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

TABLE OF CONTENTS

SECTION

SUBSECTION

PAGE III IV V 01-01-1 01-02-1 01-03-1 02-01-1 02-02-1 02-03-1 02-04-1 02-05-1 03-01-1 04-01-1 04-02-1 04-03-1 04-04-1 04-05-1 04-06-1 04-07-1 04-08-1 05-01-1 05-02-1 06-01-1 06-02-1 06-03-1 06-04-1 07-01-1 07-02-1 07-03-1 08-01-1 08-02-1 08-03-1 08-04-1 08-05-1 08-06-1 09-01-1 09-02-1 09-03-1 09-04-1 09-05-1
I

SAFETY NOTICE ................................................................................................................................... WHATS NEW ....................................................................................................................................... INTRODUCTION ................................................................................................................................... 01 SERVICE TOOLS AND PRODUCTS 01 - Mandatory service tools............................................................ 02 - Optional service tools................................................................ 03 - Service products ....................................................................... 01 - Table of contents ...................................................................... 02 - Periodic inspection chart ........................................................... 03 - Flushing and lubrication............................................................. 04 - Water-flooded engine................................................................ 05 - Storage...................................................................................... 01 - Troubleshooting ........................................................................ 01 - Table of contents ...................................................................... 02 - Leak test ................................................................................... 03 - Removal and installation ........................................................... 04 - Magneto system ....................................................................... 05 - Top end ..................................................................................... 06 - Bottom end ............................................................................... 07 - Rotary valve............................................................................... 08 - Exhaust system......................................................................... 01 - Table of contents ...................................................................... 02 - Circuit, components and care ................................................... 01 - Table of contents ...................................................................... 02 - Fuel circuit................................................................................. 03 - Air intake ................................................................................... 04 - Carburetor ................................................................................. 01 - Table of contents ...................................................................... 02 - Oil injection system................................................................... 03 - Oil injection pump ..................................................................... 01 - Table of contents ...................................................................... 02 - Ignition system.......................................................................... 03 - Charging system ....................................................................... 04 - Starting system ......................................................................... 05 - Instruments and accessories .................................................... 06 - Digitally encoded security system ............................................ 01 - Table of contents ...................................................................... 02 - Jet pump ................................................................................... 03 - Drive system ............................................................................. 04 - Reverse system ........................................................................ 05 - Variable trim system .................................................................

02

MAINTENANCE

03 04

TROUBLESHOOTING ENGINE

05

COOLING SYSTEM

06

FUEL SYSTEM

07

LUBRICATION SYSTEM

08

ELECTRICAL SYSTEM

09

PROPULSION SYSTEM

GTX RFI

TABLE OF CONTENTS

10

STEERING SYSTEM

01 - Table of contents ...................................................................... 02 - SPX model ................................................................................ 03 - GTS model ................................................................................ 04 - GS, GSX Limited, GTI and GTX Limited.................................... 05 - XP Limited ................................................................................ 06 - Alignment ................................................................................. 01 - Table of contents ...................................................................... 02 - Direct action suspension .......................................................... 01 - Table of contents ...................................................................... 02 - Adjustment and repair .............................................................. 01 - SPX model ................................................................................ 02 - GS and GSX Limited ................................................................. 03 - XP Limited ................................................................................ 04 - GTS model ................................................................................ 05 - GTI and GTX Limited................................................................. 01 - Wiring diagrams........................................................................

10-01-1 10-02-1 10-03-1 10-04-1 10-05-1 10-06-1 11-01-1 11-02-1 12-01-1 12-02-1 13-01-1 13-02-1 13-03-1 13-04-1 13-05-1 14-01-1

11

SUSPENSION

12

HULL/BODY

13

TECHNICAL DATA

14

WIRING DIAGRAMS

II

GTX RFI

SAFETY NOTICE

SAFETY NOTICE

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:

x
-

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.

III

WHATS NEW

WHATS NEW
SERVICE TOOLS AND PRODUCTS 01
Complete new section.

MAGNETO SYSTEM 04-04

New procedure to lock crankshaft on the 947 engine.

REMOVAL AND INSTALLATION 04-03

New service tool for engine alignment procedure.

TOP END 04-05

New service tool to extract the piston pin for all engines. New piston/cylinder wall and ring end gap clearances. New service tool to install dogleg circlip on the 947 engine. New RAVE valve adjustment on the 787 engine.

BOTTOM END 04-06

New service tools for PTO flywheel removal and installation on the 947 engine.

CARBURETOR 06-04
Carburetors on the 947 engine are rotated 180. There is a new calibration and the diaphragms are opened all the time to the atmosphere. There is no more need for a throttle position switch, amplifier and solenoid. Use of Loctite 242 (blue) to carburetor mounting screws is replaced by Loctite 577 on all models.

OIL INJECTION PUMP 07-03

New oil injection pump cable for the 947 engine.

IGNITION SYSTEM 08-03

New testing procedures using a multimeter.

CHARGING SYSTEM 08-04

New testing procedures using a multimeter.

IV

INTRODUCTION

INTRODUCTION
This Shop Manual covers BOMBARDIER made SEA-DOO watercraft models SPX 5838/5839, GS 5626/5844, GSX Limited 5629/5845, XP Limited 5665/5667, GTS 5819, GTI 5836/5841and GTX Limited 5837/5842.

0
All Models The Hull Identification Number is composed of 9 digits:
ZZN12345L495 Model year Serial number* Year of production Month of production
F00A0CA

HULL IDENTIFICATION NUMBER (H.I.N.)

SPX and GTS Models It is located at right hand rear side of hull.

*A letter may also be used as a digit.

ENGINE IDENTIFICATION NUMBER (E.I.N.)

717 Engine The Engine Identification Number is located on the upper side of the magneto housing.

1
F01L8XA

1. Hull Identification Number (H.I.N.)

All Other Models It is located on floorboard at the rear of the watercraft.

F01D01A

TYPICAL 1. Engine Identification Number (E.I.N.)

F08L0QA

1. Hull Identification Number (H.I.N.)

INTRODUCTION

787 Engine The Engine Identification Number is located on the upper crankcase on PTO side.

ARRANGEMENT OF THIS MANUAL

The manual is divided into 14 major sections: 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 COOLING SYSTEM 06 FUEL SYSTEM 07 LUBRICATION SYSTEM 08 ELECTRICAL SYSTEM 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 SUSPENSION 12 HULL/BODY 13 TECHNICAL DATA 14 WIRING DIAGRAMS Several sections are divided in various subsections. There is a table of contents at the beginning of many sections.

F01D87A

1. Engine Identification Number (E.I.N.)

947 Engine The Engine Identification Number is located on the upper crankcase on MAGNETO side.

F06D15A

1. Engine Identification Number (E.I.N.)

VI

INTRODUCTION

TYPICAL PAGE
Page heading indicates section and subsection detailed.

Section 03 ENGINE Subsection 04 (MAGNETO SYSTEM)

Subsection title indicates beginning of the subsection.

MAGNETO SYSTEM
717 Engine
12 11 5 Nm (44 lbfin)

Drop represents a liquid product to be applied to a surface. In this case Loctite 242 to screw threads.
Loctite 242

Italic sub-title above exploded view indicate pertaining models.

9 Nm 13 (80 lbfin)

6 4

8 Loctite 242 6 Nm (53 lbfin)

Exploded view assits you in identifying parts and related positions.

Loctite 242 6 Nm (53 lbfin) 5 9 6 Nm (53 lbfin)

Dotted box contains parts of a particular model or an exploded view.

Loctite 242 3 14 Loctite 242 1

Bold face number indicates special procedure concerning this part.

4 Loctite 648 10 15 145 Nm (107 lbfft) Anti-seize lubricant

F01D4WS

2 9 Nm (80 lbfin)

Illustration number for publishing process.

03-04-1

Tightening torque nearby fastener. In this case, nut must be torqued to 145 Nm (107 lbfft).

w CAUTION
Pay attention to torque specifications. Some of these are in lbfin instead of lbfft. Use appropriate torque wrench.
F01A09S

Page numbering system: 03: ENGINE section 04: MAGNETO SYSTEM subsection 1: First page of this subsection

VII

INTRODUTION

TYPICAL PAGE
Sub-title with part number(s) from exploded view followed by part name(s).

Section 06 FUEL SYSTEM Subsection 03 (CARBURETORS)

Title indicates main procedure to be carried-out.

CARBURETOR REMOVAL
To remove carburetors from engine, proceed as follows: Remove air vent tube support. Unlock retaining slides holding air intake silencer base. Remove air intake silencer base from watercraft. Remove screws holding flame arrester base support to cylinder head cover. Unscrew base retaining screws then remove base from carburetors and move to front of watercraft. Turn the valve to OFF position. NOTE: For fuel line removal, use pliers (P/N 295 000 054). Disconnect pulse line from fuel pump. Disconnect fuel fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable.

DISASSEMBLY AND INSPECTION

Inspect parts for corrosion dammage (shaft, butterfly, spring screw, check valve housing, etc.).

3, Diaphragm
PUMP DIAPHRAGM LEAK TEST Using a suitable pump gauge tester, perform the following test proceeding as follows: - Install pump gauge tester (P/N 295 000 083) on pulse nipple. - Pump tester until it reaches 28 kPa (4 PSI).

Sub-sub-title in capital indicates a particular testing, adjustment or repair procedure.

Service tool to be used to perform a certain procedure.

Title in italic indicates a particular procedure concerning a model. Sub-sub-title in this case indicates that particular procedure for XP is finished, so from this point, all others models are concerned.

XP Model Only Remove screws no. 6 and lock washers no. 7 retaining carburetors. All Others Models Remove 4 bolts no. 8 and lock washers no. 12 from rotary valve cover then move carburetors and rotary valve cover on top of engine.
NOTE: When removing rotary valve cover , pay attention that the rotary valve stay in place, other-wise it must be timed. Remove carburetors from intake manifold. Disconnect fuel bypass line between carburetors (twin carburetors). Remove carburetor(s) from rotary valve cover.

Illustration always follows text it is pertained to.

F01F0XB

TYPICAL Step 1 : Install pump gauge tester to pulse nipple Step 2 : Pump tester until it reaches the desired pressure 1. Fuel outlet nipple 2. Fuel inlet nipple A. 28 kPa (4 PSI)

"TYPICAL" mention indicates a general view which does not represent full detail. Numbers in a frame are used to give a sequence to be perfomed.

Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm.

Letters are used for any measures.

06-03-4

Bold numbers in the text refer to the parts shown in the exploded view at the beginning of the subsection.

Numbers are used for description of components.

F01A0AS

VIII

INTRODUCTION

GENERAL INFORMATION
The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on watercraft).

ILLUSTRATIONS AND PROCEDURES

The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.

CAUTION

These watercraft are designed with parts dimensioned in both the metric and the imperial systems. When replacing fasteners, make sure to use only those recommended by Bombardier.
F01L45B

1. Left (port) 2. Right (starboard)

The information and component/system descriptions contained in this manual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. This Shop Manual uses technical terms which may be different from the ones of the Parts Catalogs. When ordering parts always refer to the specific model Parts Catalogs.

As many of the procedures in this manual are interrelated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or subsection in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before undertaking any procedure, be sure that you have on hand all the tools required, or approved equivalents. Technical Publications Bombardier Inc. Valcourt (Quebec), Canada

IX

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS)

MANDATORY SERVICE TOOLS

ENGINE
Degree wheel P/N 295 000 007
33
0 32
31

NOTE: The numbers outlined in black (example: 1 ) are reference numbers to tools from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.

Bearing pusher P/N 290 876 500

12

Bearing pusher P/N 290 876 501

50

40

30

350 360 10 20 340 10 360 350 3 20 40

30 33
0
40

32

50

0
60

60

31

30

70

300

70

290

A00B2J4

80

F00B074

290

80

110 100 90

280

APPLICATION 717 engine. Piston circlip installer A) P/N 290 877 016 B) P/N 290 877 517 548
NEW

APPLICATION 787 engine. Starter drive bearing pusher P/N 290 876 502
NEW

90 100 11 0 280 270 26 0

260

270

250

130

120

12 0 13 250 0 24 1 0 2

24

14

A00B334

APPLICATION 717 and 787 engines. Rubber pad P/N 295 000 101 547
F06B014

F01B0J4

APPLICATION 717 and 787 engines. Rubber pad P/N 290 877 032

NEW

F06B064

APPLICATION 947 engine.

01-01-1

40

30
15

22

160

210

180 190 2 170 00 21 0 200 190 180 17 22 0 0 16 0 15 0

0 23

F06B054

APPLICATION A) 717 and 787 engines. B) 947 engine. PTO flywheel remover/installer P/N 295 000 001 553

APPLICATION 947 engine. Piston ring compressor (2) P/N 290 876 965
NEW

F01B1T4 F01J0T4

APPLICATION 717 engine. NOTE: This tool is also used for the impeller.

APPLICATION 947 engine.

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS)

Piston pin puller P/N 529 035 503

NEW

Puller P/N 295 000 106

1 5 2 4 3 6 4
F00B0T4 A00C1A4

Puller plate P/N 290 876 080

549

APPLICATION All engines.

MAG side
F01D884

PTO side

Sleeve set 200 A) P/N 529 035 542 (20 mm sleeve) B) P/N 529 035 543 (21 mm sleeve)
NEW

A00C1R4

1) Puller P/N 290 876 298 2) Protective cap (both ends) P/N 290 876 557 3) Ring (both ends) P/N 290 977 490 4) Ring halves (PTO) P/N 290 977 475 (2) 5) Distance ring (MAG) P/N 290 876 569 6) Ring halves (MAG) P/N 290 276 025 (2) 7) Screw M8 x 40 P/N 290 840 681 (2) 8) Screw M8 x 70 P/N 290 841 201 (2) APPLICATION 717 and 787 engines.

Extension handle P/N 295 000 125

550

554

F01D164

555

Screw M8 x 35 (3) P/N 290 841 591

551

556
F00B0U4

F00A094

557

APPLICATION A) 717 and 787 engines. B) 947 engine.

Sleeve (3) P/N 290 847 220

552

558 Puller P/N 290 876 488 562

F00A0A4

559

APPLICATION 717 engine. Pusher P/N 290 876 605 229

560
2
F01B0I4

APPLICATION 717 and 787 engines. Replacement parts: 1) P/N 290 240 860. 2) P/N 290 242 210.

A00C0Y4

APPLICATION 717 engine.

01-01-2

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS)

Alignment support plate kit P/N 529 035 506 1) Alignment plates A) P/N 529 035 507 B) P/N 529 035 508 2) Support P/N 529 035 511 3) Screw (2) P/N 222 082 565 Lock washer (2) P/N 213 000 001 Flat washer (2) P/N 217 081 410
NEW

MPEM programmer P/N 529 035 502

567

Engine leak tester kit P/N 295 500 352

778

A01B5B4

APPLICATION All models. Digital multimeter P/N 529 022 000 242

F01B2Q5

APPLICATION 717 and 787 engines. Ring gear puller tool P/N 420 976 235 569

F00B0F4

APPLICATION All models. A) 139.5 mm jet pump. B) 155.6 mm jet pump.

F01B1O4 F01B294

APPLICATION 787 engine. APPLICATION All models. Flywheel extractor P/N 295 000 156 777 Ring gear blocking tool P/N 295 000 155 568

Alignment shaft P/N 295 000 141

F00B0G4

APPLICATION All models.

F01B264

Adapter P/N 295 000 157

APPLICATION 787 engine.

F00B044

F00B054

APPLICATION XP Limited.

APPLICATION SPX and XP Limited.

01-01-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS)

Puller plate P/N 529 035 533

NEW

F00B0S4

APPLICATION 947 engine. Polygonal key P/N 529 035 505

NEW

F00B0Y4

APPLICATION Exhaust system of the 947 engine.

01-01-4

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS)

COOLING/FUEL/OIL SYSTEMS
Hose pincher P/N 295 000 076 2 Pliers P/N 295 000 054
Caillau

606

F01B1T4

A01B2I4

APPLICATION All models. Gear holder P/N 290 277 905 235

APPLICATION All models. NOTE: This tool is also used for the propulsion system. Coupler hose P/N 295 500 258
41 cm (16 in)

752

F01E0Z4

A00C164

APPLICATION SPX and GTS models.

APPLICATION 717 engine. Pliers P/N 295 000 070

Oetiker 1099

601

F01D174

APPLICATION All models.

01-01-5

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (MANDATORY SERVICE TOOLS)

PROPULSION SYSTEM
Impeller remover/installer P/N 295 000 001 553 Bearing/seal installer P/N 295 000 107 604 VTS tool P/N 295 000 133 607

F01J0T4

APPLICATION All models. NOTE: This tool is also used for the PTO flywheel (on some models). Pliers P/N 295 000 069
Oetiker 1090

F01B2P4

F01J4K4

APPLICATION SPX, GSX Limited and XP Limited.

APPLICATION All models. Impeller shaft guide P/N 295 000 002 605

602

F01J1O4 F01D184

APPLICATION All models. Impeller shaft holder P/N 295 000 082 603

APPLICATION All models. Pliers P/N 295 000 054

Caillau

606

F01B1T4 F01B0W4

APPLICATION All models.

APPLICATION All models. NOTE: This tool is also used for the fuel system.

01-01-6

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS)

OPTIONAL SERVICE TOOLS

ENGINE
Ring compressor P/N 290 876 979 751 Rotary valve shaft pusher P/N 290 876 609 757 Distance gauge A) P/N 529 034 800 B) P/N 529 034 900 C) P/N 290 876 627 D) P/N 290 876 622
A01B1T4

NOTE: The numbers outlined in black (example: 1 ) are reference numbers to tools from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used on both products, even if the part numbers are different.

760 561

APPLICATION 717 and 787 engines (82 mm). Coil centering tool P/N 290 876 922 209

F01B2B4

APPLICATION 787 engine.

F01B0H4

Oil seal pusher P/N 290 877 740

759

APPLICATION A) 717 engine. B) 787 engine. C) 947 engine. D) 947 engine. Puller and bolt P/N 529 035 548 (puller) P/N 529 035 549 (bolt)
NEW

A01B1V4

APPLICATION 717 engine.

F01B2C4

Cylinder aligning tool P/N 290 876 904

220

APPLICATION 787 engine. Ring halves (2) P/N 290 876 330 Ring P/N 290 977 480 761 762

A00B084

APPLICATION 717 engine. Handle P/N 290 877 650 758

F01B294 F01B2D4

A00C3V4

APPLICATION 787 and 947 engines.

APPLICATION 947 engine. NOTE: Bolt can be used with mandatory puller (P/N 420 976 235).

APPLICATION Use with pushers (P/N 290 876 609 and 290 877 740).
01-02-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS)

Stroboscopic timing light P/N 529 031 900

225

Digital/induction type tachometer P/N 295 000 100

237

Crimping tool P/N 295 100 164

NEW

A00B4F4

APPLICATION All models. A) Four-pin magneto harness 763 P/N 295 000 131 B) Six-pin magneto harness 755 P/N 295 000 136

F01B1G4

F00B0E4

APPLICATION All models. Timing mark pointer P/N 295 000 130 774

APPLICATION Contacts of AMP plug connectors. All models except SPX and GTS. Terminal remover Not sold by Bombardier
Snap-on TT 600-4

F01B1J4

F01B284

APPLICATION All models.

F01B2O4

APPLICATION A) 717 engine. B) 787 and 947 engines. Dial indicator (TDC gauge) P/N 295 000 143 230

APPLICATION 717 engine. Timing mark pointer P/N 295 000 135 754

Safety lanyard switch tool P/N 295 000 121

775

F01B244 A00B4E4

APPLICATION All models.

F01H544

APPLICATION All models.

APPLICATION 787 and 947 engines.

01-02-2

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS)

Slide hammer puller Not sold by Bombardier

Snap-on:Handle Hammer Claws CJ93-1 CJ125-6 CJ93-4

Crankshaft protector P/N 420 876 552

764

Engine lifting device Not sold by Bombardier Do it yourself Refer to 04-03 then look for REMOVAL AND INSTALLATION

F00B034

F01J0Z4

APPLICATION For use with pullers. Gear/bearing puller P/N 290 877 665 765

APPLICATION 717 and 787 engines. NOTE: This tool is also used to pull out impeller shaft seal. Protective mat P/N 295 000 128 889

F01D0A4

APPLICATION 717 engine. Feeler gauge 45 Not sold by Bombardier

F04B034

Snap-on FB 300 A

F02B0A4

APPLICATION 787 engine. Exhaust outlet tool P/N 295 000 132
1 3

APPLICATION All models.

831
F01B1K4

APPLICATION 717 and 787 engines. Steering cable tool P/N 295 000 145 780

2
F01B2A4 F06B075

1) Puller P/N 420 877 635 2) Protective cap P/N 290 877 414 3) Screw P/N 290 940 755 APPLICATION 947 engine.

APPLICATION All models.

F01B2P4

APPLICATION All models except the SPX and GTS.

01-02-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS)

COOLING/FUEL/OIL SYSTEMS
Pump gauge tester P/N 295 000 114
30

826

Spring compressor P/N 529 027 100

Flushing adapter P/N 295 500 473

20

40

2 15 1

25 3 35
50

60

10

5 4

F00B104

A01B4O4

F01B0X4

APPLICATION All models. Lighted adjustable mirror Not sold by Bombardier

Snap-on 50101

APPLICATION XP Limited. Suspension adjustment wrench P/N 529 012 200 833

APPLICATION All models except the SPX and GTS. Use with coupler hose (P/N 295 500 258).

F01B1I4

APPLICATION All models. Hose pincher P/N 529 032 500 773

A25A014

APPLICATION XP Limited. Flexible spout (oil) P/N 414 837 300 834

F04B044

F01B234

APPLICATION All models.

APPLICATION All models.

01-02-4

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS)

PROPULSION SYSTEM
Fitting P/N 295 000 086 828 Machinists square Not sold by Bombardier
Snap-on PMF 122

Impeller housing remover P/N 295 000 113

829

F01B0Z4 F02B064

APPLICATION All models. Slide hammer puller Not sold by Bombardier

Snap-on:Handle Hammer Claws CJ93-1 CJ125-6 CJ93-4

APPLICATION GTS model. Fitting remover Not sold by Bombardier Do it yourself Refer to JET PUMP 09-02
Deep socket 14 mm (9/16 in)

F01L2O4

APPLICATION SPX and GTS models.

F01J0Z4

APPLICATION All models. NOTE: This tool is also used to remove rotary valve shaft bearing. Hacksaw Not sold by Bombardier
Snap-on HS3

F01J2R4

APPLICATION SPX and GTS models. Jet pump bearing remover P/N 295 000 144 781

F01B1M4

APPLICATION All models.

F01J114

APPLICATION All models.

01-02-5

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (OPTIONAL SERVICE TOOLS)

WATERCRAFT HANDLING
Dolly (with wheels) P/N 295 000 126 876 Lift kit P/N 295 100 044

F01B014

Beach wheels (set of 2 wheels) P/N 295 000 005

877
F00B0Z4

APPLICATION All models. Tie-down 1.50 m (5 ft) long P/N 295 100 010 884

F01B074

APPLICATION Dolly. Tie-down with ratchet 3.60 m (12 ft) long P/N 295 100 011 885

F00B014

APPLICATION All models.

APPLICATION All models.

01-02-6

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

SERVICE PRODUCTS

NOTE: The numbers outlined in black (example: 1 ) are reference to product numbers from other divisions (Ski-Doo Snowmobiles and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same product is being used, even if the part numbers are different. Loctite is a trademark of Loctite Corporation. Permatex is a trademark of Loctite Corporation. Dow Corning is a trademark of Dow Corning Corporation.
Medium strength threadlocker P/N 293 800 015
Loctite 242 (blue) (10 mL)

154

High temperature threadlocker P/N 290 899 788

Loctite 648 (green) (5 g)

359

Retaining compound P/N 413 703 100

Loctite RC/609 (green) (10 mL)

151

LOCTITE
RC/609

LOCTITE
REMOVABLE
THREADLOCKER 242

A00B2S4 A00B3D4 A00B324

High strength threadlocker P/N 293 800 005

Loctite 271 (red) (10 mL)

155

High temperature retaining compound P/N 293 800 039

Loctite 642 (50 mL)

959

General purpose instant adhesive P/N 293 800 021

Loctite 495

373

A00B2V4

LOCTITE

SURE AS
RETAINING COMPOUND 642

Gasket eliminator P/N 293 800 038

Loctite 518 (50 mL)

376

LOCTITE
271
Adhesive Sealant

NET 1.69 FL .OZ. (50 ml)

518

F00B024 A00B2U4 F01B124

01-03-1

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

Gasket stripper P/N 295 000 110

(500 mL)

935

Primer for gasket eliminator 158 P/N 293 800 041

Loctite 764

Sikaflex primer 449 P/N 293 530 012

(475 mL)

918

BOM BARDIER
GASK ET STRIPPER
295 000 110
500 ml

EXTRE MELY FLAMMABLE VAPOR HARMFUL POISON

WARNING

F01B1E4 F01B1W4 A00B3N4

Thread sealant P/N 293 800 050

Loctite 577 (250 mL)

Heat resistant sealant P/N 413 709 200 358 960

Dow Corning 736 (90 mL)
DOW CORNING
RTV Sealant

374

Pipe sealant A) P/N 293 800 018 B) P/N 293 800 013
) A) Loctite 592 (50 mL) B) Loctite 567 (250 mL)

nt Seala tant Resis Heat

736

A00B3U4 F00B0W4

Solvent P/N 293 800 019

Loctite Safety Solvent 755 340 g (12 oz)

157

A00B2W4

High temp RTV silicone gasket maker P/N 413 710 300 369
(85 g)

961

Hylomar sealant P/N 293 800 001

PL-32 (100 g)

A00B3F4

Sealant P/N 293 530 011

A00B3M4

919

Sikaflex 221 (350 mL)

A02B044 F01B1D4

01-03-2

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

Dielectric grease P/N 293 550 004

Dow Corning (150 g)

350

Super Lube grease P/N 293 550 014

932

Bombardier storage oil P/N 413 711 600

(12 x 350 g)

F01B164

Super Lube
R

PERMATEX INDUSTRIAL

Deoxit contact lubricant P/N 293 550 015

(200 mL)
NEW

M Syn ul ti-Purpose t th etic Lubri can W ith Teflon R

Ne tW t. 14.5 Oz. (4 11 g )

A02B054 A00B474

Anti-seize lubricant P/N 293 800 023

Loctite anti-seize lubricant 454 g (16 oz)

362

Sea-Doo fuel stabilizer P/N 413 408 600

236 mL (8 oz)

375

F00B0X4

NEW

Grease P/N 293 550 005

(400 g)

924
F01B174

FUEL STABILIZER

BOMBARDIER LUBE P/N 293 600 016

A00B2L4

913

A00B3V4

(12 x 14 oz)

732 Multi-purpose sealant P/N 293 800 006

Dow Corning (90 mL) (clear)

917

Synthetic grease P/N 293 550 010

(400 g)

912
Sp W! wn! NEside do up rays

LUBE
REPL ACES SEA-DOO LUBE

BOMBARDIER
ANTIC ORROSIVE LUBRICANT Excellent and for high humidit salt water ents y environm

SYNTHETIC GREASE
F01B154

340 g

F01B1C4

DANGER
FLAMMABLE CONT . TED AINER MAY EXPLODE IF HEA DIRECT INHALATION OF SPRAY MAY BE HARMFUL.
Sea-D n Valcourt, oo / Ski-Doo Divisio 2LO Qubec, Canada J0E

BOMBARDIER INC.

F01B0S4

01-03-3

Section 01 SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

BOMBARDIER-ROTAX injection oil P/N 413 802 900

(12 x 1 L)

915

BOMBARDIER-ROTAX Formula XP-S synthetic injection oil 969 P/N 413 711 000 (3 x 4 L) 970 P/N 413 710 700 (205 L)

Adhesive activator P/N 293 530 036

(250 mL)

931

ACTIVEUR D'ADHSIF

250 mL

BOMBARDIER

POUR L'APPLICATION DE MOULURE PRESSION ET VINYLES SENSIBLES LA LORSQU'UNE MEILLEURE . ADHRENCE EST NCESSAIRE

Two-stroke

Injection Oil

DANGER
AVEC LA PEAU -VITER TOUT CONTACT PROLONG CONTACT. CAS DE LAVER L'EAU FROIDE EN BIEN AR. -UTILISER DANS UN ENDROIT FERM. -TENIR LE CONTENANT BIEN DES ENFANTS. -GARDEZ HORS DE LA PORTE . -CONTIENT DU TRICHLORETYLNE DE CE PRODUIT -AVERTISSEMENT ! L'INHALATION EST NOCIF. N/P 293 530 036

FABRIQU AU

BOMBARDIER
1 U.S. quart
Two-stroke FORMULA XP-S

4 U.S. quart

SYNTHETIQUE Injection Oil

Two-Stroke Oil

F01B1Z4

F01B184 F01B354

BOMBARDIER-ROTAX injection oil P/N 413 803 000 (3 x 4 L) P/N 413 803 200 (205 L)

916 962

Sealant adhesive P/N 293 800 033

Adchem 4511 (clear)

934

Jet pump oil P/N 293 600 011 (12 x 6 oz)

Sea-Doo synthetic jet pump oil

914

ADCHEM

SCELLANT ADHSIF PREMIRE QUALIT

ADS E AL
PREMIUM SEALANT ADHESIVE

F01B1S4

JET PUMP SYNTHETIC OIL

The Righ Stuff P/N 293 800 053

Permatex (198 g)
F01B0P4

F01B2H4

BOMBARDIER-ROTAX Formula XP-S synthetic injection oil P/N 413 710 500 (12 x 1 L)

937

Sea-Doo Cleaner P/N 293 110 001 (400 g) P/N 293 110 002 (4 L)

946 947

BOMBARDIER

CLEANER
400 g

BOMBARDIER BOMBARDIER

DANGER

BOMBARDIER

293 110 002

EXTREMELY FLAMMABLE. HARMFUL OR FATAL IF SWALLOWED. VAPOUR HARMFUL.

DANGER

4L

FORMULA XP-S Synthetic

Two-Stroke Oil

F01B2J4 F00B0V4
1 liter (1.05 U.S. qt)

F01B2G4

01-03-4

Section 01

SERVICE TOOLS AND PRODUCTS Subsection 03 (SERVICE PRODUCTS)

SMC spray paint A) Purple night metallic P/N 293 500 120 B) Norwegian sea metallic P/N 293 500 121 C) Titanium pearl P/N 293 500 123 D) Colorado pearl P/N 293 500 124
Sea-Doo paint for SMC

Sea-Doo spray paint for gelcoat 956 A) Super white (140 g) P/N 293 500 082 B) Viper red (140 g) P/N 293 500 114 C) Marine green (140 g) P/N 293 500 115 D) Amethyst (140 g) P/N 293 500 122 E) Ice white (140 g) P/N 293 500 125 F) Aztec red (140 g) P/N 293 500 126
VERTICAL FANSPRAY PATTERN ROTATE VALVE NOZZLE 1/4 TURN TO CHANGE SPRAY PATTERN

Gelcoat (liquid) A) Super white (1 L) P/N 293 500 075 B) Marine green (1L) P/N 293 500 097 APPLICATION A) SPX (body). GTS (body/hull). GTI (body). B) GTI (hull). Gelcoat repair kit P/N 295 500 590

943

HORIZONTAL FANSPRAY PATTERN

Danvern Fanspray re - A Sprayon Exclusive Featu

PEINT URE POUR

GELCOAT

T PAIN

F01B0Q4

APPLICATION Storage cover. A) GTS model. B) GTI model. C) XP limited. D) GTX limited.

DA NG ER

ER DANG

F01B0R4

F01B1Q4

APPLICATION All 1998 models.

APPLICATION A) SPX (body). GTS (body/hull). GTI (body). B) GSX Limited (body/hull). C) GTI (hull). D) GSI (hull). E) GTX Limited (body). F) GTX Limited (hull).

01-03-5

Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
PERIODIC INSPECTION CHART............................................................................................ FLUSHING AND LUBRICATION............................................................................................ GENERAL ........................................................................................................................... PROCEDURE ...................................................................................................................... WATER-FLOODED ENGINE................................................................................................... GENERAL ........................................................................................................................... PROCEDURE ...................................................................................................................... STORAGE...............................................................................................................................

0
02-02-1 02-03-1 02-03-1 02-03-1 02-04-1 02-04-1 02-04-1 02-05-1

GTX RFI

02-01-1

Subsection 02

Section 02 MAINTENANCE (PERIODIC INSPECTION CHART)

PERIODIC INSPECTION CHART

NOTE: Servicing period is given in hours. Shaded area shows the maintenance frequency.
FREQUENCY

0
Every 50 hours Every 100 hours or seasonally

DESCRIPTION
Lubrication/corrosion protection of metallic components Engine ignition timing Spark plug replacement Throttle/choke cables, inspection/lubrication Flame arrester inspection (717 and 787 engines) Carburetor adjustment including choke/throttle cable adjustments and linkage RAVE valve cleaning (787 and 947 engines) Engine counterbalance shaft oil level (787 and 947 engines) Water flow regulator valve inspection (787 and 947 engines) Oil injection pump adjustment Fuel filter and oil filter inspection Fuel filter and oil filter replacement Engine head bolts or nuts, retorque Steering system inspection Reverse system/reverse cable adjustment (if applicable) Variable trim system (if applicable) Fastener tightening (flame arrester support, carburetor(s), 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 Inspect/clean engine drain hose Water tank trap drain inspection (GTS) Bailer pick up inspection Battery condition Electrical 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 and seal carrier lubrication (if applicable) Water intake grate condition Hull condition Cooling system flushing

Every 10 hours

Every 25 hours

Every 10 hours in salt water use. These items have to be initially checked after 25 hours. Thereafter, servicing to be made as specified in this chart. Daily flushing in salt water or foul water use.

02-02-1

Subsection 03

Section 02 MAINTENANCE (FLUSHING AND LUBRICATION)

FLUSHING AND LUBRICATION

GENERAL
Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in water jackets (engine, exhaust manifold, tuned pipe) and/or hoses. 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. Install a hose pincher on water outlet hose.

CAUTION

This prevents water from exiting through outlet socket. Remove hose pincher after flushing operation.

CAUTION

Failure to flush cooling system, when necessary, will severely damage engine and/or exhaust system. Never flush a hot engine. Make sure engine operates during entire procedure.

PROCEDURE

F01E28A

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.

SPX MODEL 1. Fitting spigot 2. Coupler hose 3. Hose pincher

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.

SPX and GTS Models Remove seat to allow access to cooling system. Remove dust cap from fitting spigot and attach coupler hose (P/N 295 500 258). Make sure coupler hose is properly locked to fitting spigot.

F02E03A

GTS MODEL 1. Fitting spigot 2. Coupler hose 3. Hose pincher

02-03-1

Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION)

Attach other end of coupler hose to a garden hose.

CAUTION

Do not open water tap yet.

All Models Except SPX and GTS Connect a garden hose to the water outlet located at the rear of the watercraft.

F07E01A

1. Garden hose installed

All Models Start the engine then immediately open the water tap.

F06E01A

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

WARNING

1. Water outlet

NOTE: A quick connect adapter can be used to ease garden hose installation.

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.

F00E01A

1. Quick connect adapter

02-03-2

Subsection 03

Section 02 MAINTENANCE (FLUSHING AND LUBRICATION)

Close the water tap then stop the engine.

2 1 3

CAUTION

Always close the water tap before stopping the engine. Disconnect the garden hose.

SPX and GTS Models Unlock and remove coupler hose. Reinstall dust cap over fitting spigot. Remove hose pincher from water outlet hose.
F01F25A

SPX, GS, GTS AND GTI MODELS 1. Air intake silencer 2. Pull plug 3. Spray BOMBARDIER LUBE here

CAUTION

Serious engine damage can occur if hose pincher is not removed.

All Models Except SPX and GTS Models

CAUTION

Remove quick connect adapter after flushing operation (if used).

All Models Wipe up any residual water from the engine. Remove spark plug cables and connect them on the grounding device.
F06F0CA

GSX LIMITED, XP LIMITED AND GTX LIMITED 1. Air intake silencer 2. Spray BOMBARDIER LUBE here

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

WARNING

NOTE: Lubrication of engine should be done at least for 1 minute. After approximately half a minute, close fuel valve to run engine out of fuel while lubricating.

CAUTION

When engine begins to run irregularly because of fuel starvation, immediately close the water tap to stop water flow before engine dies.

02-03-3

Section 02 MAINTENANCE Subsection 03 (FLUSHING AND LUBRICATION)

F01H64A

1
F00H0AA

GTS MODEL 1. Spark plug cables on grounding device

XP LIMITED 1. Grounding device

F00H0DA

1
F06H1WA

SPX, GS AND GTI MODELS 1. Spark plug cables on grounding device

GSX LIMITED 1. Spark plug cables on grounding device

02-03-4

Subsection 03

Section 02 MAINTENANCE (FLUSHING AND LUBRICATION)

F07H07A

GTX LIMITED 1. Grounding device

Remove both spark plugs and spray BOMBARDIER LUBE lubricant into each cylinder. 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 (SPX, GS, GTS and GTI models). NOTE: Engine fogging should be done with BOMBARDIER LUBE lubricant whenever the watercraft is to be stored for a few days or a long period.

CAUTION

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

02-03-5

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

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

CAUTION

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

PROCEDURE
Check fuel and oil reservoirs for water contamination. If necessary, siphon and refill with fresh fluids. Turn fuel valve to OFF position then drain fuel filter bowl. Refer to FUEL CIRCUIT 06-02. Drain bilge if water is present. Remove spark plug cables and connect them on the grounding device.
F00H0DA

SPX, GS AND GTI MODELS 1. Spark plug cables on grounding device

WARNING

Never crank engine with spark plugs removed unless spark plug cables are connected to the grounding device.

F00H0AA

XP LIMITED 1. Grounding device

F01H64A

GTS MODEL 1. Spark plug cables on grounding device

02-04-1

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

787 and 947 Engines Remove the filler plug of the counterbalance shaft on the engine crankcase.

F06H1WA

GSX LIMITED 1. Spark plug cables on grounding device

F07D06A

787 ENGINE 1. Remove filler plug

F07H07A

GTX LIMITED 1. Grounding device

F06D2CA

Remove spark plugs and dry them with a clean cloth. A contact cleaner spray can be used. It may be preferable to replace spark plugs. Do NOT install spark plugs on engine. Crank engine to drain crankcase.

947 ENGINE 1. Remove filler plug

Insert a wire through oil level hole to check oil condition. A whitish oil indicates water contamination and must be replaced.

CAUTION

Be careful when cranking engine, water will spray out from spark plug holes. Spray BOMBARDIER LUBE lubricant (P/N 293 600 016) into spark plug holes. Crank engine again. Reinstall spark plugs and spark plug cables.

787 Engine In order to replace the oil, remove the drain plug of the counterbalance shaft located on the PTO side of the lower crankcase.

02-04-2

Section 02 MAINTENANCE Subsection 04 (WATER-FLOODED ENGINE)

2 1 3

F07D07A

1
F01F25A

1. Drain plug

Drain completely the crankcase oil of the counterbalance shaft. Reinstall drain plug with Loctite 515. Add 30 mL (1 oz) of SAE 30 motor oil. Reinstall filler plug.

717 AND 787 ENGINES 1. Air intake silencer 2. Pull plug 3. Spray BOMBARDIER LUBE here

947 Engine Siphon the oil and add 40 mL (1.35 oz) of SAE 30 motor oil. Reinstall filler plug. All Models Turn fuel valve to ON position. Start engine; It may be necessary to use the choke. If engine does not start, repeat previous steps as necessary.

CAUTION

F06F0CA

To avoid starting motor overheating, the cranking period should not exceed 5-10 seconds and a rest period of 30 seconds should be observed between cranking cycles. NOTE: If engine does not start after several attempts, check ignition system for spark occurrence. Refer to IGNITION SYSTEM 08-02. Check crankshaft if needed, it may be misaligned or deflected. Refer to BOTTOM END 04-06. After engine has started, spray BOMBARDIER LUBE lubricant through air intake silencer while engine is running.

947 ENGINE 1. Air intake silencer 2. Spray BOMBARDIER LUBE here

Run engine until it reaches its normal operating temperature.

CAUTION

Engine must be cooled using the flush kit.

02-04-3

Section 02 MAINTENANCE Subsection 05 (STORAGE)

STORAGE
Engine Draining
Check engine drain hose (lowest hose of engine). Make sure there is no sand or other particles in it and that it is not obstructed so that water can leave the engine. Clean hose and fitting as necessary.

0
Cooling System Flushing and Engine Internal Lubrication
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 02-03.

CAUTION

Water in engine drain hose must be free to flow out, otherwise water could be trapped in engine. Should water freeze in engine, severe damage will occur. Check engine drain hose for obstructions.

Propulsion System
JET PUMP Lubricant in impeller shaft reservoir should be drained. Reservoir should be cleaned and refilled with SEA-DOO synthetic 75W90 GL5 polyolester oil. Refer to JET PUMP 09-02 for proper procedure. PTO FLYWHEEL

All Models Except XP Limited Lubricate PTO flywheel at grease fitting with synthetic grease (P/N 293 550 010).

F02E05A

CAUTION

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

TYPICAL 1. Engine drain hose

Fuel System
Sea-Doo Fuel Stabilizer (P/N 413 408 600) should be added in fuel tank to prevent fuel deterioration and carburetor gumming. Follow manufacturers instructions for proper use. NOTE: Fuel stabilizer should be added prior engine lubrication to ensure carburetor protection against varnish deposit.

WARNING
F01I0BA

Fuel is flammable and explosive under certain conditions. Always work in a well ventilated area. Always turn the fuel valve to OFF position when storing the watercraft.

1. Grease PTO flywheel

02-05-1

Section 02 MAINTENANCE Subsection 05 (STORAGE)

SEAL CARRIER

CAUTION

Battery
For battery removal, cleaning and storage, refer to CHARGING SYSTEM 08-03.

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

Watercraft Cleaning
GSX Limited, XP Limited and GTX Limited Lubricate seal carrier of thru hull fitting with synthetic grease (P/N 293 550 010). Stop lubricating when grease is just coming out of seal.
Clean the bilge with hot water and mild detergent or with bilge cleaner. Rinse thoroughly. Lift front end of watercraft to completely drain bilge. If any repairs are needed to body or to the hull, touch up paint and Gelcote repair kit are available. Replace damaged labels/decals. Wash the body with soap and water solution (only use mild detergent). Rinse thoroughly with fresh water. Remove marine organisms from the hull. Apply a nonabrasive wax.

CAUTION

Never clean fiberglass and plastic parts with strong detergent, degreasing agent, paint thinner, acetone, etc. If the watercraft is to be stored outside, cover it with an opaque tarpaulin to prevent sun rays and grime from affecting the plastic components, watercraft finish as well as preventing dust accumulation.

F06I03A

1. Grease seal carrier

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

CAUTION

The watercraft must never be Ieft in water for storage. Never leave the watercraft stored in direct sunlight.

Anticorrosion Treatment
Wipe off any residual water in the engine compartment. Spray BOMBARDIER LUBE lubricant over all metallic components in engine compartment. Lubricate the throttle cable with BOMBARDIER LUBE lubricant. The seat should be partially left opened during storage (the engine cover for the XP model). This will avoid engine compartment condensation and possible corrosion.
F08I01A

1. Grease seal carrier

02-05-2

Section 02 MAINTENANCE Subsection 05 (STORAGE)

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.

SPX and GTS Models Install a hose pincher to engine drain hose near the PTO flywheel guard.
F01E1EA

1. Coupler hose 2. Fitting Spigot 3. Hose pincher

Pour the antifreeze slowly mixed with water in coupler hose until the colored solution appears in the engine drain hose. Remove hose pincher(s).

All Models Except SPX and GTS Install a hose pincher to engine drain hose.
1

F02E06A

TYPICAL 1. Hose pincher installed on engine drain hose

Install coupler hose to fitting spigot. Install a hose pincher to engine water return hose (beside fitting spigot).

F06E0DA

TYPICAL 1. Hose pincher installed on engine drain hose

02-05-3

Section 02 MAINTENANCE Subsection 05 (STORAGE)

Disconnect engine water return hose.

F06E0FA F06E0EA

717 AND 787 ENGINES 1. Disconnect engine water return hose

717 AND 787 ENGINES 1. Hose pincher installed on the 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 engine drain hose. Remove temporary hose and reconnect engine water return hose. Remove hose pinchers.

F06E05A

947 ENGINE 1. Disconnect engine water return hose

Install a hose pincher to engine water supply hose (except the 947 engine).

All Models Most of the antifreeze will drain out when removing hose pincher(s). 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.

02-05-4

Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

TROUBLESHOOTING CHART
ENGINE WILL NOT START
OTHER OBSERVATION
Engine does not turn over

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

REMEDY
If 2 short beeps are not heard when installing safety lanyard, refer to DIGITALLY ENCODED SECURITY SYSTEM 08-06 Replace Check wiring then replace fuse Check wiring, solenoid and MPEM Check/recharge Check/clean/tighten Check, refer to subsection 02-04 Check, refer to subsection 08-04 Check/repair as needed Check, refer to subsection 09-02 Check/charge/replace Check/clean pump Inspect, refer to subsection 09-02 Check, refer to subsection 02-04 Check compression, refer to subsection 04-05 Check, refer to subsection 08-04 Check/siphon and refill Clean/replace Replace Check, refer to subsection 02-04 Check, refer to subsection 06-04 Check, refer to subsection 08-02 Check, refer to subsection 06-04 Check, refer to subsection 04-07 Check, refer to subsections 04-05 and 04-06 Check timing mark, refer to subsection 08-02 Check, refer to subsection 04-07 Replace MPEM Replace MPEM or ignition module depending upon the model

Safety lanyard switch or harness damaged Burnt 5 A fuse 5 A fuse keeps on burning Discharged battery Battery connections Water/fuel hydrolock Starter Seized engine Seized jet pump Engine turns slowly Discharged/weak battery Restriction in jet pump Seizure in jet pump Partial engine hydrolock Partial engine seizure Worn starter Engine turns over Fuel water-contaminated Dirty fuel filter Fouled spark plugs Water in engine Carburetion Ignition Flooded engine Carburetor needle valve stuck open Excessive rotary valve clearance (if applicable) Internal engine damage Sheared flywheel key Incorrect rotary valve timing (if applicable) No spark at spark plugs Faulty rev limiter Faulty ignition module

03-01-1

Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ENGINE MISFIRES, RUNS IRREGULARLY

OTHER OBSERVATION
Weak spark

POSSIBLE CAUSE
Fouled, defective, worn spark plugs Faulty rev limiter or ignition module Sheared flywheel key

REMEDY
Check/verify heat range/gap/replace Check, refer to subsection 08-02 Check timing mark, refer to subsection 08-02 Check/refill Check/siphon and refill Check/clean/replace Check/clean/adjust, refer to subsection 06-04 Pressure check engine, refer to subsection 04-02 Check/replace Tighten carburetor(s) Check/adjust choke cable Check/replace Check/adjust, refer to subsection 06-04 Check, refer to subsection 06-04 Check/replace, refer to subsection 04-07 Check/adjust, refer to subsection07-03 Check, refer to subsection 06-04 Check, refer to subsection04-07

Lean fuel mixture Dry spark plug (except when water fouled)

Low fuel level Stale or water fouled fuel Fuel filter dirty or restricted Carburetion dirty or out of adjustment Leaking crankshaft seal(s), intake or rotary valve cover O-ring Restricted fuel valve Loose carburetor

Rich fuel mixture Fouled spark plug

Partially closed choke Flame arrester dirty or restricted Carburetor adjustment Loose main jet Rotary valve shaft seal leaking (if applicable) Oil pump adjustment Worn needle(s) and seal(s) Excessive rotary valve clearance (if applicable)

Difficult to start

Incorrect rotary valve timing (if applicable) Check/adjust, refer to subsection 04-07 Excessive rotary valve clearance (if applicable) Check, refer to subsection 04-07

ENGINE OVERHEATS
OTHER OBSERVATION
Monitoring beeper sounds continuously

POSSIBLE CAUSE
Restricted jet pump water intake Cooling system restriction Grounded temperature sensor or sensor wire

REMEDY
Check/clean Check/flush, refer to subsection 02-03 Check/repair/replace

03-01-2

Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ENGINE CONTINUALLY BACKFIRES

OTHER OBSERVATION
Weak spark Ignition timing

POSSIBLE CAUSE
Fouled, defective spark plugs Malfunction of rev limiter Incorrect setting Sheared flywheel key

REMEDY
Clean/replace Clean/replace, refer to subsection 08-02 Check/reset, refer to subsection 08-02 Check/replace, refer to subsections 08-02 and 04-04 Check/reset, refer to subsection 04-07 Check/adjust, refer to subsection 06-04 Pressure check engine, refer to subsection 04-02

Rotary valve (if applicable) Carburetor Engine

Incorrect timing Carburetion to lean Intake leak/crankshaft seal failure

ENGINE DETONATION OR PINGING

OTHER OBSERVATION
Ignition

POSSIBLE CAUSE
Timing too far advanced Spark plug heat range too high Defective ignition module or MPEM

REMEDY
Check/reset Check/change to correct range Check/replace, refer to subsection 08-02 Check, see engine overheats Use good quality fuel

Engine temperature

Engine overheats Fuel of poor quality

ENGINE LACKS ACCELERATION OR POWER

OTHER OBSERVATION POSSIBLE CAUSE
Weak spark Carburetion, jetting too rich/lean Throttle does not open fully Low compression Exhaust system restriction Water in fuel or oil Debris in carburetor needle valve Impeller leading edge damaged Twisted crankshaft Engine revs lower than its maximum operational RPM (787 and 947 engines) Peak performance is delayed until higher RPM range is reached (787 and 947 engines) RAVE valve does not open

REMEDY
Check/replace, refer to subsection 08-02 Check/adjust, refer to subsection 06-04 Check/readjust, refer to subsection 06-04 Check/repair, refer to subsection 04-05 Check/clean Check/siphon/replace Check/clean, refer to subsection 06-04 Check/replace, refer to subsection 09-02 Check, refer to subsection 04-06 Check, refer to subsection 04-05

RAVE valve is stuck opened

Check, refer to subsection 04-05

03-01-3

Section 03 TROUBLESHOOTING Subsection 01 (TROUBLESHOOTING CHART)

ENGINE RUNS TOO FAST

OTHER OBSERVATION
Engine RPM too high Jet pump cavitation

POSSIBLE CAUSE
Faulty rev limiter Improper impeller pitch (too low) Damaged leading or trailing edge of impeller

REMEDY
Check, refer to subsection 08-02 Check/replace, refer to subsection 09-02 Check/replace NOTE: Leading edge damage contributes to poor performance from start. Trailing edge damage contributes to poor top performance and stator vanes erosion. Check/reseal, refer to subsection 09-02 or 12-02

Sealing of ride plate, jet pump support or jet pump

ABNORMAL NOISE FROM PROPULSION SYSTEM

OTHER OBSERVATION POSSIBLE CAUSE
Weeds/debris caught in intake grate or impeller Low oil level in jet pump Worn anti-knock system Damaged or bent drive shaft Broken motor mounts

REMEDY
Check/clean Check/troubleshoot source of leak/refill supply, refer to subsection 09-02 Check/replace pusher in cover, refer to subsection 09-02 Check/replace, refer to subsection 09-03 Check/replace, refer to subsection 04-03

03-01-4

Subsection 01

Section 04 ENGINE (TABLE OF CONTENTS)

TABLE OF CONTENTS
LEAK TEST............................................................................................................................. GENERAL ........................................................................................................................... PREPARATION ................................................................................................................... TESTING PROCEDURE ..................................................................................................... ENGINE LEAKAGE DIAGNOSTIC FLOW CHART ............................................................ REMOVAL AND INSTALLATION.......................................................................................... GENERAL ........................................................................................................................... ENGINE REMOVAL ............................................................................................................ CLEANING ......................................................................................................................... INSTALLATION ..................................................................................................................

