Sea-doo GTI 5559, RX 5579, RX 5580, RX 5582, RX5581, XP 5578 Shop Manual

COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION ....................

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

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

ADDITIONAL RECOMMENDED PROTECTION ................................................................

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

02-05-9

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

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02-01-1

Section 02 MAINTENANCE

Subsection 02 (PERIODIC INSPECTION CHART)

PERIODIC INSPECTION CHART

FREQUENCY

DESCRIPTION

Lubrication/corrosion protection

➀

Support and rubber mount condition/tightness

Exhaust system fasteners

➄

RAVE valve cleaning ( if so equipped )

➄

Top end inspection (leak test, piston and ring clearance)

( DI models only)

➄

Counterbalance shaft oil level ( if so equipped )

Spark plug inspection, cleaning and gap adjustment

➄

Spark plug replacement

➄

Ignition timing ( all models except DI )

➄

TDC setting ( DI models only)

➄

Flushing

Hose condition and fasteners

Inspect/clean engine drain tubes

✔

✔➃

✔

Water flow regulator valve inspection ( if so equipped )

Carburetor adjustment including choke/throttle cable adjustments

( carburetor-equipped models )

✔

Throttle/choke cables (

Fuel filter ( carburetor-equipped models except RFI models ) and lines inspection

), inspection/lubrication

➀

✔

Fuel filter replacement ( except DI and RFI models)

Fuel filter replacement ( DI models only)

Visually check for oil leakage between cylinder head and injector ( DI models )

➄ ✔

Fuel injection system sensors (except throttle body), visual inspection

( RFI and DI models )

➄

Throttle body cleaning and their sensors ( DI models )

➄ ➅

Fuel vent line pressure relief valve inspection

✔

Fuel lines, connections ( DI models ), check-valve and fuel system pressurization

➄

Visual inspection: carburetors/throttle bodies, sensors, fuel lines, fuel rail and fittings ( if so equipped )

➄

Air intake silencer fit/tightness

Fuel tank straps visual inspection

Oil injection pump adjustment

➄

Oil filter and lines inspection

✔

Oil filter replacement

Oil reservoir straps

✔

✔➂

✔➀

✔

➈

✔

➈

✔

➇

✔

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Section 02 MAINTENANCE

Subsection 02 (PERIODIC INSPECTION CHART)

FREQUENCY

Electrical connections condition and fastening (ignition system, electrical box(es), starting system, fuel injectors ( RFI and DI models ), etc.)

MPEM mounting brackets/fasteners

Digitally Encoded Security System

Monitoring beeper

Battery condition and strap(s)

Inspection and cable adjustment

DESCRIPTION

✔

Check O.P.A.S. system operation and condition including filter

Drive shaft boot and spline condition ( if so equipped )

Drive shaft protection hose inspection

PTO flywheel and seal carrier lubrication ( if so equipped )

Shifter system/cable adjustment ( if so equipped )

VTS (Variable Trim System, ( if so equipped )

Jet pump reservoir oil level/oil condition

Jet pump cover pusher inspection ( if so equipped )

Impeller shaft seal replacement

Impeller condition and impeller/wear ring clearance

Water intake grate condition

Bailer pick-ups, check for obstructions

Hull condition

✔ ✔

✔➁

✔

✔ ✔

Replace

✔

Replace

✔

➆

✔➁

✔

NOTE: Some items are included in the PRE-OPERATION CHECKS and not necessarily repeated in this chart.

➀

Every 10 hours in salt water use.

➁

These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart.

➂

Daily flushing in salt water or foul water use.

➃

Except DI models.

➄

Emission-related component.

➅

In salt water use.

➆

Replace at 150 hours.

➇

Replace at 250 hours.

➈

Check at 350 hours or 5 years.

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Section 02 MAINTENANCE

Subsection 03 (FLUSHING AND LUBRICATION)

FLUSHING AND LUBRICATION

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 lubrication 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



WARNING

Perform this operation in a well ventilated area.

Do not touch any electrical parts or jet pump area when engine is running.

Clean jet pump by spraying water in its inlet and outlet and then spray BOMBARDIER LUBE lubricant.



WARNING

Always remove safety lanyard cap from switch to prevent accidental engine starting before cleaning the jet pump area. Engine must not be running for this operation.

Install flushing adapter (P/N 295 500 473) to the water outlet located at the rear of the watercraft.

F06E01A

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.

F00E05A

1. Quick connect adapter

2. Flushing adaptor (P/N 295 500 473)

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F07E01B

1. Garden hose installed

2. Quick connector adaptor

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02-03-1

Section 02 MAINTENANCE

Subsection 03 (FLUSHING AND LUBRICATION)

All Models

Start the engine then immediately open the water tap.



WARNING

Do not touch any electrical parts or jet pump area when engine is running.

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 approximately one minute.

All Models except DI

1 2

F01F25A

717 AND 787 ENGINES

1. Air intake silencer

2. Pull plug

3. Spray BOMBARDIER LUBE here

DI and 947 Carburetor-Equipped 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.

F12F01A

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.



WARNING

Always use spark plug cable grounding device when removing spark plugs.

F01H7CA

GTI AND GTI LE MODELS

1. Grounding device

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F08H0CA

XP MODELS

1. Grounding device

F01H7DA

RX, RX DI AND GTX CARBURETOR-EQUIPPED MODELS

1. Grounding device

Section 02 MAINTENANCE

Subsection 03 (FLUSHING AND LUBRICATION)

All Carburetor-Equipped Models

Connect safety lanyard cap to the switch.

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.

GTX RFI Models

On 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 injected into the engine.

DI Models

NOTE: Proceeding in this order, no fuel will be injected and no ignition will occur in the engine.

While engine is stopped, fully depress throttle lever 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

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 engines ).

NOTE: Engine fogging should be done with

BOMBARDIER LUBE lubricant whenever the watercraft is to be stored for a few days or a long period.

CAUTION:

Never leave rags or tools in the engine compartment or in the bilge.

F07H0AA

GTX RFI MODELS

1. Grounding device

Remove both spark plugs and spray BOMBARDIER

LUBE lubricant into each cylinder.

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02-03-3

Section 02 MAINTENANCE

Subsection 04 (WATER-FLOODED ENGINE)

WATER-FLOODED ENGINE

GENERAL

If engine is water-flooded, it must be serviced within a few hours after the event. Otherwise engine will have to be overhauled.

CAUTION:

A water-flooded engine must be properly lubricated, operated then lubricated again, otherwise parts will be seriously damaged.

PROCEDURE

Check fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids.

Turn fuel valve to OFF position ( carburetorequipped models ) then drain fuel filter bowl. Refer to FUEL CIRCUIT.

Drain bilge if water is present.

Remove spark plug cables and connect them on the grounding device.



WARNING

Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device. Be careful when cranking engine, water will spray out from spark plug holes.

F08H0CA

XP MODELS

1. Grounding device

F01H7DA

RX, RX DI, GTX AND LRV DI MODELS

1. Grounding device

F01H7CA

GTI MODELS

1. Grounding device

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F07H0AA

GTX RFI MODELS

1. Grounding device

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02-04-1

Section 02 MAINTENANCE

Subsection 04 (WATER-FLOODED ENGINE)

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 install spark plugs on engine yet.

Cover spark plug holes with a rag.



WARNING

Be careful when cranking engine in the following procedure, water will spray out from spark plug holes.

Carburetor-Equipped Models

Fully depress the throttle lever then crank the engine to drain crankcase.

NOTE: Ensure choke lever is completely pushed in.

GTX RFI Models

NOTE: Proceeding in this 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.

DI Models

NOTE: Proceeding in this order, no fuel will be injected into the engine and ignition will be cut.

While engine is stopped, fully depress throttle lever 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 necessary to remove the air intake silencer then to lean the vehicle so that water can flow out from throttle bodies.

All Models

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.

F07D06A

787 RFI ENGINE

1. Remove filler plug

Insert a wire through oil filler hole to check oil condition. 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.

F07D07A

787 RFI ENGINE

1. Drain plug

Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug with Loctite 515.

Add 30 mL (1 oz) of SAE 30 motor oil.

Reinstall filler plug.

Carburetor-Equipped Models

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.

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Section 02 MAINTENANCE

Subsection 04 (WATER-FLOODED ENGINE)

RFI and DI Models

Start engine according to normal starting procedure.

All Models

CAUTION:

To avoid starting motor overheating, the cranking period should not exceed 5-

10 seconds and a rest period of 30 seconds should be observed between cranking cycles.

NOTE: If engine does not start after several attempts, check ignition system for spark occurrence. Refer to IGNITION SYSTEM.

Check crankshaft if needed, it may be misaligned or deflected. Refer to BOTTOM END.

After engine has started, spray BOMBARDIER

LUBE lubricant through air intake silencer while engine is running.

1 2

Spray BOMBARDIER LUBE lubricant or equivalent, through hole of air intake silencer keeping engine at fast idle during one minute.

F02H0ZA

947 ENGINES

1. Air intake silencer

2. Spray BOMBARDIER LUBE here

Run engine until it reaches its normal operating temperature.

CAUTION:

Engine must be cooled using the flush kit.

F01F25A

717 AND 787 RFI ENGINES

1. Air intake silencer

2. Pull plug

3. Spray BOMBARDIER LUBE here

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02-04-3

Section 02 MAINTENANCE

Subsection 05 (STORAGE)

STORAGE

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.

F07E05A

1. Disconnect this 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.

F07E0MA

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.

F07E06A

1. Fitting

2. Hose

1 2

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.

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Section 02 MAINTENANCE

Subsection 05 (STORAGE)

DI Models

Disconnect the quick connect fitting. Press both tabs and pull fitting.

PTO Flywheel

All Models except XP

Remove PTO flywheel guard.

Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).

CAUTION:

Do not lubricate excessively. Immediately stop when a slight movement is noticed on rubber boot.

F07E0HA

DISCONNECT THIS HOSE

Lower hose as necessary so that draining can take place.

Reconnect fitting when done.

Also ensure air compressor drain line is not obstructed. 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 component service life could be reduced. Do not mix oil brands or types.

F01I0BA

1. Grease PTO flywheel

CAUTION:

Never leave any clothing, tool or other objects near PTO flywheel and drive shaft.

SEAL CARRIER

XP Models

Lubricate seal carrier of drive shaft support with synthetic grease. Stop lubricating when grease is just coming out of seal.

F08I01A

1. Grease seal carrier

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Section 02 MAINTENANCE

Subsection 05 (STORAGE)

FUEL SYSTEM

Verify fuel system. Check fuel lines and carburetor(s), if so equipped , for leaks. Replace damaged hoses or clamps if necessary.

Sea-Doo Fuel Stabilizer (P/N 413 408 600) or equivalent should be added in fuel tank to prevent fuel deterioration and, if so equipped , carburetor(s) gumming. Follow manufacturer’s 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.

CAUTION:

Fuel stabilizer should be added prior to engine lubrication to ensure fuel system components protection against varnish deposits.



WARNING

Fuel is inflammable and explosive under certain conditions. Always work in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. Fuel tank may be pressurized, slowly turn cap when opening. 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. Always wipe off any fuel spillage from the watercraft. Always turn the fuel tank valve (

if so equipped

) to OFF position when storing the watercraft.

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.

Carburetor-Equipped Models

Always turn the fuel valve to OFF position when storing the watercraft.

COOLING SYSTEM FLUSHING

AND ENGINE INTERNAL

LUBRICATION

All Models

Cooling system 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.

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ADDITIONAL RECOMMENDED

PROTECTION

NOTE: This procedure requires approximately 2.5 L

(2.6 U.S. qt.) of antifreeze.

All Models

In cool regions (where freezing point may be encountered), 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 adequately engine/exhaust system may freeze and cause severe engine damage. Always use ethylene glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines.

NOTE: When available, it is recommended to use biodegradable antifreeze compatible with internal combustion aluminum engines. This will contribute to protect the environment.

NOTE: The engine will not have to run during this operation.

02-05-3

Section 02 MAINTENANCE

Subsection 05 (STORAGE)

Hose Pinchers Installation

Some hoses have to be plugged to prevent draining, before filling cooling system jackets with the antifreeze.

All Models except DI

NOTE: On RFI models , make sure the hose is properly connected to the magneto cover.

F07E0EB

1 2 3

1. Water supply hose from crankcase heat exchanger

2. Quick connector

3. Magneto heat exchanger

F17E05A

GTI MODELS — 717 ENGINES

1. Engine drain hose

F07E0JA

947 CARBURETOR-EQUIPPED ENGINES EXCEPT XP

1. Engine drain hose

F07E0DA

RFI MODELS — 787 ENGINE

1. Hose pincher installed on engine drain hose

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NOTE: On XP models , open rear cover to have access to engine drain hose.

Section 02 MAINTENANCE

Subsection 05 (STORAGE)

F08E04A

XP MODELS — 947 ENGINE

1. Hose pincher installed on engine drain hose

Install hose pincher on injection hose going to tuned pipe.

F17E01A

717 AND 787 RFI ENGINES

1. Engine water outlet hose

F12E02A

947 CARBURETOR-EQUIPPED ENGINES

1. Engine water outlet hose

F12E0SA

GTI MODELS — 717 ENGINES

1. Hose pincher on injection hose going to tuned pipe

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F12E04A

1. Tuned pipe bleed hose

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02-05-5

Section 02 MAINTENANCE

Subsection 05 (STORAGE)

Hose Disconnection

Some hoses have to be disconnected. Disconnect hoses at the following location.

F06E0EB

717 AND 787 RFI ENGINES

1. Disconnect engine water inlet hose

F07E0LA

947 Carburetor-Equipped Engines

At this point, remove the hose pincher at tuned pipe bleed hose. If necessary, continue to pour antifreeze mix until the colored solution appears at the other cooling system bleed outlet (stern eyelet).

Remove the remaining hose pinchers in this order to allow proper flow of antifreeze.

1. Engine cylinder drain hose.

2. Water outlet hose.

787 RFI Engines

Disconnect hose just above T-fitting from as shown.

F12E03A

947 CARBURETOR-EQUIPPED ENGINES

1. Disconnect inlet ose this side of T-fitting

717 Engines

Temporarily install a short piece of hose to engine water intlet at cylinder head.

All Models except DI

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 system bleed outlet.

F15E02A

1 2

1. Hose connecting to inlet fitting of cylinder head

2. Disconnect hose above T-fitting

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787 RFI and 947 Carburetor-Equipped Engines

Install a hose pincher just below T-fitting.

Section 02 MAINTENANCE

Subsection 05 (STORAGE)

F15E03A

1. Hose pincher below T-fitting

Pour approximately 300 mL (10 oz) of antifreeze in the water regulator valve supply hose to allow antifreeze flowing through the valve and into muffler to protect it.

Reconnect hose to T-fitting and remove hose pincher ( if applicable ).

All Models except DI

Remove temporary hose on 717 engines and reconnect engine water outlet hose.

Remove hose pinchers.

DI Models

Hose Pinchers Installation

Some hoses have to be plugged to prevent draining, before filling cooling system jackets with the antifreeze.

Install hose pinchers at the following location:

F12E02A

RX DI MODELS

1. Water outlet hose

F07E0NB

LRV DI MODELS

1. Water outlet hose

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F12E0AA

1. Crankcase cooling cover outlet hose

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02-05-7

Section 02 MAINTENANCE

Subsection 05 (STORAGE)

F07E0JA

1. Engine cylinder drain hose

Hose Disconnection

Disconnect water INLET hose at engine between Tfitting and cylinder head fitting.

F07E0LA

At this point, install a hose pincher on bleed outlet hose.

F12E0BA

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.

F07E0OA

1. Bleed outlet hose

Continue to pour until antifreeze flows in air compressor water outlet hose.

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Section 02 MAINTENANCE

Subsection 05 (STORAGE)

F07E0NC

1. Air compressor water outlet hose

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.

Pour approximately 200 mL (7 oz) of antifreeze in the water regulator valve supply hose to allow antifreeze flowing through the valve and into muffler to protect it.

Remove temporary hose and reconnect engine water outlet hose.

All Models

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 cylinder water jackets and thus preventing freezing problems.

At pre-season preparation, drain the remaining antifreeze from cooling system prior to using the watercraft.

ANTICORROSION TREATMENT

Wipe off any residual water in the engine compartment.

Spray BOMBARDIER LUBE lubricant over all metallic 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 models ).

This will avoid engine compartment condensation and possible corrosion.

CHECKLIST

✔

OPERATION

Check engine drain hose(s)

Drain and clean impeller shaft reservoir

Lubricate PTO flywheel or seal carrier

Verify fuel system

Add Sea-Doo fuel stabilizer

Flush the cooling system

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)

Spray BOMBARDIER LUBE over all metallic components in engine compartment and on throttle and oil injection pump cables

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Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

TROUBLESHOOTING CHART

The following is provided to help in diagnosing the probable source of troubles. It is a guideline and should not be assumed to have all causes for all problems.

NOTE: On RFI and DI models , always check for fault codes recorded in the MPEM first using the VCK

(vehicle communication kit (P/N 529 035 844). The MPEM programmer (P/N 529 035 878) can be used on the RFI models . 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

Engine does not turn over

Engine turns slowly

POSSIBLE CAUSE

• DESS operation non functional

REMEDY

• If 2 short beeps are not heard when installing safety lanyard, refer to

ELECTRICAL SYSTEM and ENGINE

MANAGEMENT

• Wrong safety lanyard

• Starter solenoid

• Use one that has been programmed for that watercraft

• Replace • Safety lanyard switch faulty or disconnected or harness damaged

• Burnt fuse on MPEM or in rear electrical box: battery, starting system, fuel pump ( RFI models )

• Starting system fuse keeps on burning

• Battery connections

• Water/fuel hydrolock

• Starter malfunction

• Check wiring then replace fuse

• 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

• Check/clean/tighten

• Check, refer to section MAINTENANCE

• Check, refer to section ELECTRICAL

SYSTEM

• Check, refer to section ELECTRICAL

SYSTEM

• Seized or obstructed engine

• Hydraulically locked air compressor

( DI models )

• Seized jet pump

• Check/repair, refer to section ENGINE

• Check/repair as needed

• Faulty sensor ( or MPEM

RFI and DI models

• Loose battery cable connections

• Discharged/weak battery

• Restriction in jet pump

• Partial seizure in jet pump

)

• Check, refer to section PROPULSION

SYSTEM

• Check faulty codes in MPEM memory, refer to section ENGINE MANAGEMENT

• Check/clean/tighten

• Check/charge/replace

• Partial engine hydrolock

• Partial engine seizure

• Worn starter

• Outside temperature too low

• Check/clean pump

• Inspect, refer to section PROPULSION

SYSTEM

• Check, refer to section MAINTENANCE

• Check compression, refer to section

ENGINE

• Check, refer to section ELECTRICAL

SYSTEM

• Battery capacity is not sufficient for cold temperature

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03-01-1 www.SeaDooManuals.net

Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE WILL NOT START (cont’d)

OTHER OBSERVATION

Engine turns over

No spark at spark plugs

POSSIBLE CAUSE

• Faulty component in the fuel injection system ( RFI and DI models )

• Engine drowned mode is active

• Low battery voltage

REMEDY

• Check for fault codes with the VCK

(vehicle communication kit). Refer to

DIAGNOSTIC PROCEDURES in ENGINE

MANAGEMENT

• Release throttle lever

• Recharge or replace battery

• Low or no fuel pressure

( RFI and DI models

• Fuel injectors not working

( RFI and DI models )

)

• Check fuel pump operation

• Check fuel pump pressure output

• Check air/fuel rail

• Check fuel pump fuse

• Check wiring harness

• 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 • Replace MPEM

• Defective crankshaft position sensor • Check operation of CPS and replace if necessary

• Water-contaminated fuel • Check/siphon and refill

• Dirty fuel filter

• Fouled or defective spark plug

• Water in engine

• Carburetion ( carburetor models )

• Defective ignition circuit

• Clean/replace

• Replace

• Check, refer to section MAINTENANCE

• Check, refer to section FUEL SYSTEM

• Check, refer to section ELECTRICAL

SYSTEM

• Check, refer to section FUEL SYSTEM • Flooded engine

– Carburetor needle valve stuck open

( carburetor models )

• Excessive rotary valve clearance

( if so equipped )

• Incorrect rotary valve timing

( if so equipped )

• Internal engine damage

• Defective encoder wheel

• Check, refer to section ENGINE

MANAGEMENT

• Replace defective part(s)

• Check, refer to section ENGINE

• Insufficient engine compression

• Incorrect rotary valve timing

( if so equipped )

• Faulty rev limiter in MPEM

( carburetor models )

• Spark plug faulty, fouled or worn out

• Ignition

• Faulty MPEM

• Replace MPEM

• Check spark plug condition

• Check, refer to section ELECTRICAL

SYSTEM

• Replace MPEM

03-01-2

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Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE HARD TO START

OTHER OBSERVATION POSSIBLE CAUSE

• Water in fuel reservoir or contaminated fuel

• Mechanical engine failure

REMEDY

• Flush reservoir and refill with fresh gas

• Check cylinder compression

• Check for cylinder head leaks

• Wrong throttle body mechanical adjustment of cable

• Temperature too low for available battery capacity

• Check starting system

• Refer to ENGINE MANAGEMENT

• Battery capacity is not sufficient for cold temperature

• Spark plug faulty, fouled or worn out • Check spark plug condition

• Low fuel pressure

( RFI and DI models )

• 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

ENGINE STARTS BUT RUNS ONLY AT IDLE SPEED

OTHER OBSERVATION POSSIBLE CAUSE

• DI models: The system is in limp home mode.

• Broken or loose throttle cable

REMEDY

• Refer to section ENGINE and check the fault codes in the MPEM

• Change/readjust

ENGINE MISFIRES, RUNS IRREGULARLY

OTHER OBSERVATION

Weak spark

POSSIBLE CAUSE REMEDY

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

• Faulty MPEM • Check, refer to section ELECTRICAL

SYSTEM or ENGINE MANAGEMENT on RFI and DI models

• Defective encoder wheel • Check, refer to section ENGINE

MANAGEMENT

• Adjust oil injection pump • Too much oil supplied to engine

• 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

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Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE MISFIRES, RUNS IRREGULARLY (cont’d)

OTHER OBSERVATION

Lean fuel mixture

Dry spark plug (except when water fouled)

POSSIBLE CAUSE

• Low fuel level

• Low fuel pressure

( RFI and DI models )

• Stale or water fouled fuel

• Fuel filter dirty or restricted

• Carburetion dirty or out of adjustment

( carburetor models )

• Clogged fuel injectors

( RFI and DI models )

• Clogged direct injectors

( DI models )

• Defective sensor or MPEM

( RFI and DI models )

• Leaking crankshaft seal(s) or intake

( carburetor models )

• Restricted fuel valve

( carburetor models )

• Loose carburetor

( carburetor models )

REMEDY

• Check/refill

• Check pump, regulator, injectors and hose pinchers or if filter is plugged.

Replace if necessary

• Check/siphon and refill

• Check/clean/replace

• Check/clean/adjust, refer to section

FUEL SYSTEM

• Remove and clean fuel injectors

• Remove and clean direct injectors

• Check faulty codes in MPEM memory, refer to section ENGINE

MANAGEMENT

• Pressure check engine, refer to section

ENGINE

• Check/replace

• Tighten carburetors

03-01-4 www.SeaDooManuals.net

SMR2002-020_03_01A.FM

Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE MISFIRES, RUNS IRREGULARLY (cont’d)

Rich fuel mixture

Fouled spark plug

Start but run poorly

Also fuel injection misinjecting

SMR2002-020_03_01A.FM

• Partially closed choke

( carburetor models )

• Flame arrester dirty or restricted

( if so equipped )

• Check/adjust choke cable

• Check/replace

• Carburetor adjustment

( carburetor models )

• Check/adjust, refer to section FUEL

SYSTEM

• Loose main jet ( carburetor models ) • Check, refer to section FUEL SYSTEM

• Improper air/fuel rail pressure

( DI models )

• Faulty fuel injector(s)

( RFI and DI models )

• Check pressures, refer to ENGINE

MANAGEMENT

• Remove and replace fuel injector(s), refer to section ENGINE

MANAGEMENT

• Faulty direct injector(s) ( DI models ) • Remove and replace direct injector(s), refer to section

ENGINE MANAGEMENT

• Defective sensor or MPEM

( RFI and DI models )

• Check faulty codes in MPEM memory, refer to section 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 ENGINE

SECTION

• Leaking crankshaft seal(s) or intake

( DI models )

• Leak in RAVE valve system

( DI models )

• Pressure check engine, refer to section

ENGINE

• Check, refer to ENGINE MANAGEMENT

• Oil injection pump adjustment • Check/adjust, refer to section

LUBRICATION SYSTEM

• Check, refer to section FUEL SYSTEM • Worn needles and seals

( carburetor models )

• Excessive rotary valve clearance

( if so equipped )

• Check, refer to ENGINE

• Fuel pressure fluctuating ( DI models ) • Inspect fuel pressure regulators. Refer to ENGINE MANAGEMENT

• High fuel pressure

( RFI and DI models )

• Check pump, regulator, injectors, hose pinchers or if filter is plugged. Replace if necessary

• RFI and DI models: Check spark plug condition, check fault codes in the

MPEM memory, check fuel pressure, check RAVE valves operation

•

DI models: Bent or missing tooth on encoder wheel

RFI models: Bent or missing tooth on trigger wheel

• Injector wiring reversed

• Check, refer to section ENGINE

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

• Check, refer to ENGINE

MANAGEMENT under COMPONENT

INSPECTION AND ADJUSTMENT

• Damaged fuel injector

• Check, refer to ENGINE

MANAGEMENT

• Check, refer to ENGINE

MANAGEMENT

• Check/adjust, refer to ENGINE • Incorrect rotary valve timing

( if so equipped )

• Excessive rotary valve clearance

( if so equipped )

• Check, refer to ENGINE

03-01-5 www.SeaDooManuals.net

Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE CONTINUALLY BACKFIRES

OTHER OBSERVATION

Weak spark

Spark plugs

Ignition timing/TDC setting

POSSIBLE CAUSE

• Fouled, defective spark plugs

• Ignition coil leads or wiring reversed • Check with wiring diagram

• Incorrect setting • Check/reset, refer to section

ELECTRICAL SYSTEM

• Defective encoder wheel

• Clean/replace

REMEDY

• Incorrect timing

• Check/replace, refer to section

ENGINE MANAGEMENT

• Check/reset, refer to ENGINE Rotary valve

( if so equipped )

Carburetor

( if so equipped )

Engine

• Carburetion too lean

• Intake leak/crankshaft seal failure

( carburetor models )

• Check/adjust, refer to section FUEL

SYSTEM

• Pressure check engine, refer to section

ENGINE

ENGINE DETONATION OR PINGING

OTHER OBSERVATION

Ignition

POSSIBLE CAUSE

• Timing too far advanced

• Spark plug heat range too high

• Engine overheats and exhaust overheats

• Fuel octane too low of poor quality

• KS disconnected or faulty

Engine/exhaust high temperature

• Bad KS connection

• Bad Kostal connection (on engine)

REMEDY

• Check/reset

• Check/change to correct range

• Check, see engine overheats

• Use good quality fuel

• Check, refer to ENGINE

MANAGEMENT

• Check, refer to ENGINE

MANAGEMENT

• Check, refer to ENGINE

MANAGEMENT

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SMR2002-020_03_01A.FM

Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE LACKS ACCELERATION OR POWER

OTHER OBSERVATION POSSIBLE CAUSE

• Weak spark

• Carburetion, jetting too rich/lean

( carburetor models )

• Throttle does not open fully

• Low compression

• Water in fuel

• Debris in carburetor needle valve

( carburetor models )

• Impeller leading edge damaged

Engine revs lower than its maximum operational

RPM

Peak performance is delayed until higher

RPM range is reached

• Twisted crankshaft

• Poor quality

• Clogged direct injectors

( DI models )

• Clogged fuel injectors

( RFI and DI models )

• Low fuel pressure

( RFI and DI models )

• Incorrect throttle position sensor

(TPS) adjustment

( RFI and DI models )

• Overheated engine

• RAVE valve does not open

( if so equipped )

• Limp home mode activated

• RAVE valve is stuck opened

( if so equipped )

REMEDY

• Check/replace, refer to section

ELECTRICAL SYSTEM

• Check/adjust, refer to section FUEL

SYSTEM

• Check/readjust, refer to section FUEL

SYSTEM

• Check/repair, refer to section ENGINE

• Check/siphon/replace

• Check/clean, refer to section FUEL

SYSTEM

• Check/replace, refer to section

PROPULSION SYSTEM

• Check, refer to section ENGINE

• Siphon, then refill with fresh fuel

• Remove and clean direct injectors

• Remove and clean fuel injectors

• Check fuel line and fuel pump pressure

• Check and adjust TPS, refer to section

ENGINE MANAGEMENT

• See ENGINE OVERHEATS in this chart

• Check, refer to section ENGINE

• Refer to ENGINE MANAGEMENT

• Check, refer to section ENGINE

ENGINE STOPS RUNNING

OTHER OBSERVATION

Engine dies during regular operation (piston seizure)

POSSIBLE CAUSE

• Spark plug heat range too high

• Improper ignition timing ( DI models )

• Compression ratio is too high

• Poor oil quality

• Electrical noise ( DI models ) Engine was running below

2000 RPM.

No maintenance light

• Low air pressure ( DI models )

Engine stalls at idle

• Engine running out of fuel

Engine start but stops after approximately 2 seconds

• Air in fuel rail

• Low air pressure ( DI models )

REMEDY

• Check/change to correct range

• Check/reset

• Install genuine parts

• Use proper BOMBARDIER oil

• Refer to section ENGINE

MANAGEMENT

• Check air delivery circuit for leaks

• Check air compressor

• Check fuel delivery system for proper fuel pressure ( RFI and DI models ) and delivery ( all models )

• Refill fuel tank

• Check air system

(compressor, air/fuel rail etc.)

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Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE CANNOT REACH MAXIMUM RPM

OTHER OBSERVATION POSSIBLE CAUSE

• RAVE valve does not open

• Faulty water regulator valve

• DI models: The system is in limp home mode. “MAINT” is displayed on Information Center

• Low fuel pressure

( RFI and DI models )

• Jet pump related problem

• Limp home mode activated

• Exhaust gases in bilge (leak)

• Exhaust system blockage/muffler damage ( DI models)

REMEDY

• Check, refer to section ENGINE and

COOLING SYSTEM

• Check, refer to COOLING SYSTEM

• Refer to section ENGINE and COOLING

SYSTEM and check the fault codes in the MPEM

• Check fuel pump pressure output

• Check propulsion components.

Refer to JET PUMP

• Refer to ENGINE MANAGEMENT

• Check exhaust system for leaks

• Check and repair

ENGINE RUNS TOO FAST (vehicle cannot reach its top speed)

OTHER OBSERVATION

Engine RPM too high

Jet pump cavitation

O.P.A.S.

side vanes do not go up while watercraft is at speed.

