1998 seadoo gtx shop manual
www.SeaDooManuals.net
Legal deposit:
National Library of Quebec
National Library of Canada
All rights reserved. No parts of this manual may be
reproduced in any form without the prior written
permission of Bombardier Inc.
©
Bombardier Inc. 1998
Printed in Canada
*Registered trademarks of Bombardier Inc.
®
Loctite® is a trademark of Loctite Corporation
Snap-on® is a trademark of Snap-on Tools Corporation
Gelcote® is a trademark of Gelcote International Limited
www.SeaDooManuals.net
TABLE OF CONTENTS
SECTION
PAGE
SUBSECTION
SAFETY NOTICE ..................................................................................................................................
II
01
MAINTENANCE
01 - Table of contents ......................................................................
02 - Periodic inspection chart ...........................................................
03 - Flushing and lubrication.............................................................
04 - Storage......................................................................................
01-01-1
01-02-1
01-03-1
01-04-1
02
ENGINE
01 - Table of contents ......................................................................
02 - Magneto system .......................................................................
03 - Crankcase..................................................................................
02-01-1
02-02-1
02-03-1
03
COOLING SYSTEM
01 - Table of contents ......................................................................
02 - Circuit ........................................................................................
03-01-1
03-02-1
04
FUEL SYSTEM
01 - Table of contents ......................................................................
02 - Fuel injection .............................................................................
04-01-1
04-02-1
05
ELECTRICAL
SYSTEM
01 - Table of contents ......................................................................
02 - Ignition system..........................................................................
03 - Charging system .......................................................................
05-01-1
05-02-1
05-03-1
06
TECHNICAL DATA
01 - GTX RFI Model..........................................................................
06-01-1
07
WIRING DIAGRAM
01 - GTX RFI Model..........................................................................
07-01-1
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I
SAFETY NOTICE
SAFETY NOTICE
0
This manual was primarily published to be used by watercraft technicians trained by the manufacturer who are already familiar with all service and maintenance procedures relating to Bombardier made
Sea-Doo watercraft.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product.
The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and/or distributor assistance should be sought in case of doubt.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking disk,
lock nut) must be installed or replaced with new ones, where specified. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
◆
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
-
CAUTION
Denotes an instruction which, if not followed, could severely damage watercraft components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier watercraft and has been utilized safely
and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or
injuries resulting from the improper use of the contents. We strongly recommend that any services be
carried out and/or verified by a highly skilled professional technician. It is understood that certain modifications may render use of the watercraft illegal under existing federal, provincial and state regulations.
II
www.SeaDooManuals.net
Section 01 MAINTENANCE
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
0
PERIODIC INSPECTION CHART............................................................................................
01-02-1
FLUSHING AND LUBRICATION............................................................................................
GENERAL ...........................................................................................................................
PROCEDURE ......................................................................................................................
01-03-1
01-03-1
01-03-1
STORAGE...............................................................................................................................
01-04-1
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01-01-1
Subsection 02
Section 01 MAINTENANCE
(PERIODIC INSPECTION CHART)
PERIODIC INSPECTION CHART
0
NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency.
FREQUENCY
DESCRIPTION
Every
10 hours
Lubrication/corrosion protection of metallic components
Engine ignition timing
Spark plug replacement
Fuel injector cleaning
Fuel injection sensors verification
Throttle cable, inspection/lubrication
Flame arrester inspection
Throttle cable adjustment
RAVE valve cleaning
Every
25 hours
Every
50 hours
Every
100 hours or
seasonally
➀
➀
Engine counterbalance shaft oil level
Water flow regulator valve inspection
Oil injection pump adjustment
Oil filter inspection
Oil filter replacement
Engine head bolts, retorque
Steering system inspection
Reverse system/reverse cable adjustment
Fastener tightening (flame arrester support, throttle body, engine mount, exhaust
system, etc.)
Muffler, battery and reservoir fastening devices
Fuel/oil lines, check valve and hose inspection, fuel system pressurization
Fuel/vent line pressure relief valve inspection
Bailer pick up inspection
Battery condition
Ground connections (starter, battery, etc.)
Monitoring beeper
Jet pump reservoir oil level/oil condition
Jet pump oil replacement
Jet pump cover pusher inspection
Impeller condition and impeller/wear ring clearance
Drive shaft boot/spline condition (both ends)
PTO flywheel lubrication
Floating ring and boot inspection
Water intake grate condition
Hull condition
Cooling system flushing
➁
➁
➁
➂
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.
01-02-1
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Section 01 MAINTENANCE
Subsection 03 (FLUSHING AND LUBRICATION)
FLUSHING AND LUBRICATION
0
GENERAL
Flushing the cooling system with fresh water is
essential to neutralize corroding effects of salt or
other chemical products present in water. It will
help to clean up sand, salt, shells or other particles
in water jackets (engine, exhaust manifold, tuned
pipe) and/or hoses.
Flushing and engine 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
1
F06E01A
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.
1. Water outlet
NOTE: A quick connect adapter is supplied with
the watercraft and can be used to ease garden
hose installation.
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.
◆
1
F00E01A
1. Quick connect adapter
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.
To flush engine, connect a garden hose to the water outlet located at the rear of the watercraft.
F07E01A
1
1. Garden hose installed with quick connect adapter
01-03-1
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Section 01 MAINTENANCE
Subsection 03 (FLUSHING AND LUBRICATION)
Start the engine then immediately open the water
tap.
;
WARNING
;
Do not touch any electrical parts or jet pump
area when engine is running.
-
Wipe up any residual water from the engine.
Remove spark plug cables and connect them on
the grounding device near the tuned pipe.
WARNING
Always use spark plug cable grounding device when removing spark plugs.
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.
2
1
3
1
F07H0AA
1. Grounding device
F01F25A
1. Air intake silencer
2. Pull plug
3. Spray BOMBARDIER LUBE here
NOTE: Lubrication of engine should be done at
least for 1 minute.