0
04-02-1 04-02-1 04-02-1 04-02-1 04-02-6 04-03-1 04-03-1 04-03-1 04-03-4 04-03-4

MAGNETO SYSTEM ............................................................................................................. 04-04-1 GENERAL ........................................................................................................................... 04-04-4 DISASSEMBLY .................................................................................................................. 04-04-4 CLEANING ......................................................................................................................... 04-04-10 ASSEMBLY......................................................................................................................... 04-04-10 TOP END ................................................................................................................................ GENERAL ........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... ADJUSTMENT ................................................................................................................... 04-05-1 04-05-4 04-05-8 04-05-16 04-05-16 04-05-20 04-05-28

BOTTOM END........................................................................................................................ 04-06-1 DISASSEMBLY................................................................................................................... 04-06-4 CLEANING ......................................................................................................................... 04-06-11 INSPECTION ...................................................................................................................... 04-06-11 ASSEMBLY......................................................................................................................... 04-06-15 ROTARY VALVE ..................................................................................................................... GENERAL ........................................................................................................................... INSPECTION ON WATERCRAFT ....................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... ROTARY VALVE TIMING.................................................................................................... 04-07-1 04-07-2 04-07-2 04-07-4 04-07-5 04-07-6 04-07-6 04-07-9

GTX RFI

04-01-1

Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS)

EXHAUST SYSTEM ............................................................................................................... REMOVAL ........................................................................................................................... TUNED PIPE REPAIR .......................................................................................................... INSTALLATION ...................................................................................................................

04-08-1 04-08-4 04-08-8 04-08-8

04-01-2

GTX RFI

Section 04 ENGINE Subsection 02 (LEAK TEST)

LEAK TEST
GENERAL
NOTE: The leak test kit was not upgraded for the 947 engine at time of printing. A Service Bulletin will be issued. A Sea-Doo Engine Leak Test Kit (P/N 295 500 352) is available to help diagnose engine problems such as engine seizure, poor performance, oil leakage, etc. Before disassembling any components of the engine, it is important to perform a leakage test to determine which part is defective. It is also very important after servicing the engine, even for a complete engine rebuilt, to perform another leakage test; at this stage, it may avoid further engine problems and minimizing the risk of having to remove and reinstall the engine again. Static bench testing is the most effective way to conduct a leakage test. Inboard testing does not allow complete access to, and observation of all engine surfaces and should be avoided whenever possible. On the 717 engine, cylinders can not be verified individually due to leakage from one cylinder to another through a common intake manifold. When installing hoses of the Engine Leak Test Kit, use the collars provided in the kit to ensure a proper sealing. When pressurizing the engine, first confirm that the components of the Engine Leak Test Kit are not leaking by spraying a solution of soapy water on all hoses, connections, fittings, plates, etc. If there is a leak, bubbles will indicate leak location. Three areas of the engine will be tested in sequence as per the diagnostic flow chart (see the end of this sub-section). 1. Engine Cooling System 2. Bottom End and Top End 3. Rotary Valve Shaft NOTE: If a leak is found, it is important to continue testing as there is the possibility of having more than one leak. Continue pumping to compensate for the air lost to find another leak.

0
PREPARATION
Verify fuel system for leaks.

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

WARNING

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

WARNING

TESTING PROCEDURE
Engine Cooling System
Remove the tuned pipe. Remove the exhaust manifold gasket and ensure the surface is cleaned. Disconnect engine cooling hoses. Install the appropriate exhaust manifold plate (no. 1 for the 787 engine and no. 2 for 717 engine) from the Engine Leak Test Kit. Tighten plate using fasteners provided in the kit. Use hoses provided in the kit and install them on the engine. Install pump using reducer and appropriate tube(s) as necessary.

04-02-1

Section 04 ENGINE Subsection 02 (LEAK TEST)

4 3

F01B2UB

2
F01B2WA

717 ENGINE REAR VIEW 1. Engine drain hose blocked with a hose pincher

2 1

787 ENGINE 1. Loop hose and use clamps 2. Hose with clamps. Plug end with a screw 3. Block engine drain hose with a hose pincher 4. Use 2 washers with exhaust manifold stud

F01B2VA

NOTE: Water is not required for testing. Activate pump and pressurize engine cooling system to 34 kPa (5 PSI). Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking and pressure drops, verify all external jointed surfaces, temperature sensor and the O-ring between the spark plug area and the engine cylinder head cover. If none of these components are leaking, there is an internal leak and it can be detected with Bottom End and Top End testing.

717 ENGINE FRONT VIEW 1. Loop hose and use clamps 2. Use 2 washers with exhaust manifold stud 3. Hose with adapter and nipple

04-02-2

Section 04 ENGINE Subsection 02 (LEAK TEST)

Bottom End and Top End

Remove the carburetor(s) and gasket(s). Make sure the surface of the intake manifold (717 engine) or rotary valve cover (787 engine) are clean. Install the intake plate(s) no. 3 with fasteners from the kit and tighten adequately. On engines with the RAVE system, remove the RAVE valves and gaskets. Install plates no. 4 with fasteners from the kit and tighten adequately. NOTE: On engines with the RAVE system, the boot and O-ring can be checked for leakage with the valve in place. Simply remove the cover to expose the boot. Make sure the spark plugs are installed and tighten. Block pulse hose using a hose pincher. NOTE: Do not block the rotary valve shaft hoses. Install pump to the exhaust plate fitting.
3 2

4 1

3
F01B30A

787 ENGINE 1. Intake plates 2. RAVE valve plates 3. Pulse hose blocked with a hose pincher 4. Exhaust plate

Activate pump and pressurize engine to 34 kPa (5 PSI).

CAUTION

Do not exceed this pressure. Wait 3 minutes and check if pressure drops; if so, verify all testing components. If kit components are not leaking, verify engine jointed surfaces as per following areas: spark plugs cylinder head gasket cylinder base gasket crankcase halves rotary valve cover engine plugs exhaust manifold intake manifold (717 engine) oil injection pump (717 engine)

2
F01B2ZA

717 ENGINE 1. Intake plates 2. Pulse hose blocked with a hose pincher 3. Exhaust plate

04-02-3

Section 04 ENGINE Subsection 02 (LEAK TEST)

Check also small oil injection pump lines and fittings; check for air bubbles or oil column going toward pump, which indicate a defective check valve. If the above mentioned components are not leaking, block both oil hoses of the rotary valve shaft using hose pinchers. NOTE: If leakage stops at this point, proceed with Rotary Valve Shaft testing. If there is still some leakage, remove the PTO flywheel to verify outer seal. If no leak is found on the PTO side outer seal, remove magneto flywheel and verify crankshaft outer seals. Proceed with the Rotary Valve Shaft testing if the crankshaft outer seals are not leaking.

F01B33A

787 ENGINE 1. Oil return hose blocked with hose pincher

Rotary Valve Shaft

NOTE: It is preferable to drain the injection oil from the rotary valve shaft, but it is not mandatory. Block oil return hose of the rotary valve shaft with a hose pincher.

Install pump with reducer and nipple to the oil supply hose of the rotary valve shaft.
1

F01B32A

717 ENGINE 1. Pump with reducer and nipple

F01B31A

717 ENGINE 1. Oil return hose blocked with hose pincher

04-02-4

Section 04 ENGINE Subsection 02 (LEAK TEST)

F01B34A

787 ENGINE 1. Pump with reducer and nipple

Activate pump and pressurize to 5 PSI (34 kPa). Check plug of the rotary valve shaft in crankcase. Remove PTO side spark plug. If pressure drops, it indicates a defective PTO side crankshaft inner seal. Remove MAG side spark plug. If pressure drops, it indicates a defective MAG side crankshaft inner seal. If the above mentioned components are not leaking and there is a pressure drops, remove the rotary valve cover. Check the seal of the rotary valve shaft. If the rotary valve shaft is not leaking, it could indicates a defective engine casting. Disassemble engine and carefully check for defects in castings. Pay attention to tapped holes which may go through sealed areas of engine and thus lead to leakage.

04-02-5

Section 04 ENGINE Subsection 02 (LEAK TEST)

ENGINE LEAKAGE DIAGNOSTIC FLOW CHART

PRESSURIZE ENGINE COOLING SYSTEM YES

IS SYSTEM LEAKING? NO PRESSURIZE ENGINE

CHECK TESTING KIT

REPLACE O-RING OF CYLINDER HEAD AND/OR CYLINDER BASE GASKET

NO

IS ENGINE LEAKING? YES CHECK TESTING KIT

RECHECK ENGINE SEALING

CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. YES

ANY LEAK FOUND?

REPLACE GASKET OR O-RING, RE-SEAL LEAKING AREA

CHECK SMALL OIL LINES OF INJECTION PUMP

AIR BUBBLES FOUND OR OIL MOVING TOWARD PUMP?

YES

REPLACE CHECK VALVE(S) / LINE(S)

BLOCK LARGE HOSES OF ROTARY VALVE GEAR LUBRICATION SYSTEM NO IS ENGINE STILL LEAKING?

CHECK TESTING KIT

CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES YES

PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE

ARE SEALS LEAKING? NO PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE

REPLACE DEFECTIVE SEAL(S)

YES IS RESERVOIR LEAKING?

RECHECK ENGINE SEALING

UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY BY REMOVING THE APPROPRIATE SPARK PLUG

IS RESERVOIR LEAKING? NO CHECK TESTING KIT CHECK FOR LEAKAGE AT ROTARY VALVE SHAFT CRANKCASE PLUG

YES

REPLACE DEFECTIVE SEAL(S)

YES IS RESERVOIR LEAKING?

ANY LEAK FOUND? NO REMOVE ROTARY VALVE COVER, CHECK SEAL OF ROTARY VALVE SHAFT

YES

REPLACE OIL SEAL OF ROTARY VALVE SHAFT END, OR REPLACE CAP

NO

YES IS SEAL LEAKING?

REPLACE DEFECTIVE SEAL

CAREFULLY INSPECT ENGINE CASTINGS, PARTICULARLY THE THREADED HOLE AREAS

ANY LEAK FOUND?

YES

REPLACE DEFECTIVE PARTS

ENGINE IS PERFECTLY SEALED INTERNALLY

F00D07S

04-02-6

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION

GENERAL
It is not necessary to remove engine from watercraft to service TOP END, PTO FLYWHEEL or MAGNETO. However, engine removal is necessary to repair BOTTOM END.

All Models Disconnect temperature switch wire and spark plug cables. Disconnect magneto wiring harness.

ENGINE REMOVAL
In order to remove engine from watercraft proceed as follows.

CAUTION

Whenever removing engine from watercraft, engine/jet pump alignment must be performed at reinstallation.

Jet Pump Removal

To withdraw jet pump, refer to JET PUMP 09-02.
F01D8RA

Drive System
To withdraw driveshaft(s), refer to DRIVE SYSTEM 09-03.

717 ENGINE 1. Unplug connector

All Models

Electrical Connections
First, remove BLACK negative cable from battery, then RED positive cable.

WARNING

Always disconnect starter or battery cables exactly in the specified order, BLACK negative cable first. It is recommended to disconnect electrical connections prior to disconnecting fuel lines.

F06D0FA

787 ENGINE 1. Unplug connector

GTS Model Remove battery holding straps and disconnect vent tube from battery. Remove battery.

04-03-1

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

F07D08A

F02D08A

947 ENGINE 1. Unplug connector

717 ENGINE 1. Remove screw of each engine support

Cooling System
Disconnect the engine water supply hose. Disconnect the engine water return hose.

Tuned Pipe
To remove tuned pipe, refer to EXHAUST SYSTEM 04-08.

Air Intake Silencer

To remove air intake silencer, refer to AIR INTAKE 06-03.

Carburetor
All Models Except the XP Limited To remove carburetor(s), refer to CARBURETOR 06-04. XP Limited Disconnect choke and throttle cables from carburetor linkage. Disconnect fuel supply and fuel return hoses.

F06D35A

787 AND 947 ENGINES FRONT SUPPORT 1. Remove screw

Engine Support
NOTE: Be careful when removing engine support(s) or rubber mount adapters, shims could have been installed underneath. Shims control engine/jet pump alignment. Always note position of shims for reinstallation, to avoid altering engine alignment. Remove engine support mount screws.

F06D36A

787 AND 947 ENGINES REAR SUPPORT 1. Remove screws

04-03-2

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

Lifting Engine
717 Engine Engine can be easily lifted using the following suggested tools: Cut porcelain from 2 old spark plugs. Weld a lock washer approximately 20 mm diameter on each spark plug as shown.

787 and 947 Engines Engine can be easily lifted by inserting a hook into exhaust manifold eyelet.

F01D7OA

TYPICAL
F01D0AA

1. Weld a lock washer 2. Old spark plug

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

Remove spark plugs and replace by special tools. Hook a sling into holes of special tools. Using a chain block, a hoist or other suitable equipment, slightly lift engine to ease the remaining component removal.

CAUTION

Take care not to damage cable or oil injection hoses. Remove rear engine support.
1

CAUTION

Take care not to damage cable or oil injection hoses.

F06D36B

1. Rear support

04-03-3

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

All Engines Install a hose pincher to oil supply hoses of oil injection pump and rotary valve shaft (except the 947 engine); then, disconnect hoses.

F01D7RA

TYPICAL
A01B2JB

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

CLEANING
Wipe off any spillage in bilge. Clean with a bilge cleaner. Clean external parts of engine.

Install a hose pincher to oil return hose of rotary valve shaft (except the 947 engine); then, disconnect hose. Disconnect RED positive cable from starter post.

INSTALLATION
Installation of engine in watercraft is essentially the reverse of removal procedures. However pay particular attention to the following.

Rubber Mount, Shim and Screw

Check tightness and condition of rubber mounts. If they have been removed, apply Loctite 242 (blue) on screw threads. Torque screws to 25 Nm (18 lbfft).

F01H1JB

CAUTION

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

TYPICAL 1. Disconnect RED positive cable

Carry on engine lifting then tilt engine so that it can be removed from the body opening.

CAUTION

Be careful not to scratch body or to hit any component.

04-03-4

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

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

Positive Starter Cable

Torque nut of positive starter cable to 6 Nm (53 lbfin). Apply dielectric grease on nut.

Engine/Jet Pump Alignment

Alignment is necessary to eliminate possible vibration and/or damage to components. Check alignment of engine using the following alignment tools. Support plate kit (P/N 529 035 506). NOTE: Use plate (P/N 529 035 508) for the 139.5 mm (5-1/2 in) jet pump and plate (P/N 529 035 507) for the 155.6 mm (6-1/8 in) jet pump.

Loctite 242 1

1
F02D09A

Loctite 242

Loctite 242

1. Torque screws to 22 Nm (16 lbfft) 2. Torque nuts to 39 Nm (29 lbfft)

787 and 947 Engines Apply Loctite 242 (blue) to rear engine support screws and torque to 24 Nm (17 lbfft).
1

1
F00B0FA

1. Plate (P/N 529 035 507 or 529 035 508) 2. Support (P/N 529 035 511)

Alignment shaft (P/N 295 000 141).

F06D36C

1. Torque engine support screws to 24 Nm (17 lbfft)

Oil Injection Hoses

717 and 787 Engines Make sure to reinstall hoses before completely lowering engine in bilge.

1
F00B0GA

1. Alignment shaft

04-03-5

Section 04 ENGINE Subsection 03 (REMOVAL AND INSTALLATION)

XP Limited On this model, the PTO flywheel adapter (P/N 295 000 157) must be used in conjunction with the alignment shaft.

F00B05A

1
F07D05A

1. Adapter (P/N 295 000 157)

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

TYPICAL 1. Alignment shaft 2. PTO flywheel

All Models To verify alignment proceed as follows: Install the appropriate plate with the support to hull with 4 nuts.

If the alignment is incorrect loosen engine support screws to enable to align PTO flywheel with shaft end. NOTE: Use shim(s) (P/N 270 000 024) or (P/N 270 000 025) as necessary between engine supports and rubber mounts to correct alignment.

F00B0HA

Carefully slide shaft through support. Insert shaft end into PTO flywheel. NOTE: Ensure the protective hose and carbon ring (or seal carrier) is removed to check engine alignment. If the alignment is correct, the shaft will slide easily without any deflection in PTO flywheel.

F00D0CA

TYPICAL 1. Shim

CAUTION

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

04-03-6

Subsection 03

Section 04 ENGINE (REMOVAL AND INSTALLATION)

Engine Support Screws Apply Loctite 242 (blue) on screw threads. Torque engine support screws to 25 Nm (18 lbfft) when procedure is completed.
Loctite 242 1 Loctite 242 1

F06D36A

1 Loctite 242

REAR ENGINE SUPPORT 787 AND 947 ENGINES 1. Torque to 25 Nm (18 lbfft)

Final Inspection
Check throttle cable condition and lubricate cable with BOMBARDIER LUBE lubricant. After its installation, properly adjust and bleed oil injection pump as specified in OIL INJECTION PUMP 07-03. Check hose condition and pressure test fuel system, refer to FUEL CIRCUIT 06-02.

F02D0KA

717 ENGINE 1. Torque to 25 Nm (18 lbfft)

Whenever doing any type of repair on watercraft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine. Verify all electrical connections. Run engine and ensure there is no leakage.
F06D35A

WARNING

CAUTION

FRONT ENGINE SUPPORT 787 AND 947 ENGINES 1. Torque to 25 Nm (18 lbfft)

If watercraft is out of water, engine must be cooled using the flush kit.

04-03-7

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

MAGNETO SYSTEM
717 Engine
8 7 5 Nm (44 lbfin)

9 Loctite 242

9 Nm (80 lbfin)

11 10

12 Loctite 242 6 Nm (53 lbfin) 13 Loctite 242

6 Nm (53 lbfin) 15 Loctite 242 4 Loctite 16 242 3 1

14 6 Nm (53 lbfin)

GTS model only

4 Nm (35 lbfin) 17

Loctite 648 5 6 145 Nm (107 lbfft) Anti-seize lubricant

F02D0JS

2 9 Nm (80 lbfin)

PARTS

FLAT RATE

04-04-1

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

787 Engine
7 10 Loctite 242 9 Lithium grease 10 Nm (88 lbfin)

4 Loctite 648 10 Nm 11 (88 lbfin) Loctite 648 Loctite 242 5 105 Nm 6 (77 lbfft) 4.5 Nm (40 lbfin) 16

13 10 Nm (88 lbfin)

10 Nm (88 lbfin) 15 14 2 12 9 Nm (80 lbfin)

Anti-seize lubricant

3 1
F01D7TS

Synthetic grease

6 Nm (53 lbfin)

04-04-2

PARTS

FLAT RATE

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

947 Engine

9 Nm (80 lbfin) 2

Loctite 242 Anti-seize lubricant 10 13 Nm (115 lbfin) 3 Loctite 242 12 11 13 9 Loctite 242 115 Nm 6 (85 lbfft) 13 Nm (115 lbfin) Loctite 648 4 Loctite 648 7 9 Nm (80 lbfin)

5
F06D0IS

PARTS

FLAT RATE

04-04-3

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

GENERAL
The following procedures can be performed without removing engine from watercraft.
1

DISASSEMBLY
717 Engine

1, Magneto Housing Cover

Remove screws no. 2 and wire support no. 17, then withdraw cover.

4,5, Magneto Flywheel and Ring Gear

Magneto flywheel is locked with puller plate (P/N 290 876 080), sleeves (P/N 290 847 220) and extension handle (P/N 295 000 111).
1 2
F01D48A

TYPICAL 1. Sleeves on opposite side

Using a suitable socket, unscrew retaining nut no. 6 COUNTERCLOCKWISE when facing it. NOTE: If socket is found too large to be inserted in puller plate, machine or grind its outside diameter as necessary.

3 4
F01D47A

1. 2. 3. 4.

Screw Extension handle Puller plate Sleeve

Using 3 M8 x 35 screws (P/N 290 841 591), install screws through puller plate and slide sleeves on screws then secure puller plate on magneto flywheel so that sleeves are against flywheel. Install extension handle on end of puller plate.

F01D4BA

TYPICAL 1. Extension handle locking crankshaft

Remove nut and lock washer from magneto flywheel.

04-04-4

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

Magneto flywheel is easily freed from crankshaft with puller (P/N 295 000 106).

4,5, Magneto Flywheel and Ring Gear

Lay magneto flywheel on a steel plate. Tap lightly on ring gear using a hammer to release it from magneto flywheel.
1

A00C1AA

Fully thread on puller in puller plate. Tighten puller bolt and at the same time, tap on bolt head using a hammer to release magneto flywheel from its taper.

F01D3AA

1. Magneto flywheel

11, Generating Coil

1

To replace generating coil: Heat the armature plate to 93C (200F) around the screw holes to break the threadlocker bond.

3
F01D4CA

1. Puller plate 2. Puller 3. Extension handle

10, Armature Plate

Remove 3 retaining screws no. 15 and withdraw armature plate.
F00D08A

1. Heat the armature plate

7, Magneto Housing
To remove magneto housing, starter has to be removed. Refer to STARTING SYSTEM 08-04. Unscrew retaining screws no. 9, then withdraw housing.

CAUTION

Protect harness from flame. Remove screws. Uncrimp and unsolder BLACK/RED wire from coil.

04-04-5

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

Remove screws. Uncrimp and unsolder YELLOW and YELLOW/ BLACK wires from coil. Uncrimp and unsolder ground wire (BLACK) from coil core.

A25E0QA

1. Uncrimp and unsolder wire here

13, Battery Charging Coil

To replace battery charging coil: Heat the armature plate to 93C (200F) around the screw holes to break the threadlocker bond.
A25E0SA

1. Uncrimp and unsolder ground wire (BLACK) 2. Uncrimp and unsolder YELLOW and YELLOW/BLACK wires

Engine Crankcase Replacement

717 Engine Only Since replacement crankcases do not have timing mark for armature plate location, indexing marks should be made on armature plate and crankcase to ease reassembly and further ignition timing. The following procedure is to find a common reference point on both crankcases (old and new) to position armature plate. Proceed as follows: Find a crankcase locating lug (the top one in this example). Place a cold chisel at the end of chosen lug, then punch a mark on armature plate at this point.

1
F00D09A

1. Heat the armature plate

CAUTION

Protect harness from flame.

04-04-6

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

1 2

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

2 1

F01D4DA

1. Crankcase locating lug 2. Mark armature plate at the end of lug

At assembly, align armature plate mark (previously punched) with the end of the same locating lug on the new crankcase.
1

F01D4FA

TYPICAL 1. Manufacturers mark on armature plate 2. Punch a mark on crankcase lug aligned with plate mark

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

F01D4EA

F01D4GA

TYPICAL 1. Lug end of crankcase 2. Align mark and lug end here

TYPICAL 1. For further assembly, use these marks

04-04-7

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

787 Engine

1, Magneto Housing Cover

Loosen screws no. 2. Remove engine magneto cover. Remove oil pump shaft from flywheel nut.

4,5, Rotor and Flywheel

Remove starter. Refer to STARTING SYSTEM 08-04. NOTE: Crankshaft can also be locked by using the PTO flywheel. For procedure, refer to BOTTOM END 04-06. Lock ring gear using special tool.
F01D7XA

1. Screw

F01B26A

1. Ring gear blocking tool (P/N 295 000 134) 2. Retaining plate (P/N 295 000 154)

Using a suitable socket, unscrew retaining nut of engine flywheel COUNTERCLOCKWISE when facing it. Remove special tool locking ring gear. Engine flywheel is easily freed from crankshaft with puller (P/N 420 976 235) and crankshaft protective cap (P/N 290 876 557). Insert crankshaft protector to outer end of crankshaft and fully thread puller in engine flywheel.

F01D7YA F01D85A

1. Puller

1. Ring gear blocking tool with retaining plate

If desired, magneto rotor can be removed without the engine flywheel. Remove the 6 screws no. 11.

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

04-04-8

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

947 Engine

1, Cover
Loosen screws no. 2. Remove engine magneto cover.

F06D0LA

1. Screw

To remove the flywheel/rotor assembly, unscrew nut no. 6 counterclockwise when facing it.
F06D1RA

1. Cover 2. Screw

Remove oil pump shaft from flywheel nut.

F06D0MA

1. Nut

F06D23A

1. Remove oil pump shaft

4,5, Rotor and Flywheel

To remove the rotor or the flywheel, the crankshaft must be locked. For procedure, refer to BOTTOM END 04-06. If necessary, the magneto rotor can be removed without the engine flywheel. Remove the 6 screws no. 7.

The flywheel is easily freed from crankshaft with puller (P/N 420 976 235). Install protective cap (P/N 290 877 414) to crankshaft. Fully thread puller in engine flywheel.

04-04-9

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

CLEANING
Clean all metal components in a solvent.

CAUTION

Clean coils and magnets using only a clean cloth. Clean crankshaft taper and threads.

ASSEMBLY
717 Engine

11, Generating Coil

F06D0PA

1. Puller

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

8,9, Stator and Trigger Coil

Loosen screws no. 10 and no. 11 to remove the stator and trigger coil from the engine magneto cover.

Strip end of old wire then crimp and solder on new coil. Apply Loctite 242 (blue) to screws no. 12 and install the new coil on armature plate. Use magneto coil centering tool (P/N 290 876 922) and install so that it fits around armature plate before tightening screws.
1

F00D0AA

1. Magneto coil centering tool (P/N 290 876 922)

F06D0NA

CAUTION

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

1. Screws

04-04-10

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

13, Battery Charging Coil

Position new coil, crimp and solder all wires. Prior to assembly, apply Loctite 242 (blue). Use magneto coil centering tool (P/N 290 876 922) and install it so that it fits around armature plate before tightening screws no. 14.
1

Whenever replacing either ring gear or magneto flywheel, Gun Kote must be applied to prevent possible corrosion.

CAUTION

Always assemble magneto flywheel and ring gear prior to apply Gun Kote. If not done correctly, ring gear wont contact magneto flywheel flange. To apply Gun Kote proceed as follows: 1. Clean thoroughly and degrease replacement part using a non oil base solvent. 2. Apply coating in light thin coats using a spray gun. NOTE: Do not spray Gun Kote into magneto flywheel threaded holes. 3. Bake parts in oven at 175 (350F) for 1 hour to cure Gun Kote.

F00D0AA

1. Magneto coil centering tool (P/N 290 876 922)

4,5, Magneto Flywheel and Ring Gear

Apply Loctite 648 (green) to magneto flywheel mating surface. Lay ring gear on a steel plate, then heat with a propane torch in order to install it on magneto flywheel. Pay particular attention to position ring gear teeth chamfer side as per following illustration.

CAUTION

Do not eliminate Gun Kote heat curing time because it will lose all its resistance and it will not give any protection.

7, Magneto Housing
Install gasket no. 8 between magneto housing and engine crankcase. Install magneto housing and torque screws no. 9 to 9 Nm (80 lbfin).

10, Armature Plate

Position the armature plate on the crankcase, aligning the marks on both parts. Apply a drop of Loctite 242 (blue) on threads of screws no. 15 and torque to 6 Nm (53 lbfin).
F01D3BA

4, Magneto Flywheel
Apply Loctite 242 (blue) on crankshaft taper. Position Woodruff key no. 16 and magneto flywheel. Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 145 Nm (107 lbfft).

1. Teeth chamfer

NOTE: Ensure that ring gear contacts magneto flywheel flange.

04-04-11

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

Ignition Timing

CAUTION

Never use any type of impact wrench at magneto installation.

For ignition timing procedures of the 717 engine, refer to IGNITION SYSTEM 08-02.

1, Magneto Housing Cover

Properly install O-ring no. 3 in magneto housing. Apply Loctite 767 anti-seize on screws no. 2, install cover and wire support no. 17. Torque screws no. 2 in a criss-cross sequence to 9 Nm (80 lbfin).
1

F06D0DA

1. Trigger coil

787 Engine

7, Magneto Housing
To install oil seal no. 10 of magneto housing, use pusher (P/N 290 877 740) and handle (P/N 290 877 650).

12, Stator
Install the stator in magneto housing cover no. 1 and torque screws no. 13 to 10 Nm (88 lbfin). Replace wiring harness bracket no. 16 of stator and torque screws to 4.5 Nm (40 lbfin).
1 2

F01B2NA

1. Pusher 2. Handle
F06D0CA

1. Stator screws 2. Bracket

14, Trigger Coil

Install the trigger coil in magneto housing cover no. 1 and torque screws no. 15 to 10 Nm (88 lbfin). NOTE: The trigger coil is not adjustable.

04-04-12

Subsection 04

Section 04 ENGINE (MAGNETO SYSTEM)

Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 105 Nm (77 lbfft).

1, Cover

CAUTION

Never use any type of impact wrench at magneto installation.

F04D0CA

Before installation, properly install O-ring no. 3 in engine magneto cover. Apply Loctite 767 anti-seize compound on screws no. 2. Torque screws in a criss-cross sequence to 9 Nm (80 lbfin).

Install gasket no. 8 between magneto housing and engine crankcase. Install magneto housing and torque screws no. 9 to 9 Nm (80 lbfin).

947 Engine

8,9, Stator and Trigger Coil

Install the stator and trigger coil in engine magneto cover. Torque screws to 9 Nm (80 lbfin). Reinstall wiring harness bracket no. 12 using taptite screws no. 13. Torque trigger coil screws no. 11 to 9 Nm (80 lbfin). Torque stator screws no. 10 to 13 Nm (115 lbfin). NOTE: The trigger coil is not adjustable.

4,5, Rotor and Flywheel

When reinstalling magneto rotor to engine flywheel, apply Loctite 648 to mating surfaces. One of the protusion end of magneto rotor must align with hole of engine flywheel.
1 2

F01D83A F06D0NB

1. Protusion 2. Hole

Apply Loctite 648 (green) on screws no. 11 and torque to 10 Nm (88 lbfin). Apply Loctite 242 (blue) on crankshaft taper.

1. Torque to 9 Nm (80 lbfin) 2. Taptite screws 3. Torque to 13 Nm (115 lbfin)

04-04-13

Section 04 ENGINE Subsection 04 (MAGNETO SYSTEM)

4,5, Rotor and Flywheel

Apply Loctite 648 (green) on mating surface of the rotor no. 4. When reinstalling rotor to flywheel, one of the protrusion end of rotor must be aligned with hole in flywheel.
1 2

Install flywheel and make sure to align keyway with the crankshaft Woodruff key. Apply Loctite 242 (blue) on nut no. 6. Install nut with lock washer and torque to 115 Nm (85 lbfft).

CAUTION

Never use any type of impact wrench. Unlock crankshaft. Reinstall pulse fitting with washer and torque to 19 Nm (14 lbfft).

1, Cover
Before installation, properly install O-ring no. 3 in engine magneto cover. Apply Loctite 767 anti-seize compound on screws no. 2. Torque screws in a criss-cross sequence to 9 Nm (80 lbfin).
F06D0OA

1. Protrusion 2. Hole

Apply Loctite 648 (green) on screws no. 7 retaining rotor to flywheel and torque screws in a crisscross sequence to 13 Nm (115 lbfin). Apply Loctite 242 (blue) on crankshaft taper.

F06D24A

1. Loctite 242 (blue) on crankshaft taper

04-04-14

Section 04 ENGINE Subsection 05 (TOP END)

TOP END
717 Engine
24 Nm 14 (17 lbfft) Synthetic grease Loctite 242

1 11 12

Synthetic grease 24 Nm (17 lbfft) 13 Loctite 242 Loctite 518 9 34 rollers 6 10 7 5 8 3 Synthetic grease 7 8 4 3 4 5 6 34 rollers

F00D0DT

Synthetic grease

PARTS

FLAT RATE

04-05-1

Section 04 ENGINE Subsection 05 (TOP END)

787 Engine
Loctite 242 Synthetic grease 1 24 Nm 14 (17 lbfft)

11

12

2 15

20 18 16 17 19 21 Synthetic grease

Synthetic grease 13 40 Nm (30 lbfft) Loctite 518

26

25

24 23

22 9 7 8 7 8 4 5 10 Synthetic grease 6 34 rollers

Loctite 518

34 rollers

6 5 4

Synthetic grease
F01D7DU

04-05-2

PARTS

FLAT RATE

Section 04 ENGINE Subsection 05 (TOP END)

947 Engine
34 Nm (25 lbfft) 14 Synthetic grease 34 Nm (25 lbfft) 33 2 Loctite 242

30 15 Synthetic grease 19 20 21

34

16

17

18

31 Loctite 242 5 Nm (44 lbfin) 26 Loctite 9 Nm 242 (80 lbfin) 25 23 22 Loctite 242 32

29 28 27

5 3

7 8 36 rollers

9 6 Synthetic grease

4
F06D17T

5 10

PARTS

FLAT RATE

04-05-3

Section 04 ENGINE Subsection 05 (TOP END)

GENERAL
The 2-stroke ROTAX engine rotates counterclockwise seen from the rear (PTO flywheel). The 717 and 787 engines have a rotary valve to control opening and closing of the intake. The 947 engine uses reed valves in the crankcase. The 787 and 947 engines are also equipped with the RAVE system (Rotax Adjustable Variable Exhaust).

Located above the exhaust port is a guillotinetype slide valve. This rectangular valve is connected by a shaft to a diaphragm which is working against the return spring. To the outside of the return spring is a red plastic adjustment knob. Turning the adjustment in or out changes the preload on the return spring which, in turn, will change the RPM at which the RAVE valve opens and closes.

CAUTION

No engine components can be interchanged between engines.

787 Engine One small passage in the cylinder just outside the exhaust port allows exhaust gas pressure to reach the diaphragm.
1 5 3 2

787 and 947 Engines These engines are canted at a 30 degree angle (they are not canted on the same side), lowering the center of gravity of the watercraft. Cylinder exhaust ports are located on the same side of the intake, allowing a high volume tuned pipe design.

RAVE System
THEORY For a 2-stroke-cycle engine to have high power capacity at high crankshaft speeds, a high volumetric or breathing efficiency is required and the fresh charge losses must be minimized. The result is achieved by opening the exhaust port early and utilizing the resonant effects of the tuned exhaust system to control fresh charge losses. When an engine of this design is run at a medium speed, efficiency falls off quickly. The relatively high exhaust port effectively shortens the useful power stroke and because the exhaust system is tuned for maximum power, there is a large increase of fresh charge losses. As a result, the torque decreases along with a dramatic increase of the specific fuel consumption. Higher torque along with lower fuel consumption can be obtained at lower engine speeds if the time the exhaust port is open is shortened. BOMBARDIER-ROTAX has patented a remarkably simple system to automatically change the exhaust port height based on pressure in the exhaust system (and RPM for the 947 engine).
A18C01A

TYPICAL 1. Sliding valve 2. Diaphragm 3. Spring 4. Exhaust port 5. Adjustment knob

As the throttle is opened and the engine begins producing more power, the pressure against the diaphragm will overcome the pressure of the return spring and the RAVE valve will open.

F01D7GA

VALVE FULLY OPENED

04-05-4

Section 04 ENGINE Subsection 05 (TOP END)

F01D7HA

VALVE FULLY CLOSED

947 Engine On this engine, the RAVE valves are controlled by the Multi-Purpose Electronic Module (MPEM). The MPEM measures 2 factors to control the RAVE valves: engine speed (RPM) and its rate of acceleration. To open the RAVE valves, the MPEM activates a solenoid which directs the positive pressure from engine crankcase to the valves. NOTE: A check valve on the pressure line eliminates the negative pressure from the crankcase. To close the RAVE valves, the MPEM deactivates the solenoid which blocks the crankcase positive pressure. The RAVE valves are opened to the atmosphere.

04-05-5

Section 04 ENGINE Subsection 05 (TOP END)

5 3

F06D16S

RAVE VALVE OPENED 1. Pulse from crankcase 2. Check valve 3. Positive pressure to solenoid 4. Solenoid activated 5. Positive crankcase pressure to RAVE valves

04-05-6

Section 04 ENGINE Subsection 05 (TOP END)

3 2

F06D16T

RAVE VALVE CLOSED 1. Pulse from crankcase 2. Check valve 3. Positive pressure blocked by the solenoid 4. Solenoid deactivated 5. RAVE valves are opened to atmosphere

04-05-7

Section 04 ENGINE Subsection 05 (TOP END)

787 and 947 Engines The RAVE valve does not allow an engine to make higher peak horsepower than an engine not so equipped, it can make moving the peak horsepower higher practical because of its effect on the rest of the power curve. Item 2 in the following figure is the power curve of an engine with the RAVE valve held fully open through its entire RPM range. Item 6 notes the peak power produced. That peak will not change if the exhaust port time of a similar engine without a RAVE valve was the same (with all other features equal). Item 1 is the power curve of the engine with the RAVE valve closed through its entire RPM range. The shaded area (item 3) is the improvement in power at lower engine speeds that is gained because of the lower exhaust port. If the port remains at this height, however, the power would peak as noted in item 5. Raising the exhaust port at the proper RPM (item 7) will allow the engine peak power to continue to rise (item 6). Item P1 in figure is the force of the return spring against the diaphragm. The exhaust pressure must be high enough to overcome this force before the valve begins opening. Item P2 is the pressure required to completely open the RAVE valve. Between P1 and P2, the usable power curve of the engine is moving from power curve 1 to power curve 2. This transition takes place very rapidly at full throttle and from a practical standpoint can be considered to be instantaneous at item 7. Gradual application of the throttle, however, will result in the RAVE valve opening much later.
P2 1 4 7 6

MAINTENANCE There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide. Cleaning intervals would depend upon the users riding style and the quality of the oil used. Using FORMULA XP-S synthetic injection oil, we would suggest annual cleaning of the valve. If a customer uses a lower quality oil, more frequent cleaning may be required. No special solvents or cleaners are required when cleaning the valve. BORING PRECAUTION In its stock configuration the RAVE valve guillotine has a minimum of 0.5 mm (.020 in) clearance to the cylinder bore measured at the center line of the cylinder. This is the minimum production clearance. There is only a first oversize piston available for the 787 and 947 engines. That piston is 0.25 mm (.010 in) larger in diameter than the stock piston. When the oversize is installed, the guillotine will have a minimum clearance of 0.375 mm (.015 in) with the cylinder bore. This is the minimum operating clearance the guillotine should be used with. Clearance less than 0.375 mm (.015 in) will require reworking of the guillotine to achieve the proper clearance and radius.

DISASSEMBLY
15, RAVE Valve
787 Engine Remove the cover no. 18 of the valve by releasing the spring no. 16.

P1

POWER

WARNING

Firmly hold cover to valve base. The spring inside the valve is applying a pressure against the cover.
2

A18C02A

RPM

04-05-8

Section 04 ENGINE Subsection 05 (TOP END)

1
F01D8MA

F01D8HA

1. Unscrew piston 2. Hold sliding valve

1. Spring

Loosen Allen screws no. 26 and remove RAVE valve.

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

F01D8IA

F06D0QA

1. Allen screws

1. Remove screws

Remove bellow no. 21 from valve piston no. 20. Unscrew valve piston no. 20 from sliding valve no. 22. NOTE: Hold the sliding valve to prevent it from turning.

04-05-9

Section 04 ENGINE Subsection 05 (TOP END)

Remove RAVE valve no. 15. Remove the cover no. 18 of the valve by releasing the spring no. 16.

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

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

WARNING

F06D0SA

1. Spring

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

F06D0RA

1. Spring

Remove the compression spring no. 19.

F06D0TA

1. Bellows removed from piston

F06D25A

1. Remove spring

04-05-10

Section 04 ENGINE Subsection 05 (TOP END)

Unscrew valve piston no. 20 from sliding valve no. 22. NOTE: Hold the sliding valve to prevent it from turning.

Remove supporting ring no. 28.

1

F06D27A

1. Remove supporting ring

F06D0TB

Remove O-ring no. 23.

1. Unscrew piston 2. Hold sliding valve

Remove compression spring no. 29.

F06D28A

A06D26A

1. Remove O-ring

1. Remove spring

04-05-11

Section 04 ENGINE Subsection 05 (TOP END)

Remove sliding valve no. 22.

If shells, sand, salt or any other particles are present in cylinder head, clean with a vacuum cleaner. Remove cylinder head no. 2. If shells, sand, salt water or any other particles are present in cylinder cooling jacket, clean with a vacuum cleaner.

947 Engine Disconnect hose of RAVE valves. Loosen cylinder head bolts no. 14 following the sequence shown in the next photo.
6 4 2

F06D0UA

1. Remove sliding valve

Remove bellows no. 21.

1

F06D0WA

UNTORQUING SEQUENCE FOR THE CYLINDER HEAD BOLTS

Loosen nuts no. 33 following the sequence shown in the next photo.
5
F06D0VA

1. Remove bellows

1,2, Cylinder Head Cover and Cylinder Head

Disconnect temperature sensor wire and spark plug cables. Connect spark plug cables on grounding device.

717 Engine Remove air intake silencer and support, refer to AIR INTAKE 06-03. 717 and 787 Engines Remove screws no. 14. Remove cylinder head cover no. 1.
04-05-12
F06D29A

UNTORQUING SEQUENCE FOR THE NUTS

Section 04 ENGINE Subsection 05 (TOP END)

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

F06D2BA

1. Remove studs
F06D0YA

Remove cylinder block no. 9.

1. Remove gasket

9, Cylinder
787 Engine Remove air intake silencer and support, refer to AIR INTAKE 06-03. 717 and 787 Engines Remove tuned pipe and exhaust manifold, refer to EXHAUST SYSTEM 04-08. Remove screws no. 13. Remove cylinders, being careful that connecting rods do not hit crankcase edge.
F06D0ZA

WARNING

1. Remove cylinder block

If screws need to be heated for removal when engine is in watercraft, fuel system pressurization must be done first. Do not use open flame; use a heat gun. NOTE: Even if only 1 cylinder needs repair, both cylinders should be lifted to allow 1-piece cylinder base gasket replacement.

NOTE: To ease removal, a plastic tip hammer can be used. Remove cylinder base gasket no. 10.

3, Piston
NOTE: All engines feature cageless piston pin bearings.

947 Engine Remove studs no. 32. NOTE: Studs must be removed prior cylinder block.

717 and 787 Engines Bring piston to Top Dead Center and install rubber pad (P/N 295 000 101) over crankcase opening. Secure with screws. Lower piston until it sits on pad.

04-05-13

Section 04 ENGINE Subsection 05 (TOP END)

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

WARNING

Always wear safety glasses when removing piston circlips.

F01B0JA

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

If the other cylinder has been removed, completely cover its opening with a clean rag.
1

F01D0PA

TYPICAL 1. Piston notch

To extract piston pin no. 4, use piston pin puller (P/N 529 035 503) with the appropriate set of sleeves.
ENGINE 717/787 947 SLEEVE SET P/N 529 035 542 P/N 529 035 543

F01D43A

1. Openings covered with rag and rubber pad

947 Engine Install rubber pad (P/N 290 877 032) to crankcase. Secure with screws. Lower piston to be removed until it sits on pad.

1
F00B0IA

F06B06B

1. Puller 2. Shoulder sleeve 3. Sleeve

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

04-05-14

Section 04 ENGINE Subsection 05 (TOP END)

Fully thread on puller handle. Insert extractor spindle into the piston pin. Slide the sleeve and shoulder sleeve onto the spindle. Screw in extracting nut with the movable extracting ring towards spindle.
1 2 3 4

F00B0LA

1. Shoulder sleeve flush with piston recess

Loosen the extracting nut and remove puller. Remove the shoulder sleeve from piston.

F00B0JA

1. 2. 3. 4.

Puller Sleeve Shoulder sleeve Extracting nut

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

F00B0MA

1. Remove shoulder sleeve

Carefully remove the piston no. 3. The needles, thrust washers and the sleeve remain in the connecting rod bore and may be used again.

F00B0KA

1. Tool cutout toward bottom of piston

Firmly hold puller and rotate handle to pull piston pin no. 4. Rotate spindle until the shoulder sleeve is flushed with the piston recess.

04-05-15

Section 04 ENGINE Subsection 05 (TOP END)

The inspection of engine top end should include the following measurements.
1 2
ENGINE MEASUREMENT Cylinder Taper Cylinder Out of Round Piston/Cylinder Wall Clearance for the 717 Engine
F00B0NA

TOLERANCES NEW PARTS (min.) (max.) N.A. N.A. 0.10 mm (.0039 in) 0.11 mm (.0043 in) 0.09 mm (.0035 in) 0.03 mm (.001 in) 0.40 mm (.016 in) 0.05 mm (.002 in) 0.008 mm (.0003 in) N.A. WEAR LIMIT 0.1 mm (.004 in) 0.08 mm (.003 in) 0.20 mm (.008 in) 0.20 mm (.008 in) 0.20 mm (.008 in) 0.20 mm (.008 in) 1.0 mm (.039 in)

1. Needles and thrust washer 2. Sleeve

Piston/Cylinder Wall Clearance for the 787 Engine Piston/Cylinder Wall Clearance for the 947 Engine Ring/Piston Groove Clearance Ring End Gap
N.A.: Not Applicable

N.A.

CLEANING
Discard all gaskets and O-rings. Clean all metal components in a solvent. Clean water passages and make sure they are not clogged. Remove carbon deposits from cylinder exhaust port, RAVE valve (787 and 947 engines), cylinder head and piston dome. Clean piston ring grooves with a groove cleaner tool, or a piece of broken ring.

N.A. 0.07 mm (.003 in) 0.55 mm (.022 in)

INSPECTION
Visually inspect all parts for corrosion damage. Inspect piston for damage. Light scratches can be sanded with a fine sand paper. NOTE: When repairing a seized engine, connecting rods should be checked for straightness and crankshaft for deflection/misalignment. Refer to BOTTOM END 04-06 for procedures. Inspect plane surfaces for warpage. Small deformation can be corrected by grinding surface with a fine sand paper. Install sand paper on a surface plate and rub part against oiled sand paper.

NOTE: Replacement cylinder sleeves are available if necessary. Also, oversize pistons of 0.25 mm (.010 in) are available for all engines and oversize pistons of 0.5 mm (.020 in) are available for the 717 engine.

Cylinder Taper
Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder just below auxiliary transfer port, facing exhaust port. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.

04-05-16

Section 04 ENGINE Subsection 05 (TOP END)

Piston/Cylinder Wall Clearance

To determine the piston dimension, take the measurement on the piston dome.

1 A

F01D8AA

F00D0EA

1. Measuring perpendicularly (90 ) to piston pin axis 2. Auxiliary transfer port A. 16 mm (5/8 in)

1. Piston dome 2. Piston measurement

Cylinder Out of Round

Using a cylinder bore gauge, measure cylinder diameter at 16 mm (5/8 in) from top of cylinder. Measure diameter in piston pin axis direction then perpendicularly (90) to it. If the difference between readings exceed specification, cylinder should be rebored and honed or replaced.

Adjust and lock a micrometer to the specified value on the piston dome.
1

F00B08A

1. Micrometer set to the piston dimension

A 2

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

F01D8BA

1. Measuring in piston pin axis 2. Measuring perpendicularly (90 ) to piston pin axis A. 16 mm (5/8 in)
04-05-17

Section 04 ENGINE Subsection 05 (TOP END)

1 2

Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.

Ring/Piston Groove Clearance

717 and 787 Engines Using a feeler gauge, check clearance between rectangular ring and groove. If clearance exceeds specified tolerance, replace piston. NOTE: Ring/piston groove clearance can be correctly measured only on rectangular ring which is bottom ring.

F00B09A

1. Use the micrometer to set the cylinder bore gauge 2. Dial bore gauge

1
F01D0XA

1
F00B0AA

1. Feeler gauge 2. Rectangular ring (bottom)

1. Indicator set to zero

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

947 Engine Due to the semi-trapez rings, it is not possible to accurately measure ring/piston groove clearance.

Ring End Gap

Position ring halfway between exhaust port and top of cylinder. NOTE: In order to correctly position ring in cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. If gap exceeds specified tolerance, rings should be replaced.

1 A

F01D0KA

1. Measuring perpendicularly (90) to piston pin axis A. 16 mm (5/8 in)

04-05-18

Section 04 ENGINE Subsection 05 (TOP END)

717 Engine
GASKET THICKNESS 0.3 mm (.012 in) 0.5 mm (.020 in) 0.6 mm (.024 in) IDENTIFICATION HOLES 3 5 6

787 Engine
F01D0OA

1
GASKET THICKNESS 0.3 mm (.012 in) 0.4 mm (.016 in) 0.6 mm (.024 in) IDENTIFICATION HOLES 3 4 6

1. Top of cylinder 2. Ring end gap

10, Cylinder Base Gasket

Different thicknesses of cylinder base gaskets are available for a precise adjustment of the combustion chamber volume. To determine gasket thickness, refer to the identification holes on the gasket.
1

947 Engine
GASKET THICKNESS 0.5 mm (.020 in) 0.6 mm (.024 in) 0.8 mm (.031 in)
F01D67A

IDENTIFICATION HOLES 5 6 8

TYPICAL 1. Identification holes

04-05-19

Section 04 ENGINE Subsection 05 (TOP END)

15, RAVE Valve

787 and 947 Engines Check RAVE valve bellow no. 21 for cracks. 787 Engine Only Check if passages of valve housing no. 25 and cylinder no. 10 are not obstructed.

