel level gauge sender is also mounted on this
module.
TYPICAL FUEL LEVEL GAUGE SENDER MOUNTED ON FUEL
PUMP MODULE
Refer to ENGINE MANAGEMENT for fuel pump
testing. For fuel level sensor, follow procedures
below.
The resistance measured between PINK/BLACK
and PINK wires must be in accordance with fuel
level (measured from under the flange) as speci-
fied in the following charts.
F07H0OA
F01F20A
1
2
3
FUEL LEVEL AND RESISTANCE
(GTI AND GTI LE)
FUEL LEVEL
(mm)
RESISTANCE
()
From 248.9 5 and more 0 + 2.2
From 234.4 to 248.8 5 17.8 2.2
From 200.9 to 234.3 5 27.8 2.2
From 167.4 to 200.8 5 37.8 2.2
From 134.0 to 167.3 5 47.8 2.2
From 100.5 to 133.9 5 57.8 2.2
From 67.0 to 100.4 5 67.8 2.2
From 40.1 to 66.9 5 77.8 2.2
From 0 to 40.0 5 89.8 2.2
F07F09A
SMR2003-038_12_05A.FM 12-05-13
GTI LE RFI Models
RX DI and GTX DI Models
XP DI and GTX 4-TEC Series
All Models
Oil Sensor
The sensor sends the signal to the low-oil level
light in the fuel gauge or the LED in the Information
Center.
1. Oil sensor
The bottom of the sensor has a small reservoir
with two small holes underneath to let the oil en-
ter inside and one at the top to let the air enter
allowing the oil to flow out.
When there is enough oil inside the oil tank (and
therefore in the sensor reservoir), the sensor de-
tects the liquid and the light DOES NOT turn on.
When the oil level goes at critical LOW level inside
the oil tank (and therefore in sensor reservoir), the
sensor detects the absence of liquid and the light
TURNS ON.
To check the oil sensor, unplug its connector and
pull sensor out of oil tank.
Using a multimeter, check the continuity between
the BLUE and BLUE/BLACK terminals.
When sensor is out of oil tank and its reservoir is
empty, resistance must be infinite (open circuit).
NOTE: Wait about 15 - 20 seconds before taking
any reading to give the oil enough time to flow out
or inside sensor reservoir.
RESISTANCE
()
FLOAT HEIGHT
(bottom of float with bottom
of pump module) (mm)
4.8 + 2.2 228 5.0
17.8 2.2 186 5.0
27.8 2.2 164 5.0
37.8 2.2 139 5.0
47.8 2.2 114 5.0
57.8 2.4 86 5.0
67.8 2.8 57 5.0
77.8 3.6 36 5.0
89.8 3.6 16 5.0
RESISTANCE
()
FLOAT HEIGHT
4.8 2.2 228 5.0
17.8 2.2 188 5.0
27.8 2.2 164 5.0
37.8 2.2 139 5.0
47.8 2.2 114 5.0
57.8 2.4 88 5.0
67.8 2.8 57 5.0
77.8 3.6 38 5.0
89.8 3.6 16 5.0
RESISTANCE
()
FLOAT HEIGHT
4.8 2.2 247 5.0
17.8 2.2 207 5.0
27.8 2.2 183 5.0
37.8 2.2 158 5.0
47.8 2.2 133 5.0
57.8 2.4 105 5.0
67.8 2.8 76 5.0
77.8 3.6 55 5.0
89.8 3.6 35.3 5.0
F00H0LA 1
12-05-14 SMR2003-038_12_05A.FM
Soak sensor in oil so that its reservoir fills up. Max-
imum resistance should be approximately 2
(closed circuit).
1. Measure resistance here
2. Sensor reservoir
To Reinstall Sensor:
Remove rubber seal from sensor.
Install seal in oil tank hole.
Push sensor in seal.
Plug connector.
NOTE: This sensor turns the LED to ON if the con-
nector has been forgotten unconnected even when
there is enough oil in tank.
VTS Switch
Some Models
Always confirm first that the fuse is in good con-
dition.
Disconnect BLACK wire, BLUE/WHITE wire and
GREEN/WHITE wire of VTS switch.
Using a multimeter, connect test probes to switch
BLACK and BLUE/WHITE wires; then, connect test
probes to switch BLACK and GREEN/WHITE wires.
Measure resistance; in both test it should be high
when button is released and must be close to zero
when activated.
VTS Motor
Some Models
Always confirm first that the fuse is in good con-
dition.
The fuse is located on the MPEM module.
Motor condition can be checked with a multime-
ter. Install test probes on both RED/PURPLE/
WHITE and ground wires of the 2-circuit connec-
tor housing. Measure resistance, it should be
close to 1.5 ohm.
If motor seems to jam and it has not reached the
end of its stroke, the following test could be per-
formed.
First remove motor, refer to VARIABLE TRIM SYS-
TEM. Then manually rotate worm to verify VTS
system actuating mechanism for free operation.
Connect motor through a 15 A fuse directly to the
battery.
Connect wires one way then reverse polarities to
verify motor rotation in both ways.
If VTS actuating mechanism is correct and the mo-
tor turns freely in both ways, VTS module could be
defective.
If VTS motor does not stop at the end of its stroke
while installed, the motor could be defective.
VTS Control Module
Some Models
It receives its current from the battery. It is protect-
ed by its own 7.5 A fuse, located on the MPEM
module.
Resistance Test
Disconnect BROWN/BLACK wire and BROWN/
WHITE wire of VTS control module.
Connect test probes of a multimeter to BROWN/
BLACK wire and BROWN/WHITE wire of VTS con-
trol module.
Push on VTS switch down position until motor stops.
Read the resistance on the ohmmeter, it should
indicate a resistance of 24 ohms 1%.
Push on VTS switch up position until motor stops.
TEST CONDITION READING ()
Sensor OUT of oil (open circuit)
Sensor soaked IN oil 2 max. (closed circuit)
F03H0BA
1
2
SMR2003-038_12_05A.FM 12-05-15
Read the resistance on the ohmmeter, it should
indicate a resistance of 167 ohms 1%.
NOTE: If the VTS control module passes this resis-
tance test, it doesnt mean it is in perfect condition.
Water Temperature Sensor
Some Models
The water temperature sensor is integrated with
the speed sensor located on the ride plate or tran-
som. As a result, that sensor has 3 wires instead
of 2.
B.U.D.S. can be used to check its operation. Look
in the Monitoring tab.
To check if the water temperature sensor is oper-
ational, select the water temperature mode in the
Information Center.
With a garden hose, spray the speed sensor with
water. The temperature reading on the Information
Center should adjust to the water temperature.
If not, replace the speed sensor.
Exterior Temperature Sensor
Some Models
The temperature sensor is located in the storage
cover.
B.U.D.S. can be used to check the operation. Look
Remove the back panel of the storage cover to
access the temperature sensor.
1. Temperature sensor
To check if the temperature sensor is operational,
select the exterior temperature mode in the Infor-
mation Center.
Use a heat gun to warm up the sensor. The tem-
perature should raise rapidly on the gauge.
If not, replace the temperature sensor.
Compass
Some Models
The compass is located in the storage cover.
B.U.D.S. can be used to check the operation. Look
Remove the back panel of the storage cover to ac-
cess the compass.
1. Compass
RESISTANCE () NOZZLE POSITION
167 1%
24 1%
UP
DOWN
F07H01A
1
F07H02A 1
12-05-16 SMR2003-038_12_05A.FM
Remove the compass from the support.
Change the direction of the compass and keep it
horizontal ( 10). There should be a change of
direction on the Information Center.
NOTE: To check the accuracy of the compass, you
can use a portable compass and point it in the
same direction. Compare the given directions,
they should be the same.
Speedometer
Some Models
TYPICAL
The PURPLE wire is the 12 Vdc power source of
the speedometer.
The BLACK wire is the ground.
The PURPLE/YELLOW wire is the pulse signal
from the speed sensor.
Speed Sensor
Some Models
The speedometer gives a reading through a speed
sensor. Speed sensor is installed on riding plate. It
works with the water flow which turns a magnetic
paddle wheel that triggers an electronic pick-up
that in turn sends a speed signal to the speedom-
eter through the MPEM.
The paddle wheel is protected by the pick-up hous-
ing.
1. Pick-up housing
2. Paddle wheel
To check if the speed sensor is operational, dis-
connect the speed sensor connector housing
from inside bilge.
Using an appropriate terminal remover (Snap-on
TT600-4), remove the PURPLE/YELLOW and
BLACK/ORANGE wires from the tab housing of
the speed sensor.
Reconnect the PURPLE/YELLOW and BLACK/
ORANGE wires in the receptacle housing.
Connect the positive probe of a multimeter to
speed sensor PURPLE/YELLOW wire and the
negative probe to speed sensor BLACK/ORANGE
wire.
Slowly rotate the paddle wheel. Every 1/8 turn, the
observed voltage should fluctuate between 5.5
and 8.5 Vdc.
F07H0LA
2
1
F01H3VA
SMR2003-038_12_05A.FM 12-05-17
Depth Gauge
4-TEC Models
Removal
Remove muffler.
Turn depth gauge counterclockwise and pull it out.
1. Depth gauge
Inspection
Ensure the silicone pad is in good condition. There
must be no air between the bottom of the depth
gauge and the hull. Otherwise, the gauge will not
work.
If silicone pad is damaged, replace it.
Installation
Ensure O-ring is in good condition and in place.
After installation, try pulling the gauge out to en-
sure it is properly locked.
Test run gauge.
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
Nothing is displayed in the
information center
The depth gauge is not activated in the
MPEM.
Activate the depth gauge in Options
under Setting tab in B.U.D.S.
0.0 (ft or m) is displayed all
the time
Connector of the depth gauge is not
connected.
Connect it properly.
There is not 12 V or ground is open at
the depth gauge connector.
Check fuses and wiring harness.
There is a problem with the
communication link wires.
Check WHITE/BLACK and WHITE/RED
wires.
- - - - (ft or m) is displayed
and Sensor is blinking after
self test for 5 seconds
The watercraft is not in water. Launch watercraft in water and recheck.
There is air between the depth gauge
and the hull.
See procedure below.
Depth gauge is defective. Try a new depth gauge.
1 F18H1EA
Subsection 06 (DESS (CARBURETED AND RFI ENGINES))
SMR2003-039_12_06A.FM 12-06-1
DESS (CARBURETED AND RFI
ENGINES) 0
NOTE: For DI and 4-TEC models, refer to ENGINE
MANAGEMENT section.
Carburetor-Equipped Models and 787 RFI
GENERAL
The Digitally Encoded Security System (DESS)
features an anti-start protection against unautho-
rized use of the watercraft.
(MPEM), safety lanyard cap and safety lanyard
switch.
The safety lanyard cap has a magnet and a ROM
chip. The chip has a unique digital code.
The DESS circuitry in the watercraft MPEM is ac-
tivated at the factory. Therefore, a safety lanyard
must be programmed to start the engine.
NOTE: Actually, it is the memory of the MPEM
VCK (P/N 529 035 844) or with the MPEM pro-
grammer (P/N 529 035 878). Refer to the MPM
programmer Guide to program a safety lanyard or
to the Help system in the VCKs B.U.D.S. softw-
ware. For the VCK connections, see below for the
procedures.
The system is quite flexible. Up to eight safety lan-
watercraft MPEM. They can also be erased.
other watercraft equipped with the DESS.
The memory of the MPEM is permanent. If the
The MPEM features a self-diagnostic mode. Refer
to the chart below.
When ordering a new MPEM from the regular
Self-Diagnostic Mode
It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives imme-
diate monitoring. Refer to the following chart.
SIGNAL CAUSE REMEDY
2 short beeps
post).
Safety lanyard is recognized
by the MPEM.
Good contact between safety
lanyard cap and DESS post.
Ignition is authorized, engine can be started normally.
1 long beep
post).
Bad connection between safe-
ty lanyard cap and post.
Remove and reinstall the safety lanyard on the post
until 2 short beeps are heard to indicate the system
is ready to allow engine starting.
Unprogrammed or defective
safety lanyard.
Use the safety lanyard that has been programmed for
the watercraft. If it does not work, check safety lan-
yard condition with the programmer. Replace safety
lanyard if reported defective.
Salt water or dirt in safety
lanyard cap.
Clean safety lanyard cap to remove dirt or salt water.
A 2 seconds beep
every minute intervals
(RFI models).
Fuel tank level is low. Refill.
4 short beeps
every 3 seconds
interval for 2 hours.
Safety lanyard has been left
on its post without starting
engine or after engine was
stopped.
To prevent battery discharge,remove the safety lan-
yard from its post.
Subsection 06 (DESS (CARBURETED AND RFI ENGINES))
12-06-2 SMR2003-039_12_06A.FM
VCK
NOTE: For 787 RFI models refer to ENGINE MAN-
AGEMENT section.
035 844) is the primary tool to gain access to the
MPEM.
B.U.D.S., included in the VCK, is designed to al-
low, among other things, the programming of
safety lanyard(s) and entering customer informa-
tion.
DESS Post Connection
1. 6-pin adapter
2. DESS adapter
RFI Models Through the 4-Pin Connector
1. 6-pin adapter
nication.
used i s properl y sel ected i n MPI under
The MPEM programmer (P/N 529 035 718) is the
alternative tool to gain access to the MPEM.
WARNING
2
F12H0BA
1
TYPE OF
CONNECTION
ADAPTER
TO USE
PROTOCOL
TO CHOOSE
Through DESS post
6-pin and
DESS
DESS
RFI models through
the 4-pin connector
6-pin and
RFI 4-pin
2 F12H0CA 1 3
Section 13 PROPULSION SYSTEM
SMR2003-049_13_01ATOC.FM 13-01-1
TABLE OF CONTENTS 0
JET PUMP.............................................................................................................................. 13-02-1
GENERAL ........................................................................................................................... 13-02-3
JET PUMP INSPECTION ON WATERCRAFT.................................................................... 13-02-3
REMOVAL........................................................................................................................... 13-02-6
DISASSEMBLY................................................................................................................... 13-02-8
CLEANING ......................................................................................................................... 13-02-10
ASSEMBLY......................................................................................................................... 13-02-13
PUMP PRESSURIZATION ................................................................................................. 13-02-20
INSTALLATION.................................................................................................................. 13-02-21
GENERAL ........................................................................................................................... 13-02-24
JET PUMP INSPECTION ON WATERCRAFT.................................................................... 13-02-24
REMOVAL........................................................................................................................... 13-02-25
DISASSEMBLY................................................................................................................... 13-02-28
CLEANING ......................................................................................................................... 13-02-30
ASSEMBLY......................................................................................................................... 13-02-32
PUMP PRESSURIZATION ................................................................................................. 13-02-36
INSTALLATION.................................................................................................................. 13-02-37
DRIVE SYSTEM..................................................................................................................... 13-03-1
GENERAL ........................................................................................................................... 13-03-4
REMOVAL........................................................................................................................... 13-03-4
INSPECTION...................................................................................................................... 13-03-11
ASSEMBLY......................................................................................................................... 13-03-13
INSTALLATION.................................................................................................................. 13-03-14
LUBRICATION.................................................................................................................... 13-03-21
REVERSE SYSTEM................................................................................................................ 13-04-1
DISASSEMBLY................................................................................................................... 13-04-2
INSPECTION...................................................................................................................... 13-04-3
ASSEMBLY ........................................................................................................................ 13-04-3
ADJUSTMENT................................................................................................................... 13-04-4
DISASSEMBLY................................................................................................................... 13-04-7
INSPECTION...................................................................................................................... 13-04-8
ASSEMBLY......................................................................................................................... 13-04-8
ADJUSTMENT................................................................................................................... 13-04-9
13-01-2 SMR2003-049_13_01ATOC.FM
VARIABLE TRIM SYSTEM..................................................................................................... 13-05-1
GENERAL............................................................................................................................ 13-05-3
REMOVAL ........................................................................................................................... 13-05-3
DISASSEMBLY ................................................................................................................... 13-05-4
INSPECTION....................................................................................................................... 13-05-4
ASSEMBLY ......................................................................................................................... 13-05-4
INSTALLATION................................................................................................................... 13-05-5
ADJUSTMENT.................................................................................................................... 13-05-6
Subsection 02 (JET PUMP)
SMR2003-040_13_02A.FM 13-02-1
JET PUMP 0
LRV DI
Loctite
518
F15J03S
31 Nm
(23 lbfft)
38
30
32
33
28
37
24
39
20
1
31
2
3
29
30
25
41
42
23
42
21
22
36
13
26
34
40
11
12
11
10
9
4
20 Nm
(15 lbfft)
Loctite
518
Loctite
243
Synthetic
grease
7.5 Nm
(66 lbfin)
Loctite
518
35
Pipe sealant
3 Nm
(27 lbfin)
Loctite
243
21 Nm
(16 lbfft)
115 Nm
(85 lbfft)
Loctite
243
7 Nm
(62 lbfin)
9 Nm
(80 lbfin)
9 Nm
(80 lbfin)
13-02-2 SMR2003-040_13_02A.FM
All Models except LRV DI and GTX 4-TEC Series
F12J01S
Loctite
518
38
30
32
33
28
37
27
26
24
20
1
31
2
3
29
30
42
42
21
36
34
39
35
40
41
25
16
14
15
19
18
8
4
13
5
13
6
7
17
Loctite
454
6 Nm
(53 lbfin)
Loctite
518
6 Nm
(53 lbfin)
2.5 Nm
(22 lbfin)
2.5 Nm
(22 lbfin)
20 Nm
(15 lbfft)
2.5 Nm
(22 lbfin)
20 Nm
(15 lbfft)
2.5 Nm
(22 lbfin)
Loctite 243
115 Nm
(85 lbfft)
Synthetic
grease
Loctite
518
Loctite
243
Pipe
sealant
3 Nm
(27 lbfin)
20 Nm
(15 lbfft)
Loctite
243
21 Nm
(16 lbfft)
7.5 Nm
(66 lbfin)
31 Nm
(23 lbfft)
SMR2003-040_13_02A.FM 13-02-3
GENERAL
1. Nozzle
2. Venturi
3. Housing
4. Wear ring
5. Impeller
6. Stator
Impeller Identification
To identify the impellers refer to the following il-
lustration and chart.
1. Stamped part number
JET PUMP INSPECTION 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.
A lift kit (P/N 295 100 044) can be used to install
watercraft on a stand.
TYPICAL
1. Lift kit
2. Work stand
F00J0SA
5
2
1
6
3
4
F02J0VA
1
WATERCRAFT
MODEL
IMPELLER
P/N
MATERIAL PITCH
XP DI 271 000 920
Stainless
steel
Progressive
pitch
15 - 21
GTI 271 001 297
Stainless
steel
Progressive
pitch
9 - 20
GTI LE 271 001 297
Stainless
steel
Progressive
pitch
9 - 20
GTX DI 271 001 128
Stainless
steel
Progressive
pitch
15 - 21
LRV DI 271 000 920
Stainless
steel
Progressive
pitch
15 - 21
RX DI 271 000 920
Stainless
steel
Progressive
pitch
15 - 21
F01J42A
1
2
13-02-4 SMR2003-040_13_02A.FM
Impeller Condition
Condition of impeller no. 1, boot no. 2 and ring
no. 3 can be quickly checked from underneath of
the watercraft. Remove grate and look through
water inlet opening.
TYPICAL
1. Inspect impeller and boot
Impeller/Wear Ring Clearance
This clearance is critical for jet pump performance.
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove venturi/
nozzle assembly as described in OIL INSPECTION in
this subsection.
Using a feeler gauge with 30 cm (12 in) blades,
measure clearance between impeller blade tip and
wear ring. Measure each blade at its center. Clear-
ance should not exceed 1.0 mm (.040 in). If clear-
ance is greater, disassemble jet pump and inspect
impeller and wear ring. Renew worn parts.
TYPICAL MEASURING FROM WATER INLET SIDE
1. Feeler gauge
TYPICAL MEASURING FROM VENTURI SIDE
1. Feeler gauge
F01J0DA
1
F01J0EA
1
F01J0FA
1
SMR2003-040_13_02A.FM 13-02-5
Oil Inspection
Remove:
reverse gate cable
VTS rod (if so equippped)
steering cable
screws no. 10 retaining venturi to the housing.
Pull venturi.
Remove plug from cover.
TYPICAL
1. Remove plug
Check oil level, it should be at bottom of hole
threads.
If oil level is low, check impeller shaft housing for
leaks. A pressure test must be performed. See
PUMP PRESSURIZATION in this subsection.
To check oil condition, insert a wire through oil lev-
el hole then withdraw. A whitish oil indicates wa-
ter contamination.
This may involve defective impeller shaft seal
and/or O-ring of housing cover. Jet pump unit should
be overhauled to replace seal.
If everything is correct, apply Loctite pipe sealant
(P/N 293 800 018) on plug threads and reinstall it
on cover. Properly reinstall removed parts.
NOTE: The plug threads are perpendicular to the
impeller shaft.
Oil Replacement
Remove venturi as described in OIL INSPECTION.
Remove 3 screws retaining cover.
TYPICAL
1. Screws
Using a fiber hammer, gently tap cover to release
it from housing cover.
Thoroughly clean reservoir and inside of cover
with a solvent. Check O-ring condition. Replace as
necessary.
Apply a thin layer of Loctite 518 on mating surface
of cover and reinstall it with its O-ring.
Apply Loctite 243 on threads and torque screws to
7 Nm (62 lbfin).
Remove plug from cover.
Pour oil through hole until oil reaches the bottom
of hole threads. Use SEA-DOO JET PUMP SYN-
THETIC OIL (P/N 293 600 011) only. Oil will drain
slowly into center area of housing, wait a few min-
utes and readjust oil level.
CAUTION: This is a synthetic oil. Do not mix
with mineral based oil. Do not mix oil brands.
Apply Loctite pipe sealant (P/N 293 800 018) on
plug threads and reinstall it on cover.
impeller shaft.
F01J5IA
1
F02J0TB 1
13-02-6 SMR2003-040_13_02A.FM
REMOVAL
Reverse Gate (if so equipped)
All Models except LRV DI
To remove reverse gate no. 4, put shift lever in
reverse position.
Unscrew pivot bolt no. 5 retaining connecting rod
no. 6 and pivot support no. 7.
1. Pivot bolt
2. Reverse gate retaining bolt (each side)
LRV DI Models
Put shift lever in reverse position.
Disconnect reverse cable from reverse gate. Re-
move lock nut no. 9 and bolt no. 10 retaining cable
end to cable lever.
1. Bolt
2. Cable end
3. Cable lever
4. Lock nut
Unscrew and remove 2 Allen screws no. 11 retaining
reverse gate to support no. 12 and remove reverse
gate.
Pivot Support
Remove reverse gate.
Unscrew pivot support bolts no. 13.
1. Pivot bolts
2. Pivot support
3. Reverse gate
4. Pivot support bolt
Remove pivot support.
F16J04A 2
1
F07J08B 4 3 2 1
3
1
F16J05B
2 4
SMR2003-040_13_02A.FM 13-02-7
Connecting Rod
Remove:
reverse gate
pivot bolt no. 14.
Withdraw connecting rod.
Pivot Triangle
Remove:
reverse gate
connecting rod
pivot triangle bolts no. 15.
Withdraw pivot triangle no. 16.
Pivot Arm
Remove:
reverse gate
connecting rod
reverse cable
spring no. 17
pivot arm bolts no. 18. Take note of bushing
size for reinstallation.
Withdraw pivot arm no. 19.
1. Pivot bolts (each side)
2. Spring
3. Pivot arm
Nozzle
All Models except LRV DI and XP DI
Disconnect steering cable from jet pump nozzle
no. 20.
Remove:
reverse gate
spring
pivot arm bolts no. 18 retaining pivot arm and
VTS ring (if so equipped) to nozzle.
Remove nozzle.
LRV DI Models
Disconnect steering cable from jet pump nozzle.
Remove 2 retaining screws no. 21, 2 sleeves
no. 22, 2 washers no. 23.
TYPICAL
1. Screw
2. Washers
3. Sleeve
Remove nozzle.
F16J06A 2 3 1
F01J3BE
2
1
2 3
3
13-02-8 SMR2003-040_13_02A.FM
XP DI Models
Disconnect ball joint of VTS link rod.
Loosen 2 screws each side of trim ring.
1. Remove screws
Remove nozzle.
Venturi
Remove:
reverse gate (if so equipped)
nozzle
pivot arm (if so equipped).
Remove 4 retaining screws no. 39 and withdraw
venturi no. 24.
Its possible to remove the venturi without remov-
ing the reverse gate and the nozzle, see the fol-
lowing instructions.
Disconnect:
steering cable
VTS link rod (if so equipped)
reverse cable (if so equipped).
venturi no. 24.
1. Remove screws
Jet Pump Housing
Remove:
nozzle
venturi.
Loosen 4 hexagonal nuts no. 24 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
NOTE: After jet pump removal, if drive shaft re-
mains in the PTO flywheel (except XP), simply pull
it out. If drive shaft is seized in the PTO flywheel,
refer to DRIVE SYSTEM.
DISASSEMBLY
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heat-
ing discoloration, wear pattern, missing plating,
missing or broken needles in needle bearing, wa-
ter 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.
F01J5FA
1
F02J0TA
1
1
SMR2003-040_13_02A.FM 13-02-9
Cover
With pump assembly in horizontal position, remove
3 retaining screws no. 26.
Place container under cover no. 27 to catch oil.
it from jet pump housing.
Impeller
Insert impeller shaft holder (P/N 295 000 082) on
impeller shaft flat end.
Using 2 screws previously removed from venturi,
secure shaft holder to housing.