Close the water tap then stop the engine.
-
Remove both spark plugs and spray BOMBARDIER LUBE lubricant into each cylinder.
NOTE: For the storage period, use Bombardier
storage oil (P/N 413 711 600).
Fully apply the throttle lever then depress the
start/stop button to crank the engine a few turns
to distribute the oil onto cylinder wall.
Apply anti-seize lubricant on spark plug threads
then reinstall them.
Reinstall plug on air intake silencer cover.
NOTE: Engine fogging should be done whenever
the watercraft is to be stored for a few days or a
long period.
-
CAUTION
Always close the water tap before stopping
the engine.
Never leave rags or tools in the engine compartment or in the bilge.
Disconnect the garden hose.
-
CAUTION
CAUTION
Remove quick connect adapter after flushing operation (if used).
01-03-2
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Section 01 MAINTENANCE
Subsection 04 (STORAGE)
STORAGE
0
Engine Draining
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.
-
CAUTION
Water in engine must be free to flow out.
Should water freeze in engine, severe damage will occur.
Fuel System
Sea-Doo Fuel Stabilizer (P/N 413 408 600) should
be added in fuel tank to prevent fuel deterioration.
Follow manufacturer’s instructions for proper use.
NOTE: Fuel stabilizer should be added prior engine lubrication.
◆
WARNING
Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area.
Cooling System Flushing and Engine
Internal Lubrication
1
F07E05A
1. Disconnect this hose
Water should flow out of the fitting (magneto cooling circuit) and hose (crankcase heat exchanger).
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 01-03.
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 the 1998 Sea-Doo Shop Manual for
proper procedure.
F07E06A
1
1
1. Make sure water flows out of fitting and hose
01-04-1
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Section 01 MAINTENANCE
Subsection 04 (STORAGE)
PTO FLYWHEEL
Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).
-
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
-
Do not lubricate excessively. Immediately
stop when a slight movement is noticed on
rubber boot.
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.
F01I0BA
Anticorrosion Treatment
1
1. Grease PTO flywheel
-
CAUTION
Never leave any clothing, tool or other objects near PTO flywheel and drive shaft.
Battery
For battery removal, cleaning and storage, refer to
the 1998 Sea-Doo Shop Manual.
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.
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 front seat should be partially left opened during storage. This will avoid engine compartment
condensation and possible corrosion.
Additional Recommended Protection
In cool regions (where freezing point may be encountered), cooling system should be filled with
water and antifreeze solution.
-
CAUTION
Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically recommended for aluminum engines.
01-04-2
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Section 01 MAINTENANCE
Subsection 04 (STORAGE)
Install a hose pincher to water return hose of the
magneto cooling circuit.
F06E0FA
F07E07Y
TYPICAL
1. Hose pincher installed on the engine water supply hose
1
1. Hose pincher to water return hose
Disconnect engine water return hose.
F06E0EA
1
1
TYPICAL
1. Disconnect engine water return hose
Install a hose pincher to engine water supply
hose.
Temporarily install a short piece of hose to engine
water outlet at cylinder head.
Insert a funnel into hose and pour antifreeze mixed
with water in engine until the colored solution appears in the water return hose of the magneto cooling circuit.
Remove temporary hose and reconnect engine
water return hose.
Remove hose pinchers.
Most of the antifreeze will drain out from the fitting near the exhaust outlet when removing the
hose pinchers. Use a container to recover it. Dispose of 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 using the watercraft.
01-04-3
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Subsection 01
Section 02 ENGINE
(TABLE OF CONTENT)
TABLE OF CONTENT
0
MAGNETO SYSTEM .............................................................................................................
02-02-1
CRANKCASE..........................................................................................................................
02-03-1
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02-01-1
Section 02 ENGINE
Subsection 02 (MAGNETO SYSTEM)
MAGNETO SYSTEM
0
9 N•m
(80 lbf•in)
Loctite 242
Synthetic
grease
9 N•m
(80 lbf•in)
105 N•m
(77 lbf•ft)
Loctite 242
4 N•m
(35 lbf•in)
9 N•m
(80 lbf•in)
Anti-seize
lubricant
9 N•m
(80 lbf•in)
6 N•m
(53 lbf•in)
Synthetic
grease
9 N•m
(80 lbf•in)
F07D0BS
PARTS
www.SeaDooManuals.net
FLAT RATE
02-02-1
Section 02 ENGINE
Subsection 03 (CRANKCASE)
CRANKCASE
0
30 mL (1 oz)
BOMBARDIER-ROTAX
Injection oil
Loctite
518
20 N•m
(15 lbf•ft)
Synthetic
grease
9 N•m
(80 lbf•in)
Loctite
518
40 N•m
(30 lbf•ft)
Synthetic
grease
Loctite
518
Loctite
518
24 N•m
(17 lbf•ft)
24 N•m
(17 lbf•ft)
Loctite
518
9 N•m
(80 lbf•in)
Synthetic
grease
40 N•m
(30 lbf•ft)
Synthetic grease
F07D0CS
PARTS
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FLAT RATE
02-03-1
Section 03 COOLING SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
0
CIRCUIT..................................................................................................................................
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03-01-1
F07E08S
Quick
connect
hose
fitting
for easy
engine
draining
Magneto
heat
exchanger
water
supply
hose
Water
from
Water flows cylinder
through the
head to
tuned pipe
tuned
and manifold
pipe
water jackets,
water
then to the
jacket
cylinder
water jackets
Engine
Engine heat
drain
exchanger
hose
outlet
supplies
supplies
water to the crankcase
heat
magneto heat
exchanger
exchanger
Bleed
hose
(upper
point
of circuit)
Engine
heat
exchanger
inlet
Water injected Serial cooling
system:
in the tuned
pipe controlled cylinder head
combustion
by the water
flow regulator chambers are
cooled with
valve for noise
reduction and the water from
the jet pump
performance
improvement
Engine
water
return
hose
(from
cylinder
water
jacket)
Engine
water
supply
hose
Water supply
hose of the
regulator
valve
Cooling
System
Indicator
(CSI) at
stern eyelet
Magneto heat
exchanger
water outlet
hose exits
at the exhaust
outlet for
noise reduction
Water
injected
into muffler
to cool
exhaust
components
Section 03 COOLING SYSTEM
Subsection 02 (CIRCUIT)
CIRCUIT
0
03-02-1
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Section 04 FUEL SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
0
FUEL INJECTION...................................................................................................................