Install a new gasket no. 24. It must be installed at the same time as the sliding valve no. 22. Position the valve housing no. 25 onto the cylinder so that its opening is toward the bottom.

F01D8JB

1. Bottom of valve housing

F01D8JA

1. Passage of valve housing

When the valve is mounted onto the cylinder, move the valve piston no. 20 to ensure the sliding valve no. 22 moves easily and doesnt stick.

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

15, RAVE Valve

787 Engine Make sure to insert O-ring no. 23 onto rod of sliding valve no. 22. The TOP position of the sliding valve no. 22 is indicated on one side.

F01D8LA

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

3
F01D8KA

1. Sliding valve 2. O-ring 3. TOP

04-05-20

Section 04 ENGINE Subsection 05 (TOP END)

NOTE: On the 787 and 947 engines, the exhaust ports are located on the same side as the intake. Carefully cover crankcase opening as for disassembly.

4,6, Piston Pin and Roller Bearing

To install roller bearing and piston pin use, piston pin puller (P/N 529 035 503) with the appropriate set of sleeves as for disassembly. Replacement bearings are held in place by a locating sleeve outside and 2 plastic cage halves inside. Push needle bearing together with inner halves out of the locating sleeve into the connecting rod bore. Replace the inner halves by the appropriate sleeve tool in the connecting rod bore. Insert piston pin into piston until it comes flush with inward edge of piston hub. Warm piston to approximately 50-60C (122140F) and install it over connecting rod. NOTE: Make sure thrust washers are present each side of needles. Install the shoulder sleeve tool on the opposite side of the piston pin.
1 2

F06D11A

1. Bevel facing the O-ring

There is only one way to insert the sliding valve no. 22 in valve housing no. 25.

F06D12A

1. Sliding valve ridge toward housing groove

3, Piston
At assembly, place the pistons with the letters AUS (over an arrow on the piston dome) facing in direction of the exhaust port.
F00B0OA

1. Piston pin 2. Shoulder sleeve

1
AUS

A01C01A

1. Exhaust side
04-05-21

Section 04 ENGINE Subsection 05 (TOP END)

Insert extractor spindle into the piston pin, screw on extracting nut.
2 1

Make sure thrust washers are present each side of rollers.

F00B0PA

F01D0VA

1. Puller installed on the opposite side of the piston pin 2. Tighten extracting nut

1. Thrust washer each side

Rotate handle to pull piston pin carefully into the piston. Plastic Mounting Device Method This is an alternate method when no service tool is available. Replacement roller bearings are delivered in a convenient plastic mounting device. For installation, proceed as follows: Align replacement roller bearing with connecting rod bore. Carefully push inner plastic sleeve into connecting rod bore; outer plastic ring will release rollers.
1

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

F01D0RA

1. Piston pin flush here 2. Thrust washers

Place piston over connecting rod and align bores, then gently tap piston pin with a fiber hammer to push out inner plastic ring on opposite side. Support piston from opposite side.

F01D0Q A

1. Outer ring removal after inner sleeve insertion into bore

04-05-22

Section 04 ENGINE Subsection 05 (TOP END)

717 and 787 Engines Secure circlip with its opening located at the bottom of the piston.

CAUTION

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

F01D0SA

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

F06D18A

1. Circlip opening at 6 oclock (at bottom)

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

F01D0TA

1. Pulling inner sleeve half

5, Circlip
Always use new circlips.

CAUTION
1
F07D0AB

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

WARNING

1. Circlip end in piston notch

Always wear safety glasses when installing piston circlips.

04-05-23

Section 04 ENGINE Subsection 05 (TOP END)

All Engines To easily insert circlip into piston, use circlip installer.
ENGINE 717 and 787 947 TOOL P/N 290 877 016 290 877 518

F00B0RA

F06B01A

CAUTION

The hand retaining the piston should absorb the energy to protect the connecting rod.

1. Circlip installer

Remove sleeve from pusher then insert circlip into its bore. Reinstall sleeve onto pusher and push until circlip comes in end of tool.
1

9, Cylinder
717 and 787 Engines To easily slide cylinder over piston, install on piston ring compressor (P/N 290 876 979).

A01B1TA

1. Slide this edge

F00B0QA

TYPICAL 1. Circlip near end of tool

Position end of tool against piston pin opening. Firmly hold piston against tool and tap tool with a plastic tip hammer to insert circlip into its groove.

NOTE: Ring compressor will not fit on oversize parts. Make sure to align ring end gap with piston locating pin. Slide tool over rings.

04-05-24

Section 04 ENGINE Subsection 05 (TOP END)

717 Engine The aligning tool (P/N 290 876 902) or the exhaust manifold can be used to align cylinders.

F01D0ZA

1. Ring end gap aligned with piston locating pin

Slide cylinder over piston.

F01D44A

717 ENGINE 1. Exhaust flange aligning tool

F01D10A

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

F01D45A

717 ENGINE 1. Aligning cylinders using exhaust manifold

04-05-25

Section 04 ENGINE Subsection 05 (TOP END)

787 Engine The exhaust manifold is used to align cylinders.

A01B1TA

1. Slide this edge

NOTE: For each ring, make sure to align ring end gap with piston locating pin. Install cylinder block. Install O-rings no. 31.
F00D0FA

787 ENGINE 1. Aligning cylinders using exhaust manifold

CAUTION

9, Cylinder Block
947 Engine Install studs no. 32. Apply Loctite 242 to threads and torque studs to 5 Nm (44 lbfin). Install cylinder base gasket no. 10. There is only one way to install gasket. The cylinder block is positioned with locating dowels.

The O-rings must be installed and properly positioned in the cylinder block. The O-rings are meant to dampen stud vibration.

13, Cylinder Screw

717 Engine Apply synthetic grease below the screw head. Apply also Loctite 242 (blue) on screw threads. Install and torque screws in a criss-cross sequence for each cylinder to 24 Nm (17 lbfft). Refer to the following illustration.
1 4 1 4

F06D1PA

1. Dowel

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

3
F01D35A

04-05-26

Section 04 ENGINE Subsection 05 (TOP END)

787 Engine Prior installation, apply synthetic grease below screw head and Loctite 518 on screw threads. Install M10 x 105 screws on exhaust side and the M10 x 73.5 on opposite side. Torque screws in a criss-cross sequence for each cylinder to 20 Nm (15 lbfft). Repeat the procedure, retightening all cylinder screws to 40 Nm (30 lbfft).
2 3 3 2

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

947 Engine Apply Loctite 242 (blue) on the threads of the cylinder block studs no. 32. Apply Loctite 242 (blue) below head of cylinder head bolts no. 14. Apply synthetic grease on threads of cylinder head bolts no. 14. Torque bolts and nuts to 15 Nm (11 lbfft) as per following sequence in the next picture. Repeat the torquing sequence by retightening to 34 Nm (25 lbfft).
7 12 1 10 8 3 14 6

F01D7FA

2, Cylinder Head
717 and 787 Engines Make sure to install O-rings no. 12 around spark plug holes and O-ring no. 11 of cylinder head as shown in the following illustration.
1

F06D0WB

13

9 5 11

15

TORQUING SEQUENCE

1, Cylinder Head Cover

717 and 787 Engines Install cylinder head cover. Apply Loctite 242 (blue) below head of screws no. 14. Apply also synthetic grease on threads of screws no. 14. Torque cylinder head screws no. 14 to 12 Nm (9 lbfft) as per following illustrated sequence. Repeat the procedure, retightening all screws to 24 Nm (17 lbfft).

F01D5AA

1. O-rings

04-05-27

Section 04 ENGINE Subsection 05 (TOP END)

10

12

947 Engine Turn the red plastic knob no. 17 until it is fully tightened.
1

F01D46A

11
F00D0WA

TORQUING SEQUENCE

ADJUSTMENT
RAVE Valve
787 Engine Turn the red plastic knob no. 17 until it is flush to the valve cover.
1

1. Knob fully tightened

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

Combustion Chamber Volume Measurement

The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center. It is measured with the cylinder head installed on the engine.

F00D0GA

1. Knob flush with the cover

F01D5VA

1. Combustion chamber

04-05-28

Section 04 ENGINE Subsection 05 (TOP END)

NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be leveled. 1. Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge.

F00D0HA

1. Top of spark plug hole

F01D2IA

1. Bring piston to TDC

2. Obtain a graduated burette (capacity 0-50 cc) and fill with an equal part (50/50) of gasoline and injection oil.

NOTE: The liquid level in cylinder must not drop for a few seconds after filling. If so, there is a leak between piston and cylinder. The recorded volume would be false. 5. Let burette stand upward for about 10 minutes, until liquid level is stabilized. 6. Read the burette scale to obtain the quantity of liquid injected in the combustion chamber. Compare the obtained value with the table below. The volume should be in the allowable range. NOTE: When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.39 cc corresponding to the spark plug tip. The following table of combustion chamber volume includes this value.
ENGINE 717 787 947 COMBUSTION CHAMBER VOLUME 31.2 - 34.0 cc 34.7 - 37.9 cc 43.3 - 47.3 cc

7. Repeat the procedure for the other cylinder.

F00B0BA

1. Graduated burette (0-50 cc)

3. Open burette valve to fill its tip. Add liquid in burette until level reaches 0 cc. 4. Inject the burette content through the spark plug hole until liquid touches the top spark plug hole.
04-05-29

Section 04 ENGINE Subsection 06 (BOTTOM END)

BOTTOM END
717 Engine
Loctite 518 1 Lithium grease Anti-seize lubricant 4 12 5 6 4 6 Anti-seize lubricant 12 2 4 Anti-seize lubricant 3 Loctite 642 2 11

Loctite 518

Loctite 242 6

24 Nm (17 lbfft) 9

6 11

4 5 Lithium grease

Synthetic grease Loctite 518 7 24 Nm (17 lbfft)

F00D0YS

Loctite 518 Synthetic grease 8 40 Nm (30 lbfft)

10 10 Nm (88 lbfin)

PARTS

FLAT RATE

04-06-1

Section 04 ENGINE Subsection 06 (BOTTOM END)

787 Engine
30 mL (1 oz) SAE 30 motor oil

Loctite 518 11

1 15 5 4 6 18

Anti-seize lubricant Lithium grease 2 13 14 4 6 12 3 16 15

Lithium grease Anti-seize lubricant Anti-seize lubricant 19 Lithium grease Loctite 518

Loctite 642 Anti-seize lubricant 12 2 4

6 4

Loctite 242 6

Loctite 518 Synthetic grease

11 Loctite 518 Synthetic grease Loctite 518

Synthetic grease 24 Nm 7 (17 lbfft) Anti-seize lubricant

Synthetic grease 7 24 Nm (17 lbfft) 8 40 Nm (30 lbfft)

8 40 Nm (30 lbfft)
F01D8YS

04-06-2

PARTS

FLAT RATE

Section 04 ENGINE Subsection 06 (BOTTOM END)

947 Engine
26 2 16 15 17 5 14 Synthetic grease 6 Loctite 242 3 4 Loctite 242 Anti-seize lubricant 9 Nm 24 (80 lbfin) 25 26 27 23 Anti-seize lubricant 4 6 31 32 17 15 16 Synthetic grease 13 40 mL (1.35 oz) SAE 30 motor oil

Loctite 242 29 30 28

Loctite 242 9 Nm Synthetic (80 lbfin) grease Loctite 648 Loctite 242 Synthetic grease Loctite 242 5 1 22 115 Nm (85 lbfft) 20

Loctite 518 2 4

Loctite 242 Synthetic grease

21 23 Nm (17 lbfft)

Loctite 518 Synthetic grease 7 27 Nm (20 lbfft)

F06D19T

Loctite 518 Synthetic grease 7 8 10 Nm (89 lbfin)

Loctite 518 8 Synthetic grease

Loctite 518 Synthetic grease 7 27 Nm (20 lbfft) 40 Nm (30 lbfft)

27 Nm (20 lbfft)

PARTS

FLAT RATE

04-06-3

Section 04 ENGINE Subsection 06 (BOTTOM END)

DISASSEMBLY
Engine has to be removed from watercraft to open bottom end. Refer to REMOVAL AND INSTALLATION 04-03. NOTE: Before proceeding with the disassembly of the engine, it is possible to make a few verifications. See INSPECTION in this subsection.
1

1, PTO Flywheel
717 and 787 Engines To remove PTO flywheel, the crankshaft must be locked. Refer to MAGNETO SYSTEM 04-04 and follow the procedure to lock the magneto flywheel. GS, GTS and GTI Models PTO flywheel is loosen using PTO flywheel remover (P/N 295 000 001).
F00D0ZA

TYPICAL 1. Extension handle locking crankshaft

NOTE: When splines of PTO flywheel are worn out and special tool cannot be used, proceed with the following alternate method. Use a pipe wrench and install it on PTO flywheel as illustrated.

F01J0TA

Insert special tool in PTO flywheel splines.

F00D10A

TYPICAL 1. Extension handle locking crankshaft

SPX Model PTO flywheel is loosened using PTO flywheel remover (P/N 295 000 156).

F01D1AA

TYPICAL 1. PTO flywheel remover (P/N 295 000 001)

Using a suitable wrench or socket with a breaker bar, unscrew PTO flywheel COUNTERCLOCKWISE when facing it and hold extension handle locking the magneto flywheel.
04-06-4

Section 04 ENGINE Subsection 06 (BOTTOM END)

Using a suitable socket with a breaker bar, lock crankshaft. Loosen Allen screws no. 21 of coupler no. 20.
1

F00B04A

Install special tool.

1
F06D37A

1. Loosen Allen screws 2. Breaker bar locking crankshaft

Remove the coupler no. 20.

XP Limited Lock crankshaft using the PTO flywheel remover (P/N 295 000 156) and extension handle (P/N 295 000 125). Loosen Allen screw no. 21.
F06I02A

SPX MODEL 1. PTO flywheel remover

Install the extension handle (P/N 295 000 125) on the PTO flywheel remover. Loosen PTO flywheel COUNTERCLOCKWISE when facing it.

GSX Limited and GTX Limited Insert PTO flywheel remover (P/N 295 000 001) in coupler splines.

F08D01A

1. PTO flywheel remover tool 2. Extension handle 3. Loosen Allen screw

F01J0TA

PTO FLYWHEEL REMOVER TOOL

Rotate tool to remove the other 3 Allen screws no. 21. Remove coupler no. 20.

04-06-5

Section 04 ENGINE Subsection 06 (BOTTOM END)

GSX Limited, XP Limited and GTX Limited Install puller plate (P/N 529 035 533) and extension handle (P/N 295 000 125) to PTO flywheel. NOTE: Puller plate can be used without the extension handle. Loosen bolt no. 22 retaining the PTO flywheel to the crankshaft using a suitable socket and breaker bar.
3

NOTE: Puller plate can be used without the extension handle.

27, Starter Drive Assembly

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

F06D1CA F06D38A

1. Puller plate 2. Extension handle 3. Loosen bolt with socket and breaker bar

1. Cover 2. Allen screw

Remove the PTO flywheel using puller plate (P/N 529 035 533), puller (P/N 529 035 548) and bolt (P/N 529 035 549).
1

Remove starter drive cover no. 25 and spring no. 9. Remove starter drive assembly no. 27.

F06D1DA

1. Starter drive assembly

F06D39A

1. 2. 3. 4.

Puller plate Puller Bolt Extension handle

04-06-6

Section 04 ENGINE Subsection 06 (BOTTOM END)

28, Reed Valve

947 Engine Only Remove both carburetor flanges.

947 Engine Place engine upright on crankcase magneto side. Loosen crankcase screws.

F06D0JA

1. Carburetor flange

Remove reed valves from crankcase.

F07D09A

5, Seal
If a crankshaft end seal has to be replaced, bottom end must be opened (except for the MAG side seal on the 787 engine, which is mounted on the magneto housing).

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

2, Crankcase
Remove the following parts: engine supports (717 engine) magneto flywheel, refer to MAGNETO SYSTEM 04-04 magneto housing (except 947 engine) starter rotary valve cover and valve (except 947 engine) Starter drive assembly (947 engine) Reed valves (947 engine)

CAUTION

Be careful to precision machined surfaces.

717 and 787 Engines Put engine on a trestle. Loosen crankcase screws.

F01D1KA

TYPICAL 1. Separate halves by prying at provided lugs

04-06-7

Section 04 ENGINE Subsection 06 (BOTTOM END)

8
1
F01D1LA

7
F01B09A

TYPICAL 1. Separate halves by prying at provided lugs

Remove crankshaft and counterbalance shaft (787 and 947 engines).

717 ENGINE 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) 3. Distance ring, MAG side only (P/N 290 876 569) 4. Ring (both side) (P/N 290 977 490) 5. MAG side ring halves (P/N 290 276 025) 6. PTO side ring halves (P/N 290 977 475) 7. Screw M8 x 40 (P/N 290 840 681) 8. Screw M8 x 70 (P/N 290 841 201)

4,5, Bearing and Seal

NOTE: Do not needlessly remove crankshaft bearings. Remove end seal(s).

NOTE: To facilitate ring or distance ring installation, lubricate their inside diameters.

787 Engine To remove end bearings from crankshaft, use the following tools. NOTE: The outer PTO bearing and crankshaft gear can be removed in one step using another puller. See Crankshaft Gear no. 18.
1 2 3 4 5

F06D1GA

TYPICAL 1. End seal

7
F01B2MA

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

787 ENGINE 1. Puller (P/N 290 876 298) 2. Protective cap (P/N 290 876 557) 3. Distance ring (P/N 290 876 569) 4. Ring (P/N 290 977 490) 5. Ring halves (P/N 290 977 475) 6. Screw M8 x 40 (P/N 290 840 681) 7. Screw M8 x 70 (P/N 290 841 201)

NOTE: To facilitate ring or distance ring installation, lubricate their inside diameters.

04-06-8

Section 04 ENGINE Subsection 06 (BOTTOM END)

947 Engine To remove end bearings from crankshaft, use the following tools.
6 1 2 3 4 5

F06B03A

6
F01D1PA

947 ENGINE 1. Puller (P/N 420 877 635) 2. Protective cap (P/N 290 877 414) 3. Distance ring (P/N 290 876 569) 4. Ring (P/N 290 977 480) 5. Ring halves (P/N 290 876 330) 6. Screw (P/N 290 940 755)

1. Press bearings out 2. Bearing extractor

18, Crankshaft Gear

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

NOTE: To facilitate ring or distance ring installation, lubricate their inside diameters.

All Engines

F04B03A

F01D1OA

1. Puller (P/N 290 877 665)

TYPICAL 1. Removing crankshaft bearing

Install the puller as per following illustration.

Or, use a bearing extractor such as Proto no. 4332 and a press to remove two bearings at a time (except on PTO side for the 787 engine).

04-06-9

Section 04 ENGINE Subsection 06 (BOTTOM END)

5
F00B0CA

F00D0IA

1. 2. 3. 4. 5.

Puller (P/N 290 876 298) Protective cap (P/N 290 876 557) Ring (P/N 290 977 480) Ring halves (P/N 290 876 330) Screw M8 x 40 (P/N 290 840 681)

1. Puller 2. Protective cap

Secure puller in a vise and remove gear and bearing.

F00D0KA

1. Tool installed

To remove gear no. 14, first trace an index mark on the gear and counterbalance shaft. NOTE: There is no Woodruff key to position the gear on the counterbalance shaft. An index mark must be traced to ease assembly procedure.
F00D0JA

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

13, Counterbalance Shaft

787 Engine Bearings no. 15 can be removed by using the following tools:

F00D0SA

1. Index mark

04-06-10

Section 04 ENGINE Subsection 06 (BOTTOM END)

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

CLEANING
Discard all oil seals, gaskets, O-rings and sealing rings. Clean oil passages and make sure they are not clogged. Clean all metal components in a solvent. Remove old Loctite from crankcase mating surfaces with gasket remover (P/N 295 000 110).

F00D0TA

CAUTION

Be careful not to spray cleaner on the painted surface of the engine. Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing.

947 Engine Use a press to remove counterweights no. 16 and bearings no. 15.

INSPECTION
Assembled Engine
The following checks can be performed with engine in watercraft without overhauling engine.

CAUTION

There is no woodruff key to position the counterweights. An index mark must be traced to retain the proper position of the counterweight.

Crankshaft Alignment at Center Main Journal

Since it is an assembled crankshaft it can become misaligned or deflected. Crankshaft can be twisted on center main journal, changing timing of one cylinder in relation with the other.

F06D1HA

1. Trace an index mark

1
F01D1NA

Remove seals no. 17. Remove bearing no. 31 and washer no. 32. Use a press to remove gear no. 14.

1. Main journal alignment here

04-06-11

Section 04 ENGINE Subsection 06 (BOTTOM END)

To accurately check if crankshaft is twisted on center main journal, proceed as follows: Remove magneto housing cover. Remove flywheel nut (and magneto rotor for the 787 and 947 engines). Refer to MAGNETO SYSTEM 04-04 for procedures. Install Bombardier degree wheel (P/N 295 000 007) on crankshaft end. Hand-tighten nut only. Remove both spark plugs. Install a TDC gauge in spark plug hole on MAG side. Bring MAG piston at Top Dead Center. As a needle pointer, secure a wire with a cover screw and a washer. Rotate degree wheel (NOT crankshaft) so that needle pointer reads 360.

Crankshaft Alignment at Connecting Rod Journal

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

1
F01D1NB

1. Connecting rod journal alignment here

Such misalignment may cause a crankshaft hard to be manually turned. Verification can be done by measuring deflection each end of crankshaft. If deflection is found greater than specified tolerance, this indicates worn bearing(s), bent and/or disaligned crankshaft. Proceed with the disassembly of the engine.

3 4

Disassembled Engine
The following verifications can be performed with the engine disassembled.

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

F01D4IA

TYPICAL 1. TDC gauge 2. Degree wheel 3. Hand tighten nut 4. Needle pointer

4, Bearing
Inspect crankshaft bearings. Check for corrosion, scoring, pitting, chipping or other evidence of wear. Make sure plastic cage is not melted. Rotate and make sure they turn smoothly.

Remove TDC gauge and install on PTO side. Bring PTO piston at Top Dead Center. Interval between cylinders must be exactly 180 therefore, needle pointer must indicate 180 on degree wheel (360 - 180 = 180). Any other reading indicates a misaligned crankshaft.

3, Crankshaft
NOTE: If crankshaft and/or components are found defective, it must be repaired by a specialized shop or replaced.

04-06-12

Section 04 ENGINE Subsection 06 (BOTTOM END)

Connecting Rod Straightness Align a steel ruler on edge of small end connecting rod bore. Check if ruler is perfectly aligned with edge of big end.
1

F01D1TA

1. Measuring MAG side deflection in crankcase

F01D1QA

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

1. Ruler must be aligned with edge of connecting rod here 2. Align ruler here

Crankshaft Deflection
1
MEASUREMENT Crankshaft deflection (max.) MAG SIDE 0.050 mm (.002 in) PTO SIDE 0.030 mm (.001 in)

Crankshaft deflection is measured each end with a dial indicator. First, check deflection with crankshaft in crankcase. If deflection exceeds the specified tolerance, it can be either ball bearings wear, bent or twisted crankshaft at connecting rod journal.
1

F01D1UA

1. Measuring MAG side deflection on V-shaped blocks

F01D1VA

F01D1SA

1. Measuring PTO side deflection in crankcase

1. Measuring PTO side deflection on V-shaped blocks

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

04-06-13

Section 04 ENGINE Subsection 06 (BOTTOM END)

Connecting Rod Big End Axial Play

MEASUREMENT NEW PARTS (min.) (max.) WEAR LIMIT 1.2 mm (.047 in)

28, Reed Valve

947 Engine Check reed valve petals no. 29 for cracks or other defects. The reed petals must lie completely flat against the reed valve body no. 30. To check, hold against light.

Connecting rod 0.390 mm 0.737 mm big end axial play (.015 in) (.029 in)

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

2
F01D1WA F06D1JA

1. Measuring big end axial play 2. Feeler gauge

1. No play

23, Bearing
947 Engine Check bearing no. 23 of starter drive assembly no. 27 in crankcase.

In case of a play, turn reed petals upside down and recheck. If there is still a play, replace petals. Check perfect condition of rubber coating on reed valve body. Check stopper distance from center of reed valve block.

F06D1IA

1. Bearing of starter drive assembly

F06D1EA

A. 13 0.25 mm (.512 .010 in)

04-06-14

Section 04 ENGINE Subsection 06 (BOTTOM END)

NOTE: Distance should be the same on both sides. Bent stopper as required to obtain the proper distance.

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

3,4, Crankshaft and Bearing

Apply Loctite 767 anti-seize on part of crankshaft where bearing fits. Prior to installation, place bearings into a container filled with oil, previously heated to 75C (167F). This will expand bearing and ease installation. To properly position the outer bearing(s), a distance gauge must be temporarily installed against the inner bearing. Slide the outer bearing until stopped by the distance gauge, then remove it.
ENGINE 717 787 947 DISTANCE GAUGE P/N 529 034 800 (PTO) P/N 529 034 900 (MAG) P/N 290 876 627 (MAG) P/N 290 876 622 (PTO)
F01D1YA

TYPICAL 1. Distance gauge 2. Outer bearing

12, Distance Ring

When installing the distance ring, make sure to position it with its chamfer toward the counterweight of the crankshaft.

18, Crankshaft Gear

787 Engine Position the long flange of the gear toward the counterweight of the crankshaft. Also, make sure to align the gear keyway with the Woodruff key on the crankshaft.

F01B0HA

1. Distance gauge

F00D0LA

1. Woodruff key on the crankshaft

04-06-15

Section 04 ENGINE Subsection 06 (BOTTOM END)

2
F00D0MA

1. Keyway 2. Long flange toward the crankshaft counterweight

F06D1LA

5, Seal
At seal assembly, apply a light coat of lithium grease on seal lips.

1. Seal lip in crankcase recess

6, Drive Pin
Make sure drive pins of bearings are properly installed in crankcase recesses at assembly.
1

787 Engine Position PTO seal against the retaining shim; the gap between the seal and bearing will ensure proper lubrication of the bearing.

F00D0OA

1. Drive pins

13, Counterbalance Shaft

F00D0NA

1. Seal against the retaining shim

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

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

CAUTION

Counterbalance shaft must be properly assembled, otherwise engine will vibrate and premature wear will occur.

04-06-16

Section 04 ENGINE Subsection 06 (BOTTOM END)

Proceed as follows to check if the gear no. 14 is properly positioned on the counterbalance shaft: Temporarily install the counterbalance shaft in the crankcase. Rotate the counterbalance shaft to align the notch of the gear with the crankcase.

947 Engine Install bearing no. 31 and washer no. 32. When installing seals no. 17, apply a light coat of synthetic grease on seal lips. Prior to installation, place bearings no. 15 into a container filled with oil, previously heated to 75C (167F). This will expand bearings and ease their installation. Reinstall counterweights no. 16 using a press and take care to align index marks previously traced.

3,13, Crankshaft and Counterbalance Shaft

787 and 947 Engines Install crankshaft first in crankcase. After crankshaft installation, install counterbalance shaft. Make sure to properly index crankshaft and counterbalance shaft by aligning marks of gears.
F00D0UA

CAUTION

1. Gear notch aligned with the crankcase

The notch of the couterweight on the opposite end of the counterbalance shaft must also be aligned with the cranckcase.
1

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

F00D0PA F00D0VA

1. Counterweight notch aligned with the crankcase

787 ENGINE 1. Marks must be aligned

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

04-06-17

Section 04 ENGINE Subsection 06 (BOTTOM END)

F06D1MA

F06D1OA

947 ENGINE 1. Marks must be aligned

1. Seal in place

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

2, Crankcase
All Engines Crankcase halves are factory matched and therefore, are not interchangeable or available as single halves. Prior to joining crankcase halves, apply a light coat of Loctite 518 on mating surfaces. Do not apply in excess as it will spread out inside crankcase. NOTE: On aluminum material it is recommended to use Loctite Primer N to reduce curing time and increase gap filling capability. Refer to manufacturers instructions. 717 and 787 Engines Rotary valve shaft must be installed in crankcase before closing halves.

947 Engine Properly position bearing no. 31 and washer no. 32.

F06D1NA

CAUTION

1 2

Before joining crankcase halves, make sure that crankshaft gear is well engaged with rotary valve shaft gear.

1. Bearing 2. Washer in crankcase groove

Place seals no. 17 in their respective positions.

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

04-06-18

Section 04 ENGINE Subsection 06 (BOTTOM END)

947 Engine Make sure all locating dowels are in place.

7,8,9, Crankcase Screw

717 Engine Apply Loctite 518 on screw threads and synthetic grease below head screws. Torque crankcase screws to 24 Nm (17 lbfft) as per following illustrated sequence.
11 7 1 3

9 5 13

F06D1PA

8 12
F01D20A

2 10

6 14

1. Dowel

19, Bearing Cover

787 Engine Install the bearing cover with its hollow side toward the bearing.

Torque 2 M10 crankcase screws to 40 Nm (30 lbfft).

1

F01D20B

1. Torque to 40 Nm (30 lbfft)

F00D0QA

1. Hollow side facing bearing

787 Engine Apply Loctite 518 on screw threads and synthetic grease below head screws. Torque crankcase screws to 12 Nm (9 lbfft) as per following sequence. Repeat procedure, retightening all screws to 24 Nm (17 lbfft).

04-06-19

Section 04 ENGINE Subsection 06 (BOTTOM END)

11

21

22

9
9 7

12

8 13

2 14

10

14 3 1 16 5 19 11 21
F07D09B

10 23 8 20 19 4 15 13 2 17 18 6 22 12

19
F01D81A

17

15

16

18

20

As a final step, torque only M10 screws no. 8 of crankcase to 40 Nm (30 lbfft) as per following sequence.
11 7 1 3 5 9

As a final step, torque only the M10 x 73.5 bolts to 40 Nm (30 lbfft) as per following sequence.
10 9 7 8

12

10 3 1 4 2

F01D81B

5 11

6 12

947 Engine Apply synthetic grease below head of screws and Loctite 518 on threads. Torque crankcase screws to 12 Nm (9 lbfft) as per following sequence. Repeat procedure, retightening all screws to 27 Nm (20 lbfft).

F07D09C

04-06-20

Section 04 ENGINE Subsection 06 (BOTTOM END)

11, Fitting
717 and 787 Engines If inlet and outlet oil fittings of rotary valve shaft have been removed from crankcase, reinstall them with their ends pointing toward ignition housing. Apply Loctite 518 on threads of fittings.

1, PTO Flywheel
787 Engine Install O-ring onto crankshaft.
1

10, Stud
717 Engine At assembly in crankcase, apply Loctite 518 on stud threads. Torque to 10 Nm (88 lbfin).

23, Starter Drive Bearing

947 Engine To install bearing no. 23 of starter drive assembly, use pusher (P/N 290 876 502) and handle (P/N 290 877 650).

F01D84A

1. O-ring

717 and 787 Engine Apply Loctite anti-seize lubricant (P/N 293 800 023) to crankshaft threads. Using the same tools as for disassembly procedure, torque PTO flywheel to 110 Nm (81 lbfft). 947 Engine Apply Loctite 242 (blue) on bolt no. 22. Using the same tools as for disassembly procedure, torque bolt no. 22 to 115 Nm (85 lbfft). Apply Loctite 648 on mating surface of PTO flywheel and coupler. Apply Loctite 242 (blue) to Allen screws no. 21 of coupler and torque to 23 Nm (17 lbfft).

2
F06D32A

1. Handle 2. Pusher

04-06-21

Section 04 ENGINE Subsection 06 (BOTTOM END)

Final Assembly
717 and 787 Engines For rotary valve timing and assembly procedures, refer to ROTARY VALVE 04-07. 787 Engine When engine assembly is completed, add 30 mL (1oz) of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug.

F07D06A

1. Remove plug and add SAE 30 motor oil

947 Engine When engine assembly is completed, add 40 mL (1.35 oz) of motor oil SAE 30 to the counterbalance shaft gear through the crankcase filler plug.

F06D2CA

1. Remove plug and add SAE 30 motor oil

04-06-22

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

ROTARY VALVE
717 and 787 Engines

9 5 6 10 14 15 8 11 3 13 1 12 Lithium grease 4 7

1 12 2 20 Nm (15 lbfft)

787 Engine

717 Engine

2 20 Nm (15 lbfft)
F01D7SS

PARTS

FLAT RATE

04-07-1

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

GENERAL
The following verification procedures such as clearance of rotary valve cover or rotary valve shaft gear backlash can be performed without removing engine from watercraft. However engine must be removed from watercraft to work on rotary valve shaft/components. Refer to REMOVAL AND INSTALLATION 04-03 for engine removal procedure. Bottom end must be opened to remove rotary valve shaft. Refer to BOTTOM END 04-06.
1

INSPECTION ON WATERCRAFT
Remove carburetor(s). Refer to CARBURETOR 06-04.

F01D53A

1. 45 feeler gauge

1, Rotary Valve Cover

Unscrew 4 screws no. 2 and withdraw rotary valve cover and valve no. 13.

If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. SOLDER METHOD Remove O-ring from rotary valve cover. Use the following type of solder: rosin core diameter: 0.8 mm (.032 in) electronic application (available at electronic stores) Install 2 solder pieces of 13 mm (1/2 in) long directly on rotary valve, one above and one below rotary valve gear. Apply grease to hold solder in position. Reinstall cover in place WITHOUT its O-ring and torque screws to 20 Nm (15 lbfft). Remove cover then clean and measure compressed solder thickness, it must be within the specified tolerance 0.30 0.05 mm (.012 .002 in).

Rotary Valve/Cover Clearance

The clearance between the rotary valve and the cover must be 0.30 0.05 mm (.012 .002 in). NOTE: If the clearance is below 0.25 mm (.010 in) this could create an overheating situation and if the clearance is over 0.35 mm (.014 in) this could create a hard starting situation. There is 2 methods to verify rotary valve/cover clearance. One with a 45 feeler gauge, the other one with a solder. 45 FEELER GAUGE METHOD Remove O-ring from rotary valve cover. Remove intake manifold from rotary valve cover (except 787 engine). Reinstall cover in place WITHOUT its O-ring and torque screws to 20 Nm (15 lbfft). Feeler gauge blade from 0.25 mm (.010 in) to 0.35 mm (.014 in) thickness should fit between rotary valve and cover. Insert feeler gauge blade through cover inlet ports to verify clearance. At least verify clearance at two different places in each port.

04-07-2

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

1
F01D3PA

TYPICAL 1. Solder

If rotary valve cover clearance is out of specification, machine rotary valve cover seating surface or replace the cover. MACHINING INFORMATION The amount of material over tolerance must be removed from the rotary valve cover seating surface. Also cut the O-ring groove the same amount to keep the 1.0 0.03 mm (.039 .001 in) depth between the bottom of the groove and the seating surface. Remove burrs on the edges of the seating surface and O-ring groove.

F01D3OA

SAME AMOUNT REMOVED FROM COVER SEATING SURFACE AND O-RING GROOVE BASE 1. Cover seating surface 2. O-ring groove depth must be 1.0 0.03 mm (.039 .001 in)

Reverify the clearance. At assembly the rotary valve timing must remain as per original setting. NOTE: If rotary valve crankcase surface is worn, it is possible to have it reworked at the factory. Contact your dealer or distributor.

Rotary Valve Shaft Gear Backlash

Remove PTO flywheel guard. Remove spark plugs, rotary valve cover and valve. Manually feel backlash at one position, then turn crankshaft about 1/8 turn and recheck. Continue this way to complete one revolution. Backlash must be even at all positions. Otherwise overhaul engine to find which part is faulty (gear, rotary valve shaft or crankshaft with excessive deflection).

04-07-3

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

DISASSEMBLY
3, Rotary Valve Shaft
To remove the rotary valve shaft assembly, first remove snap ring no. 4 from crankcase.
1

F01D61A

1. Hold bolt

F01D22A

1. Removing snap ring

CAUTION

Bottom end must be opened to remove rotary valve shaft. To remove rotary valve shaft, use the appropriate puller (P/N 290 876 488).

F01D27A

5,6, Circlip and Spring Seat

If it is necessary to disassemble components of rotary valve shaft assembly, use seat to compress spring and remove circlips.
1
F01D23B

Place puller over rotary valve shaft end and screw on puller bolt into shaft. While retaining bolt with a wrench, turn puller nut CLOCKWISE until shaft comes out.

F01D25A

1. Compress seat 2. Remove circlips

04-07-4

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

8, Bearing
To remove bearing use a bearing extractor such as Snap-on no CJ-950 as illustrated. Slide off distance sleeve, remove snap ring no. 7 and press shaft out.

Snap-on hammer puller including: Handle CJ93-1 Hammer CJ125-6 Claws CJ93-4

F01J0ZA

F01D4NA

1. Bearing 2. Bearing extractor Snap-on CJ-950

Close puller claws so that they can be inserted in end bearing. Holding claws, turn puller shaft clockwise so that claws open and become firmly tight against bearing. Slide puller sleeve outwards and tap puller end. Retighten claws as necessary to always maintain them tight against bearing. Continue this way until bearing completely comes out.
1

9, Bearing

CAUTION

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

CAUTION

Do not remove plug against bearing in upper crankcase half.

F01D28A

1. End bearing

CLEANING
Discard all seals and O-rings. Clean all metal components in a solvent. Clean oil passages and make sure they are not clogged. Clean rotary valve shaft and inside of distance sleeve no. 14.

1
F01D4OA

1. Do not remove this plug

End bearing can be easily removed using the following suggested tool.
04-07-5

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

INSPECTION
1, Rotary Valve Cover
Inspect rotary valve cover for warpage. Small deformation can be corrected by surfacing with fine sand paper on a surface plate. Surface part against oiled sand paper.

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

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

8,9, Bearing
Inspect bearings. Check for scoring, pitting, chipping or other evidence of wear. Make sure plastic cage (on bigger bearing) is not melted. Rotate them and make sure they turn smoothly.

9, Bearing
To install end bearing in crankcase, use the appropriate pusher according to the engine.
ENGINE 717 787 PUSHER P/N 290 876 500 P/N 290 876 501

10, Gear
Visually check gear wear pattern. It should be even on tooth length all around. Otherwise it could indicate a bent shaft, check deflection. Replace gear if damaged. Check for presence of brass filings in gear housing.

Rotary Valve Shaft Deflection

Deflection is measured with a dial gauge. Install rotary valve shaft in crankcase half, without its gear. NOTE: End bearing must be in crankcase half. Measure shaft deflection next to gear splines.
A00B2JA

1. Pusher (P/N 290 876 500)

1
F00B07A

1. Pusher (P/N 290 876 501)

Position ball bearing shielded side towards rotary valve.

1

F01D2CA

1. Rotary valve shaft 2. End bearing in place

04-07-6

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

1 2 3

1
F01D2DA

1. Shield side (toward gear)

A13C0FB

Push bearing until it stops on its seat.

1

1. Seal 2. Ball bearing 3. Bearing extractor Snap-on CJ-950

Install shim no. 15, snap ring no. 7 and slide distance sleeve no. 14 on shaft.
1 2 3 4

F01D33A

2
F01D2FA

1. Bearing 2. Pusher

11, Seal
Apply lithium grease on seal lips. Position seal with shielded portion against shaft splines.

1. 2. 3. 4. 5. 6.

Seal Ball bearing Snap ring Distance sleeve Shim 0.5 mm (.020 in) Rotary valve shaft

8, Bearing
Install ball bearing as illustrated.

3, Rotary Valve Shaft Assembly

CAUTION

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

04-07-7

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

717 Engine To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 605).
1

Push shaft until it stops on bearing seat.

A00C0YA

1. Pusher

Push shaft until its stops on bearing seat.

F01D8OA

717 and 787 Engines

4, Snap Ring
Position snap ring so that its sharp edge faces outwards.

13, Rotary Valve

The rotary valve controls the opening and closing of the inlet ports. Therefore its efficiency will depend on the precision of its installation.
F01D34A

IDENTIFICATION OF THE ROTARY VALVE

ENGINE 717/787 ROTARY VALVE P/N 290 924 502 VALVE DURATION 159

1. Rotary valve shaft 2. Push shaft until it stops

787 Engine To install rotary valve shaft in crankcase, use a pusher (P/N 290 876 609) and handle (P/N 290 877 650).

There is no identification code on the valve. To find out the duration, place an angle finder on the valve and measure the valve cut-out angle or use the following template.

2 1

F01B2FA

1. Pusher 2. Handle

04-07-8

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

F01D73V

1. 159

ROTARY VALVE TIMING

32

0
50

33

40

30

350 360 10 20 340 10 360 350 3 20 40

30 33

40
32

110 100 90

Never use the ridge molded in crankcase as a timing mark. The following tools are required to measure rotary valve opening and closing angles in relation with MAG side piston.

260

270

50

31

0
60

31

60

295 000 007

280

CAUTION

30

70

300

70

290

80

290

80

90 100 11 0 280 270 26 0

250

130

120

250

120

24

24

14

0
2

13

295 000 143

F00B0DA

40

30

15

22

80 190 2 170 1 00 21 160 0 200 190 180 17 22 0 210 16 0 0 15 0

23

04-07-9

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

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

TIMING ENGINE OPENING BTDC 147 5 147 5 CLOSING ATDC 65.5 5 63.5 5

2 147

717 787

For the following instructions, lets use these specifications as example: OPENING: 147 BTDC CLOSING: 65 ATDC Proceed as follows: Turning crankshaft, bring MAG side piston to Top Dead Center using a TDC gauge.

1
F01D3DC

OPENING MARK Step 1 : Bottom of MAG inlet port. Align 360 line of degree wheel Step 2 : Find 147 on degree wheel and mark here

NOTE: Do not rotate the crankshaft. For closing mark, first align 360 line of degree wheel with TOP of MAG side inlet port. Then, find 65 line on degree wheel and mark crankcase at this point.
1

F01D2IA

65
1. Bring piston to TDC

For opening mark, first align 360 line of degree wheel with BOTTOM of MAG side inlet port. Then, find 147 line on degree wheel and mark crankcase at this point.
F01D3EB

CLOSING MARK Step 1 : Top of MAG inlet port. Align 360 line of degree wheel Step 2 : Find 65 on degree wheel and mark here

04-07-10

Section 04 ENGINE Subsection 07 (ROTARY VALVE)

Remove degree wheel. Position rotary valve on shaft splines to have edges as close as possible to these marks with the MAG piston at TDC. NOTE: Rotary valve is asymmetrical. Therefore, try flipping it over then reinstall on splines to obtain best installation position. Apply BOMBARDIER-ROTAX injection oil on rotary valve before reassembling rotary valve cover. Remove TDC gauge.

1, Rotary Valve Cover

Install O-ring no. 12 and cover then torque screws no. 2 to 20 Nm (15 lbfft) in a criss-cross sequence.

04-07-11

Subsection 08

Section 04 ENGINE (EXHAUST SYSTEM)

EXHAUST SYSTEM
SPX Model
25 Nm (18 lbfft) Loctite 242 17 Loctite 518 14 13 6 Loctite 242 19 19 18 18 19 15 4 25 Nm (18 lbfft) 20

0
5

19

Loctite 518 Loctite 648

40 Nm (30 lbfft) 12 40 Nm (30 lbfft) 12 Synthetic grease 13 16 2 4 Nm (35 lbfin) 9 7 Loctite 40 Nm 242 (30 lbfft) 9

736 sealant 10 Nm 10 (88 lbfin)

Loctite 242 40 Nm 8 (30 lbfft)

1 3

4 Nm (35 lbfin)

4 Nm (35 lbfin)

11 732 sealant

27 Nm (20 lbfft)
F01D8XS

PARTS

FLAT RATE

04-08-1

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

GS, GTS and GTI Models

Loctite 242 25 Nm (18 lbfft) 10 8 9 25 Nm 7 (18 lbfft) Loctite 242 1819 Synthetic grease 13 12 24 Nm (17 lbfft) 16 17

14

19 6 25 Nm (18 lbfft) Loctite 242 5

10 Nm (88 lbfin) 4

15

2 3

1 4 Nm (35 lbfin) 4 Nm (35 lbfin) 11

4 Nm (35 lbfin)

732 sealant 27 Nm (20 lbfft)

4 Nm (35 lbfin)

GS/GTS
4 Nm (35 lbfin) 11

GTI

732 sealant 27 Nm (20 lbfft)

F00D0XS

04-08-2

PARTS

FLAT RATE

Subsection 08

Section 04 ENGINE (EXHAUST SYSTEM)

GSX Limited, XP Limited and GTX Limited

23 Nm (17 lbfft) 2 Nm (18 lbfin) 732 sealant 2

4 Nm (35 lbfin)

2 Nm (18 lbfin) 11 3 1

14 Nm (10 lbfft) 4

736 sealant

4 Nm (35 lbfin)

Loctite 242 9

10 15 14

7 Loctite 271 40 Nm (30 lbfft) Loctite 8 242 9 16 Loctite 242 25 Nm (18 lbfft)

Loctite 242 25 Nm (18 lbfft)

19 18 19 6 25 Nm (18 lbfft)

12-13 19 18 19 20 25 Nm (18 lbfft)

Loctite 242

40 Nm (30 lbfft)

F06D33S

Loctite 242

PARTS

FLAT RATE

04-08-3

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

REMOVAL
Tuned Pipe
SPX, GS and GSX Limited Remove seat. Remove air vent tube support from body opening. XP Limited Open engine cover. Remove storage basket. GTS, GTI and GTX Limited Remove seat(s). Remove seat support (GTI and GTX Limited). GS, GTS and GTI Models Disconnect water supply hose and water injection hose. Disconnect tuned pipe bleed hose.
1 3

Remove tuned pipe retaining screw no. 6 from exhaust manifold side. Remove screws no. 7, nut no. 8 and flat washers no. 9 from tuned pipe flange. NOTE: Slightly lift tuned pipe to release nut as necessary. Take care not drop nut and flat washer. Withdraw tuned pipe head no. 10 in a forward and rotating movement.

SPX Model Remove electrical box from watercraft. Disconnect water supply hose and water injection hose at tuned pipe head.

F01D3YA

1. Water supply hose 2. Water injection hose

F01D8NA

Loosen exhaust hose collar no. 1 at tuned pipe cone outlet. Remove clamp no. 4 securing tuned pipe cone to tuned pipe head. Remove screws no. 7 and nut no. 8 with flat washers no. 9 at tuned pipe head flange.

TYPICAL 1. Bleed hose removed 2. Injection hose removed 3. Supply hose removed

Loosen exhaust hose collar no. 1 at tuned pipe outlet. Disconnect strap no. 2 retaining muffler no. 11. Remove exhaust hose no. 3 from tuned pipe by pulling muffler. Remove clamp no. 4 from tuned pipe. Remove tuned pipe cone no. 5.
F01D7IA

04-08-4

Subsection 08

Section 04 ENGINE (EXHAUST SYSTEM)

Remove retaining screw no. 20 of tuned pipe head.

Remove exhaust hose no. 3 from tuned pipe cone no. 5. Move tuned pipe cone no. 5 in front of bilge between body and fuel tank.

F01D76A

1
F01D7JA

1. Screw

Remove tuned pipe head no. 10. Remove both screws no. 6 retaining tuned pipe cone to engine.

Open storage cover and remove basket. Then, pull out tuned pipe cone no. 5 through storage compartment opening.

GSX Limited, XP Limited and GTX Limited Disconnect water supply hose at tuned pipe head no. 10.

F01D7KA

1
F06E08A

1. Water supply hose

F01D7LA

04-08-5

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Disconnect at the tuned pipe head no. 10 the water supply hose of the water flow regulator valve.

Disconnect the water bleed hose.

F06E09A

F06E0BA

1. Water bleed hose

1. Water supply hose for the regulator valve

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

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

F06D14A F06E0AA

1. Loosen clamp

1. Water injection hose

04-08-6

Subsection 08

Section 04 ENGINE (EXHAUST SYSTEM)

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

F06D1TA

F06D1SA

1. Tuned pipe flange

1. Loosen and remove clamp

Loosen bolt no. 20 of tuned pipe head above the engine magneto.

Loosen Allen screw of carburetor bracket.

F06D1UA F06D2DA

1. Remove bolt

1. Loosen Allen screw

Remove tuned pipe head no. 10.

Loosen Allen screws no. 7 and nut no. 8 at tuned pipe flange. NOTE: To loosen nut, use polygonal key (P/N 529 035 505).

04-08-7

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

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

TUNED PIPE REPAIR

This procedure is given to repair tuned pipe cracks using T.I.G. welding process.

Procedure
Sand the cracked area to obtain bare metal. Perform a 1.50 mm (1/16 in) depth chamfer over crack. Use pure argon gas with 5.55 mm (3/32 in) tungsten electrode (puretung green, zirtung brown) and AC current. Use a 5.55 mm (3/32 in) aluminum welding rod (no. 4043), to fill crack. Sand welding slightly to remove material surplus.

F06D1VA

1. Loosen bolt

Remove tuned pipe cone no. 5.

Test
Use compressed air at 124 kPa (18 PSI) to pressurize tuned pipe. NOTE: Prior to verify leaks, plug all holes and pressurize tuned pipe while immerging it in water.

Exhaust Manifold
SPX Model Remove air intake silencer and carburetors. Refer to AIR INTAKE 06-03 and CARBURETOR 06-04 for proper procedures. All Models Remove 8 Allen screws no. 12 and lock washers no. 13 then withdraw exhaust manifold.

CAUTION

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

Muffler
Disconnect hoses from muffler no. 11. Disconnect hoses of the water flow regulator valve (except 717 engine). Disconnect retaining strap no. 2 of muffler. Pull muffler no. 11 out of bilge. NOTE: On the GSX Limited and the XP Limited, remove the VTS motor. Refer to VARIABLE TRIM SYSTEM 09-05.

INSTALLATION
Installation is essentially the reverse of removal procedures. However, pay particular attention to the following.

Exhaust Manifold
Make sure gasket(s) no. 17 are properly positioned prior to finalizing manifold installation.

04-08-8

Subsection 08

Section 04 ENGINE (EXHAUST SYSTEM)

717 Engine Apply synthetic grease on threads of screws no. 12. Install exhaust manifold no. 14 and torque screws no. 12 to 24 Nm (17 lbfft) as per following illustrated sequence.

Torque exhaust manifold screws to 24 Nm (17 lbfft) as per following illustrated sequence. Repeat the procedure, retightening screws to 40 Nm (30 lbfft).

4 1 7 6

1 7 6 4

3 2 5 8

5
F01D82A

F01D59A

787 Engine Apply Loctite 518 on 2 screws no. 12. On the other screws no. 12, apply synthetic grease on threads. Install screws. Refer to the following illustration for proper position of screws.
1 2 1 2

947 Engine Apply synthetic grease on threads of Allen screws no. 12. Install and hand tighten Allen screws no. 12 as per following picture.