1. Shaft holder
Install shaft holder in a vice.
1. Shaft holder
Impeller is loosened using impeller remover tool
(P/N 295 000 001).
Insert special tool in impeller splines.
1. Impeller remover tool
Rotate impeller remover tool counterclockwise
and unscrew completely impeller.
CAUTION: Never use any impact wrench to loos-
en impeller.
To remove impeller, apply a rotating movement
and pull at same time. Slide impeller out of hous-
ing. Remove tool from impeller.
Wear Ring
NOTE: On the models with the large pump (947
engines), remove the screws retaining wear ring
in the jet pump housing.
Place jet pump housing in a vise with soft jaws. It
is best to clamp housing using a lower ear.
Cut wear ring at two places.
CAUTION: 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 such as Snap-
on HS3 or equivalent.
F00J07A 1
F00J0HA
1
F01J0TA
F00J08A
1
13-02-10 SMR2003-040_13_02A.FM
TYPICAL
TYPICAL
1. Snap-on HS3
After cutting ring, insert a screwdriver blade be-
tween jet pump housing and ring outside diameter.
Push ring so that it can collapse internally.
Pull ring out.
Impeller Shaft
Remove shaft holder tool.
Remove impeller shaft no. 28 with thrust washer
and thrust bearing.
Seal and Needle Bearing
Remove seal no. 29 and bearings no. 30 at the
same time using bearing/seal remover tool (P/N
295 000 144).
Insert bearing remover then press tool using a ar-
bor press until seal and bearings are out. However,
care should be taken not to damage bearing jour-
nals.
1. Bearing/seal remover tool
NOTE: It is always recommended to renew both
bearings, even if only one bearing needs to be re-
placed.
CLEANING
All Models
Thoroughly clean jet pump housing by applying Loc-
tite Stripper (P/N 293 110 004). Allow it some time
to dissolve the old dried Loctite (10 to 15 minutes).
CAUTION: DO NOT use Loctite Stripper on wear
ring since it will cause irreparable damage to it.
Wipe Loctite Stripper with a clean cloth.
Make sure surface is cleaned and dried of Loctite
Stripper.
Sealant on the jet pump housing can be removed
with a wire brush (disc) mounted on a drill or a
scraper.
Properly clean all threads.
Remove all O-rings and clean parts in a solvent.
F01J0VA
F01J0WA
1
F01J11A
WARNING
Technician should wear gloves when using
this cleaning product.
F00J0MA
1
SMR2003-040_13_02A.FM 13-02-11
Carefully check water passages and oil passages.
Blow low pressure compressed air through them
and make sure they are clear.
TYPICAL
1. Water passages
2. Oil passages
Brush and clean impeller shaft threads, impeller
and drive shaft splines with Pulley Flange Cleaner
(P/N 413 711 809) or equivalent. Free threads and
splines from any residue.
CAUTION: Be careful not to damage impeller
shaft diameter.
PARTS INSPECTION
Impeller
Visually inspect impeller splines. Check for wear or
deformation. Renew parts if damaged.
NOTE: Check also PTO flywheel and drive shaft
condition. Refer to BOTTOM END and DRIVE SYS-
TEM.
Examine impeller in wear ring for distortion.
Check if blade tips are blunted round, chipped or
broken. Such impeller is unbalanced and will vi-
brate and damage wear ring, impeller shaft, shaft
seal or bearings. Renew if damaged.
1. Replaced if blunted round or damaged
Check impeller for cavitation damage, deep scratch-
es or any other damage.
1. Check for cavitation, deep scratches or other damage
Wear Ring
Check wear ring no. 31 for deep scratches, irreg-
ular surface or any apparent damage.
If impeller/wear ring clearance is too large and im-
peller is in good shape, renew wear ring.
F01J13A
1
2
F02J0VB
1
F02J0UA
1
13-02-12 SMR2003-040_13_02A.FM
Needle Bearing and Impeller Shaft
WEAR
Inspect needle bearings no. 30 and their contact
surface. Check for scoring, pitting, chipping or oth-
er evidence of wear.
With your finger nail, feel contact surface of seal.
If any irregular surface is found, renew impeller
shaft no. 28.
Install bearings, then install impeller shaft and ro-
tate it. Make sure it turns smoothly.
RADIAL PLAY
Radial play is critical for jet pump unit life span.
Radial play of impeller shaft is checked with shaft
in housing, without impeller.
Retain housing in a soft jaw vise making sure not
to damage housing lug.
Set a dial gauge and position its tip onto shaft end,
close to end of threads.
Move shaft end up and down. Difference between
highest and lowest dial gauge reading is radial
play.
Maximum permissible radial play is 0.05 mm (.002 in).
TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
2. Measure close to threads at shaft end
To check both bearings, proceed the same way
with other shaft end. Position gauge tip on diam-
eter, close to flats on shaft.
TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
2. Measure close to flats at shaft end
Excessive play can come either from worn bear-
ings or impeller shaft or damaged jet pump hous-
ing bearing surfaces.
Measuring shaft diameter will determine the de-
fective parts.
Using a micrometer, measure diameter on bearing
contact surfaces. Minimum shaft diameter should
be 22.24 mm (.876 in).
1. Inspect for wear at the bearing pilot
2. Radial bearing raceway
NOTE: If shaft is to be replaced, it is recommend-
ed to replace both bearings at the same time. In
addition, it is suggested to replace thrust bearing
and thrust washer.
F01J18A
1
2
F01J19A
1
2
F01J1AA
1
2
SMR2003-040_13_02A.FM 13-02-13
Thrust Washer and Thrust Bearing
Visually inspect thrust washer no. 32, thrust bear-
ing no. 33 and their contact surface. Check for
scoring, pitting, flaking, discoloration or other evi-
dence of wear. For best inspection, use a 7X mag-
nifying glass to check wear pattern.
TYPICAL
1. Worn roller (trunnion worn on end roller)
2. Good roller (cylindrical shape)
3. Look for scoring on retainer
NOTE: When replacing either washer or bearing,
it is recommended to renew both.
Anti-Rattle Pusher
Check for melted plastic around metal pad. If so,
replace it.
Check for excessive wear of pad.
Seal
Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
other damage. Replace after 150 hours even if it
seems good.
ASSEMBLY
Wear Ring
These models are equipped with large pumps. It
is important that the screws retaining wear ring to
housing are installed on this models.
All Models
To install 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.
F01J52A
1
2
3
F08J05A
F08J06A
F08J07A
13-02-14 SMR2003-040_13_02A.FM
Manually engage ring in housing making sure it is
equally inserted all around. Press ring until it seats
into bottom of housing.
1. Seal lip
2. Press wear ring
If a press is not readily available, a piece of wood
such as a 2 4 in 12 in long, can be used.
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.
1. Piece of wood
2. Seal lip facing upward
3. Wear ring
NOTE: Do not forget, install retaining screws on
large pump models.
Seal and Needle Bearing
LRV DI Models
Bearings no. 30 and seal no. 29 will be properly
installed in housing using bearing/seal installer
tool (P/N 295 000 107).
BEARING/SEAL INSTALLER TOOL
1. Seal side
2. Bearing side
Bearing no. 30 and seal no. 29 on impeller side will
be properly installed in housing using bearing/seal
installer tool (P/N 295 000 107).
BEARING/SEAL INSTALLER TOOL
1. Seal side
2. Bearing side
For the bearing on venturi side use inner bearing
installer tool (P/N 529 035 609).
CAUTION: Failure to use this tool will cause ma-
jor damage to the pump.
F01J5DA
1
2
F01J5EA
1
3
2
F01J4KA 2
1
F01J4KA 2
1
F08B01A
SMR2003-040_13_02A.FM 13-02-15
Impeller Side
All Models
Stamped end of bearings (showing identification
markings) must be located toward outside of hous-
ing.
Properly insert bearing on tool. Using an arbor
press only, push tool until tool flange contacts
housing.
1. Stamped end this side
CAUTION: Never hammer the bearing into its
housing.
1. Press on tool until it stops
2. Bearing
CAUTION: These tools have been designed to
properly position bearings and seal, thus pro-
viding space for lubrication purposes. The tool
flanges allow this. If a different pusher type is
being used, components must be properly po-
sitioned as follows.
Bearing on impeller side must be 1.5 to 2.5 mm
(.060 - .100 in) inside reservoir measured from seal
seat. Refer to following illustration.
1. Seal seat
2. Stamped end of bearing
A. 1.5 - 2.5 mm (.060 - .100 in)
Apply Loctite 518 (P/N 293 800 038) to seal hous-
ing, all around outer diameter and on seal seat.
Properly insert seal on tool.
NOTE: Apply synthetic grease on tool to ease seal
insetion.
Install seal with the spring toward the outside.
1. Spring of seal this side
F01J1HA
1
F00J0ZA
1
2
F01J5YA
A
1
2
F01J1KA 1
13-02-16 SMR2003-040_13_02A.FM
CAUTION: Prevent sealant from contacting any
needles of bearing.
Push on tool end with a press until tool flange con-
tacts housing.
Apply synthetic grease (P/N 293 550 010) between
seal lips.
1. Loctite 518 all around and behind
2. Spring of seal lip this side
Venturi Side
LRV DI Models
Use the same procedure than impeller side.
Stamped end of bearings (showing identification
markings) must be located toward outside of hous-
ing.
Properly insert bearing on tool. Using an arbor
press only, push tool until tool flange contacts
housing.
1. Stamped end this side
CAUTION: Never hammer the bearing into its
housing.
CAUTION: These tools have been designed to
properly position bearing, thus providing
space for lubrication purposes. The tool flang-
es allow this. If a different pusher type is being
used, components must be properly posi-
tioned as follows.
F00J0CA
1
F01J1MA
1
2
F01J1HA
1
F16J09A
1
SMR2003-040_13_02A.FM 13-02-17
Bearing on venturi side must be 2 to 4 mm (.080 -
.157 in) inside reservoir measured from thrust
washer seat. Refer to following illustration.
1. Thrust washer seat
2. Stamped end of bearing
A. 2 - 4 mm (.080 - .157 in)
Thrust Washer
Position jet pump housing with the stator vanes
on top.
Insert thrust washer no. 32 in the stator seat.
1. Thrust washer properly installed in stator seat
Thrust Bearing
Apply SEA-DOO JET PUMP SYNTHETIC OIL (P/N
293 600 011) on both sides of thrust bearing.
Position thrust bearing no. 33 on thrust washer
no. 32.
1. Thrust bearing on top of thrust washer
Impeller Shaft
To prevent seal lip damage when inserting impel-
ler shaft, use impeller shaft guide (P/N 295 000
002).
Insert tool onto shaft end then carefully install
shaft in jet pump housing.
1. Impeller shaft
2. Impeller shaft guide
F01J5YB
A
1
2
F00J0DA 1
F00J0EA 1
F01J1OA
F00J0FA 1 2
13-02-18 SMR2003-040_13_02A.FM
NOTE: If jet pump housing rest against a table,
raise it slightly to allow complete shaft insertion
with the shaft guide.
Remove shaft guide.
Impeller
Apply anti-seize (P/N 293 800 070) on threads of im-
peller shaft no. 28.
Apply Loctite 243 (blue) to shaft threads.
1. Apply Loctite 243 (blue) on threads
Using 2 screws previously removed from venturi,
secure impeller shaft holder tool (P/N 295 000 082)
to housing.
Install shaft holder tool in a vice.
1. Impeller shaft holder secured in a vice
To ease impeller installation, apply BOMBARDIER
LUBE lubricant on wear ring.
Insert impeller into wear ring. Manually rotate im-
peller and push so that it slides on impeller shaft
threads. Carefully engage threads making sure
they are well aligned.
Install impeller remover/ installer tool into impeller
splines and tighten.
1. Impeller remover/installer tool
CAUTION: Make sure thrust washer and bear-
ing are not wedged in shaft groove. To check,
manually pull and push jet pump housing,
some axial play must be felt.
Torque impeller to 115 Nm (85 lbfft) then remove
tools.
CAUTION: Never use any impact wrench to
tighten impeller.
Apply synthetic grease (P/N 293 550 010) on im-
peller splines.
Insert a new boot no. 2 and ring no. 3 to impeller.
1. Boot and ring
F00J0GA 1
F00J0HA
1
F00J08A
1
F00J10A 1
SMR2003-040_13_02A.FM 13-02-19
Anti-Rattle System
Install spring no. 34 on slider no. 35.
1. Spring
2. Slider
Insert slider and spring into cover.
NOTE: Align the longer slider tab with hole.
Apply synthetic grease in the center hole of the
cover.
Install pusher no. 36 into cover. Place the flat side
in front of slider tab.
Install O-ring no. 37 to cover. Apply Loctite 518 on
O-ring.
Install cover to jet pump housing making sure to
properly position filler plug on top side. Do not
torque yet, keep a small gap.
Insert a pencil or any other plastic tool in the hole
and push on the slider tab.
CAUTION: Do not use a metal tool to push the
tab. It is possible to damage the inner threads.
Hold tab and torque screws.
Remove pencil or tool to release locking mecha-
nism.
Check if the mechanism worked properly. Push
tab with the pencil or tool; if there is a small play
the installation is correct. If not, redo the proce-
dure.
Verify if the impeller is rotating freely.
Add oil.
Oil Fill
NOTE: It is highly recommended to perform a leak-
age test prior adding the oil. See PUMP PRESSUR-
IZATION in this subsection.
Place housing horizontally as in its operating posi-
tion so that filler plug is located on top. Remove
filler plug from cover. Pour SEA-DOO JET PUMP
SYNTHETIC OIL (P/N 293 600 011) in reservoir un-
til oil comes level with bottom of hole. Let oil drain
into housing and after a few minutes add more oil
until it is level with bottom of filler hole.
F00J0VA 2 1
F00J0WA
F00J0XA
13-02-20 SMR2003-040_13_02A.FM
CAUTION: This is a synthetic oil. Do not mix
with mineral based oil. Do not mix oil brands.
NOTE: When filling reservoir, oil must be poured
into cover quite slowly to allow complete housing
fill.
Apply Loctite pipe sealant (P/N 293 800 018) on
plug threads and reinstall it on cover.
impeller shaft.
TYPICAL
1. Pour oil slowly until it is level with bottom of filler hole
Venturi
If needed, install new O-rings no. 38 around bailer
passages.
1. O-rings
Apply Loctite 518 (Gasket Eliminator) on mating
surface.
Position venturi no. 24 with bailer passages on
top.
Apply Loctite 243 (blue) on threads of screws
no. 39.
Install screws no. 39, lock washers and flat wash-
ers then torque to 21 Nm (16 lbfft).
O-Rings
Install O-rings no. 38 around bailer passages or make
sure they are in place if they were not removed.
PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a
pressure test should be done to check for leakage.
Proceed as follows:
Remove drain plug from cover.
Apply Loctite Pipe sealant on threads of fitting
tool (P/N 295 000 086) then secure on cover.
to fitting.
Pressurize pump to a maximum of 70 kPa (10 PSI).
F00J0JA 1
F00J0KA 1
F02J0TA
1
1
SMR2003-040_13_02A.FM 13-02-21
Pump must maintain this pressure for at least
10 minutes.
CAUTION: Repair any leak, failure to correct a
leak will lead to premature wear of pump com-
ponents.
NOTE: If there is a pressure drop spray soapy wa-
ter 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. If jet pump
has been overhauled, the impeller shaft seal
no. 22 may be leaking; Add a small quantity of
SEA-DOO JET PUMP SYNTHETIC OIL to wet the
oil seal. Let soak and recheck.
Disconnect pump gauge tester and remove fit-
ting.
Check oil level. Refill as necessary.
Apply Loctite Pipe sealant (P/N 293 800 018) to
threads of filler plug then secure it in cover.
impeller shaft.
INSTALLATION
Jet Pump Housing
Generously apply synthetic grease on drive shaft
splines.
Make sure rubber damper is on drive shaft end.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller.
CAUTION: Some watercraft require a shim be-
tween hull and pump; if shim has been re-
moved at pump removal, be sure to reinstall it,
otherwise engine alignment will be altered.
Apply Loctite 243 (blue) on stud threads of jet
pump housing.
Install flat washers no. 40, lock washers no. 41
and nuts no. 25. Tighten nuts of jet pump housing
in a criss-cross sequence and torque to 31 Nm
(23 lbfft).
NOTE: Sl i ght l y l ubr i cat e wear r i ng wi t h
BOMBARDIER LUBE lubricant to minimize friction
during initial start.
Nozzle
LRV DI Models
Insert bushings no. 42 in nozzle no. 20, position-
ing their flanges from inside of nozzle.
Insert sleeves no. 22 in bushings no. 42.
Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on
screw threads (or use new screws with pre-ap-
plied threadlocker). Install screws no. 21 and wash-
ers no. 23 then torque to 20 Nm (15 lbfft).
F00J0LA
13-02-22 SMR2003-040_13_02A.FM
TYPICAL
1. Washers
Pivot Triangle (if so equipped)
Install head bolts toward inside.
NOTE: Make sure the pivot triangle turn freely.
Reverse Gate (if so equipped)
Install reverse gate with spacer and washer.
Torque to 20 Nm (15 lbfft).
NOTE: When installing the reverse gate, pay at-
tention to position its lever behind the reverse
gate support stopper.
1. Stopper
XP DI Models
Install nozzle/trim ring assembly.
Torque screws to 20 Nm (15 lbfft).
NOTE: Trim ring has a tight fit; to install, insert
both sides at the same time, taking care not to
break plastic bushings. Carefully use a plastic tip
hammer if necessary. Make sure steering arm of
jet pump is on right side and trim arm is above
venturi.
Steering Cable
Refer to section, STEERING SYSTEM.
Trim System
Refer to VARIABLE TRIM SYSTEM.
Reverse Cable
Refer to REVERSE SYSTEM.
WARNING
Screws must be torqued as specified.
F01J3BA
1
2
1
F07J07A
1
F01J5FA
1
SMR2003-040_13_02A.FM 13-02-23
GTX 4-TEC Series Models
F18J1WS
Loctite 454
Primer N
Pipe sealant
592
Loctite
243
21 Nm
(16 lbfft)
7.5 Nm
(66 lbfin)
3
1
31
40
41
25
38
44
30
46
32
33
28
37
13
26
39
42
20
43
21
24 Nm
(18 lbfft)
23
22
2.5 Nm
(22 lbfin)
15
20 Nm
(15 lbfft)
2.5 Nm
(22 lbfin)
19
14
16
18
17
6
7
13
13
5
4
8
Loctite
518
6 Nm
(53 lbfin)
2
31 Nm
(23 lbfft)
34
35
36
Alsaco
grease
45
24
Loctite
767
49
48
47
GTX 4-TEC
Supercharged
models only
13-02-24 SMR2003-040_13_02A.FM
GENERAL
TYPICAL
1. Nozzle
2. Venturi
3. Housing
4. Wear ring
5. Impeller
6. Stator
Cleanness Requirements
Hands, tools, bench, rags must be clean before
pump disassembly.
CAUTION: Pump grease tube must be opened
at very last moment to avoid contamination.
Impeller Identification
To identify the impellers refer to the following il-
lustration and chart.
1. Stamped part number
JET PUMP INSPECTION ON
WATERCRAFT
To work on watercraft, securely install it on a
stand. Thus, if access is needed to water inlet ar-
ea, it will be easy to slide underneath watercraft.
A lift kit can be used to install watercraft on a stand.
TYPICAL
1. Lift kit
2. Work stand
Impeller Condition
Condition of impeller no. 1, boot no. 2 and ring
no. 3 can be quickly checked from underneath of
the watercraft. Remove grate and look through
water inlet opening.
TYPICAL
1. Inspect impeller and boot
F00J0SA
5
2
1
6
3
4
F02J0VA
1
WATERCRAFT
MODEL
IMPELLER
P/N
MATERIAL PITCH
GTX 4-TEC 271 001 386
Stainless
steel
Progressive
pitch
13 - 23
F01J42A
1
2
F01J0DA
1
SMR2003-040_13_02A.FM 13-02-25
Impeller/Wear Ring Clearance
This clearance is critical for jet pump performance.
Clearance can be checked from water inlet open-
ing or from venturi side. However, the last method
requires more work.
To check clearance from water inlet side, remove
inlet grate.
To check clearance from venturi side, remove ven-
turi/nozzle assembly.
Using a feeler gauge with 30 cm (12 in) blades,
measure clearance between impeller blade tip and
wear ring. Measure each blade at its center. For
GTX 4-TEC clearance should not exceed 0.35 mm
(.014 in). If clearance is greater, disassemble jet
pump and inspect impeller and wear ring. Renew
worn parts.
TYPICAL MEASURING FROM WATER INLET SIDE
1. Feeler gauge
TYPICAL MEASURING FROM VENTURI SIDE
1. Feeler gauge
REMOVAL
Pump Assembly
Remove OPAS U lever screw, washer and
bushings from nozzle.
TYPICAL
1. U lever screw
Disconnect steering and reverse cables.
Disconnect OPAS hose from top of pump.
Remove 4 pump retaining nuts.
F01J0EA
1
F01J0FA
1
1 F18J0DA
13-02-26 SMR2003-040_13_02A.FM
Supercharged Models Only
Remove the 2 bracket retaining bolts to remove
braket no. 47.
1. Bolts to be removed
All Models
Pull out pump.
Reverse Gate
To remove reverse gate no. 4, put shift lever in
reverse position.
Unscrew pivot bolt no. 5.
1. Pivot bolt no. 5
2. Screw no. 8
Remove both reverse gate screws no. 8.
Pivot Support
Unscrew pivot support bolts no. 13.
1. Pivot bolt
2. Pivot support
3. Reverse gate
4. Pivot support bolt no. 13
Withdraw pivot support.
Connecting Rod
Remove:
reverse gate
pivot bolt no. 14.
Withdraw connecting rod.
Pivot Triangle
Remove:
reverse gate
connecting rod
pivot triangle bolts no. 15.
Withdraw pivot triangle no. 16.
Pivot Arm
Position shift lever in forward.
Remove:
reverse gate
connecting rod
spring no. 17
reverse cable
1
F18J1XA
F16J04A 2
1
1
F18J0JA
2
3 4
SMR2003-040_13_02A.FM 13-02-27
pivot arm bolts no. 18. Take note of bushing
size for reinstallation.
Withdraw pivot arm no. 19.
1. Pivot bolts (each side)
2. Spring
3. Pivot arm
Nozzle
Remove OPAS U lever screw, washer and
bushings from nozzle.
TYPICAL
1. U lever screw
Remove 2 retaining screws no. 21, 2 sleeves
no. 22, 2 washers no. 23.
Remove nozzle.
Venturi
Remove:
reverse gate
nozzle
bracket no. 47
pivot arm.
Unplug OPAS hose from plastic elbow.
venturi no. 24.
Its possible to remove the venturi without remov-
ing the reverse gate and the nozzle, see the fol-
lowing instructions.
Disconnect:
steering cable
1. Steering cable
OPAS hose
reverse cable.
2 F18J1AA 3 1
1 F18J0DA
1
F18J0KA
13-02-28 SMR2003-040_13_02A.FM
venturi no. 24.
TYPICAL
1. Remove screws
Jet Pump Housing
Remove pump as an assembly or remove the fol-
lowing:
nozzle
venturi.
Loosen 4 hexagonal nuts no. 24 and remove flat
washers and lock washers from jet pump housing.
Remove jet pump with a wiggle movement.
CAUTION: When removing pump unit, a shim
could have been installed between hull and
pump housing. Be sure to reinstall it otherwise
engine and jet pump alignment will be altered.
NOTE: After jet pump removal, if drive shaft re-
mains in the PTO flywheel, simply pull it out. If
drive shaft is seized in the PTO flywheel, refer to
DRIVE SYSTEM.
DISASSEMBLY
NOTE: Whenever removing a part, visually check
for damage such as: corrosion, crack, split, break,
porosity, cavitation, deformation, distortion, heat-
ing discoloration, wear pattern, missing plating,
missing or broken balls in ball bearing, water dam-
age 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.
Cover
With pump housing in vertical position, remove 3
retaining screws no. 26.
it from jet pump housing. Use flat screwdriver to
remove cap.
Check for presence of water in cone and bearing.
If so, replace oil seal no. 35 and sleeve no. 30.
F02J0TA
1
1
F18J0LA
F18J0MA
SMR2003-040_13_02A.FM 13-02-29
Remove both O-rings no. 37 and circlip.
Impeller
Remove ring no. 3, impeller boot no. 2. Replace
them if damaged.
Mount impeller remover/installer (P/N 529 035
820) in a vise.
Install pump over this tool.
Using a 12 mm Allen key, unscrew the impeller.
NOTE: It may be needed to heat the impeller to
break Loctite bond.
loosen impeller.
To remove impeller, apply a rotating movement
and pull at same time. Slide impeller out of hous-
ing.
Pull pump housing out.
Remove circlip no. 49, seal no. 34 and spacer
no. 48.
F18J0NA
F18J0OA
529 035 820
F18J0PA
F18J0QA
F18J0RA
13-02-30 SMR2003-040_13_02A.FM
Use the impeller shaft pusher (P/N 529 035 818)
to press out impeller shaft no. 28 of pump hous-
ing. Bearing no. 33, shaft sleeve no. 30, O-ring
no. 46 and spacer no. 32 will come out with the
impeller shaft.
CAUTION: Bearing inner race being in 2 parts,
bearing may fall apart during removal.
Use the seal/bearing pusher (P/N 529 035 819) to
press out bearing no. 33 from impeller shaft.
From the outlet side of pump, use the seal/bearing
pusher (P/N 529 035 819) to press out the oil seal
no. 35.
Remove large O-ring no. 36 from pump housing.
Wear Ring
Remove the screws retaining wear ring in the jet
pump housing.
Place jet pump housing in a vise with soft jaws. It
is best to clamp housing using a lower ear.
Cut wear ring at two places.
CAUTION: 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 such as
Snap-on HS3 or equivalent.
After cutting ring, insert a screwdriver blade be-
tween jet pump housing and ring outside diame-
ter.
Push ring so that it can collapse internally.
Pull ring out.
CLEANING
Thoroughly clean jet pump housing by applying Loc-
tite Stripper (P/N 293 110 004). Allow it some time
to dissolve the old dried Loctite (10 to 15 minutes).
529 035 818
F18J0UA
529 035 819 F18J0VA
WARNING
Technician should wear gloves when using
this cleaning product.
529 035 819
F18J0WA
SMR2003-040_13_02A.FM 13-02-31
CAUTION: DO NOT use Loctite Stripper on
wear ring since it will cause irreparable dam-
age to it.
Wipe Loctite Stripper with a clean cloth.
Make sure surface is cleaned and dried of Loctite
Stripper.
Sealant on the jet pump housing can be removed
with a wire brush (disc) mounted on a drill or a
scraper.
Properly clean all threads.
Remove all O-rings and clean parts in a solvent.
Carefully check water passages. Blow low pres-
sure compressed air through them and make sure
they are clear.
1. Water passages
Brush and clean impeller shaft threads, impeller
and drive shaft splines with Pulley flange cleaner
(P/N 413 711 809) or equivalent. Free threads and
splines from any residue.
PARTS INSPECTION
Impeller
Visually inspect impeller splines. Check for wear
or deformation. Renew parts if damaged.
NOTE: Check also PTO flywheel and drive shaft
condition. Refer to BOTTOM END and DRIVE
SYSTEM.
Examine impeller in wear ring for distortion.
Check if blade tips are blunted round, chipped or
broken. Such impeller is unbalanced and will vi-
brate and damage wear ring, impeller shaft, shaft
seal or bearings. Renew if damaged.
1. Replaced if blunted round or damaged
Check impeller for cavitation damage, deep
scratches or any other damage.
1. Check for cavitation, deep scratches or other damage
Wear Ring
Check wear ring no. 31 for deep scratches, irreg-
ular surface or any apparent damage.
If impeller/wear ring clearance is too large and im-
peller is in good shape, renew wear ring.