O.P.A.S. side vanes do not go down while engine is at idle.

POSSIBLE CAUSE

• Faulty rev limiter in MPEM

• Improper impeller pitch (too low)

• Incorrect throttle position sensor

(TPS) adjustment ( RFI models )

• Damaged impeller

• Damaged leading or trailing edge of impeller

• Sealing of ride plate, jet pump support or jet pump

• Clogged filter, square rings damaged, leakage in hoses or mechanical malfunction.

• Broken spring inside side vane cylinder.

REMEDY

• Check, refer to section ENGINE

MANAGEMENT

• Check/replace, refer to section

PROPULSION SYSTEM

• Check and adjust TPS, refer to ENGINE

MANAGEMENT

• Replace impeller. Refer to

PROPULSION

• Check/replace

NOTE: Leading edge damage contributes to poor performance from start. Trailing edge damage contributes to poor top performance and stator vanes erosion.

• Check/reseal, refer to section

PROPULSION SYSTEM or HULL/BODY

• Refer to STEERING SYSTEM

03-01-8 www.SeaDooManuals.net

SMR2002-020_03_01A.FM

Section 03 TROUBLESHOOTING

Subsection 01 (TROUBLESHOOTING CHART)

ENGINE OVERHEATS

OTHER OBSERVATION POSSIBLE CAUSE

• Temperature sensor defect

• Worn water pump impeller

• Damaged ride plate or hoses

Monitoring beeper sounds continuously

• Restricted jet pump water intake

• Cooling system restriction

• Grounded temperature sensor or sensor wire ( carburetor models )

REMEDY

• Check/replace. Refer to ENGINE

MANAGEMENT

• Check/replace

• Check. Refer to COOLING SYSTEM and HULL/BODY

• Check/clean

• Check/flush, refer to section

MAINTENANCE

• Check/repair/replace

O.P.A.S. SYSTEM FAULTS

OTHER OBSERVATION

Watercraft is more responsive than usual while turning.

Watercraft pulls on one side.

O.P.A.S. side vanes do not go up while watercraft is at speed.

O.P.A.S. side vanes do not go down while engine is at idle.

POSSIBLE CAUSE

• Side vanes do not go up while watercraft is at speed.

REMEDY

• Refer to STEERING SYSTEM.

• One side vane does not go up while watercraft is at speed.

• Clogged filter, square rings damaged, leakage in hoses or mechanical malfunction.

• Refer to STEERING SYSTEM.

• Broken spring inside side vane cylinder. • Refer to STEERING SYSTEM.

ABNORMAL NOISE FROM PROPULSION SYSTEM

OTHER OBSERVATION POSSIBLE CAUSE

• Weeds/debris caught in intake grate or impeller

• Low oil level in jet pump

• Worn anti-rattle system

• Damaged or bent drive shaft

• Broken engine mounts

• Check/clean

REMEDY

• Check/troubleshoot source of leak/ refill supply, refer to section

PROPULSION SYSTEM

• Check/replace pusher in cover, refer to section PROPULSION SYSTEM

• Check/replace, refer to section

PROPULSION SYSTEM

• Check/replace, refer to section ENGINE

NOTE: Prior to replacing a MPEM, refer to the MPEM section or MPEM REPLACEMENT in the ENGINE

MANAGEMENT section and read carefully the tests to do before replacing a MPEM that could otherwise be good.

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Section 04 ENGINE

Subsection 01 (TABLE OF CONTENTS)

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 .........................................................................................................................

04-03-5

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

04-03-6

MAGNETO SYSTEM .............................................................................................................

04-04-1

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

04-04-5

CLEANING ......................................................................................................................... 04-04-11

ASSEMBLY......................................................................................................................... 04-04-12

TOP END ................................................................................................................................

04-05-1

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

04-05-5

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

04-05-7

CLEANING ......................................................................................................................... 04-05-16

INSPECTION ...................................................................................................................... 04-05-16

USED PISTON MEASUREMENT ...................................................................................... 04-05-17

ASSEMBLY......................................................................................................................... 04-05-20

ADJUSTMENT ................................................................................................................... 04-05-29

BOTTOM END........................................................................................................................

04-06-1

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

04-06-5

CLEANING ......................................................................................................................... 04-06-13

INSPECTION ...................................................................................................................... 04-06-14

ASSEMBLY......................................................................................................................... 04-06-18

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

04-01-1

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Section 04 ENGINE

Subsection 01 (TABLE OF CONTENTS)

EXHAUST SYSTEM ...............................................................................................................

04-08-1

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

04-08-7

TUNED PIPE REPAIR .......................................................................................................... 04-08-12

INSTALLATION ................................................................................................................... 04-08-13

04-01-2 www.SeaDooManuals.net

SMR2002-052_04_01ATOC.FM

Section 04 ENGINE

Subsection 02 (LEAK TEST)

LEAK TEST

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 performance, oil leakage, etc.

Before disassembling any components of the engine, 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 another leakage test; at this stage, it may avoid further 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 another 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 sealing.

When pressurizing the engine, first confirm that the components of the Engine Leak Test Kit or

Supplementary Engine Leak Test Kit are not leaking 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 sequence 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 all 947 engines ).

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.



WARNING

If any fuel leak is found, do not start the engine. Correct the leak and wipe off any fuel spillage. Do not use electric powered tools unless fuel system has passed pressure test.

Disconnect battery BLACK negative cable.



WARNING

Always disconnect battery cables in the specified order, BLACK negative cable first.

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 Supplementary 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.

04-02-1

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Section 04 ENGINE

Subsection 02 (LEAK TEST)

Use hoses provided in the kit and install them on the engine.

Install pump using reducer and appropriate tube(s) as necessary.

2 1

F01B2UB

717 ENGINE — REAR VIEW

1. Engine drain hose blocked with a hose pincher

F02E0DA

787 RFI ENGINE — 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

F02D0WA

787 RFI ENGINE — FRONT VIEW

1. Exhaust manifold plate

F01B2VA

717 ENGINE — FRONT VIEW

1. Loop hose and use clamps

2. Use two washers with exhaust manifold stud

3. Hose with adapter and nipple

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SMR2002-021_04_02A.FM

Section 04 ENGINE

Subsection 02 (LEAK TEST)

F08E06A

947 CARBURETOR-EQUIPPED ENGINE — REAR VIEW

1. Block engine drain hose with a hose pincher

2. Install pump to water inlet hose

F12E08A

947 DI ENGINE — SIDE VIEW

1. Block engine drain hose with a hose pincher

2. Install pump to water inlet hose

F08D04A

947 CARBURETOR-EQUIPPED ENGINE — FRONT VIEW

1. Exhaust manifold plate

F12E07A

947 DI ENGINE — 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.

04-02-3

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Section 04 ENGINE

Subsection 02 (LEAK TEST)

Activate pump and pressurize engine cooling system 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, temperature 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

Carburetor-Equipped Models

Remove the carburetor(s) and gasket(s). Make sure the surface of the intake manifold ( 717 and

947 engines ) or rotary valve cover ( 787 RFI engine ) are clean.

Install the intake plate(s) with fasteners from the kit and tighten adequately.

NOTE: For the 787 RFI and 947 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)

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 engines ) 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.

F01B2ZA

717 ENGINE

1. Intake plates

2. Pulse hose blocked with a hose pincher

3. Exhaust plate

F12D14A

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.

F01B30A

787 RFI ENGINE

1. Intake plates

2. RAVE valve plates

3. Pulse hose blocked with a hose pincher

4. Exhaust plate

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SMR2002-021_04_02A.FM

Section 04 ENGINE

Subsection 02 (LEAK TEST)

1 2

Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve.

Check for leak through counterbalancing shaft seal toward air compressor ( DI engines ). Air bubbles in lowest fitting (oil return line) underneath compressor indicates a seal leakage.

If the above mentioned components are not leaking, 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 flywheel to verify outer seal.

If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer 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.

F08D05A

947 ENGINE

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 all 947 engines )

– engine plugs

– exhaust manifold

– intake manifold ( 717 engine )

– intake flanges ( DI engine )

– oil injection pump ( 717 engine ).

F01B31A

717 ENGINE

1. Oil return hose blocked with hose pincher

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Section 04 ENGINE

Subsection 02 (LEAK TEST)

F01B33A

787 RFI ENGINE

1. Oil return hose blocked with hose pincher

Install pump with reducer and nipple to the oil supply hose of the rotary valve shaft.

F01B32A

717 ENGINE

1. Pump with reducer and nipple

F01B34A

787 RFI ENGINE

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 indicates a defective engine casting. Disassemble engine 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.

04-02-6 www.SeaDooManuals.net

SMR2002-021_04_02A.FM

Section 04 ENGINE

Subsection 02 (LEAK TEST)

ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

717 and 787 RFI Engines

PRESSURIZE ROTARY VALVE GEAR

RESERVOIR IN CRANKCASE

CHECK TESTING KIT

YES

PRESSURIZE ENGINE

COOLING SYSTEM

IS SYSTEM LEAKING?

PRESSURIZE ENGINE

IS ENGINE LEAKING?

YES

CHECK TESTING KIT

SCREW/STUD THREADS. MOUNTING

FLANGES ETC.

ANY LEAK FOUND?

CHECK SMALL OIL LINES OF

INJECTION PUMP

AIR BUBBLES FOUND

TOWARD PUMP?

BLOCK LARGE HOSES OF

LUBRICATION SYSTEM

IS ENGINE STILL LEAKING?

YES

CHECK TESTING KIT

CHECK CRANKSHAFT OUTER

MAG SIDES

ARE SEALS LEAKING?

PRESSURIZE ROTARY VALVE GEAR

RESERVOIR IN CRANKCASE

YES

IS RESERVOIR LEAKING?

SEPARATELY BY REMOVING THE

APPROPRIATE SPARK PLUG

IS RESERVOIR LEAKING?

CHECK FOR LEAKAGE AT ROTARY

VALVE SHAFT CRANKCASE PLUG

ANY LEAK FOUND?

YES

IS RESERVOIR LEAKING?

YES

IS SEAL LEAKING?

YES

ANY LEAK FOUND?

F00D07S

CHECK TESTING KIT

VALVE SHAFT END, OR

REPLACE CAP

RECHECK ENGINE SEALING

REPLACE GASKET OR O-RING,

RE-SEAL LEAKING AREA

REPLACE CHECK VALVE(S) / LINE(S)

REPLACE DEFECTIVE SEAL(S)

REPLACE DEFECTIVE SEAL

REPLACE DEFECTIVE PARTS

RECHECK ENGINE SEALING

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Section 04 ENGINE

Subsection 02 (LEAK TEST)

947 Engine

F00D28S

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SMR2002-021_04_02A.FM

Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION

GENERAL

On some models, it is not necessary to remove engine from watercraft to service TOP END, PTO

FLYWHEEL or MAGNETO. However, engine removal 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.



WARNING

Always disconnect battery cables exactly in the specified order, BLACK negative cable first then the RED positive battery cable last.

F06D0FA

787 RFI ENGINE

1. Unplug connector

Electrical Connections

It is recommended to disconnect electrical connections prior to disconnecting fuel lines.

Disconnect temperature sensor wire and spark plug cables.

Disconnect magneto wiring harness.

F01D8RA

717 ENGINE

1. Unplug connector

F07D08A

947 ENGINE

1. Unplug connector

GTX RFI Models

Disconnect throttle position sensor (TPS), air pressure 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).

04-03-1

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Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

Disconnect connectors from fuel injectors and direct injectors.

Disconnect connector from knock sensor.

Disconnect RAVE valve hose where shown. Inspect hose. If it has hardened or is slit, replace hose.

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

Carburetor-Equipped Models

Turn fuel valve to OFF.

Disconnect fuel supply and fuel return hoses.

To remove carburetor(s), refer to CARBURETOR for proper procedure.

GTX RFI Models

Disconnect fuel supply hose from fuel rail.

F16D04A

1. Disconnect hose here

Refer to ENGINE MANAGEMENT for location of sensors and connectors.

Unplug air compressor lines (inlets and outlets): cooling, oil (outlet only) and air (inlet only on throttle 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.

04-03-2

F07F11A

PRESS TABS AND PULL CONNECTOR

1. Fuel rail



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 spillage inside bilge.

DI Models

Remove air/fuel rail. Refer to ENGINE MANAGE-

MENT.

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SMR2002-022_04_03A.FM

Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

All Models

Engine Support

NOTE: Be careful when removing engine support(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.

F02D08A

717 ENGINE

1. Remove screw of each engine support

F07F12C

787 RFI AND 947 ENGINES — REAR SUPPORT

1. Remove screws

Lifting Engine

717 Engine

Engine can be easily lifted using the following suggested tools:

– Cut porcelain from two old spark plugs.

– Weld a lock washer approximately 20 mm (3/4 in) diameter on each spark plug as shown.

F06D35A

787 RFI AND 947 ENGINES — FRONT SUPPORT

1. Remove screw

SMR2002-022_04_03A.FM

F01D0AA

1. Weld a lock washer

2. Old spark plug

Remove spark plugs and replace by special tools.

Hook a sling into holes of special tools.

Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the remaining component removal.

CAUTION:

Take care not to damage cable or oil injection hoses.

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Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

787 RFI and 947 Engines

Engine can be easily lifted by inserting a hook into exhaust manifold eyelet.

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 injection pump and rotary valve shaft ( except the

947 engine ); then, disconnect hoses.

F01D7OA

TYPICAL

Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the remaining component removal.

CAUTION:

Take care not to damage cable or oil injection hoses.

Remove rear engine support.

A01B2JB

TYPICAL

1. Hose pincher (P/N 295 000 076)

Install a hose pincher to oil return hose of rotary valve shaft ( except the 947 engine ); then, disconnect hose.

F07F12A

TYPICAL

1. Rear support

04-03-4

F01D3ZA

TYPICAL — 717 ENGINE

1. Rotary valve oil supply line

2. Hose pincher installed

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SMR2002-022_04_03A.FM

Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

F04D10A

3 2 1

TYPICAL — 787 RFI ENGINE

1. Rotary valve oil supply line

2. Hose pincher installed

3. Disconnect RED positive cable

Disconnect RED positive cable from starter post.

F06H35A

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.

F01H1JB

TYPICAL

1. Disconnect RED positive cable

Disconnect BLACK negative cable from engine crankcase.

F01D7RA

TYPICAL

CLEANING

Wipe off any spillage in bilge. Clean with a bilge cleaner.

Clean external parts of engine.

04-03-5

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Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

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 N•m

(18 lbf•ft).

CAUTION:

Strict adherence to this torque is important to avoid damaging threads of aluminum insert in bilge.

Engine Support

717 Engine

Torque front and rear engine supports as shown in the following illustration.

Loctite

243

F07F12B

TYPICAL

1. Torque engine support screws to 24 N•m (17 lbf•ft)

DI Engine

Install and torque the engine support screws to

24 N•m (17 lbf•ft) in the indicated order. Refer to the following illustration.

1 2

3 5

F02D09B

Loctite

243

1. Torque screws to 22 N•m (16 lbf•ft)

2. Torque nuts to 39 N•m (29 lbf•ft)

Loctite

243

787 RFI and 947 Engines except DI Engine

Apply Loctite 243 (blue) to rear engine support screws and install them with flat washers and torque to 24 N•m (17 lbf•ft).

F12D13A

TORQUE TO 24 N•m (17 lbf•ft) AS PER SEQUENCE

NOTE: Remember to install sleeves and flat washers.

2 1 2 1 2

04-03-6

F12D13B

1. Sleeves

2. Flats washers

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SMR2002-022_04_03A.FM

Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

Oil Injection Hoses

717 and 787 RFI Engines

Make sure to reinstall hoses before completely lowering engine in bilge.

Positive Starter Cable

Torque nut of positive starter cable to 6 N•m

(53 lbf

•in

). Apply dielectric grease on nut.

Engine/Jet Pump Alignment

Alignment is necessary to eliminate possible vibration 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.

All Models except XP

To verify alignment proceed as follows:

– Install the appropriate plate with the support to hull with four nuts.

F00B0HA

– Carefully slide shaft through support.

– 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.

F00B0FA

1. Plate

2. Support

Alignment shaft (P/N 295 000 141).

F00B0GA

1. Alignment shaft

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F07D05A

2 1

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.

04-03-7

Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

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.

– alignment shaft (P/N 295 000 141)

F00B0GA

1. Alignment shaft

– PTO flywheel adapter (P/N 529 035 590).

F00D0CA

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 engines

and

3 mm (0.12 in) on the

717

and

787 engines

XP Models

Use:

– plate (P/N 529 035 507) for the 155.6 mm (6-1/8 in) jet pump

F00B11B

1. Adapter

Install support plate at rear of watercraft.

Install adapter on shaft.

NOTE: Ensure the mid bearing is loosened to check engine alignment.

Carefully slide alignment shaft (P/N 295 000 141) through support plate and seal carrier.

F00B0FA

1. Plate

2. Support

04-03-8

F05I08A

TYPICAL

1. Alignment tool

2. Seal carrier

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SMR2002-022_04_03A.FM

Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

Place grease fitting on the top and torque seal carrier nuts in a criss-cross sequence in two steps as per following illustration.

NOTE: It is very important to tighten nuts of seal carrier in a criss-cross sequence to maintain its alignment.

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.

F05I0EB

Step

: 1 to 6, torque to 3 N•m (26 lbf•

) as per sequence

Step

: 7 to 12, torque to 10 N•m (88 lbf•

) as per sequence

F00D0CA

TYPICAL

1. Shim

CAUTION:

Whenever shims are used to correct alignment, never install more than 1.3 mm (0.051 in) shim thickness.

Engine Support Screws

All Models

Apply Loctite 243 (blue) on screw threads.

Torque engine support screws to 25 N•m (18 lbf•ft) when procedure is completed.

Loctite

243

Loctite

243

F08I06A

1. Alignment shaft

2. Adapter

After the mid bearing is torqued, continue to slide the alignment shaft (P/N 295 000 141) forward and install PTO adapter (P/N 529 035 590). Insert adapter end into PTO flywheel.

If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft end.

Loctite

243

F02D0KB

717 ENGINE

1. Torque to 25 N•m (18 lbf•ft)

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Section 04 ENGINE

Subsection 03 (REMOVAL AND INSTALLATION)

F06D35A

FRONT ENGINE SUPPORT — 787 RFI AND 947 ENGINES

1. Torque to 25 N•m (18 lbf•ft)

Final Inspection

Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant.

After its installation, properly adjust and bleed oil injection 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 system, refer to FUEL CIRCUIT.



WARNING

Whenever doing any type of repair on watercraft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine.

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.

F07F12C

REAR ENGINE SUPPORT — 787 RFI AND 947 ENGINES

1. Torque to 25 N•m (18 lbf•ft)

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SMR2002-022_04_03A.FM

MAGNETO SYSTEM

717 Engine

Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

Loctite

243

5 Nm

(44 lbf in )

9 Nm

(80 lbf in )

F02D12S

Loctite

648

Loctite

243

6 Nm

(53 lbf in )

Loctite

243

Loctite 243

6 Nm

(53 lbf in )

Loctite

243

6 Nm

(53 lbf in )

10 Nm

(88 lbf

11 in )

2.6 Nm

(23 lbf in )

150 Nm

(110 lbfft)

Anti-seize lubricant

10 Nm

(88 lbf in )

10 Nm (88 lbf in )

Anti-seize lubricant

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

787 RFI Engine

9 Nm

(80 lbf in )

Anti-seize lubricant

Molykote

111

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

Molykote

111

Dielectric grease

Anti-seize lubricant

Loctite

243

9 Nm

(80 lbf in )

10 Nm

(88 lbf in )

Loctite 243

120 Nm

(89 lbfft)

Loctite

243

Loctite

243

Anti-seize lubricant

9 Nm

(80 lbf in )

F06D3KS

Dielectric grease

Ground cable

Dielectric grease 1

Molykote

111

9 Nm

(80 lbf in )

Anti-seize lubricant

Dielectric grease

Anti-seize lubricant

9 Nm

(80 lbf in )

6 Nm

(53 lbf in )

04-04-2

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

947 Carburetor-Equipped Engines

9 Nm

(80 lbf in )

Loctite

243

Loctite

243

Dielectric grease

Ground cable

Dielectric grease

115 Nm

(85 lbfft)

13 Nm

(115 lbf in )

Loctite

243

Loctite

648

Molykote

111

Loctite

243

13 Nm

(115 lbf in )

Loctite

243

5 Nm

(44 lbf in )

9 Nm

(80 lbf in )

Loctite

648

F08D0AS

SMR2002-023_04_04A.FM

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

947 DI Engines

Molykote

111

9 Nm

(80 lbf in )

Loctite

243

Molykote

111

Loctite

243

13 Nm

(115 lbf in )

5 Nm

(44 lbf in )

(80 lbf in )

Loctite

243

115 Nm

(85 lbfft)

Loctite

243

Loctite

243

F12D0SS

04-04-4

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

DISASSEMBLY

717 Engine

NOTE: On 717 engine, 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).

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.

F01D4BA

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).

F01D47A

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.

A00C1AA

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 flywheel from its taper.

F01D48A

TYPICAL

1. Sleeves on opposite side

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04-04-5

Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

F01D4CA

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 release it from magneto flywheel.

The following procedure is to find a common reference point on both crankcases (old and new) to position armature plate.

Proceed as follows:

– Before removing the armature plate, find a crankcase 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.

F01D4DA

1. Crankcase locating lug

2. Mark armature plate at the end of lug

– At assembly, align armature plate mark (previously punched) with the end of the corresponding locating lug on the new crankcase.

F01D3AA

1. Magneto flywheel

Armature Plate

Before removing, locate the manufacturer’s reference 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 crankcase to ease reassembly and further ignition timing.

F01D4EA

TYPICAL

1. Lug end of crankcase

2. Align mark and lug end here

Remove three retaining screws no. 15 and withdraw armature plate.

04-04-6

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

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 93

C (200

F) around the screw holes to break the threadlocker bond.

Battery Charging Coil

To replace battery charging coil no. 7 :

– Heat the armature plate to 93

C (200

F) around the screw holes to break the threadlocker bond.

F00D08A

1. Heat the armature plate

CAUTION:

Protect harness from flame.

– Remove screws.

– Uncrimp and unsolder BLACK/RED wire from coil.

F00D09A

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.

A25E0QA

1. Uncrimp and unsolder wire here

A25E0SA

1. Uncrimp and unsolder ground wire (BLACK)

2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires

04-04-7

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

787 RFI Engine

Magneto Housing Cover

Disconnect water hoses from heat exchanger cover.

Loosen screws no. 11 .

Remove engine magneto cover no. 1 .

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).

F07D0JA

787 RFI ENGINE

1. Disconnect water inlet hose

2. Heat exchanger cover

1 2

Remove oil pump shaft from magneto rotor nut.

F15B01A

SPECIAL TOOL (P/N 529 035 846)

F07D0IA

1. Oil pump shaft

04-04-8

F15D0AA

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).

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

Remove special tool locking ring gear.

Insert crankshaft protector to outer end of crankshaft and fully thread puller in magneto rotor.

F01B26A

1. Ring gear blocking tool (P/N 295 000 134)

2. Retaining plate (P/N 295 000 154)

F01D85A

1. Ring gear blocking tool with retaining plate

F01D7YA

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.

F07D0KA

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 puller (P/N 420 976 235) and crankshaft protective cap

(P/N 420 876 557).

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F07D0LA

REMOVE SCREWS

1. Magneto housing

04-04-9

Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

Stator Assembly

787 RFI Engine

Remove holding plate and withdraw plug from cover.

Unscrew bolts no. 20 and remove stator no. 9 from magneto cover.

3 1

Remove oil pump shaft from magneto rotor nut.

F07D0MA

787 RFI ENGINE

1. Holding plate

2. Stator assembly

3. Remove screws

947 Engines

Cover

Loosen screws no. 11 . Remove engine magneto cover no. 1 .

F06D23A

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, refer to BOTTOM END.

If necessary, the magneto rotor can be removed without removing the ring gear. Remove the six screws no. 17 .

F06D0LA

1. Screw

To remove the ring gear/rotor assembly, unscrew nut no. 13 counterclockwise when facing it.

F06D1RA

1 2

TYPICAL

1. Cover

2. Screw

04-04-10

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

F06D0MA

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 crankshaft.

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.

DI Models

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.

All 947 Engines

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.

F06D0NA

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 crankshaft.

F06D0PA

1. Puller

Tighten puller screw and at the same time, tap on screw head using a hammer to release magneto rotor from its taper.

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

ASSEMBLY

717 Engine

Generating Coil

Strip end of old wire then crimp and solder on new coil.

Apply Loctite 243 (blue) to screws no. 22 and install 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 before tightening screws.

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.

F00D0AA

1. Magneto coil centering tool (P/N 420 876 922)

CAUTION:

Before reinstalling the magneto, remove the loose epoxy from harness.

Battery Charging Coil

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 .

F00D0AA

1. Magneto coil centering tool (P/N 420 876 922)

04-04-12

F01D3BA

1. Teeth chamfer

NOTE: Ensure that ring gear contacts magneto flywheel 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 won’t contact magneto flywheel 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 flywheel threaded holes.

3. Bake parts in oven at 175

C (350

F) for 1 hour to cure Gun Kote.

CAUTION:

Do not eliminate Gun Kote heat curing 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 N•m (80 lbf•

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Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

Armature Plate

Position the armature plate on the crankcase, aligning the marks on both parts.

When reinstalling armature plate on a new crankcase housing, proceed as follows.

Find manufacturer’s mark on armature plate. In line with this mark, punch another mark on adjacent crankcase lug.

F01D4FA

TYPICAL

1. Manufacturer’s mark on armature plate

2. Punch a mark on crankcase lug aligned with plate mark

The new mark on crankcase will be used for further assembly positioning as a pre-timing position.

Magneto Flywheel

Apply Loctite 243 (blue) on crankshaft taper.

Position Woodruff key and magneto flywheel. Apply Loctite 243 (blue) on nut no. 13 . Install nut with lock washer and torque to 145 N•m (107 lbf•ft).

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. Apply 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 N•m (80 lbf•

787 RFI Engine

Stator

Install the stator no. 9 in magneto housing cover no. 1 and torque screws no. 20 to 9 N•m (80 lbf•

Install wiring harness bracket no. 26 of stator and torque screws no. 27 to 4 N•m (35 lbf•

1 2

F01D4GA

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 N•m (53 lbf•

F06D0CA

1. Stator screws

2. Bracket

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04-04-13

Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

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).

F01B2NA

1. Pusher

2. Handle

Crankshaft Position Sensor

Install crankshaft position sensor no. 18 on magneto housing. Torque screw to 9 N•m (80 lbf•

NOTE: The crankshaft position sensor is not adjustable.

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 N•m (80 lbf•

947 Engine

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 N•m

(80 lbf•

Reinstall wiring harness bracket no. 29 using taptite screws no. 16 .

Torque trigger coil screws no. 21 to 9 N•m (80 lbf•

Torque stator screws no. 20 to 13 N•m (115 lbf•

NOTE: The trigger coil is not adjustable.

F04D0CA

Install gasket no. 24 between magneto housing and engine crankcase.

Install magneto housing and torque screws no. 19 to 9 N•m (80 lbf•

Rotor and Ring Gear

Apply Loctite 243 (blue) on crankshaft taper.

Install ring gear on crankshaft.

Apply Loctite 243 (blue) on nut no. 13 . Install nut with lock washer no. 14 and torque to 120 N•m

(89 lbf•ft).

CAUTION:

Never use any type of impact wrench at magneto installation.

F06D0NB

1 2

1. Torque to 9 N•m (80 lbf•

)

2. Taptite screws

3. Torque to 13 N•m (115 lbf•

)

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SMR2002-023_04_04A.FM

Section 04 ENGINE

Subsection 04 (MAGNETO SYSTEM)

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 N•m (80 lbf•

Rotor and Ring Gear

Apply Loctite 648 (green) on mating surface of the rotor no. 8 .

When reinstalling rotor to ring gear no. 3 , one of the protrusion end of rotor must be aligned with hole in ring gear.

1 2

F15D01A

1. Protrusion

2. Hole

Apply Loctite 648 (green) on screws no. 17 retaining rotor to ring gear and torque screws in a crisscross sequence to 13 N•m (115 lbf•

Apply Loctite 243 (blue) on crankshaft taper.

F06D24A

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 N•m (85 lbf•ft).

CAUTION:

Never use any type of impact wrench.

Unlock crankshaft. Reinstall pulse fitting with washer and torque to 19 N•m (14 lbf•ft).

Cover

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 N•m (80 lbf•

DI Models

If heat exchanger cover has been removed, ensure to align its notch with the emboss in casing.

SMR2002-023_04_04A.FM

F12R0EA

1. Align notch with the emboss

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04-04-15

TOP END

717 Engine

24 Nm

(17 lbfft)

Molykote 111

Loctite 243

24 Nm

(17 lbfft)

Loctite 243

Molykote 111

Engine oil

24 Nm

(17 lbfft)

Molykote 111

Loctite 243

F17D02S

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Section 04 ENGINE

Subsection 05 (TOP END)

Engine oil

04-05-1

Section 04 ENGINE

Subsection 05 (TOP END)

787 RFI Engine

Loctite

243

Molykote

111

(34 rollers)

27 Nm

(17 lbfft)

Engine oil

Molykote

111

Molykote

111

Loctite 243

40 Nm

(30 lbfft)

Molykote 111

10 Nm

(89 lbf in )

F07D0US

3 Nm

(27 lbf in )

24 23 22

Molykote 111

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Section 04 ENGINE

Subsection 05 (TOP END)

947 Carburetor-Equipped Engines

34 Nm

(25 lbfft)

Molykote

111

Engine oil

Loctite 243

Molykote 111

34 Nm

(25 lbfft)

Loctite 243

Molykote 111 32

15 Nm

(133 lbf in )

Molykote

111

29 27

3 Nm

(27 lbf in )

24 23 22

F08D0BS

10 Nm

(89 lbf in )

Loctite 243

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Section 04 ENGINE

Subsection 05 (TOP END)

947 DI Engine

Loctite

243

Engine oil

40 Nm

(30 lbfft)

Molykote 111

16 17

3 Nm

(27 lbf in )

Molykote 111 25

24 23 22

10 Nm

(89 lbf in )

Loctite 243

F12D0TS

40 Nm

(30 lbfft)

Molykote

111

Loctite

243

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Section 04 ENGINE

Subsection 05 (TOP END)

GENERAL

The 2-stroke ROTAX engine rotates counterclockwise 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 engine uses reed valves in the crankcase.

The 787 RFI and 947 engines are also equipped with the RAVE system (Rotax Adjustable Variable

Exhaust).

CAUTION:

No engine components can be interchanged 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 and 947 with carburetor ) or a pressure from the air compressor ( 947 DI ) to inflate the bellows and open the RAVE valves.

