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 VOLUME 2 VOLUME 1 1998 www.SeaDooManuals.net 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 VOLUME 2 VOLUME 1 1998 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net Subsection 01 Section 02 ENGINE (TABLE OF CONTENT) TABLE OF CONTENT 0 MAGNETO SYSTEM ............................................................................................................. 02-02-1 CRANKCASE.......................................................................................................................... 02-03-1 VOLUME 2 VOLUME 1 1998 www.SeaDooManuals.net 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 www.SeaDooManuals.net FLAT RATE 02-03-1 Section 03 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 0 CIRCUIT.................................................................................................................................. VOLUME 2 VOLUME 1 1998 www.SeaDooManuals.net 03-02-1 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 www.SeaDooManuals.net 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 VOLUME 2 VOLUME 1 1998 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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 www.SeaDooManuals.net 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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