1
F18J0XA
1
F18J1BA
1
F18J1CA
13-02-32 SMR2003-040_13_02A.FM
Ball Bearing and Impeller Shaft
WEAR
IMPORTANT: Make sure to reassemble ball cage,
bearing inner and outer races to their original po-
sition.
Inspect ball bearing no. 33. Check for corrosion,
scoring, pitting, chipping or other evidence of
wear.
With your finger nail, feel contact surface of
sleeve. If any irregular surface is found, renew
sleeve no. 30 and seal.
Install bearing, then install impeller shaft and ro-
tate it. Make sure it turns smoothly.
RADIAL PLAY
Radial play is critical for jet pump unit life span.
Radial play of impeller shaft is checked with shaft
in housing, with impeller.
Retain housing in a soft jaw vise making sure not
to damage housing lug.
Set a dial gauge and position its tip onto metal end,
close to end of threads.
Move shaft end up and down. Difference between
highest and lowest dial gauge reading is radial play.
Maximum permissible radial play is 0.75 mm (.029 in).
MEASURING IMPELLER SHAFT RADIAL PLAY
1. Dial gauge
2. Measure close to threads at shaft end
Excessive play can come either from worn bearing
or damaged jet pump housing bearing surface.
Seal
Carefully inspect seal lips. Make sure that lips are
not worn, distorted, cracked or show signs of any
other damage. Replace after 100 hours.
Bearing
Replace bearing whenever the marks of corrosion
and presence of water is found.
OPAS Filter
OPAS filter is part of plastic elbow no. 45. Check
for cleanness. Replace or clean it as necessary.
ASSEMBLY
Hands, tools, bench, rags must be clean before
pump disassembly.
CAUTION: Pump grease tube must be opened
at very last moment to avoid contamination.
Plastic Elbow
Install plastic elbow no. 45 at 20 angle to the
right.
It may exceed inside housing by 1.0 mm (.039 in).
It may be positioned up to 2.0 mm (.078 in) from
housing edge.
A. 20
B. 2.0 mm (.078 in)
C. 1.0 mm (.039 in)
1 F18J1DA 2
A
F18J0EA
B
C
SMR2003-040_13_02A.FM 13-02-33
Wear Ring
This model is equipped with large pump. It is im-
portant that the screws retaining wear ring to
housing are installed on this model.
To install 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.
equally inserted all around. Press ring until it seats
into bottom of housing.
1. Seal lip
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.
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.
1. Piece of wood
2. Seal lip facing upward
3. Wear ring
NOTE: Do not forget, install two retaining screws
on tops of the large pump models.
F08J06A
F08J07A
F01J5DA
1
2
F01J5EA
1
3
2
13-02-34 SMR2003-040_13_02A.FM
Bearing
Using the seal/bearing pusher (P/N 529 035 819)
press the bearing no. 33 by its inner race on the
impeller shaft no. 28.
Be careful when removing the plastic retainer
from the bearing no. 33 to avoid the inner races
from falling apart. Make sure to reassemble bear-
ing parts to their original position.
The bearing no. 33 can be installed either side.
Install spacer no. 32 on shaft no. 28.
Install O-ring no. 46 in sleeve no. 30.
1. O-ring
Coat shaft surface with jet pump bearing grease
(P/N 293 550 032) then, install sleeve no. 30 on
impeller shaft no. 28.
From the outlet side of pump, press impeller shaft
assembly into housing using shaft pusher (P/N
529 035 818).
Install circlip and O-rings no. 37.
Apply 10 cc of jet pump bearing grease (P/N 293
550 032) on bearing.
529 035 819
F18J0YA
1
F18J0ZA
F18J10A
529 035 818
F18J11A
SMR2003-040_13_02A.FM 13-02-35
Press oil seal no. 35 using seal/bearing pusher
(P/N 529 035 819) until tool bottoms. Make sure
seal lips are facing up.
1. Lips facing up
On the outlet side, install 2 O-rings no. 37 in their
respective groove.
Before installing any other parts. pump can be
pressurized to insure proper seal installation. See
PUMP PRESSURIZATION below.
On the impeller side, install spacer no. 48 and seal
no. 34. While installing make sure seal lips are fac-
ing up. Install circlip no. 49.
Apply Loctite 767 on impeller shaft.
Apply BOMBARDIER Lube on the wear ring sur-
face. Start screwing the impeller on its shaft. If
impeller is too tight, use impeller tool to turn im-
peller to machine wear ring before installing on ve-
hicle. Make sure to turn it smooth enough so that
engine starter should turn it.
Mount impeller remover/installer (P/N 529 035
820) in a vise.
Install partially screwed impeller on it.
Use a 12 mm Allen key to torque impeller shaft to
Torque impeller to 125 Nm (92 lbfft) then re-
move tool.
tighten impeller shaft.
Apply 50 cc of jet pump bearing grease (P/N 293
550 032) in the impeller shaft area.
TYPICAL
Apply another 50 cc of jet pump bearing grease
(P/N 293 550 032) in the impeller cover.
F18J12A
1
F18J13A
529 035 819
F18J14A
F18J17A
13-02-36 SMR2003-040_13_02A.FM
TYPICAL
Install impeller cover with new self-locking
screws. Torque to 7 Nm (62 lbfin).
Venturi
If needed, install new O-rings no. 38 around bailer
passages.
1. O-rings
Position venturi no. 24 with bailer passages on
top.
Apply Loctite 243 (blue) on threads of screws
no. 39.
Install screws no. 39, lock washers and flat wash-
ers then torque to 21 Nm (16 lbfft).
O-Rings
Install O-rings no. 38 around bailer passages or
make sure they are in place if they were not re-
moved.
PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a
pressure test should be done to check for leakage.
Proceed as follows:
Remove impeller cover no. 13. Install pressure
cap (P/N 529 035 843) on pump housing.
to fitting.
Pressurize pump to a maximum of 70 kPa (10 PSI).
Pump must maintain this pressure for at least 5
minutes.
F18J18A
F00J0KA 1
F02J0TA
1
1
529 035 843
F18J19A
SMR2003-040_13_02A.FM 13-02-37
CAUTION: Repair any leak, failure to correct a
leak will lead to premature wear of pump com-
ponents.
NOTE: If there is a pressure drop spray soapy wa-
ter 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. There may
be 2 or 3 bubbles coming out from sleeve no. 30/
seal area. This small leak is acceptable. Leaks from
other areas must be repaired.
Disconnect pump gauge tester and remove
pressure cap.
Reinstall impeller cover no. 13 with 3 new self-
locking screws.
INSTALLATION
Jet Pump Housing
Make sure that rubber (yellow colored for all mod-
els except for Supercharged models which are
red) covered reducer no. 44 is installed as shown.
CAUTION: Misinstallation can cause overheat-
ing and damage to exhaust system.
1. Black rubber covered reducer
Generously apply synthetic grease on drive shaft
splines.
Make sure rubber damper is on drive shaft PTO
end.
Install jet pump. If necessary, wiggle jet pump to
engage drive shaft splines in impeller.
CAUTION: Some watercraft require a shim be-
tween hull and pump; if shim has been re-
moved at pump removal, be sure to reinstall it,
otherwise engine alignment will be altered.
Apply Loctite 243 (blue) on stud threads of jet
pump housing.
Install flat washers no. 40, lock washers no. 41
and nuts no. 25. Tighten nuts of jet pump housing
as per the following sequence.
From 1 to 2: 16 Nm (12 lbfft)
NOTE: Slightly lubricate wear ring with BOMBAR-
DIER LUBE lubricant to minimize friction during
initial start.
1
F18J0IA
F18J1YA
3 1 5
6 2
4
F18J1ZA
1 2
4 3
13-02-38 SMR2003-040_13_02A.FM
Nozzle
Insert bushing no. 42 in nozzle no. 20.
Insert bushing no. 43 in nozzle no. 20 with its off-
set pointing rearward.
1. Bushing offset
Position their flanges from inside of nozzle.
Insert sleeves no. 22 in bushings no. 42 and
no. 43.
Install nozzle on venturi no. 24; position its steer-
ing arm on RH side. Apply Loctite 243 (blue) on
screw threads (or use new self-locking screws).
Install screws no. 21 and washer no. 23 then
OPAS
Reconnect OPAS hose. Torque clamp screw to 1.7
Nm (15 lbfin).
Fasten OPAS U lever to nozzle. Apply Loctite
243 (blue) on screw threads (or use new self-lock-
ing screws). Torque screw to 20 Nm (15 lbfft).
Pivot Triangle
Install head bolts toward inside.
NOTE: Make sure the pivot triangle turn freely.
Reverse Gate
Install reverse gate with spacer and washer.
Torque to 20 Nm (15 lbfft).
NOTE: When installing the reverse gate, pay at-
tention to position its lever behind the reverse
gate support stopper.
1. Stopper
Steering Cable
Refer to section, STEERING SYSTEM.
Reverse Cable
Refer to REVERSE SYSTEM.
WARNING
Screws must be torqued as specified.
1
F18J0GA
F07J07A
1
Subsection 03 (DRIVE SYSTEM)
SMR2003-041_13_03A.FM 13-03-1
DRIVE SYSTEM 0
All Models except XP DI and 4-TEC Models
F02I09S
2
3
4
5
6
8
7
9
2 Nm
(18 lbfin)
10
11
13
Synthetic
grease
12
Synthetic
grease
13
2 Nm
(18 lbfin)
13-03-2 SMR2003-041_13_03A.FM
XP DI Models
F08J0CS
Loctite
243
1
20
23
22
24
19
18
22 Nm
(16 lbfft)
Loctite
243
22 Nm
(16 lbfft)
Loctite
271
Loctite
518
Synthetic
grease
23
15
17
16
15
14
Loctite
518
21
10 Nm
(89 lbfin)
5
6
8
9
10
7
11
12
13
Synthetic
grease
Synthetic
grease
Right Stuff
sealant
31 Nm
(23 lbfft)
Right Stuff
sealant
Loctite
518
Loctite 243
31 Nm
(23 lbfft)
Loctite
243
Synthetic
grease
Synthetic
grease
Loctite
243
22 Nm
(16 lbfft)
2 Nm
(18 lbfin)
28
27
30
31
32
29
SMR2003-041_13_03A.FM 13-03-3
GTX 4-TEC Models
F18I0MS
5
6
7
8
9
10
11
25
26
12
Penzoil Marine
Z-M corrosion
protectant
Penzoil Marine
Z-M corrosion
protectant
13-03-4 SMR2003-041_13_03A.FM
GENERAL
Jet pump must be removed to replace any com-
ponents of the drive system. Refer to JET PUMP
for removal procedure.
REMOVAL
PTO Flywheel Guard
Remove seat(s).
Remove vent tube support or seat support.
Remove plastic wing nuts retaining PTO flywheel
guard no. 1 to engine support.
Detach PTO flywheel guard from engine and with-
draw from bilge.
XP DI Models
Remove storage basket.
Remove vent tubes from PTO flywheel guard.
Large Clamp
Unfasten large clamp of PTO flywheel boot no. 3
as follows:
Use pliers (P/N 295 000 069).
Insert pointed tips of pliers in closing hooks.
TYPICAL
1. Closing hooks
Squeeze pliers to draw hooks together and dis-
engage windows from locking hooks.
TYPICAL
1. Locking hooks
Small Clamp
Unfasten small clamp of PTO flywheel boot as fol-
lows:
F01J0GA
1
F01J2AA
1
F01J29A
SMR2003-041_13_03A.FM 13-03-5
Use pliers (P/N 295 000 054).
To open clamp, place flat side of plier on clamp
embossment, squeeze and twist plier.
Circlip and Floating Ring
NOTE: On XP DI models, open rear access cover
to reach boot no. 10 and floating ring no. 6.
Hold floating ring no. 6 and compress boot no. 10;
then, pull out circlip no. 5 from drive shaft groove.
TYPICAL
1. Push floating ring
2. Remove circlip
4-TEC Models
NOTE: When drive shaft will be removed, some
oil will flow out. To prevent it, start engine, run at
4000 RPM for 10 seconds and stop engine at this
RPM. This will move oil out of PTO housing into
oil tank. If engine cannot be started, refer to the
procedure in PTO HOUSING/MAGNETO section
and look for PTO HOUSING REMOVAL.
Remove seat.
Detach coolant expansion reservoir from vent
tube support then move away.
1. Detach expansion reservoir
2. Remove vent tube support
Detach vent tube.
Remove supercharger. Refer to INTAKE SYSTEM
in ENGINE SECTION.
All 4-TEC Models
Floating Ring and PTO Seal
CAUTION: Strictly follow this procedure other-
wise damage to component might occur. Lift
splash guard to expose PTO seal assembly. In-
stall PTO seal support tool (P/N 529 035 842) on
bottom of PTO seal assembly as shown.
F01B1TA
F02J0PA
F06I06A
1 2
2
F18L1GB
1
13-03-6 SMR2003-041_13_03A.FM
1. PTO seal support tool
1. Insert in groove of PTO seal assembly
Remove jet pump. Refer to JET PUMP section.
Install drive shaft holder (P/N 529 035 871) on
pump support as shown.
NOTE: This is necessary so the drive shaft cannot
move rearwards when using the drive shaft/float-
ing ring tool.
1. Drive shaft holder
Disconnect EGT sensor to make room.
For the following operations, use the drive
shaft/floating ring tool (P/N 529 035 841).
NOTE: Note that there is a large opening and a
small opening on the tool. Depending on the step
involved in the procedure, it is sometimes re-
quired to reverse its installation position.
DRIVE SHAFT/FLOATING RING TOOL
1. Small opening
2. Large opening
F18B01A
1
F18I04A
1
F18B02A
1
F18B03A
F18B04B 1 2
SMR2003-041_13_03A.FM 13-03-7
Install tool as shown.
1. Largest opening on through-hull fitting side
1. Largest opening here
2. Floating ring
Turn screw clockwise so that the tool pushes the
floating ring rearwards to expose the c-clip. Do not
remove clip at this time.
NOTE: This step is done to ensure floating ring is
free and not stuck on the drive shaft.
Remove drive shaft/floating ring tool and drive
shaft holder.
Reinstall drive shaft/floating ring tool as shown.
1. Largest opening on PTO seal side
A. 18 mm (.71 in)
2. Tell tale groove
3. Lubricate O-rings contact area
1 F18I0NA
F18I06B
2 1
1 F18I0OA
1
F18I0PA
2
3
A
13-03-8 SMR2003-041_13_03A.FM
Turn screw clockwise so that the tool pushes the
PTO seal forward and the drive shaft to the rear to
expose the O-rings contact area. Continue to pull
drive shaft out until there is a distance of 18 mm
(.71 in) between the tell tale groove and the tool
edge. Lubricate O-ri ngs contact area wi th
BOMBARDIER LUBE (P/N 293 600 016).
NOTE: This is necessary to ease drive shaft re-
moval later in this procedure.
Remove drive shaft/floating ring tool and PTO seal
support.
Reinstall drive shaft holder tool.
Reinstall drive shaft/floating ring tool as shown.
Push floating ring rearwards to expose C-clip and
remove it.
1. Largest opening on PTO seal side
2. Remove C-clip
Remove drive shaft holder tool then drive shaft/
floating ring tool.
NOTE: Use this sequence to minimize the amount
of movement the drive will slide back into PTO seal
assembly.
Drive Shaft
Simply pull out drive shaft.
All Models except GTX DI, XP DI and 4-TEC
Models
NOTE: If the drive shaft is jammed into PTO fly-
wheel, make the following tool and use it in con-
junction with the jet pump housing remover (P/N
295 000 113) to withdraw drive shaft.
Raw Material:
1 aluminum alloy square of 51 mm (2 in) x 305 mm
(12 in).
2 aluminum rods of 28.5 mm (1-1/8 in) dia. x
30 mm (1-3/16 in).
F18B03A
1 F18I0OA
2
F18I0BA
1
SMR2003-041_13_03A.FM 13-03-9
1. Use ball end mill for radius. This section of the slot should be
38 mm (1-15/32 in) deep
2. Drill 25 mm (1 in) hole in center to remove material
3. Weld all around
4. Drill 9 mm (11/32 in) hole
5. Drill through 9 mm (11/32 in)
6. Drill and tap 6 mm (1/4 in) holes
A. 305 mm (12 in)
B. 105 mm (4-1/8 in)
C. 16 mm (5/8 in)
D. 51 mm (2 in)
E. 36 mm (1-25/64 in)
F. 22 mm (7/8 in)
G. 17 mm (43/64 in)
H. 19 mm (3/4 in)
I. 35 mm (1-3/8 in)
J. 20.3 mm .18 mm (.800 in .007 in)
Mount on drive shaft puller the jet pump housing
remover; then, install assembly on drive shaft us-
ing screws.
TYPICAL
1. Jet pump housing remover
2. Drive shaft puller
3. Screws
CAUTION: Be careful not to damage hull rear
section or engine rubber mounts.
XP DI Models
Rear Drive Shaft
Remove rear access panel.
Remove protective plate no. 18.
1. Remove protective plate
Pull rear drive shaft until coupler no. 19 is disen-
gage from splines.
1. Pull drive shaft to disengage coupler from splines
Remove rear drive shaft.
Remove coupler no. 19.
3
2
C
D
E
D
F
F
G
6
4
H
F01I05A
A
B
J
I
1
5
F01I06A
1
2
3
F08I03B 1
F08I04A 1
13-03-10 SMR2003-041_13_03A.FM
Front Drive Shaft
Remove PTO flywheel guard no. 1.
Remove bolts, lock nuts and sleeves from support.
1. Remove bolts, lock nuts and sleeves
Loosen bolts and lock nuts retaining the lower sup-
port of the shock absorber.
TYPICAL
1. Remove bolts and lock nuts
Loosen 4 screws and remove bottom cover of
seat.
1. Remove cover
Loosen gear clamp retaining the outer boot of the
shock absorber.
Tilt seat.
Remove front drive shaft.
F08I04B 1
F08Q01A 1
F08L11A 1
F08L12A 1
SMR2003-041_13_03A.FM 13-03-11
Seal Carrier of Mid Bearing
To remove the seal carrier from support, loosen
the 6 nuts no. 21.
1. Nut (6)
Bearing no. 16 and seals no. 15 can be easily re-
moved using the bearing/seal remover tool (P/N
295 000 144).
NOTE: The same tool is used for bearing and seals
removal of jet pump.
Properly support seal carrier housing no. 17 when
removing seals and bearing.
Remove bushings from alignment washer no. 22.
4-TEC Models
If spillage occurs, clean immediately with the pulley
flange cleaner (P/N 413 711 809) to prevent oil
stains.
NOTE: It may require a slight jerk to the rear to re-
move the drive shaft from the PTO seal assembly.
All Models
Boot
Loosen gear clamp no. 11 holding boot, then care-
fully pull boot and carbon ring no. 8 from hull in-
sert.
Carbon Ring
Loosen gear clamp no. 9 then pull carbon ring from
boot no. 10.
INSPECTION
All Models
Drive Shaft
Inspect condition of drive shaft and PTO flywheel
splines (except XP DI models).
Inspect condition of groove.
With your finger nail, feel machined surface of
drive shaft. If any irregular surface is found, renew
drive shaft.
1. Surface condition
2. Groove condition
3. Splines condition
Excessive deflection could cause vibration and
damage to drive shaft splines, impeller, flywheel
or floating ring (seal carrier depending upon the
model).
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.
F05I05A
1
F01J11A
F01I0FA 3 2 1
13-03-12 SMR2003-041_13_03A.FM
Maximum permissible deflection is 0.5 mm (.020 in).
MEASURING DRIVE SHAFT DEFLECTION
1. Dial gauge
2. V-blocks
Damper
Visually inspect shape of dampers no. 13 for de-
formation or other damage.
4-TEC Models
Discard damper no. 25 to install a new one.
Floating Ring and O-Ring
Inspect condition of O-rings no. 7 and floating ring
contact surface.
1. O-rings
2. Floating ring contact surface
PTO Seal
4-TEC Models
Discard both O-rings no. 26 and install new ones.
All Models
Boot
Inspect the condition of boot. If there is any dam-
age or evidence of wear, replace it.
To verify the preload of the boot no. 10, proceed
as follows:
NOTE: To verify the boot preload and free length,
jet pump and drive shaft must be installed.
Measure boot length when normally installed on
drive shaft. Ensure circlip no. 5 is properly in-
stalled into groove.
1. Boot
A. Measure here
Push floating ring to compress boot; then, remove
circlip out of drive shaft groove.
1
2 F01J15A
F01I0GA
1
2
F00J03A 1 A
SMR2003-041_13_03A.FM 13-03-13
2. Remove circlip
Slide floating ring far enough forward in order to
release it from carbon ring.
Measure boot free length.
Subtract the installed length measurement from
the free length measurement. A difference of 4 mm
to 12 mm (5/32 in to 15/32 in) should be obtained.
If the length is less than 4 mm (5/32 in), install a
spacer (P/N 293 250 017) between boot and thru
hull fitting.
1. Spacer
NOTE: Drive shaft must be removed to install spacer.
XP DI Models
Inspect seal carrier needle bearing no. 16. Check
parts for scoring, pitting, chipping or other evi-
dence of wear.
Inspect seals no. 15 for deterioration or excessive
wear. Replace if necessary.
4-TEC Models
Inspect PTO seal assembly. Refer to PTO HOUS-
ING/MAGNETO section.
ASSEMBLY
XP DI Models
Properly support seal carrier housing no. 17 when
installing seals and bearing.
CAUTION: Ensure to install stamped end of
bearing (showing identification markings) first
on tool. Never hammer the bearing into its
housing.
Install bearing no. 16 with the bearing/seal install-
er tool (P/N 295 000 107).
1. Press bearing in its housing
F06I06A
1 2
F00J04B
1
F01J51A
1
13-03-14 SMR2003-041_13_03A.FM
NOTE: Bearing can also be installed with the same
driver used at disassembly. Center bearing in longi-
tudinal axis of housing.
1. Push bearing centered in its housing
Install double-lip seal no. 15 with protector toward
jet pump.
On both seals no. 15, raised edge of lip must be
located outwards of seal carrier.
1. Double-lip seal toward engine
2. Double-lip seal with protector toward jet pump
3. Raised edge of lip outwards
4. Seal carrier
Apply Loctite 518 all around seals outside diameter.
Seals no. 15 can be carefully installed in housing
using bearing/seal installer tool (P/N 295 000 107).
Push seals until tool comes in contact with housing.
TYPICAL
Pack seals and bearing with synthetic grease (P/N
293 550 010).
INSTALLATION
procedure. However, pay particular attention to
the following.
XP DI Models
Install any of the alignment washers no. 22 as
shown. Insert bushings no. 27 in washer.
1. Alignment washer
2. Bushings
1
F01J2TA
F01J2FA
2
1
3
4
3
F01J1YA
2 F00B22A 1
SMR2003-041_13_03A.FM 13-03-15
Insert seal carrier housing no. 17 in remaining
alignment washer.
1. Alignment washer
2. Seal carrier housing
Install alignment washer/seal carrier housing and
properly index alignment washers no. 22 together.
Install the large washer no. 28 and nuts no. 21.
Slightly tighten nuts but keep loose so that the as-
sembly still can move and self adjust when insert-
ing the alignment shaft further in this procedure.
IMPORTANT: Completely tightening nuts would
make the alignment more difficult.
Align the seal carrier using the following tools:
support plate kit (P/N 529 035 570)
1. Plate (P/N 529 035 507)
2. Support (P/N 529 035 511)
alignment shaft (P/N 295 000 141).
1. Alignment shaft
Install support plate at rear of watercraft.
Carefully slide shaft through seal carrier and shaft
support. Ensure that shaft goes farther than shaft
support.
TYPICAL
1. Alignment tool
2. Seal carrier
If alignment tool does not slide easily through seal
carrier, perform the alignment as follows.
2 F00B23A 1
F00B0FA 1 2
F00B0GA 1
F05I08A
1 2
13-03-16 SMR2003-041_13_03A.FM
For vertical alignment, loosen damping support
nuts no. 30 and move the support no. 29 up and
down as necessary.
1. Damping support
2. Loosen nuts
When done, ensure to apply Loctite 243 on screw
threads then torque screws to 22 Nm (16 lbfft)
in a criss-cross sequence.
For horizontal alignment, loosen shaft support
screws no. 32 and move the support no. 31 side-
ways as necessary.
1. Shaft support
2. Loosen screws on both sides
When done, ensure to apply Loctite 243 on screw
threads then torque screws to 22 Nm (16 lbfft)
in a criss-cross sequence.
NOTE: Ensure the alignment washers are still
loose.
Check engine alignment. Refer to ENGINE sec-
tion.
Front Drive Shaft Coupler and Damper
Make sure to install dampers into drive shaft cou-
pler at both ends.
TYPICAL SAME COUPLER AND DAMPER AT BOTH ENDS
1. Damper
2. Drive shaft coupler
Front Drive Shaft
Install front drive shaft no. 20.
Rear Drive Shaft
NOTE: Ensure the alignment washers are still
loose.
Install damper no. 13 to rear drive shaft no. 12.
Install drive shaft and jet pump at the same time.
Insert drive shaft through carbon ring no. 8 and
floating ring no. 6.
Insert drive shaft through seal carrier no. 14 and
into the coupler assembly. Be careful not to dam-
age seals.
CAUTION: When sliding the drive shaft through
seal carrier, the double lip seal can be folded over.
This would cause a seal carrier bearing failure.
Ensure grease fitting of seal carrier is located on the
top.
Apply Loctite 243 (blue) on studs and install nuts
no. 21.
F00B25A 2
1
2
1
F00B26A
2
F08I07A
1
SMR2003-041_13_03A.FM 13-03-17
quence. Torque 1 to 6 at 3 Nm (27 lbfin) and
then 7 to 12 at 10 Nm (89 lbfin).
NOTE: It is very important to tighten nuts of seal
carrier in this sequence to maintain its alignment.
TIGHTENING SEQUENCE
Reinstall protective plate no. 18. Apply Loctite
243 (blue) on bolts and torque lock nuts to 10 Nm
(88 lbfin).
Drive Shaft and Dampers
Install dampers no. 13 on drive shaft no. 12.
NOTE: Make sure dampers were not left in PTO
flywheel or impeller.
Install drive shaft and jet pump at the same time.
Insert drive shaft through carbon ring no. 8 and
floating ring no. 6.
NOTE: Make sure to install floating ring before in-
serting the drive shaft in the PTO flywheel.
While holding jet pump, guide and engage drive
shaft splines in PTO flywheel. Rotate shaft to
properly index splines. Make sure boot is well po-
sitioned over shaft end.
Circlip
Push the floating ring to compress the boot. Insert
the circlip no. 5 in the drive shaft groove.
2. Insert circlip in the groove
Slide the floating ring onto the circlip.
Large Clamp
Secure large clamp no. 2 as follows:
Use pliers (P/N 295 000 069) as for removal.
Manually engage holding hook in large window.
This is a pre-clamping position only.
PRE-CLAMPING POSITION
1. Holding hook
2. Large window
F00B25B
9
4
7
2
11
6
10
3
8
1
12
5
F06I06A
1 2
F01J23A
1
2
13-03-18 SMR2003-041_13_03A.FM
Insert pointed tips of pliers first in closing hooks.
TYPICAL
1. Closing hooks
Squeeze pliers. When both large and small win-
dows are directly over the 2 locking hooks,
press those windows down to engage hooks in
windows.
NOTE: At installation, clamp tail should be in op-
posite direction of engine rotation.
1. Engine rotation (counterclockwise)
2. Tail in opposite direction
Small Clamp
To secure small clamp no. 4, place notch side of
plier on clamp embossment and squeeze plier.
1. Squeeze plier
4-TEC Models
NOTE: Ensure to install floating ring before insert-
ing the drive shaft in PTO seal assembly.
Before installing drive shaft, inspect PTO seal as-
sembly. The inner sleeve must be flush with outer
circumference of the assembly. Otherwise, gently
push or tap on inner sleeve until flush.
CORRECT INSTALLATION
1. Inner sleeve flush with outer circumference
1
F01J2BA
F01J23B
1
2
1
F02J0PB
F18I0EA 1
SMR2003-041_13_03A.FM 13-03-19
WRONG INSTALLATION
1. Inner sleeve not flush with outer circumference
Apply a thin coat of synthetic grease (P/N 293 550
010) on the O-rings of floating ring. Do not get
grease on its sealing surface.
1. Synthetic grease
2. No lubrication
CAUTION: Note that drive shaft features a tell
tale groove. If exposed after installation, the in-
stallation is wrong and PTO seal assembly will
be pressed into crankshaft splines which could
rub a hole in seal thus creating an oil leak.
1. Tell tale groove
Install PTO seal assembly.
Install PTO seal support tool on PTO seal assembly.
To prevent possible drive shaft corrosion, apply
Penzoil Marine
Z-M
Corrosion Protectant all