Carburetor-Equipped Engines

On top of the RAVE, there is a red plastic adjustment 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 engines , the spring preload does not have a significant effect on the valve operation.

787 RFI and 947 Carburetor-Equipped 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 3

F06D3BA

1. Solenoid

2. Pressure hose from crankcase

3. To atmospheric pressure

NOTE: A check valve on the pressure line eliminates 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 atmosphere.

F06D16A

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

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Section 04 ENGINE

Subsection 05 (TOP END)

4 5 6

F06D16B

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 Engine

To open the RAVE valves, the MPEM activates a solenoid which directs the pressure from air compressor to the valves.

F12D15A

1 2

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 necessary 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.

F12D02A

1. Pressure from solenoid

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SMR2002-024_04_05A.FM

F12D04A

RAVE VALVE OPENED

1. Pressure from air compressor

2. Solenoid activated

3. Pressure to solenoid

4. Pressure to RAVE valves

Section 04 ENGINE

Subsection 05 (TOP END)

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 user’s riding style and the quality of the oil used. We suggest annual cleaning of the valve.

If a customer uses a lower quality oil, than recommended, more frequent cleaning may be required.

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 cylinder. This is the minimum production clearance.

There is only a first oversize piston available for the

787 RFI and 947 engines . That piston is 0.25 mm

(.010 in) larger in diameter than the stock piston.

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 operating 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 and 947 Carburetor-Equipped Engines

Loosen Allen screws no. 26 each side of RAVE valve.

F12D05A

RAVE VALVE CLOSED

1. Pressure from air compressor

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

SMR2002-024_04_05A.FM

F06D0QA

1. Remove screws

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04-05-7

Section 04 ENGINE

Subsection 05 (TOP END)

Remove RAVE valve no. 15 .

Remove the cover no. 18 of the valve by releasing the spring no. 16 .



WARNING

Firmly hold cover to valve base. The compression spring inside the valve is applying pressure against the cover.

NOTE: The following procedures relates the steps for the 787 RFI and 947 carburetor-equipped engines . The DI engine is explained below.

Remove spring no. 30 retaining bellows no. 21 to valve piston no. 20 .

F06D0RA

1. Spring

Remove the compression spring no. 19 .

F06D0SA

1. Spring

Free bellows no. 21 from valve piston no. 20 .

F06D0TA

1. Bellows removed from piston

F06D25A

1. Remove spring

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Section 04 ENGINE

Subsection 05 (TOP END)

Unscrew valve piston no. 20 from sliding valve no. 22 .

NOTE: Hold the sliding valve to prevent it from turning.

Remove supporting ring no. 28 .

F06D0TB

1. Unscrew piston

2. Hold sliding valve

Remove compression spring no. 29 .

F06D27A

1. Remove supporting ring

Remove O-ring no. 23 .

F06D28A

1. Remove O-ring

A06D26A

1. Remove spring

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Section 04 ENGINE

Subsection 05 (TOP END)

Remove sliding valve no. 22 .

F06D0UA

1. Remove sliding valve

Remove bellows no. 21 .

F12D0UA

1. Remove screws

Remove RAVE valve no. 15 .

Remove the cover no. 18 of the valve by releasing the spring no. 16 .



WARNING

Firmly hold cover to valve base. The compression spring inside the valve is applying pressure against the cover.

F06D0VA

1. Remove bellows

947 DI Engine

Loosen Allen screws no. 26 each side of RAVE valve.

F12D0VA

1. Spring

04-05-10

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Remove the compression spring no. 19 .

Section 04 ENGINE

Subsection 05 (TOP END)

Remove sliding valve from valve housing.

F12D0WA

1. Remove spring

Unscrew valve piston no. 20 from sliding valve no. 22 .

NOTE: Hold the sliding valve to prevent it from turning.

F12D0YA

1. Valve piston

2. Valve housing

3. Sliding valve

2 3

Cylinder Head Cover and Cylinder Head

Disconnect temperature sensor wire and spark plug cables.

Connect spark plug cables on grounding device.

717 Engine

Remove air intake silencer and support, refer to

AIR INTAKE.

717 and 787 RFI Engines

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 vacuum cleaner.

947 Engines

Disconnect hose of RAVE valves.

On DI engines , remove air/fuel rail. Refer to EN-

GINE MANAGEMENT.

F12D0XA

1. Unscrew piston

2. Hold sliding valve

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Section 04 ENGINE

Subsection 05 (TOP END)

947 Carburetor-Equipped Engines

NOTE: Due to the cylinder mounting studs, it is recommended to remove the engine from the hull to service the top end. However, one might unfasten the engine support to allow leaning the engine so that cylinder can be pulled out.

Loosen cylinder head bolts no. 14 following the sequence shown in the next photo.

6 4 2

Remove cylinder head no. 2 .

Remove cylinder head gasket no. 34 .

F06D0WA

5 1 3 7

UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS

Loosen nuts no. 33 following the sequence shown in the next photo.

5 2 4 7

F06D0YA

1. Remove gasket

947 DI Engine

Use Snap-On Torx socket E12 and unscrew cylinder head screws no. 14 following the sequence shown in the next illustration.

F06D29A

6 3 1

UNTORQUING SEQUENCE FOR THE NUTS

04-05-12

F12D08B

Remove cylinder head no. 2 and gasket no. 34 .

Cylinder

NOTE: When removing cylinder, be careful that connecting rods do not hit crankcase edge.

787 RFI Engine

Remove air intake silencer and support, refer to

AIR INTAKE.

717 and 787 RFI Engines

Remove tuned pipe and exhaust manifold, refer to

EXHAUST SYSTEM.

Remove screws no. 13 .

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Section 04 ENGINE

Subsection 05 (TOP END)

Remove cylinders no. 9 , being careful that connecting rods do not hit crankcase edge.



WARNING

If screws need to be heated for removal when engine is in watercraft, fuel system pressurization must be done first. Do not use open flame; use a heat gun.

NOTE: Even if only 1 cylinder needs repair, both cylinders should be lifted to allow 1-piece cylinder base gasket replacement.

947 Carburetor-Equipped Engines

Remove studs no. 32 . Take two head cover nuts.

Screw nuts onto stud. Lock both nuts together and unscrew the stud. Repeat this operation for the other studs.

NOTE: Studs must be removed prior cylinder block.

NOTE: To ease removal, a plastic tip hammer can be used.

Remove cylinder base gasket no. 10 .

947 DI Engine

Remove cylinders screws then cylinders no. 9 .

Piston

NOTE: All engines feature cageless piston pin bearings.

717 and 787 RFI Engines

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.

F01B0JA

1. Rubber pad (P/N 295 000 101)

If the other cylinder has been removed, completely cover its opening with a clean rag.

F06D2BA

1. Remove studs

Remove cylinder block no. 9 .

F06D0ZA

1. Remove cylinder block

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F01D43A

1. Openings covered with rag and rubber pad

04-05-13

Section 04 ENGINE

Subsection 05 (TOP END)

947 Engines

Install rubber pad (P/N 290 877 032) to crankcase.

Secure with screws. Lower piston to be removed until it sits on pad.

To extract piston pin no. 4 , use piston pin puller

(P/N 529 035 503) with the appropriate set of sleeves.

ENGINE

717/787 RFI

947

SLEEVE SET

P/N 529 035 542

P/N 529 035 543

1 2 3

F06B06B

1. Rubber pad (P/N 290 877 032)

All Engines

To remove circlip no. 5 , insert a pointed tool in piston notch then pry it out and discard.



WARNING

Always wear safety glasses when removing piston circlips.

F00B0IA

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 extracting ring towards spindle.

1 2 3 4

F01D0PA

TYPICAL

1. Piston notch

F00B0JA

1. Puller

2. Sleeve

3. Shoulder sleeve

4. Extracting nut

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Section 04 ENGINE

Subsection 05 (TOP END)

NOTE: The tool cutout must be positioned toward the bottom of the piston.

– Loosen the extracting nut and remove puller.

– Remove the shoulder sleeve from piston.

F00B0KA

1. Tool cut-out toward bottom of piston

– Firmly hold puller and rotate handle to pull piston pin no. 4 .

– Rotate spindle until the shoulder sleeve is flushed with the piston recess.

F00B0MA

1. Remove shoulder sleeve

– Carefully remove the piston no. 3 .

– The needles, thrust washers and the sleeve remain in the connecting rod bore and may be used again.

1 2

F00B0LA

1. Shoulder sleeve flush with piston recess

F00B0NA

1. Needles and thrust washer

2. Sleeve

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Section 04 ENGINE

Subsection 05 (TOP END)

CLEANING

Discard all gaskets and O-rings.

Clean all metal components in a solvent.

Clean water passages and make sure they are not clogged.

Remove carbon deposits from cylinder exhaust port, RAVE valve ( 787 RFI and 947 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, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Refer to

BOTTOM END for procedures.

Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper.

The inspection of engine top end should include the following measurements.

ENGINE

MEASUREMENT

Cylinder taper

Cylinder out of round

TOLERANCES

NEW PARTS

(min.) (max.)

N.A.

0.05 mm

(.002 in)

0.008 mm

(.0003 in)

WEAR

LIMIT

0.1 mm

(.004 in)

0.08 mm

(.003 in)

Piston/cylinder wall clearance for the

717 engine

Piston/cylinder wall clearance for the

787 RFI engine

Piston/cylinder wall clearance for the

947 engine

Piston/cylinder wall clearance for the

947 DI engine

Ring/piston groove clearance for the

717 engine

Ring/piston groove clearance for the

787 RFI engine

Ring/piston groove clearance for the

947 engine

Ring/piston groove clearance for the

947 DI engine

Ring end gap for the

717 engine

Ring end gap for the

787 RFI engine

Ring end gap for the

947 engine

Ring end gap for the

947 DI engine

N.A.: Not Applicable

0.10 mm

(.0039 in)

0.13 mm

(.005 in)

0.09 mm

(.0035 in)

0.12 mm

(.0047 in)

0.025 mm

(.001 in)

0.025 mm

(.001 in)

0.048 mm

(.002 in)

0.044 mm

(.002 in)

0.25 mm

(.010 in)

0.40 mm

(.016 in)

0.45 mm

(.018 in)

0.55 mm

(.022 in)

N.A.

0.070 mm

(.0027 in)

0.070 mm

(.0027 in)

0.075 mm

(.0029 in)

0.089 mm

(.003 in)

0.40 mm

(.016 in)

0.55 mm

(.022 in)

0.60 mm

(.024 in)

0.7 mm

(.028 in)

0.20 mm

(.008 in)

0.22 mm

(.009 in)

0.20 mm

(.008 in)

0.20 mm

(.008 in)

0.20 mm

(.008 in)

0.24 mm

(.009 in)

0.20 mm

(.008 in)

0.20 mm

(.008 in)

1.0 mm

(.039 in)

1.0 mm

(.039 in)

1.0 mm

(.039 in)

1.1 mm

(.043 in)

04-05-16

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Section 04 ENGINE

Subsection 05 (TOP END)

NOTE: Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25

mm (.010 in) are available for all engines and oversize pistons of 0.5 mm (.020 in) are available for the 717 engine.

Cylinder Taper

Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder just below auxiliary transfer port, facing exhaust port and just below the auxiliary transfer port facing the exhaust port.

Compare readings. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.

F01D8BA

1. Measuring in piston pin axis

2. Measuring perpendicularly (90

) to piston pin axis

A. 16 mm (5/8 in)

USED PISTON MEASUREMENT

Note the measurement on the piston dome.

F01D8AA

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 diameter at 16 mm (5/8 in) from top of cylinder. Measure diameter in piston pin axis direction then perpendicularly (90

) to it. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.

F00D0EA

1. Piston dome

2. Piston measurement

2 1

04-05-17

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Section 04 ENGINE

Subsection 05 (TOP END)

Using a micrometer, measure piston skirt perpendicularly (90°) to piston pin according to the following table.

ENGINE TYPE

717

787 RFI

947

947 DI

MAXIMUM A mm (in)

29 (1.142)

28 (1.102)

24 (0.945)

F00D0EA

2 1

1. Piston dome

2. Piston measurement

Adjust and lock a micrometer to the specified value on the piston dome.

F01D0NA

1. Measuring perpendicularly (90°) to piston pin axis

A. See previous table

ENGINE TYPE

MAXIMUM PISTON SKIRT

WEAR mm (in)

0.12 (.005) All

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 measurement on the piston dome.

F00B08A

1. Micrometer set to the piston dimension

With the micrometer set to the piston dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to zero.

04-05-18

F00B09A

1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge

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Section 04 ENGINE

Subsection 05 (TOP END)

F00B0AA

1. Indicator set to zero

Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge.

F01D0XA

1. Feeler gauge

2. Rectangular ring (bottom)

947 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 cylinder, use piston as a pusher.

Using a feeler gauge, check ring end gap. If gap exceeds specified tolerance, rings should be replaced.

F01D0KA

1. Measuring perpendicularly (90°) to piston pin axis

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 indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.

Ring/Piston Groove Clearance

717 and 787 RFI Engines

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 correctly measured only on rectangular ring which is bottom ring.

F01D0OA

1. Top of cylinder

2. Ring end gap

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04-05-19

Section 04 ENGINE

Subsection 05 (TOP END)

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 determine 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 identification holes on the gasket.

RAVE Valve

787 RFI Engine

Make sure to insert O-ring no. 23 onto rod of sliding valve no. 22 .

The TOP position of the sliding valve no. 22 is indicated on one side.

F01D67A

TYPICAL

1. Identification holes

All Engines

GASKET

THICKNESS

0.3 mm (.012 in)

0.4 mm (.016 in)

0.5 mm (.020 in)

0.6 mm (.024 in)

0.8 mm (.031 in)

IDENTIFICATION

HOLES

RAVE Valve

787 RFI and 947 Engines

Check RAVE valve bellows no. 21 for cracks.

ASSEMBLY

Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following.

3 2

F01D8KA

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 .

Position the valve housing no. 25 onto the cylinder so that its opening is toward the bottom.

F01D8JB

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 doesn’t stick.

04-05-20

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Section 04 ENGINE

Subsection 05 (TOP END)

Check the sliding valve O-ring. Replace if necessary.

F01D8LA

947 Carburetor-Equipped Engines

Install the supporting ring no. 28 with the bevel side facing the O-ring no. 27 .

F12D10A

1. Sliding valve O-ring

Check the O-ring under valve housing. Replace if necessary.

F06D11A

1. Bevel facing the O-ring

947 DI Engines

Check the piston valve O-ring. Replace if necessary.

F12D11A

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 .

F12D0ZA

1. Piston valve O-ring

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04-05-21

Section 04 ENGINE

Subsection 05 (TOP END)

– 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 - 60

C (122 -

140

F) and install it over connecting rod.

NOTE: Make sure thrust washers are present each side of needles.

– Install the shoulder sleeve tool on the opposite side of the piston pin.

1 2

F06D12A

1. Sliding valve ridge toward housing groove

Piston

At assembly, place the pistons no. 3 with the letters “AUS” (over an arrow on the piston dome) facing in direction of the exhaust port.

AUS

A01C01A

1. Exhaust side

NOTE: On the 787 RFI and 947 engines , the exhaust ports are located on the same side as the intake.

Carefully cover crankcase opening as for disassembly.

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 locating 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.

F00B0OA

1. Piston pin

2. Shoulder sleeve

– Insert extractor spindle into the piston pin, screw on extracting nut.

2 1

F00B0PA

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.

04-05-22

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Section 04 ENGINE

Subsection 05 (TOP END)

Plastic Mounting Device Method

This is an alternate method when no service tool is available.

Replacement roller bearings are delivered in a convenient plastic mounting device. For installation, proceed as follows:

– Align replacement roller bearing with connecting rod bore.

– Carefully push inner plastic sleeve into connecting rod bore; outer plastic ring will release rollers.

– Insert piston pin into piston until it comes flush with inward edge of piston hub.

F01D0RA

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 opposite side. Support piston from opposite side.

F01D0Q A

1. Outer ring removal after inner sleeve insertion into bore

– Make sure thrust washers are present each side of rollers.

F01D0VA

1. Thrust washer each side

F01D0SA

– As necessary, pull halves of inner sleeve with long nose pliers.

04-05-23

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Section 04 ENGINE

Subsection 05 (TOP END)

947 Engines

Secure circlip in piston groove with its bent end in piston notch as shown.

F01D0TA

1. Pulling inner sleeve half

Circlip

Always use new circlips.



WARNING

Always wear safety glasses when installing piston circlips.

CAUTION:

Always use new circlips. At installation, take care not to deform them. Circlips must not move freely after installation.

717 and 787 RFI Engines

Secure circlip with its opening located at the bottom of the piston.

CAUTION:

To minimize the stress on the circlips, it is important to install them as described.

F07D0AB

1. Circlip end in piston notch

All Engines

To easily insert circlip into piston, use circlip installer.

ENGINE

717 and 787 RFI

947

TOOL P/N

529 035 562

529 035 563

F06B01A

1. Circlip installer

– Remove sleeve from pusher then insert circlip into its bore.

– Reinstall sleeve onto pusher and push until circlip comes in end of tool.

F06D18A

1. Circlip opening at 6 o’clock (at bottom)

04-05-24

F00B0QA

TYPICAL

1. Circlip near end of tool

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SMR2002-024_04_05A.FM

Section 04 ENGINE

Subsection 05 (TOP END)

– 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.

NOTE: Ring compressor will not fit on oversize parts.

Make sure to align ring end gap with piston locating pin. Slide tool over rings.

F00B0RA

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 replacement 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 identification holes on the gasket.

Cylinder

717 and 787 RFI Engines

To easily slide cylinder no. 9 over piston, install on piston ring compressor (P/N 290 876 979).

F01D0ZA

1. Ring end gap aligned with piston locating pin

Slide cylinder over piston.

F01D10A

When reassembling cylinders to crankcase, it is important to have them properly aligned so that exhaust flanges properly match up with exhaust manifold.

A01B1TA

1. Slide this edge

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04-05-25

Section 04 ENGINE

Subsection 05 (TOP END)

717 Engine

The aligning tool (P/N 420 876 904) or the exhaust manifold can be used to align cylinders.

F01D44A

717 ENGINE

1. Exhaust flange aligning tool

F00D0FA

787 RFI ENGINE

1. Aligning cylinders using exhaust manifold

Cylinder Block

947 Carburetor-Equipped Engine

Install studs no. 32 . Apply Molykote 111 to threads and torque studs to 15 N•m (133 lbf•

). Refer to exploded view to see what end to insert in crankcase.

Remove O-rings from studs.

All 947 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 cylinder block.

F01D45A

717 ENGINE

1. Aligning cylinders using exhaust manifold

787 RFI Engine

The exhaust manifold is used to align cylinders.

04-05-26

F02D0UA

1. Dowels

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SMR2002-024_04_05A.FM

Section 04 ENGINE

Subsection 05 (TOP END)

To easily slide cylinder block over pistons, use ring compressor (P/N 290 876 965).

Torque screws in a criss-cross sequence for each cylinder to 20 N•m (15 lbf•ft). Repeat the procedure, retightening all cylinder screws to 40 N•m

(30 lbf•ft).

2 3 3 2

A01B1TA

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 Engine

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 sequence for each cylinder to 24 N•m (17 lbf•ft). Refer to the following illustration.

1 4 1 4

F01D7FA

4 1 1 4

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 Loctite 243 (blue) below the screw heads.

Install and torque screws to 40 N•m (30 lbf•ft) in the indicated order. Refer to the following illustration.

4 1

F01D35A

2 3 2

787 RFI Engine

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.

F12D07A

All Engines

Cylinder Head

Install cylinder head gasket.

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04-05-27

Section 04 ENGINE

Subsection 05 (TOP END)

717 and 787 RFI Engines

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.

F01D5AA

1. O-rings

Apply Loctite 518 in O-ring groove of cylinder sleeves.

947 Carburetor-Equipped Engine

Apply Molykote 111 on the threads of the cylinder block studs no. 32 .

Apply Loctite 243 (blue) below head of cylinder head bolts no. 14 .

Apply Molykote 111 on threads of cylinder head bolts no. 14 .

Apply Loctite 243 under the head of the nuts no. 33 .

Torque bolts and nuts to 15 N•m (133 lbf•

) as per following sequence in the next picture. Repeat the torquing sequence by retightening to 34 N•m

(25 lbf•ft).

7 12 1 10 8 3 14 6

947 DI Engine

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 N•m (15 lbf•ft) as per following sequence in the next picture. Repeat the torquing sequence by retightening to 40 N•m (30 lbf•ft).

F12D08A

Cylinder Head Cover

717 and 787 RFI Engines

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 N•m

(9 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening all screws to 24

N•m (17 lbf•ft).

10 8 2 4 6 12

F06D0WB

13 4

TORQUING SEQUENCE

04-05-28

9 5 11 2 15

F01D46A

TORQUING SEQUENCE

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SMR2002-024_04_05A.FM

Section 04 ENGINE

Subsection 05 (TOP END)

ADJUSTMENT

RAVE Valve

787 RFI Engine

Turn the red plastic knob no. 17 until it is flush to the valve cover.

Combustion Chamber Volume

Measurement

All Engines

NOTE: This procedure is required to determine the thickness of the cylinder base gasket to be installed if a crank repair has involved replacement of connecting rods or if you are experiencing repetitive 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 installed on the engine.

F00D0GA

1. Knob flush with the cover

947 Carburetor-Equipped Engine

Turn the red plastic knob no. 17 until it is fully tightened.

F01D5VA

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 leveled.

All Engines except 947 DI

1. Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge.

F00D0WA

1. Knob fully tightened

This will ensure the correct preload on the return spring no. 19 in order to open and close the RAVE valve at the proper RPM.

SMR2002-024_04_05A.FM

F01D2IA

1. Bring piston to TDC

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04-05-29

Section 04 ENGINE

Subsection 05 (TOP END)

947 DI Engine

1. Remove both direct injectors and bring one piston 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.

F00B0BA

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.

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 volume 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 includes this value.

All Engines

ENGINE

717

787 RFI

947

947 DI

COMBUSTION CHAMBER

VOLUME

31.2 - 34.0 cc

34.7 - 37.9 cc

43.3 - 47.3 cc

45.7 - 48.4 cc

7. Repeat the procedure for the other cylinder(s).

F00D0HA

1. Top of spark plug hole

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

BOTTOM END

717 Engine

110 Nm

(81 lbfft)

Molykote

111

Anti-seize lubricant

Loctite

5910

Loctite

642

Loctite

518

24 Nm

(17 lbfft)

Molykote

111

Loctite

518

24 Nm

(17 lbfft)

10 Nm

(88 lbf in )

40 Nm

(30 lbfft)

Loctite

518

Molykote

111

F00D0YU

Loctite

243

Anti-seize lubricant

Molykote

111

04-06-1

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

787 RFI Engine

110 Nm

(81 lbfft)

30 mL (1 oz)

SAE 30 motor oil

Anti-seize lubricant

Molykote

111

Loctite

518

Anti-seize lubricant

Molykote

111

Anti-seize lubricant

F07D0VS

Loctite

642

Anti-seize lubricant

Molykote

111

Loctite

5910

Loctite

518

Molykote

111

40 Nm

(30 lbfft)

9 Nm

(80 lbf in )

Loctite

243

Molykote

111

Loctite

518

Molykote 111

Loctite

518

24 Nm

(17 lbfft)

Molykote 111

40 Nm

(30 lbfft)

24 Nm

(17 lbfft)

Anti-seize lubricant

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

947 Carburetor-Equipped Engines

Molykote

111

20 Nm

(15 lbfft)

40 mL

(1.35 oz)

SAE 30 motor oil

15 17

Molykote

111

Loctite

243

Molykote

111

7 Nm

(62 lbf in )

F06D3IS

Loctite

243

Anti-seize lubricant

Loctite

518

Molykote

111

Molykote

111

Anti-seize lubricant

27 Nm

(20 lbfft)

Molykote

111

Loctite 243

1.5 Nm

(13 lbf in )

Loctite

243

Loctite

5910

Molykote

111

6 Loctite

648

9 Nm

(80 lbf in )

Loctite

243

115 Nm

(85 lbfft)

23 Nm

(17 lbfft)

Loctite

648

Loctite

518

Loctite

518

Molykote

111

27 Nm

(20 lbfft)

20 Nm

(15 lbfft)

40 Nm

(30 lbfft)

Loctite

243

XP only

Loctite 518

Synthetic grease

Molykote 111

23 Nm

(17 lbfft)

27 Nm (20 lbfft)

40 Nm (30 lbfft)

Molykote 111

SMR2002-025_04_06A.FM

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

947 DI Engines

1.5 Nm

(13 lbf in )

Loctite

243

Loctite 243

9 Nm

(80 lbf in )

Molykote

111

Loctite

243

Molykote

111

7 Nm

(62 lbf in )

Loctite

243

F12D12S

Loctite

518

Molykote

111

Anti-seize lubricant

Molykote

111

27 Nm

(20 lbfft)

Anti-seize lubricant

6.5 Nm

(58 lbf in )

15 17

Anti-seize lubricant

Loctite

5910

Loctite 243

Molykote

111

Molykote

111

Engine oil

Loctite

648

Synthetic

22 grease

6.5 Nm

(58 lbf in )

Loctite

648

27 Nm

(20 lbfft)

Loctite

243

115 Nm

(85 lbfft)

23 Nm

(17 lbfft)

20 Nm

(15 lbfft)

40 Nm

(30 lbfft)

04-06-4

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

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 Engine

To remove PTO flywheel no. 1 , the crankshaft must be locked. Refer to MAGNETO SYSTEM and follow the procedure to lock the magneto flywheel.

PTO flywheel is loosen using PTO flywheel remover (P/N 295 000 001).

F00D0ZA

TYPICAL

1. Extension handle locking crankshaft

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.

F01J0TA

Insert special tool in PTO flywheel splines.

F00D10A

TYPICAL

1. Extension handle locking crankshaft

787 RFI Engine

PTO flywheel is loosened using PTO flywheel extractor (P/N 295 000 156).

F01D1AA

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.

F00B04A

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

Install special tool.

F06I02A

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 Engines except XP

Use PTO flywheel remover (P/N 295 000 001) to hold flywheel and remove Allen screws no. 21 retaining coupler no. 20 to PTO flywheel.

F06D37A

1. Loosen Allen screws

2. Breaker bar locking crankshaft

Remove the coupler no. 20 .

XP Models

Remove Allen screws no. 21 .

2 1

F01J0TA

PTO FLYWHEEL REMOVER TOOL

F08D02A

1. PTO flywheel

2. Coupler

3. Loosen Allen screw

Remove coupler no. 20 .

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

All 947 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 extension handle.

Loosen bolt no. 22 retaining the PTO flywheel to the crankshaft using a suitable socket and breaker bar.

Starter Drive Assembly

947 Engines Only

Loosen 2 Allen screws no. 24 retaining starter drive cover no. 25 .

F06D38A

2 1

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).

F06D1CA

2 1

1. Cover

2. Allen screw

Remove starter drive cover no. 25 and spring no. 9 .

Remove starter drive assembly no. 27 .

F06D39A

1. Puller plate

2. Puller

3. Bolt

4. Extension handle

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3 1 2

F06D1DA

947 ENGINE

1. Starter drive assembly

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04-06-7

Section 04 ENGINE

Subsection 06 (BOTTOM END)

Reed Valve

947 Engines Only

Remove both carburetor flanges.

717 and 787 RFI Engines

Put engine on a stand. Loosen crankcase screws.

F01D20C

717 ENGINE

1. M10 x 73.5 flanged screws

2. M8 x 68.5 flanged screws

3. M8 x 45 socket head screws

F06D0JA

1. Carburetor flange

Remove reed valves no. 28 from crankcase.

Crankcase

Before opening the bottom end, remove the following parts:

– engine supports ( 717 engine )

– magneto flywheel, refer to MAGNETO SYSTEM

– magneto housing ( except 947 engines )

– starter

– rotary valve cover and valve

( except 947 engines )

– starter drive assembly ( 947 engines )

– reed valves ( 947 engines )

– air compressor cover ( 947 DI engines ).

1 1

F15D05A

787 RFI ENGINE

1. M10 x 73.5 flanged screws

2. M8 x 53.5 flanged screws

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

947 Engines

Place engine upright on crankcase magneto side.

Loosen crankcase screws.

F07D09D

947 ENGINES

1. M8 x 45 flanged screws

2. M10 x 73.5 flanged screws

All Engines

Put engine back on a support. Insert a pry bar between crankcase lugs to separate halves.

CAUTION:

Be careful to precision machined surfaces.

F01D1LA

TYPICAL

1. Separate halves by prying at provided lugs

Remove crankshaft and counterbalance shaft ( 787

RFI and 947 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 engine , which is mounted on the magneto housing).

NOTE: Do not needlessly remove crankshaft bearings.

Remove end seal(s).

F01D1KA

TYPICAL

1. Separate halves by prying at provided lugs

SMR2002-025_04_06A.FM

F06D1GA

TYPICAL

1. End seal

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04-06-9

Section 04 ENGINE

Subsection 06 (BOTTOM END)

717 Engine

To remove end bearings no. 4 from crankshaft, use the following tools.

1 2 3 4

5 6

947 Engines

To remove end bearings from crankshaft, use the following tools.

6 1 3

F01B09A

717 ENGINE

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 installation, lubricate their inside diameters.

787 RFI Engine

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 .

1 2 3 4 5

F06B03A

947 ENGINES

1. Puller (P/N 420 877 635)

2. Protective cap (P/N 290 877 414)

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 420 940 755)

All Engines

F01B2MA

787 RFI ENGINE

1. Puller (P/N 420 877 635)

2. Protective cap (P/N 420 876 557)

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 installation, lubricate their inside diameters.

F01D1OA

TYPICAL

1. Removing crankshaft bearing

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

Or, use a bearing extractor such as Proto no.

4332 and a press to remove two bearings at a time (except on PTO side for the 787 RFI engine ).

Install the puller as per following illustration.

F01D1PA

1. Press bearings out

2. Bearing extractor

Crankshaft Gear

787 RFI Engine

The crankshaft gear no. 18 and bearing no. 5 can be removed in one step using the following puller.

F00D0IA

1. Puller

2. Protective cap

2 1

Secure puller in a vise and remove gear and bearing.

F00D0JA

NOTE: If the inner PTO bearing needs to be replaced, remove the Woodruff key on the crankshaft.

F04B03A

1. Puller (P/N 290 877 665)

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

Counterbalance Shaft

787 RFI Engine

Bearings no. 15 on counterbalance shaft no. 13 can be removed by using the following tools:

1 2

3 4

F00B0CA

1. Puller (P/N 420 877 635)

2. Protective cap (P/N 420 876 557)

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)

F00D0SA

1. Index mark

Use a press to remove the gear no. 14 from the counterbalance shaft.

F00D0KA

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.