F06D1YA

1. M10 x 60 Allen screws 2. M10 x 110 Allen screws

F01D82B

1. Screw with Loctite 518 2. Screw with synthetic grease

04-08-9

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Torque Allen screws to 24 Nm (17 lbfft) as per following illustrated sequence. Repeat the procedure, retightening Allen screws to 40 Nm (30 lbfft).
8 2 3 6

All Models Ensure rubber bushings no. 19 and sleeve no. 18 are not damaged and are properly installed into tune pipe support(s).

CAUTION

Damage to bushings and/or sleeve will eventually cause stress to tune pipe and may cause cracking. Make sure that gasket no. 16 is properly located on exhaust manifold prior to finalizing pipe installation. Apply Loctite 242 (blue) on nut no. 8 and screws no. 6 and no. 7. Hand tighten all fasteners before torquing any of them. For torquing specifications, see the main illustrations at the beginning of this subsection.

F06D1YB

Tuned Pipe
787 and 947 Engines Make sure to install the sealing ring no. 15 on tuned pipe cone if it was removed.

717 Engine Install tuned pipe cone no. 5 with collar no. 15 and clamp no. 4. Position clamp no. 4 as illustrated. Do not tighten clamp yet.

F01D69A F01D41A

TYPICAL 1. Sealing ring

1. Clamp 2. Exhaust collar

Apply a thin layer of heat resistant 736 sealant (P/N 413 709 200) all around sealing ring no. 15.

With hose removed, align cone outlet with muffler inlet. NOTE: Due to exhaust cone angle, it may have to be rotated to obtain alignment.

04-08-10

Subsection 08

Section 04 ENGINE (EXHAUST SYSTEM)

Push cone no. 5 until it touches tuned pipe, then tighten exhaust clamp no. 4 and torque to 10 Nm (88 lbfin).

Torque bolt of tuned pipe head above the engine magneto to 25 Nm (18 lbfft).

CAUTION

There must be no gap between tuned pipe cone and tuned pipe head. NOTE: Exhaust clamp nuts should be tightened alternately to assure no leakage and to obtain specified torque.

947 Engine
Torquing Sequence Torque Allen screws no. 7 at tuned pipe head flange to 25 Nm (18 lbfft). NOTE: Torque nut no. 8 only to 18 Nm (13 lbfft) using the polygonal key (P/N 529 035 505).

F06D1UA

1. Torque bolt to 25 Nm (18 lbfft)

Torque bolt of tuned pipe cone beside the engine water return hose to 25 Nm (18 lbfft).

F06D1TA

1
F06D1VA

1. Torque Allen screws and nut to 25 Nm (18 lbfft)

1. Torque bolt to 25 Nm (18 lbfft)

04-08-11

Section 04 ENGINE Subsection 08 (EXHAUST SYSTEM)

Torque clamp of tuned pipe head to 14 Nm (10 lbfft).

Torque exhaust hose clamp no. 1 of tuned pipe cone to 4 Nm (35 lbfin).
1

F06D1SA

F06D14A

1. Torque clamp to 14 Nm (10 lbfft)

1. Torque clamp to 4 Nm (35 lbfin)

As a final step, torque Allen screws at tuned pipe head flange to 40 Nm (30 lbfft). NOTE: Torque nut only to 28 Nm (21 lbfft) using the polygonal key (P/N 529 035 505). The nut will be at the same torque as the screws.

F06D1TA

1. Torque Allen screws and nut to 40 Nm (30 lbfft)

04-08-12

Section 05 COOLING SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

CIRCUIT, COMPONENTS AND CARE................................................................................... 05-02-1 CIRCUIT .............................................................................................................................. 05-02-5 COMPONENTS .................................................................................................................. 05-02-9 CARE .................................................................................................................................. 05-02-13

GTX RFI

05-01-1

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

CIRCUIT, COMPONENTS AND CARE

SPX Model
Loctite 592 Bleed hose Loctite 592 1.2 Nm (11 lbfin) 3 1.2 Nm (11 lbfin) Tuned pipe water inlet hose 2 Engine water return hose 1.2 Nm (11 lbfin) Engine water supply hose Cooling System Indicator (CSI)

2 Nm (18 lbfin)

Loctite 592

Water injection hose Engine drain hose 5

1 Loctite 592 Regulator valve water supply hose 6 9 0.11 Nm (1 lbfin) 10 8 0.6 Nm (5 lbfin) Loctite 592 1 To exhaust outlet Loctite 592

2.5 Nm (22 lbfin)

5 Nm 7 (44 lbfin) Loctite 592

F01E2AS

PARTS

FLAT RATE

05-02-1

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

GS and GTI Models

Loctite 592 3 Loctite 592 Bleed hose Water injection hose Tuned pipe water inlet hose Loctite 592 1.2 Nm (11 lbfin)

Engine water supply hose 1.2 Nm (11 lbfin)

Engine water outlet hose

1.2 Nm (11 lbfin)

Loctite 592 Engine drain hose

Cooling System Indicator (CSI)

1.2 Nm (11 lbfin) To exhaust outlet

F06E0GS

Loctite 592

05-02-2

PARTS

FLAT RATE

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

GTS Model

Loctite 592

3 Loctite 592 Bleed hose Water injection hose Loctite 592

1.2 Nm (11 lbfin)

Tuned pipe water inlet hose

1.2 Nm (11 lbfin) 2 Loctite 592 1.2 Nm (11 lbfin) 1 Engine water return hose 1 2 Nm (18 lbfin)

Engine water supply hose

Engine drain hose

Cooling System Indicator (CSI) 2.5 Nm (22 lbfin) Loctite 592

1.2 Nm (11 lbfin)

F02E07S

To exhaust outlet

PARTS

FLAT RATE

05-02-3

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

GSX Limited, XP Limited and GTX Limited

Loctite 592 Engine water return hose 3 Loctite 592 Loctite 592 Engine drain hose Loctite 592 Loctite 592 1.2 Nm (11 lbfin) Water injection hose Bleed hose Cooling System Indicator (CSI) 1 Loctite 592 1.2 Nm (11 lbfin) Engine water supply hose 1.2 Nm (11 lbfin) 1.2 Nm (11 lbfin)

6 9 10 0.11 Nm (1 lbfin)

Regulator valve water supply hose

Loctite 592

8 0.6 Nm (5 lbfin) Loctite 592 7

F06E0HS

5 Nm (44 lbfin)

05-02-4

PARTS

FLAT RATE

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

CIRCUIT

CAUTION

All hoses and fittings of the cooling system have calibrated inside diameters to assure proper cooling of the engine. Always replace using appropriate Bombardier part number.

717 and 787 Engines A Serial Cooling System is utilized on the 717 and 787 engines, which offers an efficient cooling of the combustion chamber to prevent the possibilities of detonation. The water supply is taken from a pressurized area in the jet pump between the impeller and venturi. Water enters the cylinder head, cooling the combustion chamber to prevent detonations. Then, water exits cylinder head toward tuned pipe.
3 2

F01D7HB

1. Water passages

No water enters crankcase. When engine is running, water must flow from bleed outlet indicating that water circulates.

CAUTION

When investigating for no water flow in the cooling system, check all elbows and straight fittings as well as all hoses for blockage. For a minimum back pressure in the exhaust, engine water outlet hose is not connected to the exhaust. It has its own outlet at the rear of the hull.

F01E1LA

1. Cylinder head cover 2. Fresh water from jet pump 3. Water exiting head assembly to tuned pipe, exhaust manifold and cylinders 4. Water from cylinder water jackets exiting engine

The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation. Water is pre-heated by the exhaust system before entering the cylinder cooling jackets. Water enters cylinder cooling jacket through passages located below exhaust ports from tuned pipe.

F01E1GA

TYPICAL 1. Engine water outlet hose

05-02-5

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

Draining of the cooling system is accomplished by a drain hose located at the lowest point of the circuit.

As with other models, the water supply is provided by a pressurized area in the jet pump between the impeller and venturi. Water is directed to the water jacket of the tuned pipe head.

F01E0FB

717 ENGINE 1. Drain hose

1
F06E08A

1. Water supply hose

Water circulates in the jackets of the tuned pipe head and the exhaust manifold. It is consequently pre-heated by the exhaust system. Then, water enters the cylinder-block water jackets through passages located above and below exhaust ports.

F01E1MA

787 ENGINE 1. Drain hose

947 Engine The 947 engine has a conventional cooling system. The water is pre-heated in the tuned pipe water jacket before entering the engine or cylinder head.
F06D20A

1. Water passages

05-02-6

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

After water has circulated in the cylinder-block water jackets, it is directed in the 1 piece cylinder head which features improved combustion chamber and spark plug cooling.

Draining of the cooling system is accomplished by the drain hose connected to a fitting at the bottom of the cylinder-block, on tuned pipe side.

F06E0IA F06D21A

1. Drain hose

Water exits cylinder head water jackets through an outlet fitting.

Bleeding of the cooling system is accomplished by the bleed hose located at the uppermost point of the circuit at the tuned pipe. The bleed hose also serves as the Cooling System Indicator (CSI).

F06E05A

1
F06E0BA

1. Engine water outlet

Water circulates in the water outlet hose and is expelled out of the cooling system through a fitting located in the jet pump support on the transom of the watercraft.

1. Bleed hose

The water supply of the water flow regulator is provided by the water jacket of the tuned pipe head.

05-02-7

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

Regulated water is injected in the tuned pipe by a calibrated fitting.

F06E09A

1 1

1. Water supply of the water flow regulator valve

The lower hose of the valve is the water supply and the upper hose is the regulated injection water for the tuned pipe.

F06E0AA

1. Injection fitting

All Models

CAUTION

Never modify cooling system arrangement, otherwise serious engine damage could occur.
TECHNICAL DATA TYPE: TLCS (Total Loss Cooling System). COOLANT FLOW: Pressure build-up at impeller housing (no water pump). TEMPERATURE CONTROL: Calibrated outlet fittings (no thermostat). SYSTEM BLEEDING: Self-bleed type (hose at uppermost point of circuit). SYSTEM DRAINING: Self-drain type (hose at lowest point of circuit). SYSTEM FLUSHING: Fitting spigot or hose adapter. MONITORING BEEPER: Turns on at 86-94C (187-201F).

1
F06E0CA

1. Water supply from tuned pipe water jacket 2. Regulated injection water to the tuned pipe 3. Muffler

05-02-8

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

COMPONENTS
1, Clamp
To cut or secure non-reusable Oetiker clamps of cooling system hoses, use pliers (P/N 295 000 070).

CAUTION

The elbow fittings are calibrated and can not be interchanged with one of a different size as severe engine damage could result. The elbow fitting can be identified by using the number stamped onto the fitting or by measuring its inside diameter. Refer to the following illustration and chart.

16
1
1

3
F00E04A

2
F01B2KA

1. Outlet diameter = 4.6 mm (.181 in) 2. Stamped number 3. Inlet diameter = 5.5 mm (.219 in)

1. Cutting clamp 2. Securing clamp

2, Fitting Spigot
The fitting spigot is used on some models to flush cooling system. Refer to FLUSHING AND LUBRICATION 02-03.

Stamped Number on Fitting 16 48

Fitting P/N 293 700 016 293 710 048

Inlet Diameter 5.5 mm (.219 in) 4.0 mm (.157 in)

Outlet Diameter 4.6 mm (.181 in) 3.5 mm (.139 in)

3, Elbow Fitting
Water injection used on exhaust system cools the exhaust gases to obtain maximum performance from the tuned pipe. The elbow fitting has a calibrated inside diameter to optimize water flow in tuned pipe. The water injection also helps in reducing noise level and cools components of the exhaust system.

4, Water Flow Regulator Valve

A water flow regulator valve is mounted on models with the 787 and 947 engines so that they can produce the maximum horsepower output and yet maintain the necessary diameter of the injection fitting at the tuned pipe head for unobstructed water flow.

05-02-9

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

The water flow regulator valve is mounted directly onto the muffler.

CAUTION

Do not change the calibration of the spring, otherwise serious engine damage can occur. At low speed, water pressure in the supply hose of the regulator valve is not sufficient to overcome the spring of the regulator valve; more water is being delivered to the injection fitting at the tuned pipe.

F01E1FA

SPX MODEL 1. Water supply hose of regulator valve 2. Regulated water to injection fitting 3. Water injected into the muffler

3
F01E2BA

LOW SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve (less restriction) 3. Water injected in the muffler
F06D1WB

GSX LIMITED, XP LIMITED AND GTX LIMITED 1. Water supply from tuned pipe water jacket 2. Regulated water to injection fitting 3. Water injected into the muffler

At higher speed, water pressure increases in the supply hose of the regulator valve and gradually overcomes the return spring of the regulator valve. Less water is being delivered to the injection fitting at the tuned pipe.

NOTE: The water injected into the muffler is not regulated by the valve. A calibrated water injection fitting of 3.0 mm (.118 in) inside diameter limits water flow into the muffler. The water flow regulator valve has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe.

05-02-10

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

F01E1RA

1. Spring 2. Cover

Remove fitting no. 7 from valve housing.

3
F01E2CA

HIGH SPEED OPERATION 1. Water entering regulator valve 2. Water exiting regulator valve (more restriction) 3. Water injected in the muffler

Adjustment The water flow regulator valve has been calibrated at the factory and should not be modified. NOTE: Water flow regulator valves ordered from the parts channel are also calibrated. If the maximum engine speed cannot be attained or if the engine has poor performance, the water flow regulator valve should be considered in the troubleshooting of the problem. Disassembly Remove the cover no. 6 of the valve by releasing the spring no. 5.

F01E1SA

1. Fitting

Unscrew the tapered needle no. 8. NOTE: Hold the valve to prevent it from turning.

WARNING

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

05-02-11

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

F01E1TA

F01E21A

1. Tapered needle

Loosen clamp to separate valve from bellows.

1

Remove the tapered needle from valve housing.

F01E24A

1. Clamp
F01E20A

1. Remove tapered needle

Pull the valve slightly. Using pliers, release the clamp which retains the bellows no. 10. Remove valve no. 9 and bellows no. 10.

Inspection Inspect parts for damage. Verify especially bellows for cracks. Assembly Assembly is essentially the reverse of disassembly procedures.

05-02-12

Subsection 02

Section 05 COOLING SYSTEM (CIRCUIT, COMPONENTS AND CARE)

CARE
For flushing purposes, the cooling system is equipped with either a fitting spigot or a hose adapter depending upon the model. For flushing operation, a coupler hose is available (unnecessary for models with the hose adapter) to connect to the fitting spigot. A garden hose is used to flush the whole system by backwash. For flushing procedure, refer to FLUSHING AND LUBRICATION 02-03. For winterization of cooling system, refer to STORAGE 02-05.
max. 90

SPX, GS, GTS and GTI Models When servicing the hull, always rotate watercraft counterclockwise (seen from the rear). Rotating watercraft on the opposite side could allow residual water in tuned pipe to enter the engine and cause damage.

F06L0GA

TYPICAL

Towing the Watercraft in Water

Max. 90

Special precautions should be taken when towing a Sea-Doo watercraft in water. Maximum recommended towing speed is 24 km/h (15 MPH). When towing your watercraft in water, pinch the water supply hose from the jet pump housing to the engine with a large Hose Pincher (P/N 529 030 400).

F01L45C

GSX Limited, XP Limited and GTX Limited When servicing the hull, always rotate watercraft clockwise (seen from the rear). Rotating watercraft on the opposite side could allow residual water in tuned pipe to enter the engine and cause damage.
F01B23A

05-02-13

Section 05 COOLING SYSTEM Subsection 02 (CIRCUIT, COMPONENTS AND CARE)

This will prevent the cooling system from filling which may lead to water being injected into and filling the exhaust system. Without the engine running there isnt any exhaust pressure to carry the water out the exhaust outlet.

CAUTION

Failure to do this may result in damage to the engine. If you must tow a stranded watercraft in water and do not have a hose pincher be sure to stay well below the maximum towing speed of 24 km/h (15 MPH). Snugly install the hose pincher on the water supply hose as shown in the following illustrations.
F08E01A

XP LIMITED 1. Hose pincher

F02E04A

GS, GTS AND GTI MODELS 1. Hose pincher

F07E03A

GSX LIMITED AND GTX LIMITED 1. Hose pincher

CAUTION

When finished towing the watercraft, the hose pincher must be removed before operating it.

F01E29A

SPX MODEL 1. Hose pincher

05-02-14

Section 06 FUEL SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

FUEL CIRCUIT........................................................................................................................ 06-02-1 GENERAL ........................................................................................................................... 06-02-6 REMOVAL........................................................................................................................... 06-02-6 INSPECTION ...................................................................................................................... 06-02-10 ASSEMBLY......................................................................................................................... 06-02-11 FUEL SYSTEM PRESSURIZATION ................................................................................... 06-02-11 AIR INTAKE ............................................................................................................................ REMOVAL........................................................................................................................... ASSEMBLY......................................................................................................................... CARBURETOR ....................................................................................................................... GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... CLEANING ......................................................................................................................... DISASSEMBLY AND INSPECTION................................................................................... ASSEMBLY......................................................................................................................... INSTALLATION .................................................................................................................. ADJUSTMENTS ................................................................................................................ 06-03-1 06-03-3 06-03-4 06-04-1 06-04-2 06-04-2 06-04-3 06-04-3 06-04-5 06-04-8 06-04-8

GTX RFI

06-01-1

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

FUEL CIRCUIT
SPX Model
3 Nm (27 lbfin) Body 2 Nm (18 lbfin) 6 7 6 Nm (53 lbfin) 3 1 2

1 Nm (9 lbfin)

22 Nm (16 lbfft) 4 Nm (35 lbfin) 4 5 12 3 Nm (27 lbfin) 10 4 Nm (35 lbfin) 4 13 11

Engine

F01F2ZS

PARTS

FLAT RATE

06-02-1

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

GS and GTI Models

3 Nm (27 lbfin) 2 Nm (18 lbfin) 7 6 1.2 Nm (11 lbfin) 6 Nm (53 lbfin) 3 1 2 1.2 Nm (11 lbfin)

Body

22 Nm (16 lbfft) 4 Nm 4 (35 lbfin) 3 Nm (27 lbfin) 5 4 Nm 4 (35 lbfin) 12 11 10 4 Nm (35 lbfin) 1.2 Nm (11 lbfin)

Dielectric grease

8 1.2 Nm Engine (11 lbfin) 9

14 13

F06F0MS

06-02-2

PARTS

FLAT RATE

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

GSX Limited and GTX Limited

3 Nm (27 lbfin) 2 Nm (18 lbfin) 7 6 6 Nm (53 lbfin) 1.2 Nm (11 lbfin) 1.2 Nm (11 lbfin) 1.2 Nm (11 lbfin) 3 1 2

Body

1.2 Nm (11 lbfin) 22 Nm (16 lbfft) 4 Nm 4 (35 lbfin) 12 11 10 1.2 Nm (11 lbfin)

3 Nm (27 lbfin)

5 4 Nm 4 (35 lbfin)

4 Nm (35 lbfin) Dielectric grease 8 9 1.2 Nm Engine (11 lbfin) 1.2 Nm (11 lbfin)

13

14

F06F0NS

PARTS

FLAT RATE

06-02-3

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

XP Limited
4 Nm (35 lbfin)

Engine 1.2 Nm (11 lbfin) 3 Nm (27 lbfin) 3 1 2 1.2 Nm (11 lbfin) 6 Nm (53 lbfin) Synthetic grease 2 Nm (18 lbfin) 1.2 Nm (11 lbfin)

1.2 Nm (11 lbfin)

12 11 10

1.2 Nm (11 lbfin)

22 Nm (16 lbfft)

4 5 4

Synthetic grease

8 9

13

4 Nm (35 lbfin)

14 13

F08F04S

06-02-4

PARTS

FLAT RATE

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

GTS Model
3 Nm (27 lbfin) 2 Nm (18 lbfin) 6 Nm (53 lbfin) 1 3 7 6 2

1.2 Nm (11 lbfin)

1.2 Nm (11 lbfin) 22 Nm (16 lbfft) 12 11 10 4 5 4 Nm (35 lbfin) 4 8 Dielectric grease 1.2 Nm (11 lbfin) Engine

13

14

F02F1RS

PARTS

FLAT RATE

06-02-5

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

GENERAL

WARNING

Whenever repairing the fuel system, always verify for water infiltration in reservoir. Replace any damaged, leaking or deteriorated fuel lines. To secure or cut Oetiker clamps on fuel lines, use pliers (P/N 295 000 070).
F01B05A

1. Securing clamp in limited access

When replacing fuel lines on SEA-DOO watercraft, be sure to use B1 hoses as available from Bombardier parts department. This will ensure continued proper and safe operation.

x
1
F01B03A

WARNING

Use of improper fuel lines could compromise fuel system integrity.

1. Cutting clamp

REMOVAL
1, Fuel Filter
All Models Except the XP Limited Open storage compartment cover. Remove basket. XP Limited Open engine cover and remove basket. GTS Model Press on vent tube upper part to enable to withdraw tube from body.

F01B04A

1. Securing clamp

06-02-6

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

Pull fuel filter no. 1 toward the bottom.

F01F04A F02L1MA

TYPICAL TYPICAL 1. Press on vent tube

8, Fuel Baffle Pick Up

NOTE: The baffle pick up has an integrated fuel sender for the fuel gauge.
1

All Models Turn the fuel valve to OFF position.

WARNING

The engine must not be running and fuel valve must be set to OFF position. Gasoline is flammable and explosive under certain conditions. Always work in a well ventilated area. Unscrew fuel filler cap to remove any fuel pressure in system. Unscrew the fuel filter bowl no. 2 counterclockwise then pull toward the bottom.
F01F20A

1. Pick up tube 2. Fuel sensor 3. Baffle pick up

Disconnect BLACK negative cable, then RED positive cable of battery.

WARNING

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

F01F01A

TYPICAL Step 1 : Loosen counterclockwise Step 2 : Pull

06-02-7

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

Empty fuel tank.

WARNING

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

GTS Model Open storage compartment cover. Remove storage basket from watercraft. Siphon fuel tank. Remove vent tube.

SPX Model Open storage compartment cover. Remove storage basket from watercraft. Siphon fuel tank. Loosen clamp no. 4 and disconnect fuel filler hose no. 5.

F02L14A

1. Remove vent tube

Disconnect fuel filler hose no. 5 from fuel tank.

1

F01F3DA

1. Disconnect fuel filler hose

Disconnect fuel sender of baffle pick up. Loosen lower clamp no. 10 and remove fuel baffle pick up.
F02F1MA

1. Disconnect fuel filler hose

Loosen lock nut and remove fuel filter from reverse system support.

F01F3EA

1. Remove fuel baffle pick up

06-02-8

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

1
F02F1PA

1. Front fuel tank strap 2. Middle fuel tank strap

F02F1NA

1. Remove fuel filter

Disconnect the fuel lines from baffle pick up and loosen lower clamp no. 10. NOTE: Identify fuel line positions to ease reassembly.
1

From the engine compartment, disconnect the strap retaining the oil injection reservoir and fuel tank. NOTE: It is not necessary to remove the oil injection reservoir. Move fuel tank forward until the fuel baffle pick up can be removed from the storage compartment opening.

GS and GSX Limited Open storage compartment cover. Remove storage basket from watercraft. Siphon fuel tank. Remove steering assembly. Refer to STEERING SYSTEM for procedure. GTI and GTX Limited Syphon fuel tank. Remove glove box. XP Limited Tilt seat. Refer to HULL/BODY for procedure. Remove access plug on body. Syphon fuel tank.

F02F1OA

1. Disconnect fuel hoses 2. Loosen lower clamp

Disconnect the middle and front fuel tank straps no. 13.

06-02-9

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

GS, GSX Limited, GTI and GTX Limited Disconnect fuel lines from baffle pick up and loosen lower clamp no. 10.
1

F01F02A

F02F1OA

1. Gasket in bowl

TYPICAL 1. Disconnect fuel hoses 2. Loosen lower clamp

WARNING

Disconnect wiring harness of fuel sender. Remove baffle from fuel tank.

Ensure that there is no leakage from the fuel filter.

All Models Remove upper clamp no. 12 from adapter no. 11 and slide adapter from baffle. Push inward on the 3 clips at the base of the baffle in order to remove the filter. Pry base off using a small slotted screwdriver (if necessary).

5, Fuel Filler Hose

Verify fuel filler hose for damage. Always ensure that clamps no. 4 are well positioned and tightened. Torque clamps to 4 Nm (35 lbfin).

6, Pressure Relief Valve

This valve will eliminate fuel spillage when the watercraft is upside down. If pressure is built up in fuel system the valve should open at 10 kPa (1.5 PSI) to release the pressure.

INSPECTION
1, Fuel Filter
Inspect fuel filter condition. Carefully use low pressure compressed air to clean fuel filter. Replace filter if permanently clogged or damaged.

WARNING

2, Fuel Filter Bowl

Check filter bowl for water contamination.

If pressure relief valve is stuck, the pressure in fuel system will build up and it may cause fuel leakage in engine compartment. NOTE: It is a one-way valve with an arrow to indicate the air flow.

3, Gasket
Inspect gasket condition. Make sure gasket is well positioned into the filter bowl no. 2.

7, Check Valve
Black side of the one-way check valve is the valve outlet. It allows air to get in reservoir.

06-02-10

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

9, Baffle Pick Up Filter

Inspect filter no. 9 of baffle pick up. Clean or replace as necessary.

GTS Model Only Insert vent tube in body and clip it in place.

14, Fuel Tank

Visually inspect the inside and outside of the fuel tank necks for crack(s). If crack(s) are existing, replace fuel tank. Check with your finger to feel the inside and outside surfaces of fuel tank. Flex fuel tank necks to ensure there are no hidden cracks.
4 2

WARNING

Vent tube must be in place to provide proper bilge ventilation.

F07F06A

F02L14A

1. 2. 3. 4. 5. A.

Tank upper surface Inspect outside, above upper surface Normal molding seam Inspect inside, above upper surface Base of the neck Approx. 4mm (5/32 in)

1. Install vent tube

FUEL SYSTEM PRESSURIZATION

NOTE: A fuel tank is comprised of 3 components: the tank, the fuel pick up neck and the filler neck. The necks are injection molded and the tank is then blow molded over the necks. During the molding process, a small molding seam may appear on the inner side of the necks at approximately 4 mm (5/32 in) from the base of the neck. It is a normal situation to have a molding seam and it should not be confused with a crack.

WARNING

Whenever doing any type of repair on watercraft or if any components of the fuel system are disconnected, a pressure test must be done before starting engine. Ensure to verify fuel line ends for damage. Always cut damaged end before reinstallation.

Pressure Test
Proceed as follows: Fill up fuel tank. Disconnect air inlet hose of fuel tank from body. Install a hose pincher (P/N 295 000 076) on fuel tank vent hose.

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

8, Baffle Pick Up
Slide adapter no. 11 onto baffle pick up no. 8 until it stops on rib. Install clamp no. 12. Install baffle pick up no. 8 into fuel tank and push it until it sits on fuel tank neck. Install clamp no. 10 and torque both clamps to 3 Nm (27 lbfin).

06-02-11

Section 06 FUEL SYSTEM Subsection 02 (FUEL CIRCUIT)

RE S T OU

F01F0KA

TYPICAL 1. Disconnect air inlet hose 2. Install a hose pincher to vent hose

Connect pump gauge tester (P/N 295 021 800) to air inlet hose. NOTE: This pump is included in the ENGINE LEAK TESTER KIT (P/N 295 500 352). Turn fuel valve to OFF position and pressurize fuel system to 34 kPa (5 PSI). If no leaks are found, turn fuel valve to ON position and pressurize once more. If pressure is not maintained locate leak and repair/replace component leaking. To ease leak search spray a solution of soapy water on components, bubbles will indicate leak location. NOTE: The system must maintain a pressure of 34 kPa (5 PSI) during 10 minutes. Never pressurize over 34 kPa (5 PSI). Reconnect air inlet hose of fuel tank to body.

WARNING

If any leak is found, do not start the engine and wipe off any fuel leakage. Do not use electric powered tools on watercraft unless system has passed pressure test. NOTE: Before removing the hose pincher, block with your finger the outlet fitting to feel if air is coming out when removing hose pincher. This will indicate that pressure relief valve and the outlet fitting are not blocked. Remove hose pincher from fuel tank vent hose.

06-02-12

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

AIR INTAKE
SPX, GS, GTS and GTI Models

9 10 Nm (89 lbfin) 2 Loctite 242 8 Loctite 242 5 4 10 Nm (89 lbfin)

8 Loctite 242

10

SPX

Loctite 242 10 Nm (89 lbfin) 7 Loctite 518 Loctite 518

GS/GTS/GTI

F00F0DS

PARTS

FLAT RATE

06-03-1

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

GSX Limited, XP Limited and GTX Limited

Loctite 242 4 10 Nm (89 lbfin) Loctite 242 10 Nm (89 lbfin) 2 Loctite 242 3 24 Nm (17 lbfft)

Super Lube grease

F06F0DS

06-03-2

PARTS

FLAT RATE

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

REMOVAL
SPX, GS, GTS and GTI Models

7, Flame Arrester Base

Remove flame arrester no. 5. Remove screws no. 8 retaining support no. 6 of flame arrester base to the cylinder head cover (717 engine) or to the exhaust manifold (787 engine).

1, Air Intake Silencer Cover

Unlock the 6 retaining slides holding air intake silencer cover and remove cover.

F01F2OA

F00F03A

TYPICAL 1. Air intake silencer cover 2. Unlock

1. Remove support

Remove screws no. 10 from flame arrester base then withdraw base.

4, Air Intake Silencer Base

Remove screws no. 2 of retaining plate no. 3. Pull out retaining plate no. 3 and air intake silencer base no. 4.
1

GSX Limited, XP Limited and GTX Limited

1, Air Intake Silencer

Remove the air vent tube support from body opening (GSX Limited). Remove seat support (GTX Limited). Unlock the clip no. 2 on top of air intake silencer.

F00F02A

1. Retaining plate 2. Remove screws

F06D34A

1. Clip

06-03-3

Section 06 FUEL SYSTEM Subsection 03 (AIR INTAKE)

Push the air intake silencer out of the carburetor adapter no. 3. Pull the air intake silencer rearward to remove it from the lower bracket no. 4 and remove it in a rotating movement. The air intake silencer is a molded piece and it can not be opened. It has an integrated flame arrester.

WARNING

Do not operate watercraft without flame arrester.

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

SPX Model Position the flame arrester with its embossment toward TOP.

CAUTION
F00F04A

Do not modify air intake system, otherwise calibration will be affected.

SPX, GS, GTS and GTI Models

9, Gasket
Inspect condition of gasket. Make sure to properly installed gasket.

7, Flame Arrester Base

Apply Loctite 518 on mating surfaces of flame arrester base. Apply Loctite 242 (blue) on screws no. 10 and torque to 10 Nm (88 lbfin).

GSX Limited, XP Limited and GTX Limited

1, Air Intake Silencer

Apply Super Lube grease (P/N 293 550 014) to mating surface of air intake silencer. Make sure the air intake silencer is retained by the lower bracket no. 4.

5, Flame Arrester
Inspect condition of flame arrester. Replace or clean as necessary.

06-03-4

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

CARBURETOR
Mikuni BN-38I, BN-40I and BN-46I
12 3 20 Loctite 242 6 20 Nm (15 lbfft) Loctite 577 13 Loctite 242 8 7 1 15 Anti-seize lubricant 19 5 4

14

9 11 10

21

13 2

Synthetic grease

21 20 18 17 16

F06F0ES

PARTS

FLAT RATE

06-04-1

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

GENERAL
The following illustration shows which part of the carburetor begins to function at different throttle plate openings.

1 2 4 5 6
F06F0LA

TYPICAL 1. Pulse line 2. Loosen gear clamp

3
F01F13A

VIEW FROM AIR INTAKE OPENING 1. Throttle plate openings 2. Throttle plate closed 3. Throttle plate wide opened 4. Low-speed screw 5. Pilot jet 6. Main jet and high-speed screw

Disconnect fuel supply line from fuel pump. Disconnect fuel return line. Disconnect oil injection pump cable, throttle cable and choke cable. Remove screws no. 20 and lock washers no. 21 retaining carburetor(s).
1 1

The carburetor(s) is (are) equipped with a fuel accelerator pump. The fuel accelerator pump is linked to the throttle valve via a linkage. A metering jet in the fuel inlet hose controls fuel flow to the pump. A check valve no. 21 on the fuel outlet hose helps to prime the system.

REMOVAL
To remove carburetor(s) from engine, proceed as follows: Remove air vent tube support (SPX, GSI and GSX Limited. Remove air intake silencer. Refer to AIR INTAKE 06-03. Turn fuel valve to OFF position. Disconnect pulse line.
06-04-2

F07F03A

TYPICAL 1. Screw

Remove carburetor(s).

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

CLEANING
The carburetor exterior surfaces should be cleaned with a general solvent and dried with compressed air before disassembly.
1

CAUTION

Be careful at carburetor cleaning not to remove paint. Paint removal will cause carburetor to rust very rapidly. Repaint if necessary. Carburetor body and jets should be cleaned with a carburetor cleaner. Follow manufacturers instructions.

F01F0XA

x
-

WARNING

Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.

TYPICAL 1. Pump gauge tester 2. Install on pulse nipple

Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm.

CAUTION

4, Pump Body
Check fuel pump valve operation as follows: Connect a clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with the mouth. The inlet valve should release with pressure and hold under vacuum.

Heavy duty carburetor cleaner may be harmful to the rubber parts, O-rings, etc. Therefore, it is recommended to remove these parts prior to cleaning. Inspect O-rings, diaphragms and gaskets.

WARNING

DISASSEMBLY AND INSPECTION

Inspect parts for corrosion damage (shaft, throttle plate, spring, screw, check valve housing, etc.).

Some fuel may be present in fuel pump. Be careful not to swallow fuel when under vacuum.

1, Needle Valve
Inspect needle valve tip for a grooved condition. If worn, needle and seat must be replaced as a matched set.
1

2, Low Speed Screw

Check tip for a grooved condition. Replace if necessary.
2

3, Diaphragm
PUMP DIAPHRAGM LEAK TEST Using a suitable pump gauge tester, perform the following test proceeding as follows: Install pump gauge tester (P/N 295 000 114) on pulse nipple. Pump tester until it reaches 28 kPa (4 PSI).
F01F0WA

TYPICAL 1. Fuel outlet nipple 2. Pulse nipple 3. Inlet nipple

06-04-3

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

Repeat the same procedure at the outlet nipple. This time the outlet valve should hold with pressure and release under vacuum. Inspect valves. The pumping area should be free of holes, tears or imperfections. Replace as needed.

5, Filter
To verify filter condition proceed as follows: Remove pump cover no. 16, gasket no. 17, diaphragm no. 18 and then pump body no. 4 and diaphragm no. 19. Remove filter from carburetor body then clean filter and blow carefully with compressed air (low pressure). Replace filter if damaged.

F06F06A

TYPICAL 1. Fuel inlet hose 2. Fuel outlet hose

Using a suitable pump gauge tester, perform the following test proceeding as follows: Install pump gauge tester (P/N 295 000 083) on inlet nipple. Obstruct outlet nipple with a finger and hold while pumping. Pump tester until it reaches 28 kPa (4 PSI).

F01F0YA

TYPICAL 1. Filter

20, Fuel Accelerator Pump

Disconnect inlet and outlet hoses from accelerator pump nipples.

F06F07A

1. Pump gauge tester 2. Hose installed to inlet nipple 3. Outlet nipple obstructed

Diaphragm must stand pressure for 10 seconds. If pressure drops, replace diaphragm. Verify accelerator pump check valves operation as follows:

06-04-4

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

Connect a clean plastic tubing to the valve inlet nipple and alternately apply pressure and vacuum. The check valve should release with pressure and hold under vacuum.

WARNING

Pump tester. Injector check valve should open at 13 3 PSI. NOTE: If the obtained valve is too low, the check valve is leaking. If it is too high, less fuel will be delivered which may lead to engine hesitation under acceleration.

Some fuel may be present in fuel pump.

ASSEMBLY
When assembling pump, ensure to properly position components together. Refer to previous illustrations if necessary.

6,7, Choke Plate and Throttle Plate

When installing plate onto shaft, close plate so that it centers into carburetor bore. Firmly tighten screws.

CAUTION

Always apply Loctite 242 (blue) on screw threads prior to installing screws.

F06F08A

8, Needle Valve Lever

Rounded end of needle valve lever must be flush with surrounding metering chamber floor and not with body assembly. Place the end of a ruler over lever to check adjustment.

TYPICAL 1. Apply pressure and vacuum at inlet nipple

To check the injector, install pump gauge tester to the injector hose. NOTE: Injectors are also equipped with check valves.
1

F04F0JB

F01F0ZA

TYPICAL 1. Install pump gauge tester to injector hose 2. Injector

1. Metering chamber floor 2. Lever end 3. Flush

06-04-5

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

To adjust, bend lever very slightly to change its height.

3 1

CAUTION

When adjusting lever, do not pry it so that it applies pressure on needle. This could damage valve seat/needle.
1 2

2
F01F10A

F01F0HA

HIGH LEVER Step 1 : Depress here Step 2 : Push tab down

TYPICAL 1. Pump gauge tester 2. Install on inlet nipple 3. Obstruct outlet nipple

Refer to the following table for pop-off pressure specifications:

2
MODELS SPX GS GSX Ltd V.S. (mm) 1.5 1.5 2.0 2.0 1.5 1.5 2.0 SPRING POP OFF POP OFF (g) (min.) (max.) 95 95 95 95 95 95 95 36 36 19 19 36 36 19 40 40 23 23 40 40 23

F01F34A

XP Ltd GTS GTI GTX Ltd

LOW LEVER Step 1 : Depress here Step 2 : Pry up here

POP-OFF PRESSURE TEST Proceed as follows: Install pump gauge tester on carburetor fuel inlet nipple. Obstruct fuel return nipple with a finger. Pump tester until inlet release pressure is reached (seen by a sudden pressure drop).

NOTE: Pressure test should be performed three times to obtain a valid reading. If pop-off pressure is not within specification, check control lever adjustment. Replace spring as necessary.

CAUTION

Do not stretch or cut spring. LEAK TEST Needle valve must stand a pressure of 69 kPa (10 PSI) for 30 seconds. Otherwise, hold carburetor upside down, pour oil over needle valve and apply pressure.

06-04-6

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

Check for bubbles. If they come from seat or O-ring, bubbles will exit around seat. Retighten as necessary. If it still leaks remove needle and seat and replace O-ring. If bubbles come from needle, replace needle and seat.

11, Check Valve Assembly

The check valve is needed if a back pressure occurs into carburetor. It will prevent fuel from flowing back into carburetor lower portion. Inspect check valve, it should be free of holes, tears or imperfections. Replace as needed.
1

9,10, Main Jet and Pilot Jet

Pilot jet and main jet are replaceable. Different jet sizes are available to suit temperature and altitude conditions. Always inspect spark plug tip condition when dealing with pilot jet and main jet. Spark plug tip condition gives a good indication of carburetor mixture setting.

F01F12A

CAUTION

1. Check valve

Adjustments vary with temperature and altitude. Always observe spark plug condition for proper jetting. NOTE: To have access to pilot jet or main jet, check valve housing must be removed.

NOTE: Prior to check valve assembly installation, remember to set gasket.

3,12, Diaphragm and Cover

Install diaphragm with its integrated O-ring into carburetor groove. Make sure that the tab of cover is inserted into carburetor notch.

2 1

13, O-ring
When installing O-rings of low speed and high speed screws, apply some BOMBARDIER LUBE (P/N 293 600 016) to prevent sticking.

20, Fuel Accelerator Pump

3

Lubricate pump plunger, roller and cam with synthetic grease (P/N 293 550 010) and roller shaft with BOMBARDIER LUBE (P/N 293 600 016).

F01F11A

TYPICAL 1. Pilot jet 2. Gasket 3. Main jet 4. Check valve housing removed
F06F06B

TYPICAL 1. Apply synthetic grease to plunger 2. Apply BOMBARDIER LUBE on roller shaft
06-04-7

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

INSTALLATION
At installation, pay attention to the following: Install carburetor(s) with gasket(s) to intake manifold (rotary valve cover for the 787 engine). Apply Loctite 577 on screws no. 20. Then, install screws no. 20 with lock washers no. 21 and torque to 20 Nm (15 lbfft).
1

Fuel Lines and Hose Clamps

If fuel line ends are damaged, cut damaged end before reinstallation. Properly install clamps.
F01F1YA

2 3
1. Jam nuts 2. Adjustment nut 3. Flat surfaces

WARNING

Make sure there is no leak in fuel system. For fuel system pressurization, refer to FUEL CIRCUIT 06-02.

ADJUSTMENTS
Twin Carburetor Synchronization
With idle speed screw not touching throttle lever stopper on MAG carburetor, both throttle plates are in closed position.

Tighten jam nuts and torque to 3 Nm (27 lbfin). NOTE: Grease carburetor linkage at both ends with synthetic grease (P/N 293 550 010). Connect linkage between both carburetor levers. Ensure both throttle plates are still in closed position. NOTE: The linkage installation is done with the marks located near PTO carburetor throttle lever to ease adjustment if to be performed in the watercraft.

1
F01F32A

1
F01F31A

2
787 ENGINE SHOWN 1. Throttle lever PTO side 2. Marks

787 ENGINE SHOWN 1. Stopper 2. Idle speed screw

Loosen jam nuts on carburetor linkage and adjust linkage with adjustment nut. Make sure threads length is the same on each side of linkage and flat surfaces of both ends are parallel with each other.

CAUTION

Throttle plates must open simultaneously, otherwise this will cause engine to vibrate and/or misfire.

06-04-8

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

Throttle Cable
Lubricate cable with BOMBARDIER LUBE lubricant. Throttle lever must reach handlebar grip without causing strain to cable or carburetor cable bracket.

F01F32B

1
F01K08A

1. Must touch handlebar grip

787 ENGINE 1. Throttle lever stoppers (behind levers) 2. Adjustment nut

Ensure carburetor throttle plate(s) is (are) fully open at full throttle position. At this position, throttle lever stopper is almost in contact (0.5 mm (1/64 in)) with carburetor body. NOTE: Apply a light pressure on the throttle plate(s), a slight play should be obtained.

CAUTION

Improper cable adjustment will cause strain on cable and/or damage cable bracket or throttle lever at handlebar. To adjust, loosen jam nut then turn adjustment nut as necessary.
F06F0FA

947 ENGINE 1. Throttle cable 2. Adjustment nut

Tighten jam nut and recheck adjustment.

WARNING

Make sure idle speed screw contacts stopper when throttle lever is fully released at handlebar. After throttle cable adjustment, always proceed with the oil injection pump cable adjustment. Refer to OIL INJECTION PUMP 07-03.
F01G0YC

717 ENGINE 1. Adjustment nut 2. Jam nut 3. Throttle lever stopper

CAUTION

Improper oil injection pump synchronization with carburetor can cause serious engine damage.

06-04-9

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

2, Low Speed Screw

CAUTION

Do not attempt to set engine idle speed with low-speed screw.

1

Tighten low speed screw until a slight resistance is felt. Then, back it off to the specification as per following chart.
WATERCRAFT MODEL SPX GS/GTS/GTI LOW SPEED SCREW 1.5 turns 1.25 turns 2 turns

F06F0GA

GSX Limited/ XP Limited/GTX Limited

717 ENGINE 1. Low speed screw

NOTE: Turning screw clockwise leans mixture and turning screw counterclockwise enriches mixture. Start and warm up engine.

CAUTION

If watercraft is out of water, engine must be cooled using the flush kit. Check that engine idles and runs smoothly. Make sure engine reacts quickly to throttle lever depression. If necessary, readjust low speed screw ( 1/4 turn). NOTE: On twin carburetor engines, both low speed screws must be adjusted exactly the same way. Never adjust screws more than 1/4 turn at a time.
1

F01F33A

787 ENGINE 1. Low speed screw (PTO) 2. Low speed screw (MAG)

14, High Speed Screw

The high speed screw is sealed with a plastic cap that allows an adjustment of 1/4 turn. NOTE: Turning screw 1/4 turn counterclockwise enriches mixture and turning screw clockwise leans mixture.

CAUTION

Do not attempt to adjust high speed screw by removing plastic cap.

F06F0HA

947 ENGINE 1. Low speed screw (PTO side shown)

06-04-10

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

F06F0PB

F06F0IA

947 ENGINE 1. High speed screw (PTO side shown)

717 ENGINE 1. High speed screw

15, Idle Speed Screw

Turning screw clockwise increases engine idle speed and turning screw counterclockwise decreases engine idle speed.

F01F2QA

787 ENGINE 1. High speed screws

F01G0YD

ROT
1 1
717 ENGINE 1. Idle speed screw
06-04-11

Section 06 FUEL SYSTEM Subsection 04 (CARBURETOR)

CAUTION

If watercraft is out of water, engine must be cooled using the flush kit. Turn screw so that engine idles at 1500 RPM in water or 3000 RPM out of water.

20, Fuel Accelerator Pump

Ensure throttle cable is properly adjusted and idle speed is set at 1500 RPM in water. With the engine not running, start adjustment by loosening adjustment screw until there is a small gap between lever tab and pump plunger.
1

F01F32C

787 ENGINE 1. Idle speed screw

F06F0KA

1
F02F1QA

947 ENGINE 1. Idle speed screw

NOTE: On twin carburetor engines, there is only one idle speed screw. Connect an induction-type tachometer (P/N 295 000 100) on spark plug cable of magneto side to measure engine speed. NOTE: To adjust idle speed, ensure flame arrester and air intake silencer are installed. Start engine and bring to normal operating temperature.

717 ENGINE SHOWN 1. Adjustment screw 2. Small gap

Turn adjustment screw clockwise until lever tab touches plunger. Then, turn adjustment screw an additional 1/4 turn clockwise. The adjustment is now completed.

06-04-12

Section 07 LUBRICATION SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
OIL INJECTION SYSTEM ...................................................................................................... GENERAL ........................................................................................................................... OIL SYSTEM PRESSURIZATION ...................................................................................... OIL INJECTION PUMP .......................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... CLEANING ......................................................................................................................... ASSEMBLY......................................................................................................................... ADJUSTMENT ................................................................................................................... CHECKING OPERATION....................................................................................................

0
07-02-1 07-02-7 07-02-7 07-03-1 07-03-4 07-03-4 07-03-4 07-03-4 07-03-5 07-03-7

07-01-1

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

OIL INJECTION SYSTEM

SPX and GTS Models
To electrical box Dielectric grease

27 Nm (20 lbfft) 1 3.5 Nm (31 lbfin) 2 1 3.5 Nm (31 lbfin)

1.2 Nm (11 lbfin)

1.2 Nm (11 lbfin)

1.2 Nm (11 lbfin)

F02G07S

PARTS

FLAT RATE

07-02-1

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

GS Model

Loctite 518

27 Nm (20 lbfft) 3.5 Nm (31 lbfin) 1

3.5 Nm (31 lbfin) 1.2 Nm (11 lbfin) 4 1.2 Nm (11 lbfin) Dielectric grease

F06G03S

07-02-2

PARTS

FLAT RATE

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

GSX Limited

Loctite 518

27 Nm (20 lbfft)

3.5 Nm 1 (31 lbfin) 4

Dielectric grease

F06G04S

PARTS

FLAT RATE

07-02-3

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

XP Limited
Dielectric grease

To oil injection pump

F08G01S

07-02-4

PARTS

FLAT RATE

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

GTI Model

To oil injection pump

To engine crankcase (return)

27 Nm (20 lbfft) 1
FR AVON AN T T

3.5 Nm (31 lbfin) 2

To engine crankcase (supply) 1.2 Nm (11 lbfin) 1.2 Nm (11 lbfin) 2

1 3.5 Nm (31 lbfin) 1.2 Nm (11 lbfin) 3

F07G01S

PARTS

FLAT RATE

07-02-5

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

GTX Limited

27 Nm (20 lbfft) 3.5 Nm (31 lbfin) 1

2 4

Dielectric grease

1 3.5 Nm (31 lbfin)

F07G03S

07-02-6

PARTS

FLAT RATE

Section 07 LUBRICATION SYSTEM Subsection 02 (OIL INJECTION SYSTEM)

GENERAL
Whenever repairing the oil injection system, always verify for water infiltration in reservoir. Perform also a pressure test of the oil injection system.

Install a hose pincher to oil injection pump supply hose. Connect pump gauge tester (P/N 529 021 800) to check valve of oil injection reservoir vent. NOTE: Use the same pump included in the ENGINE LEAK TESTER KIT (P/N 295 500 352).
1

All Models Except the XP Limited

1,2, Clamp and Hose

Verify oil filler neck hose for damage. Always ensure that clamps are well positioned and tightened. Torque clamps to 3.5 Nm (31 lbfin).

All Models

3, Check Valve
Black side of the one-way check valve is the valve outlet. It allows air to get in reservoir.

4, Oil Filter
Oil filter should be replaced annually.

F01G0IA

OIL SYSTEM PRESSURIZATION

TYPICAL 1. Connect pump to check valve

WARNING

Whenever oil system components are disconnected or replaced, a pressure test must be done before starting engine. Ensure to verify oil line ends for damage. Always cut damaged end before reinstallation.

Pressurize oil system to 21 kPa (3 PSI). If pressure is not maintained, locate leak and repair/replace component leaking. To ease leak search spray a solution of soapy water on components, bubbles will indicate leak location. NOTE: The system must maintain a pressure of 21 kPa (3 PSI) for at least 10 minutes. Never pressurize over 21 kPa (3 PSI).

Pressure Test
Proceed as follows: Fill up oil reservoir. Install a hose pincher to rotary valve shaft oil supply hose (except the 947 engine). Install a hose pincher to rotary valve shaft oil return hose (except the 947 engine).

CAUTION

If any leak is found, do not start the engine and wipe off any oil leakage. Disconnect pump gauge tester and remove hose pinchers.