over drive shaft.
NOTE: Drive shaft should be dry and clean prior to
applying the corrosion protectant. If the drive shaft
is corroded, a rotating wire brush may be used.
Wait 2 hours prior to using the watercraft to allow
protectant to dry.
Slide drive shaft far enough to install floating ring.
F18I0FA 1
1
F18I0KA
2
WARNING
Always work in a well ventilated area. Carefully
read application instructions on product can.
F18I0QA 1
F18I02A
13-03-20 SMR2003-041_13_03A.FM
Continue pushing drive shaft towards engine care-
fully guiding it in the PTO seal then in crankshaft
splines.
Then, push drive shaft until it bottoms against the
engine.
While someone is pushing drive shaft, slide float-
ing ring rearward and guide drive shaft in PTO seal
assembly. It may be necessary to move PTO seal
assembly up and down to position it in the same
axis as the drive shaft.
When properly aligned, maintain PTO seal assem-
bly in the proper position and tap shaft end until it
bottoms against engine. At this time, the tell tale
MUST NOT be visible. This validate the correct po-
sition.
1. PTO seal support
2. Drive shaft end
3. Insert floating ring on shaft end
GOOD INSTALLATION
1. PTO seal assembly
2. Shaft pushed in, hiding tell tale groove
3. Inner sleeve flush with outer circumference
WRONG INSTALLATION
1. PTO seal assembly
2. Tell tale groove visible
3. Inner sleeve NOT flush with outer circumference
Install drive shaft holder tool.
F18I0HA 1 2 3
3
F18I0IA 2
1
3
F18I0JA 2
1
SMR2003-041_13_03A.FM 13-03-21
Install Drive shaft/floating ring tool as shown. En-
sure PTO seal support is still in place.
Push floating ring rearwards and install C-clip.
1. Largest opening on through-hull fitting side
1. Largest opening
2. Install C-clip
Remove drive shaft/floating ring tool, drive shaft
holder then PTO seal support.
NOTE: Pushing boot no. 10 rearwards will ease
removal of PTO seal support tool.
Now ensure everything is properly positioned: Tell
tale is not exposed, inner sleeve is flush with outer
circumference of PTO seal assembly and C-clip is
not exposed.
If tell tale mark is exposed, push PTO seal assem-
bly rearwards to fully extend it.
If inner sleeve is not flush, gently tap it until it is
flush.
Reposition splash guard.
Reconnect EGT sensor.
Install jet pump. Refer to JET PUMP section.
Check engine oil level. Refill as necessary.
Run watercraft then ensure there is no oil leak in
PTO seal area.
LUBRICATION
PTO Flywheel
Using a grease gun, carefully lubricate PTO fly-
wheel with synthetic grease (P/N 293 550 010),
until boot is just beginning to expand. At this point,
immediately stop greasing.
F18B03A
1 F18I0NA
F18I06A
2 1
F01I0BB
13-03-22 SMR2003-041_13_03A.FM
XP DI Models
Using a grease gun, lubricate seal carrier of mid
bearing with synthetic grease (P/N 293 550 010).
TYPICAL
1. Grease fitting
Corrosion Protection
4-TEC Models
To prevent possible drive shaft corrosion, apply
Penzoil Marine
Z-M
Corrosion Protectant as de-