F00D0TA

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SMR2002-025_04_06A.FM

947 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.

Section 04 ENGINE

Subsection 06 (BOTTOM END)

F00D2BA

F06D1HA

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.

Clean all metal components in a solvent.

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 perpendicularly (90°) to the first pass cross (hatch).

CAUTION:

Do not wipe with rags. Use a new clean hand towel only.

F00D2CA

FIRST PASS

SMR2002-025_04_06A.FM

F00D2DA

SECOND PASS

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04-06-13

Section 04 ENGINE

Subsection 06 (BOTTOM END)

Finish the cleaning with acetone.

CAUTION:

Ensure to clean compressor lubrication 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 engine 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 twisted on center main journal, changing timing of one cylinder in relation with the other.

– 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

F01D1NA

1. Main journal alignment here

To accurately check if crankshaft is twisted on center main journal, proceed as follows:

– Remove magneto housing cover.

– Remove flywheel nut (and magneto rotor for the 787 RFI and 947 engines ). Refer to MAG-

NETO SYSTEM for procedures.

F01D4IA

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 crankshaft.

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SMR2002-025_04_06A.FM

Section 04 ENGINE

Subsection 06 (BOTTOM END)

Crankshaft Alignment at Connecting

Rod Journal

Counterweights can also be twisted on connecting rod journal on any or both cylinder(s).

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.

F01D1NB

1. Connecting rod journal alignment here

Such misalignment may cause a crankshaft hard to be manually turned. Verification can be done by measuring deflection each end of crankshaft.

If deflection is found greater than specified tolerance, this indicates worn bearing(s), bent and/or disaligned crankshaft. Proceed with the disassembly of the engine.

Disassembled Engine

The following verifications can be performed with the engine disassembled.

Crankcase

Inspect plane surfaces for warpage. Small deformation 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 corrosion, scoring, pitting, chipping or other evidence of wear. Make sure plastic cage is not melted. Rotate 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.

F01D1QA

1. Ruler must be aligned with edge of connecting rod here

2. Align ruler here

Crankshaft Deflection

All Models

MEASUREMENT

Crankshaft deflection (max.)

MAG SIDE

0.050 mm

(.002 in)

PTO SIDE

0.030 mm

(.001 in)

Crankshaft deflection is measured each end with a dial indicator.

First, check deflection with crankshaft in crankcase. If deflection exceeds the specified tolerance, it can be either ball bearings wear, bent or twisted crankshaft at connecting rod journal.

F01D1SA

1. Measuring PTO side deflection in crankcase

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

F01D1TA

1. Measuring MAG side deflection in crankcase

Remove crankshaft bearings and check deflection again on V-shaped blocks as illustrated.

NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe.

Connecting Rod Big End Axial Play

CONNECTING ROD BIG END AXIAL PLAY

MODEL

NEW PARTS

(min.) (max.)

WEAR

LIMIT

947 engine

787 RFI engine

717 engine

0.390 mm

(.015 in)

0.737 mm

(.029 in)

0.230 mm

(.008 in)

0.617 mm

(.024 in)

0.311 mm

(.012 in)

0.677 mm

(.026 in)

1.2 mm

(.047 in)

1.2 mm

(.047 in)

1.2 mm

(.047 in)

Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight.

F01D97A

1. Measuring MAG side deflection on V-shaped blocks

F01D1WA

1. Measuring big end axial play

2. Feeler gauge

F01D98A

1. Measuring PTO side deflection on V-shaped blocks

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SMR2002-025_04_06A.FM

Section 04 ENGINE

Subsection 06 (BOTTOM END)

Starter Drive Bearing

947 Engines Only

Check bearing no. 23 of starter drive assembly no. 27 in crankcase.

Reed Valve

947 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.

F06D1IA

1. Bearing of starter drive assembly

Removal

Starter drive bearing can be easily removed from lower crankcase half using the following suggested tool or equivalent:

– Snap-on hammer puller including:

– handle CJ93-1

– hammer CJ125-6

– claws CJ93-4.

F06D1JA

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.

Check stopper distance from center of reed valve block.

F01J0ZA

Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing.

Slide puller hammer outwards and tap puller end.

Retighten claws as necessary to always maintain them tight against bearing. Continue this way until bearing completely comes out.

For installation, see below in this section.

F06D1EA

A. 13 ± 0.25 mm (.512 ± .010 in)

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04-06-17

Section 04 ENGINE

Subsection 06 (BOTTOM END)

NOTE: Distance should be the same on both sides.

Bent stopper as required to obtain the proper distance.

Air Compressor

Refer to ENGINE MANAGEMENT for components 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 filter replaced.

CAUTION:

Failure to properly clean the oil system will result in serious engine damage.

ASSEMBLY

Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following.

NOTE: It is recommended to spray BOMBARDIER-

ROTAX injection oil on all moving parts when reassembling 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 75

(167

F). This will expand bearing and ease installation.

To properly position the outer bearing(s), a distance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it.

ENGINE

717

787 RFI

947

DISTANCE GAUGE

P/N 529 034 800 (PTO)

P/N 529 034 900 (MAG)

P/N 529 035 100 (MAG)

P/N 529 035 000 (PTO)

F01B0HA

1. Distance gauge

F01D1YA

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.

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

Crankshaft Gear

787 RFI Engine

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.

787 RFI Engine

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.

F00D0LA

1. Woodruff key on the crankshaft

F00D0NA

1. Seal against the retaining shim

947 Engines

Seals are positioned with the outer lip in the crankcase recess.

F00D0MA

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.

F06D1LA

1. Seal lip in crankcase recess

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04-06-19

Section 04 ENGINE

Subsection 06 (BOTTOM END)

Drive Pin

Make sure drive pins no. 6 of bearings are properly installed in crankcase recesses at assembly.

F00D0OA

1. Drive pins

Counterbalance Shaft

787 RFI Engine

Press gear no. 14 onto counterbalance shaft no. 13 taking care to align both marks previously traced.

CAUTION:

Counterbalance shaft must be properly 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.

F00D0UA

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.

F00D0VA

1. Counterweight notch aligned with the crankcase

If notches are not aligned with the crankcase, remove the gear and repeat the procedure until the notches are properly aligned.

947 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 75°C

(167°F). This will expand bearings and ease their installation.

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

Reinstall counterweights no. 16 using a press and take care to align index marks previously traced.

Crankshaft and Counterbalance Shaft

787 RFI and 947 Engines

Install crankshaft no. 3 first in crankcase.

After crankshaft installation, install counterbalance shaft no. 13 . Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears.

CAUTION:

Marks on the crankshaft and counterbalance shaft must be aligned, otherwise engine will vibrate and premature wear will occur.

Turn by hand the crankshaft and counterbalance shaft. Make sure they do not interfere with the crankcase.

947 Engines

Properly position bearing no. 31 and washer no. 32 . Ensure to position lubrication hole on top

( if so equipped ).

F12R16A

3 2 1

1. Bearing

2. Washer in crankcase groove

3. Lubrication hole on top ( if so equipped )

Place seals no. 17 in their respective positions.

F00D0PA

787 RFI ENGINE

1. Marks must be aligned

F06D1MA

947 ENGINES

1. Marks must be aligned

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F06D1OA

1. Seal in place

Air Compressor

947 DI Engines

Refer to ENGINE MANAGEMENT for procedures.

04-06-21

Section 04 ENGINE

Subsection 06 (BOTTOM END)

Crankcase

All Engines

Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves.

717 and 787 RFI Engines

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 rotary valve shaft gear.

717 Engine

Temporarily install armature plate to align crankcase halves with each other.

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 in the counterbalance shaft gear cavity.

CAUTION:

Using different type of oil may reduce 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 application without lumps. If you do not use the roller method, you may use your finger to uniformly distribute the sealant (unlike the Drei Bond sealing compound, using a finger will not affect the adhesion).

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 siliconebased 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 microscospic 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 printmaking) 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.

F12R17A

F12R18A

Do not apply in excess as it will spread out inside crankcase.

CAUTION:

If sealant spread 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 sealant. The sealant curing time is similar to the Loctite 518 without using the Primer N, which is 4 to

24 hours.

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

7 11 1 3 9 5 13

All 947 Engines

Make sure all locating dowels are in place.

F01D20D

8 12 4 2 10 6 14

Torque 2 M10 crankcase screws to 40 N•m (30 lbf•ft).

F06D1PA

1. Dowel

Counterbalance Shaft Bearing Cover

787 RFI Engine

Install the bearing cover no. 19 with its hollow side toward the bearing.

F01D20B

1. Torque to 40 N•m (30 lbf•ft)

787 RFI Engine

Apply Loctite 518 on screw threads and Molykote

111 below head screws.

Torque crankcase screws to 12 N•m (106 lbf•

) as per following sequence. Repeat procedure, retightening all screws to 24 N•m (17 lbf•ft).

11 7 21 1 3 22 5 9

F00D0QA

1. Hollow side facing bearing

Crankcase Screws

717 Engine

Apply Loctite 518 on screw threads and Molykote

111 below head screws.

Torque crankcase screws to 24 N•m (17 lbf•ft) as per following illustrated sequence.

F15D05B

19 12 17 8 13 15 4 2 16 14 18 6 20 10

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Section 04 ENGINE

Subsection 06 (BOTTOM END)

As a final step, torque only M10 screws no. 8 of crankcase to 40 N•m (30 lbf•ft) as per following sequence.

11 7 1 3 5 9

F15D05C

12 8 4 2

All 947 Engines

Apply Molykote 111 below head of screws and

Loctite 518 on threads.

Torque crankcase screws to 12 N•m (106 lbf•

) as per following sequence. Repeat procedure, retightening all screws to 27 N•m (20 lbf•ft).

F07D09E

As a final step, torque only the M10 x 73.5 bolts to 40 N•m (30 lbf•ft) as per following sequence.

F06D32A

1. Handle

2. Pusher

F07D09C

Oil Fittings

717 and 787 RFI Engines

If inlet and outlet oil fittings no. 11 of rotary valve shaft have been removed from crankcase, reinstall them with their end pointing toward ignition housing. Apply Loctite 518 on threads of fittings.

Stud

717 Engine

At assembly in crankcase, apply Loctite 518 on threads of studs no. 10 . Torque to 10 N•m (89 lbf•

Starter Drive Bearing

947 Engines

To install bearing no. 23 of starter drive assembly, use pusher (P/N 290 876 502) and handle (P/N 420

877 650).

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PTO Flywheel

787 RFI Engine

Install O-ring onto crankshaft.

Section 04 ENGINE

Subsection 06 (BOTTOM END)

787 RFI Engine

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.

F01D84A

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 procedure, torque PTO flywheel to 110 N•m (81 lbf•ft).

947 Engines

Apply Loctite 243 (blue) on bolt no. 22 .

Using the same tools as for disassembly procedure, torque bolt no. 22 to 115 N•m (85 lbf•ft).

Apply Loctite 648 on mating surface of PTO flywheel and coupler.

Apply Loctite 243 (blue) to Allen screws no. 21 of coupler and torque to 23 N•m (17 lbf•ft).

Final Assembly

717 and 787 RFI Engines

For rotary valve timing and assembly procedures, refer to ROTARY VALVE.

F07D06A

1. Remove plug and add SAE 30 motor oil

947 Carburetor-Equipped Engines

When engine assembly is completed, add 40 mL

(1.35 oz) of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug.

F06D2CA

1. Remove plug and add SAE 30 motor oil

947 DI Engines

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.

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

ROTARY VALVE

717 and 787 RFI Engines

20 Nm

(15 lbfft)

Anti-seize lubricant

9 Nm

(80 lbf

)

787 RFI engine

Molykote

111

Engine oil

Loctite

243

717 engine

20 Nm

(15 lbfft)

F00D26T

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

GENERAL

The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from watercraft.

However engine must be removed from watercraft to work on rotary valve shaft/components.

Refer to REMOVAL AND INSTALLATION for engine 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 engine ).

Reinstall cover no. 1 in place WITHOUT its O-ring and torque screws to 20 N•m (15 lbf•ft).

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 rotary valve and cover.

F01D53A

1. 45

feeler gauge

If rotary valve cover clearance is out of specifications, 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 solder in position.

Refer to the following illustration for proper position or rotary valve and pieces of soldering wire.

F01D3PA

TYPICAL

1. Soldering wire

Reinstall cover in place WITHOUT its O-ring and torque screws to 20 N•m (15 lbf•ft).

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

Remove cover then clean and measure compressed soldering wire thickness, it must be within the specified tolerance 0.30 ± 0.05 mm (.012 ± .002 in).

If rotary valve cover clearance is over specified tolerances, machine rotary valve cover seating surface or replace the cover.

MACHINING INFORMATION

The amount of material over tolerance must be removed from the rotary valve cover seating surface.

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.

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 deflection).

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 engine 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.

F01D3OA

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 PTO flywheel guard.

Remove spark plugs, rotary valve cover and valve.

F01D22A

1. Removing snap ring

To remove rotary valve shaft assembly, use the appropriate puller (P/N 290 876 488).

F01D23B

PULLER (P/N 290 876 488)

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

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.

Shaft Bearing

To remove bearing no. 8 use a bearing extractor such as Snap-on no. CJ-950 (or equivalent) as illustrated. Slide off distance sleeve no. 14 , remove snap ring no. 7 and washer no. 15 then press shaft out.

F01D61A

1. Hold bolt

F01D27A

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 .

F01D4NA

1. Bearing

2. Bearing extractor Snap-on CJ-950

CAUTION:

Ensure that rotary valve shaft is perfectly perpendicular with press tip.

End Bearing

CAUTION:

Do not remove plug against bearing in upper crankcase half.

F01D4OA

1. Do not remove this plug

F01D25A

1. Compress seat

2. Remove circlips

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

End bearing no. 9 can be easily removed from upper crankcase half using the following suggested tool (or equivalent):

– Snap-on hammer puller including:

– handle CJ93-1

– hammer CJ125-6

– claws CJ93-4.

F01J0ZA

Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing.

Slide puller hammer outwards and tap puller end.

Retighten claws as necessary to always maintain them tight against bearing. Continue this way until bearing completely comes out.

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 scoring, 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 indicate 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.

F01D28A

1. End bearing

CLEANING

Discard all seals and O-rings.

Clean all metal components in a solvent.

Clean oil passages and make sure they are not clogged.

Clean rotary valve shaft and inside of distance sleeve no. 14 .

F01D2CA

1. Rotary valve shaft

2. End bearing in place

Deflection must not exceed 0.08 mm (.003 in). Replace shaft as necessary.

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

ASSEMBLY

Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following.

Bearing

To install end bearing no. 9 in crankcase, use pusher (P/N 420 876 501).

Seal

Apply Molykote 111 on seal lips. Position seal no. 11 with shielded portion against shaft splines.

Bearing

Install ball bearing as illustrated.

F00B07A

1. Pusher (P/N 420 876 501)

Position ball bearing shielded side towards rotary valve.

A13C0FB

1. Seal

2. Ball bearing

3. Bearing extractor Snap-on CJ-950

Install washer no. 15 , snap ring no. 7 and slide distance sleeve no. 14 on shaft.

1 2 3 4

F01D2DA

1. Shield side (toward gear)

Push bearing until it stops on its seat.

F01D2FA

1. Seal

2. Ball bearing

3. Snap ring

4. Distance sleeve

5. Washer 0.5 mm (.020 in)

6. Rotary valve shaft

Rotary Valve Shaft Assembly

CAUTION:

Crankcase halves must be separated and crankshaft must not be present to install rotary valve shaft assembly in crankcase.

F01D99A

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

717 Engine

To install rotary valve shaft in crankcase, use a pusher (P/N 420 876 605).

Push shaft until it stops on bearing seat.

A00C0YA

1. Pusher

Push shaft until its stops on bearing seat.

F01D34A

1. Rotary valve shaft

2. Push shaft until it stops

787 RFI Engine

To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 609) and handle (P/N 420 877

650).

F01D8OA

717 and 787 RFI Engines

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

ENGINE

717/787 RFI

ROTARY

VALVE P/N

420 924 502

VALVE

DURATION

159°

F01B2FA

1. Pusher

2. Handle

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

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.

159°

F01D73W

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SMR2002-026_04_07A.FM

Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

ROTARY VALVE TIMING

CAUTION:

Never use the ridge molded in crankcase as a timing mark.

The following tools are required to measure rotary valve opening and closing angles in relation with

MAG side piston.

529 035 607

330

340

350 360

20 10

330

320

310

Proceed as follows:

– Turning crankshaft, bring MAG side piston to

Top Dead Center using a TDC gauge.

210

200

170

180 190

180

200

170

210

160

295 000 143

F00B0DB

Rotary valve must be set so that timing occurs as follows:

ENGINE

717

787 RFI

OPENING

BTDC

147° ± 5

TIMING

CLOSING

ATDC

65.5° ± 5

147° ± 5 63.5° ± 5

Timing Procedure

The following specifications are used in this procedure:

OPENING: 147° BTDC

CLOSING: 65° ATDC

F01D2IA

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.

147°

F01D3DC

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.

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Section 04 ENGINE

Subsection 07 (ROTARY VALVE)

– 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.

65°

F01D3EB

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 N•m (15 lbf•ft) in a crisscross sequence.

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SMR2002-026_04_07A.FM

EXHAUST SYSTEM

717 Engine Model GTI and GTI LE

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

25 Nm

(18 lbfft)

7-9

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

1 2

4 Nm

(35 lbf in )

F17D01S

SMR2002-027_04_08A.FM

6-19

25 Nm

(18 lbfft)

15 5 3 www.SeaDooManuals.net

04-08-1

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

787 RFI Engine

Loctite

243

48 Nm

(35 lbfft)

Loctite 518

25 Nm

(18 lbfft)

Loctite

243

40 Nm

(30 lbfft) 25 Nm

4 Nm

(35 lbf

)

(18 lbfft)

Loctite 243

25 Nm

(18 lbfft)

Loctite

82046

Loctite

82046

Loctite

82046

4 Nm

(35 lbf

)

Silicone sealant

Loctite

82046

F15D02U

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

947 Carburetor-Equipped Engines (XP Model)

25 Nm

(18 lbfft)

40 Nm

(30 lbfft)

14 Nm

(124 lbf in )

7 9

48 Nm

(35 lbfft)

Loctite 243

48 Nm

(35 lbfft)

8 9

25 Nm

(18 lbfft)

16 22 21

47 Nm

(35 lbfft)

F07D0PU

40 Nm

(30 lbfft)

Loctite 82046

Loctite

243

14 12-13

Silicone sealant

23 Nm

(17 lbfft)

4 Nm

(35 lbf in )

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

947 Carburetor-Equipped Engines (GTX Model)

14 Nm

(125 lbf in )

Loctite

82046

7 9 10

48 Nm

(35 lbfft)

Loctite 243

48 Nm

(35 lbfft)

21 22

47 Nm

(35 lbfft)

25 Nm

(18 lbfft)

40 Nm

(32 lbfft)

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

25 Nm

(18 lbfft)

12-13

4 Nm

(35 lbf in )

40 Nm

(30 lbfft)

Loctite

82046

Loctite

296

F07D0TT

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

947 Carburetor-Equipped Engines (RX Model)

25 Nm

(18 lbfft)

Loctite 243

4 Nm

(35 lbf in )

Loctite

243

40 Nm

(30 lbfft)

Loctite

82046

7 9

14 Nm

(124 lbf in )

48 Nm

(35 lbfft)

Loctite

82046

Loctite

243

Loctite 243

48 Nm

(35 lbfft)

8 9

25 Nm

(18 lbfft)

16 22 21

47 Nm

(35 lbfft)

F16D05S

40 Nm

(30 lbfft)

12-13

Silicone sealant

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

947 DI Engines

48 Nm

(35 lbfft)

14 Nm

(124 lbf in )

16 22

Loctite

82046

12-13

25 Nm

(18 lbfft)

40 Nm

(30 lbfft)

48 Nm

(35 lbfft)

8 9

Loctite 243

25 Nm

(18 lbfft)

4 Nm

(35 lbf in )

Loctite 243

40 Nm

(30 lbfft)

F12D0RT

Loctite 82046

Loctite

82046

Loctite 82046

Body

Silicone sealant

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

REMOVAL

All Models except XP

Remove seat(s).

Remove rear vent hose support from body opening.

XP Model

Open engine compartment cover.

Remove storage basket.

Tuned Pipe

717 Engine

Disconnect water supply hose and water injection hose.

Disconnect tuned pipe bleed hose.

1 3

F06L0WA

GS SHOWN

1. Rear vent hose support

Remove seat support (all models except RX and

XP).

F07L1KA

TYPICAL

1. Seat support

2. Remove screws

2 1

F01D8NA

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 exhaust manifold side.

Remove screws no. 7 , nut no. 8 and flat washers no. 9 from tuned pipe flange.

NOTE: Slightly lift tuned pipe to release nut as necessary. Take care not drop nut and flat washer.

Withdraw tuned pipe head no. 10 in a forward and rotating movement.

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

787 RFI Engine

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.

F06E08A

1. Water return hose

2. Disconnect small hose from water outlet fitting at the tuned pipe head no. 10 .

F06D14A

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 Engine

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 procedure. 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 .

F06E09A

1. Disconnect hose from outlet fitting

3. Disconnect the water injection hose at tuned pipe head no. 10 .

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

6. Loosen and remove clamp no. 4 retaining tuned pipe head no. 10 to tuned pipe cone no. 5 .

F06E0AA

1. Water injection hose

4. Disconnect the water bleed hose.

F06D1SA

1. Loosen and remove clamp

7. Loosen Allen screw retaining carburetor bracket to tuned pipe head.

F06E0BA

1. Water bleed hose

5. Loosen clamp no. 1 retaining exhaust hose no. 3 to tuned pipe cone no. 5 .

F06D3JA

1. Loosen Allen screw

8. Remove external seal.

F06D14A

TYPICAL

1. Loosen clamp

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04-08-9

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

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).

11. Remove tuned pipe head no. 10 .

12. Loosen bolt no. 6 of tuned pipe cone beside the engine water return hose.

F06D1TA

1. Tuned pipe flange

10. Loosen bolt no. 20 of tuned pipe head above the engine magneto then remove bolts retaining bracket to engine.

F06D1UA

1. Remove bolt

F06D1VA

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 selflocking fasteners.

Tuned Pipe Removal without Separation from

Tuned Pipe Head and Tuned Pipe Cone

Execute the above procedures 1 through 5.

Later, use the following procedure:

Remove the strap no. 2 retaining the muffler then remove the exhaust hose no. 3 from tuned pipe cone no. 5 .

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SMR2002-027_04_08A.FM

Loosen Allen screw retaining carburetor bracket to tuned pipe head.

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

F06D2DA

1. Loosen Allen screw

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).

F06D1TA

1. Tuned pipe flange

Loosen bolt no. 20 of tuned pipe head above the engine magneto then remove bolts retaining bracket to engine.

F06D1UA

1. Remove bolt

Remove tuned pipe assembly.

Block exhaust opening in the manifold to keep debris 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.

CAUTION:

It is very important that the threads are free of debris before installing new selflocking fasteners.

Exhaust Manifold

Remove 8 Allen screws no. 12 and lock washers no. 13 then withdraw exhaust manifold.

Resonators

GTI, GTI LE and RX Models

Remove vent tube support.

Upper Type Resonators

Detach resonator from body.

Loosen clamps and disconnect hoses. Withdraw resonator from watercraft.

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

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 engine ).

F07L1DA

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 (GTX RFI and GTX).

F07L1EA

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.

04-08-12

F01E1FD

1 2

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 and XP 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 surplus.

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

Test

– Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe.

CAUTION:

Always ensure water passages are not blocked partially or completely while welding tuned pipe.

NOTE: Prior to verify leaks, plug all holes and pressurize 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. 17 are properly positioned prior to finalizing manifold installation.

717 Engine

Apply Molykote 111 on threads of screws no. 12 .

Install exhaust manifold no. 14 and torque screws no. 12 to 24 N•m (17 lbf•ft) as per following illustrated sequence.

787 RFI Engine

Apply Loctite 518 on 2 screws no. 12 . On the other screws no. 12 , apply Molykote 111 on threads.

Install screws. Refer to the following illustration for proper position of screws.

1 2 1 2

F01D82B

1. Screw with Loctite 518

2. Screw with Molykote 111

Torque exhaust manifold screws to 24 N•m

(17 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40 N•m

(30 lbf•ft).

7 6

1 3

F01D82A

F01D59A

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

947 Engine

Apply Molykote 111 on threads of Allen screws no. 12 .

Install and hand tighten Allen screws no. 12 as per following picture.

F06D1YA

2 1

1. M10 x 60 Allen screws

2. M10 x 110 Allen screws

Torque Allen screws to 24 N•m (17 lbf•ft) as per following illustrated sequence. Repeat the procedure, retightening Allen screws to 40 N•m (30 lbf•ft).

8 2

3 6

Tuned Pipe

717 Engine

CAUTION:

Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, selflocking fasteners, etc.) must be installed or replaced 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 tune pipe and may cause cracking.

Make sure that gasket no. 16 is properly located on exhaust manifold prior to finalizing pipe installation.

Apply Loctite 243 (blue) on nut no. 8 and screws no. 6 and no. 7 .

NOTE: Hand tighten all fasteners before torquing any of them. For torquing sequence, see the following illustrations.

5 2

25 Nm

(18 lbfft)

25 Nm

(18 lbfft)

1 3

F06D1YB

7 4 1 5

F00D29A

Install tuned pipe cone no. 5 with collar no. 15 and clamp no. 4 .

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Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

Position clamp no. 4 as illustrated. Do not tighten clamp yet.

F01D41A

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 N•m

(35 lbf•

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

CAUTION:

NOTE: Loosen all pipe supports from engine before install tuned pipe.

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 installation.

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.

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04-08-15

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

25 Nm (18 lbfft)

NOTE: Press the pipe support on the engine before torquing the pipe support bolt.

25 Nm

(18 lbfft)

25 Nm

(18 lbfft)

6 Nm

(53 lbf in )

48 Nm

(35 lbfft)

25 Nm

(18 lbfft)

1 Nm

(9 lbf in )

40 Nm

(30 lbfft)

40 Nm

(30 lbfft)

F15D06S

6 Nm

(53 lbf in )

48 Nm

(35 lbfft)

04-08-16 www.SeaDooManuals.net

SMR2002-027_04_08A.FM

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

947 Engine

CAUTION:

NOTE: Loosen all pipe supports from engine before install tuned pipe.

Make sure to install the sealing ring no. 15 on tuned pipe cone if it was removed.

Apply a thin layer of Loctite 30542 heat resistant sealant (P/N 293 800 090) all around sealing ring no. 15 .

CAUTION:

Damage to bushings and/or sleeve will eventually cause stress to tuned pipe and may cause cracking.

CAUTION:

It is very important that the threads are free of debris before installing new selflocking 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 N•m (35 lbf•ft).

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 N•m (22 lbf•

Use special tool (P/N 529 035 505).

Install external seal no. 22 and secure with a locking tie.

F07D0RA

TYPICAL

1. Sealing ring

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04-08-17

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

40 Nm

(30 lbfft)

6 Nm

(53 lbf in )

14 Nm

(124 lbf in )

40 Nm

(30 lbfft)

6 Nm

(53 lbf in )

25 Nm

(18 lbfft)

6 Nm

(53 lbf in )

25 Nm

(18 lbfft)

F07D0SS

6 Nm

(53 lbf in )

48 Nm

(35 lbfft)

2.5 Nm

(22 lbf in )

48 Nm

(35 lbfft)

04-08-18 www.SeaDooManuals.net

6 Nm

(53 lbf in )

48 Nm

(35 lbfft)

6 Nm

(53 lbf in )

48 Nm

(35 lbfft)

SMR2002-027_04_08A.FM

Install exhaust hose.

F06D14A

1. Torque clamp to 4 N•m (35 lbf•

)

Section 04 ENGINE

Subsection 08 (EXHAUST SYSTEM)

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04-08-19

Section 05 ENGINE MANAGEMENT (RFI)

Subsection 01 (TABLE OF CONTENTS)

OVERVIEW.............................................................................................................................

05-02-1

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

05-02-2

FUEL DELIVERY.................................................................................................................

05-02-2

FUEL PUMP .......................................................................................................................

05-02-2

FUEL PRESSURE REGULATOR ........................................................................................

05-02-2

FUEL FILTERS ....................................................................................................................

05-02-3

FUEL PUMP MODULE.......................................................................................................

05-02-3

FUEL INJECTORS ..............................................................................................................

05-02-3

ELECTRONIC MANAGEMENT..........................................................................................

05-02-4

ELECTRONIC CONTROL UNIT (ECU)...............................................................................

05-02-4

MPEM (MULTI-PURPOSE ELECTRONIC MODULE)........................................................

05-02-4

DIAGNOSTIC PROCEDURES ................................................................................................

05-03-1

DIAGNOSTIC OPTION EXAMPLE.....................................................................................

05-03-1

FAULT CODE TABLES.......................................................................................................

05-03-2

ECU FAULTS......................................................................................................................

05-03-2

INPUT SIGNAL FAULTS ...................................................................................................

05-03-2

OUTPUT SIGNAL FAULTS ...............................................................................................

05-03-3

COMPONENT INSPECTION..................................................................................................

05-04-1

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

05-04-1

AIR INDUCTION SYSTEM.................................................................................................

05-04-3

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

FUEL DELIVERY.................................................................................................................

05-04-3

FUEL FILTER ......................................................................................................................

FUEL PUMP .......................................................................................................................

REGULATOR ......................................................................................................................

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

05-04-4

LEAK TEST (SUPPLY AND VENTILATION CIRCUITS) ....................................................

05-04-5

HIGH PRESSURE TEST (FUEL PUMP CIRCUIT) ..............................................................

05-04-5

ELECTRONIC MANAGEMENT..........................................................................................

05-04-6

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

05-04-6

CRANKSHAFT POSITION SENSOR (CPS) .......................................................................

05-04-7

AIR TEMPERATURE SENSOR (ATS) ................................................................................

05-04-8

WATER TEMPERATURE SENSOR (WTS) ........................................................................

05-04-8

AIR PRESSURE SENSOR (APS) .......................................................................................

05-04-9

RAVE SOLENOID ............................................................................................................... 05-04-10

RFI SENSORS RESISTANCE VALUES .............................................................................. 05-04-11

05-01-1

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 01 (TABLE OF CONTENTS)

TROUBLESHOOTING SUMMARY ........................................................................................

05-05-1

ENGINE DOES NOT START ..............................................................................................

05-05-1

FLOODED ENGINE FEATURE............................................................................................

05-05-1

SPARK PLUG INSPECTION ...............................................................................................

05-05-1

ECU FAULT CODES ...........................................................................................................

05-05-1

ENGINE STARTS BUT RUNS POORLY ............................................................................

05-05-1

ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS .....................

05-05-1

ENGINE CANNOT REACH MAXIMUM REVOLUTIONS ..................................................