07-02-7

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

OIL INJECTION PUMP

717 Engine

Loctite 518

5 10 Nm (89 lbfin) 3 6 Nm 6 (53 lbfin) Loctite 242 Loctite 242

8 Nm (71 lbfin) 4.5 Nm (40 lbfin)

Loctite 242

5 Nm (44 lbfin)

F00G02S

PARTS

FLAT RATE

07-03-1

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

787 Engine

6 Nm (53 lbfin)

8 6 1 3 Nm (27 lbfin)

4.5 Nm (40 lbfin) Loctite 242 4.5 Nm (40 lbfin) 7

4.5 Nm (40 lbfin)

F01G0TT

07-03-2

PARTS

FLAT RATE

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

947 Engine

Loctite 242

4.5 Nm (40 lbfin)

4.5 Nm (40 lbfin) 4.5 Nm (40 lbfin)

F06G05S

PARTS

FLAT RATE

07-03-3

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

REMOVAL
1, Oil Injection Pump
717 Engine Remove air intake silencer (refer to AIR INTAKE 06-03). Remove carburetor (refer to CARBURETOR 06-04). Remove rotary valve cover (refer to ROTARY VALVE 04-07). Remove Allen screws no. 5 retaining intake manifold no. 2 to rotary valve cover. Separate intake manifold from rotary valve cover. To separate oil pump from intake manifold no. 2, remove oil pump gear no. 3 using gear holder (P/N 290 277 905) and unscrew lock nut no. 4.

DISASSEMBLY
NOTE: Some oil pump parts are not available in single parts. A gasket set is available for the pump. If the pump is found defective, it should be replaced by a new one.

CLEANING
Discard all seals and O-rings. Clean metal components in a solvent.

ASSEMBLY
717 Engine

1,2, Oil Injection Pump and Intake Manifold

Install oil injection pump to intake manifold. Torque screws no. 5 to 6 Nm (53 lbfin).

CAUTION

Whenever oil injection lines are removed, always make the routing as shown.

A00C17B

1. Gear holder

Remove 2 Allen screws no. 6 with flat washers retaining oil injection pump to intake manifold no. 2. Remove pump.

947 Engine Remove tuned pipe head. Refer to EXHAUST SYSTEM 04-08.
1

787 and 947 Engines Disconnect oil injection pump cable no. 7. Remove 2 Allen screws no. 6 with flat washers retaining oil injection pump to magneto housing cover. Pull pump. Disconnect oil hoses from fittings of oil injection pump.

F01D4SA

TYPICAL 1. Small oil line

3, Oil Pump Gear

Install gear to oil injection pump shaft. Torque lock nut no. 4 to 6 Nm (53 lbfin). NOTE: Make sure 1 washer is installed on each side of gear.

07-03-4

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

2, Intake Manifold
Install intake manifold to rotary valve cover and torque screws no. 5 to 10 Nm (89 lbfin).

Turn idle speed screw until it contacts stopper. Turn idle speed screw 2 turns. Turn cable adjustment nut to align marks on pump. NOTE: A mirror may be used to facilitate this verification.

717 Engine

1 2
F01D4RC

TYPICAL A. 10 Nm (89 lbfin)

787 and 947 Engines

1,8, Oil Injection Pump and Shaft

Make sure shaft no. 8 is installed in crankshaft end. Install pump. Secure with flat washers and screws no. 6. Torque to 6 Nm (53 lbfin). Install oil injection pump cable.

F01D4RE

TYPICAL 1. Jam nut 2. Adjustment nut 3. Aligned marks

787 and 947 Engines

ADJUSTMENT

CAUTION

As oil injection pump adjustment is dependent on throttle cable position, make sure to perform throttle cable adjustment first.

Preliminary Synchronization
NOTE: To check synchronization of pump as a routine maintenance, see Final Synchronization. Make sure idle speed of engine is properly adjusted. Ensure carburetor butterfly(ies) is (are) in closed position. NOTE: On a twin carburetor engine, make sure carburetors are properly synchronized. If necessary, refer to CARBURETOR 06-04.

1
F07G02B

1. Aligned marks

07-03-5

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

787 Engine NOTE: The adjustment nut and jam nut for the oil injection pump cable are located at the cable support on PTO side carburetor.

Adjust idle speed to specification. Refer to CARBURETOR 06-04. Stop engine.

Final Synchronization
Eliminate throttle cable free-play by depressing throttle lever until a slight resistance is felt. In this position, marks on pump body and lever must align. NOTE: A mirror may be used to facilitate this verification. If necessary, turn cable adjustment nut to obtain pump mark alignment. Refer to above illustrations. Tighten jam nut and recheck alignment marks.

1 2
F01F32G

1. Adjustment nut on this side 2. Jam nut

CAUTION

947 Engine NOTE: The adjustment nut and jam nut for the oil injection pump cable are located at the cable support on MAG side carburetor.

Proper oil injection pump adjustment is very important. Any delay in the opening of pump can result in serious engine damage.

Bleeding

CAUTION

Oil injection system must be bled and adjustment checked before operating engine. Ensure oil injection reservoir is sufficiently filled. Install a dry rag below oil injection pump. Loosen bleed screw to allow oil to flow.

F06F0OB

1. Adjustment nut

All Engines Start and bring engine to normal operating temperature.

CAUTION
F01D4SC

If watercraft is out of water, engine must be cooled using the flush kit. If air bubbles are present in the oil injection system, bleed system before operating engine.

717 ENGINE 1. Bleed screw

07-03-6

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

If not, remove pump assembly and check the pump gear (717 engine) or shaft (787 and 947 engines) for defects, replace as necessary. Test pump as describes below: NOTE: Through normal use, oil level must not drop in small tubes. If oil drops, verify check valve operation. Replace as necessary.

Bench Test
The oil pump must be removed out of watercraft. Connect a hose filled with injection oil to main line fitting. Insert other hose end in an injection oil container. Using a counterclockwise (reverse position) rotating drill rotate pump shaft. Oil must drip from fittings in parts of rotary valve cover while holding lever in a fully open position.
2

F07G02A

787 and 947 ENGINES 1. Bleed screw

Keep bleeding until all air has escaped from line. Make sure no air bubbles remain in oil supply line. Tighten bleed screw. Wipe any oil spillage. Check small oil lines of pump. They must be full of oil. If not, run engine at idle speed while manually holding pump lever in fully open position. Do not activate throttle lever.

CAUTION
4 3
F01G02A

If watercraft is out of water, engine must be cooled using the flush kit.

CHECKING OPERATION
On Watercraft
NOTE: Oil line supply must be full of oil. See bleeding procedure above. Start engine and run at idle while holding the pump lever in fully open position. Oil must advance into small oil lines. NOTE: The engine should have a rich mixture, idling irregularly and emitting smoke at exhaust outlet.

TYPICAL 1. Supply oil line to an oil container 2. Hold lever in fully open position 3. Counterclockwise (reverse) rotating drill 4. Oil must drip here

For an accurate test, each port should be checked separately to ensure equal delivery on both ports. To obtain a precise result of the oil pump delivery rate, rotate it counterclockwise at 1500 RPM for a total time of 30 seconds. NOTE: To ensure accuracy of test, oil lines should be completely filled before starting test.

07-03-7

Section 07 LUBRICATION SYSTEM Subsection 03 (OIL INJECTION PUMP)

Compare the results with the chart below. If oil pump is out of specification, replace it.
ENGINE 717 787 947 OIL PUMP FLOW RATE AT 1500 RPM (30 SECONDS) 1.24 - 1.51 mL (each port) 0.71 - 0.87 mL (each port) 0.83 - 1.01 mL (each port)

NOTE: Test can also be done at 3000 RPM. Double quantities in chart.

07-03-8

Section 08 ELECTRICAL SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

IGNITION SYSTEM................................................................................................................ 08-02-1 GENERAL ........................................................................................................................... 08-02-1 IGNITION TIMING ............................................................................................................. 08-02-5 IGNITION SYSTEM TESTING PROCEDURE .................................................................... 08-02-12 SPARK PLUGS ................................................................................................................... 08-02-16 CHARGING SYSTEM............................................................................................................. GENERAL ........................................................................................................................... TESTING PROCEDURE ..................................................................................................... BATTERY ............................................................................................................................ 08-03-1 08-03-1 08-03-1 08-03-4

STARTING SYSTEM .............................................................................................................. 08-04-1 GENERAL ........................................................................................................................... 08-04-4 STARTING SYSTEM TROUBLESHOOTING ..................................................................... 08-04-5 STARTER REMOVAL.......................................................................................................... 08-04-6 STARTER DISASSEMBLY.................................................................................................. 08-04-6 CLEANING ......................................................................................................................... 08-04-8 PARTS INSPECTION .......................................................................................................... 08-04-9 STARTER ASSEMBLY........................................................................................................ 08-04-9 STARTER INSTALLATION ................................................................................................. 08-04-11 STARTER SPECIFICATION ................................................................................................ 08-04-14 INSTRUMENTS AND ACCESSORIES .................................................................................. GENERAL ........................................................................................................................... INSPECTION ...................................................................................................................... DIGITALLY ENCODED SECURITY SYSTEM ........................................................................ GENERAL ........................................................................................................................... 08-05-1 08-05-1 08-05-1 08-06-1 08-06-1

GTX RFI

08-01-1

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

IGNITION SYSTEM
GENERAL
717 Engine The digital Capacitor Discharge Ignition (CDI) system includes the following components:

0
Ignition Coil

Magneto
It is the primary source of electrical energy. It transforms magnetic field into electric current. The flywheel contains 4 permanent magnets and spins around the generating coil. This electric current flows to the ignition coil (GTS model) or the Multi-Purpose Electronic Module (GS and GTI models).

F01H2NA

TYPICAL

GTS Model The ignition coil performs two functions: It has an integrated capacitor discharged ignition (CDI) module, which controls the spark occurrence (ignition timing curve). Every half revolution of the flywheel, a critical point occurs when the position of the magnets changes the polarity of the current flowing from the generating coil. The CDI module detects the change of polarity and signals at the right time the primary winding of the ignition coil. The secondary winding of the ignition coil steps up the voltage input to high voltage current for both spark plugs. GS and GTI Models The ignition coil steps up the voltage input from the Multi-Purpose Electronic Module to high voltage current for both spark plugs. The ignition coil is located in the rear electrical box, on right side of watercraft.

F00H0EA

1. Flywheel 2. Generating coil

08-02-1

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

Multi-Purpose Electronic Module (MPEM)

The MPEM is directly powered by the battery. It has a micro-processor inside of its sealed case. The MPEM is responsible of the following electrical functions: interpreting information distributing information start/stop function timer Digitally Encoded Security System ignition (GS and GTI models) engine rev limiter Fuses are directly mounted onto the MPEM.

F00H0FA

TYPICAL

GTS Model

787 and 947 Engines The 787 and 947 engines have a digital Direct Current-Capacitor Discharge Ignition (DC-CDI) system. Compared to the magneto system, the DC-CDI system offers a more powerful and stable ignition at low RPM. SPX, GSX Limited and GTX Limited The high amperage/voltage components are located into a rear electrical box.

F01H2OA

TYPICAL

GS and GTI Models On these models, the MPEM is also used as a junction box, eliminating the need of an electrical box. All electrical components or accessories are directly linked to the MPEM. Wire position are identified with a series of number on the MPEM. AMP plug connectors are used. The regulator/rectifier is also mounted on the MPEM.

F00H0DB

SPX MODEL 1. Rear electrical box

08-02-2

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

F06E06A

GSX LIMITED 1. Electrical box

F00H0AB

XP LIMITED 1. Electrical box

SPX Model The other components are located in the conventional electrical box. GSX Limited, XP Limited and GTX Limited The other components are integrated to the MultiPurpose Electronic Module (MPEM). SPX, GSX Limited, XP Limited and GTX Limited The ignition system includes the following components:
F07H07B

GTX LIMITED 1. Electrical box

Battery
The battery is the primary power source for this system.

XP Limited The high amperage/voltage components are located into a front electrical box.

F00H0KA

08-02-3

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

Trigger Coil
The trigger coil is mounted outside the rotor (inside the magneto housing of the engine) and is not adjustable.

Multi-Purpose Electronic Module (MPEM)

The MPEM is directly powered by the battery. It has a micro-processor inside of its sealed case. The MPEM is responsible of the following electrical functions: interpreting information distributing information start/stop function timer Digitally Encoded Security System ignition engine rev limiter Fuses are directly mounted onto the MPEM.

SPX Model
F06H04A

Its purpose is to signal the engine position to the Multi-Purpose Electronic Module. The rotor has two protrusions (180 degrees apart) that, when coupled with the trigger coil, accomplish the signaling.
7

4 5 N 2 S
A00E4JA

3
F00H0JA

6 1 N 1 2 S

1. 2. 3. 4. 5. 6. 7.

Coil Magnet Rotor protrusion Magnetic field outside of coil Magnetic field crossing coil Current to MPEM Rotor

GSX Limited, XP Limited and GTX Limited On these models, the MPEM is also used as a junction box, eliminating the need of an electrical box. All electrical components or accessories are directly linked to the MPEM. Wire position are identified with a series of number on the MPEM. AMP plug connectors are used. The regulator/rectifier is also mounted on the MPEM.

08-02-4

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

F06H0SA

1. Multi-Purpose Electronic Module

Ignition Coil
The ignition coil steps up the voltage input from the Multi-Purpose Electronic Module to high voltage current for both spark plugs.

787 and 947 Engines Normally ignition timing adjustment should not be required. It has been set at factory and it should remain correctly adjusted since every part is fixed and not adjustable. The only time the ignition timing might have to be changed would be when replacing the crankshaft, the magneto rotor, the trigger coil and the MPEM. If the ignition timing is found incorrect, you should first check for proper crankshaft alignment. This might be the indication of a twisted crankshaft. With this DC-CDI system, the ignition timing can be checked with either the engine hot or cold. Also, the ignition timing is to be checked at 3500 RPM with the timing light. NOTE: Between 3000 and 4000 RPM, the spark advance does not change. So when checking ignition timing at 3500 RPM, a change in engine speed within 500 RPM will not affect the timing mark when checked with the timing light.

IGNITION TIMING
Before checking ignition timing with a stroboscopic timing light (dynamic test), it is mandatory to scribe a timing mark on the PTO flywheel (static test) corresponding to the specific engine. Also, the timing mark scribed on the PTO flywheel can be used to troubleshoot a broken magneto woodruff key. NOTE: Do not use the factory mark found on the PTO flywheel to check ignition timing or troubleshoot any problems.

Static Test
All Engines 1. Disconnect MAG side spark plug wire and connect wire to grounding device then remove spark plug. 2. Remove PTO flywheel guard. 717 Engine 3. Install timing mark pointer tool on engine using wing nuts previously removed.

CAUTION

The relation between the PTO flywheel mark position and crankshaft position may change as the PTO flywheel might tighten/loosen on the crankshaft. As an example, when the engine is accelerated out of water, PTO flywheel may tighten then loosen when the engine is decelerated. This will result in a false ignition timing reading. Always verify PTO flywheel mark position before checking ignition timing with an appropriate timing light. If mark does not align with tool, repeat static test to ensure flywheel has not loosen before changing the ignition timing.

F01H5SA

1. Timing mark pointer tool (P/N 295 000 130)

08-02-5

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

787 and 947 Engines 4. Remove middle screw securing the engine to the rear engine mount. Reinstall screw with timing mark pointer tool.

6. Rotate PTO flywheel counterclockwise (when facing it) until piston is at Top Dead Center.

90

80

10

70 30

20

F06H05A

1. Timing mark pointer tool (P/N 295 000 135)

F01H4LA

All Engines 5. Install and adjust a TDC gauge (P/N 295 000 143) in MAG side spark plug hole.
1

TYPICAL 1. Adjust gauge dial at zero

7. From this point, rotate flywheel clockwise to reach proper specification according to engine. Refer to the following chart.
ENGINE 717 787 947 IGNITION TIMING (BTDC) 2.59 mm (.102 in) 3.38 mm (.133 in) 3.60 mm (.142 in)

8. Scribe a thin mark on PTO flywheel in the middle of tool slot (717 engine) or aligned with timing mark pointer tool (787 and 947 engines).

F01H5TA

TYPICAL 1. TDC gauge on MAG side

08-02-6

40

50

60

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

717 Engine NOTE: To perform this procedure, make sure to use a stroboscopic timing light rated up to 6000 RPM. Otherwise, an inaccurate reading will be obtained. The ignition components are affected by temperature variation, therefore, timing must be checked when engine is cold, after idling for a MAXIMUM of 20 seconds. 1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire.
1 2

F01H5SB

TYPICAL 1. Tool slot 2. Flywheel mark

NOTE: This mark becomes the reference when using the stroboscopic timing light.

CAUTION

The static test cannot be used as a timing procedure, therefore, always check the timing with a stroboscopic timing light.
F00H0GA

9. Remove TDC gauge. 10. Reinstall spark plug and connect wire.

1. Tachometer pick-up

Dynamic Test
To check ignition timing, use Bombardier timing light (P/N 529 031 900).

2. Connect timing light pick-up to MAG side spark plug wire.

1

F00H0HA

1. Timing light pick-up

A00B4FA

08-02-7

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

3. Start engine and point timing light straight in line with timing tool slot. Bring engine to 6000 RPM.
1

787 and 947 Engines 1. Connect an induction-type tachometer (P/N 295 000 100) to spark plug wire.
1

F00H0IA

F06H06A

1. Timing light straight in line with tool slot

1. Tachometer pick-up

CAUTION

2. Connect timing light pick-up to MAG side spark plug wire.

1

If engine is to be run more than a few seconds, engine must be cooled using the flush kit. 4. Check if PTO flywheel mark aligns with timing tool slot. NOTE: On this system, timing advance decreases as engine speed increases. If timing mark aligns with tool slot, timing is properly set. If mark does not align with tool slot, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen.
F00H0HA

1. Timing light pick-up

3. Rev the engine to 3500 RPM and point beam of timing light straight in line with timing mark pointer.

08-02-8

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

2
F06H07A A25E0RA

1. Timing light straight in line with tool slot

CAUTION

TYPICAL 1. To retard 2. To advance

If engine is to be run more than a few seconds, engine must be cooled using the flush kit. NOTE: If mark on PTO flywheel is perfectly aligned with timing mark pointer, no adjustment is required. If mark does not align with pointer, recheck PTO flywheel mark before adjusting ignition timing to ensure PTO flywheel has not loosen.

To adjust, loosen 3 armature plate retaining screws and slightly rotate armature plate in proper direction. NOTE: As a guideline, turn the armature plate the same amount needed to align mark on PTO flywheel.

Ignition Timing Adjustment

717 Engine Remove battery (GTS model). Remove magneto housing cover and wire support. For removal of magneto, refer to MAGNETO SYSTEM 04-04. Timing is performed by moving armature plate; clockwise to retard spark occurrence or counterclockwise to advance.

1 1
A25E0VA

TYPICAL 1. Retaining screw

08-02-9

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

Example 1 When PTO flywheel mark is on right side of timing tool slot, it indicates advanced timing.

Reinstall removed parts. Refer to MAGNETO SYSTEM 04-04. Recheck ignition timing (make sure engine is cold). Repeat armature plate positioning procedure if timing mark position is not adequate.

787 and 947 Engines To correct the ignition timing, the data of the MPEM is changed using the MPEM programmer (P/N 295 000 127). NOTE: For more information on the programmer, refer to its guide. Through the MPEM programmer, the ignition timing can be advanced up to 3 or retarded up to 4.

F01H5UA

CAUTION

1. Too advanced timing

In this case, turn armature plate clockwise when facing it. Example 2 When PTO flywheel mark is on left side of timing tool slot, it indicates retarded timing.

If the ignition timing is adjusted too advanced, this will cause serious damage to the engine. The timing mark refer to the physical component position when the spark must occur. The MPEM must be synchronized with the mark. For instance, on a particular engine, the timing correction may need to be advanced to 2 so that the mark aligns with timing mark pointer tool. This is not the real spark advance, just a correction for the tolerances of the mechanical components. Knowing that, you select with the programmer the higher or lower number to advance or retard the actual timing correction by referring to the following chart.
TIMING CORRECTION CHART PROGRAMMER NUMBER (MPEM) 2 IGNITION TIMING CORRECTION 3 2 1 0 -1 -2 -3 -4

F01H5VA

3 4 1 5 6 7 8

1. Retarded timing

In this case, turn armature plate counterclockwise when facing it. After adjustment, tighten armature plate retaining screws.

CAUTION

Armature plate screws must have Loctite 242 (blue) applied before tightening. Make sure armature plate screws are well secured.
08-02-10

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

Examples: a. You found the flywheel mark advanced. You must retard the ignition timing. The programmer gives you the number 3. Referring to the chart, number 3 returns a correction of 2 (advanced) and this is too much in this case. You estimate the correction should be set to 1 (advanced) to align flywheel mark. Back in the chart, look to find 1 (advanced). This gives number 4. Enter this number with the programmer. You recheck the timing with the timing light and if the mark is aligned, ignition timing is properly set. b. You found the flywheel mark advanced. You must retard the ignition timing. The programmer gives you the number 3. Referring to the chart, number 3 returns a correction of 2 (advanced) and this is too much in this case. You estimate the correction should be set to 1 (advanced) to align flywheel mark. Back in the chart, look to find 1 (advanced). This gives number 4. Enter this number with the programmer. You recheck the timing with the timing light and found that the flywheel mark is still too advanced. You know now that the correction made previously was not enough and you estimate the correction should be set to - 2 (retarded) to align flywheel mark. Back in the chart, look to find - 2 (retarded). This gives number 6. Enter this number with the programmer. You recheck the timing with the timing light and if the mark is aligned, ignition timing is properly set. c. You found the flywheel mark retarded. You must advance the ignition timing. The programmer gives you the number 4. Referring to the chart, number 4 returns a correction of 1 (advanced) and this is not enough in this case. You estimate the correction should be set to 2 (advanced) to align flywheel mark. Back in the chart, look to find 2 (advanced). This gives number 3. Enter this number with the programmer.

You recheck the timing with the timing light and if the mark is aligned, the ignition timing is properly set. Proceed as Follows to Adjust the Ignition Timing with the MPEM Programmer: 1. Connect the communication cable to the MPEM programmer and the other end to the safety lanyard switch on the craft. 2. Press the ON/C button on programmer and enter your password. 3. Press 3 to choose Vehicle info in programmer. 4. Press 4 to choose Engine param. 5. Press 2 to choose Timing adjust. 6. The programmer display a number that is stored in the MPEM. 7. Press to choose yes for modify then press Enter. 8. Now punch in the number that corresponds to the degree you want for the ignition timing then press Enter. 9. Press Menu to go back one level. 10. Press 8 to choose Save + Quit (even if item no. 8 is not visible on the display, it is active when you select it). 11. Press Enter to confirm yes you want to save modifications to the MPEM. 12. You must see Operation successful . This confirms that the new timing data has been stored in the MPEM. 13. Unplug communication cable from safety lanyard switch on craft. 14. Press Off to close the programmer. At this point, you can install the watercraft safety lanyard and start the engine to check the effect of the correction on the ignition timing. If further adjustment is required, repeat the procedure. NOTE: The MPEM features a permanent (nonvolatile) memory and keeps the ignition timing programmed even when the watercraft battery is disconnected.

08-02-11

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

IGNITION SYSTEM TESTING PROCEDURE

When dealing with ignition problems, the following items should be verified in this order: 1. Spark occurrence/spark plug condition. 2. Battery condition. 3. Electrical connections. 4. Engine start/stop switch. 5. Safety lanyard switch. 6. Timer. 7. Multi-Purpose Electronic Module (MPEM). 8. Magneto output (717 engine). 9. Ignition coil output.

Connect one test probe to the BLACK wire and the other test probe to the switch ring. Measure resistance, it must be close to 0 ohm. Safety Lanyard on Switch Connect test probes to switch BLACK and BLACK/ YELLOW wires. Measure resistance, it must be close to 0 ohm.

Timer Verification
The timer is integrated into the MPEM. Always confirm first that the fuses are in good condition. To confirm operation of timer, remove safety lanyard from switch. After a 5 seconds delay, depress start/stop button once. The timer should stay on for about 33 seconds (for example, gauge(s) will be activated) and then turn off.

CAUTION

Whenever replacing a component in ignition system, check ignition timing. NOTE: To perform verification, a good quality multimeter such as Fluke 73 (P/N 529 022 000) should be used.

Rev Limiter Verification

To check engine rev limiter, connect an induction tachometer (P/N 295 000 100), start engine and check its maximum speed; it should be at 7000 50 RPM for a 717 engine, and 7200 50 RPM for 787 and 947 engines.

Engine Start/Stop Switch Verification

Disconnect the YELLOW/RED wire of the start/ stop switch. Using an ohmmeter, connect test probes to YELLOW/RED wire and to ground. Measure resistance, it must be an open circuit (switch is normally open). Depress and hold switch, the ohmmeter should read close to 0 ohm.

Multi-Purpose Electronic Module (MPEM) Verification

GTS Model The multi-purpose electronic module testing must be done with all wires disconnected from circuit. Otherwise testing equipment (ohmmeter) could be damaged.

Safety Lanyard Switch Verification

If 2 short beeps are not heard when installing the safety lanyard, refer to DIGITALLY ENCODED SECURITY SYSTEM 06-06. The following continuity tests can also be performed using an ohmmeter: Disconnect switch wires. Safety Lanyard Removed Connect test probes to switch BLACK and BLACK/ YELLOW wires. Measure resistance, there should be no continuity (open circuit). Connect one test probe to the WHITE/GRAY wire and the other test probe to the switch terminal. Measure resistance, it must be close to 0 ohm.

CAUTION

When disconnecting wires, BLACK/RED wire must never touch solenoid positive terminal. When replacing a MPEM, make sure to replace it with the right model. Refer to the following chart for MPEM testing. Always respect polarity in chart.

08-02-12

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

METER (+) LEAD RED (ring terminal) RED (ring terminal) RED (ring terminal) BLACK/RED WHITE/GREY TAN/BLACK YELLOW/RED (female terminal) YELLOW/RED (male terminal) BLACK (ring terminal)

METER (-) RED (female terminal) RED/PURPLE (female terminal) BLACK (ring terminal) BLACK (ring terminal) BLACK (ring terminal) BLACK (ring terminal) BLACK (ring terminal) BLACK (ring terminal) RED (ring terminal)

VALUE < 1 < 1 > 20 k > 10 k > 100 k > 200 k

Generating Coil Verification

717 Engine
STATIC TEST Disconnect magneto wiring harness connector. Install the 4-pin magneto harness adapter (P/N 295 000 131).

F01B28A

> 10 k > 50 k > 10 k

TYPICAL

Check resistance with a multimeter. Refer to the following table for values and wire colors.
PART NAME Generating coil ADAPTER WIRE BLACK with RED/BLACK RESISTANCE 40-76

Most of circuit can be tested with an ohmmeter but a 100% test doesnt mean the MPEM is in perfect condition.

CAUTION

Whenever connecting MPEM, always have battery disconnected from circuit. If MPEM must be connected when circuit is activated, always connect BLACK/RED wire first to ignition coil/CDI module to prevent wire from touching solenoid positive terminal.

All Other Models It is not possible to accurately check the MPEM condition without specialized tools. Therefore, replace MPEM with a good known unit to conduct testing. NOTE: Before replacing the MPEM, make sure all connectors are properly secured and there is no water in connectors. Check also the signal and power contacts in the AMP plug connectors. See WIRING DIAGRAMS 14-01.

F01H5WA

1. 2. 3. 4.

Multimeter Four-pin magneto harness adapter RED/BLACK wire BLACK wire

08-02-13

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

DYNAMIC TEST 1. Connect spark plug cables to grounding device. 2. Disconnect magneto wiring harness connector. 3. Install the 4-pin magneto harness adapter (P/N 295 000 131). 4. Connect positive test probe of the multimeter to the RED/BLACK wire of the 4-pin magneto harness adapter. 5. Connect negative test probe of the multimeter to BLACK wire of the 4-pin magneto harness adapter. 6. Set multimeter to Vac scale. 7. Crank engine and note result. The obtained value should be between 18 and 25 Vac. 8. If the generating coil is out of specification, replace it. NOTE: If the generating coil tests good, disconnect the primary wires of the ignition coil. Crank engine and check voltage at primary wires. It should be at least 20 Vdc. If there is insufficient or no voltage, either the MPEM or wiring harness is defective.

F01H5YA

1. 2. 3. 4.

Multimeter Six-pin magneto harness adapter WHITE wire BLACK/YELLOW wire

Trigger Coil Verification

787 and 947 Engines
STATIC TEST: CONTINUITY 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136).

DYNAMIC TEST 1. Disconnect magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Connect one of the multimeter probes to the WHITE wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter probe to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Crank engine and note result. The obtained value should be between 0.2 and 0.5 Vac. 6. If the trigger coil is out of specification, replace it.

Ignition Coil Verification

All Engines Before conducting any testing on the ignition coil, make sure there is at least 20 Vdc at the primary wires. If there is insufficient voltage, the ignition problem is occurring before the ignition coil.
STATIC TEST NOTE: An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level which is not detectable with an ohmmeter.

F01B28A

3. Connect one of the multimeter probes to the WHITE wire of the 6-pin magneto harness adapter. 4. Connect the other multimeter probe to the BLACK/ YELLOW wire of the 6-pin magneto harness adapter. 5. Measure resistance; it should be between 190300 ohms.

08-02-14

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

Primary Winding

DYNAMIC TEST

GTS Model Due to the integrated CDI module, it is not possible to take any resistance measurement. All Other Models 1. Remove the 2 female spade connectors from the primary side of the ignition coil. 2. With the multimeter set on the resistance scale, connect the meter probes to the primary terminals of the coil. 3. Resistance should be between 0.34 - 0.62 ohm.
Secondary Winding The spark plug caps must be removed from high tension cables, because they are resistor caps. The cap resistance is 4.48 K ohms.
1

All Models Except GTS Use an ignition coil tester, available from aftermarket tool/equipment suppliers.

CAUTION

Do NOT use coil tester on metal work bench. Follow manufacturer instructions. 1. With ignition coil removed from craft, disconnect spark plug caps from high tension cables. 2. Hook high tension leads from tester to ignition coil high tension cables. 3. Connect 2 smaller tester leads to primary of ignition coil.
1

ON OFF 12 V

A00E0QA

1. Resistor cap 2. High-tension cable

6V

IGNITION COIL PART NAME Secondary winding (GTS model) Secondary winding (all other models) WIRE End of each spark plug cable, spark plug caps removed End of each spark plug cable, spark plug caps removed RESISTANCE 9 - 15 k
F00H14 A

TYPICAL 1. Leads to secondary 2. Leads to primary

8.4 - 15.6 k

4. Turn power switch to 12 volts and you should observe spark jumping at a predetermined gap of 7 to 8 mm (.276 to .311 in). If there is no spark, if it is weak or intermittent, the coil is defective and should be replaced.

NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter.

08-02-15

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

SPARK PLUGS
Disassembly
First unscrew the spark plug one turn. Clean the spark plug and cylinder head with pressurize air then completely unscrew.

CAUTION

Severe engine damage might occur if a wrong heat range plug is used. A too hot plug will result in overheating and preignition, etc. A too cold plug will result in fouling or may create carbon build up which can heat up red-hot and cause pre-ignition or detonation.

Heat Range
The proper heat range of the spark plugs is determined by the spark plugs ability to dissipate the heat generated by combustion. The longer the heat path between the electrode tip to the plug shell, the hotter the spark plug operating temperature will be and inversely, the shorter the heat path, the colder the operating temperature will be. A cold type plug has a relatively short insulator nose and transfers heat very rapidly into the cylinder head. Such a plug is used in heavy duty or continuous high speed operation to avoid overheating. The hot type plug has a longer insulator nose and transfers heat more slowly away from its firing end. It runs hotter and burns off combustion deposits which might tend to foul the plug during prolonged idle or low speed operation.

Fouling
Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible causes are: prolonged idling, or running on a too rich mixture due to a faulty carburetor adjustment or incorrect fuel. The plug face of a fouled spark plug has either a dry coating of soot or an oily, glossy coating given by an excess either of oil or of oil with soot. Such coatings form a conductive connection between the center electrode and ground.

Spark Plug Analysis

1
A00E0AA

A00E09A

1. Overheated (light grey) 2. Normal (brownish) 3. Fouled (black)

1. Cold 2. Hot

The plug face (and piston dome) reveals the condition of the engine, operating condition, method of driving and fuel mixture. For this reason it is advisable to inspect the spark plug at regular intervals, examining the plug face (i.e. the part of the plug projecting into the combustion chamber) and the piston dome.

08-02-16

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

Spark Plug Installation

Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap according to the following chart. 2. Apply anti-seize lubricant over the spark plug threads to prevent possible seizure. 3. Hand screw spark plug into cylinder head and tighten with a torque wrench and a proper socket.
1 2

A00E0BA

1. Proper socket 2. Improper socket

Spark Plug Chart

ENGINE 717 787 947 SPARK PLUG NGK BR8ES TORQUE Nm (lbfft) 24 (17) GAP mm (inch) 0.5-0.6 (.020-.024)

NOTE: Refer to next page for NGK Spark Plug Symbol Explanation.

08-02-17

Section 08 ELECTRICAL SYSTEM Subsection 02 (IGNITION SYSTEM)

NGK Spark Plug Symbol Explanation

PREFIX SUFFIX WIDE GAP
10: 1.0 mm (.040") 11: 1.1 mm (.044") 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080")

B R 8 E S
Thread diameter Heat rating numbers
2
14 mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach

15
Reach

Firing end construction

A: B: C: D: E: J:

18 mm

Hot

E: F:

19 mm (3/4") Taper Seat 12.7 mm (1/2") 11.2 mm (7/16") 21 mm (53/54")

A: B: C: G: GV: L: S:

Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V-Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V-Grooved Center Electrode

H:
5

L: Z:

Construction

M: P: R: U: Z:
F02H0MS

Compact Type Projected Insulator Type Resistor Type Surface Discharge Inductive Suppressor Type

Blank
8

V:
18 mm 12 mm (31/64") 14 mm 9.5 mm (3/8")

X: Y:

10

Cold

CROSSCUTS AND GAP STYLES OF SPARK PLUGS

A01E1PS

Standard Type

Projected Insulator Type

Taper Seat Type

V-Type

Surface Discharge Type

08-02-18

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

CHARGING SYSTEM
GENERAL
Magneto
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).

0
XP Limited Two 15 A fuses protect the charging system. The first one is mounted on the MPEM and the other one is located in the front electrical box. All Models If the battery is regularly discharged, check fuse condition. The rectifier/regulator could be the culprit of a blown fuse. To check, simply disconnect the rectifier/ regulator from the circuit. If the fuse still burns, check for a defective wire.

717 Engine The magneto has a three-pole coil. Capacity is 160 watts. 787 and 947 Engines The magneto has a 3 phase, Y wound stator on 18 poles. Capacity is 180 watts.

CAUTION

Do not use a higher rated fuse as this cause severe damage.

Rectifier/Regulator
717 Engine A half-wave rectifier receives magneto AC current and transforms it into direct current (DC) to allow battery charging. Included in the same unit, a regulator keeps voltage at a steady level (14.5 to 14.8 volts) to prevent any damage to components. 787 and 947 Engines A dual 1/2 wave series rectifier receives the magneto AC current and transforms it into direct current (DC) to allow battery charging. Included in the same unit, a regulator keeps voltage at a steady level (14.5 to 14.8 volts) to prevent any damage to components.

TESTING PROCEDURE
NOTE: First, ensure that battery is in good condition prior to performing the following tests.

Rectifier/Regulator
NOTE: All models with a 947 engine, the rectifier/ regulator is integrated in the MPEM. STATIC TEST: CONTINUITY 1. Due to internal circuitry, there is no static test available. DYNAMIC TEST Current Test Proceed as follows: Start engine. Lay an inductive ammeter on positive cable of battery. Bring engine to approximately 5500 RPM. Depending on battery charge, current reading should be approximately 4 amperes for the 717 engine or 5 amperes for the 787 and 947 engines. If not, check magneto output prior to concluding that rectifier is faulty.

Battery
The battery is the DC source for the electric starter, the Multi-Purpose Electronic Module and all accessories.

Fuse
GTS Model A 15 A fuse protects the charging system. All Models Except GTS and XP Limited Two 15 A fuses protect the charging system. The first one is mounted on the MPEM and the other one is located in the rear electrical box.

08-03-1

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

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.

Battery Charging Coil

717 Engine
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 and YELLOW/BLACK wires of the magneto harness adapter. Refer to the following table.
PART NAME Battery charging coil ADAPTER WIRE COLOR YELLOW with YELLOW/BLACK RESISTANCE () 0.05-0.6

SPX, GS, GTS and GTI Models If there is no charging at the battery with the preceding voltage test, the following test can also be performed. SPX and GTS Models Open the electrical box. Disconnect the RED and BLACK wires of the rectifier/ regulator. GS and GTI Models Disconnect the connector housing of the rectifier/ regulator. Using an appropriate terminal remover (Snap-on TT600-4), remove the RED and BLACK wires from the tab housing of the rectifier/regulator. Reconnect the connector housing. SPX, GS, GTS and GTI Models Connect the positive probe of a multimeter to the RED wire and the negative probe to the BLACK wire. Set multimeter to Vdc scale. Start and rev engine to 3500 RPM. The obtained value should be between 12 and 25 Vdc. NOTE: If the rectifier/regulator is within the specification, either the MPEM or wiring harness between the rectifier and battery is defective. If the rectifier/regulator is out of specification and the battery charging coil (or stator) test good, the rectifier/ regulator is defective.

NOTE: A short circuit will read 0 ohm (or close to) on ohmmeter.
1 2 3

F02H0KA

1. Multimeter 2. Magneto harness adapter 3. YELLOW and YELLOW/BLACK wires

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 and YELLOW/BLACK wires of the 4-pin magneto harness adapter. 4. Start and rev engine to 3500 RPM. The obtained value should be between 25 and 40 Vac. 5. If the battery charging coil is out of specification, replace it.

08-03-2

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

Stator
787 and 947 Engines
STATIC TEST: CONTINUITY 1. Disconnect the magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Check resistance between two of the YELLOW wires. The resistance should be between 0.1 to 1.0 ohm.
3 1

F01H60A

1. 2. 3. 4.

Multimeter Magneto harness adapter Positive (+) probe to YELLOW wire Negative (-) probe to ground

5. Repeat test with the other two YELLOW wires of the 6-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.
F01H5ZA

1. Multimeter 2. Magneto harness adapter 3. YELLOW wires

4. Place either meter lead into the remaining YELLOW wire and note the resistance (same as step no. 3). If the readings are out of specification, the stator will need to be replaced. STATIC TEST: INSULATION 1. Disconnect the magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Insert multimeter positive (+) probe to one of the YELLOW wire of the 6-pin magneto harness adapter. 4. Ground the multimeter negative (-) probe to the engine or the stator iron core and note the reading.

DYNAMIC TEST 1. Disconnect the magneto wiring harness connector. 2. Install the 6-pin magneto harness adapter (P/N 295 000 136). 3. Connect test probes of the multimeter to two of the YELLOW wires of the 6-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. If the stator is out of specification, replace it.

08-03-3

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

BATTERY
Troubleshooting
SYMPTOM: DISCHARGED OR WEAK BATTERY CAUSE 1. Battery posts and/or cable terminal oxidized. 2. Loose or bad connections. 3. Faulty battery (sulfated, doesnt keep a full charge, damaged casing, loose post). 4. 15 amp fuse(s) burnt or faulty rectifier. 5. Faulty battery charging coil (or stator). REMEDY Clean and coat with dielectric grease. Check wiring and connector cleanliness, damaged or short circuit. Replace.

CAUTION

Should any electrolyte spillage occur, immediately wash off with a solution of baking soda and water.

Cleaning
Clean the battery casing, caps, cables and battery posts using a solution of baking soda and water.

CAUTION

Do not allow cleaning solution to enter battery. Remove corrosion from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well.

First check fuse. If it is in good condition, check rectifier/regulator. Replace.

Inspection
Visually inspect battery casing for cracks or other possible damage. If casing is damaged, replace battery and thoroughly clean battery tray and close area with water and baking soda. Inspect battery posts for security of mounting. Inspect for cracked or damaged battery caps, replace defective caps.

Removal

WARNING

Battery BLACK negative cable must always be disconnected first and connected last. Never charge or boost battery while installed in watercraft. Proceed as follows: 1. Disconnect the BLACK negative cable first. 2. Disconnect the RED positive cable last. 3. Remove the vent line from the battery. 4. Remove the holding strap(s). 5. Withdraw battery from watercraft being careful not lean it so that electrolyte flows out of vent elbow.

WARNING

Battery caps do not have vent holes. Make sure that vent line is not obstructed. Electrolyte Level Check electrolyte level in each cell, add distilled water up to upper level line.

Battery Testing

CAUTION

Add only distilled water in an activated battery.

WARNING

Electrolyte is poisonous and dangerous. Avoid contact with eyes, skin and clothing. Wear a suitable pair of non-absorbent gloves when removing the battery by hand.

There are 2 types of battery tests: unloaded and loaded. An unloaded test is made on a battery without discharging current. It is the simplest and commonly used. A loaded test gives more accuracy of the battery condition.

08-03-4

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

Unload Test Check charge condition using either a hydrometer or multimeter. With a multimeter, voltage readings appear instantly to show the state of charge. Always respect polarity. A fully charge battery will have a reading of 12.6 Vdc. A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. A fully charge battery will have a specific gravity between 1.265 to 1.280. Most hydrometers give a true reading at 21C (70F).

This chart will be useful to find the correct reading.

ELECTROLYTE TEMPERATURE C 38 32 27 21 16 10 4 -1 EXAMPLE NO. 1
Temperature above 21C (70F): Hydrometer reading: 1.250 Electrolyte temperature: -1C (30F) Subtract .016 Sp. Gr. Corrected Sp. Gr. is 1.234

F 100 90 80 70 60 50 40 30

OPERATION TO PERFORM

.012 .008 .004

Add to the reading

correct reading .004 .008 .012 .016 Subtract from the reading

EXAMPLE NO. 2
Temperature above 21C (70F): Hydrometer reading: 1.235 Electrolyte temperature: 38C (100F) Add .012 Sp. Gr. Corrected Sp. Gr. is 1.247

A17E0JA

1. Specific gravity 1.265

In order to obtain correct readings, adjust the initial reading by adding .004 points to the hydrometer readings for each 5.5C (10F) above 21C (70F) and by subtracting .004 point for every 5.5C (10F) below 21C (70F).

Load Test This is the best test of battery condition under a starting load. Use a load testing device that has an adjustable load. Apply a load of 3 times the ampere-hour rating of the battery. At 14 seconds into the test, check battery voltage; if battery is in good condition, it will have at least 10.5 Vdc.

Battery Storage
Disconnect and remove battery from watercraft as explained in Removal. Check electrolyte level in each cell, add distilled water up to upper level line.

Do not overfill.

CAUTION

The battery must always be stored in fully charged condition. If required, charge until specific gravity of 1.265 is obtained.

CAUTION

Battery electrolyte temperature must not exceed 50C (122F). The casing should not feel hot.
08-03-5

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

Clean battery terminals and cable connections using a wire brush. Apply a light coat of dielectric grease on terminals. Clean battery casing and caps using a solution of baking soda and water.

WARNING

Failure to remove the sealing tube could result in an explosion. 2. Remove caps and fill battery to UPPER LEVEL line with electrolyte (specific gravity: 1.265 at 21C (70F)). NOTE: This battery may fill slower than others due to the anti-spill check ball design.

CAUTION

Do not allow cleaning solution to enter battery. Rinse battery with clear water and dry well using a clean cloth. Store battery on a wooden shelf in a cool dry place. Such conditions reduce self-discharging and keep fluid evaporation to a minimum. Keep battery away from dew, high moisture and direct sunlight. During the storage period, recheck electrolyte level and specific gravity readings at least every month. If necessary, keep the battery at its upper level line and near full charge as possible (trickle charge).

3 1

Activation of a New Battery

A17E0FB

WARNING

1. Sealing tube removed 2. Battery electrolyte 3. Upper level line

Never charge or boost battery while installed in watercraft. A new battery is factory fresh dry charged. For storage purposes, it is fitted with a temporary sealing tube.

3. Allow the battery to stand for 30 minutes MINIMUM so that electrolyte soak through battery cells.

CAUTION

Do not remove the sealing tube or loosen battery caps unless activation is desired. NOTE: In case of accidental premature removal of caps or sealing tube, battery should be given a full charge. Perform the following operations anytime a new battery is to be installed. 1. Remove the sealing tube from the vent elbow.

1
A17E0GA

1. 30 minutes

08-03-6

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

4. Readjust the electrolyte level to the UPPER LEVEL line.

6. Disconnect battery charger.

1 1 2

A17E0IB A17E0RB

1. Battery electrolyte 2. Upper level line

Step 1 : Unplug battery charger Step 2 : Disconnect - lead Step 3 : Disconnect + lead

5. Connect a 2 A battery charger for 3 to 5 hours.

7. Test battery state of charge. Use a hydrometer.

3 2

A17E0IA

A17E0JA

Step 1 : Connect + lead to battery + post Step 2 : Connect - lead to battery - post Step 3 : Plug battery charger

1. Specific gravity 1.265

CAUTION

If charging rate raises higher than 2.4 A reduce it immediately. If cell temperature rises higher than 50C (122F) or if the casing feels hot, discontinue charging temporarily or reduce the charging rate.

8. If electrolyte level has dropped after charging, fill with distilled water to UPPER LEVEL line. After water is added, continue charging for 1 to 2 hours to mix water with electrolyte. 9. Reinstall caps and clean any electrolyte spillage using a solution of baking soda and water.

Charging a Used Battery

WARNING

WARNING

Always charge in a well ventilated area. Always turn battery charger off prior to disconnecting cables.

Never charge battery while installed in watercraft. For best results, battery should be charged when the electrolyte and the plates are at room temperature. A battery that is cold may not accept current for several hours after charging begun.

08-03-7

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

Do not charge a frozen battery. If the battery charge is very low, the battery may freeze. If it is suspected to be frozen, keep it in a heated area for about 2 hours before charging.

WARNING

Always charge battery in a well ventilated area. The time required to charge a battery will vary depending on some factors such as: Battery temperature: The charging time is increased as the temperature goes down. The current accepted by a cold battery will remain low. As the battery warms up, it will accept a higher rate of charge. State of charge: Because the electrolyte is nearly pure water in a completely discharged battery, it cannot accept current as well as electrolyte. This is the reason the battery will not accept current when the charging cycle first begins. As the battery remains on the charger, the current from the charger causes the electrolytic acid content to rise which makes the electrolyte a better conductor and then, the battery will accept a higher charging rate. Type of charger: Battery chargers vary in the amount of voltage and current that they can supply. Therefore, the time required for the battery to begin accepting measurable current will also vary. Charging a Very Flat or Completely Discharged Battery The battery charger should have an adjustable charging rate. Variable adjustment is preferred, but a unit which can be adjusted in small increments is acceptable. The battery charger must be equipped with an ammeter capable of accurately measuring current of less than 1 ampere. Unless this procedure is properly followed, a good battery may be needlessly replaced.

Measure the voltage at the battery posts with an accurate voltmeter. If it is below 10 volts, the battery will accept current at very low rate, in term of milliamperes, because electrolyte is nearly pure water as explained above. It could be some time before the charging rate increases. Such low current flow may not be detectable on some charger ammeters and the battery will seem not to accept any charge. Exceptionally for this particular case, set the charger to a high rate. NOTE: Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly. This will make it appear that the battery will not accept a charge. Follow the charger manufacturers instruction on how to bypass or override this circuitry so that the charger will turn on and charge a low-voltage battery. Since the battery chargers vary in the amount of voltage and current they provide, the time required for the battery to accept measurable charger current might be up to approximately 10 hours or more. If the charging current is not up to a measurable amount at the end of about 10 hours, the battery should be replaced. If the charging current is measurable before the end or at the end of about 10 hours, the battery is good and charging should be completed in the normal manner as specified in Activation of a new battery. It is recommended that any battery recharged by this procedure be load tested prior to returning it to service.

Charging Two or More Batteries at a Time

Connect all positive battery posts together and use a charger with a capacity (rated) equal to: number of battery to be charged multiply by 2 A. For example: Charging 5 batteries at a time requires a 10 A rated charger (5 x 2 A = 10 A).

08-03-8

Section 08 ELECTRICAL SYSTEM Subsection 03 (CHARGING SYSTEM)

NOTE: On the SPX model, secure the negative battery cable on top of the small ground wire without using a washer.

A17E0PA

TYPICAL 1. Two batteries = 4 A

F01H63A

WARNING

Always charge battery(ies) in a well ventilated area.

SPX MODEL 1. Negative battery cable on top of small ground wire

5. Apply dielectric grease on battery posts. 6. Verify cable routing and attachment.

Battery Installation

WARNING

GTS Model Secure RED positive battery cable using right strap of battery.

Always connect battery cables exactly in the specified order, RED positive cable first BLACK negative cable last. Proceed as follows: 1. Install battery in its emplacement. 2. Secure vent line to the battery and support. Ensure vent line is not kinked or obstructed.

WARNING

Vent line must be free and open. Avoid skin contact with electrolyte. 3. First connect RED positive cable. 4. Connect BLACK negative cable last.
F01H0AA

GTS MODEL 1. Strap retaining RED positive cable 2. Vent tube connected and secured in support

08-03-9

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM
717 Engine

7 8 9 10

11

1 2 4 3 22 Nm (16 lbfft) 13 Loctite 242 5 Nm (44 lbfin) 12 5

Dielectric grease 17

22 Nm (16 lbfft) 14 Loctite 271 Ground cable 15 22 Nm (16 lbfft) 16 Loctite 242
F00H0BT

PARTS

FLAT RATE

08-04-1

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

787 Engine

7 8 9 10

11

1 2 4 22 Nm (16 lbfft) 13 Loctite 242 5 Nm 12 (44 lbfin) 3 5

17

25 Nm (18 lbfft) Dielectric 19 grease Loctite 242 18

22 Nm (16 lbfft ) 14 Loctite 271 Ground cable 15

Loctite 242 16 22 Nm (16 lbfft)

Loctite 242 16
F00H13S

22 Nm (16 lbfft)

08-04-2

PARTS

FLAT RATE

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

947 Engine

Dielectric grease Loctite 242 17 10 10 Nm (89 lbfin) Ground cable Loctite 271 12 10 Nm (89 lbfin) Loctite 242 10 10 Nm (89 lbfin) 6 8 9 Synthetic grease Synthetic grease

11 7 1

3
F06H1XS

PARTS

FLAT RATE

08-04-3

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

GENERAL
Causes of troubles are not necessarily related to starter but may be due to a burnt fuse, faulty battery, start/stop switch, safety lanyard switch, MPEM, solenoid, electrical cables or connections. Check these components before removing starter. Consult also the starting system troubleshooting table on next page for a general view of possible problems.