INTRODUCTION ................................................................................................................
AIR INDUCTION.................................................................................................................
FUEL DELIVERY .................................................................................................................
ELECTRONIC MANAGEMENT..........................................................................................
DIAGNOSTIC PROCEDURES ............................................................................................
FAULT CODE TABLES.......................................................................................................
COMPONENT INSPECTION..............................................................................................
AIR INDUCTION SYSTEM.................................................................................................
FUEL DELIVERY .................................................................................................................
ELECTRONIC MANAGEMENT..........................................................................................
TROUBLESHOOTING SUMMARY....................................................................................
ENGINE DOES NOT START..............................................................................................
ENGINE STARTS BUT RUNS POORLY............................................................................
ENGINE STARTS BUT STALLS AFTER APPROXIMATELY 30 SECONDS.....................
ENGINE CANNOT REACH MAXIMUM REVOLUTIONS..................................................
ADJUSTMENT ...................................................................................................................
THROTTLE POSITION SENSOR (TPS) .............................................................................
REMOVAL AND INSTALLATION......................................................................................
THROTTLE POSITION SENSOR (TPS) .............................................................................
AIR TEMPERATURE SENSOR (ATS)................................................................................
AIR PRESSURE SENSOR (APS) .......................................................................................
WATER TEMPERATURE SENSOR (WTS)........................................................................
CRANKSHAFT POSITION SENSOR (CPS) .......................................................................
FUEL PUMP ASSEMBLY...................................................................................................
FUEL INJECTOR ................................................................................................................
04-02-1
04-02-1
04-02-2
04-02-2
04-02-3
04-02-6
04-02-7
04-02-8
04-02-8
04-02-8
04-02-9
04-02-13
04-02-13
04-02-13
04-02-14
04-02-14
04-02-15
04-02-15
04-02-16
04-02-16
04-02-16
04-02-16
04-02-16
04-02-16
04-02-16
04-02-17
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04-01-1
Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
FUEL INJECTION
0
INTRODUCTION
1
15
3
4
5
7
2
8
14
6
10
11
13
9
12
F07F0OS
DESCRIPTION OF THE FUEL INJECTION SYSTEM
1. Fuel tank
2. Fuel filter
3. Fuel pump
4. Regulator
5. Fuel rail
6. Fuel injector
7. Electronic Control Unit (ECU)
8. Multi-Purpose Electronic Module (MPEM)
9. Throttle plate
10. Throttle Position Sensor (TPS)
11. Air Pressure Sensor (APS)
12. Air Temperature Sensor (ATS)
13. Crankshaft Position Sensor (CPS)
14. Water Temperature Sensor (WTS)
15. Battery
04-02-1
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
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. The injector should run
cleaner and longer service intervals.
This system delivers the following benefits:
– easier cold engine starting (no choke)
– easier hot engine starting
– 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: Air Induction, Fuel Delivery and Electronic Management.
FUEL DELIVERY
An electric fuel pump supplies the fuel to the fuel
rail and injectors.
F07F0JA
FUEL PUMP
A regulator maintains a constant fuel pressure of
400-414 kPa (58-60 PSI).
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.
F07F0IA
REGULATOR
A dual piece fuel filter protects the fuel pump, regulator and injectors.
1
F07F08A
THROTTLE BODY
2
F07F0KA
1. Fuel pump assembly
2. External fuel filter
04-02-2
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
ELECTRONIC MANAGEMENT
Electronic Control Unit (ECU)
1
2
The electronic fuel injection is equipped with a
Bosch Electronic Control Unit (ECU).
F07F0LA
1. End cap of fuel pump assembly removed
2. Internal fuel filter
All these components are comprised in a single
module mounted in the fuel tank. The fuel gauge
sender is also mounted on this module.
F07F0BA
ELECTRONIC CONTROL UNIT (ECU)
F07F09A
FUEL PUMP ASSEMBLY
The injectors inject a metered quantity of fuel in
the cylinder rear transfer port in accordance with
the signal from the Electronic Control Unit (ECU).
F07F0AA
INJECTOR
The ECU is mounted behind the MPEM in the
front of the watercraft, in a watertight box.
The ECU controls the following functions:
1. Electronic fuel injection
The ECU receives the signals from 5 sensors
which indicate engine operating conditions at
milli-second 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 airfuel ratio.
2. 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 best engine operation.
3. Maximum engine speed
The ECU limits the maximum allowable engine
speed. The rev limiter is set at 7080 ± 50 RPM.
4. 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.
04-02-3
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
5. 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.
Multi-Purpose Electronic Module
(MPEM)
The MPEM is also used with the Rotax Fuel Injection system.
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.
F07H0BA
MPEM
04-02-4
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
PARAMETERS
SENSORS
Intake air
pressure
Air Pressure
Sensor
(APS)
Fuel tank
Crankshaft
position and
engine speed
Crankshaft
Position
Sensor (CPS)
Fuel filter
Throttle valve
position (Idle to
wide open throttle
Throttle
Position
Sensor (TPS)
Fuel pump
Engine
temperature
Water
Temperature
Sensor (WTS)
Regulator
Intake air
temperature
Air
Temperature
Sensor (ATS)
Injectors
FUEL
DELIVERY
Battery
voltage
Start/stop
signal
To engine
Multi-Purpose Electronic Module
(MPEM)
Electronic Control Unit
(ECU)
F07F0NS
SIGNAL MANAGEMENT
04-02-5
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
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 (static and dynamic) 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
ENTER.