05-05-1

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

05-06-1

THROTTLE CABLE ADJUSTMENT ...................................................................................

05-06-1

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

05-06-1

CLOSED TPS.......................................................................................................................

05-06-1

IDLE SPEED ........................................................................................................................

05-06-1

REMOVAL AND INSTALLATION ..........................................................................................

05-07-1

MPEM..................................................................................................................................

05-07-1

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

05-07-1

AIR TEMPERATURE SENSOR (ATS) ................................................................................

05-07-1

AIR PRESSURE SENSOR (APS) ........................................................................................

05-07-1

WATER TEMPERATURE SENSOR (WTS) ........................................................................

05-07-1

CRANKSHAFT POSITION SENSOR (CPS)........................................................................

05-07-1

FUEL PUMP ASSEMBLY ...................................................................................................

05-07-1

REGULATOR.......................................................................................................................

05-07-2

FUEL FILTER .......................................................................................................................

05-07-2

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

05-07-2

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SMR2002-052_05_01ATOC.FM

OVERVIEW

Section 05 ENGINE MANAGEMENT (RFI)

Subsection 02 (OVERVIEW)

F07F18S

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)

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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

05-02-1

Section 05 ENGINE MANAGEMENT (RFI)

Subsection 02 (OVERVIEW)

The Rotax Fuel Injection (RFI) is a semi-direct electronic 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, temperature 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 controls under all engine operating conditions by managing 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.

FUEL DELIVERY

FUEL PUMP

An electric fuel pump provides fuel pressure and flow rate to the system.

F07F0JA

FUEL PUMP

FUEL PRESSURE REGULATOR

A regulator maintains a constant fuel pressure of

386 - 414 kPa (56 - 60 PSI).

F07F0IA

REGULATOR

F07F08A

THROTTLE BODY

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 02 (OVERVIEW)

FUEL FILTERS

A dual piece fuel filter protects the fuel pump, regulator and injectors.

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.

F07F0KA

1. Fuel pump assembly

2. External fuel filter

1 2

F07F09A

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).

F07F0LA

1. End cap of fuel pump assembly removed

2. Internal fuel filter

F07F0AA

INJECTOR

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 02 (OVERVIEW)

ELECTRONIC MANAGEMENT

ELECTRONIC CONTROL UNIT

(ECU)

The electronic fuel injection is equipped with a

Bosch Electronic Control Unit (ECU).

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 sensor network. The malfunction is recorded in the memory of the ECU. The memory of the ECU can be checked using the MPEM programmer tool.

MPEM

(multi-purpose electronic module)

The MPEM is also used with the Rotax Fuel Injection system.

F07F0BA

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. Using 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.

05-02-4

F07H0BA

MPEM

It is responsible of the following electrical functions:

– 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 revolutions are limited to 4480 RPM.

When voltage reaches 7 volts for at least 30 seconds, the engine is automatically shut off by the

MPEM.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 02 (OVERVIEW)

PARAMETERS

Intake air pressure

Crankshaft position and engine speed

Throttle valve position (Idle to wide open throttle)

Engine temperature

Intake air temperature

Battery voltage

Start/stop signal

SENSORS

Air Pressure

Sensor

(APS)

Crankshaft

Position

Sensor (CPS)

Throttle

Position

Sensor (TPS)

Water

Temperature

Sensor (WTS)

Air

Temperature

Sensor (ATS)

Multi-Purpose Electronic Module

(MPEM)

Electronic Control Unit

(ECU)

F07F0NS

SIGNAL MANAGEMENT

FUEL

DELIVERY

Fuel tank

Fuel filter

Fuel pump

Regulator

Injectors

To engine

05-02-5

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 03 (DIAGNOSTIC PROCEDURES)

DIAGNOSTIC PROCEDURES

The MPEM programmer is the primary 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 updated with the latest software version. For a complete overview of the programmer, refer to the

MPEM Programmer Guide

(P/N 219 700 090).

DIAGNOSTIC OPTION EXAMPLE

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

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 second 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 identification of the watercraft and the MPEM/ECU.

By selecting READ FAULT , the MPEM programmer 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 explanation of the fault codes.

After reading the fault codes in the memory of the

ECU, PRESS ANY KEY will return the programmer 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 .

05-03-1

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 03 (DIAGNOSTIC PROCEDURES)

FAULT CODE TABLES

ECU FAULTS

FAULT DETECTION

No fault detected

Electronic Control Unit Internal memory

Electronic Control Unit

EEPROM

FAULT CODE

MPEM programmer

B.U.D.S.

FF FF 88

FF FF 00

TYPE OF FAULT

N.A.

• No defect

P 0604 • Internal defect

FF FF 1B

FF FE 2B

P 0605 • Not plausible = EEPROM defect

P 1600 • EEPROM not programmed

EEPROM Data Setting

FF FD 10

FF FD 25

P 1601 • Data in EEPROM out of range (1 of 3 bytes)

P 1602 • Data in EEPROM out of range

(all 3 bytes different)

INPUT SIGNAL FAULTS

Crankshaft Position Sensor

(CPS)

Crankshaft Position Sensor

(CPS)

FAULT DETECTION

Supply voltage to ECU

Engine Water Temperature

Sensor (WTS)

Throttle Position Sensor (TPS)

Air Intake Temperature Sensor

(ATS)

Air Pressure Sensor (APS)

FAULT CODE

MPEM programmer

B.U.D.S.

02 14 07

02 14 06

02 0A 1D

P 0562

P 0563

P 0117

TYPE OF FAULT

• Voltage from the battery too low

• Voltage from the battery too high

• Sensor circuit shorted to ground

02 0A 1E

02 0A 1B

02 06 1F

02 06 1C

02 1F 06

02 1F 23

02 01 03

P 0118 • Signal interruption or short circuit to battery

P 0116 • Non plausible signal

P 0122 • Sensor circuit shorted to ground

P 0123 • Sensor circuit shorted to battery

P 0219 • Signal exceeding RPM limits

02 01 1B

02 0F 1D

02 0F 1E

02 10 1D

02 10 1E

P 0335 • No signal detected (fault code active when engine is not running and ignition is on)

P 0336 • Synchronization error (sensor/toothed wheel)

P 0112 • Sensor circuit shorted to ground

P 0113 • Signal interruption or short circuit to battery

P 0107 • Sensor circuit shorted to ground

P 0108 • Signal interruption or short circuit to battery

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 03 (DIAGNOSTIC PROCEDURES)

OUTPUT SIGNAL FAULTS

FAULT DETECTION

Injector 1

Injector 2

Fuel pump

Not applicable

RAVE vacuum solenoid

FAULT CODE

MPEM programmer

B.U.D.S.

04 E1 1C

04 E1 1D

04 E1 1E

04 E2 1C

P 0262

P 0261

P 1200

P 0265

TYPE OF FAULT

• Short circuit to battery

• Short circuit to ground

• Interruption or open circuit

• Short circuit to battery

04 E2 1D

04 E2 1E

04 EB 1C

04 FC

04 DB 1C

04 DB 1D

04 DB 1E

P 0264

P 1201

P 0230

N.A.

• Short circuit to ground

• Interruption or open circuit

• Short circuit to battery

• Not applicable

P 0478 • Short circuit to battery

P 0477 • Short circuit to ground

P 0479 • Interruption or open circuit

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05-03-3

Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

COMPONENT INSPECTION

GENERAL



WARNING

– Always disconnect battery properly prior to working on the fuel system.



WARNING

Fuel lines remain under pressure at all times.

Always proceed with care and use appropriate safety equipment when working on pressurized fuel system. Wear safety glasses 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. Cover the fuel line connection with an absorbent shop rag.

Slowly disconnect the fuel hose to minimize spilling. Wipe off any fuel spillage in the bilge.

Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Always disconnect battery prior to 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

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. Perform 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.



WARNING

Ensure to verify fuel line connections for damage and that NO fuel line is disconnected prior to installing the safety lanyard on the DESS post. 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.

CAUTION:

Never use injector cleaning products.

They may contain additive that could damage injector components. A copper wire brush may be used to clean the tip of the direct injectors if necessary.

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 performed to detect any faulty components.

NOTE: Troubleshooting should be performed using the MPEM programmer tool. See TROUBLE-

SHOOTING 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 remove 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. Visual inspection could lead to false results.



WARNING

All electrical actuators (injectors, fuel pump,

RAVE solenoid, ignition coil and starter solenoid) are permanently connected to the battery positive terminal, even when the safety lanyard is removed. Always disconnect the battery prior to disconnecting any electric or electronic parts.

To perform verifications, a good quality multimeter such as Fluke 111 (P/N 529 035 868) should be used.

05-04-1

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

Pay particular attention to ensure that pins are not out of their connectors or out of shape. The troubleshooting procedures cover problems not resulting from one of these causes.



WARNING

Ensure all terminals are properly crimped on wires and connector housings are properly fastened.

Before replacing a MPEM, always check electrical connections. Make sure that they are very tight and they make good contact and that they are corrosionfree. A “defective module” could possibly be repaired 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 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 genuine

— particularly in the ignition system. Installing resistive caps, non-resistive spark plug cables (or modified length) or non-resistive spark plugs may lead to generate fault codes or bad operation.

NOTE: Diagnostics Communication Kit. See DI-

AGNOSTICS 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 20°C

(69°F). The resistance value of a resistance varies with the temperature. The resistance value for usual resistor or windings (such as injectors) increases 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

20°C (69°F). Use this table for resistance variation relative to temperature for temperature sensors.

100

110

120

TEMPERATURE

°C °F

- 30

- 20

- 22

- 4

- 10

158

176

194

212

104

122

140

230

248

RESISTANCE (ohms)

NOMINAL LOW HIGH

12600

11400

11800

11000

13400

11800

9500

5900

3800

2500

1700

1200

840

630

440

325

245

195

145

115

8000

4900

3100

2200

1500

1080

750

510

370

280

210

160

125

100

CONVERSION CHART FOR TEMPERATURE SENSORS

11000

6900

4500

2800

1900

1320

930

750

510

370

280

210

160

125

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.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

Also remember this validates the operation of the sensor at ambient temperature. It does not validate 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 generate 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 directly supply the injector from the MPEM. If it now works, replace the defective wire. A Noid light

(available from after-market tool/equipment suppliers) 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 follows.

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.

F07F0DA

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 connect fitting.

F07F11A

1. Fuel rail



WARNING

Fuel is under pressure. Wipe off any fuel spillage in the bilge.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

Install a fuel pressure gauge (P/N 529 035 591) to the quick connect fitting of the fuel hose.

FUEL INJECTOR

F02B0BA

FUEL PRESSURE GAUGE (P/N 529 035 591)

Install the safety lanyard cap on the switch to activate 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 components:

– fuel hoses and connections

– fuel filter

– fuel pump

– regulator

– voltage at fuel pump (minimum 8 Vdc).

F07F0CA

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, disconnect the plug connector from the injector and check the signal from the MPEM.

To check the signal, verify voltage at the plug connector. There should be at least 6 Vdc while cranking engine.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

Check the resistance of the fuel injector circuits.

Disconnect the AMP plug connector no. 4 on the

MPEM.

Using a multimeter, check resistance value between terminal as follows.

Injector no. 1

Injector no. 2

CONTACT LOCATION

18 and 20

19 and 21

18 19 20 21

Install the safety lanyard cap on the switch to activate the fuel pump.

Check for fuel leakage from the injector nozzle.

There should be less than 1 drop of fuel per minute.

F07F15A

The resistance should be between 2.3

Ω

and

2.5

Ω

at temperature of 20°C (68°F).

If resistance value is incorrect, check wiring harness between AMP plug connector and fuel injectors for damaged wires or bad connections. Repair if necessary.

Recheck resistance value at AMP plug connector no. 4 .

If not within specification, replace the fuel injector.

Leakage Test (fuel injector)

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.

F07F16A

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.



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 spillage inside bilge.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

Press on both tabs and pull quick connect fitting to disconnect the fuel hose from fuel rail.

ELECTRONIC MANAGEMENT

THROTTLE POSITION SENSOR

(TPS)

Check the resistance value of the throttle position sensor.

F02F1XA

2 1

1. Quick connect fitting

2. Fuel rail

Install fuel pressure gauge (P/N 529 035 591) between fuel rail and fuel hose from fuel tank.

F07F0EA

1. Throttle position sensor (TPS)

Disconnect the AMP plug connector no. 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

Ω

and

2.4 k

Ω

Check also the resistance between terminal 4

(BLACK/BROWN wire) and terminal 11 (WHITE/

BROWN wire) with the throttle plate in idle position.

F02B0BA

FUEL PRESSURE GAUGE (P/N 529 035 591)

Install the safety lanyard cap on the switch to activate the fuel pump.

The fuel pump should run for approximately 1 second and the fuel pressure should be between 386 -

414 kPa (56 - 60 PSI).

Check hose connections at fuel pump and at fuel rail.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

The resistance should be between 710

Ω

and

1380

Ω

CRANKSHAFT POSITION

SENSOR (CPS)

Check the resistance of the crankshaft position sensor.

3 4 11

F07F15B

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 defective wire or terminal.

Reconnect the throttle position sensor connector and recheck resistance values at AMP plug connector no. 4 .

If not within specification, replace the throttle position sensor.

NOTE: Whenever the TPS is replaced, removed or adjusted, the TPS closed position must be readjusted.

Voltage Test

If the sensor resistance value is good, check the voltage 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 lanyard removed to activate the timer. There should be 5 Vdc.

F07H0CA

1. Crankshaft position sensor (CPS)

Disconnect the AMP plug connector no. 4 from the MPEM module.

Using a multimeter, check the resistance between terminal 7 (GREY/YELLOW wire) and terminal 14

(GREY/RED wire) on the plug connector.

The resistance should be between 774

Ω

and

946

Ω at temperature above 20°C (68°F).

14 7

F07F15C

If not within specification, replace the crankshaft position sensor.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

AIR TEMPERATURE SENSOR

(ATS)

NOTE: When testing the resistance of the air temperature sensor (ATS), it is important to check the ambient temperature. The resistance values for the sensor will be different according to the temperature.

Check the air temperature sensor resistance.

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 defective wire or terminal.

Reconnect the air temperature sensor connector and recheck the resistance between terminal 6 and terminal 13 in the AMP plug connector no. 4 .

If not within specification, replace the air temperature sensor.

WATER TEMPERATURE SENSOR

(WTS)

Resistance Test

Check the water temperature sensor resistance.

F07F0FA

1. Air temperature sensor (ATS)

Disconnect the AMP plug connector no. 4 from the MPEM module.

Using a multimeter, check the resistance between terminal 6 (BLACK/WHITE wire) and terminal 13

(WHITE/GREY wire) on the plug connector.

The resistance should be between 2.280 k

Ω

and

2.736 k

Ω at temperature of 19°C to 21°C (66°F to

70°F).

F07F0GA

1. Water temperature sensor (WTS)

Disconnect the AMP plug connector no. 4 from the MPEM module.

Using a multimeter, check the resistance between terminal 5 (BLACK/ORANGE wire) and terminal 12

(TAN/ORANGE wire) on the plug connector.

F07F15D

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

The resistance should be between 2.280 k

Ω

and

2.736 k

Ω at temperature of 19°C to 21°C (66°F to

70°F).

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 position 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 connector. Press the start/stop button, and check for

5V 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 connector, 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)

F07F15E

12 5

If not within specification, continue with the following tests.

Operation Test

Remove WTS from engine and keep it connected.

Place the WTS in a metal container filled with water 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.



WARNING

Do not use an open flame in the bilge area.

Fuel vapors may be present and this may lead to an explosion.

Heat up above 94°C (201°F) then start engine.

CAUTION:

Do not run the engine longer than 1 minute. If so, 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.

F07F0HA

1. Air pressure sensor (APS)

Check the air pressure sensor resistance.

Disconnect the AMP plug connector no. 4 from the MPEM module.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

Using a multimeter, check the resistance between terminal 9 (WHITE/BLUE wire) and terminal 2

(BLACK/BLUE wire) on the plug connector.

RAVE SOLENOID

F07F15F

The resistance should be between 3.4 k

Ω

and

8.2 k

Ω

Check also the resistance between terminal 2

(BLACK/BLUE wire) and terminal 1 (PURPLE/

BLUE wire) of the plug connector.

The resistance should be between 2.4 k

Ω

and

8.2 k

Ω

If not within specification, disconnect the connector of the water temperature sensor and check resistance 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 no. 4 .

If not within specification, replace the air temperature 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.

Depress the start/stop button with the safety lanyard removed to activate the timer. There should be 5 Vdc.

F07D0GA

RAVE SOLENOID

Disconnect the AMP plug connector no. 4 from the

MPEM module.

Check resistance value between terminal 16 and terminal 23 on the plug connector.

16 23

F07F15G

The resistance value should be 30

Ω

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 04 (COMPONENT INSPECTION)

RFI SENSORS RESISTANCE VALUES

COMPONENT

Air pressure sensor

Throttle position sensor

Water temperature sensor

Air temperature sensor

Crankshaft position sensor

Rave solenoid

Injector no. 1

Injector no. 2

TERMINAL

NUMBER

1 and 2

9 and 2

3 and 4

4 and 11

5 and 12

6 and 13

7 and 14

16 and 23

18 and 20

19 and 21

WIRE COLOR

PU/BL and BK/BL

WH/BL and BK/BL

PU/BW and BK/BW

BK/BW and WH/BW

BK/OR and TA/OR

BK/WH and WH/GY

GY/YL and GY/RE

PU/GY and BK/GY

BL/PU and BL/BK

GR/PU and BK/GR

RESISTANCE

VALUE

2.4 k - 8.2 k ohms

3.4 k - 8.2 k ohms

1.6 k - 2.4 k ohms

710 - 1380 ohms

2280 - 2736 ohms

774 - 946 ohms

30 ohms

2.3 - 2.5 ohms

VOLTS

5 Vdc between

PU/BL and BK/BL

5 Vdc between

PU/BW and

BK/BW

N.A.

6 Vdc at the plug connector

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 05 (TROUBLESHOOTING SUMMARY)

TROUBLESHOOTING SUMMARY

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, proceed as follows:

Remove spark plug cables and connect them on the grounding device.

Remove spark plugs and dry them using a rag.

Cover spark plug holes with 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 expelled.

Reinstall spark plugs and connect cables.

Start engine normally without applying the throttle.

SPARK PLUG INSPECTION

Whenever replacing the spark plugs, always use

NGK BR8ES with the resistor feature. The spark plug gap is set at 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 engine 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. Reversed high tension cables will cause backfires.

ECU FAULT CODES

Fault codes in the ECU memory will identify potential 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 connector. 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 defective.

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.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 06 (ADJUSTMENT)

ADJUSTMENT

THROTTLE CABLE

ADJUSTMENT

Fully depress throttle lever. Lever must touch handlebar grip.

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 contact the throttle plate stopper.

Loosen the adjustment of the throttle cable.

F01K08A

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.

THROTTLE POSITION SENSOR

(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 removed.

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:

Access the BOSCH SYSTEM in the MPEM programmer. Then, select ADJUSTMENT in the submenu.

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.

F07F17A

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 position must be readjusted.

IDLE SPEED

Access the BOSCH SYSTEM in the MPEM programmer. 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.

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Section 05 ENGINE MANAGEMENT (RFI)

Subsection 07 (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION

MPEM

IMPORTANT : When MPEM is replaced, the safety lanyard(s), the TPS closed position and the TDC setting must be reprogrammed/reset. Refer to their specific section for adjustment.

THROTTLE POSITION SENSOR

(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 air intake silencer.

Remove the flame arrester.

Disconnect the connector of the ATS.

Pull the ATS from the grommet retaining it.

AIR PRESSURE SENSOR (APS)

Remove the air intake silencer.

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 assembly.

Cover the quick connect fitting with a shop towel.

Press on both tabs and disconnect the quick connect fitting.



WARNING

Fuel is under pressure. Wipe off any fuel spillage in the bilge. Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area.

Loosen nuts retaining the fuel pump assembly to the fuel tank.

SMR2002-028_05_07A.FM

F07F0DB

1. Loosen nuts

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05-07-1

Section 05 ENGINE MANAGEMENT (RFI)

Subsection 07 (REMOVAL AND INSTALLATION)

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 INJECTOR

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.

Press on both tabs and disconnect the quick connect fitting.

Disconnect the wire connectors of both fuel injectors.

F07F0SA

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.

F07F0RA

1. Press retaining clip to unlock the connector

Loosen both screws retaining the fuel rail to the cylinders.

F07F0TA

1. Pry the clip

When reinstalling the fuel injector, install the retaining clip to the injector, then insert the injector to the fuel rail.

Apply a thin layer of injection oil to O-rings of fuel injectors to ease fuel rail installation.

CAUTION:

Whenever removing fuel injector, always replace both injector O-rings with new ones.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 01 (TABLE OF CONTENTS)

OVERVIEW.............................................................................................................................

06-02-1

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

06-02-2

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

06-02-2

AIR COMPRESSOR SYSTEM............................................................................................

06-02-2

FUEL DELIVERY SYSTEM.................................................................................................

06-02-2

BASIC OPERATION ...........................................................................................................

06-02-2

AIR/FUEL RAIL ASSEMBLY ..............................................................................................

06-02-2

FUEL PUMP MODULE.......................................................................................................

06-02-3

ELECTRONIC MANAGEMENT..........................................................................................

06-02-4

MPEM (multi-purpose electronic module) ......................................................................

06-02-4

IGNITION SYSTEM............................................................................................................

06-02-8

COMPONENT INSPECTION AND ADJUSTMENT ..............................................................

06-03-1

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

06-03-1

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

06-03-1

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

06-03-2

AMP CONNECTOR PIN-OUT ............................................................................................

06-03-3

QUICK FUEL PRESSURE TEST ........................................................................................

06-03-4

AIR INDUCTION SYSTEM.................................................................................................

06-03-5

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

06-03-5

AIR COMPRESSOR............................................................................................................

06-03-8

PRESSURE TEST ...............................................................................................................

06-03-8

REPAIR ...............................................................................................................................

06-03-9

FUEL DELIVERY................................................................................................................. 06-03-12

FUEL PRESSURE REGULATOR ........................................................................................ 06-03-12

FUEL INJECTOR ................................................................................................................ 06-03-14

AIR/FUEL RAIL ................................................................................................................... 06-03-15

DIRECT INJECTOR ............................................................................................................ 06-03-16

FUEL PUMP ....................................................................................................................... 06-03-17

ELECTRONIC MANAGEMENT.......................................................................................... 06-03-21

MPEM REPLACEMENT ..................................................................................................... 06-03-21

THROTTLE POSITION SENSOR (TPS) ............................................................................. 06-03-22

CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 06-03-24

MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 06-03-26

WATER TEMPERATURE SENSOR (WTS) ........................................................................ 06-03-26

MANIFOLD AIR PRESSURE SENSOR (MAPS) ................................................................ 06-03-27

EXHAUST GAS TEMPERATURE SENSOR (EGT) ............................................................ 06-03-28

KNOCK SENSOR (KS) ....................................................................................................... 06-03-28

RAVE SOLENOID ............................................................................................................... 06-03-29

IGNITION COIL .................................................................................................................. 06-03-30

TDC SETTING .................................................................................................................... 06-03-32

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 01 (TABLE OF CONTENTS)

SPARK PLUGS .................................................................................................................... 06-03-35

CRANKING SYSTEM.......................................................................................................... 06-03-36

DI SYSTEM TEST SUMMARY........................................................................................... 06-03-36

DIAGNOSTIC PROCEDURES.................................................................................................

06-04-1

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

06-04-1

DESS SYSTEM ...................................................................................................................

06-04-2

FAULT DETECTION AND COMPENSATORY ACTIONS ..................................................

06-04-4

COMPONENT FAILURE WARNING SYSTEM ..................................................................

06-04-4

VCK (VEHICLE COMMUNICATION KIT) ...........................................................................

06-04-6

DI SYSTEM FAULT CODES ...............................................................................................

06-04-7

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OVERVIEW

Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

F12F03T

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

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 pneumatically assisted direct injection system, a unique combustion chamber geometry and a precise 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.

F12F05A

TWIN 46 mm THROTTLE BODIES

1. Throttle position sensor (TPS)

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 driven by the counterbalance shaft. It also supplies the air pressure required to operate the RAVE valves.

F12D01A

FUEL DELIVERY SYSTEM

BASIC OPERATION

When the piston reaches the correct position, the

MPEM opens the fuel injector and fuel is discharged into a cavity inside the direct injector.

Next, the direct injector opens and the fuel is discharged into the combustion chamber by the compressed 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

2 4 3 2 6

F12F06A

5 7

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 8

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

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 to the direct injector.

Fuel Pressure Regulator

A fuel pressure regulator controls the pressure inside 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 exposed 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

F12D0AA

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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

ELECTRONIC MANAGEMENT

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.

F12D0EA

TYPICAL

1. Multi-purpose electronic module (MPEM)

The MPEM is mounted in the front of the watercraft.

The MPEM is directly powered by the battery. It is responsible for the following engine management/ electrical functions:

– interpreting information

– distributing information

– start/stop function

– timer

– 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

Automatic Power Shut-Down

The MPEM is equipped with an automatic power shut-down. This feature prevents the battery from losing its charge if the safety lanyard cap is left on the post when the engine is not running.

After connecting the safety lanyard cap, the

MPEM will remain in standby mode during the next 10 minutes, waiting for a starting. If the start/ stop button is not depressed, then the MPEM will be automatically powered down.

Antistart Feature

This system allows starting the vehicle only with safety lanyard(s) that has been programmed to operate 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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

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 watercraft MPEM is activated 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 lanyards may be programmed in the memory of the watercraft MPEM. They can also be erased individually.

The MPEM 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 48 km/h (30 MPH).

Such feature is ideal for first time riders or renters.



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.

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. Engine starting is not allowed.

The memory of the MPEM features two selfdiagnostic modes for the DESS operation. 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.

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Gauges Current Supply

The purpose of this function is to allow reading of gauges without the engine running. It will give access to most functions of the information center gauge without starting the engine.

Gauges are supplied with current for 33 seconds when connecting the safety lanyard cap on its post or when pressing the start/stop switch without the safety lanyard on the DESS post.

NOTE: The fuel pump will be activated for 2 seconds to build up pressure in the fuel injection system, 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 switch is pressed.

If the safety lanyard is left on the DESS post for more than 10 minutes after stopping the engine, the MPEM may send out 1 long beep when pressing the start/stop switch. The current supply to gauges will be stopped as explained in the ANTI-

START FEATURE section. A light pressure on the safety lanyard or removing and reinstalling the safety lanyard is required to allow the MPEM to read and validate the safety lanyard, the engine can then be started.

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 and hold start/stop switch or remove the safety lanyard cap from its post.

If the engine is stopped by removing the safety lanyard, it is possible to restart the engine as explained in the ENGINE STARTING section.

If safety lanyard cap is reconnected within 6 seconds, the current supply to gauges is cut for a brief moment and comes back on with the audible signal of safety lanyard validation.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

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 for 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

The MPEM distributes power from battery to all accessories. Accessories are protected by fuses integrated in the MPEM. Fuses are identified besides their holder.

IMPORTANT: The sensors and injectors are continuously powered with the supply from the battery. The MPEM switches the ground to complete the electrical circuits it controls. Take this into account when troubleshooting the electrical system.

MPEM — Engine Management Functions

F12D0CS

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

This engine management system controls both the fuel injection and the ignition timing.

As shown in the DI CONTROL SYSTEM illustration, the MPEM 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 MPEM also stores the fault codes and general information such as: operating conditions, vehicle hours, serial numbers, customer and maintenance information.

Electronic Fuel Injection

The MPEM receives the signals from different sensors which indicate engine operating conditions at milli-second intervals.

Signals from sensors are used by the MPEM to determine the injection parameters (fuel maps) required 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 under all operating conditions. Using engine operating 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 detonation 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 possible conditions: Cranking, flare, idle, warm up, normal operation, Sea-Doo LK™ (learning key) (limited vehicle speed), engine speed limiter, drowned engine and limp home (see below).

Flooded Engine (drowned mode)

If the engine does not start and it is flooded, proceed as follows:

Remove spark plug cables and connect them on the grounding device.

Remove spark plugs and dry them using a rag.

Cover spark plug holes with 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 components of the electrical system. When a fault occurs, it sends visual messages through the information center and/or audible signals through a beeper to inform you of a particular condition. Refer to the DIAGNOSTIC PROCEDURES subsection for the displayed messages and the beeper coded signals chart.

Limp Home Modes

Besides the signals as seen above, the MPEM may automatically set default parameters to the engine management to ensure the adequate operation 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 as usual.

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 allow retrieving normal operation.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 02 (OVERVIEW)

These performance-reduced modes allow the rider 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 magneto. Part of the AC current is rectified and regulated for the charging system.

A 12 volts battery supplies the Multi-Purpose Electronic 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 phases, 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 corresponding spark plug.

This ignition system allows spark plugs to spark independently.

CAUTION:

Do not interchange spark plug cables. 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.

2 1

F12R0UC

TYPICAL

1. PTO side ignition coil

2. MAG side ignition coil

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

COMPONENT INSPECTION AND

ADJUSTMENT

GENERAL

Engine problems are not necessarily related to the electronic fuel injection system.

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 operating 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.



WARNING

Air compressor hose may be hot. Use a rag or gloves or let hose cool down.

FUEL SYSTEM



WARNING

The fuel system of a fuel injection system holds much more pressure than on a carbureted watercraft. Prior to disconnecting a hose or to removing a component from the fuel system, follow the recommendation described here. Pay attention that some hoses may have more than one clamp at their ends. Ensure to reinstall the same quantity of clamps at assembly.

– Use the VCK (Vehicle Communication Kit) (P/N 529

035 844) to release the fuel pressure in the system.

Look in the Activation section of the software

B.U.D.S.



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 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 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 minimize spilling. Wipe off any fuel spillage in the bilge. Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Always disconnect battery prior to working on the fuel system. After performing a pressure test, use the valve on the fuel pressure gauge to release the pressure (

if so equipped

– Always disconnect battery properly prior to working on the fuel system.

Properly reconnect the battery.



WARNING

Ensure to verify fuel line connections for damage 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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

CAUTION:

Never use injector cleaning products.

They may contain additive that could damage injector components. A copper wire brush may be used to clean the tip of the direct injectors if necessary.

To check air/fuel rail for leaks, first pressurize the system then spray soapy water on all hose connections, regulators and injectors. Air bubbles will show the leaking area. Check also for leaking fuel or fuel odor.



WARNING

Never use a hose pincher on high pressure hoses.

ELECTRICAL SYSTEM

It is important to check that the electrical system is functioning properly:

– battery

– fuses

– DESS

– ignition (spark)

– ground connections

– wiring connectors.



WARNING

All electrical actuators (injectors, fuel pump,

To perform verifications, a good quality multimeter such as Fluke 111 (P/N 529 035 868) should be used.