scribed here.
If drive shaft has been removed and lubricated be-
fore installation, nothing more is required. Other-
wise, proceed as follows.
Drive shaft should be dry and clean prior to apply-
ing the corrosion protectant.
Place a plastic sheet underneath hull to recover
the excess of sprayed corrosion protectant.
From underneath hull, spray the corrosion pro-
tectant through the intake grate all over the visible
portion of drive shaft. Spray also towards through-
hull fitting and towards splines of impeller.
Dispose of the soiled plastic sheet as per your lo-
cal environmental regulations.
NOTE: On Supercharged models, remove inlet
hose from supercharger to gain access.
From inside bilge, lift splash guard to expose PTO
seal assembly.
Cover carbon seal ring with a rag or plastic wrap
to prevent the protectant to reach the carbon ring.
Place a rag on bottom of hull to recover the excess
of sprayed corrosion protectant. Spray the visible
portion of drive shaft. When done, dispose soiled
rag as per your local environmental regulations.
1. Protect carbon seal area
2. Spray here
NOTE: On Supercharged models, reinstall inlet
hose to supercharger.
Reposition splash guard.
Wait 2 hours prior to using the watercraft to allow
the protectant to dry.
WARNING
Always work in a well ventilated area. Care-
fully read application instructions on product
can.
F05I09A
1
1
F18I0KA
2
Subsection 04 (REVERSE SYSTEM)
SMR2003-042_13_04A.FM 13-04-1
REVERSE SYSTEM 0
LRV DI Models
F07J0TS
4
9
7
8
22
10
6
21
5
3
23
12
13
16
19 15
20
3.5 Nm
(31 lbfin)
17
18
14
Loctite 243
1
11
4 Nm
(35 lbfin)
3 Nm
(27 lbfin)
Loctite
243
10 Nm
(89 lbfin)
2.5 Nm
(22 lbfin)
Synthetic grease
2.5 Nm
(22 lbfin)
6 Nm
(53 lbfin)
7 Nm (62 lbfin) 2
Loctite 243
6 Nm
(53 lbfin)
5 Nm
(44 lbfin)
9 Nm
(80 lbfin)
9 Nm
(80 lbfin)
4
3 Nm (27 lbfin)
Loctite 243
Silicone
sealant
13-04-2 SMR2003-042_13_04A.FM
DISASSEMBLY
Reverse Gate
Put shift lever in reverse position.
Disconnect reverse cable from reverse gate no. 1.
Remove lock nut no. 3 and bolt no. 2 retaining cable
end no. 21 to cable lever no. 5.
1. Bolt
2. Cable end
3. Cable lever
4. Lock nut
Unscrew and remove 2 Allen screws no. 4 retain-
ing reverse gate to support no. 10 and remove re-
verse gate.
Cable Lever
Remove Allen screw no. 6 and detach cable lever
from reverse gate.
Pawl Lock and Spring
To remove pawl lock no. 7 and spring no. 8 re-
move roll pin no. 9.
Reverse Gate Support
Unscrew 4 bolts which retain reverse gate support
no. 10 to venturi.
Remove reverse gate support from venturi.
1. Reverse gate support
2. Remove bolts
Interior Lever
Remove glove box to have access to the shifting
lever mechanism.
1. Remove glove box
F07J08B 4 3 2 1
F07J02A
1 2 2
2 2
1 F07L1FA
SMR2003-042_13_04A.FM 13-04-3
Remove bolt no. 12 and lock nut no. 13 retaining
reverse cable end to interior lever no. 11.
1. Reverse cable
2. Interior lever
From outside of body, unscrew bolt no. 14 retain-
ing the shift lever no. 20.
1. Bolt
2. Shift lever
Remove the interior lever no. 11 and spring no. 15.
Reverse Cable Support
Unscrew bolts no. 18 and remove retaining block
no. 17. Detach adjustment nut no. 23 from reverse
cable support no. 16.
Remove 3 bolts no. 19 retaining reverse cable sup-
port no. 16 to body.
Remove reverse cable support.
INSPECTION
Visually inspect parts for wear or cracks. Replace
parts as required.
ASSEMBLY
bly procedures. However, pay particular attention
to the following.
CAUTION: Refer to the main illustration at the
beginning of this subsection for torque specifi-
cations and service products to be used.
Spring
Make sure to properly install spring no. 15 into in-
terior lever no. 11 as per following illustration.
1. Spring
Interior Lever and Shift Lever
Install the interior lever no. 11 in a rotating move-
ment. Engage properly the interior lever tabs in the
shift lever slots.
1. Shift lever
2. Interior lever tabs
F07J03A
1 2
F07J04A
1 2
F07J05A 1
F07J04B
2 1
13-04-4 SMR2003-042_13_04A.FM
Make sure the shift lever action is smooth and pre-
cise. Forward, neutral and reverse positions should be
easy to select with a detent position between each.
Spring and Pawl Lock
Make sure spring no. 8 is properly installed. One
end of the spring is hooked in the pawl lock no. 7
and the other end is retained by the stopper lock
nut.
1. Pawl lock
2. Spring
3. Stopper lock nut
Reverse Gate
When installing the reverse gate, pay attention to
position its lever behind the reverse gate support
stopper.
1. Stopper
Reverse Cable
Install reverse cable to cable lever as per following
illustration.
1. Bolt
2. Ball joint
3. Cable lever
4. Flat washer
5. Lock nut
CAUTION: Ensure cable ball joint is parallel to
cable lever (90 5) to minimize tension on ca-
ble. Adjust as required.
ADJUSTMENT
Put shift lever in forward position.
Pull shift lever approximately 50 mm (2 in) and
push it back slowly in forward position.
The pawl lock no. 7 must be engaged in the an-
chor no. 22.
F07J06A
3
2
1
F07J07A
1
WARNING
When adjusting reverse cable, make sure le-
ver is well engaged into the spring slot.
F07J08A 4 5 3 4 2 1
SMR2003-042_13_04A.FM 13-04-5
If not, adjust reverse cable. Loosen 2 bolts no. 18
at reverse cable support no. 16. Turn adjustment
nut no. 23 as required.
1. Reverse cable support
2. Loosen bolts
3. Adjustment nut
When adjustment is completed, there should be
gap of 0 to 5 mm (0 to 3/16 in) between handle and
left cover.
A. 0 to 5 mm (0 to 3/16 in)
F07J09A
1
2
3
2
F07J0AA
AA
13-04-6 SMR2003-042_13_04A.FM
GTI Series, RX DI and GTX Series
F18J1VS
5
Loctite
243
4
10
9
8
6
2
7
9
Loctite
243
7
Silicone
sealant
3
Synthetic
grease
2
1 7 Nm
(62 lbfin)
2.5 Nm
(22 lbfin)
10 Nm
(89 lbfin)
4 Nm
(35 lbfin)
2.5 Nm
(22 lbfin)
2 Nm
(18 lbfin)
2 Nm
(18 lbfin)
Loctite
243
3.3 Nm
(29 lbfin)
2 Nm
(18 lbfin)
2.5 Nm
(22 lbfin)
11
12
4
9
9
10
Loctite 243
Loctite 243
Loctite 243
2.5 Nm
(22 lbfin)
4 Nm
(35 lbfin)
Silicone
sealant
Silicone sealant
GTX series
5
2.5 Nm
(22 lbfin)
SMR2003-042_13_04A.FM 13-04-7
DISASSEMBLY
Reverse Gate
To remove reverse gate, refer to JET PUMP section.
Reverse Cable
Unscrew bolt no. 1, washers and the elastic stop
nut retaining reverse cable no. 2 on pivot arm.
1. Reverse cable
2. Pivot arm
3. Bolt
4. Washer
5. Elastic stop nut
Unscrew the cable lock no. 11 then remove the
half rings no. 12.
Remove the seat and the glove box. Refer to
HULL/BODY.
GTX Series
Push the vent tube toward the front of the vehicle
to get greater access to the interior lever and the
reverse cable support.
To release the vent tube, press down its locking
tabs and move the tube.
There are two locking tabes; one above and one
underneath the hose.
DO NOT REMOVE the vent tube completely.
1. Engine vent tube
2. Vent tube locking tab
3. Interior lever
4. Reverse cable support
On the interior lever no. 3, unscrew the elastic
stop nut and the washer retaining the reverse ca-
ble.
Remove the bracket no. 6.
NOTE: Before removing reverse cable from hull,
note cable routing for reinstallation.
1. Interior lever
2. Elastic stop nut and washer
3. Reverse cable
4. Bracket
3 F18J1HA
1 2
5 4
2
3
F18J1IA
4
1
1
F18J1JA
2
3
4
13-04-8 SMR2003-042_13_04A.FM
On the interior lever no. 3, unscrew the elastic stop
nut and the washer retaining the reverse cable.
Remove the bracket no. 6.
NOTE: Before removing reverse cable from hull,
note cable routing for reinstallation.
Interior Lever
Detach the reverse cable from interior lever no. 3.
Unscrew the shift lever retaining bolt no. 4, wash-
er and nut, then remove interior lever.
1. Reverse cable
2. Interior lever
Shift Lever
Unscrew the shift lever retaining bolt no. 4, wash-
er and nut.
Disengage the shift lever slots from interior lever
tabs, then remove the shift lever no. 5.
1. Shift lever retaining bolt
2. Shift lever slot
3. Interior lever tab
4. Shift lever
Reverse Cable Support
Remove:
shift lever
interior lever
bracket no. 6
1. Bracket
2. Reverse cable
bolts no. 7.
Withdraw reverse cable support no. 8.
Handle Housing
Remove:
shift lever
interior lever
reverse cable support
bolts no. 9.
Then, remove handle housing no. 10.
INSPECTION
Visually inspect parts for wear or cracks on friction
parts. Replace all defective parts.
ASSEMBLY
to the following.
Insert interior lever cursor into reverse cable sup-
port slider and make sure that the cursor slides
freely in the slider.
1 F16J0DA 2
4 F18J1KA 3 1 2
2 F16J0FA 1
SMR2003-042_13_04A.FM 13-04-9
1. Interior lever cursor
2. Reverse cable support slider
Interior Lever
Apply synthetic grease on the interior lever pivot
and in the reverse cable support hole.
Install the interior lever in a rotating movement.
Engage properly the interior lever tabs in the shift
lever slots.
Make sure the shift lever action is smooth and pre-
cise. Forward and reverse positions should be easy
to select with a detent position between each.
Reverse Gate
Refer to JET PUMP section.
Reinstall glove box and seat.
ADJUSTMENT
Put shift lever in forward position.
Place reverse gate in the up position.
Turn the joint at the end of reverse cable and align
its hole with hole in pivot arm.
Secure with bolt, washers, spacer and elastic stop
nut. Torque to 7 Nm (62 lbfin).
WARNING
When adjusting reverse cable, make sure le-
ver is well engaged into the spring slot.
1
F18J1LA
2
Subsection 05 (VARIABLE TRIM SYSTEM)
SMR2003-043_13_05A.FM 13-05-1
VARIABLE TRIM SYSTEM 0
RX DI Models
F16J01U
1
2
3
5
6
7
8
9
10
7 Nm
(62 lbfin)
11
12
14
2
20 Nm
(15 lbfft)
Loctite
Primer N
5 Nm
(44 lbfin)
3 Nm
(27 lbfin)
Synthetic
grease
7 Nm
(62 lbfin)
13
Dielectric
grease
7 Nm
(62 lbfin)
4
Loctite
243
20 Nm
(15 lbfft)
Synthetic
grease
Loctite
Primer N
13-05-2 SMR2003-043_13_05A.FM
XP DI Models
F08J10S
7
Synthetic
grease
8
9
10
2
3
2
13
1
14
16
2.5 Nm
(23 lbfin)
10 Nm
(89 lbfin)
15
5
6
12
5 Nm
(44 lbfin)
7 Nm
(62 lbfin)
11
Loctite
Primer N
Dielectric
grease
4
Loctite
243
20 Nm
(15 lbfft)
7 Nm
(62 lbfin)
20 Nm
(15 lbfft)
20 Nm
(15 lbfft)
Synthetic
grease
Loctite
Primer N
SMR2003-043_13_05A.FM 13-05-3
GENERAL
To test VTS control module, motor or switch, refer
to INSTRUMENTS AND ACCESSORIES.
To have access to VTS module, remove seat on
RX DI models and remove rear access cover on
XP DI).
REMOVAL
All Models
Remove nut no. 14 and bolt no. 13 retaining VTS
rod no. 1 to sliding shaft no. 10.
Remove clamps no. 2.
Remove boot no. 3.
RX DI MODELS
1. VTS rod
2. Bolt
3. Lock nut
4. Rubber boot
XP DI MODELS
1. VTS rod
2. Bolt
3. Lock nut
4. Rubber boot
RX DI Models
Disconnect:
steering cable
reverse cable.
Unscrew the pivot arm bolts (one on each side).
Move the pivot arm backwards.
All Models
To loosen nut no. 4, use VTS socket tool (P/N 295
000 133).
Remove sealing washer no. 5.
All Models
Disconnect wiring harnesses.
Pull out VTS assembly no. 6 from bilge.
1
F16J0AA
3 4 2
F06J01E
1 2 3 4
F01B2PA
13-05-4 SMR2003-043_13_05A.FM
DISASSEMBLY
Cover
Remove VTS cover no. 7 by pressing on tabs.
1. Press tabs to remove cover
Motor
Disconnect wires from motor no. 8.
Remove retaining nuts no. 11.
1. Remove nuts
2. Disconnect wires
Pull on motor to remove it.
Worm and Sliding Shaft
Simply pull on worm no. 9 and sliding shaft no. 10
in order to remove them.
INSPECTION
Boot
Make sure boot no. 3 is in good condition. If it is
cracked or torn, replace boot.
Worm
Inspect threads and splines of worm no. 9 for
wear. If worm replacement is necessary, renew
also sliding shaft.
1. Inspect threads and splines
ASSEMBLY
to the following.
Motor, Worm and Sliding Shaft
Apply synthetic grease to worm.
Screw worm no. 9 to sliding shaft no. 10.
Mesh worm splines to gear of motor.
1. Mesh worm spline to gear of motor
F01J1WA
1
1
F01J1XA
1
2
F01J25A 1
F01J2PA
1
SMR2003-043_13_05A.FM 13-05-5
Install motor no. 8, worm and sliding shaft in VTS
housing.
Tighten nuts no. 11 to 7 Nm (62 Ibfin).
Connect wires of motor.
CAUTION: Make sure wire color codes match.
Install cover no. 7.
NOTE: Make sure seal no. 12 is in place.
INSTALLATION
procedures. However pay particular attention to
the following.
Nut and Sealing Washer
Place sealing washer no. 5 on nut no. 4. Make
sure seal lips are facing toward hull.
1. Seal lips facing hull
2. Nut
Apply Loctite Primer N (P/N 293 800 041) to threads
of VTS housing, and to nut no. 4.
Apply Loctite 243 (blue) to nut no. 4.
Install nut with sealing washer and torque to
7 Nm (62 lbfin) using the VTS socket tool (P/N
295 000 133).
Apply synthetic grease to sliding shaft.
Boot and Clamps
Install rubber boot no. 3 over sliding shaft and se-
cure with clamps.
VTS Rod
RX DI Models
Install:
pivot arm
reverse cable
steering cable
boot with clamps.
Secure the VTS rod onto the sliding shaft end us-
ing bolt no. 13 and nut no. 14. Torque nut to 7
Nm (62 lbfin).
XP DI Models
Install rubber boot no. 3, over sliding shaft and se-
cure with clamps.
Install ball joint on LEFT side of sliding shaft no. 10
using bolt no. 13, washers no. 15 and nut no. 14.
Torque nut to 10 Nm (88 lbfin).
TYPICAL
1. Washers
2. Bolt
3. Lock nut
F01J2GA
F01J2LA
1
2
F06J01C
2 1 3
13-05-6 SMR2003-043_13_05A.FM
ADJUSTMENT
RX DI Models
No adjustment is required.
XP DI Models
Push on VTS button up position until motor stops.
When the nozzle is up (8), nozzle edge must not
interfere with venturi (there should be a gap of
1 mm (.039 in)).
NOTE: Install safety lanyard to be able to position
VTS.
1. No interference
2. Nozzle up
If an adjustment is necessary, loosen jam nut no. 16
of VTS rod no. 1. Turn adjustment nut of VTS rod
to obtain the desired gap between trim ring and
venturi.
TYPICAL
1. Turn adjustment nut of VTS rod
Tighten jam nut of VTS rod to 2.5 Nm (23 lbfin)
when adjustment is completed.
F01J3IA
1
2
8
F06J01A
1
Section 14 STEERING SYSTEM
SMR2003-049_14_01ATOC.FM 14-01-1
TABLE OF CONTENTS 0
STEERING SYSTEM.............................................................................................................. 14-02-1
DISASSEMBLY................................................................................................................... 14-02-3
ASSEMBLY......................................................................................................................... 14-02-8
DISASSEMBLY .................................................................................................................. 14-02-13
ASSEMBLY......................................................................................................................... 14-02-16
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)................................................ 14-02-18
GENERAL........................................................................................................................................... 14-02-19
SIDE VANE......................................................................................................................... 14-02-19
CYLINDER SUPPORT ASSEMBLY ................................................................................... 14-02-20
TIE ROD.............................................................................................................................. 14-02-21
SEALED TUBE ................................................................................................................... 14-02-22
FILTER ................................................................................................................................ 14-02-22
VALVE................................................................................................................................. 14-02-22
WATER HOSE .................................................................................................................... 14-02-23
CROSS SUPPORT PLATE ................................................................................................. 14-02-23
ALIGNMENT .......................................................................................................................... 14-03-1
Subsection 02 (STEERING SYSTEM)
SMR2003-044_14_02A.FM 14-02-1
STEERING SYSTEM 0
All Models except XP DI, GTX DI and GTX 4-TEC Series
F07K12S
6
6
5
5
1
3
2
4
4
12
14
13
8
18
16
15
17
9
10
11
10 Nm
(88 lbfin)
10 Nm
(89 lbfin)
Loctite 243
4 Nm
(35 lbfin)
13 Nm
(115 lbfin)
Loctite 243
5 Nm
(44 lbfin)
Loctite 243
6 Nm
(53 lbfin)
6 Nm
(53 lbfin)
Loctite
243
6 Nm
(53 lbfin)
Loctite 243
26 Nm
(19 lbfft)
7 Nm
(62 lbfin)
23
22
2.5 Nm
(22 lbfin)
2.5 Nm
(22 lbfin)
19
20
21
25
24
27
26
Carburetor-equipped
engines
7
Synthetic
grease
5 Nm
(44 lbfin)
14-02-2 SMR2003-044_14_02A.FM
GTX DI Models and GTX 4-TEC Series
F18K19S
39
40 7 Nm
(62 lbfin)
26 Nm
(19 lbfft)
Loctite 243
42
41
5
4
4
8
6
5
45
7
1 Nm
(9 lbfin)
2
3
23
1
38
44
19 22
35
37
36
10 Nm
(89 lbfin)
5 Nm
(44 lbfin)
14
12
13 Nm
(115 lbfin)
13
8
18
16
15
17 6 Nm (53 lbfin)
Loctite 243
5 Nm
(44 lbfin)
2.5 Nm
(22 lbfin)
6 Nm
(53 lbfin)
9
Loctite 243
10
24
27 25 10 Nm
(89 lbfin)
19
11
Loctite 243
2.5 Nm
(22 lbfin)
4 Nm
(35 lbfin)
32
33
30
Loctite
243
34
29
Synthetic
grease
48
49
50
47
Loctite
767
Loctite 271
26 Nm
(19 lbfft)
GTX 4-TEC Supercharged LTD only
46
Synthetic grease
7 Nm
(62 lbfin)
31
Loctite
243
10 Nm
(89 lbfin)
SMR2003-044_14_02A.FM 14-02-3
DISASSEMBLY
GTX 4-TEC Supercharged Limited Models Only
Adjustment Handle
Set handlebar to its lowest position by turning ad-
justment handle no. 30 counterclockwise.
While holding adjustment handle no. 30, turn sup-
port bushing no. 31 clockwise.
TYPICAL
1. Adjustment handle
2. Support bushing
Hold jam nut no. 34 and unscrew adjustment han-
dle no. 30 from adjuster screw no. 29.
TYPICAL
1. Loosen jam nut
All Models
Handle Grip and Grip Insert
To remove handle grip no. 1, pull out cap no. 2 and
remove screw no. 3.
Pull out grip and remove grip insert from handlebar
no. 4.
1. Handle grip
2. Remove screw
NOTE: Verify grip insert for damage.
Steering Cover
Remove grips no. 1.
Loosen set screws no. 5 of handlebar housings
no. 6.
GTX DI MODELS AND GTX 4-TEC SERIES ONLY
1. Set screw
2
1 F07K0MA
1
F07K0NA
1 F18K0AA 2
1 F18K0BA
14-02-4 SMR2003-044_14_02A.FM
All Model except GTX DI and GTX 4-TEC Series
1. Set screw
Remove 4 screws no. 7.
TYPICAL
1. Cover
2. Screws
Remove 2 screws no. 20 and flat washers no. 21
each side of cover.
1. Remove screws
Remove cover.
GTX DI Models and GTX 4-TEC Series Only
Remove 2 tapping screws no. 42.
1. Tapping screw
2. Handle bar housing
Remove handlebar housing cover no. 8 and throt-
tle handle housing no. 39.
Unhook throttle cable from throttle handle no. 40.
Pry out the throttle cable housing from throttle
handle housing no. 41.
1. Throttle cable
2. Throttle handle housing
3. Throttle cable handle
Remove 6 screws no. 7 and flat washers no. 45
each side of cover.
F00K01A
1
F00K02A
2
1
1 F07K0JA
2 F18K0CA 1
2 F18K0DA 1 3
SMR2003-044_14_02A.FM 14-02-5
Remove lower steering cover no. 4.
1. Steering cover
2. Screws
Unscrew DESS switch nut using safety lanyard
switch tool (P/N 529 034 600).
Remove upper steering cover no. 4.
1. DESS switch nut
Steering Padding
Remove steering cover as mentioned above.
Remove 2 screws no. 35 and flat washers no. 36.
Remove steering padding no. 37.
1. Screws
2. Steering padding
Handlebar
Remove 4 elastic stop nuts M8 retaining steering
clamp no. 44.
TYPICAL
1. Remove nuts
2. Steering clamp
1 F18K0EA 2
1 F18K0FA
1
2
F18K0GA
F07K0SA 1 2
14-02-6 SMR2003-044_14_02A.FM
Detach steering clamp no. 44 and remove handle-
bar no. 22. Withdraw rubber pad no. 32 and stop-
per no. 33.
TYPICAL
1. Rubber pad
2. Stopper
All Models except GTX 4-TEC Supercharged
Limited
Remove steering cover and steering padding as
mentioned above.
Remove 4 nuts no. 38 to remove handle bar
no. 22 from steering stem no. 46 and steering
clamp no. 44.
1. Nuts
2. Handlebar
3. Steering stem
4. Steering clamp
All Models
Cable Support
Loosen bolts no. 9 and remove retaining block
no. 10.
1. Retaining block
Loosen bolts no. 11 each side of steering support
no. 12.
1. Steering support
2. Bolt
F07K0TA
1
2
2 F18K0HA 3 4
1
1
1 F18K0IA
F07K02A
1 2
SMR2003-044_14_02A.FM 14-02-7
1. Steering support
2. Bolts
Remove cable support no. 8.
Steering Support
Cut locking tie securing wiring harness boot.
1. Boot
2. Locking tie
Disconnect the throttle and choke cables from car-
buretor levers.
Disconnect the wiring harnesses leading out of
steering stem and cut locking tie.
ALL OTHER MODELS EXCEPT XP DI
1. Tie rap
2. Connectors
Disconnect the steering cable from the steering
stem arm no. 15.
1. Steering stem arm
2. Steering cable
Remove bolts no. 11 retaining cable support no. 8
to steering support no. 12.
1 2
F07K03A
F07K04A
1 2
F07K05A
2 1
F07K06A
1
2
14-02-8 SMR2003-044_14_02A.FM
Remove bolts no. 13 and lock nuts no. 14 from
steering retaining strip studs.
1. Steering support
2. Retaining strip studs
Remove steering support no. 12 with handlebar,
wiring harnesses and cables.
Steering Stem Arm and Support
Loosen bolts no. 17 retaining steering stem arm
no. 15 to support no. 16.
1. Steering stem arm
2. Bolts
Remove steering stem arm and support.
Steering Stem and Steering Support
Unscrew nut and remove pivot bolt no. 47 retaining
steering support no. 48 to steering stem no. 49.
Remove adjuster screw from block and detach steer-
ing support from steering stem.
Unscrew threaded pivots to remove threaded block
from steering stem no. 49.
1. Steering stem
2. Steering support
3. Support bushing
4. Adjuster screw
5. Threaded block
6. Threaded pivots
All Models
Steering Cable
Disconnect steering cable no. 24 from steering
stem arm no. 15.
Remove retaining block no. 10.
Disconnect ball joint no. 19 from jet pump nozzle.
Remove ball joint no. 19 and jam nut from cable.
Loosen nut no. 25, then remove half rings no. 26
and O-ring no. 27.
NOTE: To loosen nut, use steering cable tool (P/N
295 000 145).
Remove steering cable from watercraft.
ASSEMBLY
bly procedures. However, pay particular attention
to the following.
CAUTION: Apply all specified torques and ser-
vice products as per main illustration at the be-
ginning of this subsection.
1 F18K0JA 2
F07K08A
2 1
2
F07K0PA
2
3
1
5
4
6
SMR2003-044_14_02A.FM 14-02-9
When installing the grip insert no. 21 in the han-
dlebar no. 22, ensure that it is properly inserted in
the slot at the end of the handlebar tubing.
1. Grip insert
Install grip no. 1 on handlebar no. 22 matching it
to the notch in the handlebar.
Install flat washer no. 23 and screw no. 3.
Torque screw to 7 Nm (62 lbfin).
Install cap no. 2.
1. Grip insert
2. Grip
3. Flat washer
4. Screw. Torque to 7 Nm (62 lbfin)
5. Cap
CAUTION: Ensure to install flat washer other-
wise screw will damage grip end.
Position steering stem arm no. 15 and support
no. 16 onto steering stem.
1. Keyways
2. Integrated flat key
Replace lock nuts no. 18 by new ones.
Torque bolts no. 17 of steering stem arm to 6 Nm
(53 lbfin).
Steering Stem and Steering Support
Install support bushings no. 50 on steering support.
Apply Loctite 767 antiseized lubricant (P/N 413 701
000) on pivot bolt no. 47.
CAUTION: Make sure antiseize lubricant does
not come in contact with threads of bolt.
1. Antiseize lubricant
2. Loctite 271
3. Loctite 243
WARNING
Make sure the integrated flat keys of the steering
stem arm and support are properly seated in
steering stem keyways. Steering stem arm must
be locked in place before torquing the bolts.
F02K0JA 1
F02K0KA
1
2 4
5 3
F07K09A
2
1
2
F07K0PB
1
2
3
3
2
1
14-02-10 SMR2003-044_14_02A.FM
Install steering support no. 48 to steering stem
no. 49 and secure with pivot bolt no. 47. Install
nut and torque to 26 Nm (19 lbfft).
1. Adjuster screw
2. Apply Loctite 243
3. Locking tie
Ensure wire harness is properly secured to steer-
ing support with a locking tie.
1. Locking tie holding harness to steering support
Handlebar
Before installing handlebar, position stopper no. 33
and rubber pad no. 32.
CAUTION: Rubber pad must not exceed stop-
per.
1. Pad must not exceed stopper
Position handlebar no. 22. Install steering clamp
no. 44 and secure with new elastic stop nuts M8.
Torque nuts to 26 Nm (19 lbfft) as per the fol-
lowing sequence.
TORQUE SEQUENCE
All Models
Ball Joint
Secure the steering cable ball joint no. 19 to the
nozzle as per following illustrations.
CAUTION: Ensure the ball joint is parallel ( 5)
to the nozzle arm.
F07K0RA
1
3 2
F07K0WA 1
F07K0UA
1
1
F07K0VA
1
3
2
4
SMR2003-044_14_02A.FM 14-02-11
TYPICAL
1. Ball joint on top of steering arm
2. Torque nut to 7 Nm (62 lbfin)
STEERING ALIGNMENT
For steering alignment procedure, refer to ALIGN-
MENT.
F06K01A
1 2
14-02-12 SMR2003-044_14_02A.FM
XP DI Models
F08K0SS
10 Nm
(89 lbfin)
Loctite 243
4 Nm
(35 lbfin)
6
9
1 Nm
(9 lbfin)
2
3
4
1
5
28
7 Nm
(62 lbfin)
18
8
13
Synthetic
grease
7 Nm
(62 lbfin)
7
Loctite
243
10
26 Nm
(19 lbfft)
13 Nm
(10 lbfft)
Engine
cover
Loctite
243
2.5 Nm
(22 lbfin)
Loctite
243
Loctite
243
20
19
6 Nm
(53 lbfin)
11
24
21
2.5 Nm
(22 lbfin)
23
7 Nm
(62 lbfin)
22
26
25
27
Engine
cover
17
6 Nm
(53 lbfin)
Loctite
243
16
15
7 Nm
(62 lbfin)
Synthetic
grease
14
7
10 Nm
(89 lbfin)
12
1 Nm
(9 lbfin)
3 Nm
(27 lbfin)
SMR2003-044_14_02A.FM 14-02-13
DISASSEMBLY
To remove handle grip no. 1, pull out cap no. 2
from grip end and remove screw no. 3 and washer
no. 4.
Pull out grip and remove grip insert from handle-
bar.
NOTE: Verify grip insert no. 5 for damage.
Steering Cover
To remove the steering cover no. 6, loosen set
screws no. 7 of handlebar housing.
1. Set screws
Remove 4 screws no. 8 and washers.
TYPICAL
1. Cover
2. Screws
Remove 2 screws no. 9 and flat washers each
side of cover.
1. Remove screws
Detach upper and lower section of cover from
steering.
1. Upper section
2. Lower section
F00K01A
1
F00K02A
2
1
1 F07K0JA
2 F07K0KA
1
14-02-14 SMR2003-044_14_02A.FM
Lever
Remove the top section of the engine cover by
loosening the 10 Allen screws located inside the
cover.
1. Loosen Allen screws
Lift the top section of the engine cover and discon-
nect wiring harnesses.
Remove the top section of the engine compart-
ment cover.
Disconnect steering cable no. 11 from lever no. 10.
1. Disconnect steering cable
Remove link rod no. 12.
1. Remove link rod
Remove bolt no. 13 and washer retaining lever
no. 10 to steering support no. 18.
1. Remove bolt and washer
1
F08L0KB
1 1
1 1
F08K05A 1
F08K06A
1
F08K07A
1
SMR2003-044_14_02A.FM 14-02-15
Loosen bolts no. 17 retaining steering stem arm
no. 15 and support no. 16.
1. Loosen bolts
Loosen nuts and bolts retaining steering support
no. 18.
1. Loosen nuts and bolts
Lift steering support no. 18 and slightly pullback
steering stem no. 14 in order to remove the sup-
port no. 16 and steering stem arm no. 15.
1. Remove support and steering stem arm
Steering Stem
Disconnect wiring harnesses, choke and throttle
cables from engine.