Safety Lanyard Switch

The following continuity tests can be performed using an ohmmeter: Disconnect switch wires. Safety Lanyard Removed Connect test probes to switch BLACK and BLACK/ YELLOW wires. Measure resistance, there should be no continuity (open circuit). Connect one test probe to the WHITE/GRAY wire and the other test probe to the switch terminal. Measure resistance, it must be close to 0 ohm. Connect one test probe to the BLACK wire and the other test probe to the switch ring. Measure resistance, it must be close to 0 ohm. Safety Lanyard on Switch Connect test probes to switch BLACK and BLACK/ YELLOW wires. Measure resistance, it must be close to 0 ohm.

WARNING

Short circuiting electric starter is always a danger, therefore disconnect the battery ground cable before carrying out any kind of maintenance on starting system. Do not place tools on battery.

Fuse
Make sure 5 A fuse on MPEM is in good condition. The solenoid may be the cause of a burnt fuse. If the solenoid checks good, one of the accessory may be defective.

Solenoid
NOTE: Solenoid is located in the electrical box. Inspect connections and clean as necessary. Static Test: Continuity With a multimeter, check primary winding resistance. It should be approximately 5 ohms. There should be no continuity between the positive posts of the solenoid. Dynamic Test Depress start/stop button and measure the voltage on the solenoid positive posts with a multimeter. If there is no voltage and battery is in good condition, replace the solenoid.

Battery
To check battery condition, refer to STARTING SYSTEM 08-04.

MPEM
If 2 short beeps are not heard when installing the safety lanyard, refer to DIGITALLY ENCODED SECURITY SYSTEM 08-06.

Engine Start/Stop Switch

Switch condition can be checked with an ohmmeter. Disconnect the switch YELLOW/RED wire. Connect 1 test probe to the YELLOW/RED wire and the other test probe to ground. Measure resistance, it must be an open circuit (switch is normally open). Depress and hold switch, the ohmmeter should read close to 0 ohm.

Electrical Cables or Connections

Check all connections, cables and wires. Tighten any loose cables. Replace any chafe wires.

08-04-4

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

STARTING SYSTEM TROUBLESHOOTING

SYMPTOM Starter does not turn. CAUSE Burnt 5 A fuse. Poor contact of battery terminal(s). Poor battery ground cable connection. Weak battery. Poor contact of start/stop switch, safety lanyard switch or solenoid. Open circuit: start/stop switch or solenoid. Safety lanyard or MPEM. Starter engages; but does not crank the engine. Poor contact of brush. Burnt commutator. Worn commutator segments. Shorted armature. Weak brush spring tension. Weak magnet. Worn bushings. Weak battery. Starter turns, but overrunning clutch pinion does not mesh with ring gear. Worn clutch pinion gear. Defective clutch. Poor movement of clutch on splines. Worn clutch bushing. Worn ring gear. Starter motor keeps running. Shorted solenoid winding. Melted solenoid contacts. Sticking or defective starter clutch. Presence of salt water in the electrical box which gives continuity. REMEDY Check wiring condition and replace fuse. Clean and tighten terminal(s). Clean and tighten. Recharge or replace battery. Replace. Replace. Refer to DIGITALLY ENCODED SECURITY SYSTEM 08-06. Straighten commutator and brush. Turn commutator in lathe. Undercut mica. Repair or replace armature. Replace brush holder or spring. Replace yoke assembly. Replace clutch. Recharge or replace battery. Replace clutch. Replace clutch. Clean and correct. Replace clutch. Replace ring gear. Replace solenoid. Replace solenoid. Lubricate or replace. Verify electrical box watertightness.

08-04-5

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

STARTER REMOVAL
Disconnect BLACK cable ground connection from battery.

STARTER DISASSEMBLY
717 and 787 Engines Before disassembling, trace index marks on yoke no. 1 and clutch housing no. 10 to ease further assembly.
1

WARNING

Always disconnect ground cable first and reconnect last. Disconnect RED cable connection from battery.

717 and 787 Engines Remove the following parts: cables from starter screw no. 13 of starter rear support starter mount screws no. 16 947 Engine Disconnect starter cables and loosen Allen screws no. 16 retaining starter bracket to engine.
3 2
F01H0PA

TYPICAL 1. Trace indexing marks

Remove starter support nuts no. 12 then through bolts no. 5. Separate end frame no. 3 from yoke assembly no. 1. Withdraw yoke assembly from armature no. 11. Brush holder no. 2 can be removed from end frame no. 3 by unscrewing nut retaining terminal. Check that the radial play between the armature shaft and end frame is not greater than 0.20 mm (.008 in). Replace end frame if so. Tap the pinion stop collar no. 7 using a screwdriver. Remove circlip no. 6. Disassemble pinion stop collar no. 7 and spring no. 8.

F06H1EA

3
1

1. Positive starter cable 2. Negative starter cable 3. Allen screw

Remove bracket and starter. NOTE: To remove the starter drive assembly, magneto flywheel has to be removed. Refer to MAGNETO SYSTEM 04-04 and BOTTOM END 04-06.

A03E04A

1. Pinion stop collar

08-04-6

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

Turn clutch assembly no. 9 clockwise to remove it from armature assembly no. 11. Pull housing from armature.

947 Engine Locate index marks on yoke no. 1 and end covers no. 3 and no. 6.
1

F06H1HA

1. Thrust washer

F06H1FA

Remove the other end cover no. 6 and gasket. Remove the 3 washers no. 8 and no. 9 from armature shaft.

1. Index marks

Loosen through bolts no. 5.

1

1
F06H1IA

1. Washers

Remove armature no. 11.

F06H1GA

1. Through bolts

Remove end cover no. 3 and gasket on armature shaft side. Remove thrust washer no. 7 from armature shaft.

F06H1JA

1. Pull armature shaft

08-04-7

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

Release brush wires of yoke from brush holder no. 2. Remove brush holder no. 2.

To remove bearing and seal in end cover, release tabs of retainer.

1

1
F06H1MA F06H1KA

1. Retainer

1. Remove brush holder

To remove brushes from yoke no. 1, loosen nut and remove washers.

CLEANING

CAUTION

Yoke assy and drive unit assembly must not be immersed in cleaning solvent. Discard all O-rings. Clean brushes and holders with a clean cloth soaked in solvent. Brushes must be dried thoroughly with a clean cloth. Blow brush holders clean using compressed air.
1

WARNING

Always wear safety glasses when using compressed air.

F06H1LA

1. Loosen nut and remove washers

Remove brushes.

Remove dirt, oil or grease from commutator using a clean cloth soaked in suitable solvent. Dry well using a clean, dry cloth. Clean engine ring gear teeth and drive unit (clutch). NOTE: Bushings or bearings must not be cleaned with grease dissolving agents. Immerse all metal components in cleaning solution. Dry using a clean, dry cloth.

08-04-8

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

PARTS INSPECTION
11, Armature
NOTE: An ohmmeter may be used for the following testing procedures, except for the one concerning shorted windings in armature. Check commutator for roughness, burnt or scored surface. If necessary, turn commutator on a lathe, enough to resurface only. Check commutator for mica depth. If depth is less than 0.20 mm (.008 in), undercut mica. Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed.
1

2, Brush Holder
Check brush holder for insulation using an ohmmeter. Place one test probe on insulated brush holder and the other test probe on brush holder plate. If continuity is found, brush holder has to be repaired or replaced.

4, Brush
Measure brush length. If less than 8.5 mm (.335 in), replace them. NOTE: New brush length is 12 mm (.472 in).

2 1

F01H0RA
A03E05A

1. Commutator undercut 0.20 mm (.008 in)

Check commutator out of round condition with Vshaped blocks and an indicator. If commutator out of round is more than 0.40 mm (.016 in), commutator should be turned on a lathe. Check commutator outer diameter. If less than 27 mm (1.063 in), replace.

1. New 2. Wear limit, 8.5 mm (.335 in)

9, Overrunning Clutch
Pinion of overrunning clutch should turn smoothly in clockwise direction, and should not slip in a counterclockwise direction. If defective, replace. Check pinion teeth for wear and damage. If defective, replace. NOTE: Always check engine ring gear teeth for wear and damage. If defective replace ring gear. Refer to MAGNETO 04-04.

STARTER ASSEMBLY
Reverse the order of disassembly to reassemble starter. However, attention should be paid to the following operations.
A03E06A

717 and 787 Engines Prior to assembling, coat sliding surfaces on armature shaft splines, overrunning clutch and bushing (717 engine) with G.E. Versilube G 341 M or ESSO Beacon 325 lubricant or equivalent. After placing pinion stop collar no. 7 on armature shaft no. 11, fit circlip no. 6 into armature shaft, then make sure that it is properly secured.
08-04-9

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

Slide stop collar no. 7 over circlip no. 6 and secure in place by punching it at 2 or 3 places.

Open brushes no. 4 and slide over commutator. Align end frame locating notch with yoke locating protrusion and properly sit brush holder no. 2 into yoke no. 1.
1

4 1 2 3

A03E0EA

1. 2. 3. 4.

Armature shaft Circlip Pinion stop collar Punch

F01H0SA

1. Locating protrusion is the higher one

1,10, Yoke Assembly and Clutch Housing

Align previously traced indexing marks.
1

F01H0TA

1. Brush holder locating notch

F01H0QA

TYPICAL 1. Align marks

To ease end frame installation, retain brush holder with a small screwdriver while installing end frame.

08-04-10

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

Install the 3 washers no. 8 and no. 9 onto armature shaft, with the thicker one in the middle.
1

1
F06H1NA

F01H0UA

1. Thick washer in the middle

Step 1 : Retaining brush holder with a screwdriver Step 2 : Align here

Align end frame notch with brush holder notch/ yoke protrusion.

When installing end covers no. 3 and no. 6 to yoke, align index marks. Apply Loctite 271 (red) on through bolts no. 5 and torque to 6 Nm (53 lbfin).

CAUTION

STARTER INSTALLATION
Installation is essentially the reverse of removal procedure. However, pay particular attention to the following. Make sure that starter and engine mating surfaces are free of debris. Serious trouble may arise if starter is not properly aligned.

Make sure end frame fits perfectly on yoke.

947 Engine Install new O-rings and gaskets. Insert thrust washer no. 7 onto armature shaft with the non-metallic surface facing the end cover.

717 and 787 Engines

13,16, Screw
Apply Loctite 242 (blue) on threads and torque starter screws to 22 Nm (16 lbfft).

17, Nut
Connect the RED positive cable to the starter and torque nut to 6 Nm (53 lbfin). Apply dielectric grease on terminal and nut.

F06H1HA

1. Non-metallic surface on this side

08-04-11

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

14,15, Screw and Teeth Washer

Apply Loctite 271 (red) to screw. Connect BLACK negative cable to starter using flat washer, teeth washer and screw. Torque screw to 22 Nm (16 lbfft). Apply dielectric grease on terminal and screw.

787 Engine

18, Locking Collar

Install the locking collar of the fuel hose. Apply Loctite 242 (blue) on nut no. 19 and torque to 25 Nm (18 lbfft).

2 3 4
F01H1JC

4
F07H03A

717 ENGINE SHOWN Step Step Step Step

1 2 3 4

: Torque nut to 6 Nm (53 lbfin) : Apply Loctite 271 on screw : Torque screw to 22 Nm (16 lbfft) : Apply dielectric grease

787 ENGINE 1. Locking collar 2. Nut

947 Engine

10, Screw
Apply Loctite 242 (blue) to Allen screws of starter bracket and torque to 10 Nm (89 lbfin).

WARNING

Always connect RED positive cable first then BLACK negative cable last. Whenever connecting the RED positive cable to the starter motor make sure the battery cables are disconnected to prevent electric shock.

17, Nut
Connect the RED positive cable to the starter and torque nut to 6 Nm (53 lbfin). Apply dielectric grease on terminal and nut.

08-04-12

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

12, Screw
Apply Loctite 271 (red) to Allen screw. Connect BLACK negative starter cable using flat washer, teeth washer and screw. Torque to screw 10 Nm (89 lbfin). Apply dielectric grease.
3 2

F06H1EA

947 ENGINE 1. Torque nut to 6 Nm (53 lbfin), apply dielectric grease and install protection cover 2. Apply Loctite 271 to threads and torque screw to 10 Nm (89 lbfin) 3. Apply Loctite 242 to threads and torque screw to 10 Nm (89 lbfin)

WARNING

Always connect RED positive cable first then BLACK negative cable last. Whenever connecting the RED positive cable to the starter motor make sure the battery cables are disconnected to prevent electric shock.

08-04-13

Section 08 ELECTRICAL SYSTEM Subsection 04 (STARTING SYSTEM)

STARTER SPECIFICATION
717 and 787 Engines
Nominal output Voltage Rated time Rotation Weight Performance specification at 20C (68F) No load Load Stall Battery 11.5 V 8.5 V 5V 0.6 kW 12 V 30 seconds Counterclockwise (viewed from pinion side) Approx. 2 kg (4.4 lb) 20 A max. 170 A max. 350 A max. 19 Ah 5500 RPM 2200 RPM 0 RPM

947 Engine
Nominal output Voltage Rated time Rotation Weight Performance specification at 20C (68F) No load Load Stall Battery 10.9 V 9V 2.25 V 0.8 kW 12 V 30 seconds Counterclockwise (viewed from pinion side) 1.7 kg (3.7 lb) 45 A max. 120 A max. 390 A max. 12 V, 19 Ah 8600 RPM 5350 RPM 0 RPM

08-04-14

Subsection 05

Section 08 ELECTRICAL SYSTEM (INSTRUMENTS AND ACCESSORIES)

INSTRUMENTS AND ACCESSORIES

GENERAL
It is possible to activate the instruments when the engine is not running. Make sure the safety lanyard is removed, then depress the start/stop button. The timer of the MPEM will maintain the gauge(s) activated during a period of approximately 33 seconds.

Lake Temperature Sensor

GSX Limited and GTX Limited The lake temperature sensor is integrated with the speed sensor located on the ride plate. To check if the lake temperature sensor is operational, activate the Info Center and select the lake temperature mode. With a garden hose, spray the speed sensor with water. The lake temperature on the Info Center should adjust to the water temperature. If not, replace the speed sensor.

INSPECTION
Exterior Temperature Sensor
GTX Limited The temperature sensor is located in the storage cover. Remove the back panel of the storage cover to access the temperature sensor.

Compass
GTX Limited The compass is located in the storage cover. Remove the back panel of the storage cover to access the compass.

F07H01A

F07H02A

1. Temperature sensor

1. Compass

To check if the temperature sensor is operational, activate the Info Center and select the exterior temperature mode. Use a heat gun to warm up the sensor. The temperature should raise rapidly on the gauge. If not, replace the temperature sensor.

Remove the compass from the support. Activate the Info Center. Change the direction of the compass and keep it horizontal ( 10). There should be a change of direction on the Info Center. NOTE: To check the accuracy of the compass, you can use a portable compass and point it in the same direction. Compare the given directions, they should be the same.

08-05-1

Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES)

Tachometer
GTX Limited

3 2 1 0

5
x 1000

RPM

6 7

Bombardier

8
R

F07H04A

The PURPLE wire is the 12 Vdc power source of the tachometer. The BLACK wire is the ground. The GRAY wire is the pulse signal from the multipurpose electronic module (MPEM).

To check if the speed sensor is operational, disconnect the speed sensor connector housing from inside bilge. Using an appropriate terminal remover (Snap-on TT600-4), remove the PURPLE/YELLOW and BLACK/ORANGE wires from the tab housing of the speed sensor. Reconnect the PURPLE/YELLOW and BLACK/ ORANGE wires in the receptacle housing. Connect the positive probe of a multimeter to speed sensor PURPLE/YELLOW wire and the negative probe to speed sensor BLACK/ORANGE wire. With the safety lanyard removed, depress the start/ stop button to activate the MPEM timer. Slowly rotate the paddle wheel. Every 1/8 turn, the observed voltage should fluctuate between 5.5 and 8.5 Vdc.

Speedometer
GSX Limited, XP Limited, GTI and GTX Limited

Speed Sensor
GSX Limited, XP Limited, GTI and GTX Limited The speedometer gives a reading through a speed sensor. Speed sensor is installed on riding plate. It works with the water flow which turns a magnetic paddle wheel that triggers an electronic pick-up that in turn sends a speed signal to the speedometer. The paddle wheel is protected by the pick-up housing.
F07H05A

30 20 10 0

40 50 60 70
R

MPH

The PURPLE wire is the 12 Vdc power source of the speedometer. The BLACK wire is the ground. The PURPLE/YELLOW wire is the pulse signal from the speed sensor.
1

F01H3VA

1. Pick-up housing 2. Paddle wheel

08-05-2

Subsection 05

Section 08 ELECTRICAL SYSTEM (INSTRUMENTS AND ACCESSORIES)

Info Center
GSX Limited and GTX Limited

As a self test, all LCD segments and the LED will turn on for 3 seconds each time the watercraft is started. SCROLLING FUNCTIONS Press the MODE button until the desired function is displayed on the Info Center.

Bombardier

RESET A FUNCTION To reset a function such as the chronometer, peak speed, trip meter, etc., select the desired function using the MODE button then press and hold the SET button for 2 seconds. DISPLAY PRIORITIES The clock (and compass for the GTX Limited) is the basic mode of the Info Center. The chronometer, tachometer and speedometer are the only other functions that may be chosen to replace the clock mode. If an another function is chosen, the clock mode will be displayed again after 4 seconds. In the event of a warning message such as low fuel is displayed, the message will blink and override any other functions. If more than one warning message is displayed, the messages will blink and reappear every 4 seconds. LANGUAGE OPTION While in the clock mode, press and hold the SET button for 2 seconds. Language option will be displayed. Press the MODE button to scroll language (English, French and Spanish). Press the SET button to confirm the selected language and return to the clock mode. ENGLISH/METRIC OPTION Press and hold both MODE and SET buttons for 2 seconds. The system will be automatically changed. CHRONOMETER Select the chronometer mode and press the SET button to start or stop the chronometer. Press the SET button for 2 seconds to reset the chronometer. CLOCK SETTING While in the clock mode, press and hold both MODE and SET buttons for 2 seconds. The clock will blink to confirm the setting mode.
08-05-3

F07H06A

TYPICAL

This is a LCD multifunction gauge. It features the following functions: fuel level low fuel level low oil level low voltage overheating hourmeter clock maintenance information chronometer tachometer speedometer peak speed average speed trip meter VTS (GSX Limited) compass (GTX Limited) exterior temperature (GTX Limited) lake temperature The Info Center also features a red warning LED which blinks whenever one of the following circumstances occur: low fuel, low oil, low voltage and overheating. For example, if the fuel level is low, the LED and the message LOW FUEL will blink.

Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES)

Press the MODE button to adjust the hours and the SET button to adjust the minutes. Press again on both the MODE and SET buttons to exit the setting mode (or the gauge will automatically exit the setting mode after 10 seconds). MAINTENANCE INFORMATION When the watercraft is due for a maintenance inspection, the message MAINT will blink. To clear the MAINT message, press the SET button for 2 seconds during the message blinking. Verification The PURPLE wire is the 12 Vdc power source of the Info Center. The BLACK wire is the ground. The RED/PURPLE wire is the 12 Vdc from the battery protected by a 5 A fuse on the MPEM. The accuracy of some features of the Info Center can be checked with a potentiometer. FUEL LEVEL Disconnect the 4-circuit connector housing of the Info Center. Using an appropriate terminal remover, remove the PINK wire from the tab housing. Reconnect the connector housing. Disconnect the 2-circuit connector housing which contains a PURPLE and BLACK wires. Remove the BLACK wire from the receptacle housing. Reconnect the connector housing. Connect potentiometer test probes to the PINK and BLACK wires. Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge. NOTE: The gauge must be activated to obtain a reading.

RESISTANCE () 0 + 2.2 17.8 2.2 27.8 2.2 37.8 2.2 47.8 2.2 57.8 2.2 67.8 2.2 77.8 2.2 89.0 2.2

FUEL LEVEL LCD GRAPHIC FULL 7/8 3/4 5/8 1/2 3/8 1/4 1/8 EMPTY

LOW FUEL LEVEL RED LIGHT OFF OFF OFF OFF OFF OFF OFF ON ON

VTS

GSX Limited Disconnect the 2-circuit connector housing of the Info Center. Connect potentiometer test probes to the BROWN/ WHITE and BROWN/BLACK wires. Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge. NOTE: The gauge must be activated to obtain a reading.
RESISTANCE () 167.3 2.2 153.0 2.2 138.7 2.2 124.4 2.2 110.1 2.2 95.8 2.2 81.5 2.2 67.2 2.2 52.9 2.2 38.6 2.2 24.3 2.2 VTS LEVEL LCD GRAPHIC 11/11 (UP) 10/11 9/11 8/11 7/11 6/11 5/11 4/11 3/11 2/11 1/11 (DOWN)

08-05-4

Subsection 05

Section 08 ELECTRICAL SYSTEM (INSTRUMENTS AND ACCESSORIES)

LAKE TEMPERATURE Disconnect the 2-circuit connector housing of the Info Center which contains a BLACK/ORANGE and TAN/ORANGE wires. Connect potentiometer test probes to the BLACK/ ORANGE and TAN/ORANGE wires. Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge. NOTE: The gauge must be activated to obtain a reading.
RESISTANCE () 25407.3 19911.1 15718.0 12495.0 10000.0 8054.9 6528.3 RESISTANCE () 22799.0 17262.0 13470.0 10496.3 8264.4 6528.3 DISPLAY TEMPERATURE (C) 52 10 2 15 2 20 2 25 2 30 2 35 2 DISPLAY TEMPERATURE (F) 45 4 55 4 65 4 75 4 85 4 95 4

NOTE: The gauge must be activated to obtain a reading.

RESISTANCE () 25590.1 20005.8 15761.7 12510.2 10000.0 8047.8 6518.7 RESISTANCE () 22919.8 17491.7 13487.5 10501.5 8252.0 6518.7 DISPLAY TEMPERATURE (C) 52 10 2 15 2 20 2 25 2 30 2 35 2 DISPLAY TEMPERATURE (F) 45 4 55 4 65 4 75 4 85 4 95 4

Fuel Gauge/Low Oil Warning Light

SPX, GS, GTS, GTI and XP Limited The fuel gauge has a pointer which indicates fuel level in the tank. The low oil warning light is part of the gauge. It will light when injection oil level is low.

EXTERIOR TEMPERATURE Disconnect the 2-circuit connector housing of the Info Center which contains a TAN/WHITE and BLACK/WHITE wires. Connect potentiometer test probes to the TAN/ WHITE and BLACK/WHITE wires. Adjust potentiometer to the resistance values as per following chart to test the accuracy of the gauge.

08-05-5

Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES)

VTS

1
Bombardier

Bombardier
2
F01G07A F01H4RA

SPX, GTS AND XP LIMITED 1. Low oil warning light

TYPICAL 1. Bow up 2. Bow down

Bombardier

Accuracy of gauge can be checked with a potentiometer. Disconnect 2-circuit connector housing of BROWN/BLACK and BROWN/WHITE wires of gauge. Connect potentiometer test probes to BROWN/ BLACK and BROWN/WHITE wires of gauge. Adjust potentiometer to the resistance values as per following chart to test accuracy of gauge. NOTE: Gauge must be activated to obtain a reading.
RESISTANCE () 10 95 180 GAUGE NEEDLE POSITION - 45 0 + 45

1
F06H0DA

GS AND GTI MODELS 1. Low oil warning light

Variable Trim Gauge

SPX and XP Limited The trim gauge shows the riding angle of the watercraft.

+ 45

VTS

45
F01H0EA

Bombardier

If gauge is not within the specifications, replace it.

08-05-6

Subsection 05

Section 08 ELECTRICAL SYSTEM (INSTRUMENTS AND ACCESSORIES)

Fuel Baffle Pick Up Sender

The baffle pick-up has an integrated fuel sender. To verify fuel sender, a resistance test should be performed with a multimeter allowing the float to move up through a sequence.
1

FUEL LEVEL AND RESISTANCE (GTS) FUEL LEVEL (mm) From 257.9 5 and more From 234.4 to 257.8 5 From 200.9 to 234.3 5 From 167.4 to 200.8 5 From 134 to 167.3 5 RESISTANCE () 0 + 2.2 17.8 2.2 27.8 2.2 37.8 2.2 47.8 2.2 57.8 2.2 67.8 2.2 77.8 2.2 89.8 2.2

From 100.5 to 133.9 5 From 67 to 100.4 5 From 40.1 to 66.9 5

3
F01F20A

From 0 to 40 5

1. Pick up tube 2. Fuel sender 3. Baffle pick-up

FUEL LEVEL AND RESISTANCE (GS, GSX Limited, GTI and GTX Limited) FUEL LEVEL (mm) From 248.9 5 and more From 234.4 to 248.8 5 From 200.9 to 234.3 5 From 167.4 to 200.8 5 From 134.0 to 167.3 5 From 100.5 to 133.9 5 From 67.0 to 100.4 5 From 40.1 to 66.9 5 From 0 to 40.0 5 RESISTANCE () 0 + 2.2 17.8 2.2 27.8 2.2 37.8 2.2 47.8 2.2 57.8 2.2 67.8 2.2 77.8 2.2 89.8 2.2

The resistance measured between PINK/BLACK and PINK wires must be in accordance with fuel level (measured from under the flange) as specified in the following charts.
FUEL LEVEL AND RESISTANCE (SPX) FUEL LEVEL (mm) From 206.1 5 and more From 189.1 to 206 5 From 162.1 to 189 5 From 135.1 to 162 5 From 108.1 to 135 5 From 81.1 to 108 5 From 54.1 to 81 5 From 40.1 to 54 5 From 0 to 40 5 RESISTANCE () 0 + 2.2 17.8 2.2 27.8 2.2 37.8 2.2 47.8 2.2 57.8 2.2 67.8 2.2 77.8 2.2 89.8 2.2

08-05-7

Section 08 ELECTRICAL SYSTEM Subsection 05 (INSTRUMENTS AND ACCESSORIES)

FUEL LEVEL AND RESISTANCE (XP Limited) FUEL LEVEL (mm) From 325 5 and more From 294 to 325 5 From 263 to 294 5 From 225 to263 5 From 190 to 225 5 From 149 to 190 5 From 93 to 149 5 From 41 to 93 5 From 0 to 41 5 RESISTANCE () 0 + 2.2 17.8 2.2 27.8 2.2 37.8 2.2 47.8 2.2 57.8 2.2 67.8 2.2 77.8 2.2 89.8 2.2

When the oil level goes at critical LOW level inside the oil tank (and therefore in sensor reservoir), the sensor detects the absence of liquid and the light TURNS ON. To check the oil sensor, unplug its connector and pull sensor out of oil tank. Using a multimeter, check the continuity between the BLUE and BLUE/BLACK terminals. When sensor is out of oil tank and its reservoir is empty, resistance must be infinite (open circuit). NOTE: Wait about 15-20 seconds before taking any reading to give the oil enough time to flow out or inside sensor reservoir. Soak sensor in oil so that its reservoir fills up. Maximum resistance should be approximately 2 (closed circuit).
TEST CONDITION Sensor OUT of oil Sensor soaked IN oil READING () (open circuit) 2 max. (closed circuit)

Oil Sensor
The sensor sends the signal to the low-oil level light in the fuel gauge or the LED in the Info Center.

2
F03H0BA

1. Measure resistance here 2. Sensor reservoir

F00H0LA

1. Oil sensor

The bottom of the sensor has a small reservoir with two small holes underneath to let the oil enter inside and one at the top to let the air enter allowing the oil to flow out. When there is enough oil inside the oil tank (and therefore in the sensor reservoir), the sensor detects the liquid and the light DOES NOT turn on.

To Reinstall Sensor: Remove rubber seal from sensor. Install seal in oil tank hole. Push sensor in seal. Plug connector. NOTE: This sensor turns the LED to ON if the connector has been forgotten unconnected even when there is enough oil in tank.

08-05-8

Subsection 05

Section 08 ELECTRICAL SYSTEM (INSTRUMENTS AND ACCESSORIES)

VTS Switch
SPX, GSX Limited and XP Limited Always confirm first that the fuse is in good condition. Disconnect BLACK wire, BLUE/WHITE wire and GREEN/WHITE wire of VTS switch. Using a multimeter, connect test probes to switch BLACK and BLUE/WHITE wires; then, connect test probes to switch BLACK and GREEN/WHITE wires. Measure resistance; in both test it should be high when button is released and must be close to zero when activated.

VTS Control Module

SPX, GSX Limited and XP Limited It receives its current from the battery. It is protected by its own 7.5 A fuse.
RESISTANCE TEST Disconnect BROWN/BLACK wire and BROWN/ WHITE wire of VTS control module. Connect test probes of a multimeter to BROWN/ BLACK wire and BROWN/WHITE wire of VTS control module. NOTE: To permit VTS actuation when engine is not running, remove safety lanyard from switch and depress start/stop button to activate MPEM timer. Push on VTS switch down position until motor stops. Read the resistance on the ohmmeter, it should indicate a resistance of 24 ohms 1%. Push on VTS switch up position until motor stops. Read the resistance on the ohmmeter, it should indicate a resistance of 167 ohms 1%.
RESISTANCE () 167 1% NOZZLE POSITION UP

VTS Motor
SPX, GSX Limited and XP Limited Always confirm first that the fuse is in good condition. Motor condition can be checked with a multimeter. Install test probes on both BLUE/ORANGE and GREEN/ORANGE wires. Measure resistance, it should be close to 1.5 ohm. If motor seems to jam and it has not reached the end of its stroke, the following test could be performed. First remove motor, refer to VARIABLE TRIM SYSTEM 09-05. Then manually rotate worm to verify VTS system actuating mechanism for free operation. Connect motor through a 15 A fuse directly to the battery. Connect wires one way then reverse polarities to verify motor rotation in both ways. If VTS actuating mechanism is correct and the motor turns freely in both ways, VTS module could be defective. If VTS motor does not stop at the end of its stroke while installed, the motor could be defective.

24 1%

DOWN

NOTE: If the VTS control module passes this resistance test, it doesnt mean it is in perfect condition.

08-05-9

Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM)

DIGITALLY ENCODED SECURITY SYSTEM

GENERAL
The Digitally Encoded Security System (DESS) features an anti-start protection against unauthorized use of the watercraft. The following components are specially designed for this system: Multi-Purpose Electronic Module (MPEM), safety lanyard cap and safety lanyard switch. The safety lanyard cap has a magnet and a ROM chip. The chip has a unique digital code. The DESS circuitry in the watercraft MPEM is activated at the factory. Therefore, a safety lanyard must be programmed to start the engine. NOTE: Actually, it is the memory of the MPEM which is programmed to recognize the digital code of the safety lanyard cap. This is achieved with the MPEM programmer (P/N 529 034 500). Refer to its Guide to program a safety lanyard. The system is quite flexible. Up to eight safety lanyards may be programmed in the memory of the watercraft MPEM. They can also be erased. NOTE: If desired, a safety lanyard can be used on other watercraft equipped with the DESS. The memory of the MPEM is permanent. If the battery is disconnected, no information is lost. The memory of the MPEM has also two selfdiagnostic modes. When ordering a new MPEM from the regular parts channel, the DESS circuitry will be activated.

08-06-1

Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM)

Basic Self-Diagnostic Mode

It is self-activated when the safety lanyard cap is being installed on the watercraft switch. It gives immediate monitoring. Some codes may occur only when pressing the start/stop button. Refer to the following chart.
SIGNAL 2 short beeps (while installing safety lanyard on watercraft switch) 1 long beep (while installing safety lanyard on watercraft switch or when pressing start/stop button) CAUSE Safety lanyard is recognized by the MPEM. REMEDY Ignition is authorized, engine can start.

Safety lanyard on switch for more than 10 minutes without starting engine. Bad connection between safety lanyard cap and switch. Unprogrammed or defective safety lanyard.

Remove and reinstall safety lanyard on switch.

Remove and replace the safety lanyard on the switch until 2 short beeps are heard to indicate the system is ready to allow engine starting. Use the safety lanyard that has been programmed for the watercraft. If it does not work, check safety lanyard condition with the programmer. Replace safety lanyard if reported defective. If it still does not work, enable more detail about the failure. Clean safety lanyard cap to remove salt water. Enable advanced diagnostic mode to obtain more detail about the failure. Replace MPEM. Refer to TROUBLESHOOTING CHART 03-01.

Salt water in safety lanyard cap. Improper operation of MPEM or defective wiring harness. 8 short beeps Continuous beep Defective MPEM (memory). Engine overheating.

08-06-2

Section 08 ELECTRICAL SYSTEM Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM)

Advanced Self-Diagnostic Mode

It needs to be enabled manually. Proceed as follows: 1. Remove safety lanyard cap from watercraft switch. 2. Press 5 times on the watercraft start/stop button. NOTE: 1 short beep and 1 long beep must be heard. They validate beginning of diagnostic mode. 3. Install safety lanyard on watercraft switch. 4. Press the watercraft start/stop button again. NOTE: If everything is correct, engine will start. Otherwise, refer to the following chart.
SIGNAL No beep 1 long and 1 short beeps CAUSE Engine actually starts. No safety lanyard has ever been programmed in watercraft MPEM. REMEDY Everything is correct. Use programmer and program a safety lanyard. This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed. Check safety lanyard cap condition with the MPEM programmer. Replace safety lanyard if reported defective. Check switch wiring harness. Use the safety lanyard that has been programmed for the watercraft. If the problem is not resolved, check safety lanyard cap condition with the MPEM programmer. Replace safety lanyard if reported defective. Check wiring harness and safety lanyard switch.

2 short beeps

MPEM can not read the digital code of the safety lanyard cap or the magnet is defective. Mixed wires at safety lanyard switch connectors or bad connections.

2 long beeps

Wrong safety lanyard or bad connection of the DESS wires.

3 short beeps

Wiring harness of DESS switch is grounded or there is a short circuit.

If you need to listen again the coded beeps, remove safety lanyard and repeat the procedure to activate the diagnostic mode. If there is more than one problem, the MPEM will send only one error code. When the problem is solved, the MPEM will send a second code and so on until all problems are resolved.

08-06-3

Section 09 PROPULSION SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS

JET PUMP .............................................................................................................................. 09-02-1 GENERAL ........................................................................................................................... 09-02-2 JET PUMP INSPECTION ON WATERCRAFT .................................................................... 09-02-2 REMOVAL........................................................................................................................... 09-02-5 DISASSEMBLY................................................................................................................... 09-02-6 CLEANING ......................................................................................................................... 09-02-9 PARTS INSPECTION .......................................................................................................... 09-02-9 ASSEMBLY......................................................................................................................... 09-02-12 PUMP PRESSURIZATION ................................................................................................. 09-02-18 INSTALLATION .................................................................................................................. 09-02-19 DRIVE SYSTEM ..................................................................................................................... 09-03-1 GENERAL ........................................................................................................................... 09-03-5 REMOVAL........................................................................................................................... 09-03-5 DISASSEMBLY................................................................................................................... 09-03-9 INSPECTION ...................................................................................................................... 09-03-9 ASSEMBLY......................................................................................................................... 09-03-11 INSTALLATION .................................................................................................................. 09-03-12 LUBRICATION.................................................................................................................... 09-03-15 REVERSE SYSTEM................................................................................................................ 09-04-1 GENERAL ........................................................................................................................... 09-04-2 DISASSEMBLY................................................................................................................... 09-04-2 ASSEMBLY......................................................................................................................... 09-04-3 ADJUSTMENT ................................................................................................................... 09-04-5 DISASSEMBLY................................................................................................................... 09-04-8 INSPECTION ...................................................................................................................... 09-04-8 ASSEMBLY ........................................................................................................................ 09-04-9 ADJUSTMENT ................................................................................................................... 09-04-10 VARIABLE TRIM SYSTEM .................................................................................................... GENERAL ........................................................................................................................... REMOVAL........................................................................................................................... DISASSEMBLY................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY......................................................................................................................... INSTALLATION .................................................................................................................. ADJUSTMENT ................................................................................................................... 09-05-1 09-05-3 09-05-3 09-05-3 09-05-3 09-05-4 09-05-4 09-05-5

09-01-1

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

JET PUMP
SPX/GTS
28

0
All models except GS, GTS and GTI

15

20 21 Loctite 518 Synthetic grease

17

Right Stuff 29

16

SPX/ GSX Limited/ XP Limited/ GTX Limited

17

Right Stuff

10 Loctite 518

22 23

29 9 Loctite 518 Loctite 242 8 23 25 26 6 Loctite 271 24 27 18 Loctite PST Synthetic oil 11 14 13 12 Loctite 242 3 5 1 20 Nm (15 lbfft) 19 3

GS/GTS/GTI 20 Nm 1 (15 lbfft) Loctite 242

4 2

2 4 Loctite 242

F00J05T

PARTS

FLAT RATE

09-02-1

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

GENERAL
The jet pump housing and venturi are made of plastic. On the GS, GTS and GTI models, the jet pump housing is a one piece plastic unit, including the stator. On other models, the jet pump housing has a stator made of bronze which offers greater strength. The nozzle is made of plastic on the GS, GTS and GTI models, and of aluminum on the other models.

WATERCRAFT MODEL SPX

IMPELLER P/N 271 000 828

MATERIAL Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel

PITCH Progressive pitch 16-23 Progressive pitch 11-22 Progressive pitch 16-25 Progressive pitch 16-25 Progressive pitch 11-22 Progressive pitch 11-22 Progressive pitch 14-21

GS

271 000 821

GSX Limited

271 000 810

Impeller Identification
To identify the impellers refer to the following illustration and chart.

XP Limited

271 000 818

GTS

271 000 826

GTI

271 000 885

GTX Limited

271 000 786

JET PUMP INSPECTION ON WATERCRAFT

F02J0VA

1. Stamped part number

To work on watercraft, securely install it on a stand. Thus, if access is needed to water inlet area, it will be easy to slide underneath watercraft. A lift kit (P/N 295 100 044) can be used to install watercraft on a stand.

F01J42A

TYPICAL 1. Lift kit 2. Work stand

09-02-2

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Impeller Condition
Condition of impeller no. 20, boot no. 15 and ring no. 16 can be quickly checked from underneath of the watercraft. Remove grate and look through water inlet opening.

F01J0EA

TYPICAL MEASURING FROM WATER INLET SIDE 1. Feeler gauge

F01J0DA

TYPICAL 1. Inspect impeller and boot

Impeller/Wear Ring Clearance

This clearance is critical for jet pump performance. Clearance can be checked from water inlet opening or from venturi side. However, the last method requires more work. To check clearance from water inlet side, remove inlet grate. To check clearance from venturi side, remove venturi/nozzle assembly as described in Oil Inspection in this subsection. Using a feeler gauge with 30 cm (12 in) blades, measure clearance between impeller blade tip and wear ring. Measure each blade at its center. Clearance should not exceed 1.0 mm (.040 in). If clearance is greater, disassemble jet pump and inspect impeller and wear ring. Renew worn parts.

F01J0FA

TYPICAL MEASURING FROM VENTURI SIDE 1. Feeler gauge

Oil Inspection
Detach ball joint of steering cable from nozzle.

SPX, GSX Limited and XP Limited Detach ball joint of VTS link rod. GTS, GTI and GTX Limited Detach ball joint of reverse cable and springs from reverse gate (GTS model only).

09-02-3

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

All Models Remove 4 screws retaining venturi to jet pump housing. GTI and GTX Limited Remove reverse gate and support. All Models Pull nozzle and venturi from jet pump housing. NOTE: On the GTS model, the venturi and reverse gate are removed as an assembly. Remove plug from cover.

Oil Replacement
Remove venturi as described in Oil Inspection. Remove 3 screws retaining cover.

F02J0TB

1. Screws

F01J5IA

TYPICAL 1. Remove plug

Check oil level, it should be at bottom of hole threads. If oil level is low, check impeller shaft housing for leaks. A pressure test must be performed. See PUMP PRESSURIZATION in this subsection. To check oil condition, insert a wire through oil level hole then withdraw. A whitish oil indicates water contamination. This may involve defective impeller shaft seal and/or O-ring of housing cover. Jet pump unit should be overhauled to replace seal. If everything is correct, apply Loctite PST 592 on plug and reinstall it on cover. Properly reinstall removed parts.

Using a fiber hammer, gently tap cover to release it from housing cover. Thoroughly clean reservoir and inside of cover with a solvent. Check O-ring condition. Replace as necessary. Apply a thin layer of Loctite 518 on mating surface of cover and reinstall it with its O-ring. Torque screws to 4 Nm (35 lbfin). Remove plug from cover. Pour oil through hole until oil reaches the bottom of hole threads. Use SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011) only. Oil will drain slowly into center area of housing, wait a few minutes and readjust oil level.

CAUTION

This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. Apply Loctite PST 592 on plug and reinstall it on cover. Properly reinstall removed parts.

09-02-4

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

REMOVAL
5, Nozzle
Disconnect steering cable from jet pump nozzle.

11, Venturi
Remove nozzle no. 5 prior removing venturi. Remove 4 retaining screws and withdraw venturi.
1

GS, GTS, GTI and GTX Limited Remove 2 retaining screws no. 1, 2 sleeves no. 2, 4 locking disks no. 4.
3 2

F02J0TA

1. Remove screws

9, Jet Pump Housing

F01J3BE

TYPICAL 1. Screw 2. Locking disks 3. Sleeve

Remove nozzle.

SPX and GTS Models Remove air vent tube support from body opening (SPX model). Disconnect engine water supply hose and both bailer pick-up tubes in bilge.
1

SPX, GSX Limited and XP Limited Disconnect ball joint of VTS link rod. Loosen 2 screws each side of trim ring.

F01J0IA

TYPICAL 1. Bailer pick-up tubes 2. Engine water supply hose

F01J5FA

1. Screws

SPX, GSX Limited and XP Limited Detach ball joint of VTS link rod.

Remove nozzle.
09-02-5

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

GTS, GTI and GTX Limited Detach ball joint of reverse cable and springs (GTS model) from reverse gate. All Models except GTS Disconnect steering cable from jet pump nozzle. Loosen 4 hexagonal nuts no. 6 and remove flat washers and lock washers from jet pump housing. Remove jet pump with a wiggle movement. GTS Model Disconnect steering cable from jet pump nozzle. Remove nozzle. Loosen 4 hexagonal nuts no. 6 and remove flat washers and lock washers from jet pump housing. Using screws previously removed from nozzle, install jet pump housing remover tool (P/N 295 000 113) on venturi.

DISASSEMBLY
NOTE: Whenever removing a part, visually check for damage such as: corrosion, crack, split, break, porosity, cavitation, deformation, distortion, heating discoloration, wear pattern, missing plating, missing or broken needles in needle bearing, water damage diagnosed by black-colored spots on metal parts, etc. Renew any damaged part. As a quick check, manually feel clearance and end play, where applicable, to detect excessive wear.

SPX and GTS Models

17, Fitting
Fittings can be removed with deep socket or vise grip. Do not contact hose mounting area. Fittings can be removed from pump housing with the following suggested tool: Use a 14 mm (9/16 in) deep socket. Drill deep socket with a 14 mm (9/16 in) drill bit, starting at hexagon head end as shown in following illustration. Drill a 2.40 mm (3/32 in) hole in center of deep socket as shown in following illustration. Install 2.40 mm (3/32 in) roll pin in the center hole.

A 1

F01J5JA

TYPICAL

Rotate handle clockwise to remove jet pump.

B 2

All Models

CAUTION

F01J2RA

When removing pump unit, a shim could have been installed between hull and pump housing. Be sure to reinstall it otherwise engine and jet pump alignment will be altered. NOTE: After jet pump removal, if drive shaft remains in the PTO flywheel (except XP Limited), simply pull it out. If drive shaft is seized in the PTO flywheel, refer to DRIVE SYSTEM 09-03.
09-02-6

1. 2. A. B.

Deep socket 14 mm (9/16 in) Roll pin 2.40 mm (3/32 in) 42.50 mm (1-43/64 in) 36.80 mm (1-29/64 in)

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

All Models

18, Cover
With pump assembly in horizontal position, remove 3 retaining screws no. 19. Place container under cover to catch oil. Using a fiber hammer, gently tap cover to release it from jet pump housing.
1

20, Impeller
Insert impeller shaft holder (P/N 295 000 082) on impeller shaft flat end. Using 2 screws previously removed from venturi, secure shaft holder to housing.
F00J0HA

1. Shaft holder

Impeller is loosened using impeller remover tool (P/N 295 000 001).

F01J0TA

F00J07A

Insert special tool in impeller splines.

1

1. Shaft holder

Heat impeller center with a propane torch to approximately 150C (300F) to break the Loctite bond. Install shaft holder in a vice.

F00J08A

1. Impeller remover tool

09-02-7

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Rotate impeller remover tool counterclockwise and unscrew completely impeller.

CAUTION
1

Never use any impact wrench to loosen impeller. To remove impeller, apply a rotating movement and pull at same time. Slide impeller out of housing. Remove tool from impeller.

21, Wear Ring

Place jet pump housing in a vise with soft jaws. It is best to clamp housing using a lower ear. Cut wear ring at two places. NOTE: Wear ring can be cut using a jigsaw, a small grinder or a low clearance hacksaw such as Snapon HS3 or equivalent.
F01J0WA

TYPICAL 1. Snap-on HS3

CAUTION

After cutting ring, insert a screwdriver blade between jet pump housing and ring outside diameter. Push ring so that it can collapse internally. Pull ring out.

When cutting ring, be careful not to damage jet pump housing.

24, Impeller Shaft

Remove shaft holder tool. Remove impeller shaft with thrust washer and thrust bearing.

22,23, Seal and Needle Bearing

Remove seal and bearings at the same time using bearing/seal remover tool (P/N 295 000 144).

F01J0VA

TYPICAL

F01J11A

Insert bearing remover then press tool using a arbor press until seal and bearings are out. However, care should be taken not to damage bearing journals.

09-02-8

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Brush and clean impeller shaft threads, impeller and drive shaft splines with Loctite Safety solvent 755 (P/N 293 800 019) or equivalent. Free threads and splines from any residue.

CAUTION

Be careful not to damage impeller shaft diameter.

PARTS INSPECTION
20, Impeller
Visually inspect impeller splines. Check for wear or deformation. Renew parts if damaged. NOTE: Check also PTO flywheel and drive shaft condition. Refer to BOTTOM END 04-06 and DRIVE SYSTEM 09-03. Examine impeller in wear ring for distortion. Check if blade tips are blunted round, chipped or broken. Such impeller is unbalanced and will vibrate and damage wear ring, impeller shaft, shaft seal or bearings. Renew if damaged.
1

F00J0MA

1. Bearing/seal remover tool

NOTE: It is always recommended to renew both bearings, even if only one bearing needs to be replaced.

CLEANING
Sealant can be removed with a wire brush (disc) mounted on a drill or a scraper. Properly clean all threads. Remove all O-rings and clean parts in a solvent. Carefully check water passages and oil passages. Blow low pressure compressed air through them and make sure they are clear.

1
F02J0VB

1. Replaced if blunted round or damaged

Check impeller for cavitation damage, deep scratches or any other damage.

F01J13A

TYPICAL 1. Water passages 2. Oil passages

09-02-9

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

F02J0UA

F01J18A

1. Check for cavitation, deep scratches or other damage

21, Wear Ring

Check wear ring for deep scratches, irregular surface or any apparent damage. If impeller/wear ring clearance is too large and impeller is in good shape, renew wear ring.

TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to threads at shaft end

To check both bearings, proceed the same way with other shaft end. Position gauge tip on diameter, close to flats on shaft.
1

22,24, Needle Bearing and Impeller Shaft

WEAR Inspect needle bearings and their contact surface. Check for scoring, pitting, chipping or other evidence of wear. With your finger nail, feel contact surface of seal. If any irregular surface is found, renew impeller shaft. Install bearings, then install impeller shaft and rotate it. Make sure it turns smoothly. RADIAL PLAY Radial play is critical for jet pump unit life span. Radial play of impeller shaft is checked with shaft in housing, without impeller. Retain housing in a soft jaw vise making sure not to damage housing lug. Set a dial gauge and position its tip onto shaft end, close to end of threads. Move shaft end up and down. Difference between highest and lowest dial gauge reading is radial play. Maximum permissible radial play is 0.05 mm (.002 in).

F01J19A

TYPICAL MEASURING IMPELLER SHAFT RADIAL PLAY 1. Dial gauge 2. Measure close to flats at shaft end

Excessive play can come either from worn bearings or impeller shaft or damaged jet pump housing bearing surfaces. Measuring shaft diameter will determine the defective parts. Using a micrometer, measure diameter on bearing contact surfaces. Minimum shaft diameter should be 22.24 mm (.876 in).

09-02-10

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

18,24, Cover and Impeller Shaft

1

END PLAY End play of impeller shaft is checked with shaft in housing, without impeller and with cover installed. Retain housing in a soft jaw vise making sure not to damage housing lug. Set a dial gauge and position its tip on the end of shaft. Move shaft end by pulling and pushing. Difference between highest and lowest dial gauge reading is end play. Maximum permissible end play (new) is 0.12 - 0.54 mm (.005 .021 in). Make sure vise is secured and not adding to your measurement as you move impeller shaft.

F01J1AA

1. Inspect for wear at the bearing pilot 2. Radial bearing raceway

NOTE: If shaft is to be replaced, it is recommended to replace both bearings at the same time. In addition, it is suggested to replace thrust bearing and thrust washer.

25,26, Thrust Washer and Thrust Bearing

Visually inspect thrust washer, thrust bearing and their contact surface. Check for scoring, pitting, flaking, discoloration or other evidence of wear. For best inspection, use a 7X magnifying glass to check wear pattern.
1 2 3

F01J2SA

1. Tip on shaft end

Excessive play comes from a worn anti-knock pusher inside cover and wear of impeller shaft nose. Using pliers, remove anti-knock pusher and spring from cover.

F01J52A

TYPICAL 1. Worn roller (trunnion worn on end roller) 2. Good roller (cylindrical shape) 3. Look for scoring on retainer

F00J09A

NOTE: When replacing either washer or bearing, it is recommended to renew both.

TYPICAL 1. Pusher

Inspect pusher for any damage or deterioration.

09-02-11

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Refer to the following illustration to determine the wear limit of the pusher.

ASSEMBLY
21, Wear Ring
The wear ring features a lip on one edge; position lip outwards of housing. NOTE: To ease insertion into housing, apply BOMBARDIER LUBE lubricant (P/N 293 600 016) onto outside circumference of wear ring. To install ring in housing, use a square steel plate of approximately 180 180 mm 6 mm thick (7 7 in 1/4 in) and a press. Manually engage ring in housing making sure it is equally inserted all around. Press ring until it seats into bottom of housing.