Pay particular attention to ensure that pins are not out of their connectors or out of shape. The troubleshooting procedures cover problems not resulting from one of these causes.



WARNING

Ensure all terminals are properly crimped on wires and connector housings are properly fastened.

Ensure that all electronic components are genuine — particularly in the ignition system. Installing resistive caps, non-resistive spark plug cables (or modified length) or non-resistive spark plugs may lead to generate fault codes or bad operation.

NOTE: Diagnostics Communication Kit. See DI-

AGNOSTICS section.

After a problem has been solved, ensure to clear the fault(s) in the MPEM using the VCK. Refer to

DIAGNOSTIC PROCEDURES.

Communication Errors Between

B.U.D.S. and the MPEM

Remember that if there has not been active communication between B.U.D.S. and the MPEM for more than 10 minutes, the MPEM automatically shuts down. This causes false “communication errors”. This occurs quite frequently and confuses many technicians. Whenever this occurs, simply remove and replace the lanyard to restart the

MPEM. In fact, one should get into the habit of resetting the MPEM with the lanyard whenever the MPEM does not seem to respond. It must be kept “awake”.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Resistance Measurement

When measuring the resistance with an ohmmeter, all values are given for a temperature of 20°C

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

20°C (69°F). Use this table for resistance variation relative to temperature for temperature sensors.

100

110

120

TEMPERATURE

°C °F

- 30

- 20

- 22

- 4

- 10

158

176

194

212

104

122

140

230

248

1700

1200

840

630

440

325

245

195

145

115

RESISTANCE (ohms)

NOMINAL LOW HIGH

12600

11400

11800

11000

13400

11800

9500

5900

3800

2500

8000

4900

3100

2200

11,000

6900

4500

2800

1500

1080

750

510

370

280

210

160

125

100

1900

1320

930

750

510

370

280

210

160

125

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.

A solution would be to use a jumper wire to directly supply the injector from the MPEM. If it now works, replace the defective wire. A noid light

(available from after-market tool/equipment suppliers) may also be used to validate the injector operation.

AMP CONNECTOR PIN-OUT

Use this diagram to locate the pin numbers on the

AMP connector no. 3 and no. 4 of the wiring harness when performing tests.

18 19 20 21

F07F15A

AMP CONNECTOR PIN-OUT (WIRING HARNESS SIDE)

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Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

QUICK FUEL PRESSURE TEST



WARNING

Read PRESSURE TEST under AIR/FUEL RAIL farther in this section for precautions and setup to take care of, before performing this test. The procedure here is a quick summary.

Disconnect outlet hose (the one with the fuel filter) from fuel pump using tool (P/N 529 035 714).

Connect adapter to pressure gauge as shown.

F12R08A

1. Pressure gauge (P/N 529 035 709)

2. T-adapter (P/N 529 035 710)

Install pressure gauge between disconnected hose

( inline installation).

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F12R09A

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.

FUEL REGULATOR PRESSURE

(when installing safety lanyard)

185 ± 14 kPa (27 ± 2 PSI)

If pressure is within limits, air/fuel rail is working adequately. Proceed with the fuel pressure test below.

If pressure is out of limits, go to FUEL DELIVERY part and proceed with the tests described there.

Crank or start engine and observe fuel pressure.

FUEL PRESSURE

(when cranking engine or when engine is running)

738 ± 14 kPa (107 ± 2 PSI)

If pressure is within limits, fuel and air systems are working adequately. No subsequent tests are necessary 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.

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Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

AIR INDUCTION SYSTEM

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 modifying them in any way will not increase performance 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 returning 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.

SMR2002-030 _06_03A.FM

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 THROTTLE

POSITION SENSOR (TPS) in ELECTRONIC MAN-

AGEMENT below.

Properly attach throttle bodies together if previously detached.

Adjustment

Throttle Body Synchronization

NOTE: If both throttle bodies are replaced together with new ones, no synchronization is required as it has already been set at the factory. However, proceed with throttle cable and closed TPS adjustments as described below. If only one throttle body is replaced, proceed with the complete following adjustments. Ensure to perform all the adjustments prior to starting the engine. Otherwise, engine 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 me synchronized with the master.

1 7

F12R0XA

4 5 8 6

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

2 3

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

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. Ensure screw end clears the lever stopper.

F12R0YA

2 1

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

Ω below is used to open the throttle plates the same amount on each throttle body to obtain the proper synchronization. It is the equivalent of using a drill bit in the throttle bore to open throttle plate on carburetors.

Master TPS

Snap throttle plate a few times to ensure it is completely closed.

Using an ohmmeter, measure resistance between pins 2 and 3. Note the resistance value. Add

175

Ω

to that value.

Turn idle set screw clockwise until ohmmeter reading reaches the computed value above ± 20

Ω

F12R1BA

2 1

1. Measure resistance between pins 2 and 3

2. Turn screw clockwise to increase resistance

Tighten lock nut.



WARNING

Do not apply any threadlocker to the screw threads. The threadlocker may leak off the screw and onto the throttle mechanism and cause the throttle to stick.

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.



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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Ensure spring is still well positioned on stoppers.

Properly reinstall the plastic cap to the synchronization screw.

Apply Loctite 5900 (P/N 293 800 066) flange sealant on idle set screw head.

F12R1DA

1. Gap here

2. Spring removed

Snap throttle plate a few times to ensure it is completely closed.

Measure resistance between pins 2 and 3. Note the resistance value. Substract 175

Ω

from that value.

Properly reinstall the spring. Ensure that master throttle plate is still closed.

Turn synchronizing screw clockwise until reading reaches the computed value above ± 20

Ω

F12R10A

1. Plastic cap

2. Wider spaced tabs here

3. Loctite 5910 flange sealant



WARNING

Ensure no Loctite product protrudes screw head.

F12R1CA

1. Measure resistance between pins 2 and 3

2. Turn screw clockwise to decrease resistance

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Throttle Cable Adjustment

Mechanically adjust the throttle cable using the adjusting device underneath body, below steering.

Slacken lock nut to allow adjuster rotation. Freeplay on lever should be between 2 and 3.5 mm

(1/16 and 1/8 in). When done, tighten lock nut.

Injection Oil Pump Cable Adjustment

As oil injection cable is throttle dependent, always proceed with the oil injection pump cable adjustment after throttle cable adjustment. Refer to OIL

INJECTION PUMP.

CAUTION:

Improper oil injection pump synchronization 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 gaskets, hoses and fittings. Soapy water can be sprayed on components. Repair any leak.

Disconnect hose outlet from air compressor.

F12R1GB

1. Slacken nut

2. Turn adjuster

NOTE: On LRV 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 adjustment until Throttle Opening meter indicates between 95% and 99%.

Closed TPS Adjustment

Perform the CLOSED TPS ADJUSTMENT as described in THROTTLE POSITION SENSOR (TPS) in ELECTRONIC MANAGEMENT below.

F12R02A

Connect adapters and pressure relief valve to pressure gauge as shown.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

F12R03A

4 3

1. Pressure gauge (P/N 529 035 709)

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:

Ensure to install the pressure relief valve to allow excess pressure to go out. Note the arrow on the valve. Otherwise, air compressor components might be damaged.

Install pressure gauge to air compressor.

NOTE: To prevent fuel to be injected and thus going out the disconnected hose, use the drowned engine mode to crank engine. While engine is stopped, depress and HOLD the throttle lever at full throttle position for cranking.

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.



WARNING

Be careful of pressure relief valve outlet. Compressed air may flow out there.

MINIMUM AIR PRESSURE (at cranking)

621 ± 14 kPa (90 ± 2 PSI)

If pressure is within limits, air compressor is working 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 compressor 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 completely 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 compressor 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 opening. Holes must not be obstructed by the opening edges.

F12R04A

1 2

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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

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 connecting rod.

Remove connecting rod retaining screw.

As a puller, use a M7 x 1.0 x 50 mm screw to release connecting rod “crankpin”.

IMPORTANT: Trace a mark on “crankpin” (bushing) outer end. This is needed for reinstallation.

F12R05A

1. O-ring on top of cylinder sleeve

Ensure to position screw from the bottom up as show. Torque nut to 2.7 N•m (24 lbf•

2.7 Nm

(24 lbf in )

F12D0BA

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. Install a new gasket, new O-ring, compressor head and cover. Apply synthetic grease below screw head and Loctite 243 on threads. Install screws then torque to 5 N•m (44 lbf•

) to then finalize to

11 N•m (97 lbf•

Bottom End

To gain access to piston, rings and connecting rod, engine PTO flywheel must be removed. Refer to

ENGINE section.

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F12R06A

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 pins for wear and heat discoloration. Check connecting rod for straightness.

Replace damaged components.

Inspect piston for damage. Light scratches can be sanded with a fine sand paper.

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 filter replaced.

CAUTION:

Failure to properly clean the oil system will result in serious engine damage.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

The inspection of top end should include the following measurements.

TOLERANCES

ENGINE

MEASUREMENT NEW PARTS

(min.) (max.)

Piston/cylinder wall clearance

0.12 mm

(.005 in)

N.A.

WEAR

LIMIT

0.2 mm

(.008 in)

Ring end gap

0.1 mm

(.004 in)

0.25 mm

(.010 in)

0.5 mm

(.020 in)

N.A.: Not applicable

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 cylinder sleeve is worn and needs replacement. Otherwise, replace piston.

Ring End Gap

Position ring close to top of cylinder top.

NOTE: In order to correctly position ring in cylinder, use piston as a pusher.

Using a feeler gauge, check ring end gap. If gap exceeds specified tolerance, rings should be replaced.

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 should be towards the top of the piston.

F12R1OA

1. Beveled edge

Position ring openings 180° apart.

F12R07A

2 1

1. Top of cylinder

2. Ring end gap

Assembly

Apply injection oil in cylinder and on rings prior to installing.

F12R15A

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 on the bench from the bottom if desired.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

When attaching connecting rod to “crankpin”, strictly follow this procedure:

1. Block counterbalance shaft to prevent any rotation.

2. Install the “crankpin” (bushing) with the previously marked end outside. If the mark is not present anymore, place a straight edge against bushing end to find the tapered end (concave).

A very small gap between the edge and the bushing will identify the tapered end to be installed against the counterweight.

3. Install a NEW screw and torque to 6.5 N•m

(58 lbf•

). Do not apply any thread locker product.

4. Turn the screw clockwise an additional 80 degrees ± 5 degrees.

CAUTION:

Failure to strictly follow this procedure may cause screw to loosen and lead to engine damage. The bushing tapered 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 coating.

Ensure to correctly position O-ring on access cover and install cover.

Reinstall remaining removed parts. Ensure to check engine alignment.

FUEL DELIVERY

FUEL PRESSURE REGULATOR

Pressure Test

The pressure test will show the available pressure at the air/fuel rail. It validates the pressure regulator and leaks in the system.

IMPORTANT: Before checking air/fuel rail pressure, make sure the fuel pressure from the fuel pump and the air pressure from the air compressor are within specifications. See the procedures elsewhere in this section.

Also ensure there is no leak from hoses and fittings. Repair any leak.

Ensure there is enough gas in fuel tank.

Release the fuel pressure in the system.

Disconnect outlet hose (the one with the fuel filter) from fuel pump using tool (P/N 529 035 714).

Connect adapter to pressure gauge as shown.

F12R08A

1. Pressure gauge (P/N 529 035 709)

2. T-adapter (P/N 529 035 710)

Install pressure gauge between disconnected hose

( inline installation).

F12R09A

1. Fuel filter

2. Fuel line going to air/fuel rail

3. Pressure gauge between disconnected hose ( inline installation)

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Install safety lanyard and observe fuel pressure.

Do not crank engine .

FUEL REGULATOR PRESSURE

(when installing safety lanyard)

185 ± 14 kPa (27 ± 2 PSI)

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 indication of a leaking fuel pressure regulator diaphragm.

Remove pressure gauge and reinstall fuel hose. At installation apply engine oil on O-ring.



WARNING

Wipe off any fuel spillage in the bilge. Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area.

Fuel Pressure Regulator Replacement

Removal

Release the fuel pressure in the system.

Disconnect spark plug cables from spark plugs.

Disconnect the fuel injector wires, if necessary.

F12R0DA

1. Push clip toward injector to release connector

Unscrew rail retaining screws.

F12R19A

1. Retaining screws

Gently pull rail up by hand, working each side slightly at a time.

Pull rail out.

Unscrew retaining plate screws.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

4 2 5

F12R1AA

2 3

1. Retaining plate

2. Screws

3. Fuel injector

4. Fuel pressure regulator and cover

5. Air pressure regulator

1 3 2

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 recommended 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 to O-ring to ease insertion in rail.

Apply Loctite 243 on rail retaining screws then torque to 25 N•m (18 lbf•ft).

FUEL INJECTOR

Leakage Test

Testing the fuel injector operation can be performed with the air/fuel rail installed.

The leakage test is validated when performing the

FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW

CHART elsewhere in this section.

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 plug connector from the injector.

Install a temporary connector to the injector with wires long enough to make the connection outside the bilge and apply voltage (12 V) to this test harness.

This will validate the injector mechanical and electrical operation.

If it does not work, replace it.

Otherwise, check the resistance of the fuel injector circuit.

Reconnect the injector and disconnect the AMP plug connector number 4 on the MPEM.

Using a multimeter, check resistance value between terminals as follows.

COMPONENT

Fuel injector MAG

Fuel injector PTO

CONTACT LOCATION

7 and 13

8 and 14

The resistance should be between 1.7 and 1.9

Ω

If resistance value is correct, try a new MPEM.

Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug 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 remove any regulator.

To remove fuel injector, pull it out of rail.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Installation

For the installation, reverse the removal procedure. Paying attention to the following details.

If the same injector is reinstalled, it is recommended to change the O-rings.

Insert the fuel injector in place with your hand. Do not use any tool.

NOTE: A thin film of injection oil may be applied to O-ring to ease insertion in rail.

Apply Loctite 243 on rail retaining screws then torque to 25 N•m (18 lbf•ft).

AIR/FUEL RAIL

Pressure Test

Crank or start engine and observe fuel pressure.

FUEL PRESSURE

(when cranking engine or when engine is running)

738 ± 14 kPa (107 ± 2 PSI)

If pressure is within limits, fuel and air systems are working adequately. No subsequent tests are necessary 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, check air/fuel rail for leaks. If it is not leaking then replace air regulator

A higher pressure may be an indication of a pinched or clogged air regulator outlet line.

Air Pressure Regulator Replacement

Removal

See FUEL PRESSURE REGULATOR REMOVAL above for procedure.

Remove the fuel regulator then the air regulator.

Installation

For the installation, reverse the removal procedure but pay attention to the following.

NOTE: A thin film of injection oil may be applied to O-ring to ease insertion in rail.

Apply Loctite 243 on rail retaining screws then torque to 25 N•m (18 lbf•ft).

Air/Fuel Rail Replacement

Removal

Release the fuel pressure in the system.

Disconnect air compressor supply hose from rail.

Disconnect fuel hoses (supply and return) at their inline connectors.

Temporarily connect those hose ends together to prevent rail draining.

Disconnect spark plug cables from spark plugs and fuel injector wires. Cut locking ties of wiring.

Unscrew rail retaining screws.

3 1 4 2

F12R0CA

1. Air/fuel rail

2. Air supply hose

3. Fuel supply hose

4. Retaining screws

SMR2002-030 _06_03A.FM

F12R0DA

1. Push clip toward injector to release connector

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Gently pull rail up by hand, working each side slightly at a time.

Pull rail out.

Disconnect hose ends at their inline connectors and drain fuel rail.

Disconnect air and fuel hoses from 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 temperature from the combustion chamber will make visible overheated area. Replace damaged components.

F12R0FA

1. Air and fuel return hoses

2. Fuel supply hose

Electrical Test

Using the vehicle communication kit (VCK) with the B.U.D.S. software, energize the direct injector in the Activation section.

If the injector does not work, disconnect the plug connector from the injector.

Install a temporary connector to the injector with wires long enough to make the connection outside the bilge and apply voltage (12 V) to this test harness.

This will validate its mechanical and electrical operation.

If it does not work, replace the direct injector.

Otherwise, check the resistance of the direct injector circuit.

Reconnect the injector and disconnect the AMP plug connector number 4 on the MPEM.

Using a multimeter, check resistance value between terminals as follows.

NOTE: When lifting/removing air/fuel rail, we recommend replacing carbon dams on direct injectors that have been running for 50 hours or more.

Remove fuel injector, fuel pressure regulator and air pressure regulator.

COMPONENT

Direct injector MAG

Direct injector PTO

CONTACT LOCATION

5 and 15

6 and 21

Installation

For installation, reverse the removal process but pay attention to the following.

A thin film of injection oil may be applied to O-rings of fuel injectors to ease rail installation.

Apply Loctite 243 on rail retaining screws then torque to 25 N•m (18 lbf•ft).

When installing fuel or air hoses fitting to the air/ fuel rail, use Loctite Krylox (no. 29-719).

DIRECT INJECTOR

The resistance should be between 1 and 1.6

Ω

If resistance value is correct, try a new MPEM.

Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connector and 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.

06-03-16

Direct Injector Replacement

IMPORTANT: Do not remove direct injector 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. Otherwise, sealing efficiency might be affected.

Remove air/fuel rail retaining screws. Partially lift rail to allow direct injector removal.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Disconnect direct injector connector then pull injector out of cylinder head.

F12R0GA

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 paying attention to carbon dam insertion. Ensure to position connector pointing toward bottom of cylinder head.

NOTE: A thin film of injection oil may be applied to carbon dam if necessary to ease insertion in cylinder head.

Reconnect electrical connector.

Carbon Dam Replacement

Remove direct injector. See procedure above.

NOTE: When replacing a carbon dam, it is recommended to replace it on both injectors. It is also recommended to replace all O-rings. When servicing 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 injector. 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

The pressure test will show the available pressure from the fuel pump.

Ensure there is no leak from hoses and fittings.

Repair any leak.

Ensure there is enough gas in fuel tank.

Use the VCK (Vehicle Communication Kit) to release 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 adapters and pressure relief valve to pressure gauge as shown.

F12R0HA

1. Carefully insert direct injector

2. Connector pointing toward bottom of cylinder head

Reinstall air/fuel rail.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

F12R0AA

1. Pressure gauge (P/N 529 035 709)

2. T-adapter (P/N 529 035 710)

3. Pressure relief valve (P/N 529 035 711)

CAUTION:

Ensure to install the pressure relief valve to allow excess pressure to flow back through return line. Note the arrow on the valve.

Otherwise, fuel pump components might be damaged.

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.

F12R0BA

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)

Install safety lanyard and observe fuel pressure.

MINIMUM FUEL PUMP PRESSURE

(when installing safety lanyard)

721 kPa (105 PSI)

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 plug connector from the fuel pump.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Install a temporary connector to 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 plug connector number 4 on the MPEM.

Using a multimeter, check continuity between terminals 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 plug connector and fuel pump.

Fuel Pump Replacement

Removal

Open front storage compartment cover.

Remove the storage basket.

Remove glove box (see HULL/BODY section).

Remove front vent tubes.

RX DI

Remove tube Y-connector.

Remove tube bracket by unscrewing nuts from bilge (front storage area).

F12R0IA

1 2

1. Fuel pump

2. Retaining screw

Disconnect electrical connector.

Disconnect vent tube from fuel pump.

Release the fuel pressure in the system.

Disconnect inlet and outlet hoses from fuel pump using tool (P/N 529 035 714).

RX DI

Compress springs of pump module to reduce its height to allow pulling pump out.

All Models

Pull fuel pump toward front of vehicle. Wipe off any fuel spillage in the bilge.

F12R0KA

1. Vent tube bracket

2. Nut

All Models

From glove box opening, remove fuel pump retaining nuts.

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F12R0JA

1. Pull fuel pump toward front

Installation

For installation, reverse the removal process but pay attention to the following.

Tighten fuel pump screws in a criss-cross sequence.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART

NOTE:

The tolerance for the pressure is ± 14 kPa (2 PSI).

Fuel pump does not run Connect safety lanyard

Fuel pump runs for 2 sec. then stops

Check fuses

Check lanyard connection

Check pump module operation

Repair or replace if necessary

Install fuel pressure gauge on fuel pressure line

Connect safety lanyard

Fuel pump runs

Repair or replace

Fuel pressure less than 185 kPa (27 PSI)

Fuel pressure more than

185 kPa

(27 PSI)

Check for blocked fuel return line

Repair or replace yes

Check fuel lines for leaks

Check fuel filters

Fuel pressure is 185 kPa

(27 PSI)

Line OK

Replace fuel pump module fails

Perform fuel pump test Crank or start engine test OK

Fuel pressure lower than 735 kPa (107 PSI)

Fast pressure drop yes

Replace fuel pump module fails

Perform fuel pump test no

Verify fuel pump check valve

OK fails fails pass

Proceed to air compressor pressure test

Ensure air/fuel rail is not leaking no yes

Replace fuel pump

Check fuel injector

OK fails

Repair/replace air/fuel rail

Air pressure less than 621 kPa

(90 PSI) fails

Check

RAVE for air leaks no leaks

Repair leaks

Repair air compressor no leaks

Direct injector

Replace fuel injector

Replace fuel pressure regulator

F12A06S

NOTE:

The tolerance for the

Check for air leaks

Air pressure more than 621 kPa

(90 PSI)

Check direct injector

Check air/fuel rail for leaks fails yes

Repair leaks

Replace direct injector

Repair/replace air/fuel rail

Fuel pressure greater than

735 kPa

(107 PSI)

Fuel pressure is 735 kPa

(107 PSI)

Check air return line for blockage line

Replace air pressure regulator

Retest

Replace fuel pressure regulator

System OK

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

ELECTRONIC MANAGEMENT

MPEM REPLACEMENT

General

Prior to replacing a suspected MPEM, ensure that all the recommendations in the general introduction of this section have been followed.

IMPORTANT: When MPEM is replaced, the safety lanyard(s), the TPS closed position and the TDC setting must be reprogrammed/reset. Refer to their specific section for adjustment.

To allow transferring the previous recorded information from the old MPEM to the new one, use the vehicle communication kit (VCK) with the B.U.D.S.

software. Use Replace in the MPEM 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.

Replacement

Disconnect battery cables.



WARNING

Battery BLACK negative cable must always be disconnected first and connected last.

Disconnect AMP connectors from MPEM.

Remove MPEM.

Install the new MPEM to the vehicle.

Reconnect AMP connectors to MPEM then battery cables.

Transfer the data from the previous MPEM to the new one using B.U.D.S. then proceed with the required resets after the following verification has been done.

Select the Activation tab.

Point the mouse cursor over the PTO TPS. Check the ADC reading. It must be between 23 and 45.

Activation

F12R1JA

3 2

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 ADC’s 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 Diagnostic Cap Missing fault).

Start the engine and increase engine speed above

5000 RPM to be sure no fault appears.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

THROTTLE POSITION SENSOR

(TPS)

General

The throttle position sensor (TPS) is a potentiometer that sends a signal to the MPEM which is proportional to the throttle shaft angle. On the DI system, 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.

F12F05A

1. Throttle position sensor (TPS)

IMPORTANT: Prior to testing the TPS, ensure that mechanical components/adjustments are adequate according to THROTTLE BODY in AIR IN-

DUCTION 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 physical 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 needle “sticks”, bounces, suddenly drops or if any discrepancy 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 generate 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 voltage output from MPEM to the desired throttle position sensor.

Disconnect plug connector from throttle position sensor and connect a voltmeter to the wiring harness.

Check the voltage readings on the PTO side as follows.

CONNECTION

Pin 1 with engine ground

Pin 2 with engine ground

Pin 3 with engine ground

VOLTAGE

5 V

0-0.5 V

0 V

Check the voltage readings on the MAG side as follows.

CONNECTION

Pin 1 with engine ground

Pin 2 with engine ground

Pin 3 with engine ground

VOLTAGE

5 V

0-0.5 V

4.75-5 V

Remove and reinstall the safety lanyard to activate the MPEM. There should be 5 Vdc in each test.

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

Disconnect the AMP plug connector number 3 on the MPEM.

Using a multimeter, check resistance value between terminal 10 and 14.

The resistance should be 1600 - 2400

Ω

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Check the resistance between terminal 5 and terminal 14 with the throttle plate in idle position.

The resistance should be 2500

Ω

Check the resistance between terminal 5 and terminal 10 with the throttle plate in idle position.

The resistance should be 1200

Ω

PTO Side

Disconnect the AMP plug connector number 4 on the MPEM.

Using a multimeter, check resistance value between terminal 3 and 18.

The resistance should be 1600 - 2400

Ω

Check the resistance between terminal 1 and terminal 3 with the throttle plate in idle position.

The resistance should be 1000

Ω

Check the resistance between terminal 1 and terminal 18 with the throttle plate in idle position.

The resistance should be 2500

Ω

Test Results — Both TPS

If resistance values are correct, try a new MPEM. Refer to MPEM replacement procedures elsewhere in this section.

If resistance values are incorrect, repair the wiring harness/connectors between AMP plug connector and the TPS.

Replacement

Remove the air intake silencer.

Remove the air duct.

Disconnect the connector of the TPS.

Loosen two Allen screws retaining the TPS.

Remove TPS.

1 2

F12R0LA

MAG SIDE THROTTLE BODY

1. Allen screws

2. Throttle position sensor (TPS)

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 “adjustment”, it is not really an adjustment. Rather, it performs 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 mapping and several MPEM calculations.

NOTE: Reset must be done each time the throttle position sensor (TPS) is loosened or removed or throttle body(ies) is(are) replaced or MPEM is replaced.

CAUTION:

An improperly adjusted TPS may lead to poor engine performance and emission compliance could possibly be affected.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Use the vehicle communication kit (VCK) with the

B.U.D.S. software to perform this adjustment.

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 adjustment. Refer to

THROTTLE BODY in AIR INDUCTION SYSTEM above.

Push the Reset button in the Setting section of

B.U.D.S.

NOTE: There is no idle speed adjustment to perform. 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 not accept the setting.

Start engine and make sure it operates normally through its full engine RPM range. If fault codes appear, refer to DI SYSTEM FAULT CODES in DIAG-

NOSTIC PROCEDURES section for more information.

CRANKSHAFT POSITION

SENSOR (CPS)

2 1

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 center 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 pins and wires.

Encoder Wheel Inspection

To check the encoder wheel for bent teeth, proceed as follows.

Remove magneto cover. Refer to magneto system in ENGINE section.

Install a dial indicator on crankcase casting. Position 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.

F12R0OA

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 approximately 300 RPM, the CPS circuitry is properly working.

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F12R1HA

1. Encoder wheel

2. Dial indicator

Properly reinstall cover.

The encoder wheel for bent teeth can also be inspected by the following alternative method.

Remove magneto cover. Refer to MAGNETO SYS-

TEM in ENGINE section.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Install a pointed wire on one of the threaded hole of crankcase with the screw as shown in the following illustration.

1 2

F12R1MA

1. Pointed wire

2. Screw on the threaded hole

Rotate the flywheel one time and adjust the pointer so that it slightly touches the highest tooth. Using a feeler gauge, check and measure the clearance between each tooth and pointer.

F12R1NA

1. Pointed 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.

Properly reinstall cover.

Voltage Test

Unplug magneto connector.

Check connector pins for corrosion or damage.

Remove and reinstall the safety lanyard to activate the MPEM.

Check the voltage readings on the harness side as follows:

CONNECTION

Pin 4 with engine ground

Pin 5 with engine ground

Pin 6 with engine ground

VOLTAGE

0 V ± a small mV tolerance

12 V

5 V

If voltage tests good, the CPS is defective and needs replacement.

If voltage does not test good, perform the following tests.

Resistance Test

Check the continuity of the wiring harness.

Disconnect the AMP plug connector number 2 on the 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.

Otherwise, repair the wiring harness/connectors between AMP plug connector and the CPS.

Replacement

Remove tuned pipe.

Unscrew front engine support and slightly lift engine to have access to magneto cover screws.

Block engine in this position.

Disconnect connector and remove magneto cover.

Remove CPS.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

F12R0NA

1. CPS inside magneto cover

Apply Loctite 243 on screw threads then install the new CPS.

Reinstall remaining removed parts.

MANIFOLD AIR TEMPERATURE

SENSOR (MATS)

Using a multimeter, recheck resistance value between terminals 16 and 19.

If resistance value is correct, try a new MPEM. Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connector and the MATS.

Replacement

Remove the air intake silencer.

Remove the air duct.

Disconnect the connector of the MATS.

Pull MATS out while turning right and left.

Install the new MATS.

Reinstall remaining removed parts.

WATER TEMPERATURE SENSOR

(WTS)

F12R0MA

PTO SIDE THROTTLE BODY

1. Manifold air temperature sensor (MATS)

Resistance Test

Disconnect the plug connector from the MATS and check the resistance of the sensor itself.

The resistance should be between 2280

Ω

and

2740

Ω.

Otherwise, replace the MATS.

If resistance tests good, reconnect the MATS and disconnect the AMP plug connector number 4 on the MPEM.

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F12R0PA

1. Water temperature sensor (WTS)

Resistance Test

Disconnect the plug connector from the WTS and check the resistance of the sensor itself.

The resistance should be between 2280

Ω

and

2740

Ω

Otherwise, replace the WTS.

If resistance tests good, reconnect the WTS and disconnect the AMP plug connector number 4 on the MPEM.

Using a multimeter, recheck resistance value between terminals 9 and 11.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

If resistance value is correct, try a new MPEM. Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connector and 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 temperature sensor.

Disconnect WTS connector and remove WTS.

Apply Loctite 518 on threads of the WTS then install.

Reinstall remaining removed parts.

MANIFOLD AIR PRESSURE

SENSOR (MAPS)

F12R0LB

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 sensor 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 elbow adaptor.

Otherwise, the MAPS could generate a fault code for an unexpected sensor range at idle when it reads the atmospheric pressure. Ensure the correct 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 voltage output from MPEM to the manifold air pressure sensor (MAPS).

Disconnect plug connector from throttle position sensor and connect a voltmeter between pin 1 and

3 and also between pin 1 and 2 of wiring harness.

Remove and reinstall the safety lanyard to activate the MPEM. There should be 5 Vdc in each test.

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 AMP plug connector number 3 on the MPEM.

Using a multimeter, check continuity of circuits 3-3,

3-6 and 3-7.

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 plug connector and the MAPS.

Replacement

Remove the air intake silencer.

Remove the air duct.

Disconnect MAPS connector and remove the MPAS.

Install the new MAPS paying attention to index its tab into the adaptor notch.

Reinstall remaining removed parts.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

KNOCK SENSOR (KS) EXHAUST GAS TEMPERATURE

SENSOR (EGT)

F12R0SA

1. Muffler

2. Exhaust gas temperature sensor (EGT)

Resistance Test

Disconnect the plug connector from the EGT and check the resistance of the sensor itself.