Remove steering stem no. 14.
Steering Cable
Remove glove box.
Disconnect steering cable no. 11 at lever no. 10.
1. Disconnect steering cable
F08K08A 1
F08K09A
1 1
F08K0AA
1
F08K05A 1
14-02-16 SMR2003-044_14_02A.FM
Unscrew bolts from retaining block no. 20 to re-
move steering cable from cable support no. 19.
1. Cable support
2. Remove M6 bolts
Disconnect ball joint no. 21 of steering cable from
jet pump nozzle.
Remove ball joint no. 21, jam nut no. 22 and boots
no. 23 and no. 24.
Loosen nut no. 25 and remove half rings no. 26
and O-ring no. 27.
NOTE: To loosen nut, use steering cable tool (P/N
295 000 145).
Remove steering cable from watercraft.
ASSEMBLY
bly procedure. However, pay particular attention
to the following.
Lever
Prior installing lever no. 10, apply synthetic grease to
pivot.
Steering Stem
Apply synthetic grease to front and rear thrust
bearing surface.
1. Apply synthetic grease
Position steering stem arm no. 15 and support
no. 16 onto steering stem no. 14.
When installing the grip insert no. 5 in the handle-
bar no. 28, ensure that it is properly inserted in the
slot at the end of the handlebar tubing.
1. Grip insert
1 F08K0KA 2
WARNING
Make sure integrated flat keys of steering
stem arm and support are properly seated in
steering stem keyways.
1
F08K0MA
F02K0JA 1
SMR2003-044_14_02A.FM 14-02-17
Install flat washer no. 4 and screw no. 3.
Torque screw to 7 Nm (62 lbfin).
1. Grip insert
2. Grip
3. Flat washer
4. Torque screw to 7 Nm (62 lbfin)
5. Cap
CAUTION: Ensure to install flat washer other-
wise screw will damage grip end.
Ball Joint
Secure the steering cable ball joint no. 21 to the
nozzle as per following illustration.
CAUTION: Ensure the ball joint is parallel ( 5)
to the nozzle arm.
TYPICAL
1. Ball joint on top of steering arm
2. Torque nut to 7 Nm (62 lbfin)
STEERING ALIGNMENT
For steering alignment procedure, refer to ALIGN-
MENT.
WARNING
Correct torque must be strictly followed.
F02K0KA
1
2 4
5 3
F06K01A
1 2
14-02-18 SMR2003-044_14_02A.FM
OFF-POWER ASSISTED STEERING SYSTEM (O.P.A.S.)
F18K1AS
Body
Hull
Hull
12
19
13
14
20
15
18
10
4.5 Nm
(40 lbfin)
9
11
24
1.2 Nm
(10 lbfin)
12
22
5.5 Nm
(49 lbfin)
27
Hull
36
25
31
1.7 Nm
(15 lbfin)
32
30
23
6
7 Nm
(62 lbfin)
7
29
28
2.2 Nm
(19 lbfin)
8
2
20 Nm
(15 lbfft)
3
4
5
1
7
6
7 Nm
(62 lbfin)
Hull
8
2.2 Nm
(19 lbfin)
28
29
23
26
34
2.2 Nm
(19 lbfin)
33
35
1.7 Nm
(15 lbfin)
26
36
25
12
1.2 Nm
(10 lbfin)
24
22
5.5 Nm
(49 lbfin)
2.2 Nm
(19 lbfin)
11
9
10
17
16
21
27
21
2.2 Nm
(19 lbfin)
SMR2003-044_14_02A.FM 14-02-19
GENERAL
The Off-Power Assisted Steering (O.P.A.S.) system
uses a dual side vanes design that assists the water-
craft steering in deceleration, to redirect watercraft
path when steering is turned after throttle has been
released or engine stopped.
The side vanes on the rear sides of the hull, turn as
the steering is turned to assist the watercraft turning.
At first, carefully experiment turning with this system.
1. Side vanes turn following steering movement
When engine is running at approximately 75% or
more RPM, the side vanes are automatically raised
to upper position since they are not required at that
vehicle speed range.
Between 30% and 75% engine RPM, side vanes
are gradually raised from lower position to upper
position.
1. Side vane in upper position
When throttle is released and engine RPM drops,
the side vanes are automatically lowered thus as-
sisting steering control.
1. Side vane in lower position
SIDE VANE
Disassembly
Removal procedure for RH and LH side vane no. 9
is same.
Turn the steering for removal of tie rod retaining
screw.
Remove tie rod retaining screw no. 10 and socket
screw no. 11.
1. Tie rod screw
2. Side vane
3. Cylinder support assembly
4. Tie rod retaining stabilizer
1 F18K03A 1
F18K02A 1
1 F18K01A
1
2
F18K0LA
4
3
14-02-20 SMR2003-044_14_02A.FM
1. Socket screw
Lift shaft while holding top of side vane.
Pull side vane out.
Adjustment
Put the steering in straight ahead position.
Measure the portion of tie rod stabilizing fitting
no. 21 exceeding from cylinder support.
The exceeding distance of tie rod stabilizing fitting
no. 21 from the cylinder support should be 42 1 mm
(1.65 .04 in).
A. 42 1 mm (1.65 .04 in)
Assembly
Assembly is the reverse process of disassembly.
Torque tie rod retaining screw no. 10 to 4.5 Nm
(40 lbfin).
Torque socket screw no. 11 to 2.2 Nm (19 lbfin).
CYLINDER SUPPORT ASSEMBLY
Disassembly
Removal procedure for RH and LH cylinder sup-
port assembly is same.
Remove side vane as mentioned above.
Unscrew bottom nut using O.P.A.S. cylinder nut
wrench (P/N 529 035 840).
1. Bottom nut
2. Cylinder support
3. Pivot rod
4. O.P.A.S. cylinder nut wrench
Remove cylinder assembly out of cylinder support.
1. Pivot rod
2. Spacer
3. Cylinder cap assembly
4. Piston
5. Spring
Unscrew tie rod stabilizing fitting no. 21 from tie
rod no. 23.
1
F18K0MA
A
F18K0ZA
4 F18K0NA
2
1
3
1 F18K1DA 3 2 4 5
SMR2003-044_14_02A.FM 14-02-21
Unscrew 4 socket screws no. 22.
1. Socket screws
Remove Oetiker clamp no. 25 to remove water
hose no. 26 from the cylinder support no. 12.
1. Oetiker clamp
2. Water hose
3. Cylinder support
Assembly
Assembly is the reverse process of disassembly,
make sure of the following when doing assembly:
Always discard old threaded cover rod no. 14
and replace with new one.
1. Replace threaded cover
Check pivot rod no. 13 for cracks or scratches.
Replace pivot rod, if necessary.
Socket screws no. 22 should be turned 2-3 turns
by hand before tightening with tool.
Replace the cylinder seal ring whenever servicing.
Torque socket screw no. 22 to 5.5 Nm (49 lbfin).
TIE ROD
Disassembly
Removal procedure for RH and LH tie rod is same.
Remove side vane and cylinder support assembly
as mentioned above.
Remove O.P.A.S. U lever screw no. 2, flat wash-
er no. 3, bushing no. 4 and venturi bushing no. 5
from nozzle.
Remove jet pump (refer PROPULSION SYSTEM).
Remove screw no. 6 and washers no. 7 to remove
U lever no. 1 from tie rod connecting levers no. 8.
TYPICAL
1. U lever screw
2. Screw
3. Tie rod connecting lever
4. Tie rod
Pull tie rod out from jet pump side.
Unscrew lever from the tie rod.
Assembly
Torque screw no. 6 to 7 Nm (62 lbfin).
Torque O.P.A.S. U lever screw no. 2 to 20 Nm
(177 lbfin).
F18K0PA
1 1
3 F18K0QA 1 2
1 F18K0YA
2 F18K0RA 1 3
4
14-02-22 SMR2003-044_14_02A.FM
SEALED TUBE
Disassembly
Removal procedure for RH and LH sealed tube
no. 27 is same.
Remove side van, cylinder housing assembly and
O.P.A.S. U lever as mentioned above.
Remove jet pump (refer PROPULSION SYSTEM).
Remove Phillips screws no. 28 and remove rod
grommet no. 29.
1. Phillips screws
2. Rod grommet
Pull sealed tube out with tie rod from inside of
bilge towards jet pump side.
TYPICAL
1. Sealed tube
2. Tie rod
Assembly
Apply silicone grease on the screws before install-
ing.
Torque Phillips screws no. 28 to 2.2 Nm (19 lbfin).
FILTER
For removal and installation procedure refer to
PROPULSION SYSTEM.
O.P.A.S. filter is part of plastic elbow no. 30.
Check for cleanness. Replace or clean it as neces-
sary.
VALVE
Disassembly
Remove O.P.A.S. U lever screw no. 2, flat
washer no. 3, bushing no. 4 and venturi bushing
no. 5 from nozzle.
Remove jet pump, filter and formed hose no. 32
(refer PROPULSION SYSTEM).
Remove gear clamps no. 35 to remove water hos-
es no. 26 from valve.
1. Gear clamps
2. Valve
3. Water hoses
2 F18K0SA
1
1 F18K0TA 2
F18K0UA 3
2
1
SMR2003-044_14_02A.FM 14-02-23
Unscrew bottom nut of valve no. 33 using O.P.A.S.
cylinder nut wrench (P/N 529 035 840).
1. O.P.A.S. cylinder nut wrench
2. Valve
Remove 2 Phillips screws no. 34 from valve collar.
TYPICAL
1. Phillips screws
Remove valve downwards from pump tunnel.
Assembly
Check for cracks on formed hose no. 32,
change if necessary.
Make sure the valve is installed in the right po-
sition.
Torque Phillips screws no. 34 to 2.2 Nm (19 lbfin).
Tighten gear clamps no. 31 manually to 1.7 Nm
(15 lbfin).
WATER HOSE
Disassembly
Removal procedure for RH and LH water hose is
same.
as mentioned above.
Remove gear clamps no. 35 to remove water
hose no. 26 from valve.
Pull out the water hose no. 26 from exterior.
Assembly
Water hose must be installed from the out side
to the inside of hull by turning it, oriented to-
wards valve.
Tighten gear clamps no. 35 manually to 1.7 Nm
(15 lbfin).
CROSS SUPPORT PLATE
Disassembly
For LH Side Cross Support Plate
Remove Gooseneck pipe, exhaust pipe and LH
muffler (refer to EXHAUST SYSTEM).
For RH Side Cross Support Plate
Remove RH muffler (refer to EXHAUST SYSTEM).
For RH and LH Cross Support Plates
as mentioned above.
Unscrew the screw no. 24.
1. Remove screw
Remove cross support plate no. 36 from the in-
side of bilge.
1 F18K0VA 2
1
F18K0WA
1
F18K0XA
14-02-24 SMR2003-044_14_02A.FM
Assembly
Check for cracks and deterioration of screw
threads on cross support plate, change if nec-
essary.
Verify the condition of gaskets before installa-
tion, change if necessary.
1. Gasket
2. Support plate
GASKET INSTALLED ON SUPPORT PLATE
Torque screw no. 24 to 1.2 Nm (10 lbfin).
1 F18K1BA 2
F18K1CA
Subsection 03 (ALIGNMENT)
SMR2003-044_14_03A.FM 14-03-1
ALIGNMENT 0
Position handlebar in straight ahead position by
measuring each side the distance from handlebar
grip end to floorboard.
TYPICAL
1. Measuring handlebar grip end/floorboard distance
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.
TYPICAL
1. Measure the distance on each side of the straight edge
If necessary, steering alignment adjustment should
be performed at steering cable support.
Open storage compartment cover and remove bas-
ket (if so equipped).
Loosen 2 bolts retaining block at cable support.
Turn adjustment nut as required.
ALL MODELS EXCEPT XP DI
1. Retaining block
2. Adjustment nut
3. Loosen bolts
XP DI Models
To have access to the cable adjustment nut, open
upper storage compartment cover and remove stor-
age basket.
1. Remove storage basket
F01K07A
1
F01J5ZA
1
1
3
F01K18A
2
F01H6WA 1
Subsection 03 (ALIGNMENT)
14-03-2 SMR2003-044_14_03A.FM
TYPICAL XP DI MODELS
1. Support
2. Adjustment nut
3. Loosen bolts
All Models
After adjustment, torque retaining block bolts to
6 Nm (53 Ibfin).
CAUTION: Verify when the handlebar is turned
completely to the left or right side, that there is
no interference with venturi or VTS ring.
F08K03B
1
2
3
Section 15 SUSPENSION
SMR2003-049_15_01ATOC.FM 15-01-1
TABLE OF CONTENTS 0
DIRECT ACTION SUSPENSION............................................................................................ 15-02-1
REMOVAL .......................................................................................................................... 15-02-2
INSPECTION ...................................................................................................................... 15-02-3
ASSEMBLY......................................................................................................................... 15-02-3
Subsection 02 (DIRECT ACTION SUSPENSION)
SMR2003-045_15_02A.FM 15-02-1
DIRECT ACTION SUSPENSION 0
XP DI Models
10
11
3
13
12
5
8
6
9
4
7
F08Q02T
34 Nm
(25 lbfft)
2
1
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
Loctite
243
Loctite
243
34 Nm
(25 lbfft)
5 Nm
(44 lbfin)
15-02-2 SMR2003-045_15_02A.FM
REMOVAL
Shock Absorber
Loosen 4 screws and remove bottom cover of seat.
1. Remove cover
Loosen gear clamp no. 2 of outer boot no. 3, then
pull outer boot downward.
Remove rear access panel from body.
Loosen lower gear clamp no. 4, then push inner
boot no. 5 upward.
Remove bolt no. 6 and lock nut no. 7 from shock
absorber lower support no. 8.
1. Bolt
2. Lock nut
F08L11A 1
F08L12A 1
F08I03B 1
F08Q03A 2 1
SMR2003-045_15_02A.FM 15-02-3
Tilt seat upward.
Loosen upper gear clamp no. 9 of inner boot no. 5.
Remove bolt no. 10 and lock nut no. 11 from shock
absorber upper support.
1. Bolt
2. Lock nut
Remove shock absorber/coil spring assembly.
Outer Boot
Pull outer boot to remove it from body.
Coil Spring
Install spring compressor tool (P/N 529 027 100)
in a vise.
Install shock absorber/coil spring assembly in
spring compressor tool.
Compress spring and remove cup no. 13.
Unload tool and remove spring from shock absorber.
INSPECTION
Boot
Inspect condition of boots. If there are any signs
of tear, renew boot(s).
Shock Absorber
Inspect shock absorber for wear. Extend and com-
press the piston several times over its entire
stroke; it should move smoothly and with uniform
resistance.
Pay attention to the following conditions that will
denote a defective shock absorber:
A skip or a hang back when reversing stroke at
mid travel.
Seizing or binding condition except at extreme
end of either stroke.
Oil leakage.
A gurgling noise, after completing one full com-
pression and extension stroke.
Renew if any defects are present.
ASSEMBLY
bly procedure. Refer to the main illustration at the
beginning of this subsection for torque specifica-
tions and service products to be used.
WARNING
Do not attempt to dismantle a spring without
using the proper tool.
F08L13A 1
F08Q04A 2 1
F05L0NA
Section 16 HULL/BODY
SMR2003-049_16_01ATOC.FM 16-01-1
TABLE OF CONTENTS 0
ADJUSTMENT AND REPAIR ................................................................................................ 16-02-1
GLOVE BOX....................................................................................................................... 16-02-22
SEAT ADJUSTMENT......................................................................................................... 16-02-23
STORAGE COMPARTMENT INNER SHELL ..................................................................... 16-02-24
STORAGE COVER SHOCK................................................................................................ 16-02-27
STORAGE COMPARTMENT COVER ADJUSTMENT ...................................................... 16-02-28
ACCESS PANEL ADJUSTMENT....................................................................................... 16-02-29
MIRROR.............................................................................................................................. 16-02-29
INFO CENTER (LCD gauges) ............................................................................................ 16-02-29
DEFLECTOR AND/OR UPPER GRID.................................................................................. 16-02-30
FINITION PLATE................................................................................................................. 16-02-30
INLET GRATE..................................................................................................................... 16-02-31
RIDING PLATE.................................................................................................................... 16-02-32
JET PUMP SUPPORT ........................................................................................................ 16-02-33
DEFLECTOR ....................................................................................................................... 16-02-34
DRAIN PLUG INSTALLATION........................................................................................... 16-02-35
SEAT REMOVAL ................................................................................................................ 16-02-35
SEAT COVER REPLACEMENT .......................................................................................... 16-02-37
BUMPER REPLACEMENT................................................................................................. 16-02-37
WAKE PYLON.................................................................................................................... 16-02-38
SPONSON REPLACEMENT .............................................................................................. 16-02-39
ENGINE COMPARTMENT COVER REMOVAL ................................................................. 16-02-41
DECALS REPLACEMENT .................................................................................................. 16-02-41
HULL AND BODY REPAIR................................................................................................. 16-02-42
TOOLS AND MATERIALS LIST......................................................................................... 16-02-44
THRU-HULL FITTING INSTALLATION............................................................................. 16-02-45
Subsection 02 (ADJUSTMENT AND REPAIR)
SMR2003-046_16_02A.FM 16-02-1
ADJUSTMENT AND REPAIR 0
GTI, GTI LE RFI and GTI LE Models (bow)
F17L14S
Loctite
29647
5 Nm
(44 lbfin)
3 Nm
(26 lbfin)
8 Nm
(71 lbfin)
7 Nm
(62 lbfin)
8 Nm
(71 lbfin)
Loctite
29647
15 Nm
(133 lbfin)
Body
16-02-2 SMR2003-046_16_02A.FM
GTI, GTI LE RFI and GTI LE Models (stern)
F17L15S
Silicone
sealant
2.5 Nm
(22 lbfin)
15 Nm
(133 lbfin)
8 Nm
(71 lbfin)
Silicone
sealant
15
4
5
5
Silicone
sealant
Dart
fastex
12
SMR2003-046_16_02A.FM 16-02-3
GTI, GTI LE RFI and GTI LE Models (cover)
F17L16S
Loctite
243
4 Nm
(35 lbfin)
1
4 Nm
(35 lbfin)
5 Nm
(44 lbfin)
Loctite
243
Loctite
454
15 Nm
(133 lbfin)
GTI LE
Loctite
243
Synthetic grease
4 Nm
(35 lbfin)
3 Nm
(26 lbfin)
8 Nm
(71 lbfin)
4 Nm
(35 lbfin)
16-02-4 SMR2003-046_16_02A.FM
GTI, GTI LE RFI and GTI LE Models (seats)
F07L2OS
GTI (seats)
Loctite
414
SMR2003-046_16_02A.FM 16-02-5
RX DI (bow)
F16L11S
Silicone
sealant
5 Nm
(44 lbfin)
3 Nm
(26 lbfin)
8 Nm
(71 lbfin)
8 Nm
(71 lbfin)
7 Nm
(62 lbfin)
Loctite
271
15 Nm
(133 lbfin)
Loctite
271
Body
Silicone
sealant
16-02-6 SMR2003-046_16_02A.FM
RX DI (stern)
2.5 Nm
(22 lbfin)
Loctite 271
12
13
4
Loctite 271
5
12
14
12
12
4
5
15 Nm
(133 lbfin)
15
Silicone
sealant
2.2 Nm
(19 lbfin)
F16L12S
Silicone
sealant
SMR2003-046_16_02A.FM 16-02-7
RX DI (cover)
F16L13S
Loctite
243
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
Loctite
243
Loctite
243
Loctite
454
2.5 Nm
(22 lbfin)
8 Nm
(71 lbfin)
2.5 Nm
(22 lbfin)
8 Nm
(71 lbfin)
8 Nm
(71 lbfin)
Synthetic grease
3 Nm
(26 lbfin)
4 Nm
(35 lbfin)
8 Nm
(71 lbfin)
4 Nm
(35 lbfin)
16-02-8 SMR2003-046_16_02A.FM
RX DI (seat)
F16L14S
5.5 Nm
(49 lbfin)
SMR2003-046_16_02A.FM 16-02-9
LRV DI (bow)
F11L0LS
Loctite
271
8 Nm
(71 lbfin)
Loctite
243
5 Nm
(44 lbfin)
5 Nm
(44 lbfin)
Loctite
29647
15 Nm
(133 lbfin)
Loctite
29647
Body
10
6
16-02-10 SMR2003-046_16_02A.FM
LRV DI (stern)
F11L0MS
Loctite
271
8 Nm
(71 lbfin)
13
Loctite
29647
Icebox foam
Loctite
243
15 Nm
(133 lbfin)
Loctite
243
Body
Icebox
foam
Loctite
29647
2.2 Nm
(19 lbfin)
4
5
12
12
12
5
SMR2003-046_16_02A.FM 16-02-11
LRV DI (cover)
F07L1MT
Loctite
243
0.8 Nm
(7 lbfin)
8 Nm
(71 lbfin)
1.4 Nm
(12 lbfin)
5 Nm
(44 lbfin)
Loctite
243
5 Nm
(44 lbfin)
8 Nm
(71 lbfin)
Loctite
243
5 Nm
(44 lbfin)
Loctite
243
3 Nm
(26 lbfin)
16-02-12 SMR2003-046_16_02A.FM
LRV DI (seat)
F11L0NS
Loctite
414
Loctite
243
Loctite
414
Loctite 243
4 Nm
(35 lbfin)
5 Nm
(44 lbfin)
Loctite
243
5 Nm
(44 lbfin)
SMR2003-046_16_02A.FM 16-02-13
XP DI Models (bow)
F08L1JT
Loctite
243
Silicone
sealant
10
6
Loctite
243
Silicone
sealant
Body
15 Nm
(11 lbfft)
Loctite
271
8
7
16-02-14 SMR2003-046_16_02A.FM
XP DI Models (stern and rear)
23
4 4
5
5
12
13
12
3
5 Nm
(44 lbfin)
Loctite 243
Front tray
Body
Loctite
243
4 Nm
(35 lbfin)
4 Nm
(35 lbfin)
Loctite
243
Body
5 Nm
(44 lbfin)
Loctite
243
3
F12L0KS
SMR2003-046_16_02A.FM 16-02-15
XP DI Models (seat)
F12L0LS
Loctite 243
15 Nm
(11 lbfft)
17
5 Nm
(44 lbfin)
Loctite 271
13 Nm
(10 lbfft)
3 Nm
(27 lbfin)
23
22
21
20
19
18
3 Nm
(27 lbfin)
24
Synthetic
grease
16-02-16 SMR2003-046_16_02A.FM
XP DI Models (suspension and engine cover)
F08L1KT
Loctite
243
4 Nm
(35 lbfin)
Loctite
243
8 Nm
(71 lbfin)
Loctite
243
4 Nm
(35 lbfin)
Loctite
243
4 Nm
(35 lbfin)
Loctite
648
8 Nm
(71 lbfin)
Loctite
243
SMR2003-046_16_02A.FM 16-02-17
XP DI Models (front cover)
Engine
cover
Synthetic
grease
3 Nm
(27 lbfin)
Loctite
271
2 Nm
(18 lbfin)
Loctite
243
Loctite
243
F12L0MS
16-02-18 SMR2003-046_16_02A.FM
GTX DI and GTX 4-TEC Models (seats)
F18L1HS
Loctite
414
Loctite
414
Loctite
414
Loctite
414
Loctite
414
SMR2003-046_16_02A.FM 16-02-19
GTX DI and GTX 4-TEC Models (front storage compartment)
F18L34S
Body
4-TEC Limited and
Wakeboard Edition only
Synthetic
grease
Loctite
243
5 Nm
(44 lbfin)
3 Nm
(26 lbfin)
Loctite 271
Loctite 243
Loctite
243
16-02-20 SMR2003-046_16_02A.FM
GTX 4-TEC Models and GTX DI Models (body-front view)
F18L1JS
GTX 4-TEC
only
Body
GTX DI only
10
11
8
12
9
7
7 Nm
(62 lbfin)
Loctite
29647
Loctite 29647
Loctite 243
SMR2003-046_16_02A.FM 16-02-21
GTX 4-TEC Models and GTX DI Models (body-rear view)
F18L35S
2.5 Nm
(22 lbfin)
6
GTX 4-TEC
Limited only
GTX 4-TEC
or
GTX DI
Loctite 29647
Loctite
29647
1
2
3
1
4
15
7.5 Nm
(13 lbfin)
GTX 4-TEC
Wakeboard Edition only
Loctite
29647
15 Nm
(11 lbfin)
Loctite 29647
10 Nm
(88 lbfin)
Loctite
243
8 Nm
(70 lbfin)
Loctite
5900
21
23
25
20
26
24
16-02-22 SMR2003-046_16_02A.FM
GLOVE BOX
LRV DI
Open the glove box cover then unscrew the four
screws.
Pull the glove box out of body.
GTX 4-TEC and GTX DI Models
Lift the glove box top cover and pull the glove box
locking device.
Pull the glove box out of body.
GTI, GTI LE, GTI LE RFI and RX DI Models
Removal
Remove handle from shift lever.
1. Unscrew
Remove darts and then remove side panels.
1. Unscrew the darts
GTI, GTI LE and RX DI Models
Open front storage cover and remove the access
panel.
Detach the latch retaining vent tube to bracket.
1. Unlatch
Pull vent tube out.
From the engine compartment, insert a hand
through the vent tube hole and press glove box
lock tabs to release.
1. Insert your hand here to release the lock tabs
1 F16L07A
1 F16L08A
1 F17L0OA
1 F16L0AA
SMR2003-046_16_02A.FM 16-02-23
From front storage compartment, pull glove box
out.
1. Lock tabs
Installation
Reverse the removal procedure.
SEAT ADJUSTMENT
Seat Retainer
NOTE: Apply Loctite 243 on threads of lock pin
when the adjustment is required or when the lock
pin is removed then reinstalled. The threads on
new lock pin are coated with a self-locking prod-
uct, do not apply Loctite 243 on threads.
TYPICAL GTX DI, GTX 4-TEC SERIES AND LRV DI FRONT
SEAT
1. Lock pin
2. Adjustment nut (Loctite 243). Torque to 5 Nm (44 lbfin)
A. 33 1 mm (1-35/64 3/64 in)
TYPICAL GTX DI, GTX 4-TEC SERIES, AND LRV DI REAR
SEAT
1. Lock pin
2. Adjustment nut (apply Loctite 243). Torque to 5 Nm (44 lbfin)
A. 35 1 mm (1-5/16 3/64 in)
GTI AND GTI LE MODELS FRONT SEAT
1. Lock pin
A. 34 1 mm (1-11/32 3/64 in)
1 F16L0BA
F07L08A
A
2
1
F06L03A
A
1
2
A
2
F17L0PA
1
16-02-24 SMR2003-046_16_02A.FM
GTI AND GTI LE MODELS REAR SEAT
1. Lock pin
A. 34 1 mm (1-11/32 3/64 in)
RX DI MODELS
1. Lock pin
A. 36 1 mm (1-35/64 3/64 in)
STORAGE COMPARTMENT
INNER SHELL
GTI, GTI LE and RX DI Models
To remove inner shell, proceed as follows:
CAUTION: Failure to follow this order may lead
to damaging inner plastic studs.
Remove retaining screws.
Gently pull on large end (rear end) and pull apart
towards the small end (front). See illustration.
1. Gently pull starting this end
2. Finish with this end
For installation, proceed as follows:
Sand both inner and outer shells in area to be
glued (except GTI).
Clean to remove any dust with isopropylic alco-
hol. Let dry.
Apply a 2 mm (3/32 in) bead of Loctite 454.
Reinstall inner shell with its retaining screws.
Tighten screws starting with the one at the
small end (front) and finish with rear end. Care-
fully hand tighten.
GTX DI and GTX 4-TEC
Removal and Installation
To remove inner shell, proceed as follows:
CAUTION: Failure to follow this order may lead
to damaging inner plastic studs.
Open storage cover.
Remove access panel.
Disconnect multi-function connector.
1. Access panel
2. multi-function connector
A
2
F17L0QA
1
A
2
F16L0TA
1
1 F16L05A
2
1
2
F18L1MA
SMR2003-046_16_02A.FM 16-02-25
Unlock shock rod from circlip and remove washer.
1. Shock rod
2. Circlip
3. Washer
Remove one long retaining screw (front).
Remove two short retaining screws locate in
the back lower side and hold cover firmly.
1. One long retaining screw (front)
2. Short retaining screw (one on each side to the back)
Remove storage cover.
Remove seven inner skin short screws
(flanged screws).
Remove two long inner skin screws
(hex screws).
1. Storage cover
2. Inner skin
3. Inner skin short screws (x 7)
4. Inner skin long screws (x 2)
Use a rubber hammer to remove the inner skin
from the cover. If the inner skin is too stiff, in-
stall a piece of 2 x 4 against the inner skin and
hit it with the rubber hammer.
1. Storage cover
2. Inner skin
3. Rubber hammer
Remove connector harness from the inner skin
by cutting tie-raps.
1. Inner skin
2. Storage cover
3. Connector harness
1
F18L1NA
2
3
2 F18L1OA
1
1
F18L1PA
2
3
3
4
3
3
1
F18L1QA
2
3
2
1
F18L1RA 3
3
16-02-26 SMR2003-046_16_02A.FM
Remove compass by removing dart (2).
Remove temperature sensor from grommet.
1. Inner skin
3. Compass
1. Dart (x2)
2. Compass
2. Grommet
Install new inner skin in the reverse process.
For installation, proceed as follows:
Install the compass and secure it with the two
darts.
Install the temperature sensor in grommet.
Install the tie-raps around wire harnesses.
Align inner skin with storage cover and make
sure that the lateral locking hooks in the inner
skin get engaged in the storage cover locking
bracket. If the two lateral locking hooks get
properly aligned and engaged the storage cover
back locking hook will be engaged properly in
the inner skin back locking bracket.
1. Inner skin lateral locking hook
2. Inner skin back locking bracket
1. Storage cover lateral locking bracket
2. Inner skin lateral locking hook
3
1
F18L1SA
2
1 F18L1TA 1 2
1 F18L1UA
2
F18L1PB
2
1
1
1
F18L1VA
2
SMR2003-046_16_02A.FM 16-02-27
1. Storage cover back locking hook
2. Inner skin back locking bracket
Secure the inner skin in the storage cover by
using the rubber hammer.
Fasten the seven inner skin short screws and
the two inner skin long screws.
STORAGE COVER SHOCK
GTX DI, GTX 4-TEC Series, GTI LE and GTI LE
RFI
To remove storage cover shock proceed as fol-
lows:
Unlock shock rod from circlip and remove wash-
er.
1. Shock rod
2. Circlip
3. Washer
Release the shock from top linkage bracket and
bottom support bracket by inserting a flat
screwdriver in the shock top and bottom locking
devices.
1. Top linkage bracket
2. Shock top locking device
1. Bottom support bracket
2. Shock bottom locking device
WARNING
Make sure to have a 2x4 piece of wood
around the work bench to support the storage
cover while changing the cover shock.
1
F18L1WA
2
1
F18L1NA
2
3
2 F18L1YA
1
2 F18L1ZA 1
16-02-28 SMR2003-046_16_02A.FM
1. Shock absorber
2. Flat screwdriver
3. Shock top locking device
STORAGE COMPARTMENT
COVER ADJUSTMENT
NOTE: Apply Loctite 243 on threads of lock pin