F00J0QA

A. Wear limit 8.0 mm (.315 in)

Pusher should be replaced if it is not within specification. Be sure to check end play after installing a new pusher (if necessary). Inspect impeller shaft nose for wear.
1

2
F01J5DA

1. Seal lip 2. Press wear ring

F00J0AA

1. Impeller shaft nose

22, Seal
Carefully inspect seal lips. Make sure that lips are not worn, distorted, cracked or show signs of any other damage. Renew as necessary.

If a press is not readily available, a piece of wood such as a 2 4 in 12 in long, can be used. Manually engage ring in housing making sure it is equally inserted all around. Place wood piece over ring. Using a hammer, strike on wood to push ring. Strike one side then rotate wood piece about 90 and strike again. Frequently rotate wood piece so that ring slides in evenly until it seats into bottom of housing.

09-02-12

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

2 1
F01J1HA

1. Stamped end this side

F01J5EA

1. Piece of wood 2. Seal lip facing upward 3. Wear ring

CAUTION

Never hammer the bearing into its housing.

22,23, Seal and Needle Bearing

Bearings and seal will be properly installed in housing using bearing/seal installer tool (P/N 295 000 107).
1

F01J4KA

BEARING/SEAL INSTALLER TOOL 1. Seal side 2. Bearing side

Stamped end of bearings (showing identification markings) must be located toward outside of housing. Properly insert bearing on tool. Using an arbor press only, push tool until tool flange contacts housing. Proceed the same way for both bearings.

F00J0BA

1. Press on tool until it stops

CAUTION

This tool have been designed to properly position bearings and seal, thus providing space for lubrication purposes. The tool flanges allow this. If a different pusher type is being used, components must be properly positioned as follows.

09-02-13

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Bearing on impeller side must be 1.5 to 2.5 mm (.060 - .100 in) inside reservoir measured from seal seat. Bearing on venturi side must be 2 to 3 mm (.080 - .120 in) inside reservoir measured from thrust washer seat. Refer to following illustration.

CAUTION

Prevent sealant from contacting any needles of bearing. Push on tool end with a press until tool flange contacts housing.

A 1 2

B 3 4

F01J1JA

1. 2. 3. 4. A. B.

Seal seat Stamped end of bearing Thrust washer seat Stamped end of bearing 1.5 - 2.5 mm (.060 - .100 in) 2 - 3 mm (.080 - .120 in)

F00J0CA

1. Press on tool until it stops

Apply synthetic grease (P/N 293 550 010) between seal lips.
1

Seal must be installed so that lips raised edges are toward outside of housing (toward impeller). Apply Loctite 518 (P/N 293 800 038) to seal housing, all around outer diameter and on seal seat. Properly insert seal on tool. NOTE: It is important when installing seals to pack seal lip with grease before inserting bearing/seal installer tool. Properly insert tool in seal with a rotating movement.
2

F01J1MA

1. Loctite 518 all around and behind 2. Raised edge of seal lip this side

1
F01J1KA

1. Raised edge of seal this side

09-02-14

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

25, Thrust Washer

Position jet pump housing no. 9 with the stator vanes on top. Insert thrust washer no. 25 in the stator seat.

24, Impeller Shaft

To prevent seal lip damage when inserting impeller shaft, use impeller shaft guide (P/N 295 000 002).

F01J1OA

Insert tool onto shaft end then carefully install shaft in jet pump housing.

F00J0DA

1. Thrust washer properly installed in stator seat

26, Thrust Bearing

Apply Sea-Doo jet pump synthetic oil (P/N 293 600 011) on both sides of thrust bearing. Position thrust bearing no. 26 on thrust washer no. 25.

F00J0FA

1. Impeller shaft 2. Impeller shaft guide

NOTE: If jet pump housing rest against a table, raise it slightly to allow complete shaft insertion with the shaft guide. Remove shaft guide.

20, Impeller
F00J0EA

1. Thrust bearing on top of thrust washer

Apply Loctite primer N (P/N 293 600 012) on threads of impeller shaft no. 24. Allow to dry for 2 minutes. NOTE: Loctite primer is used to reduce Loctite 271 curing time and to activate stainless steel and aluminum surfaces for better bonding action. If applied, complete curing time is 6 hours, if primer is not used, allow 24 hours for curing time.

09-02-15

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Apply Loctite 271 (red) to shaft threads.

F00J08A

1. Impeller remover/installer tool

F00J0GA

1. Apply Loctite 271 (red) on threads

CAUTION

Using 2 screws previously removed from venturi, secure impeller shaft holder tool to housing. Install shaft holder tool in a vice.

Make sure thrust washer and bearing are not wedged in shaft groove. To check, manually pull and push jet pump housing, some axial play must be felt. Torque impeller to 70 Nm (52 lbfft) then remove tools.

CAUTION

Never use any impact wrench to tighten impeller. Apply synthetic grease (P/N 293 550 010) on impeller splines. Insert a new boot no. 15 and ring no. 16 to impeller.

F00J0HA

1. Impeller shaft holder secured in a vice

To ease impeller installation, apply BOMBARDIER LUBE lubricant on wear ring. Insert impeller into wear ring. Manually rotate impeller and push so that it slides on impeller shaft threads. Carefully engage threads making sure they are well aligned. Install impeller remover/installer tool into impeller splines and tighten.
F00J0IA

1. Boot and ring

09-02-16

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

18, Cover
Install O-ring no. 27 to cover. Apply Loctite 518 on O-ring. Make sure spring and anti-knock pusher are in place.
3

Place housing horizontally as in its operating position so that filler plug is located on top. Remove filler plug from cover. Pour SEA-DOO JET PUMP SYNTHETIC OIL (P/N 293 600 011) in reservoir until oil comes level with bottom of hole. Let oil drain into housing and after a few minutes add more oil until it is level with bottom of filler hole.

CAUTION

This is a synthetic oil. Do not mix with mineral based oil. Do not mix oil brands. NOTE: When filling reservoir, oil must be poured into cover quite slowly to allow complete housing fill.

F00J0PA

1. Spring 2. Pusher 3. O-ring with Loctite 518

Install cover to jet pump housing making sure to properly position filler plug on top side.

F00J0JA

TYPICAL 1. Pour oil slowly until it is level with bottom of filler hole

11, Venturi
If needed, install new O-rings no. 10 around bailer passages.

F01J5IA

1. Filler plug toward top side of pump housing

Apply Loctite 242 (blue) on screw threads and evenly tighten cover screws. Torque to 4 Nm (35 lbfin). Oil Fill NOTE: It is highly recommended to perform a leakage test prior adding the oil. See PUMP PRESSURIZATION in this subsection.
F00J0KA

1. O-rings
09-02-17

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

Apply Loctite 518 (Gasket Eliminator) on mating surface. Position venturi with bailer passages on top. Apply Loctite 242 (blue) on threads of screws no. 12. NOTE: On the GTI and GTX models, install the reverse support with the venturi. Install screws no. 12, lock washers no. 13 and flat washers no. 14 then torque to 21 Nm (16 lbfft).
1

Proceed as follows: Remove drain plug from cover. Apply Loctite PST 592 on threads of fitting tool (P/N 295 000 086) then secure on cover. Connect pump gauge tester (P/N 295 000 085) to fitting. Pressurize pump to a maximum of 70 kPa (10 PSI).

F00J0LA

F02J0TA

Pump must maintain this pressure for at least 10 minutes.

1. Torque screws to 21 Nm (16 lbfft)

17, Fitting
SPX and GTS Models Apply Loctite PST 592 on plastic fitting threads. Then thread fitting into pump housing until threads are bottomed.

CAUTION

Repair any leak, failure to correct a leak will lead to premature wear of pump components. NOTE: If there is a pressure drop spray soapy water around cover. If there are no bubbles, impeller shaft, impeller shaft seal, or jet pump housing is leaking through porosity and has to be replaced. Jet pump unit has to be disassembled. If jet pump has been overhauled, the impeller shaft seal no. 22 may be leaking; Add a small quantity of Sea-Doo jet pump synthetic oil to wet the oil seal. Let soak and recheck. Disconnect pump gauge tester and remove fitting. Check oil level. Refill as necessary. Apply Loctite PST 592 to threads of filler plug then secure it in cover.

29, O-Rings
GS, GSX Limited, XP Limited, GTI, and GTX Limited Install O-rings no. 29 around bailer passages or make sure they are in place if they were not removed.

PUMP PRESSURIZATION
Whenever doing any type of repair on jet pump, a pressure test should be done to check for leakage.

09-02-18

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

INSTALLATION
28, Neoprene Seal
SPX, GSX Limited, XP Limited and GTX Limited If neoprene seal is damaged, replace it with a new one.

GTS Model Apply Loctite Right Stuff around bailer and water supply fittings as well as around wear ring lip.
1

F01J21B

1. Apply Loctite Right Stuff where indicated

F01J50A

TYPICAL 1. Neoprene seal

9, Jet Pump Housing

SPX Models Apply Loctite Right Stuff around bailer and water supply fittings.
1

All Models Generously apply synthetic grease on drive shaft splines. Make sure rubber damper is on drive shaft end. Install jet pump. If necessary, wiggle jet pump to engage drive shaft splines in impeller.

CAUTION

Some watercraft require a shim between hull and pump; if shim has been removed at pump removal, be sure to reinstall it, otherwise engine alignment will be altered. Apply Loctite 242 (blue) on stud threads of jet pump housing. Install flat washers no. 8, lock washers no. 7 and nuts no. 6. Tighten nuts of jet pump housing in a criss-cross sequence and torque to 33 Nm (24 lbfft). NOTE: Slightly lubricate wear ring with BOMBARDIER LUBE lubricant to minimize friction during initial start.

F01J21A

1. Apply Loctite Right Stuff where indicated

09-02-19

Section 09 PROPULSION SYSTEM Subsection 02 (JET PUMP)

SPX and GTS Models Secure water supply hose and both bailer tubes to jet pump housing using tie raps.
1

WARNING

Whenever removing screw always renew locking disks. Screw must be torqued as specified.

SPX, GSX Limited, and XP Limited Install nozzle/trim ring assembly. Torque screws to 14 Nm (10 lbfft). NOTE: Trim ring has a tight fit; to install, insert both sides at the same time, taking care not to break plastic bushings. Carefully use a plastic tip hammer if necessary. Make sure steering arm of jet pump is on right side and trim arm is above venturi.

F01J0IA

1. Bailer tubes 2. Water supply hose

Reinstall air vent tube support onto body (SPX model).

5, Nozzle
GS, GTS, GTI and GTX Limited Insert bushings no. 3 in nozzle no. 5, positioning their flanges from inside of nozzle. Insert sleeves no. 2 in bushings no. 3. Install nozzle no. 5 on venturi no. 11; position its steering arm on RH side. Apply Loctite 242 (blue) on screw threads (or use new screws with preapplied threadlocker). Install screws no. 1 and locking disks no. 4 then torque to 20 Nm (15 lbfft).
1

F01J5FA

1. Torque screws to 14 Nm (10 lbfft)

Steering Cable
Refer to section 10, STEERING SYSTEM.

Trim System
Refer to VARIABLE TRIM SYSTEM 09-05.

Reverse Cable
2

Refer to REVERSE SYSTEM 09-04.

1
F01J3BA

TYPICAL 1. Locking disks 2. Torque screws to 20 Nm (15 lbfft)

09-02-20

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

DRIVE SYSTEM
SPX Model

2 3

1 4 5 6 7 2 Nm (18 lbfin) 8 9 2 Nm (18 lbfin) 11

10

13 Synthetic grease 12

Synthetic grease 13

F01I0KS

PARTS

FLAT RATE

09-03-1

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

GS, GTS and GTI Models

Loctite 271

2 3 4 5 6 7 8 2 Nm (18 lbfin) 9 10

13

Synthetic grease

2 Nm (18 lbfin) 11

12

Synthetic grease 13

F02I05S

09-03-2

PARTS

FLAT RATE

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

GSX Limited and GTX Limited

2 3 4 15 Synthetic grease 16

14

Loctite 518 17 15

13 Synthetic grease

Loctite 518 Synthetic grease Loctite 518 12

2 Nm (18 lbfin) 2 Nm (18 lbfin) 11

10

Synthetic grease 13

F06I05S

PARTS

FLAT RATE

09-03-3

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

XP Limited
1

22 Nm (16 lbfft)

24 23

Synthetic grease

20 18 24 23 19

22 Nm (16 lbfft) Loctite 242

22 Nm (16 lbfft)

Synthetic grease 14

22

Loctite 15 518 16 17 15 Loctite 518 Synthetic grease Loctite 518

Loctite 518 Synthetic grease Loctite 518

Loctite 271 14 10 2 Nm (18 lbfin) 11 10 Nm (88 lbfin)

21 15 17 16 15

9 2 Nm (18 lbfin)

Synthetic grease 12

Loctite Right Stuff

Synthetic grease 13

31 Nm (23 lbfft)

Loctite 518
F08I02S

31 Nm (23 lbfft)

09-03-4

PARTS

FLAT RATE

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

GENERAL
Jet pump must be removed to replace any components of the drive system. Refer to JET PUMP 09-02 for removal procedure.

Insert pointed tips of pliers in closing hooks.

REMOVAL
1, PTO Flywheel Guard
SPX, GS and GSX Limited Remove seat (s). Remove vent tube support. Remove PTO flywheel guard. GTS, GTI and GTX Limited Remove seat(s). Remove seat support (except GTS model). Remove PTO flywheel guard. XP Limited Open engine cover. Remove storage basket. Remove vent tubes from PTO flywheel guard. Remove PTO flywheel guard.

F01J2AA

TYPICAL 1. Closing hooks

Squeeze pliers to draw hooks together and disengage windows from locking hooks.

2, Large Clamp
Unfasten large clamp of PTO flywheel boot no. 3 as follows: Use pliers (P/N 295 000 069).

1
F01J29A

F01J0GA

TYPICAL 1. Locking hooks

4, Small Clamp
Unfasten small clamp of PTO flywheel boot as follows: Use pliers (P/N 295 000 054).

09-03-5

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

All Models Except the XP Limited

12, Drive Shaft

Simply pull out drive shaft. NOTE: If the drive shaft is jammed into PTO flywheel, make the following tool and use it in conjunction with the jet pump housing remover (P/N 295 000 113) to withdraw drive shaft.
F01B1TA

To open clamp, place flat side of plier on clamp embossment, squeeze and twist plier.

Raw Material: 1 aluminum alloy square of 51 mm (2 in) 305 mm (12 in). 2 aluminum rods of 28.5 mm (1-1/8 in) dia. 30 mm (1-3/16 in).
2 1

I A B D E C

3
F02J0PA

H 4 F F 5 6

SPX, GS, GTS and GTI Models

5,6, Circlip and Floating Ring

Hold floating ring no. 6 and compress boot no. 10; then, pull out circlip no. 5 from drive shaft groove.
1 2

F01I05A

1. Use ball end mill for radius. This section of the slot should be 38 mm (1-15/32 in) deep 2. Drill 25 mm (1 in) hole in center to remove material 3. Weld all around 4. Drill 9 mm (11/32 in) hole 5. Drill through 9 mm (11/32 in) 6. Drill and tap 6 mm (1/4 in) holes A. 305 mm (12 in) B. 105 mm (4-1/8 in) C. 16 mm (5/8 in) D. 51 mm (2 in) E. 36 mm (1-25/64 in) F. 22 mm (7/8 in) G. 17 mm (43/64) H. 19 mm (3/4 in) I. 35 mm (1-3/8 in) J. 20.3 mm .18 (.800 in .007)

Mount on drive shaft puller the jet pump housing remover; then, install assembly on drive shaft using screws.

F06I06A

1. Push floating ring 2. Remove circlip

09-03-6

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

F01I06A

3
F08I04A

TYPICAL 1. Jet pump housing remover 2. Drive shaft puller 3. Screws

1. Pull drive shaft to disengage coupler from splines

XP Limited

CAUTION

Remove rear drive shaft. Remove coupler no. 19.

Be careful not to damage hull rear section or engine rubber mounts.

20, Front Drive Shaft

Remove PTO flywheel guard no. 1. Remove bolts, lock nuts and sleeves from support.

12, Rear Drive Shaft

Remove rear access panel. Remove protective plate no. 18.

F08I04B

1. Remove bolts, lock nuts and sleeves

F08I03A

Loosen bolts and lock nuts retaining the lower support of the shock absorber.

1. Remove protective plate

Pull rear drive shaft until coupler no. 19 is disengage from splines.

09-03-7

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

F08Q01A

F08L12A

1. Remove bolts and lock nuts

1. Loosen gear clamp

Loosen 4 screws and remove bottom cover of seat.

Tilt seat. Remove front drive shaft.

14, Seal Carrier of Mid Bearing

To remove the seal carrier from support, loosen the 6 nuts no. 21.
1

F08L11A

1. Remove cover

Loosen gear clamp retaining the outer boot of the shock absorber.
F05I05A

1. Nut (6)

SPX, GS, GTS and GTI Models

10, Boot
Loosen gear clamp no. 11 holding boot, then carefully pull boot and carbon ring no. 8 from hull insert.

8, Carbon Ring
Loosen gear clamp no. 9 then pull carbon ring from boot no. 10.

09-03-8

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

GSX Limited, XP Limited and GTX Limited

10, Boot
Loosen gear clamp no. 11 holding boot, then pull boot with seal carrier.

14, Seal Carrier of Thru Hull Fitting

Loosen gear clamp no. 9 and remove seal carrier from boot no. 10.
1 2
F01I0FA

DISASSEMBLY
GSX Limited, XP Limited and GTX Limited

14, Seal Carrier

Bearing no. 16 and seals no. 15 can be easily removed using the bearing/seal remover tool (P/N 295 000 144).

1. Surface condition 2. Groove condition 3. Splines condition

F01J11A

Excessive deflection could cause vibration and damage to drive shaft splines, impeller, flywheel or floating ring (seal carrier depending upon the model). Place drive shaft on V-blocks and set-up a dial gauge in center of shaft. Slowly rotate shaft; difference between highest and lowest dial gauge reading is deflection. Refer to the following illustration. Maximum permissible deflection is 0.5 mm (.020 in).

NOTE: The same tool is used for bearing and seal removal of jet pump. Properly support seal carrier housing no. 17 when removing seals and bearing.

INSPECTION
12, Drive Shaft
Inspect condition of drive shaft and PTO flywheel splines. Inspect condition of groove. With your finger nail, feel machined surface of drive shaft. If any irregular surface is found, renew drive shaft.
1

F01J15A

MEASURING DRIVE SHAFT DEFLECTION 1. Dial gauge 2. V-blocks

13, Damper
Visually inspect shape of dampers for deformation or other damage.

09-03-9

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

SPX, GS, GTS and GTI Models

6,7, Floating Ring and O-ring

Inspect condition of O-rings and floating ring contact surface.
1

F06I06A

1. Push floating ring 2. Remove circlip

F01I0GA

1. O-rings 2. Floating ring contact surface

10, Boot
To verify the preload of the boot, proceed as follows: Measure installed length of boot.

Slide floating ring far enough forward in order to release it from carbon ring. Measure boot free length. Subtract the installed length measurement from the free length measurement. A difference of 4 mm to 12 mm (5/32 in to 15/32 in) should be obtained. If the length is less than 4 mm (5/32 in), install a spacer (P/N 293 250 017) between boot and thru hull fitting.
1

1
F00J03A

F00J04B

1. Boot A. Measure here

1. Spacer

Push floating ring to compress boot; then, remove circlip out of drive shaft groove.

NOTE: Drive shaft must be removed to install spacer.

GSX Limited, XP Limited and GTX Limited

16, Needle Bearing

Inspect seal carrier needle bearing. Check parts for scoring, pitting, chipping or other evidence of wear.
09-03-10

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

ASSEMBLY
GSX Limited, XP Limited and GTX Limited

14, Seal Carrier

Properly support seal carrier housing no. 17 when installing seals and bearing.

Install double-lip seal no. 15 with protector toward jet pump. On both seals no. 15, raised edge of lip must be located outwards of seal carrier.

CAUTION

2 1

Ensure to install stamped end of bearing (showing identification markings) first on tool. Never hammer the bearing into its housing. Install bearing no. 16 with the bearing/seal installer tool (P/N 295 000 107).
3 3 4

F01J2FA

1. 2. 3. 4.

Double-lip seal toward engine Double-lip seal with protector toward jet pump Raised edge of lip outwards Seal carrier

F01J51A

Apply Loctite 518 all around seals outside diameter. Seals no. 15 can be carefully installed in housing using bearing/seal installer tool (P/N 295 000 107). Push seals until tool comes in contact with housing.

1. Press bearing in its housing

NOTE: Bearing can also be installed with the same driver used at disassembly. Center bearing in longitudinal axis of housing.
1

F01J1YA

TYPICAL
F01J2TA

1. Push bearing centered in its housing

Pack seals and bearing with synthetic grease (P/N 293 550 010).
09-03-11

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

INSTALLATION
Installation is essentially the reverse of removal procedure. However, pay particular attention to the following.

PTO flywheel adapter (P/N 295 000 157).

XP Limited

14, Seal Carrier of Mid Bearing

Properly index flanges no. 22 together. Install seal carrier and hand tighten nuts no. 21. NOTE: Apply Loctite 242 (blue) on studs. Align the seal carrier using the following tools: Support plate kit (P/N 529 035 506). NOTE: Use plate (P/N 529 035 507) for the 155.6 mm (6-1/8 in) jet pump.
F00B05A

1. PTO flywheel adapter

Install support plate at rear of watercraft. Install adapter on shaft. Carefully slide shaft through support plate and seal carrier. Insert adapter end into PTO flywheel.

F05I08A

1
F00B0FA

TYPICAL 1. Alignment tool 2. Seal carrier

1. Plate (P/N 529 035 507) 2. Support (P/N 529 035 511)

Alignment shaft (P/N 295 000 141).

Torque seal carrier nuts no. 21 in a criss-cross sequence in 2 steps as per following illustration. NOTE: It is very important to tighten nuts of seal carrier in a criss-cross sequence to maintain its alignment.

1
F00B0GA

1. Alignment shaft

09-03-12

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

3, Drive Shaft
Install drive shaft and jet pump at the same time.

SPX, GS, GTS and GTI Models Insert drive shaft through carbon ring no. 8 and floating ring no. 6. NOTE: Make sure to install floating ring before inserting the drive shaft in the PTO flywheel. GSX Limited and GTX Limited Insert drive shaft through seal carrier no. 14 being careful not to damage seals.

F05I0EA

CAUTION

Step 1: Torque to 3 Nm (26 lbfin) as per sequence Step 2: Torque to 10 Nm (88 lbfin) as per sequence

23,24, Damper and Bushing

Make sure to install dampers and bushing.

When sliding the drive shaft through seal carrier, the double lip seal can be folded over. This would cause a seal carrier bearing failure.

All Models Except the XP Limited While holding jet pump, guide and engage drive shaft splines in PTO flywheel. Rotate shaft to properly index splines. Make sure boot is well positioned over shaft end. XP Limited

12, Rear Drive Shaft

Insert drive shaft through seal carrier no. 14 being careful not to damage seals. Engage drive shaft splines in coupler no. 20. Rotate shaft to properly index splines.

F05I0FA

ENGINE SIDE SHOWN 1. Damper 2. Bushing

18, Protective Plate

Apply Loctite 242 (blue) on bolts and torque lock nuts to 10 Nm (88 lbfin).

19,20, Coupler and Front Drive Shaft

Install front drive shaft with coupler.

SPX, GS, GTS and GTI Models

12,24, Rear Drive Shaft and Damper

Install damper to rear drive shaft.

5, Circlip
Push the floating ring to compress the boot. Insert the circlip in the drive shaft groove.

All Models Except the XP Limited

13, Damper
Install dampers no. 13 on drive shaft no. 12. NOTE: Make sure dampers were not left in PTO flywheel or impeller.

09-03-13

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

F06I06A

1. Push floating ring 2. Insert circlip in the groove

F01J2BA

Slide the floating ring onto the circlip.

TYPICAL 1. Closing hooks

All Models Except the XP Limited

2, Large Clamp
Secure large clamp no. 2 as follows: Use pliers (P/N 295 000 069) as for removal. Manually engage holding hook in large window. This is a pre-clamping position only.
1

Squeeze pliers. When both large and small windows are directly over the 2 locking hooks, press those windows down to engage hooks in windows.
1

2
F01J23A

F02J0IA

1. Press to engage hooks in windows

PRE-CLAMPING POSITION 1. Holding hook 2. Large window

NOTE: At installation, clamp tail should be in opposite direction of engine rotation.

Insert pointed tips of pliers first in closing hooks.

09-03-14

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

LUBRICATION
PTO Flywheel
All Models Except the XP Limited Using a grease gun, carefully lubricate PTO flywheel with synthetic grease (P/N 293 550 010), until boot is just beginning to expand. At this point, immediately stop greasing.

2
F01J23B

1. Engine rotation (counterclockwise) 2. Tail in opposite direction

4, Small Clamp
To secure small clamp no. 4, place notch side of plier on clamp embossment and squeeze plier.
1

F01I0BB

Seal Carrier
GSX Limited, XP Limited and GTX Limited Using a grease gun, carefully lubricate seal carrier of thru hull fitting until grease is just coming out of seal.

F02J0PB

1. Squeeze plier

F06I03A

1. Grease seal carrier

09-03-15

Section 09 PROPULSION SYSTEM Subsection 03 (DRIVE SYSTEM)

XP Limited Using a grease gun, lubricate seal carrier of mid bearing with synthetic grease (P/N 293 550 010).

F05I09A

TYPICAL 1. Grease fitting

09-03-16

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

REVERSE SYSTEM
GTS Model
2 5 1 Synthetic grease 4 8 Nm (71 lbfin) 7 Nm (62 lbfin) 3 Nm (27 lbfin) 8 Nm (71 lbfin) 7 10 Nm (88 lbfin) 7 Nm (62 lbfin) 10 Nm (88 lbfin) 6 Nm (53 lbfin)

6 2.5 Nm (22 lbfin) 3

3 Nm (27 lbfin)

Loctite 242

20 Nm (15 lbfin) Loctite 242

F02J0NS

PARTS

FLAT RATE

09-04-1

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

GENERAL
It is not necessary to remove reverse system from watercraft for servicing. However reverse system removal is necessary to replace reverse support.

DISASSEMBLY
Remove storage tray from watercraft. Press on vent tube upper part to enable to withdraw tube from body.
2 1

F02J04A

TYPICAL 1. Sliding block 2. Spring

Withdraw shift lever stem and locking lever no. 1 from sliding block no. 5, then slide off locking lever from stem.

F02L1MA

TYPICAL 1. Press on vent tube

3, Shift Lever
To remove shift lever, unhook spring no. 2 from sliding block no. 5 and pull spring from shift lever stem.
1
F02J05A

TYPICAL 1. Locking lever

4,5, Triangular Lever and Sliding Block

Remove screw, lock nut, washers and bushing holding reverse cable to triangular lever. Remove lock nut and washer holding sliding block to triangular lever and to support. Remove screw, lock nut, washer and bushing holding triangular lever to reverse support.

09-04-2

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

7, Reverse Gate
1

Unhook reverse gate springs and remove ball joint fasteners to release reverse cable from reverse gate.

3 2
F02J06A

TYPICAL 1. Reverse support 2. Reverse cable 3. Triangular lever

6, Reverse Support
In order to have access to screw holding lower part of reverse support, remove front seat by pulling on each side to release it from body. Remove screw, lock nut and washers holding lower part of support. Remove reverse cable from support. Remove 2 Allen screws, lock nut and washer holding guide plate and support.

F02J08A

1. Reverse cable 2. Reverse gate spring (each side)

Unscrew reverse gate retaining screws from venturi, then remove gate.

F02J09A

1. Screw (each side)

ASSEMBLY
3
F02J07A

TYPICAL 1. Guide plate 2. Allen screw 3. Screw and washer

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

7, Reverse Gate
Install reverse gate with sleeve and washer. Apply Loctite 242 (blue) on threads and torque to 20 Nm (15 lbfft).

09-04-3

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

CAUTION

Always hook reverse gate springs in order to ease reverse gate operation.

Torque triangular lever screw to 8 Nm (71 lbfin). Install sliding block to lever and torque nut to 8 Nm (71 lbfin).

1,5, Locking Lever and Sliding Block

Insert locking lever end in support hole then align lever and sliding block holes.

F02J02B

1 1
F02J0DA

1. Screws, washers and sleeves

6, Reverse Support
For reverse support installation, torque screw to 8 Nm (71 lbfin) and Allen screws to 2 Nm (18 lbfin).

TYPICAL 1. Support hole

3, Shift Lever
NOTE: Always install shift lever with its open end facing left side of watercraft, then push shift lever stem through locking lever no. 1 and sliding block no. 5 holes.

4,5, Triangular Lever and Sliding Block

Insert bushing in triangular lever and then install lever to reverse support.

F02J0CA

F02J0EA

TYPICAL 1. Bushing

TYPICAL 1. Install shift lever as shown

Install reverse cable to triangular lever with bushing, plastic washer(s) and flat washers. Torque cable screw to 7 Nm (62 lbfin).
09-04-4

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

2, Spring
Insert spring in lever stem hole and then install curved end in sliding block groove.

ADJUSTMENT
7, Reverse Gate
Position handlebar in a straight ahead position, nozzle should be parallel to rear of watercraft. Using a square, set it to 129 3 mm (5-5/64 7/64 in), then position square end at the top middle of nozzle.

1
F02J0KA

TYPICAL 1. Sliding block groove

Shift Lever Lubrication

Lubricate sliding block support sliding area and triangular lever with synthetic grease. Also, lubricate sliding washer and shift lever stem.
2
F02J0HA

A. 129 3 mm (5-5/64 7/64 in)

Pull shift lever in REVERSE position.

1

F02D03A

3
F02J0GA

TYPICAL 1. Sliding washer 2. Sliding block 3. Support plate

TYPICAL 1. Shift lever in REVERSE position

With the gate down to REVERSE position it should be at the specification. NOTE: Push slightly on the gate in order to recover spring tension and to obtain proper position of the gate.

09-04-5

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

Tighten adjustment nuts and recheck gate position. Reinstall vent tube.

WARNING

Vent tube must be in place to provide proper bilge ventilation.

F02J0FA

1 1

1. REVERSE position

If reverse gate needs to be readjusted, it can be done at support with adjustment nuts. Turn cable nuts to obtain position. NOTE: If reverse gate adjustment is not done adequately, performance and steering control will be reduced at reverse position.
F02L14A

1. Install vent tube

Reinstall storage tray.

2
F02J06B

TYPICAL 1. Support 2. Adjustment nuts

09-04-6

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

GTI and GTX Limited

11 Synthetic grease 13 2.5 Nm (22 lbfin) 15 3 Nm 19 (27 lbfin) Loctite 242 16 Loctite 242 3.5 Nm (31 lbfin) 20

12 23 18 17 6 Nm (53 lbfin) 3 Nm (27 lbfin) Loctite 242 7 Nm (62 lbfin) 2.5 Nm (22 lbfin) 10 Nm (88 lbfin) 4 9 Nm (80 lbfin) 7 8 9 1 4 9 Nm (80 lbfin) 2 21 5 3 Loctite 242 6 Nm 6 (53 lbfin) 4 Nm (35 lbfin) Sealant 732

14

10

22

5 Nm (44 lbfin)

F07J01S

PARTS

FLAT RATE

09-04-7

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

DISASSEMBLY
1, Reverse Gate
Put shift lever in reverse position. Disconnect reverse cable by loosing bolt no. 2 and lock nut no. 3 from cable lever. Loosen 2 Allen screws no. 4 and remove reverse gate.

5, Cable Lever
Loosen Allen screw no. 6 and remove cable lever.

7,8, Pawl Lock and Spring

F07J03A

Remove roll pin no. 9.

10, Reverse Gate Support

Loosen 4 bolts which retains reverse gate support to venturi.
2 1 2

1. Reverse cable 2. Interior lever

Loosen bolt no. 14 retaining the interior lever.

1 2

F07J04A

F07J02A

1. Bolt 2. Shift lever

1. Support 2. Bolt

Remove the interior lever and spring no. 15.

11, Interior Lever

Remove glove box. Disconnect reverse cable by loosing bolt no. 12 and lock nut no. 13.

16, Reverse Cable Support

Remove retaining block no. 17 of reverse cable support by loosing bolts no. 18. Loosen 3 bolts no. 19 retaining reverse cable support to body. Remove reverse cable support.

INSPECTION
Visually inspect parts for wear or cracks. Replace parts as required.

09-04-8

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

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

Make sure the shift lever action is smooth and precise. Forward, neutral and reverse positions should be easy to select with a detent position between each.

15, Spring

CAUTION

8, Spring
Make sure spring is properly installed. One end of the spring is hooked in the pawl lock and the other end is retained by the stopper lock nut.

Apply all specified torques and service products as per main illustration.

Make sure to properly installed spring in reverse cable support as per following illustration.

3 2

F07J06A

1. Pawl lock 2. Spring 3. Stopper lock nut

F07J05A

1, Reverse Gate
When installing the reverse gate, pay attention to position its lever behind the reverse gate support stopper.
1

1. Spring

11,20, Interior Lever and Shift Lever

Install the interior lever in a rotating movement. Engage properly the interior lever tabs in the shift lever slots.
1 2

F07J07A

1. Stopper

F07J04B

1. Shift lever 2. Interior lever tabs

09-04-9

Section 09 PROPULSION SYSTEM Subsection 04 (REVERSE SYSTEM)

21, Reverse Cable

Install reverse cable to cable lever as per following illustration.
1

2 3 2

F07J09A

F07J08A

5 4

4 2

1. Reverse cable support 2. Loosen bolts 3. Adjustment nut

1. 2. 3. 4. 5.

Bolt Ball joint Cable lever Flat washer Lock nut

When adjustment is completed, there should be gap of 2 to 3 mm (5/64 to 7/64 in) between handle and left cover.

CAUTION

Ensure cable ball joint is parallel to cable lever (90 5) to minimize tension on cable. Adjust as required.

ADJUSTMENT
Put shift lever in forward position. Pull shift lever approximately 50 mm (2 in) and push it back slowly in forward position. The pawl lock no. 7 should be engaged in the anchor no. 22. If not, adjust reverse cable. Loosen 2 bolts no. 18 at reverse cable support no. 16. Turn adjustment nut no. 23 as required.
A

F07J0AA

A. 2 to 3 mm (5/64 to 7/64 in)

09-04-10

Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM)

VARIABLE TRIM SYSTEM

SPX Model
12

7 Loctite 242 11

9 8 Synthetic grease 10 Synthetic grease Loctite 242 17 5 4 6

2 3 2

5 Nm (44 lbfin)

732 sealant 10 Nm (89 lbfin) 13 1 16 2.5 Nm (23 lbfin)

14

15 14 13 Nm (10 lbfft) Loctite 242 Loctite 242 7 Nm (62 lbfin)

13 Nm (10 lbfft)
F01J5XS

Loctite 242

13 Nm (10 lbfft)

PARTS

FLAT RATE

09-05-1

Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM)

GSX Limited and XP Limited

12 7 Loctite 242 11

9 8 6 Synthetic grease Loctite 242 10 Synthetic grease 2 3 2 5 Nm (44 lbfin) 5 4

10 Nm (89 lbfin) 13 14 1

15 7 Nm (62 lbfin)

16 2.5 Nm (23 lbfin)

13 Nm (10 lbfft) Loctite 242

Loctite 242

13 Nm (10 lbfft) Loctite 242

F06J03S

13 Nm (10 lbfft)

09-05-2

PARTS

FLAT RATE

Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM)

GENERAL
To test VTS control module, motor or switch, refer to INSTRUMENTS AND ACCESSORIES 08-05.

8, Motor
Disconnect wires of motor. Remove retaining nuts no. 11.
1

REMOVAL
Disconnect ball joint no. 1. Remove clamps no. 2. Remove boot no. 3. To loosen nut no. 4, use VTS socket tool (P/N 295 000 133).

F01J1XA

1. Remove nuts 2. Disconnect wires

F01B2PA

Pull on motor to remove it. Remove sealing washer no. 5.

SPX Model Remove the spacer no. 17. All Models Disconnect wiring harnesses. Pull out VTS assembly no. 6 from bilge.

9,10, Worm and Sliding Shaft

Simply pull on worm and sliding shaft in order to remove them.

INSPECTION
3, Boot
Make sure boot is in good condition. If it is cracked or teared, replace boot.

DISASSEMBLY
7, Cover
Remove VTS cover by pressing on tabs.
1

9, Worm
Inspect threads and splines of worm for wear. If worm replacement is necessary, renew also sliding shaft.

VTS
F01J1WA

1. Press tabs to remove cover

09-05-3

Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM)

F01J25A

F01J2GA

1. Inspect threads and splines

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

Apply Loctite 242 (blue) to nuts no. 11 and tighten to 7 Nm (62 Ibfin). Connect wires of motor.

CAUTION

8,9,10, Motor, Worm and Sliding Shaft

Apply synthetic grease to worm. Screw worm to sliding shaft. Mesh worm splines to gear of motor.

Make sure wire color codes match. Install cover no. 7. NOTE: Make sure seal no. 12 is in place.

INSTALLATION
Installation is essentially the reverse of removal procedures. However pay particular attention to the following.

4,5, Nut and Sealing Washer

Place sealing washer on nut. Make sure seal lips are facing toward hull.
1
F01J2PA

1. Mesh worm spline to gear of motor

Install motor, worm and sliding shaft in VTS housing.

F01J2LA

1. Seal lips facing hull 2. Nut

09-05-4

Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM)

Apply Primer N to threads of VTS housing and Loctite 242 (blue) to nut no. 4. Install nut with sealing washer and torque to 6 Nm (53 lbfin) using the VTS socket tool.

1, Ball Joint
SPX Model Install ball joint on RIGHT side of sliding shaft no. 10 using bolt no. 13, washers no. 14 and nut no. 15. Torque nut to 10 Nm (88 lbfin). NOTE: Install boot on sliding shaft before securing ball joint.
3 1 2
F06J01C

1. Washers 2. Bolt 3. Lock nut

ADJUSTMENT
Push on VTS button up position until motor stops. When the nozzle is up (8), nozzle edge must not interfere with venturi (there should be a gap of 1 mm (.039 in)). NOTE: Activate timer to be able to position VTS.
1
F01J0JA

1. Washers 2. Bolt 3. Nut

GSX Limited and XP Limited Install ball joint on LEFT side of sliding shaft no. 10 using bolt no. 13, washers no. 14 and nut no. 15. Torque nut to 10 Nm (88 lbfin). NOTE: Install boot on sliding shaft before securing ball joint.
F01J3IA

2
1. No interference 2. Nozzle up

09-05-5

Section 09 PROPULSION SYSTEM Subsection 05 (VARIABLE TRIM SYSTEM)

If an adjustment is necessary, loosen jam nut no. 16 of link rod ball joint no. 1. Turn adjustment nut of ball joint to obtain the desired gap between trim ring and venturi.
1

F06J01A

GSX LIMITED SHOWN 1. Turn adjustment nut of ball joint

Tighten jam nut of ball joint to 2.5 Nm (23 lbfin) when adjustment is completed.

09-05-6

Section 10 STEERING SYSTEM Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
SPX MODEL........................................................................................................................... REMOVAL AND INSTALLATION ....................................................................................... GTS MODEL........................................................................................................................... REMOVAL AND INSTALLATION ....................................................................................... GS, GSX LIMITED, GTI AND GTX LIMITED......................................................................... DISASSEMBLY................................................................................................................... ASSEMBLY......................................................................................................................... XP LIMITED............................................................................................................................ DISASSEMBLY .................................................................................................................. ASSEMBLY......................................................................................................................... ALIGNMENT ..........................................................................................................................

0
10-02-1 10-02-2 10-03-1 10-03-2 10-04-1 10-04-2 10-04-4 10-05-1 10-05-2 10-05-4 10-06-1

10-01-1

Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL)

SPX MODEL
1 1 Nm (8.5 lbfin) 19 6 4 8 3 2 12 1 Nm (8.5 lbfin)

7 14 Nm (10 lbfft)

3 2 0.5 Nm (4 lbfin) 8 Nm (72 lbfin) 15 Nm (11 lbfft)

26 Nm (19 lbfft)

14

15 Nm (11 lbfft) 10 15 2.5 Nm (22 lbfin)

17 11 13

Synthetic grease

13 6 Nm 16 (53 lbfin) 6 Nm (53 lbfin) 23 2.5 Nm (22 lbfin) 24 22 21 19 7 Nm (63 lbfin)

18

10 Nm (88 lbfin)
F01K1VS

PARTS

FLAT RATE

10-02-1

Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL)

REMOVAL AND INSTALLATION

1, Cover
To replace the cover, loosen set screws no. 19 of handlebar housing.
1

When installing the grip insert in the handlebar no. 12, ensure that its notch is properly inserted in the hole beneath the handlebar. Install grip no. 4 on handlebar no. 12 matching it to the hex form on the grip insert. Install flat washer no. 7 and screw no. 6. Torque screw to 13 Nm (10 lbfft). Install cap no. 5.

3 5

1
F00K01A

1. Set screw
F01K1PA

Remove and reinstall 4 screws no. 2 and washers no. 3.

1 2

1. 2. 3. 4. 5.

Grip insert Grip Flat washer Screw. Torque to 13 Nm (10 lbfft) Cap

CAUTION

Ensure to install flat washer otherwise screw will damage grip end.

9,12, Steering Stem and Handlebar

Disconnect wiring harnesses leading out of steering stem no. 9. Disconnect throttle cable at carburetor. Remove throttle cable from tie-blocks. Unscrew bolts no. 16 retaining support no. 11 to steering stem arm no. 10.

F00K02A

1. Cover 2. Screws

4,8, Grip and Grip Insert

To remove grip, just pull out cap no. 5 from grip end and remove screw no. 6 and washer no. 7. Pull out grip. To verify grip insert for damage, remove it from handlebar.

10-02-2

Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL)

F01K1FA

F01K17A

1. Bolts 2. Steering stem arm

FRONT SUPPORT 1. Apply synthetic grease 2. Thrust ring

Remove support no. 11 and steering stem arm no. 10 from steering stem. NOTE: It is not necessary to remove steering cable from steering stem arm. Pull out handlebar assembly.

NOTE: Make sure thrust rings are properly installed. Install support no. 11 to steering stem arm no. 10. NOTE: Insert lock nuts no. 17 in support no. 11. Screw only a few threads of the bolts no. 16.
3

CAUTION
1

While performing this procedure, take precautions to avoid damaging throttle cable and wiring harnesses. Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. Lubricate with synthetic grease thrust ring no. 13 of rear support no. 14 and front support no. 15.

4
F01K09A

TYPICAL 1. Support 2. Steering stem arm 3. Insert lock nuts 4. Screw only a few threads of the bolts

Install handlebar assembly into rear support no. 14, taking care at the same time to insert throttle cable and wiring harnesses.
2

F01K0HA

REAR SUPPORT 1. Apply synthetic grease 2. Thrust ring shown removed for more clarity
10-02-3

Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL)

From bilge, route throttle cable and wiring harnesses into support no. 11 and steering stem arm no. 10, and finally in front steering support no. 15.

Position steering stem arm no. 10 and support no. 11 onto steering stem.

WARNING

CAUTION

While performing this procedure, take precautions to avoid damaging throttle cable and wiring harnesses.

Make sure integrated flat key of steering stem arm is properly seated in steering stem keyway. Steering stem arm must be locked in place before torquing the bolts. Torque bolts of steering stem arm no. 10 to 6 Nm (53 lbfin).

1 3

F01K1NA

F01K0AA

1. Install handlebar assembly 2. Route throttle cable and wiring harnesses at the same time

1. 2. 3. 4. 5.

Steering stem Steering stem arm Support Torque to 6 Nm (53 lbfin) Integrated flat key must be seated in keyway and steering stem arm locked in place

Push handlebar assembly until steering stem no. 9 is well seated into steering supports no. 14 and no. 15.

NOTE: Once steering stem arm is properly tightened, look between body and front support to make sure there is no gap between steering stem arm and its support. If there is a gap, components are not properly installed. Connect wiring harnesses. Route throttle cable alongside bilge. Insert cable barrel into carburetor throttle lever. Insert throttle cable alongside choke cable in tieblocks. For throttle cable adjustment, refer to CARBURETOR 06-04.

3 2
F01K1BA

1. Rear support (steering collar) 2. Front support 3. Steering stem

10-02-4

Section 10 STEERING SYSTEM Subsection 02 (SPX MODEL)

18, Steering Cable

Disconnect steering cable from steering stem arm no. 10.

Remove battery. For procedure, refer to CHARGING SYSTEM 08-03. Loosen nut no. 20 of steering cable. Pull cable from rear of watercraft and remove half rings no. 21, O-ring no. 22 and retaining ring no. 23. Remove steering cable. Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. Make sure to secure steering cable in bilge using tie raps. Secure steering cable ball joint no. 19 on top of steering arm.

F01K1WA

CAUTION

1. Disconnect steering cable

Remove retaining block no. 24 of cable support.

Ensure the ball joint is parallel ( 5) to the nozzle arm.

F06K01A

1. Ball joint on top of arm 2. Torque nut to 7 Nm (62 lbfin)

STEERING ALIGNMENT For steering alignment procedure, refer to ALIGNMENT 10-06.

F01K18C

1. Remove retaining block

Disconnect ball joint no. 19 of steering cable from jet pump nozzle. Remove ball joint no. 19.
10-02-5

Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL)

GTS MODEL
1 3.5 Nm (30 lbfin) 30 8 26 Nm (19 lbfft) 3 2 29 3.5 Nm (30 lbfin) 13 Nm 7 6 (10 lbfft) Anti-seize lubricant 4 Loctite 242 5

15 Nm (11 lbfft)

Loctite 242 17 15 Nm (11 lbfft) 16 Loctite 242 28

15 28

14 15 Nm (11 lbfft) Loctite 242 18

19 20

Loctite 271 40 Nm 13 (30 lbfft)

10 30 6 Nm (53 lbfin) 22 2 Nm (18 lbfin) 2.5 Nm (23 lbfin) 25 26 27 22 20 Nm 12 (15 lbfft) 7 Nm (63 lbfin) 10 Nm 24 (88 lbfin) 23 21 12

9 7 Nm 11 (63 lbfin)

F02K0BS

PARTS

FLAT RATE

10-03-1

Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL)

REMOVAL AND INSTALLATION

1, Cover
To replace the cover, loosen set screws no. 30 of handlebar housing.
1

Install grip no. 4 on handlebar no. 29 matching it to the hex form on the grip insert. Install flat washer no. 7 and screw no. 6. Torque screw to 13 Nm (10 lbfft). Install cap no. 5.

3 5

F01K1PA

F00K01A

1. Set screw

Remove and reinstall 4 screws no. 2 and washers no. 3.

1 2

1. 2. 3. 4. 5.

Grip insert Grip Flat washer Screw. Torque to 13 Nm (10 lbfft) Cap

CAUTION

Ensure to install flat washer otherwise screw will damage grip end.

17,29, Steering Stem and Handlebar

Disconnect wiring harnesses leading out of dashboard hole. Disconnect throttle cable at carburetor. Remove throttle cable from tie-block and clip. Unscrew nut no. 11 retaining locking plate no. 9; then remove locking plate and washers no. 12. Unscrew screw no. 13 of steering stem arm no. 10. Pull out handlebar and steering stem. NOTE: It is not necessary to disconnect steering cable to remove handlebar and steering stem. Inspect bushings no. 28 for wear, cracks, scoring, etc. Replace as necessary. Installation is essentially the reverse of removal procedures. However, pay particular attention to the following. Insert throttle cable through dashboard hole and slide grommet no. 14 on cable.

F00K02A

1. Cover 2. Screws

4,8, Grip and Grip Insert

To remove grip, just pull out cap no. 5 from grip end and remove screw no. 6 and washer no. 7. Pull out grip. To verify grip insert for damage, remove it from handlebar. When installing the grip insert in handlebar no. 29, ensure that its notch is properly inserted in the hole beneath the handlebar.
10-03-2

Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL)

Insert grommet no. 14 in dashboard hole and pull it from inside bilge. NOTE: To ease installation, apply water on grommet. Insert wires of monitoring beeper and start/stop button. Insert spring washer no. 15 and the shim no. 16 onto steering stem no. 17. Insert steering stem into support no. 18.
6 1 2
F01K0VA

2 1 3 5

4
TYPICAL 1. Steering stem tenon 2. Steering stem arm 3. Mortise 4. Large flat washer with X 5. Lock washer 6. Screw, apply Loctite 271 and torque to 40 Nm (30 Ibfft)

3 4
F02K05A

1. 2. 3. 4.

Steering stem Grommet Spring washer Shim

Properly position steering stem arm no. 10 on steering stem. Make sure to insert stem tenon into arm mortise. Apply Loctite 271 (red) on threads of screw no. 13. Install large flat washer no. 19, lock washer no. 20 and screw no. 13. Torque screw to 40 Nm (30 Ibfft).

Position 8 mm flat washer no. 12 on steering stopper screw then install locking plate no. 9 over steering stem head screw. NOTE: Ensure locking plate slot is inserted in steering stopper screw. Install a second 8 mm flat washer no. 12 and secure locking plate using jam nut no. 11. Torque nut to 7 Nm (62 Ibfin).

1 2

CAUTION

3 5

Always install large flat washer with the X stamped side facing the lock washer.

WARNING

F01K10A

The recommended torque and Loctite must be applied on screw. Steering arm mortise must seat properly on steering stem tenon.

STEERING CABLE NOT SHOWN FOR MORE CLARITY 1. Steering stem head screw 2. Locking plate 3. Steering stopper screw 4. 8 mm flat washers 5. Torque nut to 7 Nm (62 lbfin)

10-03-3

Section 10 STEERING SYSTEM Subsection 03 (GTS MODEL)

F02K0CA

TYPICAL

Disconnect rear ball joint no. 22 of steering cable at jet pump nozzle; then, remove ball joint. From bilge, unscrew nut no. 24 retaining steering cable to hull. Remove half rings no. 25, rubber washer no. 26 and retaining ring no. 27. NOTE: Move shift lever in reverse position to lower reverse gate. It will ease parts removal. Remove steering cable from tie-block and clips. Pull out steering cable. Assembly is essentially the reverse of disassembly procedures. However pay particular attention to the following. Inspect and reuse ball joints no. 22 only if they are in good condition. Secure rear ball joint to nozzle.

21, Steering Cable

To replace steering cable, proceed as follows: Disconnect front ball joint no. 22 of steering cable at steering stem arm no. 19. Loosen nuts no. 30 and open retaining block no. 23.
1

CAUTION

Ensure the ball joint is parallel ( 5) to the nozzle arm.