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, a fault code
will be displayed for the CPS. 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 allows fault code
erasing without first viewing in the READ FAULT.
04-02-6
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
FAULT CODE TABLES
ECU Faults
FAULT DETECTION
FAULT CODE
TYPE OF FAULT
No fault detected
FF FF
88 = no defect
Electronic Control Unit not OK
FF FF
00 = internal defect
1B = not plausible = EEPROM defect
EEPROM not assembly-line
programmed
FF FE
2B = EEPROM not programmed
EEPROM triple inconsistent
FF FD
10 = out of tolerance
25 = defect = all 3 bytes different
Input Signal Faults
FAULT DETECTION
FAULT CODE
TYPE OF FAULT
Supply voltage
02 14
07 = signal too small
Water Temperature Sensor (WTS)
02 0A
1D = short circuit to ground
1E = interruption or short circuit to battery
1B = no plausible signal
Throttle Position Sensor (TPS)
02 06
1F = interruption or short circuit to ground
1C = short circuit to battery
Crankshaft Position Sensor (CPS)
02 1F
23 = do not indicate
06 = signal too large
Crankshaft Position Sensor (CPS)
02 01
03 = no signal (provisional after ignition on)
1B = no plausible signal (tooth gap error)
Air Intake Temperature Sensor (ATS)
02 0F
1D = short circuit to ground
1E = interruption or short circuit to ground
Air Pressure Sensor (APS)
02 10
1D = short circuit to ground
1E = interruption or short circuit to battery
Output Signal Faults
FAULT DETECTION
FAULT CODE
TYPE OF FAULT
Injector 1
04 E1
1C = short circuit to battery
1D = short circuit to ground
1E = interruption or short circuit to battery
Injector 2
04 E2
1C = short circuit to battery
1D = short circuit to ground
1E = interruption or short circuit to battery
Fuel pump
04 EB
1C = short circuit to battery
Not applicable
04 FC
Not applicable
RAVE
04 DB
1C = short circuit to battery
1D = short circuit to ground
1E = interruption or short circuit to battery
04-02-7
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
COMPONENT INSPECTION
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 TROUBLESHOOTING in this subsection.
AIR INDUCTION SYSTEM
Throttle Body
Check that the throttle plate moves freely and
smoothly.
1
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.
;
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.
If not, check the 7.5 A fuse on the MPEM module.
Regulator
The regulator is mounted on top of the fuel pump
assembly.
WARNING
Fuel is under pressure. Wipe off any fuel
spillage in the bilge.
Install a fuel pressure gauge to the quick connect
fitting of the fuel hose.
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 regulator.
If the pressure is too low, check the following
components:
– fuel hoses and connections
– fuel filter
– fuel pump
– regulator
04-02-8
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
Fuel Injector
Reinstall both injectors to the fuel rail.
Reconnect the wire connector of the injector.
Place each injector in a clean bowl.
Install the safety lanyard cap on the switch to activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 fuel drop of fuel per
minute.
If not within specification, replace the fuel injector(s).
1
2
3
4
ELECTRONIC MANAGEMENT
5
Throttle Position Sensor (TPS)
Check the resistance of the throttle position sensor.
6
F07F0CA
1.
2.
3.
4.
5.
6.
7.
7
Inlet side
Filter
Wiring terminal
Coil
Plunger
Needle valve
Injection side
Using a sound scope, it is possible to check the
operating noise from each injector.
With the engine running or cranking, check that
there is normal operating noise in proportion to
engine revolutions.
If there is no noise from the injector, check the
wiring connector, injector or the signal from the
MPEM.
To check the signal, verify voltage at the injector
connector. There should be at least 6 Vdc.
Check the resistance of the fuel injector.
Disconnect the connector of the fuel injector.
Using a multimeter, check resistance between
both terminals.
The resistance should be between 2.3 Ω and
2.5 Ω at temperature of 20°C (68°F).
If not within specification, replace the fuel injector.
Leakage Test
To perform a leakage test, the injectors and fuel
rail have to be removed. See REMOVAL in this
sub-section for the procedure.
F07F0EA
1
1. Throttle position sensor (TPS)
Remove the air intake silencer.
Disconnect the connector of the throttle position
sensor.
Using a multimeter, check the resistance between the terminals 1 and 2 of the throttle position sensor.
The resistance should be between 1.6 kΩ and 2.4
kΩ.
Check also the resistance between the terminals
2 and 3 with the throttle plate in idle position.
The resistance should be between 710 Ω and
1380 Ω.
If not within specification, replace the throttle position sensor.
04-02-9
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
NOTE: As an alternate method, the resistance of
the throttle position sensor can also be checked
through the connector no. 4 of the MPEM following this procedure.
Disconnect the AMP plug connector no. 4 on the
MPEM.
Disconnect the connector of the throttle position
sensor.
Using a multimeter, check the resistance of the
PURPLE/BROWN wire between the AMP plug
connector (position 3) and the throttle position
sensor connector (terminal 1).
Check the resistance of the BLACK/BROWN wire
between the AMP plug connector (position 4) and
the throttle position sensor connector (terminal 2).
Check also the resistance of the WHITE/BROWN
wire between the AMP plug connector (position
11) and the throttle position sensor connector
(terminal 3).
If there is an open circuit, repair the defective wire
or terminal. If not, proceed as follows to test the
throttle position sensor.
Connect the throttle position sensor connector.
Check the resistance between the PURPLE/BROWN
wire (position 3) and the BLACK/BROWN wire (position 4) in the AMP plug connector no. 4. Deduct the
total resistance value of the wires.
The resistance should be between 1.6 kΩ and
2.4 kΩ.
Check the resistance between the BLACK/BROWN
wire (position 4) and the WHITE/BROWN wire (position 11) in the AMP plug connector no. 4. Deduct the
total resistance value of the wires.