when the adjustment is required or when the lock
pin is removed then reinstalled. The threads on
new lock pin are coated with a self-locking prod-
uct, do not apply Loctite 243 on threads.
All Models
Adjust lock pin no. 3 as per following specifica-
tions:
FIXED TYPE LOCK PIN
1. Lock pin (apply Loctite 243)
2. Adjustment nut. Torque to 5 Nm (44 lbfin)
A. 34 1 mm (1-11/32 3/64 in)
FLOATING TYPE
1. Lock pin (apply Loctite 243)
2. Rubber washer
3. Lock nut. Torque to 5 Nm (44 lbfin)
A. 39.2 1 mm (1-35/64 3/64 in)
NOTE: Some models have a floating type lock pin.
It is normal to have a front and aft play of the lock
pin. To adjust, tighten lock pin until any vertical play
is eliminated. Make sure a front and aft play re-
mains when pressing by hands.
XP DI MODELS
1. Lock pin. Torque to 4 Nm (35 lbfin)
A. 13.4 mm (17/32 in)
1
F18L20A
3
2
F06L04A
A
2
1
2
F16L0UA
1
3
A
F08L1AA
A
1
SMR2003-046_16_02A.FM 16-02-29
ACCESS PANEL ADJUSTMENT
XP DI Models
Adjust lock pin no. 3 of access panel as per follow-
ing specifications:
1. Lock pin
2. Adjustment nut (Loctite 243)
3. Lock nut. Torque to 5 Nm (44 lbfin)
A. 39 1 mm (1-17/32 3/64 in)
Adjust bolts no. 16 of access panel arms as per
following specifications:
1. Lock nut. Torque to 22 Nm (16 lbfft)
A. 20 1 mm (25/32 3/64 in)
MIRROR
GTI LE and RX DI
Place the mirror frame in hot water to soften the
material to allow mirror installation in its frame.
GTX 4-TEC Series and GTX DI
To remove mirror proceed as follows:
Remove storage compartment inner shell from
storage cover as described earlier in this sec-
tion.
Remove two hexagonal screws and flat wash-
ers.
Remove defective mirror with a spatula.
1. Mirror
2. Spatula
Place the mirror frame in hot water to soften
the material to allow mirror installation in its
frame.
Reinstall storage compartment inner shell.
INFO CENTER (LCD gauges)
GTX DI
Info gauges can be pulled directly out from the
storage cover.
GTX 4-TEC
To remove the Info center (Speedometer and LCD
Info gauge) proceed as follows:
Carefully pull each side of the Info Center (LCD
Gauges) using a suction cup (P/N 295 000 163)
to remove Info Center from the storage cover.
F08L1BA
1
2
3
A
F05L0VA
A
1
1
F18L21A
2
16-02-30 SMR2003-046_16_02A.FM
NOTE: Clean the Info Center before installing the
suction cup (P/N 295 000 163) clean and dry sur-
face helps the tool to hold and easily remove the
Info Center.
1. Ventouse installed on one side of Info Center
Refer to ELECTRICAL section to unplug gauges
from harnesses.
Install new Info center.
Refer to ELECTRICAL section to plug gauges
on the harnesses.
DEFLECTOR AND/OR UPPER GRID
GTX 4-TEC Supercharged Limited
To remove the deflector and/or the upper grid pro-
ceed as follows:
Remove storage from storage cover compart-
ment inner shell as described earlier in this sec-
tion to get access.
Remove the defective deflector and/or the up-
per grid from plastic retaining clip. Use two
screwdrivers to release the deflector or the
grid.
1. Inner skin
2. Deflector retaining clips
RELEASE DEFLECTOR
FINITION PLATE
GTX 4-TEC and GTX DI
The removal procedure for RH finition with grid
and LH finition with grid is the same.
Remove the two darts holding the grid to the body.
1
F18L36A
1
2
F18L22A
2
F18L23A
SMR2003-046_16_02A.FM 16-02-31
Make a hole into the luggage compartment as
shown in the illustration below to gain access to
the finition plate screw.
Remove screw and finition plate.
After installing finition plate, plug (P/N 291 000
279) the finition plate screw hole.
1. Plug (P/N 291 000 279)
For GTX 4-TEC Supercharged Limited
Removal procedure for RH finition, deflector with
grid and LH finition, deflector with grid the is
same.
Finition plate is mounted on deflector.
Remove three darts holding deflector and grid.
INLET GRATE
Loosen screws and remove inlet grate.
NOTE: An impact screwdriver should be used to
loosen tight screws.
GTI LE RFI and LRV DI
When reinstalling inlet grate, apply Loctite 271 on
threads and torque screws to 11 Nm (8 lbfft).
GTX DI, GTX 4-TEC Series, GTI, GTI LE, XP DI
and RX DI
When reinstalling inlet grate, apply Loctite 271 on
threads.
Follow this sequence referring to the illustration:
Hand tighten screw numbers , then .
Torque screw numbers and to 11 Nm
(97 lbfin).
Torque screw number to 26 Nm (19 lbfft).
GTX DI and GTX 4-TEC
Follow this sequence referring to the illustration:
Hand tighten screw numbers , , then .
Torque screw numbers , and to 11 Nm
(97 lbfin).
155 mm
(6.1 in)
F18L29A
55 mm
(2.2 in)
25 mm
(1 in)
1 F18L2AA
F16L06A
3
2
1
Subsection 02 (ADJ USTMENT AND REPAIR)
16-02-32 SM R 2003-046_16_02A .FM
Torque screw num ber to 26 N m (19 lbfft).
RIDING PLATE
Removal
All Models
R em ove inlet grate.
R em ove jet pum p. R efer to JET PU M P.
R em ove the speed sensor from the riding plate (if
applicable).
Loosen riding plate screw s.
NOTE: A n im pact screw driver should be used to
loosen tight screw s.
U sing a low height hydraulic bottle jack and 2 steel
plates, pry out riding plate.
TYPICAL
1. H ydraulic bottle jack
2. Steel plates
Cleaning
Scrape off all excess of sealant from riding plate
and hull.
C lean hull surface w ith acetone based solvent to
elim inate grease, dust and any residue of sealant.
Installation
All Models except GTX DI and GTX 4-TEC
Models
A pply Loctite The R ight Stuff G asket as indicated
by the shaded areas in the next illustrations. Fol-
low also the torquing sequence as show n in the
sam e illustrations.
NOTE: A pply Loctite The R ight Stuff G asket as in-
dicated by the shaded area.
GTI, GTI LE, GTI LE RFI, LRV DI XP DI AND RX DI MODELS
F18L24A
1
3
2
4
F05J03A
2 1
F08L1TA
6 4
8 2
7 1
5 3
SM R 2003-046_16_02A .FM 16-02-33
GTX DI and GTX 4-TEC Models
A pply Loctite R TV silicone sealant (P/N 293 800
066) as indicated by the shaded areas in the next
illustrations. Follow also the torquing sequence as
show n in the sam e illustrations.
GTX 4-TEC SERIES MODELS
GTX DI MODELS
NOTE: A pply Loctite R TV silicone sealant
(P/N 293 800 066) as indicated by the shaded area.
J ET PUMP SUPPORT
Removal
R em ove jet pum p. R efer to JET PU M P.
R em ove inlet grate and riding plate.
R em ove ball joint, boot, nut, half rings and O -rings
from steering cable.
TYPICAL
1. U nscrew nut
R em ove ball joint, boot, nut, half rings and O -rings
from reverse cable.
R em ove boot and nut from VTS sliding shaft (RX
DI and XP DI models).
D isconnect w ater supply hose, w ater return hose
and bailer hoses.
R em ove nuts, lock w ashers and flat w ashers re-
taining jet pum p support.
TYPICAL
1. Rem ove nuts
3
F18L26A
4
5
1 7
2 8
6
F18L27A
3 5
4 6
2 8
1 7
F05K02A
1
F07L0AA
1
16-02-34 SM R 2003-046_16_02A .FM
U sing a heat gun, heat jet pum p support until it is
possible to pull it.
NOTE: Shim s m ay have been installed betw een
support and body. D o not rem ove these shim s,
otherw ise jet pum p alignm ent w ill be altered.
Installation
A pply Loctite The R ight Stuff G asket (RTV silicone
sealant (P/N 293 800 066) for G TX D I and G TX 4-
TEC Series) as indicated by the shaded areas in
the next illustrations. Follow also the torquing se-
quence as show n in the sam e illustrations.
GTI, GTI LE, GTI LE RFI, RX DI AND XP DI MODELS
LRV DI MODELS
GTX DI AND GTX 4-TEC MODELS
DEFLECTOR
GTI LE RFI and LRV DI
Removal
U sing a heat gun, heat deflector and pry it using a
piece of w ood.
Installation
A pply Loctite The R ight Stuff G asket as indicated
by the shaded area in the follow ing illustrations.
LRV DI MODELS
4
2 1
F08L1OA
3
F12L0GA
2
4
1
3
F18L28A
4
3
1 2
F12L0JA
SMR2003-046_16_02A.FM 16-02-35
GTI LE RFI MODELS
DRAIN PLUG INSTALLATION
Refer to the following illustration to install drain plug
no. 15.
1. Drain plug
2. Silicone sealant (P/N 293 800 086) around the middle hole and in
the screw holes
3. Torque screws to 2.2 Nm (19 lbfin)
SEAT REMOVAL
XP DI Models
Loosen 4 screws and remove bottom cover no. 17
of seat.
1. Remove cover
Loosen gear clamp of outer boot; then, pull outer
boot downward.
F07L2NA
2
F00L2RA
3
3
1
F08L11A 1
F08L12A 1
16-02-36 SMR2003-046_16_02A.FM
Loosen gear clamp of inner boot; then, pull boot
downward.
1. Gear clamp
Remove bolt and lock nut from shock absorber up-
per support.
1. Bolt
2. Lock nut
Remove protective caps no. 18 and loosen screws
no. 19 to remove eyelet no. 20 on each side of
seat.
1. Loosen screws of eyelet
Remove cup no. 21 on each side of seat.
Loosen nut no. 23 on each side of seat.
1. Loosen nut
Tilt seat.
Loosen screws no. 24 on each side of seat retain-
ing the side covers.
Lower seat.
Remove side covers.
Pull seat frame out of pivots.
Remove seat.
Seat installation is essentially the reverse of re-
moval procedure. Refer to the main illustration of
seat at the beginning of this subsection for proper
torque specifications and service products to be
used.
F08L13A 1
F08Q04A 2 1
F08L1EA
1
1
F08L1FA
SMR2003-046_16_02A.FM 16-02-37
SEAT COVER REPLACEMENT
Install staples with an electric tacker such as Ar-
row tacker no. ETN-50 or with a manual tacker
such as Arrow tacker no. T-50.
NOTE: For an easier installation, its highly recom-
mended to use an electric tacker.
Ensure that the seat rest firmly against a hard sur-
face such as a piece of wood. This is done to get
the staples completely pushed in place.
TYPICAL
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
After cover installation cut all around the excess
of material.
BUMPER REPLACEMENT
All Models except GTX DI and GTX 4-TEC
Series Models
1. Remove trim no. 5 from side bumper rail no. 4.
2. Drill pop rivets no. 12 to remove side bumper rail
no. 4.
3. Mark hole positions on body straight and bow
sections.
TYPICAL
1. Front bumper
2. Corner bumper
3. Straight section
4. Bow section
4. Slide bumper rail no. 4 under front bumper
no. 13.
5. Using a 4.80 mm (3/16 in) drill bit, drill first hole
through bumper rail no. 4 at front of bow sec-
tion. Use locating mark as a guide. Then install
a rivet no. 12.
CAUTION: When drilling, be careful not to dam-
age bumper rail and/or hull.
6. Position bumper rail no. 4 properly onto body
and cut excess length if necessary.
7. Slide bumper rail no. 4 in corner bumper no. 14.
8. Using hole positions previously marked on
body, drill holes in bumper rail no. 4 and install
rivets no. 12.
9. Install trim no. 5 using soapy water.
10. Repeat procedure for the other side.
F01L3YA 2
1
F07L2JA 4 3
1 2
16-02-38 SMR2003-046_16_02A.FM
WAKE PYLON
GTX 4-TEC Wakeboard Edition only
Removal
Remove the rear seat and storage basket under it.
Remove nuts no. 24 and 26.
1. Screws to be removed
1. U-clamp
Remove finition U-clamp no. 21, and screws
no. 25 and pull out wake post no. 20.
Disassembly
Loosen the stopper screw.
1. Stopper screw
Pull the safety lock pin to unlock and pull out the
cylinder.
1. Safety lock pin
1 F18L37A
1 F18L38A
1 F18L39A
1 F18L3AA
SMR2003-046_16_02A.FM 16-02-39
Assembly
Before assembly verify the physical condition of
cylinder groove and adjustment holes.
1. Groove
2. Adjustment holes.
Align groove with stopper screw, while inserting
the cylinder into housing.
Tighten the stopper screw.
Installation
Before Installation, make sure:
inside cylinder slides up and down freely with-
out obstruction from grab handle
saftey lock pin operates properly
stopper screw stops cylinder at its most up-
wards position.
To Install the wake post no. 20, reverse removal
procedure.
GTX DI and GTX 4-TEC Series Models
Remove trim no. 1 from side bumper rail no. 2.
Remove screws no. 4 to remove side bumper rail
no. 2.
Mark hole positions on body straight and bow sec-
tions.
TYPICAL
1. Front bumper
2. Corner bumper
3. Straight section
4. Bow section
Slide bumper rail no. 2 under front bumper no. 6.
Using a 4.80 mm (3/16 in) drill bit, drill first hole
through bumper rail no. 2 at front of bow section.
CAUTION: When drilling, be careful not to
damage bumper rail and/or hull.
Position bumper rail no. 2 properly onto body and
cut excess length if necessary.
Slide bumper rail no. 2 in corner bumper no. 3.
Install trim no. 1 using soapy water.
Repeat procedure for the other side.
SPONSON REPLACEMENT
Removal and installation procedure for RH and LH
sponson is same.
Pry out sponson cover from back end with screw-
driver.
1. Sponson
2. Sponson cover
2 F18L3BA 1 2
4 F18L01A 3
2 1
2 F18L2BA 1
16-02-40 SMR2003-046_16_02A.FM
Slide sponson cover towards front to about
15 mm and pull it out from sponson.
Unscrew nut no. 10 and remove sponson no. 8.
1. Sponson
2. Nuts
Clean any residues of sealant adhesive on hull.
On installation of sponson, apply silicone sealant
(P/N 293 800 086) around sponson studs.
Apply Loctite 243 on sponson studs and nuts.
Install sponsons no. 8 on hull.
Tighten nuts no. 10 to 7 Nm (62 lbfin).
Clean hull and sponsons of any sealant adhesive
surplus
RX DI
Remove retaining screw from rear of sponson.
Pull sponson out.
At installation, apply Loctite 271 (red) on screw
threads and on sponson nut. Torque screw to 6
Nm (53 lbfin)
Apply silicone sealant (P/N 293 800 086) on the
base of the studs.
Other Models
Remove seat (access cover for the XP DI mod-
els).
Remove seat support (GTI, GTI LE, GTI LE RFI
and LRV DI).
Remove muffler.
Remove battery.
From inside bilge, remove lock nuts no. 10 using a
10 mm deep socket with an extension.
Remove sponsons no. 6. Clean any residues of
sealant adhesive on hull.
Install gaskets no. 7 on new sponsons no. 6.
Apply silicone sealant (P/N 293 800 086) around
sponson studs.
Apply Loctite 243 (blue) on sponson studs.
Install sponsons no. 6 on hull.
From inside bilge, first insert flat washers no. 8
over sponson studs. Secure with lock nuts no. 10.
Tighten to 5 Nm (44 lbfin).
NOTE: To ease flat washer and lock washer instal-
lation, use a flexible 4-claw Snap-on pick-up tool.
Reinstall removed parts.
Clean hull and sponsons of any sealant adhesive
surplus.
WARNING
Recommended torques and use of Loctite
must be strictly followed.
WARNING
1
2
F18L2CA
WARNING
F01P09A
SMR2003-046_16_02A.FM 16-02-41
ENGINE COMPARTMENT COVER
REMOVAL
XP DI Models
Disconnect throttle and choke cables at carburetor
linkage.
Disconnect wiring harnesses of start/stop button,
monitoring beeper, safety lanyard switch and
gauges.
Loosen bolts and nuts of hinge from watercraft
body.
Disconnect the gas assist cylinder.
Remove engine compartment cover.
Engine cover installation is essentially the reverse
of removal procedure. Refer to the main illustra-
tion of engine cover at the beginning of this sub-
section for proper torque specifications and ser-
vice products to be used.
All Models
DECALS REPLACEMENT
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.
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 sec-
onds to let it cool, then peel it off.
Installation
There are 2 types of decals used on watercraft. One
has a protective film on back side and the other has
a protective film on both sides. They are used on 3
types of materials; plastic, gelcoat and metal.
DECALS HAVING A PROTECTIVE FILM ON
BACK SIDE ONLY
These decals usually contain written information
(ex.: warning) and are used on gelcoat or metal.
Clean surface with a good solvent such as ACRYLI-
CLEAN DX 330 from PPG or equivalent (refer to
manufacturer instructions).
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.
DECALS HAVING A PROTECTIVE FILM ON
BOTH SIDES
These decals usually contain graphics and are used
on gelcoat or plastic.
INSTALLATION ON GELCOAT
Clean surface with a good solvent such as ACRYLI-
CLEAN DX 330 from PPG or equivalent (refer to
manufacturer instructions).
For best result apply an activator (P/N 293 530
036) to prepare the surface using a clean cloth.
After a few seconds, when the activator evapo-
rates, the surface is ready.
Using a pencil and the decal as a template mark
For better adhesion a dry application is recom-
mended, however, to ease decal installation a mild
solution of soapy water can be sprayed over sur-
face where decal will be installed.
Remove back protective film from decal and align
decal with marks. When well aligned squeegee
decal beginning at center and working outward us-
ing firm, short, overlapping strokes.
Remove front protective film once decal has ad-
hered to hull.
INSTALLATION ON PLASTIC
(storage cover)
Clean surface with isopropyl alcohol.
Using a pencil and the decal as a template, mark
Apply an activator (P/N 293 530 036) to prepare the
surface using a clean cloth. After a few seconds,
when the activator evaporates, the surface is ready.
CAUTION: Do not use soapy water to locate de-
cal on plastic parts.
Remove back protective film from decal and care-
fully 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 ad-
hered.
16-02-42 SMR2003-046_16_02A.FM
HULL AND BODY REPAIR
General
Gelcoat is the smooth and durable cosmetic finish
which coats the fiberglass hull and body of a Sea-
Doo watercraft. It also provides a protective barri-
er against water and sun. It consists of a mixture
of resin, pigment (coloring), fillers, monomers and
catalyst which is sprayed into the mold.
The body and hull of the Sea-Doo are 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. This type of construc-
tion is very accommodating for high quality re-
pairs. With patience, the proper techniques and
materials, a damaged area can be restored to an
original finish.
NOTE: Fiberglass repair kit is available through au-
tomotive or marine suppliers. Gelcoat repair kits
are available directly from GELCOTE INTERNA-
TIONAL LTD.
Air Bubbles
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.
FILLING THE CAVITY
The prepared surface must be cleaned with ace-
tone 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 tempera-
ture, amount of putty and percentage of catalyst.
After 2 hours, press lightly on the surface with fin-
gers to test the hardness. When the area becomes
hard, remove the plastic film.
SANDING
Begin block sanding the patch with 320-grit sand-
paper until you come close to the original surface.
Remove dust with a water soaked cloth and con-
tinue sanding with a 400-grit wet paper. Finish wet
sanding with a 600-grit to remove deeper scratch-
es. If needed you can wet sand with finer grit pa-
per 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 buff-
ing with a white medium compound. Finish off us-
ing a fine compound. While buffing, pay close at-
tention to avoid overheating the surface.
Blisters
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.
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 ma-
terials 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.
SMR2003-046_16_02A.FM 16-02-43
Minor Gelcoat Fractures
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,
then additional reinforcement may be necessary.
This subject will be covered in Compound Frac-
tures.
PREPARING THE SURFACES
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 sandpa-
per.
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. De-
pending 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 de-
sired 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 buff-
ing with a white medium compound. Finish off us-
ing a fine compound. While buffing, pay close at-
tention to avoid overheating the surface.
Compound Fractures
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 lay-
ers 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 neces-
sary, 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 piec-
es of fiberglass mat necessary to build up the area.
The pieces should be cut so they overlap each oth-
er 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.
16-02-44 SMR2003-046_16_02A.FM
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 alternat-
ing pieces of fiberglass mat and cloth in overlap-
ping 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 lay-
ing 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. Fol-
low 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 pieces
evenly. Try to work quickly, you may only have 15
or 20 minutes. You may clean the brush with ace-
tone.
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. Ap-
ply the same procedure as for outside repair when
laminating the alternating pieces of fiberglass ma-
terial. If a backing support was used, remove it
before starting the repair. After the area has hard-
ened, remove sharp edges of material from sur-
face. If required paint the surface.
SANDING
Outside
This surface will have to be prepared for applica-
tion of gelcoat. The size of the area will determine
the gelcoating procedure to be used. Refer to the
repair procedure for minor gelcoat fractures.
BUFFING AND WAXING
Refer to the buffing and waxing for Minor Gelcoat
Fractures.
TOOLS AND MATERIALS LIST
Tools
safety glasses
air mask
white cloths
sanding block
putty knife
plastic film
stirring stick
cover sheets (for Sea-Doo)
scissors
buffing pad
heavy-duty polisher
power sander
paint brush
plastic container (mixing)
spray gun
plastic squeegee.
Materials
fiberglass mat
fiberglass cloth
polyester resin
cardboard
masking tape
sandpaper (100-grit, 220-grit, 320-grit, 400-grit,
600-grit, 1000-grit)
24-grit sanding disks
gelcoat putty
liquid gelcoat
acetone
cabosil
epoxy filler
medium compound (white)
fine compound (white)
wax.
SMR2003-046_16_02A.FM 16-02-45
THRU-HULL FITTING
INSTALLATION
All Models except GTX 4-TEC Series Models
For hull insert repair proceed as follows:
Cut plastic hull insert flush with hull using a saw.
1. Hull
2. Plastic hull insert
Mix epoxy glue (3M-05895), follow manufacturer
instructions.
Apply epoxy glue on aluminum insert (P/N 292 000
075) knurled surface and on plastic insert inner
bore.
CAUTION: If you notice any clearance between
plastic insert and aluminum insert, fill gap with
epoxy glue to obtain good adhesion of alumi-
num insert.
1. Knurled surface
2. Inner bore
Install aluminum insert into plastic hull insert.
NOTE: Align aluminum insert as much as possible
with PTO flywheel.
1. Aluminum insert
NOTE: The epoxy glue curing time is 30 minutes.
F01L2UA
1
2
F01L2VA
1
2
F01L2WA
1
Section 17 TECHNICAL DATA
Subsection 01 (GTI AND GTI LE MODELS)
SMR2003-047_17_01A.FM 17-01-1
GTI AND GTI LE MODELS 0
ENGINE GTI GTI LE
Engine type BOMBARDIER-ROTAX 717
Induction type Rotary valve
Exhaust system
Type Water cooled, water injected
Water injection fitting
(head)
3.5 mm (.139 in)
(cone)
3.5 mm (.139 in)
Starting system Electric start
Lubrication
Fuel/oil mixture VROI (Variable Rate Oil Injection)
Oil injection pump Gear driven
Oil injection type
BOMBARDIER Formula XP-S II synthetic injection oil
OR BOMBARDIER injection oil (or equivalent)
Number of cylinders 2
Bore
Standard 82 mm (3.228 in)
First oversize 82.25 mm (3.238 in)
Second oversize 82.50 mm (3.248 in)
Stroke 68 mm (2.677 in)
Displacement 718.2 cm (43.81 in)
Corrected compression ratio 6.2:1
Cylinder head volume 42.4 0.4 cc
Cylinder head warpage (maximum) 0.05 mm (.002 in)
Piston ring type and quantity 1 semi-trapez 1 rectangular
Ring end gap
New 0.25 - 0.40 mm (.010 - .016 in)
Wear limit 1.00 mm (.039 in)
Ring/piston groove
clearance
New 0.025 - 0.070 mm (.001 - .003 in)
Piston/cylinder
wall clearance
New (minimum) 0.10 mm (.0039 in)
Cylinder taper (maximum) 0.10 mm (.004 in)
Cylinder out of round (maximum) 0.080 mm (.003 in)
Connecting rod big end
axial play
New 0.311 - 0.677 mm (.012 - .027 in)
Crankshaft deflection MAG: 0.050 mm (.002 in); PTO: 0.030 mm (.001 in)
Rotary valve timing
Opening 147 5 BTDC
Closing 65.5 5 ATDC
Rotary valve duration 159
Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)
Connecting rod/
crankshaft pin radial
clearance
New 0.020 - 0.033 mm (.0008 - .0013 in)
Connecting rod/
piston pin radial clearance
New 0.003 - 0.012 mm (.00012 - .00047 in)
ADDITIONAL INFORMATION:
17-01-2 SMR2003-047_17_01A.FM
ELECTRICAL GTI GTI LE
Magneto generator output 160 W @ 6000 RPM
Ignition system type Digital CDI
Spark plug
Make and type NGK BR8ES
Gap 0.4 - 0.5 mm (.016 - .020 in)
Ignition timing (BTDC)
mm (in) 2.59 (.102)
Degrees 20 1.5
Generating coil 40 - 76
Battery charging coil 0.05 - 0.6
Ignition coil
Primary 0.34 - 0.62
Secondary 9 - 15
Engine rev limiter setting 7100 50 RPM
Battery 12 V, 19 Ah (Yuasa/Exide)
Fuse
MPEM 5 A
Main electrical system 15 A
Charging system 15 A
ADDITIONAL INFORMATION: Engine cold @ 6000 RPM.
CARBURETION GTI GTI LE
Carburetor
Type Mikuni BN-40i diaphragm, fuel accelerator pump
Quantity 1
Main jet 167.5
Pilot jet 75
Spring 130 g (4.6 oz) 115 g (4.1 oz)
Adjustment
Low-speed screw 1 turn 1/4
High-speed screw 0
Idle speed (in water) 1500 100 RPM
Idle speed (out of water) 3000 RPM
Fuel
Type Regular unleaded gasoline
Minimum octane no. 87
Fuel return line orifice 0.8 mm (.031 in)
COOLING GTI GTI LE
Type Open circuit Direct flow from jet propulsion unit
Thermostat Not applicable
Monitoring beeper setting 86 - 94C (187 - 201F)
SMR2003-047_17_01A.FM 17-01-3
PROPULSION GTI GTI LE
Propulsion system BOMBARDIER Formula Pump
Jet pump type Axial flow single stage
Impeller rotation (seen from rear) Counterclockwise
Transmission Direct drive
Coupling type Crowned splines
Oil type
SEA-DOO JET PUMP SYNTHETIC
POLYOLESTER OIL 75W90 GL5
Steering nozzle pivoting angle 20
Minimum required water level 90 cm (35 in)
Drive shaft deflection (maximum) 0.5 mm (.020 in)
Impeller outside diameter 155.3 mm (6.114 in)
Impeller/wear ring
clearance
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller shaft end play (new) 0
Impeller shaft radial play 0.05 mm (.002 in)
Impeller pitch/material Progressive pitch/stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS GTI GTI LE
Number of passenger (driver included) 3
Overall length 307 cm (121 in)
Overall width 120 cm (47 in)
Overall height 104 cm (41 in)
Dry weight 272 kg (600 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 243 kg (536 lb)
CAPACITIES GTI GTI LE
Fuel tank (including reserve) 56.5 L (15 U.S. gal)
Fuel tank reserve 11.4 L (3 U.S. gal)
Oil injection reservoir 6 L (1.6 U.S. gal)
Jet pump impeller shaft
reservoir
Capacity 100 mL (3.38 U.S. oz)
Oil level height Up to plug
17-01-4 SMR2003-047_17_01A.FM
MATERIALS GTI GTI LE
Hull Composite
Inlet grate Aluminum
Impeller housing/stator/venturi/nozzle Plastic/plastic/aluminum/aluminum
Air intake silencer Thermoplastic
Flame arrester Multi-layer wire screen
Steering padding Thermoplastic
Fuel tank Polyethylene
Oil injection reservoir Polyethylene
Seat Polyurethane foam
PERFORMANCE GTI GTI LE
Estimated pump power 26.1 kW (35 HP)
Maximum fuel consumption at wide open throttle 33.5 L/h (8.8 U.S. gal/h)
Cruising time at full
throttle
Fuel tank without reserve 1.21 hour
Fuel tank reserve 21 minutes
Subsection 02 (GTI LE RFI MODELS)
SMR2003-047_17_02A.FM 17-02-1
GTI LE RFI MODELS 0