The resistance should be between 2280

Ω

and

2740

Ω

Otherwise, replace the EGT.

If resistance tests good, reconnect the EGT and disconnect the AMP plug connector number 4 on the MPEM.

Using a multimeter, recheck resistance value between terminals 10 and 12.

If resistance value is correct, try a new MPEM. Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connector and the EGT.

Replacement

Disconnect EGT connector and remove EGT.

Apply Loctite 518 on threads of the EGT then install.

Replug connector.

F12R0QA

1. Knock sensor (KS)

Dynamic Test

Using the vehicle communication kit (VCK) with 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 sensor is good.

Otherwise, do the following.

Ensure sensor and head contact surfaces are clean and mounting bolt and washer are correct and properly torqued down.

Check the knock sensor resistance.

Disconnect the AMP plug connector number 4 from the MPEM module.

Static Resistance Test

Using a multimeter, check the resistance between terminal 2 and terminal 17 on the plug connector.

The resistance should be approximately

5 M

Ω

Otherwise, check the continuity of the knock sensor circuit 4-2 and 4-17.

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 plug connector and knock sensor.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Replacement

Unscrew and remove knock sensor.

Clean contact surface, apply Loctite 243 in threaded hole then install the new knock sensor.

Torque screw to 20 N•m (15 lbf•ft).

CAUTION:

Improper torque might prevent sensor 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 removing the cap and feeling the movement with a hand.

Another test can be done using the vehicle communication 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, indicating the RAVE system is working on the electronic side. However, pneumatic test still have to be performed 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.

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 defective and needs to be replaced.

Using the vehicle communication kit (VCK) with the B.U.D.S. software, energize the RAVE solenoid from the Activation section.

The pressure should drop when the solenoid is activated. If the solenoid does not work, disconnect the plug connector from the solenoid.

Install a temporary connector to the solenoid with wires long enough to make the connection outside the bilge and apply voltage (12 V) to this test harness.

If it does not work, replace the solenoid. Otherwise, proceed with the resistance test below.

Reconnect hose to compressor.

Unplug the outlet hose from RAVE solenoid.

F12R0RA

1. Air compressor

2. Disconnect RAVE supply hose

SMR2002-030 _06_03A.FM

1 2

F12R0TA

3 1

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 pressure. 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 pressure drops, replace the defective seal inside RAVE valve.

Take into account that the RAVE may be mechanically stuck in the cylinder slot. Open the RAVE and check for free operation. Refer to ENGINE and look in TOP END.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Pressure Relief Circuit

When RAVE valve is released, the pressure escape from this vented hose. If the RAVE valves does not return when the solenoid is released, ensure the return spring is in good condition, this hose is not kinked or plugged and the solenoid allows pressure to bleed there.

Although it is not related with RAVE operation, we suggest to verify the check valve operation which prevent the pressure going down to crankcase. Install a hose pincher after the T-fitting to adequately pressurize the check valve portion.

3 2

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.

Using the vehicle communication kit (VCK) with 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 prevent spark occurring in the bilge. Otherwise, perform the following checks.



WARNING

Never make a spark test with spark plug removed. Flammable vapors may be present in the bilge and ignited which could cause an explosion.

Primary Winding

Disconnect the plug connector from the ignition coil and check the resistance of the primary circuit.

F12R0TB

1. RAVE solenoid

2. Pressure relief hose

3. Install hose pincher here

Resistance Test

Reconnect the solenoid and disconnect the AMP plug connector number 4 on the MPEM.

Using a multimeter, check resistance value between terminals 20 and 23.

The resistance should be 24

Ω

If resistance value is correct, try a new MPEM. Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connector and solenoid.

F12R0UA

3 1

1. PTO side ignition coil

2. Mag side ignition coil

3. Primary winding connector

The resistance should be between .45 - .55

Ω at

20°C (68°F).

Otherwise, replace the ignition coil.

If resistance tests good, reconnect the ignition coil connector and disconnect the AMP plug connector number 3 on the MPEM.

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Section 06 ENGINE MANAGEMENT (DI)

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Using a multimeter, recheck resistance value between terminals 21 and 22 for MAG side and terminals 20 and 23 for PTO side.

If resistance value is correct, try a new MPEM. Refer to MPEM REPLACEMENT procedures elsewhere in this section.

If resistance value is incorrect, repair the wiring harness/connectors between AMP plug connector and the ignition coil.

Secondary Winding

Static Test

NOTE: An ignition coil with good resistance measurement 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.

Using a multimeter, check the resistance between the terminals C and the coil post.

The resistance should be between 6800 and

10200

Ω

at 20°C (68°F).

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.

MODEL

RX DI

LRV DI

SIDE

MAG

PDM

MAG

PTO

VALUE OHM

5700

4300

5700

4900

Check continuity between ignition coil ground circuits and engine.

Dynamic Test

Use an ignition coil tester, available from after-market tool/equipment suppliers.



WARNING

Do NOT use coil tester on metal work bench.

Follow manufacturer instructions.

1. With ignition coil removed from craft, hook high tension leads from tester to ignition coil high tension cables.

2. Connect 2 smaller tester leads to primary of ignition coil.

F12H0UA

TYPICAL

1. Lead to secondary

2. Leads to primary

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.



WARNING

Always reconnect spark plug cables at the same spark plugs where they come from. The cable coming out the edge of the electrical box must be connected to the MAG side spark plug. Otherwise, severe backfire may occur with possible damage to exhaust system components. The white tape on the ignition coil should match the white tape on the high tension cable.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

2 3 1

F12R0UB

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 on 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 woodruff key.

CAUTION:

The relation between the PTO flywheel mark position and crankshaft position may change as the PTO flywheel might move on crankshaft when engine is ran. This will result in a false ignition timing reading. Always verify

PTO flywheel mark position before checking ignition timing with an appropriate timing light.

If mark does not align with tool, repeat static test to ensure flywheel 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 correctly set since every part is fixed and not adjustable. The only time the TDC setting might have to be changed would be when replacing the crankshaft, 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 temperature lower for a longer time. Ensure to properly cool the engine through the flushing fitting.

NOTE: When checking the TDC setting, the spark advance has to be locked to allow proper verification of the TDC marks. See TDC SETTING below.

Static Test

1. Disconnect MAG side spark plug wire and connect wire to grounding device then remove spark plug.

CAUTION:

Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device.

2. Remove PTO flywheel guard.

3. Remove middle screw securing the engine to the rear engine mount. Reinstall screw with timing mark pointer tool.

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F12R1IA

1. Timing mark pointer tool (P/N 295 000 135)

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Section 06 ENGINE MANAGEMENT (DI)

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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 piston is just Before Top Dead Center.

1 2 3

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).

F12R0VA

1. Outer ring

2. Adaptor lock nut

3. Adaptor

4. Roller

5. Roller lock nut

5 4

– Install roller on dial gauge end. Ensure to position 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 measurement, ensure that dial gauge face is positioned in the same direction as the connecting rod.

– Rotate magneto flywheel clockwise until piston 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).

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A00B4FA

10. Connect timing light pick-up to MAG side spark plug wire.

F00H1QA

TYPICAL

1. Timing light pick-up

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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 timing 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.

CAUTION:

If the TDC setting is adjusted too advanced, 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 adjustment 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 reference is synchronized with the engine crankshaft.

F06H07A

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 aligned with timing mark pointer, no adjustment is required. 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 529 035 844). 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 .

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F12R0WA

1. “Setting” tab

2. Ignition offset section

3. “Locked” box

4. Current angle in MPEM

5. Arrows to change the angle

1. Choose the Setting tab and look under Ignition

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 timing 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.

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NOTE: This will write the new value immediately to the MPEM. There is no need to write the document to the MPEM for the TDC setting unless other changes were made. However, we recommend to reset the service hours when you perform a service action such as the TDC setting.

NOTE: The MPEM features a permanent (nonvolatile) memory and keeps the TDC setting programmed even when the watercraft battery is disconnected.

Engine Start/Stop Switch Verification

A quick operation test can be done using the vehicle communication kit (VCK) with the B.U.D.S. software, 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, wiring harness going to the solenoid, starter motor. Refer 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. Otherwise, replace switch.

If the switch tests good, check continuity of circuits 2-8 and 2-11 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 performed 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 resistance, it must be close to 0 ohm.

Safety Lanyard on Switch

Connect test probes to switch BLACK and BLACK/

YELLOW wires. Measure resistance, it must be close to 0 ohm.

SPARK PLUGS

Disassembly

First unscrew the spark plug one turn.

Clean the spark plug and cylinder head with pressurize air then completely unscrew.

Heat Range

The proper heat range of the spark plugs is determined 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 operating temperature will be — and conversely, 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 cylinder 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 deposits which might tend to foul the plug during prolonged idle or low speed operation.

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1 2

A00E09A

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 preignition, 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.

Fouling

Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged 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 connection between the center electrode and ground.

Spark Plug Installation

Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free of grime.

1. Using a wire feeler gauge, set electrode gap according to the following chart.

2. Apply anti-seize lubricant over the spark plug threads to prevent possible seizure.

3. Hand screw spark plug into cylinder head. Then, tighten the spark plug clockwise an additional

1/4 turn with a proper socket.

A00E0BA

1. Proper socket

2. Improper socket

ENGINE

SPARK

PLUG

NGK

ZFR4F-11

TORQUE

Hand tighten

+ 1/4 turn with a socket

GAP mm (in)

1.1

(.043)

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

COMPONENT

Air compressor

Fuel pressure regulator

Fuel pressure

Fuel pump

VALUE kPa (PSI)

621 ± 14 (90 ± 2) at cranking

185 ± 14 (27 ± 2) when installing safety lanyard

738 ± 14 (107 ± 2) inline test at cranking or when engine is running

721 (105) minimum at cranking

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Electrical Tests

COMPONENT

Fuel pump

Fuel injector MAG

Fuel injector PTO

Direct injector

MAG

Direct injector PTO

Throttle position sensor MAG

(TPS)

Throttle position sensor PTO

(TPS)

Crankshaft position sensor

(CPS)

CONNECTOR

AMP no. 4

TPS

AMP no. 3

TPS

AMP no. 4

CPS

(Deutsche conn.)

AMP no. 2

TERMINAL

NUMBER

26 and pin B

24 and pin D

7 and 13

8 and 14

5 and 15

6 and 21

1 and engine ground

2 and engine ground

3 and engine ground

10 and 14

5 and 14

5 and 10

1 and engine ground

2 and engine ground

3 and engine ground

3 and 18

1 and 3

1 and 18

Pin 4 and ground

Pin 5 and ground

Pin 6 and ground

Pin 7 and pin 6 of CPS

Pin 6 and pin 5 of CPS

Pin 14 and pin 4 of CPS

Manifold air temperature sensor (MATS)

Water temperature sensor (WTS)

AMP no. 4

16 and 19

Manifold air pressure sensor

(MAPS)

AMP no. 3

9 and 11

Pin 3 and pin 1 of MAPS

Pin 6 and pin 3 of MAPS

Pin 7 and pin 2 of MAPS

WH/GY and BK/WH

TA/OR and BK/OR

PU/BL

WH/BL

BK/BL

WIRE COLOR

PU/PK

BK/PK

BL/PU and BL/BK

GR/PU and GR/BK

BL/BR and BL/PK

GR/BR and GR/PK

PU/BR

BK/BR

PU/BR

PU/BR and BK/BR

WH/BR and BK/BR

WH/BR and PU/BR

PU/RD

BK/RD

WH/RD

BK/RD and PU/RD

WH/RD and BK/RD

GY/RD

GY/YL

GY/RD

VALUE

0 ohm (continuity)

1.7 - 1.9 ohms

1 - 1.6 ohms

5 V

0 - 0.5V

4.75-5 V

1600 - 2400 ohms

2500 ohms at idle

1200 ohms at idle

5 V

0-0.5 V

0 V

1600 - 2400 ohms

1000 ohms at idle

2500 ohms at idle

0 V (with a small mV tolerance)

12 V

5 V

0 ohm (continuity)

2280 - 2740 ohms

0 ohm (continuity)

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

(

COMPONENT

Exhaust gas temperature (EGT)

Knock sensor (KS)

Rave solenoid (RS)

CONNECTOR

AMP no. 4

AMP no. 3

Ignition coil MAG

—

AMP no. 3

Ignition coil PTO

High tension leads

RX DI models )

High tension leads

LRV DI models )

—

MAG

PTO

MAG

PTO

TERMINAL

NUMBER

10 and 12

2 and 17

20 and 23

21 and 22

Coil terminal C and coil post

20 and 23

Coil terminal C and coil post

—

WIRE COLOR

TA/GY and BK/TA

BK/BL and YL/BL

PU/GY and BK/GY

RD/GN and WH/GN

—

RD/BL and WH/BL

—

White tape

—

White tape

VALUE

2280 - 2740 ohms

5 M ohms

24 ohms

.45 - .55 ohms primary winding

6800 - 10200 ohms secondary winding w/o high tension leads

.45 - .55 ohms primary winding

6800 - 10200 ohms secondary winding w/o high tension leads

5700 ohms lead alone

4300 ohms lead alone

5700 ohms lead alone

4900 ohms lead alone

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SMR2002-030 _06_03A.FM

Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

DIAGNOSTIC PROCEDURES

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 RAVE valves if stuck.

– Check fuel pump pressure.

– Check air compressor pressure.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

DESS SYSTEM

Basic Self-Diagnostic Mode

It is self-activated when the safety lanyard cap is being installed on the watercraft post. It gives immediate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.

SIGNAL CAUSE REMEDY

2 short beeps

(while 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 normally.

1 long beep

(while 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 safety lanyard condition with the programmer. Replace safety lanyard if reported defective. If it still does not work, enable advanced diagnostic mode to obtain more details about the failure.

8 short beeps

Other beeps

• Salt water or dirt in safety lanyard cap.

• Clean safety lanyard cap to remove dirt or salt water.

• Improper operation of MPEM or defective wiring harness.

• Enable advanced diagnostic mode to obtain more detail about the failure.

• Defective MPEM

(memory).

• Replace MPEM.

• Refer to COMPONENT FAILURE WARNING SYSTEM below.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

Advanced Self-Diagnostic Mode

It needs to be enabled manually. Proceed as follows:

1. Remove safety lanyard cap from watercraft post.

2. Press 5 times on the watercraft start/stop button.

NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode.

3. Install safety lanyard on watercraft post.

4. Press the watercraft start/stop button again.

NOTE: If everything is correct, engine will start. Otherwise, refer to the following chart.

SIGNAL

No beep

1 long and

1 short beeps

2 short beeps

2 long beeps

3 short beeps

CAUSE

• Engine actually starts.

• No safety lanyard has ever been programmed in watercraft MPEM.

• MPEM can not read the digital code of the safety lanyard cap or the magnet is defective.

REMEDY

• Everything is correct.

• Use MPEM programmer or the VCK and program a safety lanyard. This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed.

• Check safety lanyard cap condition with the MPEM programmer or the

VCK. Replace safety lanyard if reported defective.

• Check post wiring harness.

• Mixed wires at safety lanyard post connectors or bad connections.

• Wrong safety lanyard or bad connection of the DESS wires.

• Wiring harness of DESS post is grounded or there is a short circuit.

• Use the safety lanyard that has been programmed for the watercraft. If the problem is not resolved, check safety lanyard cap condition with the MPEM programmer or the VCK. Replace safety lanyard if reported defective.

• Check wiring harness and safety lanyard post.

If you need to listen again to the coded beeps, remove safety lanyard and repeat the procedure to activate the diagnostic mode.

If there is more than one problem, the MPEM will send only one error code. When the problem is solved, the MPEM will send a second code and so on until all problems are resolved.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

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

Manifold air pressure sensor

(MAPS)

Manifold air temperature sensor

(MATS)

“MAINT”

OFF

Throttle position sensor (single TPS)

“MAINT” ON ON 4

LIMP HOME MODE

➀

Limited RPM

“MAINT”

OFF/( ON )

OFF

6/(4)

Limited RPM

(idle speed if both

TPS’s fail)

Limited RPM

(code 4 if EGT also fails)

Limited RPM

Water temperature sensor (WTS)

Direct injector

(single injector)

Fuel injector

(single injector)

Ignition

(no firing on one cylinder)

RAVE solenoid

Starter solenoid

Fuel pump

Exhaust gas temperature sensor

(EGT)

Fuel level sensor

Diagnostic cap fault

Knock sensor

Engine drowned mode activated

(it is not a fault)

“MAINT”

None

OFF

OFF/( ON )

OFF

6/(4)

Limited RPM

Engine may not start

Limited RPM

(code 4 if WTS also fails)

None

Limited RPM

Engine will not run.

Release throttle

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SMR2002-031_06_04A.FM

Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

System Failures

Refers to operating conditions outside normal and/or safe ranges such as demand system failures, extreme voltages, over temperature conditions or low fuel/oil levels.

PROBLEM INFO CENTER RED LED BUZZER

BUZZER

CODE

LIMP HOME MODE

➀

Manifold air pressure sensor (MAPS),

ATM fault (bad atmospheric pressure reading)

Throttle position sensor (single TPS)

Throttle position sensor (dual TPS)

Throttle position sensor

(single adaption fault)

Throttle position sensor

(dual adaption fault)

“MAINT”

None

“MAINT”

OFF

Limited RPM

Idle RPM

None

Limited RPM

Sensor supply fault

(TPS and MAPS)

“MAINT” ON ON /OFF 4/(6)

Limited RPM

(code 6 and idle RPM if both in fault)

Encoder (CPS) fault

(bad pattern)

Low battery voltage

Very low battery voltage

High battery voltage

Very high battery voltage

High water temperature

Exhaust over temperature

Low oil level

Low fuel level

Setup fault

(TDC or TPS not set on a new MPEM)

MPEM fault

“MAINT”

“12 V LOW”

“MAINT”

“HI-TEMP”

“OIL-LOW”

“FUEL-LO”

“MAINT”

OFF

Limited RPM

None

Limited RPM

None

Idle RPM

None

Idle RPM

“MAINT” ON OFF 6 Engine will not start

➀

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...”.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

Buzzer Code

BUZZER

CODE

BUZZER PATTERN

OFF

2 SEC.

15 MIN.

OFF

2 SEC.

58 SEC.

OFF

2 SEC. 2 SEC.

OFF

1 SEC.

OFF

F12H13S

VCK

(vehicle communication kit)

The VCK (Vehicle Communication Kit) (P/N 529

035 844) is the primary tool to diagnose fuel injection related problems.

B.U.D.S. is designed for the DI model to allow sensor inspection, diagnostic options and adjustment such as the Throttle Position Sensor (TPS) and the

TDC setting.

For more information pertaining to the use of the software B.U.D.S., use its help which contains detailed information on its functions.

Always OFF

NOTE

2 second beep every 15 minutes

2 second beep every 58 seconds

2 second beep every 2 seconds

1 second beep every second

Always ON (continuously beep)



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.

IMPORTANT: When using the software B.U.D.S., 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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

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 seconds. 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 system), 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 knock sensor wiring/routing may lead to generate this fault code.

– Electrical noise might also lead engine to occasional 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 connector 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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

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 recommended to release the throttle quickly as this may also show up a fault that is intermittent.

POSSIBLE CAUSES

Check if wrong connector is connected to TPS

Check if sensor is loose

Inspect sensor for damage or corrosion

Inspect wiring (voltage test)

Inspect wiring and sensor (resistance test)

Test sensor operation (wear test)

RESULT

Yes

Failed

ACTION

• Fix.

• Fix and reset closed TPS.

• Replace and reset closed TPS.

• Repair.

• If bad wiring, repair.

• If bad TPS, replace and reset closed TPS.

• Replace and reset closed TPS.

TPS “ADAPTATION FAILURE” Fault

It is caused by the idle position moving out of an acceptable range.

RESULT POSSIBLE CAUSES

Sensor has been replaced and TPS closed position not reset

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

Sensor is loose

Throttle bracket is loose

Idle screw or synchronization screw worn or loose

Yes

ACTION

• Reset closed TPS.

• Fix and reset closed TPS.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

DI System Fault Code Chart

SERVICE ACTION

AND

POSSIBLE CAUSES

P1100

Direct injector

MAG

AIR_INJ_1

Open or short circuit

Yes

P1101

Direct injector PTO

AIR_INJ_2

Open or short circuit

Yes

P0201

Fuel injector

MAG

FUEL_INJ_1

Open or short circuit

Yes

P0202

Fuel injector

PTO

FUEL_INJ_2

Open or short circuit

Yes

P0351

Ignition coil, primary winding

MAG

IGN_CYL_1

P0352

Ignition coil, primary winding PTO

IGN_CYL_2

Open or short circuit on ignition primary circuit

Yes

P0335

Encoder

(CPS)

Encoder

Wrong pattern sensed

Yes

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.

Service action:

Check for 1 - 1.6 ohm resistance between system circuits 4-21 and 4-6. 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.

Service action:

Check for 1.7 - 1.9 ohm resistance between system circuits 4-13 and 4-7. 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.

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:

Damaged injector, damaged circuit wires, damaged connector, damaged ECU output pins. ECU failure.

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, damaged ECU output pins. ECU failure.

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, damaged ECU output pins. ECU failure.

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.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

SERVICE ACTION

AND

POSSIBLE CAUSES

P0120

P0220

P0116

P0217

P0110

TPS, PTO

TPS, MAG

P1103 TPS,

WTS

MATS

TPI_1

TPI_2

TPI_1_ADAP

TPI_2_ADAP

Sensor out of range

Yes

COOL_SENS

Sensor out of range

Yes

COOL_RED

Throttle position adaption failure

Overheat warning

Yes

MCT_SENS

Sensor out of range

Yes

Return to idle

Full reset.

Key off and on

Full reset.

Key off and on

Return to idle

As soon as fault is not present

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.

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.

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.

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.

Service action:

Check for resistance approx. 2280 ohms to 2736 ohms at temperature of 19 to 21°C (66 to 70°F) between system circuits 4-9 and

4-11.

Possible causes:

Damaged sensor, damaged circuit wires, damaged connector, damaged ECU pins. ECU failure.

Service action:

Check for debris or blockage in cooling system. Check for resistance approx. 2280 ohms to 2736 ohms at temperature of 19 to

21°C (66 to 70°F) between system circuits 4-9 and 4-11.

Possible causes:

Engine overheated, damaged sensor.

Service action:

Check for resistance approx. 2280 ohms to 2736 ohms at temperature of 19 to 21°C (66 to 70°F) between system circuits 4-16 and

4-19.

Possible causes:

Damaged sensor, damaged circuit wires, damaged connector, damaged ECU pins. ECU failure.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

SERVICE ACTION

AND

POSSIBLE CAUSES

P0106

P0105

MAPS

P1400 EGT

P1401 EGT

P0460

P0230

P0475

P1300

P0563

Fuel level sensor

Fuel pump

RAVE solenoid

Starting system solenoid

(winding)

Battery voltage

SMR2002-031_06_04A.FM

MAP

MAP_ATM

EXH_SENS

EXH_RED

FUEL_SENS

FUEL_PUMP

RAVE

CRANK

BV_HI_WARN

Sensor out of range

Bad atmospheric reading

Sensor out of range

Overheat warning

Sensor out of range

Open or short circuit

Battery voltage high

Yes

Yes, short circuit

Yes, open and short circuit

Yes

Yes, open circuit

Yes

Return to idle

Full reset.

Key off and on

Return to idle

As soon as fault is not present

Return to idle

As soon as fault is not present

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, unexpected reading at idle. Sensor fallen out of housing. Leaking Inlet system, ECU failure.

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, damaged circuit wires, damaged connector, damaged ECU pins. ECU failure.

Service action:

Check for resistance approx. 2280 ohms to 2736 ohms at temperature of 19 to 21°C (66 to 70°F) between system circuits 4-10 and

4-12.

Possible causes:

Damaged sensor, damaged circuit wires, damaged connector, damaged ECU pins. ECU failure.

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.

Service action:

TBD.

Possible causes:

Damaged sensor, damaged circuit wires, damaged connector, damaged ECU pins. ECU failure.

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, damaged ECU output pins. ECU failure.

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, damaged ECU output pins. ECU failure.

Service action:

Check for resistance of 6ohms between system circuits 3-19 and

3-15.

Possible causes:

Damaged solenoid, damaged circuit wires, damaged connector, damaged ECU output pins. ECU failure.

As soon as fault is not present

Possible causes:

Battery failure, rectifier failure, battery terminal connection.

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Section 06 ENGINE MANAGEMENT (DI)

Subsection 04 (DIAGNOSTIC PROCEDURES)

SERVICE ACTION

AND

POSSIBLE CAUSES

P1500

P0562

P1501

P0122

P0222

Battery voltage

Sensor supply (TPS,

MAG and

MAPS)

Sensor supply (TPS,

PTO)

P1600 ECU

P0606

P0325

P1601

ECU

BV_HI_RED

BV_LO_RED

XDRP_1

XDRP_2

ECU_FAULT

Battery voltage very high

BV_LO_WARN

Battery voltage low

Battery voltage very low

Sensor

5 volt supply failure

Yes

TDC and

ECU not initialized

Yes

Internal

ECU faults

Yes

Knock sensor

KNOCK_SENS

Knock sensor failure

Yes, over

4500

Diagnostic cap

SETUP

Sensor

5 volt supply failure

COMMS_CAP

Diagnostic cap is not installed on wiring harness

Yes

Full reset.

Key off and on

Possible causes:

Battery failure, rectifier failure, battery terminal connection.

As soon as fault is not present

Return to idle

Reinitialize from

B.U.D.S.

Full reset.

Key off and on

Return to idle

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.

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.

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.

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.

Service action:

Initialize ECU.

Possible causes:

ECU not initialised, TDC not setup, throttle sensors not initalised.

Service action:

Check ignition leads, coils and correct spark plugs, replace ECU.

Possible causes:

Incorrect software, ignition noise causing errors, internal EE-

PROM failure.

Service action:

Bring engine to 4500 RPM. If fault code appears, check for resistance approx. 4.8 ohms between system circuits 4-2 and 4-17.

Possible causes:

Damaged sensor, damaged circuit wires, damaged connector, damaged ECU pins. ECU failure.

Service action:

Reinstall cap on wiring harness.

Possible causes:

Cap is not installed on wiring harness.

06-04-12

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Section 07 COOLING SYSTEM

Subsection 01 (TABLE OF CONTENTS)

CIRCUIT, COMPONENTS AND CARE...................................................................................

07-02-1

CIRCUIT .............................................................................................................................. 07-02-10

COMPONENTS .................................................................................................................. 07-02-14

CARE .................................................................................................................................. 07-02-17

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07-01-1

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

CIRCUIT, COMPONENTS AND CARE

GTI and GTI LE Models (717 engine)

Loctite

567

Loctite

567

Bleed hose

Tuned pipe water inlet hose

Water injection hose

Loctite

567

F17E04T

SMR2002-032_07_02A.FM

Loctite

567

Engine drain hose

Engine water supply hose

1.2 Nm

(11 lbf in )

Engine water return hose

Pump support

07-02-1 www.SeaDooManuals.net

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

GTX RFI Models (787 RFI engine)

Water injection hose

Loctite

592

1.2 Nm

(11 lbf in )

Loctite 592

Loctite 567

Tuned pipe water inlet hose

1.2 Nm

(11 lbf in )

Loctite 567

Regulator valve water supply hose

Inlet

Outlet

F15E04T

0.11 Nm

(1 lbf in )

0.6 Nm

(5 lbf in )

5 Nm

(44 lbf in )

Outlet

Inlet

Loctite

592

Engine drain hose

07-02-2

SMR2002-032_07_02A.FM

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

GTX Models (947 carburetor-equipped engine)

Loctite

567

Loctite

567

1.2 Nm

(11 lbf

)

Loctite

567

Loctite

567

Loctite

567

F02E09V

Loctite 567

0.11 Nm

(1 lbf

)

0.6 Nm

(5 lbf

)

5 Nm

(44 lbf

)

Loctite

567

1.2 Nm

(11 lbf

)

Loctite

567

SMR2002-032_07_02A.FM

07-02-3 www.SeaDooManuals.net

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

XP and RX Models (947 carburetor-equipped engine)

Loctite

567

Loctite

567

Loctite

567

Loctite

567

Loctite

567

0.11 Nm

(1 lbf in )

0.6 Nm

(5 lbf in )

F08E07T

5 Nm

(44 lbf in )

Loctite 567

Loctite

567

Loctite

567

07-02-4 www.SeaDooManuals.net

SMR2002-032_07_02A.FM

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

RX DI and LRV DI (947 DI engines)

Loctite 567

Loctite

567

0.11 Nm

(1 lbf in )

0.6 Nm

(5 lbf in )

5 Nm

(44 lbf in )

Loctite 567

F12E0XS

Loctite

567

Loctite

567

Loctite

567

Loctite

567

Loctite 243

Body

Silicone sealant

Loctite

567

Loctite

296

Loctite primer N

Loctite 518

SMR2002-032_07_02A.FM

07-02-5 www.SeaDooManuals.net

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

717 Engines

Temperature sensor activates monitoring beeper when temperature exceeds 96 - 99°C (205 - 210°F)

Uppermost point of circuit

(tuned pipe) allows bleeding

Calibrated cylinder head limits water flow

Fresh water enters engine head for additional combustion chamber cooling

Engine water hose outlet

Calibrated outlet fitting limits water flow.

ALSO used as flushing connector

Water flows through tuned pipe and manifold water jackets

Water injected directly into exhaust gases for noise reduction and performance improvement

Tuned pipe bleed hose injects water into muffler to cool exhaust components

Cooling System

Indicator (CSI):

Small stream of water flows out of bleed outlet located under bumper line on front port side

F17E06S

Lowest point of circuit allows draining whenever engine is stopped

Calibrated outlet fitting limits water flow

Pressure zone

07-02-6

SMR2002-032_07_02A.FM

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

787 RFI Engines

Cooling System Indicator (CSI) at

Water injected to cool exhaust ater supply hose of the regulator

Engine water return hose (from cylinder water jacket)

Bleed hose (upper point cylinder head combustion chambers are cooled with the water from the jet pump ater injected in the tuned pipe controlled by the water flow regulator valve for noise reduction and performance improvement cylinder head to tuned pipe water jacket

F15E06S through the tuned pipe and manifold water jackets, then to the

SMR2002-032_07_02A.FM

www.SeaDooManuals.net

Engine heat exchanger water outlet hose exits at the exhaust

Engine water supply hose

Engine heat

Engine drain hose from cylinder exchanger outlet hose supplies water to the engine heat exchanger

Quick connect hose fitting for easy engine draining water supply hose

07-02-7

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

947 Engine — Carburetor-Equipped Models

Drain hose (lowest point of circuit) into muffler to cool exhaust components

Bleed hose (upper point of circuit)

Engine water supply hose

Engine water return hose from tuned pipe water

Engine water supply hose

Exhaust hose (GTX only)

Cooling System Indicator (CSI)

Temperature sensor activates monitoring temperature exceeds 86-94°C (187-201°F) ater injected in the tuned pipe controlled by the water flow

F16E02S

07-02-8 ater flows out of tuned pipe water jacket

SMR2002-032_07_02A.FM

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

947 DI Engines

cool exhaust components

Temperature sensor activate monitoring beeper when temperature

Quick connect for easy engine draining

Drain hose (lowest point of circuit)

Engine water return hose from tuned pipe water

Engine water supply hose from jet pump

Cooling System Indicator (CSI) sensor activates monitoring beeper when temperature ater injected in the tuned pipe

F12E0WS noise reduction and performance ater flows out of tuned pipe water jacket

SMR2002-032_07_02A.FM

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07-02-9

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

CIRCUIT

CAUTION:

All hoses and fittings of the cooling system have calibrated inside diameters to assure proper cooling of the engine. Always replace using appropriate Bombardier part number.