If not within specification, replace the throttle position sensor.
If the sensor test good, check the voltage between
the PURPLE/BROWN wire and the BLACK/BROWN
wire.
Depress the start/stop button with the safety lanyard removed to activate the timer. There should
be 5 Vdc.
Crankshaft Position Sensor (CPS)
Check the resistance of the crankshaft position
sensor.
1
F07H0CA
1. Crankshaft position sensor (CPS)
Disconnect the connector of the crankshaft position sensor.
Using a multimeter, check the resistance between both terminals.
The resistance should be between 774 Ω and
946 Ω at temperature above 20°C (68°F).
If not within specification, replace the crankshaft
position sensor.
Air Temperature Sensor (ATS)
Check the air temperature sensor resistance.
F07F0FA
1
1. Air temperature sensor (ATS)
04-02-10
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
Disconnect the connector of the air temperature
sensor.
Using a multimeter, check the resistance between both terminals.
The resistance should be between 2.280 kΩ and
2.736 kΩ at temperature of 19°C to 21°C (66°F to
70°F).
If not within specification, replace the air temperature sensor.
NOTE: As an alternate method, the resistance of
the air temperature sensor can also be checked
through the connector no. 4 of the MPEM following this procedure.
Disconnect the AMP plug connector no. 4 on the
MPEM.
Disconnect the connector of the air temperature
sensor.
Using a multimeter, check the resistance of the
BLACK/WHITE wire between the AMP plug connector (position 6) and the air temperature sensor
connector (terminal 1).
Check also the resistance of the WHITE/GREY
wire between the AMP plug connector (position
13) and the air temperature sensor connector (terminal 2).
If there is an open circuit, repair the defective wire
or terminal. If not, proceed as follows to test the
air temperature sensor.
Connect the air temperature sensor connector.
Check the resistance between the BLACK/WHITE
wire (position 6) and the WHITHE/GREY wire (position 13) in the AMP plug connector no. 4. Deduct the total resistance value of the wires.
If not within specification, replace the air temperature sensor.
Water Temperature Sensor (WTS)
Check the water temperature sensor resistance.
1
F07F0GA
1. Water temperature sensor (WTS)
Disconnect the connector of the water temperature sensor.
Using a multimeter, check the resistance between both terminals.
The resistance should be between 2.280 kΩ and
2.736 kΩ at temperature of 19°C to 21°C (66°F to
70°F).
If not within specification, replace the water temperature sensor.
Air Pressure Sensor (APS)
1
F07F0HA
1. Air pressure sensor (APS)
04-02-11
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
Check the air pressure sensor resistance.
Disconnect the connector of the air pressure sensor.
Using a multimeter, check the resistance between the terminals 1 and 2 of the air pressure
sensor.
F07F0MA
3
2
1
AIR PRESSURE SENSOR
1. Terminal 1
2. Terminal 2
3. Terminal 3
The resistance should be between 3.4 kΩ and
8.2 kΩ.
Check also the resistance between the terminals
2 and 3 of the air pressure sensor.
The resistance should be between 2.4 kΩ and
8.2 kΩ.
If not within specification, replace the air pressure
sensor.
If the sensor test good, check the voltage between
the PURPLE/BLUE wire and the BLACK/BLUE wire.
Depress the start/stop button with the safety lanyard removed to activate the timer. There should
be 5 Vdc.
04-02-12
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
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.
;
WARNING
Always use spark plug cable grounding device when removing spark plugs.
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.
Depress the start/stop button to crank the engine
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.
WARNING
Always use spark plug cable grounding device when removing spark plug cables.
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.
Spark Plug Inspection
Whenever replacing the spark plugs, always use
NGK BR8ES with the resistor feature. The spark
plug gap is set at 0.6 - 0.8 mm (.024 - .031 in).
To check for ignition, attach an inductive timing
light to the high tension lead while turning the engine with the starter.
-
CAUTION
If wires are mixed, engine will run but could
be damaged.
04-02-13
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
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.
04-02-14
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
ADJUSTMENT
THROTTLE POSITION SENSOR
(TPS)
This adjustment is very important. The setting of
the TPS will determine the basic parameters for
all fuel mapping.
-
CAUTION
An improperly adjusted TPS may lead to serious engine damage.
The adjustment of the TPS is performed using the
MPEM programmer.
Closed TPS
Idle Speed
Turn idle speed screw until it touches the stopper.
Turn idle speed screw 2-3/4 turns as a preliminary
adjustment.
For a precise adjustment of the idle speed, it
should be finalized in water.
Idle speed in water is 1400 ± 50 RPM.
NOTE: The ECU is programmed to maintain idle
speed at 1400 RPM. The ECU has the learning capacity to compensate if the idle speed is not precisely set at 1400 RPM. The ECU will correct the
idle speed, step by step, each time the engine is
started. Trying to set idle speed different than specified may cause rough idling.
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.
-
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.
Selecting “YES” will instantly readjust the close
throttle position adjustment to the new setting.
NOTE: If the ECU is replaced, the TPS must be
readjusted.
04-02-15
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
REMOVAL AND INSTALLATION
THROTTLE POSITION SENSOR
(TPS)
FUEL PUMP ASSEMBLY
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)
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.
;
Remove the air intake silencer.
Remove the flame arrester.
Disconnect the connector of the ATS.
Pull the ATS from the grommet retaining it.
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.
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 242 (blue) on screw
threads.
1
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)
F07F0DB
1. Loosen nuts
Remove fuel pump assembly from fuel tank.
Disconnect the connector of the CPS.
Loosen Allen screw retaining the CPS.
Remove the CPS.
At installation, apply Loctite 242 (blue) on the Allen
screw.
NOTE: Clean treads prior installing screw.
04-02-16
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Section 04 FUEL SYSTEM
Subsection 02 (FUEL INJECTION)
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
1. Loosen screws retaining the fuel rail
Remove the fuel rail with both fuel injectors.