ENGINE GTI LE RFI
Engine type BOMBARDIER-ROTAX 787
Induction type Rotary valve
Exhaust system
Type Water cooled, water injected with regulator
Water injection fitting (head) 3.5 mm (.139 in)
Water injection fitting (cone) Not applicable
(muffler)
3.5 mm (.139 in)
Exhaust valve Rotax Adjustable Variable Exhaust (RAVE)
Lubrication
Oil injection pump Direct driven
Oil injection type BOMBARDIER Formula XP-S II (synthetic)
Bore
Second oversize Not applicable
Stroke 74 mm (2.91 in)
Displacement 781.6 cm (47.7 in)
Cylinder head warpage (maximum) 0.05 mm (.002 in)
Piston ring type and quantity 1 semi-trapez 1 rectangular
Ring end gap
New 0.40 - 0.55 mm (.016 - .022 in)
Ring/piston groove
New 0.025 - 0.070 mm (.001 - .003 in)
Piston/
cylinder wall clearance
axial play
New 0.230 - 0.617 mm (.009 - .024 in)
Crankshaft deflection MAG: 0.050 mm (.002 in); PTO: 0.030 mm (.001 in)
Rotary valve timing
Opening 147 5 BTDC
Closing 63.5 5 ATDC
Rotary valve duration 159
Rotary valve/cover clearance 0.25 - 0.35 mm (.010 - .014 in)
Connecting rod/
clearance
New 0.023 - 0.034 mm (.0009 - .0013 in)
Connecting rod/
piston pin radial clearance
New 0.003 - 0.012 mm (.00012 - .00047 in)
17-02-2 SMR2003-047_17_02A.FM
ELECTRICAL SYSTEM GTI LE RFI
Ignition system type Digital, inductive
Spark plug
Make and type NGK BR8ES
Gap 0.4 - 0.5 mm (.016 - .020 in)
mm (in) 1.02 (.040)
Degrees 12 1.0 (fixed timing mode at any RPM)
Battery charging coil 0.1 - 1
Ignition coil
Primary 0.3 0.6
Secondary Not applicable
Fuses
MPEM 5 A
Battery 15 A
VTS 7.5 (installed but not in use)
Info center Not applicable
Fuel pump 10 A
FUEL SYSTEM GTI LE RFI
Fuel injection type Rotax Fuel Injection, semi-direct, single throttle body (56 mm)
1.6 k - 2.4 k (terminals 1-2)
710 - 1380 (terminals 2-3)
Crankshaft Position Sensor (CPS) 774 - 946
Air Temperature Sensor (ATS) 2.280 k - 2.74 k
Water Temperature Sensor (WTS) 2.280 k - 2.74 k
Air Pressure Sensor (APS)
3.4 k and 8.2 k (terminals 3-2)
RAVE solenoid 30
Fuel injector 2.4 0.1
Fuel
COOLING GTI LE RFI
SMR2003-047_17_02A.FM 17-02-3
PROPULSION GTI LE RFI
Propulsion system BOMBARDIER Formula Pump
Oil type
Impeller/wear ring
clearance
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller shaft radial play 0.05 mm (.002 in)
DIMENSIONS GTI LE RFI
Number of passenger (driver incl.) 3
CAPACITIES GTI LE RFI
Fuel tank (including reserve) 56.5 L (15 U.S. gal)
Fuel tank reserve (from low level signal) 11.4 L (3 U.S. gal)
reservoir
17-02-4 SMR2003-047_17_02A.FM
MATERIALS GTI LE RFI
Hull Composite
Impeller housing/stator/venturi/nozzle Plastic/plastic/plastic/aluminum
Flame arrester Multi-layer wire screen
PERFORMANCE GTI LE RFI
Estimated pump output 30.4 kW (40.76 HP)
Maximum fuel consumption at wide open throttle 41.5 L/h (11 U.S. gal/h)
Cruising time at full
throttle
Fuel tank without reserve 1 hour 5 minutes
Fuel tank reserve 17 minutes
Subsection 03 (GTX DI, RX DI, XP DI MODELS)
SMR2003-047_17_03A.FM 17-03-1
GTX DI, RX DI, XP DI MODELS 0
ENGINE GTX DI RX DI XP DI
Engine type BOMBARDIER-ROTAX 947 DI, 2-stroke
Induction type Reed valve
Exhaust system
Water injection fitting (muffler) 3 mm (.118 in)
Exhaust valve RAVE
Lubrication
Oil injection type
BOMBARDIER
Formula XP-S II (synthetic injection oil only)
Bore
Stroke 78.20 mm (3.079 in)
Displacement 951.2 cm (58 in)
Corrected compression ratio 6.0: 1
Cylinder head warpage (maximum) 0.10 mm (.004 in) total
Piston ring type and quantity 2 semi-trapez chrome coated steel rings
Ring end gap
New 0.55 - 0.7 mm (.022 - .028 in)
Ring/
piston groove clearance
New 0.044 - 0.089 mm (.002 - .003 in)
Piston/
cylinder wall clearance
axial play
New 0.390 - 0.737 mm (.015 - .029 in)
Crankshaft deflection MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in)
Rotary valve timing
Opening Not applicable
Closing Not applicable
Rotary valve duration Not applicable
Rotary valve/cover clearance Not applicable
Connecting rod/
clearance
New 0.017 - 0.034 mm (.0006 - .0013 in)
Connecting rod/piston pin
radial clearance
New 0.001 - 0.014 mm (.00039 - .00055 in)
Air compressor
Type Piston
Displacement 43 cm (2.6 in)
Drive Balancing shaft
Intake side Reed valves
Exhaust side Reed valves
17-03-2 SMR2003-047_17_03A.FM
ELECTRICAL GTX DI RX DI XP DI
Ignition system type Digital Inductive
Spark plug
Make and type NGK ZFR4F
Gap 1.1 mm (.04 in)
TDC setting (BTDC)
mm (in)
5.39 0.30 (.212 .011) (direct) measured through direct
injector hole 7.87 0.30 (.310 .011) (indirect)
measured through spark plug hole
Degrees 27 1.5 @ 1450 RPM
Trigger coil Not applicable
Ignition coil
Primary 0.45 - 0.55
Secondary 6.8 - 10.2 k without high tension leads
Fuses
Main 30 A
Injection system (INJ) 15 A
Charging system (REG) 25 A
Information center (ACC) Not applicable
Fuel pump (FP) 15 A
Battery 25 A
VTS system (VTS)
Installed but not in
use
7.5 A 7.5 A
FUEL SYSTEM GTX DI RX DI XP DI
Fuel injection type Orbital Direct Fuel Injection, twin throttle body (46 mm (1.81 in))
Fuel pressure 105.2 PSI - 108 PSI
Idle speed (in water/out of water) 1450 50 RPM
Throttle Position Sensor (TPS) 1.6 k - 2.4 k
Crankshaft Position Sensor (CPS) 5 volts
Manifold Air Temperature Sensor (MATS) 2.28 k - 2.74 k
Exhaust Gas Temperature Sensor (EGTS) 2.28 k - 2.74 k
Manifold Air Pressure Sensor (MAPS) 0 (continuity between terminals 3 and 1)
Knock Sensor (KS) 5 M
RAVE solenoid 24
Fuel injector 1.7 - 1.9
Direct injector 1.0 - 1.6
Fuel
SMR2003-047_17_03A.FM 17-03-3
COOLING GTX DI RX DI XP DI
Thermostat None
PROPULSION GTX DI RX DI XP DI
Propulsion system BOMBARDIER Formula pump
Oil type
Impeller/wear ring clearance
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller shaft side play 0.05 mm (.002 in)
DIMENSIONS GTX DI RX DI XP DI
Number of passenger (driver incl.) 3 2 2
Overall length 331 cm (130 in) 285 cm (112 in) 272 cm (107 in)
Overall width 122 cm (48 in) 120 cm (47 in) 112 cm (44 in)
Overall height 113 cm (44 in) 104 cm (41 in) 104 cm (41 in)
Dry weight 351 kg (775 lb) 285kg (628 lb) 274 kg (605 lb)
Load limit (passenger and 10 kg (22 lb) luggage) 272 kg (600 lb) 181 kg (400 lb) 181kg (400 lb)
CAPACITIES GTX DI RX DI XP DI
Fuel tank (including reserve)
56.5 L
(15 U.S. gal)
56.5 L
(15 U.S. gal)
51 L
(13.5 U.S. gal)
Fuel tank reserve (from low level signal) 9.8 L (2.6 U.S. gal)
Oil injection reservoir 6 L (1.6 U.S. gal) 6 L (1.6 U.S. gal) 4 L (1.05 U.S. gal)
reservoir
17-03-4 SMR2003-047_17_03A.FM
MATERIALS GTX DI RX DI XP DI
Hull Composite
Flame arrester Tubular wire screen
PERFORMANCE GTX DI RX DI XP DI
Estimated pump power 51 kW (68.4 HP) 53.6 kW (71.9 HP) 53.7 kW (72 HP)
Maximum fuel consumption at wide open throttle 47 L/h (12.4 U.S. gal/h)
Cruising time at full throttle
Fuel tank without reserve 60 minutes
Fuel tank reserve
(from low level signal)
12 minutes
Subsection 04 (LRV DI MODELS)
SMR2003-047_17_04A.FM 17-04-1
LRV DI MODELS 0
ENGINE LRV DI
Engine type BOMBARDIER-ROTAX 947 DI LE
Induction type Reed valve
Exhaust system
Water injection fitting (muffler) 3 mm (.118 in)
Exhaust valve Rotax Adjustable Variable Exhaust (RAVE)
Lubrication
Oil injection type BOMBARDIER Formula XP-S II (synthetic)
Bore
Stroke 78.20 mm (3.079 in)
Displacement 951.2 cm (58 in)
Cylinder head warpage (maximum) 0.10 mm (.004 in) total
Piston ring type and quantity 2 semi-trapez
Ring end gap
New
0.55 - 0.7 mm
(.022 - .028 in)
Ring/piston groove
clearance
New 0.044 - 0.089 mm (.002 - .004 in)
clearance
axial play
New 0.390 - 0.737 mm (.015 - .029 in)
Crankshaft deflection
MAG side: 0.050 mm (.002 in);
PTO side: 0.030 mm (.001 in)
Rotary valve timing
Opening Not applicable
Closing Not applicable
Rotary valve duration Not applicable
Rotary valve/cover clearance Not applicable
17-04-2 SMR2003-047_17_04A.FM
ENGINE LRV DI
Connecting rod/
clearance
New 0.017 - 0.034 mm (.0006 - .0013 in)
Connecting rod/
piston pin radial
clearance
New 0.001 - 0.014 mm (.000039 - .00055 in)
Air compressor
Type Piston
Displacement 43 cm (2.6 in)
Drive Balancing shaft
Intake side Reed valves
Exhaust side Reed valves
ELECTRICAL LRV DI
Ignition system type Digital Inductive
Spark plug
Make and type NGK ZFR4F
Gap 1.1 mm (.04 in)
mm (in)
5.39 mm (.212 in) (direct) measured
through direct injector hole 7.87 (.310) (indirect)
measured through spark plug hole
Degrees 27 1.5 @ 1450 RPM
Generating coil Not applicable
Trigger coil Not applicable
Ignition coil
Primary 0.45 - 0.55
Secondary 6.84 - 10.2 k without high tension leads
Fuses
VTS system Not applicable
Battery 25 A
Info center 2 A
Fuel pump 15 A
Injection 15 A
SMR2003-047_17_04A.FM 17-04-3
FUEL SYSTEM LRV DI
Fuel injection type
Orbital Direct Fuel Injection, twin throttle body
(46 mm (1.81 in))
1.6 k - 2.4 k (terminals 3-4)
710 - 1380 (terminals 4-11)
Crankshaft Position Sensor (CPS) 774 - 946
Exhaust Gas Temperature Sensor (EGT) 2.280 k - 2.74 k
Manifold Air Pressure Sensor (MAPS)
RAVE solenoid 24
Direct injector 1.0 - 1.6
Fuel
Fuel return line orifice Not applicable
COOLING LRV DI
17-04-4 SMR2003-047_17_04A.FM
PROPULSION LRV DI
Coupling type Crown splines
Oil type
New 0.0 - 0.4 mm (.000 - .016 in)
DIMENSIONS LRV DI
Overall height 108 cm (42.5 in)
CAPACITIES LRV DI
Fuel tank (including reserve) 95 L (25 U.S. gal)
Fuel tank reserve 19 L (5.0 U.S. gal) (from low level signal)
reservoir
SMR2003-047_17_04A.FM 17-04-5
MATERIALS LRV DI
Hull Composite
PERFORMANCE LRV DI
Estimated pump power 50.2 kW (67.3 HP)
Maximum fuel consumption at wide open throttle 47 L/h (12.4 U.S. gal/h)
Fuel tank without reserve 1 hour
Fuel tank reserve
12 minutes
Subsection 05 (GTX 4-TEC MODELS)
SMR2003-047_17_05A.FM 17-05-1
GTX 4-TEC MODELS 0
ENGINE
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Engine type
BOMBARDIER-ROTAX 1503 4-TEC, 4-stroke,
Single Over Head Camshaft (SOHC), liquid cooled
Number of valves 12 valves with hydraulic lifters (no adjustment)
Bore Standard 100 mm (3.9 in)
Stroke 63.4 mm (2.49 in)
Displacement 1493.8 mm (58.81 in)
Compression ratio 10.6:1 8.1:1
Induction type Normally-aspirated
Mechanically-driven
supercharger
Maximum HP RPM 7300 50 RPM
Lubrication
Type
Dry sump (2 oil pumps). Replaceable oil filter.
Water-cooled oil cooler.
Oil type
4-stroke engine oil SAE 10W40
(API service classification SG, SH or SJ)
Oil filter Bombardier
Exhaust system Type
Water cooled/water injected.
Direct flow from propulsion unit
Intake valve opening 10 BTDC
Intake valve closing 45 ABDC
Exhaust valve opening 50 BBDC
Exhaust valve closing 5 ATDC 0 ATDC
Valve stem diameter
Intake
Minimum (new) 5.961 mm (.2347 in)
Maximum (new) 5.975 mm (.2352 in)
Exhaust
Valve guide diameter
Valve spring free length
Inner
Nominal (new) 41.02 mm (1.615 in)
Wear limit 38.8 mm (1.499 in)
Outer
Nominal (new) 45.45 mm (1.789 in)
Wear limit 43 mm (1.693 in)
Valve seat contact width
Intake
Nominal (new) 1.1 to 1.3 mm (.043 to .051 in)
Exhaust
Nominal (new) 1.25 to 1.55 mm (.049 to .061 in)
Rocker arm bore diameter
Rocker arm shaft diameter
17-05-2 SMR2003-047_17_05A.FM
Cylinder head screw Service limit 148.5 mm (5.846 in)
Piston ring type and quantity
1
st
Upper compression ring
2
nd
Lower compression ring
3
rd
Oil scraper ring
Ring end gap
Rectangular
Minimum (new)
0.15 mm (.006 in)
Taper-face 0.15 mm (.006 in)
Oil scraper ring 0.15 mm (.006 in)
Rectangular
Maximum (new)
0.3 mm (.012 in)
All Wear limit 1.5 mm (.06 in)
Ring/piston groove clearance
Rectangular
Minimum (new)
0.025 mm (.001 in)
Rectangular
Maximum (new)
0.07 mm (.0028 in)
All Wear limit 0.15 mm (.006 in)
Piston/cylinder wall clearance
Minimum (new)
0.024 - 0.056 mm
(.001 - .0022 in)
0.04 mm
(.001 in)
Camshaft bearing journal
Front
PTO and center
Minimum (new) 39.892 mm (1.5705 in)
Maximum (new) 39.905 mm (1.5711 in)
Camshaft bore
Front
PTO and center
Cam lobe
Intake
Exhaust
Crankshaft axial clearance
Connecting rod big end clearance Wear limit 0.09 mm (.0035 in)
Crankshaft journal diameter
Crankshaft radial clearance Wear limit 0.007 mm (.0028 in)
ENGINE
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
SMR2003-047_17_05A.FM 17-05-3
Connecting rod big end diameter Service limit 45.080 mm (1.7740 in)
Connecting rod big end clearance Service limit 0.09 mm (.0035 in)
Connecting rod big end axial play
Crankshaft deflection 0.050 mm (.002 in)
Connecting rod small end diameter
Piston pin diameter
Piston pin bore clearance Wear limit 0.080 mm (.0035 in)
Balance shaft journal diameter
Balance shaft radial clearance Wear limit 0.07 mm (.0028 in)
Balance shaft axial clearance
Supercharger shaft driven plate journal depth
Minimum (new) Not applicable 9.960 mm (.3921 in)
Maximum (new) Not applicable 10.0 mm (.3937 in)
Wear limit Not applicable 9.700 mm (.3819 in)
Supercharger drive gear thickness
Supercharger lock washer thickness
ENGINE
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
17-05-4 SMR2003-047_17_05A.FM
ELECTRICAL
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Ignition system type DI (Digital Induction)
Ignition timing Not adjustable
Spark plug
Make and type NGK DCPR8E
Gap 0.75 mm (.030 in)
Generating coil N.A.
Battery charging coil 0.1 - 1.0
Ignition coil
Primary 0.45 - 0.55
Secondary 6.8 - 10.2 k
Engine RPM limiter setting 7650 RPM
Battery 12 V, 30 Ah
Fuse
TOPS 10 A
Battery fuse 30 A
Cylinder 1, ignition coil and injection 10 A
Electric bilge pump (optional) 3 A
Starting system, electric fuel pump 10 A
EMS, start/stop circuit 5 A
Main 30 A
MPEM 5 A
Information center 1 A
SMR2003-047_17_05A.FM 17-05-5
FUEL SYSTEM
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Fuel injection type
Rotax EMS (engine management system)
Multipoint Fuel Injection.
Single throttle body (52 mm (2.05 in))
Fuel pressure 42 PSI - 45 PSI
Idle speed (in water/out of water) 1800 50 RPM
Throttle Position Sensor (TPS) 1.6 k - 2.4 k
Crankshaft Position Sensor (CPS) 5 volts
Camshaft Position Sensor (CAPS) 12 volts
Camshaft Position Sensor (CAPS) 1.2 k
Coolant Temperature Sensor (CTS) 2.28 k - 2.74 k
Exhaust Gas Temperature Sensor (EGT) 2.28 k - 2.74 k
Manifold Air Pressure Sensor (MAPS) 0 (continuity between terminals 3 and 1)
Oil Pressure Switch (OPS) 0 , if oil pressure is greater than 26 - 32 PSI
Oil Separator Pressure Switch (OSPS) 0 , if blow-by pressure is less than 6 PSI
TOPS valve 1.27 - 2.47
Fuel
Type
Regular unleaded
gasoline with 87 octane
(Ron + Mon)/2
specification
Recommended:
Premium unleaded
gasoline with 91 octane
(Ron + Mon)/2
specification for
optimum performance
Minimum: Regular
unleaded gasoline with
87 octane (Ron +
Mon)/2 specification
Minimum octane no. See above
COOLING
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Type
Liquid cooled. Closed loop for engine
(see also exhaust system)
Coolant
Ethylene-glycol 50%/50% antifreeze/water.
Coolant containing corrosion inhibitors for internal
combustion aluminum engines
Thermostat 87C (188F)
Monitoring beeper setting 100C (212F)
17-05-6 SMR2003-047_17_05A.FM
PROPULSION
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Jet pump type Axial flow single stage. Greased bearings
Coupling type Crown splines
Reverse system Yes
O.P.A.S. system Yes
Grease type
Sea-Doo grease (P/N 293 550 032),
10 mL front bearing, 50 mL rear of bearing,
50 mL in pump cap
Impeller outside diameter 155.3 0.3 mm (6.122 .0118 in)
New 0.0 - 0.4 mm (.000 - .016 in)
Impeller material Stainless steel
DIMENSIONS
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Dry weight 385 kg (850 lb) 397 kg (875 lb)
CAPACITIES
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Engine oil
3 L (2.7 U.S. qt) oil change w/filter
4.5 L (4.1 U.S. qt) total
Cooling system (coolant) 5.5 L (4.8 U.S. qt) total
Fuel tank (including reserve) 60 L (15.9 U.S. gal)
Fuel tank reserve (from low level signal) 15 L (4 U.S. gal)
SMR2003-047_17_05A.FM 17-05-7
MATERIALS
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Hull Composite
Steering cover Thermoplastic
Air intake silencer N.A.
PERFORMANCE
GTX 4-TEC/
GTX 4-TEC VANS
TRIPLE CROWN
EDITION
GTX 4-TEC
SUPERCHARGED/
GTX 4-TEC
SUPERCHARGED
LIMITED
Estimated pump power 52.6 kW (70.54 HP) 61.7 kW (82.74 HP)
Maximum fuel consumption at wide open throttle
43.1 L/h
(11.4 U.S. gal/h)
62 L/h
(16.4 U.S. gal/h)
Fuel tank without reserve 63 minutes 44 minutes
Fuel tank reserve
20 minutes 14 minutes
Section 18 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
SMR2003-048_18_01A.FM 18-01-1
WIRING DIAGRAMS 0
WIRE COLOR CODES
First color of a wire is the main color. Second color
is the tracer.
Example: YELLOW/BLACK (YL-BK) is a YELLOW
wire with a BLACK tracer.
WIRE DIGIT CODES
First number indicates in which connector the
wire is plugged in.
Second number indicates the position of the wire
in the connector.
The letter at the end of the number (if applicable)
indicates a common circuit in the MPEM printed
circuit with another wire bearing the same letter.
Example: 2-18 (g)
The first number indicates that the wire is posi-
tioned in the connector no. 2 of the MPEM.
The second number indicates that the wire is po-
sitioned in cavity no. 18 of the connector.
The letter (g) indicates a common circuit with an-
other wire(s) bearing the same letter (g) in the cir-
cuit.
EMS ECU
GTX 4-TEC Models
On the EMS ECU, circuits are identified by a letter
followed by a number.
The letter indicates in which connector the wire is
plugged in.
The number indicates the position of the wire in
the connector.
The connector A is connected to the engine wir-
ing harness.
The connector B is connected to the watercraft
wiring harness.
DEUTSCH CONNECTORS
All Models
Deutsch connectors are used to connect wiring
harness to the magneto the electrical box (some
models) and the VCK (DI and 4-TEC models).
Removal from Engine Connector
Bracket
GTX 4-TEC Models
To remove Deutsch connectors from engine con-
nector bracket, remove coolant container, slide a flat
screwdriver between the connector bracket and the
Deutsch connectors and remove connectors.
1. Coolant plastic container
2. Coolant plastic container bracket
2. Deutsch connectors
1 F18Z0IA 2
1 F18Z0JA
2
18-01-2 SMR2003-048_18_01A.FM
3. Flat screwdriver
To disconnect the two Deutsch connectors, slide
a flat screwdriver between each other to disen-
gage, press the release button and disconnect
them.
1. Flat screwdriver
1. Release button
2. Press release button
1 F18Z0KA
2 3
1
F18Z0LA 2
2
F18Z0MA 2 1
F18Z0NA 1 2
SMR2003-048_18_01A.FM 18-01-3
Connector Disassembly
All Models
1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap
CAUTION: Do not apply dielectric grease on ter-
minal inside connector.
To remove terminals from connector, proceed as
follows:
Using a long nose pliers, pull out the lock.
FEMALE CONNECTOR
1. Female lock
MALE CONNECTOR
1. Male lock
NOTE: Before extraction, push wire forward to re-
lieve pressure on retaining tab.
Insert a 4.8 mm (.189 in) wide screwdriver
blade inside the front of the terminal cavity.
Pry back the retaining tab while gently pulling
wire back until terminal is removed.
FEMALE CONNECTOR
1. Retaining tab
To install:
For insertion of a terminal, make sure the lock
is removed.
Insert terminal into appropriate cavity and push
as far as it will go.
F00H1CA
1
3
4
2
3
1 V01G0OA
V01G0PA 1
V01G0QA
1
1
18-01-4 SMR2003-048_18_01A.FM
Pull back on the terminal wire to be sure the
retention fingers are holding the terminal.
After all required terminals have been inserted,
the lock must be installed.
1. Wire identification numbers
PACKARD CONNECTOR
Packard connectors are used to connect electrical
harnesses and gauges.
VIEW OF A 3-PIN PACKARD CONNECTOR
1. Identification letters
To remove terminal from Packard connector, use
Snap-on TT600-4 tool.
AMP PLUG CONNECTOR
These connectors are found on the MPEM.
When servicing electrical system, special care must
be taken when working with AMP plug connectors
in order to prevent any malfunction of the system.
Description
AMP PLUG CONNECTOR
1. Male connector
2. Cover assembly
3. Mating seal
4. Wedge lock
5. MPEM connector
6. Seal plug
7. Power wire
8. Signal wire
9. Locking tab
F04H6LA
1 1
F04H45A
1
A B C
WARNING
wires and connector are properly fastened.
F01B1JA
F00H0WB
2
3
4
5
6
7
8
9
9
1
SMR2003-048_18_01A.FM 18-01-5
Removal
To remove the male connector from the MPEM,
press both tabs and pull connector.
Step : Press tabs (both sides)
Step : Pull male connector
Installation
Apply a thin coat of DEOXIT contact lubricant (P/N
293 550 034) on the pins of the MPEM connector
only.
1. Apply a thin coat of DEOXIT contact lubricant
CAUTION: Do not apply lubricant excessively.
Care must be taken so that the lubricant will not
come in contact with the mating seal; the seal
may lose its sealing capacities. Do not apply
lubricant on terminals inside plug connector.
Each male connector is mechanically keyed to
mate only with identical mechanical keyed con-
nector on the MPEM.
1. Mechanically keyed
F00H0NA
1
2
1
2
F00H11A
1
F00H12A 1
18-01-6 SMR2003-048_18_01A.FM
Terminal Removal
SIGNAL WIRE
Insert a screwdriver blade between the connector
and the wedge lock tab.
Release the locking tab and at the same time, pry
the wedge lock to the open position.
CAUTION: The wedge lock should never be re-
moved from the connector for insertion or re-
moval of the signal wire terminals.
1. Screwdriver between wedge lock and connector
2. Locking tab
Repeat the same steps for the other locking tab
retaining the wedge lock.
The wedge lock is now in the open position.
1. Wedge lock opened
While rotating the wire back and forth over a half
turn (1/4 turn in each direction), gently pull the wire
until the terminal is removed.
1. Rotate wire back and forth
2. Pull wire
POWER WIRE TERMINAL
NOTE: The wedge lock must be removed to ex-
tract power terminal.
Open the wedge lock.
Pull both locking tabs and remove wedge lock
from connector.
1. Pull locking tab (both sides)
F00H0OA
1 2
F00H0PA
1
F00H0QA
1
2
F00H0RA
1
SMR2003-048_18_01A.FM 18-01-7
Before extraction, push wire forward to relieve pres-
sure on retaining tab.
Insert a 4.8 mm (.189 in) wide screwdriver blade
inside the front of the terminal cavity.
Pry back the retaining tab while gently pulling wire
back until terminal is removed.
Terminal Crimping
The size of the wires must be 20 to 16 AWG with
a wire insulation diameter having a minimum di-
mension of 1.7 mm (.067 in) and a maximum di-
mension of 2.78 mm (.106 in).
The wire strip length must be 5.1 mm (13/64 in).
NOTE: When stripping wires, ensure conductor is
not nicked, scrapped or cut. Wire stripping tool
jaws may leave marks on the surface of the wire
insulation. If these marks occur at the location of
the wire seal, leakage may result. Insulation sur-
face within 25 mm (1 in) from the tip of the termi-
nal must be smooth.
All terminals in AMP plug connectors must be
crimped using the crimping tool (P/N 295 100 164).
CAUTION: If terminals are not crimped using
the proper crimping tool, the wire seal may be
damaged.
CRIMPING TOOL (P/N 295 100 164)
All circuits are sealed by a diaphragm in the rubber
wire seal. When installing a terminal in connector,
the diaphragm is pierced as the terminal passes
through it.
If the diaphragm is pierced and the cavity is not
used, install a seal plug, large end first, into circuit
cavity as far as it will go.
NOTE: It is suggested that all unused circuit cavi-
ties be sealed with a seal plug, even if they are not
pierced.
1. Seal plug
2. Wire seal
CAUTION: Do not pierce the diaphragm with a
sharp point when performing electrical trou-
bleshooting. The resulting pinholes in the insu-
lation will allow moisture to penetrate the sys-
tem and possibly result in system failure.
F00H0ZA
F00B0EA
F00H10A
1
2
18-01-8 SMR2003-048_18_01A.FM
Terminal Installation
For insertion of signal terminal, make sure the
wedge lock is in the open position.
NOTE: For insertion of power terminal, the wedge
lock may or may not be on the open position.
Insert terminal into appropriate circuit cavity and
push as far as it will go.
Pull back on the terminal wire to be sure the reten-
tion fingers in the connector are holding the con-
tact properly.
After all required terminals have been inserted,
the wedge lock must be closed to its locked posi-
tion.
IDENTIFICATION OF
CONNECTOR PINS
AMP Connectors of MPEM
AMP Connectors of Wiring Harness
EMS ECU CONNECTORS
4-TEC Models Only
There are two EMS ECU connectors used on the
4-TEC models and they are connected on the
EMS ECU. The engine harness female connector
is connected on the module male connector A
and the watercraft system control harness female
connector is connected to the module male con-
nector B. The engine connector has 41 pins.
1. EMS ECU
2. A connector (engine harness)
3. B connector (watercraft system harness)
CAUTION: Do not disconnect the EMS ECU con-
nectors needlessly. They are not designed to be
disconnected/reconnected frequently.
26 25 24
23
15
8
16
9
1
F04H6RA
F04H6GA
9
1
F18Z02A
2
3
SMR2003-048_18_01A.FM 18-01-9
CAUTION: Probe on top of terminal only. Do not
try to probe inside terminal or to use a paper
clip to probe inside terminal, it can damage the
square-shaped terminal.
Terminal Removal
Unlock the connector cover by pushing in the tabs
on top of the connector with a flat screwdriver to
be able to flip the top cover up.
1. Push in tab
Lift the cover by pushing it forward.
1. Cover
Cut both tie raps that secure the harness to the
connector.
1. Tie raps
Turn the connector over and remove the orange
locking tab by pushing and then pulling toward the
wire harness.
A terminal remover such as Snap-On TT600-1 (or a
0.76 mm (.030 in) oxyacetylene torch tip cleaner or
a #68 drill bit) must be inserted into the terminal
cavity to release the locking tab from the connector.
1
F18Z0RA
1
F18Z06A
1
F18Z07A
F18Z0SA
F18Z0TA
18-01-10 SMR2003-048_18_01A.FM
CAUTION: Using a tool tip larger than 0.76 mm
(.030 in) may damage the terminal.
Insert the tool tip into the terminal cavity as
shown, and locate its wire in the back of the con-
nector. You may have to pry the tool tip against
the locking tab to release it, then remove the ter-
minal from the connector.
Check the locking tab on the terminal, it may have
to be bent out a little so it will lock in its cavity
when it is re-inserted.
If the wire is in good condition but the terminal is
rusted or corroded, remove defective terminal and
crimp a new one. If wire and terminal are defec-
tive, replace with a new genuine wire and new
terminal and crimp them together as explained be-
low.
IMPORTANT: Use genuine wires only. Otherwise
wires will not fit properly.
When re-inserting the terminal, the locking tab
must be installed facing the smaller cutout of the
terminal cavity.
Insert the terminal, ensuring the locking tab snaps
into its cavity.
Re-install the orange locking tab, attach the 2 tie
raps, and close the connector cover.
Terminal Crimping
To crimp a new terminal, use the EMS ECU crimp-
ing tool (P/N 529 035 905).
1. EMS ECU crimping tool
F18Z0UA
F18Z0VA
F18Z0WA
F18Z0XA
1
F18Z0QA
SMR2003-048_18_01A.FM 18-01-11
Install the new terminal in the crimping tool swiv-
el. Close the swivel in place. Place the wire on
terminal barrel and crimp the wire firmly.
1. New terminal
2. Crimping tool swivel
3. Crimping tool
1. Crimping tool swivel
2. Crimping tool
3. Wire
Lubrication
Apply a thin coat of DEOXIT contact lubricant (P/N
293 550 034) to the pins of the connector on the
EMS ECU only.
MAIN FUSE HOLDER JOINT
CONNECTOR
DI Models
The fuse holder is located in the rear electrical box.
1. Main fuse holder joint connector
NOTE: In the following illustrations, the joint insu-
lator has been removed for clarity purpose only. It
is not necessary to remove it to separate the joint.
The same procedure is to be used each side of the
joint.
Insert the Deutsch joint connector tool (no. 114010)
on the wire and push tool toward the joint to re-
lease it. While holding the joint insulator, push the
tool until it bottoms. It is now unlocked. Maintain-
ing the pressure with the tool, pull the wire out.
DEUTSCH JOINT CONNECTOR TOOL (NO. 114010)
1. Hold the insulator
2. Push the tool until it bottoms
1
F18Z0GA
2 3
1
F18Z0HA
2
3
1 F12H0ZA
F12H10A
1
F12H11A
2
18-01-12 SMR2003-048_18_01A.FM
1. While holding tool pressure, pull wire until terminal releases
2. Joint connector
For installation, simply push the wire in the con-
nector. You should hear a locking click. Try to
pull the wire out to ensure terminal is properly
locked. If not, remove the wire and bend the tabs
inside the joint connector to allow proper locking.
Recheck.
1 F12H12A 2
NOTE
NOTE
F00Z0D
2003 GTI MODEL
WARNING :
F00Z0C
2003 GTI LE MODEL
WARNING :
F00Z0E
2003 GTI LE RFI MODEL
WARNING :
F00Z0J
2003 RX DI MODEL
WARNING :
F00Z0I
2003 GTX DI MODEL
WARNING :
F00Z0K
2003 XP DI MODEL
WARNING :
F00Z0F
2003 GTX 4-TEC MODEL
WARNING :
F00Z0G
2003 GTX 4-TEC MODEL WITH AUXILIARY DESS MODULE
WARNING :
F00Z0B
2003 GTX 4-TEC AND GTX 4-TEC SUPERCHARGED MODELS
WARNING :
B
A
B
A
2003 LRV DI MODELS
F11Z03
I
N
J
.
B
A
T
T
. 2
5
A
B
I
L
G
E
3
A
R
E
G
. 2
5
A
A
C
C
. 2
A
F
P
1
5
A
N
S
E W
RE-PU
RE
G
Y
-
R
E
G
Y
-
R
E
WARNING :

Seadoo Service 4 Tec, 2 Stroke, Manual

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What are some of the safety notices mentioned in the document?

What are some of the safety notices mentioned in the document?

What models are covered in the wiring diagrams section?

What models are covered in the wiring diagrams section?

2003

Bombardier Inc. 2003

*Registered trademarks of Bombardier Inc.

is a trademark of Castrol Ltd. Used under license

is a trademark of Loctite Corporation

is a trademark of Snap-on Tools Corporation

is a trademark of Gelcote International Limited

BOMBARDIER-ROTAX Formula XP-S Synthetic Injection Oil

is a trademark of Loctite Corporation.

is a trademark of Loctite Corporation.

is a trademark of Dow Corning Corporation.

repair kit are available. Replace

6800 - 10200 ohms

6800 - 10200 ohms

Manifold air pressure

Corrosion Protectant all

Corrosion Protectant as de-

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