717 Engines

A Serial Cooling System is utilized on the 717 engines , 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 combustion chamber to prevent detonations. Then, water exits cylinder head toward tuned pipe.

3 2

F01E1LA

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 passages located below exhaust ports from tuned pipe.

F01D7HB

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, engine water outlet hose is not connected to the exhaust. 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 circuit.

F01E0FB

717 ENGINE

1. Drain hose

07-02-10

SMR2002-032_07_02A.FM

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

787 RFI Engines

The 787 RFI engines features a heat exchanger system. This system allows water coming out of the cylinder head to circulate through a magneto heat exchanger and the crankcase heat exchanger.

Water is directed to the water inlet fitting at cylinder head.

F15E07A

2 3

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.

F08E05A

1. Water supply hose

DI Models

Water from inlet hose also supplies the water regulator on muffler and magneto cover and crankcase cover.

Water then is expulsed through the pump support drain.

All 947 Engines

Water circulates through the one piece cylinder head which features improved combustion chamber and better spark plug cooling.

F02E0BA

1. Heat exchanger water supply hose

2. Quick connect hose fitting

The water coming out of the engine heat exchanger is evacuated at the exhaust outlet for noise reduction.

947 Engines

The 947 engines has a conventional cooling system. The water is entering the engine by the water inlet fitting at the cylinder head.

As with other models, the water supply is provided by a pressurized area in the jet pump between the impeller and venturi.

F06D21A

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

Water enters cylinder block water jackets and is directed to the water jackets of the exhaust manifold and tuned pipe head through passages located above and below exhaust ports.

DI Models

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 transom.

Water continues to flow in the crankcase water jacket to cool the crankcase area to then be expulsed to the transom area.

All 947 Engines

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.

F06D20A

1. Water passages

Water exits tuned pipe water jackets through an outlet fitting.

F06E0IA

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).

F06E08A

1. Engine water outlet

Water circulates in the water outlet hose and is expelled out of the cooling system through a fitting located in the jet pump support on the transom of the watercraft.

947 Carburetor-Equipped Engines

Water flows out of tuned pipe water jacket from upper fitting of tuned pipe and is expulsed to the cooling system indicator.

F06E0BA

1. Bleed hose

07-02-12

SMR2002-032_07_02A.FM

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

The water supply of the water flow regulator is provided by the water supply hose coming from the pump.

F06E09A

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.

F06E0CA

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.

F06E0AA

1. Injection fitting

All Models

CAUTION:

Never modify cooling system arrangement, otherwise serious engine damage could occur.

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 - 94°C (187 - 201°F).

07-02-13

SMR2002-032_07_02A.FM

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Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

COMPONENTS

Clamp

To cut or secure non-reusable Oetiker clamps of cooling system hoses, use pliers (P/N 295 000 070).

The elbow fitting can be identified by using the number stamped onto the fitting or by measuring its inside diameter. Refer to the following illustration and chart.

F01B2KA

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 level 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.

F00E04A

1. Stamped number

A. Outlet diameter = 4.6 mm (.181 in)

B. Inlet diameter = 5.5 mm (.219 in)

STAMPED

NUMBER

FITTING

P/N

INLET

DIAMETER

OUTLET

DIAMETER

293 700 016

293 710 048

5.5 mm

(.219 in)

4.0 mm

(.157 in)

4.6 mm

(.181 in)

3.5 mm

(.139 in)

Water Flow Regulator Valve

A water flow regulator valve is mounted on models with the 787 RFI and 947 engines so that they can produce the maximum horsepower output and yet maintain the necessary diameter of the injection fitting at the tuned pipe head for unobstructed water flow.

07-02-14 www.SeaDooManuals.net

SMR2002-032_07_02A.FM

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

The water flow regulator valve no. 2 is mounted directly onto the muffler.

F01E1FA

1 2

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 valve. A calibrated water injection fitting of 3.0 mm (.118 in) on carburetor-equipped models and 4.0 mm (.156 in) on DI models inside diameter limits water flow into the muffler.

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 water flow regulator valve, otherwise serious engine damage can occur. In many countries it is illegal to tamper with this valve as this will affect 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.

F01E2BA

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.

F01E2CA

HIGH SPEED OPERATION

1. Water entering regulator valve

2. Water exiting regulator valve (more restriction)

3. Water injected in the muffler

SMR2002-032_07_02A.FM

07-02-15 www.SeaDooManuals.net

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

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

Remove the cover no. 4 of the valve by releasing the spring no. 3 .



WARNING

Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover.

F01E1SA

1. Fitting

Unscrew the tapered needle no. 6 .

NOTE: Hold the valve to prevent it from turning.

F01E1RA

1. Spring

2. Cover

Remove fitting no. 5 from valve housing.

F01E1TA

1. Tapered needle

Remove the tapered needle from valve housing.

07-02-16

F01E20A

1. Remove tapered needle

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SMR2002-032_07_02A.FM

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

Pull the valve slightly. Using pliers, release the clamp which retains the bellows no. 8 .

Remove valve no. 7 and bellows no. 8 .

For winterization of cooling system, refer to STOR-

AGE.

GTI and GTI LE Models

When servicing the hull, always rotate watercraft counterclockwise (seen from the rear). Rotating watercraft on the opposite side could allow residual water in tuned pipe to enter the engine and cause damage.

Max. 90

F01E21A

Loosen clamp to separate valve from bellows.

F01E24A

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 depending 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.

SMR2002-032_07_02A.FM

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F01L45C

All Other Models

When servicing the hull, always rotate watercraft clockwise (seen from the rear). Rotating watercraft on the opposite side could allow residual water in tuned pipe to enter the engine and cause damage.

max. 90°

F06L0GA

TYPICAL

07-02-17

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

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).

F08E03A

XP MODELS

1. Hose pincher on water supply hose

F01B23A

This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isn’t any exhaust pressure to carry the water out the exhaust outlet.

CAUTION:

Failure to do this may result in damage 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 maximum towing speed of 24 km/h (15 MPH).

Snugly install the hose pincher on the water supply hose as shown in the following illustrations.

F07E03A

GTX MODELS

1. Hose pincher

F02E04A

GTI AND GTI LE MODELS

1. Hose pincher on water supply hose

07-02-18

F07E04A

GTX RFI MODELS

1. Hose pincher

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SMR2002-032_07_02A.FM

Section 07 COOLING SYSTEM

Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

F12E01A

TYPICAL — RX SERIES AND LRV DI MODELS

1. Hose pincher on water supply hose on this side of the T-fitting

CAUTION:

When finished towing the watercraft, the hose pincher must be removed before operating it.

SMR2002-032_07_02A.FM

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07-02-19

Section 08 FUEL SYSTEM

Subsection 01 (TABLE OF CONTENTS)

FUEL CIRCUIT........................................................................................................................

08-02-1

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

08-02-7

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

08-02-7

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

08-02-9

ASSEMBLY......................................................................................................................... 08-02-10

FUEL SYSTEM PRESSURIZATION ................................................................................... 08-02-11

AIR INTAKE ............................................................................................................................

08-03-1

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

08-03-5

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

08-03-6

CARBURETOR .......................................................................................................................

08-04-1

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

08-04-2

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

08-04-2

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

08-04-3

DISASSEMBLY AND INSPECTION...................................................................................

08-04-3

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

08-04-5

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

08-04-7

ADJUSTMENTS ................................................................................................................

08-04-7

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08-01-1

FUEL CIRCUIT

GTI and GTI LE Models

Body

GTI/GTI LE

Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

2 Nm

(18 lbf in )

1.2 Nm

(11 lbf in )

3 Nm

(27 lbf in )

6 Nm

(53 lbf in )

1.2 Nm

(11 lbf in )

22 Nm

(16 lbfft)

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

Dielectric grease

3 Nm

(27 lbf in )

4 Nm

(35 lbf in )

1.2 Nm

(11 lbf in )

1.2 Nm

(11 lbf in )

Engine

F06F18S

SMR2002-033_08_02A.FM

08-02-1 www.SeaDooManuals.net

Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

GTX Models

Body

2 Nm

(18 lbf in )

1.2 Nm

(11 lbf in )

3 Nm

(27 lbf in )

6 Nm

(53 lbf in )

1.2 Nm

(11 lbf in )

1.2 Nm

(11 lbf in )

1.2 Nm

(11 lbf in )

22 Nm

(16 lbfft)

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

3 Nm

(27 lbf in )

1.2 Nm

(11 lbf

Dielectric grease

1.2 Nm

(11 lbf in )

Engine

1.2 Nm

(11 lbf in ) in )

4 Nm

(35 lbf in )

F06F0RS

08-02-2

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Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

XP Models

1.2 Nm

(11 lbf in )

Engine

1.2 Nm

(11 lbf in )

6 Nm

(53 lbf in )

1.2 Nm

(11 lbf in )

1.2 Nm

(11 lbf in )

2 Nm

(18 lbf in )

22 Nm

(16 lbfft)

4 Nm

(35 lbf in )

F08F06S

SMR2002-033_08_02A.FM

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Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

GTX RFI Models

Body

F02F27S

08-02-4

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

22 Nm

(16 lbfft)

14 www.SeaDooManuals.net

SMR2002-033_08_02A.FM

Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

RX (carburetor-equipped models)

Body

2 Nm

(18 lbf in )

1.2 Nm

(11 lbf in )

3 Nm

(27 lbf in )

6 Nm

(53 lbf in )

1.2 Nm

(11 lbf in )

1.2 Nm

(11 lbf in )

1.2 Nm

(11 lbf in )

22 Nm

(16 lbfft)

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

Dielectric grease

3 Nm

(27 lbf in )

1.2 Nm

(11 lbf

1.2 Nm

(11 lbf in )

Engine

1.2 Nm

(11 lbf in ) in )

4 Nm

(35 lbf in )

F06F0RV

SMR2002-033_08_02A.FM

08-02-5 www.SeaDooManuals.net

F12F15S

08-02-6

Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

DI Models

22 Nm

(16 lbfft)

4 Nm

(35 lbf in )

4 Nm

(35 lbf in )

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SMR2002-033_08_02A.FM

Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

GENERAL



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 described in ENGINE MANAGEMENT (DI) under

FUEL SYSTEM.



WARNING

Whenever repairing the fuel system, always verify for water infiltration in reservoir. Replace any damaged, leaking or deteriorated fuel lines.

When working with fuel, pay attention to the following warning.



WARNING

Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Always wipe off any fuel spillage from the watercraft.

To secure or cut Oetiker clamps on fuel lines, use pliers (P/N 295 000 070).

F01B04A

1. Securing clamp

F01B03A

1. Cutting clamp

F01B05A

1. Securing clamp in limited access

When replacing fuel lines on SEA-DOO watercraft, be sure to use “B1” hoses as available from

Bombardier parts department. On DI models , use hoses ass’y available as parts replacement only.

This will ensure continued proper and safe operation.



WARNING

Use of improper fuel lines could compromise fuel system integrity.

REMOVAL

Fuel Filter

All Models except XP, GTI, GTI LE, RFI and DI

Models

Open storage compartment cover.

Remove basket.

XP Models

Open engine cover and remove basket.

08-02-7

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Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

GTI, GTI LE Models

Remove seat.

Carburetor-Equipped Models

Turn the fuel valve to OFF position.



WARNING

The engine must not be running and fuel valve must be set to OFF position. Gasoline is flammable and explosive under certain conditions. Always work in a well ventilated area.

Unscrew fuel filler cap to remove any fuel pressure in system.

Unscrew the fuel filter bowl no. 2 counterclockwise then pull toward the bottom.

GTX 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).

DI Models

A replaceable inline filter is located near the fuel tank. Refer to ENGINE MANAGEMENT (DI) section.



WARNING

The inline filter needs to be replaced only with

4 Oetiker clamps (2 on each side).

CAUTION:

A pressure test needs to be complete after replacement.

Fuel Baffle Pick Up

All Models except GTX RFI and DI

NOTE: The baffle pick up has an integrated fuel sender for the fuel gauge.

F01F01A

TYPICAL

Step

: Loosen counterclockwise

Step

: Pull

Pull fuel filter no. 1 toward the bottom.

F01F04A

TYPICAL

08-02-8

F01F20A

1. Pick up tube

2. Fuel sensor

3. Baffle pick up

Disconnect BLACK negative cable, then RED positive cable of battery.



WARNING

Always disconnect battery cables exactly in the specified order, BLACK negative cable first.

RX, GTI AND GTI LE Models

Open storage compartment cover.

Remove storage basket from watercraft ( if so equipped ).

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Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

Remove rear panel of storage compartment ( if so equipped ).

Siphon fuel tank.

Remove steering assembly. Refer to STEERING

SYSTEM for procedure.

GTX Models

Syphon fuel tank.

Remove glove box.

XP Models

Tilt seat. Refer to HULL/BODY for procedure.

Remove access plug on body.

Syphon fuel tank.

All Models except RFI and DI

Disconnect fuel lines from baffle pick up and loosen lower clamp no. 10 .

Fuel tank

All Models

NOTE: On all models (except GTX, GTX RFI and

LRV DI ), it is necessary to remove the engine. Refer to REMOVAL and INSTALLATION 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.

INSPECTION

Fuel Filter

All Models except GTX RFI and DI

Inspect fuel filter condition. Carefully use low pressure compressed air to clean fuel filter. Replace 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 .

F02F1OA

TYPICAL

1. Disconnect fuel hoses

2. Loosen lower clamp

Disconnect wiring harness of fuel sender.

Remove baffle from fuel tank.

All Models

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 and DI Models

Refer to appropriate ENGINE MANAGEMENT section.

F01F02A

1. Gasket in bowl

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Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)



WARNING

Ensure that there is no leakage from the fuel filter.

RFI Models

The filter at fuel pump inlet is not replaceable individually. 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 permanently 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 ensure that clamps no. 4 are well positioned and tightened. Torque clamps to 4 N•m (35 lbf•

Pressure Relief Valve

This valve will eliminate fuel spillage when the watercraft is upside down. If pressure is built up in fuel system the valve should open at 3.5 kPa (0.5

PSI) for XP , DI and RFI models and at 10 kPa (1.5

PSI) for all other models to release the pressure.



WARNING

If pressure relief valve is stuck, the pressure in fuel system will build up and it may cause fuel leakage in engine compartment.

NOTE: It is a one-way valve with an arrow to indicate 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 GTX RFI and DI

Inspect filter no. 9 of baffle pick up. Clean or replace 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, replace fuel tank no. 14 .

Check with your finger to feel the inside and outside surfaces of fuel tank. Flex fuel tank necks to ensure there are no hidden cracks.

3 A 5

F07F06A

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 appear on the inner side of the necks at approximately 4 mm (5/32 in) from the base of the neck. It is a normal situation to have a molding seam and it should not be confused with a crack.

ASSEMBLY

Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following.

Baffle Pick Up

All Models except GTX RFI and DI

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 N•m (27 lbf•

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Section 08 FUEL SYSTEM

Subsection 02 (FUEL CIRCUIT)

FUEL SYSTEM PRESSURIZATION



WARNING

Whenever doing any type of repair on watercraft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine. Ensure to verify fuel line ends for damage. Always cut damaged end before reinstallation.

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.

RES

F01F0KA

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 GTX RFI and DI ).

– Pressurize fuel system to 34 kPa (5 PSI).

– If no leaks are found, turn fuel valve to ON position 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 components, 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.



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.

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 and DI Models

Refer to the appropriate ENGINE MANAGEMENT section.



WARNING

Prior to installing the safety lanyard, refer to the appropriate ENGINE MANAGEMENT section for safety precautions to take.

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Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

AIR INTAKE

717 Engines

10 Nm

(89 lbf in )

10 Nm

(89 lbf in )

F02F2CS

Loctite 518

10 Nm

(89 lbf in )

Loctite

243

Loctite 518

Loctite 243

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08-03-1

10 Nm

(89 lbf in )

Loctite

243

F15F01T

08-03-2

Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

787 RFI Engine

10 Nm

(89 lbf in )

Loctite

243

10 Nm

(89 lbf in )

6 www.SeaDooManuals.net

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947 Carburetor-Equipped Engines

Loctite 243

11 12

Loctite

243

Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

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08-03-3

Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

947 DI Engines

F12F14S

08-03-4

Loctite 243

1112

Super

Lube

Loctite

243

Loctite 243

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Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

REMOVAL

717 and 787 RFI Engines

Air Intake Silencer Cover

Unlock the 6 retaining slides holding air intake silencer cover no. 1 and remove cover.

1 2

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 engine ) or to the exhaust manifold ( 787 engine ).

F01F2OA

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 .

F00F03A

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 .

All 947 Engines

Air Intake Silencer

Pull hair pin out to allow removal of clip no. 2 .

F00F02A

1. Retaining plate

2. Remove screws

SMR2002-034_08_03A.FM

F00F0FA

1. Air intake silencer

2. Clip

3. Hair pin

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08-03-5

Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

Unlock the clip no. 2 on top of air intake silencer.

Remove bolts retaining both air ducts to engine (both sides).

XP Model

Pull the air silencer forward to remove it from the lower bracket no. 4 and remove it in a rotating movement.

F08F08A

1. Remove bolts

Pull air ducts out.

F08F09A

1. Air duct

On XP model , detach retaining straps and pull oil reservoir out.

NOTE: Do not disconnect oil lines.

Push the air intake silencer out of the carburetor adapter no. 3 and throttle body.

GTX and RX Models

Pull the air intake silencer rearward to remove it from the lower bracket no. 4 and remove it in a rotating movement.

08-03-6

F08F0AA

XP MODEL

The air intake silencer is a molded piece and it can not be opened. It has an integrated flame arrester.

ASSEMBLY

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.

717 Engines

Flame Arrester Base

Apply Loctite 518 on mating surfaces of flame arrester base no. 7 .

Apply Loctite 243 (blue) on screws no. 10 and torque to 10 N•m (88 lbf•

Flame Arrester

Inspect condition of flame arrester no. 5 . Replace or clean as necessary. rester.

www.SeaDooManuals.net



WARNING

Do not operate watercraft without flame ar-

SMR2002-034_08_03A.FM

Section 08 FUEL SYSTEM

Subsection 03 (AIR INTAKE)

Gasket

Inspect condition of gasket no. 9 . Make sure to properly install gasket.

All 947 Engines

Air Intake Silencer

Ensure that support plate edges no. 14 are properly crimped to air intake silencer. Use pliers as necessary.

Make sure that gaskets no. 11 are installed into carburetor holes of air intake silencer or throttle bodies on DI engines .

Check O-rings no. 12 on carburetor intake adaptors or throttle bodies on DI engines 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 carburetor intake adaptor or throttle bodies on DI engines and latch in place.

Clip air intake silencer back in place.



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.

Properly reinstall hair pin to secure clip no. 2 .

947 DI Engines

Ensure the elbow adaptor is well inserted and that it has not pushed the gasket inside the air box.

All 947 Engines

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 vehicle 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.

1 2 3 7 8

F06F0VA

4 6 5

TYPICAL — 947 CARBURETOR-EQUIPPED 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

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

CARBURETOR

For fuel system on RFI and DI models , refer to appropriate ENGINE MANAGEMENT section.

Mikuni BN-40i and BN-46i

20 Nm

(15 lbfft)

Synthetic grease

Loctite

243

Synthetic grease

21 13

Loctite 243

Anti-seize lubricant

PTO/MAG

PTO

F02F1ZT

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

GENERAL

The following illustration shows which part of the carburetor begins to function at different throttle plate openings.

F01F13A

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(s) is (are) 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(s) from engine, proceed as follows:

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.

F06F0LA

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(s).

1 1

F07F03A

TYPICAL

1. Remove screws

Remove carburetor(s).

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

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 carburetor to rust very rapidly. Repaint if necessary.

Carburetor body and jets should be cleaned with a carburetor cleaner. Follow manufacturer’s instructions.



WARNING

Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.

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).

SMR2002-035_08_04A.FM

F01F0XA

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.



WARNING

Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vacuum.

F01F0WA

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.

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

Internal Fuel Filter

To verify condition of filter no. 5, proceed as follows:

Remove pump cover no. 16 , gasket no. 17 , diaphragm no. 18 and then pump body no. 4 and diaphragm no. 19 .

Remove filter no. 5 from carburetor body then clean filter and blow carefully with compressed air

(low pressure).

Replace filter if damaged.

– Obstruct outlet nipple with a finger and hold while pumping.

– Pump tester until it reaches 28 kPa (4 PSI).

1 2 3

F01F0YA

TYPICAL

1. Filter

Fuel Accelerator Pump

Disconnect inlet and outlet hoses from accelerator pump nipples.

F06F07A

1. Pump gauge tester

2. Hose installed to inlet nipple

3. Outlet nipple obstructed

Diaphragm must stand pressure for 10 seconds.

If pressure drops, replace accelerator pump diaphragm.

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.



WARNING

Some fuel may be present in fuel pump.

F06F06A

1 2

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. 20 .

08-04-4

F06F08A

TYPICAL

1. Apply pressure and vacuum at inlet nipple

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SMR2002-035_08_04A.FM

Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

To check the injector, install pump gauge tester to the injector hose.

NOTE: Injectors are also equipped with check valves.

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.

F04F0JB

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 position components together. Refer to previous illustrations 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.

F01F0ZA

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.

1 2

F01F0HA

HIGH LEVER

Step

: Depress here

Step

: Push tab down

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

1 2

F01F34A

LOW LEVER

Step

: Depress here

Step

: Pry up here

POP-OFF Pressure Test

Proceed as follows:

– Install pump gauge tester on carburetor fuel inlet nipple.

– Obstruct fuel return nipple with a finger.

– Pump tester until inlet release pressure is reached (seen by a sudden pressure drop).

3 1

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 carburetor 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 condition for proper jetting.

NOTE: To have access to pilot jet no. 10 or main jet no. 9 , check valve housing must be removed.

F01F10A

TYPICAL

1. Pump gauge tester

2. Install on inlet nipple

3. Obstruct outlet nipple

Refer to the following table for pop-off pressure specifications:

MODELS

GTI , GTI LE

XP, GTX

POP OFF PRESSURE min./max. (PSI)

36/40

19/23

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.

08-04-6

F01F11A

TYPICAL

1. Pilot jet

2. Gasket

3. Main jet

4. Check valve housing removed

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

Check Valve Assembly

The check valve is needed if a back pressure occurs into carburetor. It will prevent fuel from flowing back into carburetor lower portion.

Inspect check valve no. 11 . It should be free of holes, tears or imperfections. Replace as needed.

F01F12A

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.

Fuel Accelerator Pump

Lubricate pump plunger, roller and cam with synthetic grease (P/N 293 550 010) and roller shaft with BOMBARDIER LUBE (P/N 293 600 016).

INSTALLATION

Carburetors

At installation, pay attention to the following:

Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for the 787 RFI engine ).

Apply synthetic grease on screws no. 20 . Then, install screws no. 20 with lock washers no. 21 and torque to 20 N•m (15 lbf•ft).

Fuel Lines and Hose Clamps

If fuel line ends are damaged, cut damaged end before reinstallation.

Properly install clamps.



WARNING

Make sure there is no leak in fuel system.

For fuel system pressurization, refer to FUEL CIR-

CUIT.

ADJUSTMENTS

GTI/LE California

Carburetor Adjustment

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 engine not to meet the California emission control regulations.

Twin Carburetor Synchronization

NOTE: Trying to bypass the anti-tamper screws could damage the carburetor. It could also change the engine emission level and lead the engine not to meet the California emission control regulations.

With idle speed screw not touching throttle lever stopper on MAG carburetor, both throttle plates are in closed position.

F06F06B

2 1

TYPICAL

1. Apply synthetic grease to plunger

2. Apply BOMBARDIER LUBE on roller shaft

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08-04-7

Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

F01F31A

1 2

TYPICAL

1. Stopper

2. Idle speed screw

Loosen jam nuts on carburetor linkage and adjust linkage with adjustment nut.

Make sure threads length is the same on each side of linkage and flat surfaces of both ends are parallel with each other.

F01F32A

TYPICAL

1. Throttle lever PTO side

2. Marks

CAUTION:

Throttle plates must open simultaneously, otherwise this will cause engine to vibrate and/or misfire.

Throttle Cable Adjustment

NOTE: Do not activate throttle lever unnecessarily. Carburetors are equipped with fuel accelerator pump. This pump is injecting fuel into carburetors each time throttle lever is depressed.

717 Engine

Lubricate cable with BOMBARDIER LUBE lubricant.

Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket.

F01F1YA

1. Jam nuts

2. Adjustment nut

3. Flat surfaces

Tighten jam nuts and torque to 3 N•m (27 lbf•

NOTE: Grease carburetor linkage at both ends with synthetic grease (P/N 293 550 010).

Connect linkage between both carburetor levers.

Ensure both throttle plates are still in closed position.

NOTE: The linkage installation is done with the marks located near PTO carburetor throttle lever to ease adjustment if to be performed in the watercraft.

F01K08A

1. Must touch handlebar grip

Ensure carburetor throttle plate(s) is (are) fully open at full throttle position. At this position, throttle lever 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.

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Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

F01G0YC

3 1 2

717 ENGINE

1. Adjustment nut

2. Jam nut

3. Throttle lever stopper

Tighten jam nut and recheck adjustment.



WARNING

Make sure idle speed screw contacts stopper when throttle lever is fully released at handlebar.

After throttle cable adjustment, always proceed with the oil injection pump cable adjustment. Refer to OIL INJECTION PUMP.

CAUTION:

Improper oil injection pump synchronization with carburetor can cause serious engine damage.

947 Engine

Throttle cable is equipped with a sensor which will send a signal to the MPEM at 80% throttle opening in order to control the spark advance.

F08F0CA

2 1

THROTTLE CABLE ASSEMBLY

1. Sensor

2. Throttle lever section

3. Carburetor section

4. Oil pump section

4 3

NOTE: Always perform the throttle cable adjustment in the specified order, as described in following procedure.

Unscrew idle adjustment screw to obtain a small gap between stopper and screw.

SMR2002-035_08_04A.FM

F06F0KA

1. Idle speed screw

1 www.SeaDooManuals.net

08-04-9

Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

Ensure throttle plates are completely closed on both carburetors.

Loosen jam nut and turn adjustment nut to eliminate all the slack in the throttle cable between sensor and carburetor.

Tighten jam nut.

F02F21A

1. Jam nut

2. adjustment nut

3. Throttle cable

Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket.

F02F20A

947 ENGINE

1. Throttle cable

2. Adjustment nut

3. Jam nut

Turn idle adjustment screw clockwise until it comes in contact with stopper. Refer to IDLE SPEED

SCREW ADJUSTMENT section for the proper adjustment.

Adjust oil pump cable. Refer to OIL INJECTION

PUMP.

NOTE: It is important to adjust oil pump cable prior to finalize adjustment of throttle cable.

CAUTION:

Improper oil injection pump synchronization with carburetor throttle opening can cause serious engine damage.

Adjust throttle cable to obtain proper lever position at full throttle.

Turn adjuster knob as required to obtain proper throttle lever adjustment.

F01K08A

1. Lever must touch handlebar grip

CAUTION:

Improper cable adjustment will cause strain on cable and/or damage cable bracket or throttle lever at handlebar.

All models except GTI LE California

Low Speed Screw Adjustment

08-04-10

F06F0GA

717 ENGINE

1. Low speed screw

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SMR2002-035_08_04A.FM

Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

CAUTION:

Do not attempt to adjust high speed screw by removing plastic cap.

F06F0HA

947 ENGINE

1. Low speed screw (PTO side shown)

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.

ENGINE TYPE

717

947

LOW SPEED SCREW

1.0 ± 0.25 turns

1.5 ± 0.25 turns

NOTE: Turning screw clockwise leans mixture and turning screw counterclockwise enriches mixture.

Start and warm up engine.

CAUTION:

If watercraft is out of water, engine must be cooled using the flush kit.

Check that engine idles and runs smoothly. Make sure engine reacts quickly to throttle lever depression. If necessary, readjust low speed screw

(± 1/4 turn).

NOTE: On twin carburetor engines, both low speed screws must be adjusted exactly the same way.

Never adjust screws more than 1/4 turn at a time.

All models except GTI LE California

High Speed Screw

The high speed screw no. 14 is sealed with a plastic cap that allows an adjustment of 1/4 turn.

NOTE: Turning screw 1/4 turn counterclockwise enriches mixture and turning screw clockwise leans mixture.

F06F0IA

717 ENGINE

1. High speed screw

F06F0PB

947 ENGINE

1. High speed screw (PTO side shown)

Idle Speed Screw

Turning screw no. 15 clockwise increases engine idle speed and turning screw counterclockwise decreases engine idle speed.

SMR2002-035_08_04A.FM

08-04-11 www.SeaDooManuals.net

Section 08 FUEL SYSTEM

Subsection 04 (CARBURETOR)

Fuel Accelerator Pump

All Engines

Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM for the 717 engines and

1400 RPM for the 947 engines in water.

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.

F01G0YD

717 ENGINE

1. Idle speed screw

F02F1QA

F06F0KA

08-04-12

947 ENGINE

1. Idle speed screw

NOTE: On twin carburetor engines, there is only one 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 temperature.

CAUTION:

If watercraft is out of water, engine must be cooled using the flush kit.

Turn screw so that engine idles at 1500 RPM in water or 3000 RPM out of water.

TYPICAL

1. Adjustment screw

2. Small gap

NOTE: Turning the adjustment screw clockwise will increase the gap.

Choke Camble

Ensure choke lever has a free-play of 0.5 to 2.0 mm

(1/64 to 5/64 in).

F07F02A

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.

Tighten jam nut and recheck adjustment.

SMR2002-035_08_04A.FM

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Section 09 LUBRICATION SYSTEM

Subsection 01 (TABLE OF CONTENTS)

OIL INJECTION SYSTEM ......................................................................................................

09-02-1

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

09-02-6

OIL SYSTEM PRESSURIZATION ......................................................................................

09-02-6

OIL INJECTION PUMP ..........................................................................................................

09-03-1

OIL PUMP IDENTIFICATION .............................................................................................

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

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

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