To remove the fuel injector from the fuel rail, pry
off the retaining clip.
1
F07F0RA
F07F0TA
1. Press retaining clip to unlock the connector
1
1. Pry the clip
Loosen both screws retaining the fuel rail to the
cylinders.
When reinstalling the fuel injector, install the retaining clip to the injector, then insert the injector
to the fuel rail.
04-02-17
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Section 05 ELECTRICAL SYSTEM
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
0
IGNITION SYSTEM................................................................................................................
GENERAL ...........................................................................................................................
INSPECTION ......................................................................................................................
IGNITION TIMING .............................................................................................................
05-02-1
05-02-1
05-02-1
05-02-1
CHARGING SYSTEM.............................................................................................................
GENERAL ...........................................................................................................................
TESTING PROCEDURE .....................................................................................................
05-03-1
05-03-1
05-03-1
VOLUME
2
VOLUME
1 1998
www.SeaDooManuals.net
05-01-1
Section 05 ELECTRICAL SYSTEM
Subsection 02 (IGNITION SYSTEM)
IGNITION SYSTEM
0
GENERAL
IGNITION TIMING
On this ignition system, the spark plugs spark independently.
The Electronic Control Unit (ECU) controls the ignition timing and signals the ignition coil at the
right time for optimum engine performance.
Adjustment
INSPECTION
Ignition Coil
2
1
To perform this adjustment, proceed as follows:
NOTE: For the static and dynamic tests, refer to
the 1998 Sea-Doo Shop Manual.
Access the BOSCH SYSTEM in the MPEM programmer. Then, select ADJUSTMENT in the submenu.
Choose IGNITION in the ADJUSTMENT menu.
The screen will display the actual adjustment of
the ignition timing in degrees and it will also offer
to adjust it.
Unlike the other models, the number in the
MPEM programmer corrects the ignition timing in
0.75° increments.
TIMING CORRECTION CHART
F07H0EA
3
IGNITION COIL
1. Primary side
2. Secondary side
3. Ground wire
Primary Winding
Disconnect the wire connector on the primary
side of the ignition coil.
Using a multimeter, check the resistance between the terminals 1 and 2. Repeat a resistance
test between terminals 2 and 3.
The resistance should be 0.41 ± 0.05 Ω at 20°C.
If not within specification, replace the ignition coil.
If the ignition coil test good, check the power supply on the primary side.
There should be 12 Vdc between the RED and
WHITE/BLUE wires or between the RED and
WHITE/GREEN wires while starting the engine.
If there is no voltage, either the MPEM or the wiring harness is defective.
PROGRAMMER NUMBER
(MPEM)
IGNITION TIMING
CORRECTION
4
3°
3
2.25°
2
1.50°
1
0.75°
0
0
-1
-0.75°
-2
-1.50°
-3
-2.25°
-4
-3°
Ignition timing is set at 11° BTDC at 3300 RPM.
Secondary Winding
Due to the integrated diode, it is not possible to
take any resistance measurement.
05-02-1
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Section 05 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)
CHARGING SYSTEM
0
GENERAL
TESTING PROCEDURE
Magneto
NOTE: First, ensure that battery is in good condition prior to performing the following tests.
The purpose of the charging system is to keep the
battery at a full state of charge.
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric
current (AC).
The magneto has a 3 phase, delta wound stator
on 18 poles. Capacity is 270 watts.
Rectifier/Regulator
The unit used is a 3 phase in series rectifier/regulator.
It transforms the alternating current (AC) from the
magneto into direct current (DC) to allow battery
charging.
Included in the same unit, a regulator keeps voltage at a steady level of 14.2 volts to prevent any
damage to components.
1
Rectifier/Regulator
STATIC TEST: CONTINUITY
1. Due to internal circuitry, there is no static test
available.
DYNAMIC TEST
Voltage Test
Proceed as follows:
– Start engine.
– Connect a multimeter to battery posts. Set multimeter to Vdc scale.
– Bring engine to approximately 5500 RPM.
If multimeter reads over 15 volts, regulator is defective. Replace it.
NOTE: If it is continually necessary to add distilled
water to the battery, this indicates an over voltage
situation, requiring replacement of the rectifier/
regulator. If, on the other hand, the battery will not
stay charged, the problem can be any of the
charging circuit components. If these all check
good, you would be accurate in assuming the
problem to be in the rectifier/regulator.
If there is no charging at the battery with the preceding voltage test, check the output of the magneto.
Magneto
F07H08A
1. Rectifier/regulator
Battery
The battery is the DC source for the electric starter, the Multi-Purpose Electronic Module (MPEM),
the Electronic Control Unit (ECU) and all accessories.
Fuse
The charging system is protected by 2 fuses.
A 15 A fuse is mounted on the MPEM and a 20 A
fuse is located in the rear electrical box.
STATIC TEST: CONTINUITY
1. Disconnect the magneto wiring harness connector.
2. Install the 4-pin magneto harness adapter (P/N
295 000 131).
3. Check resistance between the YELLOW/BLACK
and the BLACK wires of the 4-pin magneto harness adpater. The resistance should be between
0.1 to 1.0 ohm.
4. Place either meter lead into the RED/BLACK
wire and note the resistance (same as step no. 3).
If the readings are out of specification, the stator
will need to be replaced.
05-03-1
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Section 05 ELECTRICAL SYSTEM
Subsection 03 (CHARGING SYSTEM)
STATIC TEST: INSULATION
1. Disconnect the magneto wiring harness connector.
2. Install the 4-pin magneto harness adapter (P/N
295 000 131).
3. Insert multimeter positive (+) probe to the YELLOW/
BLACK wire of the 4-pin magneto harness
adapter.
4. Ground the multimeter negative (-) probe to the
engine or the stator iron core and note the reading.
5. Repeat test with the other BLACK and RED/
BLACK wires of the 4-pin magneto harness
adapter.
NOTE: There should be no continuity (infinity) between the stator insulated coils and ground. If
there is a reading, the stator coils and/or the wiring from the coils is grounded and needs to be
replaced or repaired.
DYNAMIC TEST
1. Disconnect the magneto wiring harness connector.
2. Install the 4-pin magneto harness adapter (P/N
295 000 131).
3. Connect test probes of the multimeter to the
YELLOW/BLACK and RED/BLACK wires of the
4-pin magneto harness adapter.
4. Set multimeter to Vac scale.
5. Start and rev engine to 3500 RPM. The obtained value should be between 45 and 70 Vac.
6. Repeat test with the BLACK wire and either the
RED/BLACK or YELLOW/BLACK wires of the
4-pin magneto harness adapter.
7. If the stator is out of specification, replace it.
05-03-2
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Section 06 TECHNICAL DATA
Subsection 01 (GTX RFI MODEL)
GTX RFI MODEL
ENGINE
Engine type
Induction type
Exhaust system
Type
Water injection fitting
(head)
Water injection fitting
(cone)
Water injection fitting
(muffler)
Exhaust valve
Starting system
Lubrication
Fuel/oil mixture
Oil injection pump
Oil injection type
Number of cylinders
Bore
Standard
First oversize
Second oversize
Stroke
Displacement
Corrected compression ratio
Combustion chamber volume
Cylinder head warpage (maximum)
Piston ring type and quantity
New
Ring end gap
Wear limit
New
Ring piston groove
Wear limit
New (minimum)
Piston/cylinder wall
clearance
Wear limit
Cylinder taper (maximum)
Cylinder out of round (maximum)
New
Connecting rod big end
axial play
Wear limit
Crankshaft deflection
Rotary valve timing
Opening
Closing
Rotary valve duration
Rotary valve/cover clearance
Connecting rod/crankshaft New
pin radial clearance
Wear limit
New
Connecting rod/piston pin
radial clearance
Wear limit
ADDITIONAL INFORMATION:
0
GTX RFI (5666/5843)
BOMBARDIER-ROTAX 787
Rotary valve
Water cooled, water injected with regulator
3.5 mm (.139 in)
Not applicable
3.5 mm (.139 in)
Rotax Adjustable Variable Exhaust (RAVE)
Electric start
VROI (Variable Rate Oil Injection)
Direct driven
Formula XP-S (synthetic)
2
82 mm (3.228 in)
82.25 mm (3.238 in)
Not applicable
74 mm (2.91 in)
781.6 cm³ (47.7 in³)
6.0: 1
36.3 ± 1.6 cc
0.05 mm (.002 in)
1 Semi-trapez — 1 Rectangular
0.40 - 0.55 mm (.016 - .022 in)
1.00 mm (.039 in)
0.025 - 0.070 mm (.001 - .003 in)
0.2 mm (.008 in)
0.15 mm (.006 in)
0.20 mm (.008 in)
0.10 mm (.004 in)
0.08 mm (.003 in)
0.230 - 0.617 mm (.009 - .024 in)
1.2 mm (.047 in)
MAG side: 0.050 mm (.002 in);
PTO side: 0.030 mm (.001 in)
147° ± 5 BTDC
63.5° ± 5 ATDC
159°
0.25 - 0.35 mm (.010 - .014 in)
0.023 - 0.034 mm (.0009 - .0013 in)
0.050 mm (.002 in)
0.003 - 0.012 mm (.00012 - .00047 in)
0.015 mm (.00059 in)
06-01-1
www.SeaDooManuals.net
Section 06 TECHNICAL DATA
Subsection 01 (GTX RFI MODEL)
ELECTRICAL SYSTEM
Magneto generator output
Ignition system type
Spark plug
Ignition timing
(BTDC)
Make and type
Gap
mm (in)
Degrees
Battery charging coil
Ignition coil
Primary
Secondary
Engine rev limiter setting
Battery
Starting system
Fuse
Charging system
Fuel pump
MPEM
ADDITIONAL INFORMATION:
FUEL SYSTEM
Fuel injection type
Idle speed (in water)
Throttle Position Sensor (TPS)
Crankshaft Position Sensor (CPS)
Air Temperature Sensor (ATS)
Water Temperature Sensor (WTS)
Air Pressure Sensor (APS)
Fuel injector
Type
Minimum octane no.
ADDITIONAL INFORMATION:
Fuel
COOLING
Type
Thermostat
Monitoring beeper setting
ADDITIONAL INFORMATION:
GTX RFI (5666/5843)
270 W @ 6000 RPM
Digital, inductive type
NGK BR8ES
0.6 - 0.8 mm (.024 - .031 in)
0.858 (.0338)
11° @ 3300 RPM
0.1 Ω - 1 Ω
0.41 Ω ± 0.05 Ω
Not applicable
7080 (± 50) RPM
12 V, 19 A•h (Yuasa/Exide)
5A
15 A (1)
20 A (1)
7.5 A
5A
GTX RFI (5666/5843)
Rotax Fuel Injection, semi-direct,
single throttle body (56 mm)
1400 (± 50) RPM
1.6 kΩ - 2.4 kΩ (terminals 1-2)
710 Ω - 1380 Ω (terminals 2-3)
774 Ω - 946 Ω
2.375 kΩ - 2.625 kΩ
2.375 kΩ - 2.625 kΩ
3.4 kΩ and 8.2 kΩ (terminals 1-2)
2.4 kΩ and 8.2 kΩ (terminals 2-3)
2.3 Ω - 2.5 Ω
Regular unleaded gasoline
87
GTX RFI (5666/5843)
Open circuit — Direct flow from jet propulsion unit
None
86-94°C (187-201°F)
06-01-2
www.SeaDooManuals.net
Section 06 TECHNICAL DATA
Subsection 01 (GTX RFI MODEL)
PROPULSION
Propulsion system
Jet pump type
Impeller rotation (seen from rear)
Transmission
Coupling type
GTX RFI (5666/5843)
Bombardier Formula Pump
Axial flow single stage
Counterclockwise
Direct drive
Crown splines
SEA-DOO JET PUMP SYNTHETIC
Oil type
POLYOLESTER OIL 75W90 GL5
Steering nozzle pivoting angle
23°
Minimum required water level
90 cm (35 in)
Drive shaft deflection (maximum)
0.5 mm (.020 in)
Impeller outside diameter
139.5 mm (5.490 in)
New
0.0
- 0.4 mm (.000 - .016 in)
Impeller/wear ring
clearance
Wear limit
1.00 mm (.040 in)
Impeller shaft end play (new)
0.12 - 0.54 mm (.005 - .021 in)
Impeller shaft radial play
0.05 mm (.002 in)
Impeller pitch/material
Progressive pitch 12° - 25°/stainless steel
ADDITIONAL INFORMATION: Do not mix different brands or oil types.
DIMENSIONS
Number of passenger (driver incl.)
Overall length
Overall width
Overall height
Dry weight
Load limit (passenger and 10 kg (22 lb) luggage)
ADDITIONAL INFORMATION:
GTX RFI (5666/5843)
3
312 cm (122.8 in)
119 cm (47 in)
94 cm (37 in)
288 kg (635 lb)
242 kg (534 lb)
CAPACITIES
Fuel tank
Oil injection reservoir
GTX RFI (5666/5843)
56.5 L (15 U.S. gal)
6 L (1.6 U.S. gal)
100 mL (3.4 U.S. oz)
Up to plug
Capacity
Oil level height
ADDITIONAL INFORMATION:
Jet pump impeller shaft
reservoir
06-01-3
www.SeaDooManuals.net
Section 06 TECHNICAL DATA
Subsection 01 (GTX RFI MODEL)
MATERIALS
Hull
Inlet grate
Impeller housing/stator/venturi/nozzle
Air intake silencer
Flame arrester
Exhaust muffler
Resonator
Steering padding
Fuel tank
Oil injection reservoir
Seat
ADDITIONAL INFORMATION:
GTX RFI (5666/5843)
Composite
Aluminum
Plastic/plastic/plastic/aluminum
Thermoplastic
Multi-layer wire screen
Aluminum
Plastic
Thermoplastic with polyethylene foam
Polyethylene
Polyethylene
Polyurethane foam
STANDARD EQUIPMENT
Safety lanyard
Digitally Encoded Security System
Fuel tank reserve
Monitoring beeper
Speedometer
Tachometer
Info Center
Ajustable handlebar
Reverse
Storage compartment
Glove box
Rear grab handle
Boarding step
Extinguisher holder
Tool kit
ADDITIONAL INFORMATION:
GTX RFI (5666/5843)
Standard
Standard
Not applicable
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
PERFORMANCE
GTX RFI (5666/5843)
41.5 L/h
(11 U.S. gal/h)
1 hour 20 minutes
Maximum fuel consumption at wide open throttle
Cruising time at full throttle
ADDITIONAL INFORMATION:
06-01-4
www.SeaDooManuals.net
Section 06 TECHNICAL DATA
Subsection 01 (GTX RFI MODEL)
GTX RFI (5666/5843)
40 N•m (30 lbf•ft)
105 N•m (77 lbf•ft)
110 N•m (81 lbf•ft)
M8
24 N•m (17 lbf•ft)
Crankcase screws
M10
40 N•m (30 lbf•ft)
Crankcase/engine support nuts
35 N•m (26 lbf•ft)
Engine mount/hull
25 N•m (18 lbf•ft)
Cylinder head screws
24 N•m (17 lbf•ft)
Crankcase/cylinder screws
40 N•m (30 lbf•ft)
Tuned pipe flange screws/nut
40 N•m (30 lbf•ft)
Tuned pipe fixation screws
25 N•m (18 lbf•ft)
Flame arrester screws
10 N•m (89 lbf•in)
Magneto housing cover screws
9 N•m (80 lbf•in)
Starter mounting screws
22 N•m (16 lbf•ft)
Spark plugs
24 N•m (17 lbf•ft)
Impeller
70 N•m (52 lbf•ft)
Pump/hull nuts
31 N•m (23 lbf•ft)
Venturi/pump housing screws
21 N•m (16 lbf•ft)
Pump housing cover screws
4 N•m (35 lbf•in)
Inlet grate screws
8 N•m (71 lbf•in)
Riding plate screws
22 N•m (16 lbf•ft)
Cable retaining block bolts
6 N•m (53 lbf•in)
Steering cable/stem arm bolt
3 N•m (26 lbf•in)
Steering stem arm bolts
6 N•m (53 lbf•in)
Handlebar clamp bolts
26 N•m (19 lbf•ft)
Steering cable ball joint bolt (nozzle)
7 N•m (62 lbf•in)
Steering support bolts
15 N•m (11 lbf•ft)
Handlebar grip screw
13 N•m (10 lbf•ft)
ADDITIONAL INFORMATION: Apply where indicated; (1) Loctite 242 (blue)
(2) Loctite 271 (red)
(3) Loctite 518
(4) Synthetic grease
(5) Anti-seize lubricant
STEERING
JET PUMP
ENGINE
TIGHTENING TORQUES
Exhaust manifold screw
Magneto flywheel nut
Flywheel (PTO side)
;
(3) (4)
(1)
(5)
(3) (4)
(3) (4)
(1)
(1)
(1) (4)
(3) (4)
(1)
(1)
(1)
(5)
(1)
(5)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
WARNING
Correct torques and use of Loctite must be strictly followed.
06-01-5
www.SeaDooManuals.net
www.SeaDooManuals.net
GTX RFI MODEL
5666/5843
www.SeaDooManuals.net
www.SeaDooManuals.net
www.SeaDooManuals.net
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