F02K0HA

1. One washer each side of arm 2. Torque nut to 2 Nm (18 lbfin)

STEERING ALIGNMENT For steering alignment procedure, refer to ALIGNMENT 10-06.

F02K0DE

TYPICAL 1. Ball joint 2. Steering cable 3. Retaining block

10-03-4

Subsection 04

Section 10 STEERING SYSTEM (GS, GSX LIMITED, GTI AND GTX LIMITED)

GS, GSX LIMITED, GTI AND GTX LIMITED

4 14 Nm (10 lbfft) 20 21 2 3 23 1 21 Loctite 242 10 Nm (89 lbfin) 5 26 Nm (19 lbfft) 5 6 6

22 4 Nm (35 lbfin) 4 12 14 Nm 13 (10 lbfft) Loctite 242

14 7 7 18 16 15 Loctite 242 6 Nm (53 lbfin) 11 6 Nm (53 lbfin) 8

Loctite 242

17 3 Nm (26 lbfin) 2.5 Nm (22 lbfin) 10 9 6 Nm Loctite (53 lbfin) 242 24 27

F07K0ES

2.5 Nm (22 lbfin) 19

26

25 10 Nm (88 lbfin)

PARTS

FLAT RATE

10-04-1

Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED)

DISASSEMBLY
1,21, Grip and Grip Insert
To remove grip, pull out cap no. 2 and remove screw no. 3. Pull out grip. To verify grip insert for damage, remove it from handlebar no. 22.

Remove cover.

8, Cable Support
Loosen bolts no. 9 and remove retaining block no. 10.

4, Cover
Remove grips no. 1. Loosen set screws no. 5 of handlebar housings no. 6.
1

F00K01A

1. Set screw

F01K18C

Remove 4 screws no. 7.

1 2

1. Retaining block

Loosen bolts no. 11 each side of steering support no. 12.

1 2

F00K02A

TYPICAL 1. Cover 2. Screws

F07K02A

Remove 2 screws no. 20 and flat washers no. 21 each side of cover.
10-04-2

1. Steering support 2. Bolt

Subsection 04

Section 10 STEERING SYSTEM (GS, GSX LIMITED, GTI AND GTX LIMITED)

F07K03A

1. Steering support 2. Bolts

F06K03A

Remove support.

12, Steering Support

GTI and GTX Limited Cut tie rap securing wiring harness boot.

GS AND GSX LIMITED 1. Tie rap 2. Connectors

F07K05A

F07K04A

GTI AND GTX LIMITED 1. Tie rap 2. Connectors

1. Boot 2. Tie rap

Disconnect the steering cable from the steering stem arm no. 15.

All Models Disconnect the throttle and choke cables from carburetor levers. Disconnect the wiring harnesses leading out of steering stem and cut tie rap.

10-04-3

Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED)

15,16, Steering Stem Arm and Support

Loosen bolts no. 17 retaining steering stem arm to support.
1 1 2 2

F07K06A

1. Steering stem arm 2. Steering cable

Loosen bolts no. 11 retaining cable support no. 8 to steering support no. 12. Loosen bolts no. 13 and lock nuts no. 14.

F07K08A

1. Steering stem arm 2. Bolt

Remove steering stem arm and support.

24, Steering Cable

Disconnect steering cable from steering stem arm no. 15. Remove retaining block no. 10. Disconnect ball joint no. 19 from jet pump nozzle. Remove ball joint no. 19 and jam nut from cable. Loosen nut no. 25, then remove half rings no. 26 and O-ring no. 27. NOTE: To loosen nut, use steering cable tool (P/N 295 000 145). Remove steering cable from watercraft.

1 2

3 2 3
F07K07A

1. Steering support 2. Bolt 3. Lock nut

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

Remove steering support with handlebar, wiring harnesses and cables.

CAUTION

Apply all specified torques and service products as per main illustration at the beginning of this sub-section.

10-04-4

Subsection 04

Section 10 STEERING SYSTEM (GS, GSX LIMITED, GTI AND GTX LIMITED)

1,21, Grip and Grip Insert

When installing the grip insert no. 21 in the handlebar no. 22, ensure that its notch is properly inserted in the hole beneath the handlebar. Install grip no. 1 on handlebar no. 22 matching it to the hex form on the grip insert. Install flat washer no. 23 and screw no. 3. Torque screw to 13 Nm (10 lbfft). Install cap no. 2.
2

3 5

F07K09A

1. Keyways 2. Integrated flat key

Replace lock nuts no. 18 by new ones. Torque bolts no. 17 of steering stem arm to 6 Nm (53 lbfin).

19, Ball Joint

F01K1PA

1. 2. 3. 4. 5.

Grip insert Grip Flat washer Screw. Torque to 13 Nm (10 lbfft) Cap

Secure the steering cable ball joint no. 19 to the nozzle as per following illustrations.

CAUTION

CAUTION

Ensure the ball joint is parallel ( 5) to the nozzle arm.

Ensure to install flat washer otherwise screw will damage grip end.

GSX Limited and GTX Limited

15,16, Steering Stem Arm and Support

Position steering stem arm and support onto steering stem.

WARNING

Make sure the integrated flat keys of the steering stem arm and support are properly seated in steering stem keyways. Steering stem arm must be locked in place before torquing the bolts.
F06K01A

TYPICAL 1. Ball joint on top of steering arm 2. Torque nut to 7 Nm (62 lbfin)

10-04-5

Section 10 STEERING SYSTEM Subsection 04 (GS, GSX LIMITED, GTI AND GTX LIMITED)

GS and GTI Models

1

F00J01A

TYPICAL 1. Bolt 2. Flat washers 3. Lock nut. Torque to 2 Nm (18 lbfin)

STEERING ALIGNMENT For steering alignment procedure, refer to ALIGNMENT 10-06.

10-04-6

Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED)

XP LIMITED
Loctite 242 10 Nm (89 lbfin) 6 9 2 Nm (17 lbfin)

4 Nm (35 lbfin)

13 Nm (10 lbfft)

8 13 Nm (10 lbfft) 18

1 5 28 7 26 Nm (19 lbfft) 7

Synthetic grease 13 Loctite 242

7 Nm (62 lbfin) 10 Loctite 242

Engine cover Loctite 242 Loctite 242 19 20

2.5 Nm (22 lbfin) 17 Loctite 242

12

14 Synthetic grease 7 Nm (62 lbfin)

15 6 Nm (53 lbfin) 6 Nm (53 lbfin) Engine cover 6 Nm (53 lbfin) 11 24 16

2.5 Nm 21 (22 lbfin) 22 23 10 Nm (89 lbfin) 25 27 26 7 Nm (62 lbfin)

F08K04S

PARTS

FLAT RATE

10-05-1

Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED)

DISASSEMBLY
1, Grip
To remove grip, pull out cap no. 2 from grip end and remove screw no. 3 and washer no. 4. Pull out grip.

Remove 2 screws no. 9 and flat washers each side of cover.

10, Lever
Open engine cover. Remove the top section of the engine cover by loosening the 10 Allen screws located inside the cover.

5, Grip Insert
To verify grip insert for damage, remove it from handlebar.

6, Cover
To remove the cover, loosen set screws no. 7 of handlebar housing.
1

1
F08L0KB F00K01A

1. Loosen Allen screws 1. Set screws

Remove 4 screws no. 8 and washers no. 9.

1 2

Lift the top section of the engine cover and disconnect wiring harnesses. Remove the top section of the engine cover. Disconnect steering cable no. 11.

F00K02A

TYPICAL 1. Cover 2. Screws

F08K05A

1. Disconnect steering cable

10-05-2

Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED)

Remove link rod no. 12.

15,16, Steering Stem Arm and Support

Loosen bolts no. 17 retaining steering stem arm no. 15 and support no. 16.

F08K08A

1. Loosen bolts

Loosen nuts and bolts of steering support no. 18.

F08K06A

1. Remove link rod

Remove bolt no. 13 and washer.

1
F08K09A

1. Loosen nuts and bolts

F08K07A

1. Remove bolt and washer

10-05-3

Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED)

Lift steering support no. 18 and slightly pullback steering stem no. 14 in order to remove the support no. 16 and steering stem arm no. 15.

Loosen cable support no. 19.

F08k0AA

1. Remove support and steering stem arm

14, Steering Stem

Disconnect wiring harnesses, choke and throttle cables from engine. Remove steering stem.
F08K0BB

1. Loosen cable support

11, Steering Cable

Remove glove box. Disconnect steering cable at lever no. 10.

Remove retaining block no. 20. Disconnect ball joint no. 21 of steering cable from jet pump nozzle. Remove ball joint no. 21, jam nut no. 22 and boots no. 23 and no. 24. Loosen nut no. 25 and remove half rings no. 26 and O-ring no. 27. NOTE: To loosen nut, use steering cable tool (P/N 295 000 145). Remove steering cable from watercraft.

ASSEMBLY
Assembly is essentially the reverse of disassembly procedure. However, pay particular attention to the following.
F08K05A

10, Lever
Prior installing lever, apply synthetic grease to pivot.

1. Disconnect steering cable

10-05-4

Section 10 STEERING SYSTEM Subsection 05 (XP LIMITED)

14, Steering Stem

Apply synthetic grease to front and rear thrust bearing surface.

21, Ball Joint

CAUTION

Ensure to install flat washer otherwise screw will damage grip end.

15,16, Steering Stem Arm and Support

Position steering stem arm and support onto steering stem no. 14. Secure the steering cable ball joint no. 21 to the nozzle as per following illustration.

WARNING

Make sure integrated flat keys of steering stem arm and support are properly seated in steering stem keyways.

CAUTION

Ensure the ball joint is parallel ( 5) to the nozzle arm.

1,5, Grip and Grip Insert

When installing the grip insert no. 5 in the handlebar no. 28, ensure that its notch is properly inserted in the hole beneath the handlebar. Install grip no. 1 on handlebar no. 28 matching it to the hex form on the grip insert no. 5. Install flat washer no. 4 and screw no. 3. Torque screw to 13 Nm (10 lbfft).

WARNING
F06K01A

Correct torque must be strictly followed.

1 2

TYPICAL 1. Ball joint on top of steering arm 2. Torque nut to 7 Nm (62 lbfin)

3 5

STEERING ALIGNMENT For steering alignment procedure, refer to ALIGNMENT 10-06.

F01K1PA

1. 2. 3. 4. 5.

Grip insert Grip Flat washer Torque screw to 13 Nm (10 lbfft) Cap

10-05-5

Section 10 STEERING SYSTEM Subsection 06 (ALIGNMENT)

ALIGNMENT
Position handlebar in straight ahead position by measuring each side the distance from handlebar grip end to floorboard.

0
All Models Except the XP Limited Open storage compartment cover and remove basket. XP Limited Remove glove box.

All Models Loosen retaining block at cable support. Turn adjustment nut as required.

F01K07A

TYPICAL 1. Measuring handlebar grip end/floorboard distance

Check jet pump nozzle position by placing a straight edge on nozzle outer end. Measure the distance on each side of the straight edge. It must be equalled.
1

F01K18A

1
F01J03A

SPX, GS, GSX LIMITED, GTI AND GTX LIMITED 1. Retaining block 2. Adjustment nut 3. Bolts

TYPICAL 1. Measure the distance on each side of the straight edge

If necessary, steering alignment adjustment should be performed at steering cable support.

10-06-1

Section 10 STEERING SYSTEM Subsection 06 (ALIGNMENT)

2 3
F08K0BA

3
F03K03A

XP LIMITED 1. Support 2. Adjustment nut 3. Bolts

GTS MODEL 1. Retaining block 2. Adjustment nut 3. Bolts

After adjustment, torque retaining block bolts to 6 Nm (53 Ibfin).

CAUTION

Verify when the handlebar is turned completely to the left or right side, that there is no interference with venturi.

10-06-2

Section 11 SUSPENSION Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
DIRECT ACTION SUSPENSION............................................................................................ REMOVAL .......................................................................................................................... INSPECTION ...................................................................................................................... ASSEMBLY.........................................................................................................................

0
11-02-1 11-02-2 11-02-3 11-02-3

11-01-1

Subsection 02

Section 11 SUSPENSION (DIRECT ACTION SUSPENSION)

DIRECT ACTION SUSPENSION

XP Limited

10 5 Nm 2 (44 lbfin)

11 34 Nm (25 lbfft)

13 12

9 5 1 4 6 8 Loctite 242 Loctite 242

F08Q02S

34 Nm 7 (25 lbfft)

10 Nm (89 lbfin)

10 Nm (89 lbfin)

PARTS

FLAT RATE

11-02-1

Section 11 SUSPENSION Subsection 02 (DIRECT ACTION SUSPENSION)

REMOVAL
1, Shock Absorber
Loosen 4 screws and remove bottom cover of seat.

Loosen lower gear clamp no. 4, then push inner boot no. 5 upward.

F08I03B

1. Loosen gear clamp

F08L11A

Remove bolt no. 6 and lock nut no. 7 from shock absorber lower support no. 8.

1. Remove cover

Loosen gear clamp no. 2 of outer boot no. 3, then pull outer boot downward.

F08Q03A

1. Bolt 2. Lock nut

F08L12A

1. Loosen gear clamp

Remove rear access panel from body.

Tilt seat upward. Loosen upper gear clamp no. 9 of inner boot no. 5.

11-02-2

Subsection 02

Section 11 SUSPENSION (DIRECT ACTION SUSPENSION)

F08L13A

1
F05L0NA

1. Loosen gear clamp

Remove bolt no. 10 and lock nut no. 11 from shock absorber upper support.

Compress spring and remove cup no. 13. Unload tool and remove spring from shock absorber.

INSPECTION
3,5, Boot
Inspect condition of boots. If there is any tear, renew boot(s).

1, Shock Absorber
Inspect shock absorber for wear. Extend and compress the piston several times over its entire stroke; it should move smoothly and with uniform resistance. Pay attention to the following conditions that will denote a defective shock absorber: A skip or a hang back when reversing stroke at mid travel. Seizing or binding condition except at extreme end of either stroke. Oil leakage. A gurgling noise, after completing one full compression and extension stroke. Renew if any defects are present.

F08Q04A

1. Bolt 2. Lock nut

Remove shock absorber/coil spring assembly.

3, Outer Boot
Pull outer boot to remove it from body.

12, Coil Spring

Install spring compressor tool (P/N 529 027 100) in a vise.

WARNING

ASSEMBLY
Assembly is essentially the reverse of disassembly procedure. Refer to the main illustration at the beginning of this sub-section for torque specifications and service products to be used.
11-02-3

Do not attempt to dismantle a spring without using the proper tool. Install shock absorber/coil spring assembly in spring compressor tool.

Section 12 HULL/BODY Subsection 01 (TABLE OF CONTENTS)

TABLE OF CONTENTS
ADJUSTMENT AND REPAIR ................................................................................................ SEAT ADJUSTMENT......................................................................................................... STORAGE COMPARTMENT COVER ADJUSTMENT ...................................................... ACCESS PANEL ADJUSTMENT ....................................................................................... INLET GRATE REMOVAL................................................................................................... RIDING PLATE.................................................................................................................... JET PUMP SUPPORT ........................................................................................................ DEFLECTOR ....................................................................................................................... DRAIN PLUG INSTALLATION ........................................................................................... SEAT REMOVAL................................................................................................................. SEAT COVER REPLACEMENT .......................................................................................... BUMPER REPLACEMENT ................................................................................................. SPONSON REPLACEMENT .............................................................................................. BAFFLE SEALING .............................................................................................................. ENGINE COVER REMOVAL............................................................................................... DECALS REPLACEMENT .................................................................................................. HULL AND BODY REPAIR ................................................................................................. TOOLS AND MATERIALS LIST ......................................................................................... HULL INSERT REPAIR .......................................................................................................

0
12-02-1 12-02-17 12-02-19 12-02-20 12-02-20 12-02-20 12-02-21 12-02-22 12-02-22 12-02-23 12-02-24 12-02-24 12-02-25 12-02-25 12-02-26 12-02-26 12-02-27 12-02-29 12-02-30

12-01-1

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

ADJUSTMENT AND REPAIR

SPX Model
2 Loctite 271 5 Nm (44 lbfin) 8 Nm (71 lbfin) Loctite 242 1 Loctite 271 3

Loctite 271

5 Nm (44 lbfin)

Sealant 732

5 Nm 10 (44 lbfin) Sealant 732 7 6 15 Nm (11 lbfft) 9 8

Loctite 242

Loctite 271 Sealant 732

Body

F01L6HS

PARTS

FLAT RATE

12-02-1

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

13 12

Loctite 242

6 Nm (53 lbfin)

15 Nm (11 lbfft) Sealant 732 Loctite 271

12

Loctite 271 Sealant 732 Sealant 732

4 5 12 14 4

12 15 5

1.5 Nm (13 lbfin)

F01L6IS

12-02-2

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

GTS Model

2 Loctite 271

1 Loctite 271 3

5 Nm (44 lbfin)

8 Nm (71 lbfin) Loctite 242

Loctite 271

5 Nm (44 lbfin)

Loctite 242 Sealant 732 9 10 5 Nm 7 8 (44 lbfin) 6

Sealant 732 11 15 Nm (11 lbfft) Loctite 271

F02L26S

PARTS

FLAT RATE

12-02-3

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

7 Nm (62 lbfin)

Loctite 242

13 12 15 Nm (11 lbfft) Loctite 271 4 5 4 12 12 5 14 Sealant 732 1.5 Nm (13 lbfin) Sealant 732

12
F02L27S

15

12-02-4

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

GS and GSX Limited

5 Nm (44 lbfin) Loctite 242

5 Nm (44 lbfin)

Loctite 242 Loctite 242 5 Nm (44 lbfin) Loctite 271

5 Nm (44 lbfin) 5 Nm (44 lbfin) Loctite 271

3 5 Nm (44 lbfin)

5 Nm (44 lbfin)

8 Nm (71 lbfin) Loctite 242

Loctite 242 Sealant 732 7 6

F06L01S

10 5 Nm (44 lbfin)

PARTS

FLAT RATE

12-02-5

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

Loctite 271

8 Nm (71 lbfin)

Loctite 242

13

15 Nm (11 lbfft) Sealant 732

12

Sealant 732 15

Loctite 271 2.5 Nm (22 lbfin) Sealant 732

4 5

4 5 12 14 12

12

F06L02S

12-02-6

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

GTI and GTX Limited

Loctite 271 5 Nm (44 lbfin) Loctite 271 5 Nm (44 lbfin)

8 Nm (71 lbfin) Loctite 271 5 Nm (44 lbfin)

Loctite 242 3 Loctite 242

10 8 Nm (71 lbfin)

Loctite 271

Loctite 242 Sealant 732 8 10 5 Nm 9 (44 lbfin)

Body Left side only Loctite 271 15 Nm (11 lbfft) Sealant 732

F07L03S

PARTS

FLAT RATE

12-02-7

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

Loctite 271

8 Nm (71 lbfin) 13 12

Loctite 242

15 Nm (11 lbfft) Loctite 271 8 Nm (71 lbfin) Sealant 732 Sealant 732 1.5 Nm (13 lbfft) 15 5 12 14
F07L04S

Loctite 271

4 5

Sealant 732

12 12

12-02-8

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

1.4 Nm (12 lbfin)

8 Nm (71 lbfin) 0.8 Nm (7 lbfin) Loctite 242

Loctite 242 5 Nm (44 lbfin)

5 Nm (44 lbfin)

8 Nm (71 lbfin)

Loctite 242 3 Nm (26 lbfin) Loctite 242

F07L05S

5 Nm (44 lbfin)

PARTS

FLAT RATE

12-02-9

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

Loctite 242 4 Nm (35 lbfin) 5 Nm (44 lbfin) Loctite 242 Loctite 242 4 Nm (35 lbfin)

Loctite 242 5 Nm (44 lbfin)

Loctite 242
F07L06S

5 Nm (44 lbfin)

12-02-10

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

XP Limited

Loctite 242 732 sealant 7 6 Loctite 242 15 Nm (11 lbfft) Body 732 sealant 8 9 10 5 Nm (44 lbfin)

F08L14S

PARTS

FLAT RATE

12-02-11

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

12

3 Loctite 271

13

Body 5 Nm (44 lbfin) 3 Loctite 271

Body 5 Nm (44 lbfin)

15 Nm (11 lbfft) Body Loctite 271 4 5 12 12

F08L15S

4 14 5 12

732 sealant 1.5 Nm (13 lbfin)

732 sealant 15

12-02-12

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

Loctite 242 15 Nm (11 lbfft) Loctite 242

4 Nm (35 lbfin)

17

13 Nm (10 lbfft)

24 5 Nm (44 lbfin) 23 22 Loctite 271 21 20 3 Nm (27 lbfin) Synthetic grease

19 3 Nm 18 (27 lbfin)
F08L16S

PARTS

FLAT RATE

12-02-13

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

Loctite 242 4 Nm (35 lbfin) 4 Nm (35 lbfin) Loctite 242 8 Nm (71 lbfin) 3 Nm (27 lbfin)

Loctite 242

Loctite 242 Loctite 648 Loctite 242 8 Nm (71 lbfin) 4 Nm (35 lbfin)

F08L17S

12-02-14

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

Loctite 271

3 Nm (27 lbfin)

Engine cover 2 Nm (18 lbfin)

F08L18S

PARTS

FLAT RATE

12-02-15

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

Loctite 242

Loctite 242 22 Nm (16 lbfft) 4 Nm (35 lbfin)

Loctite 242 4 Nm (35 lbfin)

F08L19S

12-02-16

PARTS

FLAT RATE

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

SEAT ADJUSTMENT
All Models Except the XP Limited Adjust seat retainer no. 1 as per following specifications:
2 1

F02L24A

GTS MODEL 1. Front hook 2. Adjustment nut (Loctite 271) 3. Nut (Loctite 242). Torque to 8 Nm (71 lbfin) A. 22.5 (+ 1, - 0) mm (51/64 (+ 1/32, - 0) in)

F02L24A

SPX, GTI AND GTX LIMITED 1. Seat retainer 2. Adjustment nut (Loctite 271) 3. Nut (Loctite 242). Torque to 8 Nm (71 lbfin) A. 25 1 mm (63/64 3/64 in)

Adjust lock pin no. 2 as per following specifications:

1

3 3
F02L25C

F02L24A

GS AND GSX LIMITED 1. Seat retainer 2. Adjustment nut (apply Loctite 271) 3. Nut (apply Loctite 242 and torque to 8 Nm (71 lbfin) A. 21 1 mm (53/64 3/64 in)

SPX MODEL 1. Lock pin 2. Adjustment nut (Loctite 271) 3. Lock nut. Torque to 5 Nm (44 lbfin) A. 37 1 mm (1-29/64 3/64 in)

12-02-17

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

A A

F06L03A

F07L08A

GS AND GSX LIMITED 1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 33.5 1 mm (1-5/16 3/64 in)

GTI AND GTX LIMITED FRONT SEAT 1. Lock pin 2. Adjustment nut (Loctite 271) A. 39 1 mm (1-35/64 3/64 in)

3
F02L25C F06L03A

GTS MODEL 1. Lock pin 2. Adjustment nut (Loctite 271) 3. Lock nut. Torque to 5 Nm (44 lbfin) A. 38 1 mm (1-1/2 3/64 in)

GTI AND GTX LIMITED REAR SEAT 1. Lock pin 2. Adjustment nut (apply Loctite 271) A. 33.5 1 mm (1-5/16 3/64 in)

12-02-18

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

STORAGE COMPARTMENT COVER ADJUSTMENT

Adjust lock pin no. 3 as per following specifications:

A 1 3

F07L09A

3
F02L25C

GTI AND GTX LIMITED 1. Lock pin (apply Loctite 242) 2. Rubber washer 3. Flat washers A. 39.2 1 mm (1-35/64 3/64 in)

SPX AND GTS MODELS 1. Lock pin 2. Adjustment nut (Loctite 271) 3. Lock nut. Torque to 5 Nm (44 lbfin) A. 37 1 mm (1-29/64 3/64 in)

NOTE: The GTI and GTX Limited have a floating type lock pin. It is normal to have a front and aft play of the lock pin. To adjust, tighten lock pin until any vertical play is eliminated. Make sure a front and aft play remains when pressing by hands.
1

A 2

F06L04A

F08L1AA

GS AND GSX LIMITED 1. Lock pin (apply Loctite 271) 2. Adjustment nut A. 34 1 mm (1-11/32 3/64 in)

XP LIMITED 1. Lock pin A. 13.4 mm (17/32 in)

12-02-19

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

ACCESS PANEL ADJUSTMENT

XP Limited Adjust lock pin no. 3 of access panel as per following specifications:

Remove jet pump. Refer to JET PUMP 09-02. Remove the speed sensor from the riding plate (if applicable). Loosen riding plate screws. NOTE: An impact screwdriver should be used to loosen tight screws. Using a low height hydraulic bottle jack and 2 steel plates, pry out riding plate.

3
F08L1BA

1. 2. 3. A.

Lock pin Adjustment nut (Loctite 271) Lock nut. Torque to 5 Nm (44 lbfin) 39 1 mm (1-17/32 3/64 in)
F05J03A

Adjust bolts no. 16 of access panel arms as per following specifications:

TYPICAL 1. Hydraulic bottle jack 2. Steel plates

Installation
Apply Loctite The Right Stuff Gasket as indicated by the shaded areas in the next illustrations. Follow also the torquing sequence (if applicable) as shown in the same illustrations.
A

1
F05L0VA

1. Lock nut. Torque to 22 Nm (16 lbfft) A. 33 1 mm (1-19/64 3/64 in)

INLET GRATE REMOVAL

Loosen screws and remove inlet grate. NOTE: An impact screwdriver should be used to loosen tight screws.

1
F01J1VA

RIDING PLATE
Removal
Remove inlet grate.
12-02-20

SPX AND GTS MODELS 1. Apply Loctite The Right Stuff Gasket as indicated by the shaded area

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

71

82

F05K02A

F07L0DA

TYPICAL 1. Unscrew nut

GS, GSX LIMITED, GTI AND GTX LIMITED

82

Remove ball joint, boot, nut, half rings and O-rings from reverse cable (GTI and GTX Limited). Remove boot and nut from VTS sliding shaft (GSX Limited and XP Limited). Disconnect water supply hose, water return hose and bailer hoses. Remove nuts, lock washers and flat washers retaining jet pump support.

71

5
F08L1CA

3
1

XP LIMITED
F07L0AA

JET PUMP SUPPORT

All Models Except SPX and GTS

TYPICAL 1. Remove nuts

Removal
Remove jet pump. Refer to JET PUMP 09-02. Remove inlet grate and riding plate. Remove ball joint, boot, nut, half rings and O-rings from steering cable.

Using a heat gun, heat jet pump support until it is possible to pull it.

12-02-21

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

NOTE: Shims may have been installed between support and body. Do not remove these shims, otherwise jet pump alignment will be altered.

Installation
Apply Loctite 598 Ultra Black as indicated by the shaded area in the following illustration.

Installation
Apply Loctite The Right Stuff Gasket as indicated by the shaded areas in the next illustrations. Follow also the torquing sequence as shown in the same illustrations.
3 4

F07L0BA

DRAIN PLUG INSTALLATION

Refer to the following illustration to install drain plug no. 15.
1
F07L0CA

GS, GSX LIMITED, GTI AND GTX LIMITED

2 4 1

3 4 1
F08L1DA

2
1. 2. 3. 4.

F05L13A

XP LIMITED

Drain plug Gasket and 732 sealant Torque screws to 1.5 Nm (13 lbfin) From inside bilge, apply 732 sealant on screws

DEFLECTOR
GS, GSX Limited, GTI and GTX Limited

Removal
Using a heat gun, heat deflector and pry it using a piece of wood.

12-02-22

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

SEAT REMOVAL
XP Limited Loosen 4 screws and remove bottom cover no. 17 of seat.

F08L13A

1. Gear clamp

Remove bolt and lock nut from shock absorber upper support.
F08L11A

1. Remove cover

Loosen gear clamp of outer boot; then, pull outer boot downward.

F08Q04A

1. Bolt 2. Lock nut

F08L12A

1. Loosen gear clamp

Loosen gear clamp of inner boot; then, pull boot downward.

12-02-23

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

Remove protective caps no. 18 and loosen screws no. 19 to remove eyelet no. 20 on each side of seat.

SEAT COVER REPLACEMENT

Install staples with an electric tacker such as Arrow tacker no. ETN-50 or with a manual tacker such as Arrow tacker no. T-50. NOTE: For an easier installation, its highly recommended to use an electric tacker. Ensure that the seat rest firmly against a hard surface such as a piece of wood. This is done to get the staples completely pushed in place.

F08L1EA

1. Loosen screws of eyelet

Remove cup no. 21 on each side of seat. Loosen nut no. 23 on each side of seat.
1

1
F01L3YA

TYPICAL 1. Piece of wood 2. ETN-50 (electric) or T-50 (manual)

After cover installation cut all around the excess of material.

F08L1FA

1. Loosen nut

BUMPER REPLACEMENT
1. Remove trim no. 5 from side bumper rail no. 4. 2. Drill pop rivets no. 12 to remove side bumper rail no. 4. 3. Mark hole positions on body straight and bow sections.

Tilt seat. Loosen screws no. 24 on each side of seat retaining the side covers. Lower seat. Remove side covers. Pull seat frame out of pivots. Remove seat. Seat installation is essentially the reverse of removal procedure. Refer to the main illustration of seat at the beginning of this subsection for proper torque specifications and service products to be used.
12-02-24

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

1
RES

4
F01L4GA

TYPICAL 1. Front bumper 2. Corner bumper 3. Straight section 4. Bow section

From bilge, unscrew sponsons no. 6 using a 10 mm deep socket with an extension. Remove sponsons no. 6. Clean any residues of sealant adhesive on hull. Install gaskets no. 7 on new sponsons no. 6. Apply 732 sealant (P/N 293 800 006) or sealant adhesive (P/N 293 800 033) around sponson studs. Apply Loctite 242 (blue) on sponson studs. Install sponsons no. 6 on hull. From bilge, first insert flat washers no. 8 over sponson studs, then lock washers no. 9. Secure with lock nuts no. 10. Tighten to 5 Nm (44 lbfin). NOTE: To ease flat washer and lock washer installation, use a flexible 4-claw Snap-on pick-up tool.

4. Slide bumper rail no. 4 under front bumper no. 13. 5. Using a 4.80 mm (3/16 in) drill bit, drill first hole through bumper rail no. 4 at front of bow section. Use locating mark as a guide. Then install a rivet no. 12.

CAUTION

F01P09A

When drilling, be careful not to damage bumper rail and/or hull. 6. Position bumper rail no. 4 properly onto body and cut excess length if necessary. 7. Slide bumper rail no. 4 in corner bumper no. 14. 8. Using hole positions previously marked on body, drill holes in bumper rail no. 4 and install rivets no. 12. 9. Install trim no. 5 using soapy water. 10. Repeat procedure for the other side.

Reinstall removed parts. Clean hull and sponsons of any sealant adhesive surplus.

Recommended torques and use of Loctite must be strictly followed.

WARNING

BAFFLE SEALING
GTS Model Apply Sikaflex primer 449 (P/N 293 530 012) on rear baffle no. 11 and body sections to be sealed.

SPONSON REPLACEMENT
Remove seat (access cover for the XP Limited). Remove air vent tube support (SPX, GS and GSX Limited). Remove seat support (GTI and GTX Limited). Remove muffler. Remove battery.

CAUTION

Allow at least 30 minutes for primer to cure. Apply Sikaflex sealant 221 (P/N 293 530 011) on rear baffle section to be sealed. Before using the watercraft wait 3 days for Sikaflex curing time.

12-02-25

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

ENGINE COVER REMOVAL

XP Limited Disconnect throttle and choke cables at carburetor linkage. Disconnect wiring harnesses of start/stop button, monitoring beeper, safety lanyard switch and gauges. Loosen bolts and nuts of hinge from watercraft body. Disconnect the gas assist cylinder. Remove engine cover. Engine cover installation is essentially the reverse of removal procedure. Refer to the main illustration of engine cover at the beginning of this subsection for proper torque specifications and service products to be used.

Remove half of the decal back protective film and align decal with marks. Start sticking it from center and remove the other half of the film to stick it completely. Carefully squeegee decal beginning at center and working outward using, firm, short, overlapping strokes. DECALS HAVING A PROTECTIVE FILM ON BOTH SIDES These decals usually contain graphics and are used on gelcoat or plastic. INSTALLATION ON GELCOAT Clean surface with a good solvent such as ACRYLI-CLEAN DX 330 from PPG or equivalent (refer to manufacturer instructions). For best result apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready. Using a pencil and the decal as a template mark the area where decal will be located. For better adhesion a dry application is recommended, however, to ease decal installation a mild solution of soapy water can be sprayed over surface where decal will be installed. Remove back protective film from decal and align decal with marks. When well aligned squeegee decal beginning at center and working outward using firm, short, overlapping strokes. Remove front protective film once decal has adhered to hull. INSTALLATION ON PLASTIC (STORAGE COVER) Clean surface with isopropyl alcohol. Using a pencil and the decal as a template, mark the area where decal will be located. Apply an activator (P/N 293 530 036) to prepare the surface using a clean cloth. After a few seconds, when the activator evaporates, the surface is ready.

DECALS REPLACEMENT
Removal
Using a heat gun warm up one end of decal for a few seconds until decal can roll off when rubbing with your finger. Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off. If decal tears while pulling off, it has to be heated for a few seconds longer. If decal tends to stretch while pulling off, stop heating and wait a few seconds to let it cool, then peel it off.

Installation
There are 2 types of decals used on watercraft. One has a protective film on back side and the other has a protective film on both sides. They are used on 3 types of materials; plastic, gelcoat and metal. DECALS HAVING A PROTECTIVE FILM ON BACK SIDE ONLY These decals usually contain written information (ex.: warning) and are used on gelcoat or metal. Clean surface with a good solvent such as ACRYLICLEAN DX 330 from PPG or equivalent (refer to manufacturer instructions). Using a pencil and the decal as a template, mark the area where decal will be located.

CAUTION

Do not use soapy water to locate decal on plastic parts. Remove back protective film from decal and carefully align decal with marks. When well aligned squeegee decal beginning at center and working outward using firm, short, overlapping strokes. Remove front protective film once decal has adhered.

12-02-26

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

HULL AND BODY REPAIR

General
Gelcoat is the smooth and durable cosmetic finish which coats the fiberglass hull and body of a SeaDoo watercraft. It also provides a protective barrier against water and sun. It consists of a mixture of resin, pigment (coloring), fillers, monomers and catalyst which is sprayed into the mold. The body and hull of the Sea-Doo are constructed of chopped fiberglass, saturated with resin. It is sprayed on the layer of gelcoat along with pieces of fiberglass mat, cloth and woven rowing which are added at required areas. This type of construction is very accommodating for high quality repairs. With patience, the proper techniques and materials, a damaged area can be restored to an original finish. NOTE: Fiberglass repair kit is available through automotive or marine suppliers. Gelcoat repair kits are available through regular channel.

FILLING THE CAVITY The prepared surface must be cleaned with acetone on a cloth. Use the Bombardier gelcoat repair kit (P/N 295 500 100). Follow the mixing instructions in the kit when preparing the gelcoat putty. Carefully mix the required amount while making sure there are no air bubbles in the mixture. With a putty knife, fill the repair area and cover with plastic film. Curing time may depend on temperature, amount of putty and percentage of catalyst. After 2 hours, press lightly on the surface with fingers to test the hardness. When the area becomes hard, remove the plastic film. SANDING Begin block sanding the patch with 320-grit sandpaper until you come close to the original surface. Remove dust with a water soaked cloth and continue sanding with a 400-grit wet paper. Finish wet sanding with a 600-grit to remove deeper scratches. If needed you can wet sand with finer grit paper such as 1000-grit. BUFFING AND WAXING Buff the surface using a heavy duty polisher with a buffing pad. Make sure the pad is free of dirt or you may damage the gelcoat. Carefully begin buffing with a white medium compound. Finish off using a fine compound. While buffing, pay close attention to avoid overheating the surface.

Protect skin, wear gloves when in contact with resin, hardeners and gelcoat. A barrier skin cream may also be used. Do not expose area to open flame or lit cigarette. Some of the materials are flammable. Protect eyes, wear safety glasses when grinding, sanding or spraying. Use a dust mask when sanding or grinding. When spraying wear a respirator or paint mask. Always read warning labels on products.

WARNING

Blisters
Possible causes: Insert catalyst. Improper catalyst/gelcoat ratio. A blister is a visible bump on the watercraft surface that may not necessarily come right through the gelcoat layer. In the case of only a few blisters, follow the same repair procedure as for air bubbles. If they are numerous and in close concentration, spray liquid gelcoat to achieve proper repair. This procedure is covered in Minor Gelcoat Fractures.

Air Bubbles
Possible cause: Air pocket trapped between layers of laminate and gelcoat. PREPARATION OF SURFACE Remove all of the damaged gelcoat surrounding the air bubble with a putty knife or preferably a carbide grinding tip. Make sure all loose and weak areas are completely removed. Sand a small area of the gelcoat surface with 220-grit sandpaper. If needed, sand the cavity itself. These areas must have a rough surface to allow the gelcoat putty to bond properly.

Minor Gelcoat Fractures

Possible Causes: Flexing of fiberglass laminate. Gelcoat thickness. Direct result of impact.

12-02-27

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

In case of fractures which have not penetrated past the gelcoat layer, the repair concerns the gelcoat only. If flex cracking or impact are evident, then additional reinforcement may be necessary. This subject will be covered in Compound Fractures. PREPARING THE SURFACES Small Fractures Open the cracks up with a sharp triangular can opener or preferably a carbide tipped die grinder. The V groove will provide a good bonding area for the gelcoat. With 220-grit sandpaper, sand the sides of the notched out areas. Numerous Fractures Using a grinder with a 24-grit disk, remove the gelcoat. Sand the area edge with 220-grit sandpaper. FILLING THE REPAIR AREA Small Fractures Refer to the same procedure as in the Air Bubbles. Numerous Fractures Over Large Surface: Prepare the area for spray application of liquid gelcoat. Wipe down the surface with acetone. Mask the area off to protect the watercraft from overspray. Mix the needed quantity of gelcoat and catalyst according to suppliers recommendations. The gelcoat can be thinned with acetone up to 10%. If it needs more consistency you can add cabosil. Make sure that the air supply is free of oil, dirt and water. Test spray the gelcoat mixture on paper to verify its consistency and pattern. You may have to apply 5 or 6 coats to cover the area properly. Overlap each coat further than the last, leaving at least 30 seconds between passes. Avoid trying to coat the surface with only a few heavy coats, this will not allow the gelcoat to dry properly. Apply a coat of polyvinyl alcohol to seal off the air and protect the gelcoat surface from dust. PVA speeds up the curing process because gelcoat will not cure properly when exposed to air.

SANDING Wash the polyvinyl alcohol off with water. Depending on the size of the area repaired, you can either block sand as per previous procedure or you may use an air sander. Sand the surface down with progressively finer grits of sandpaper until the desired finish is achieved. BUFFING AND WAXING Buff the surface using a heavy duty polisher with a buffing pad. Make sure the pad is free of dirt or you may damage the gelcoat. Carefully begin buffing with a white medium compound. Finish off using a fine compound. While buffing, pay close attention to avoid overheating the surface.

Compound Fractures
Possible causes: Thickness of fiberglass laminate. Direct result of impact. Compound fractures are those that have gone past the gelcoated surface and in through the layers of fiberglass laminate. Two types of repairs have to be performed. The first is to restore the structural integrity of the damaged area. Fracture types can vary from a simple crack to a large hole. Usually, fiberglass reinforcement becomes necessary, especially if the fracture can be attributed to weakness. The final part of the repair is the gelcoating, which cannot be done until the interior and exterior laminate surfaces have been repaired. Outside Remove the damaged gelcoat and fiberglass with a 24-grit disk using a power sander. Grind outward at least 2 inches from the fracture to allow the patch to bond to strong material. Cut enough pieces of fiberglass mat necessary to build up the area. The pieces should be cut so they overlap each other by at least a half inch. For a smoother finish, the last layer should be fiberglass cloth. If the fracture is small enough all you may have to do is fill the area with an epoxy filler. Inside For the interior repair, you can grind more. This will allow for more fiberglass material which will strengthen the area. If the fracture opening is too large after surface preparation, you may need a backing support to cover the opening. Cut alternating pieces of fiberglass mat and cloth in overlapping sizes.

12-02-28

Subsection 02

Section 12 HULL/BODY (ADJUSTMENT AND REPAIR)

PATCHING THE REPAIR AREA Outside The outside should be done first. Wipe clean the area with acetone on a cloth, then mask off area. For a small crack use an epoxy filler in the same way you would use Bombardiers gelcoat repair putty. When laying up a larger area you will use mat, cloth and fiberglass resin and hardener. Use a clean container to mix the resin, mix only what you will need. Follow the recommended catalyst ratio. Using a clean paintbrush, brush the mixed resin on the surface. Place the smallest piece of mat over the fracture and then wet out the mat. Follow with the remaining pieces of mat and final layer of cloth. While wetting the pieces make sure you work the air bubbles out and saturate all the pieces evenly. Try to work quickly, you may only have 15 or 20 minutes. You may clean the brush with acetone. Wait until the repair has hardened before moving on to the interior repair. If the size of the opening is too large for the pieces to maintain the proper shape, you will have to use a backing support. It is a shaped piece of cardboard that fits flush to the interior surface and has a plastic layer on the repair side. It is held in place by tape or a support. Inside Wipe down the area with acetone on a cloth. Apply the same procedure as for outside repair when laminating the alternating pieces of fiberglass material. If a backing support was used, remove it before starting the repair. After the area has hardened, remove sharp edges of material from surface. If required paint the surface. SANDING Outside This surface will have to be prepared for application of gelcoat. The size of the area will determine the gelcoating procedure to be used. Refer to the repair procedure for minor gelcoat fractures. BUFFING AND WAXING Refer to the buffing and waxing for Minor Gelcoat Fractures.

TOOLS AND MATERIALS LIST

Tools
safety glasses air mask white cloths sanding block putty knife plastic film stirring stick cover sheets (for Sea-Doo) scissors buffing pad heavy-duty polisher power sander paint brush plastic container (mixing) spray gun plastic squeegee

Materials
fiberglass mat fiberglass cloth polyester resin cardboard masking tape sandpaper (100-grit, 220-grit, 320-grit, 400-grit, 600-grit, 1000-grit) 24-grit sanding disks Bombardier gelcoat putty Bombardier liquid gelcoat acetone cabosil epoxy filler medium compound (white) fine compound (white) wax

12-02-29

Section 12 HULL/BODY Subsection 02 (ADJUSTMENT AND REPAIR)

HULL INSERT REPAIR

For hull insert repair proceed as follows: Cut plastic hull insert flush with hull using a saw.
1

2
F01L2VA

1. Knurled surface 2. Inner bore

F01L2UA

1. Hull 2. Plastic hull insert

Install aluminum insert into plastic hull insert. NOTE: Align aluminum insert as much as possible with PTO flywheel.

Mix epoxy glue (3M-05900), follow manufacturer instructions. Apply epoxy glue on aluminum insert (P/N 292 000 075) knurled surface and on plastic insert inner bore.

CAUTION

If you notice any clearance between plastic insert and aluminum insert, fill gap with epoxy glue to obtain good adhesion of aluminum insert.
1
F01L2WA

1. Aluminum insert

NOTE: The epoxy glue curing time is 30 minutes.

12-02-30

Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL)

SPX MODEL
ENGINE
Engine type Induction type Type Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler)

0
SPX (5838/5839)
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 BOMBARDIER-ROTAX 2 82 mm (3.228 in) 82.25 mm (3.238 in) Not applicable 74 mm (2.91 in) 781.6 cm (47.7 in) 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) 0.11 mm (.0043 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)

Exhaust system

Exhaust valve Starting system Lubrication Number of cylinders Bore Standard First oversize Second oversize Fuel/oil mixture Oil injection pump Oil injection type

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 Opening Rotary valve timing Closing Rotary valve duration Rotary valve/cover clearance New Connecting rod/crankshaft pin radial clearance Wear limit New Connecting rod/piston pin radial clearance Wear limit ADDITIONAL INFORMATION:

13-01-1

Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL)

ELECTRICAL
Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Battery charging coil Trigger coil Ignition coil Engine rev limiter setting Battery Starting system Charging system VTS system ADDITIONAL INFORMATION: Fuse Primary Secondary Make and type Gap mm (in) Degrees

SPX (5838/5839)
180 W @ 6000 RPM or 5.0 A @ 6000 RPM Digital DC-CDI NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) 3.38 (.133) 22 1 @ 3500 RPM 0.1 - 1 190 - 300 0.33 - 0.62 8.4 - 15.6 k 7200 ( 50) RPM 12 V, 19 Ah (Yuasa/Exide) 5A 2 x 15 A 7.5 A

CARBURETION
Carburetor Main jet Pilot jet Spring Valve seat Low-speed screw High-speed screw Idle speed (in water) Idle speed (out of water) Type Minimum octane no. Type Quantity

SPX (5838/5839)
Mikuni BN-40I (diaphragm) Fuel accelerator pump 2 140 (MAG) 142.5 (PTO) 67.5 95 g 1.5 mm 1.5 turn 1/4 0 1500 RPM 3000 RPM Regular unleaded gasoline 87 MAG and PTO: 0.8 mm (.031 in)

Adjustment

Fuel

Fuel return line orifice ADDITIONAL INFORMATION:

COOLING
Type Thermostat Monitoring beeper setting ADDITIONAL INFORMATION:

SPX (5838/5839)
Open circuit Direct flow from jet propulsion unit None 86-94C (187-201F)

13-01-2

Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL)

PROPULSION Propulsion system Jet pump type Impeller rotation (seen from rear) Transmission Coupling type

SPX (5838/5839) Bombardier Formula Pump Axial flow single stage Counterclockwise Direct drive Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOL ESTER OIL 75W90 GL5 Steering nozzle pivoting angle 26 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 16 - 23/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:

SPX (5838/5839) 2 254 cm (100 in) 105 cm (41.3 in) 92 cm (36.2 in) 194 kg (428 lb) 159 kg (351 lb)

CAPACITIES Fuel tank (including reserve) Fuel tank reserve Oil injection reservoir Capacity Oil level height ADDITIONAL INFORMATION: Jet pump impeller shaft reservoir

SPX (5838/5839) 34 L (9 U.S. gal) 5 L (1.3 U.S. gal) 4.5 L (1.2 U.S. gal) 80 mL (2.7 U.S. oz) Up to plug

13-01-3

Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL)

MATERIALS
Hull Inlet grate Impeller housing/stator/venturi/nozzle Air intake silencer Flame arrester Exhaust muffler Steering padding Fuel tank Oil injection reservoir Seat ADDITIONAL INFORMATION:

SPX (5838/5839)
Composite Plastic Plastic/brass/plastic/aluminum Thermoplastic Multi-layer wire screen Aluminum Thermoplastic with polyethylene foam Polyethylene Polyethylene Polyurethane foam

STANDARD EQUIPMENT
Safety lanyard Digitally Encoded Security System Fuel tank reserve Monitoring beeper Speedometer Fuel/oil gauge (analog) Tachometer Variable trim system (VTS) Reverse Storage compartment Rear grab handle Extinguisher holder Tool kit ADDITIONAL INFORMATION:

SPX (5838/5839)
Standard Standard Standard Standard Optional Standard Optional Standard Not applicable Standard Standard Standard Standard

PERFORMANCE
Estimated pump output Maximum fuel consumption at wide open throttle Fuel tank without reserve Fuel tank reserve ADDITIONAL INFORMATION: Cruising time at full throttle

SPX (5838/5839)
34 kW (46 hp) 44.5 L/h (11.7 U.S. gal/h) 39 minutes 7 minutes

13-01-4

Section 13 TECHNICAL DATA Subsection 01 (SPX MODEL)

TIGHTENING TORQUES
Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) M8 M10 Crankcase/engine support nuts Engine mount/hull Cylinder head screws Crankcase/cylinder screws Tuned pipe flange screws/nut Tuned pipe fixation screws Flame arrester screws Magneto housing cover screws Starter mounting screws Spark plugs Impeller Pump/hull nuts Venturi/pump housing screws VTS ring screws Pump housing cover screws Inlet grate screws Riding plate screws Cable retaining block bolts Steering cable/stem arm bolt Steering stem arm bolts Handlebar clamp bolts Steering cable ball joint bolt (nozzle) Front support bolts Rear support/cable bracket bolts Handlebar grip screw Crankcase screws

SPX (5838/5839)
40 Nm 105 Nm 110 Nm 24 Nm 40 Nm 35 Nm 25 Nm 24 Nm 40 Nm 40 Nm 25 Nm 10 Nm 9 Nm 22 Nm 24 Nm 70 Nm 33 Nm 21 Nm 13 Nm 4 Nm 8 Nm 10 Nm 6 Nm 3 Nm 6 Nm 26 Nm 7 Nm 15 Nm 15 Nm 13 Nm (30 lbfft) (77 lbfft) (81 lbfft) (17 lbfft) (30 lbfft) (26 lbfft) (18 lbfft) (17 lbfft) (30 lbfft) (30 lbfft) (18 lbfft) (89 lbfin) (80 lbfin) (16 lbfft) (17 lbfft) (52 lbfft) (24 lbfft) (16 lbfft) (10 lbfft) (35 lbfin) (71 lbfin) (89 lbfin) (53 lbfin) (26 lbfin) (53 lbfin) (19 lbfft) (62 lbfin) (11 lbfft) (11 lbfft) (10 lbfft) (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)

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

Correct torques and use of Loctite must be strictly followed.

WARNING

13-01-5

Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED)

GS AND GSX LIMITED

ENGINE Engine type Induction type Type Exhaust system Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler) GS (5626/5844) BOMBARDIER-ROTAX 717 Rotary valve

Exhaust valve Starting system Lubrication Number of cylinders Bore Standard First oversize Second oversize Fuel/oil mixture Oil injection pump Oil injection type

Stroke Displacement Corrected compression ratio Combustion chamber volume Cylinder head warpage (maximum) Piston ring type and quantity Ring end gap Ring/piston groove clearance Piston/cylinder wall clearance New Wear limit New Wear limit New (minimum) Wear limit

Cylinder taper (maximum) Cylinder out of round (maximum) Connecting rod big end axial play Crankshaft deflection Rotary valve timing Rotary valve duration Rotary valve/cover clearance Connecting rod/ crankshaft pin radial clearance New Opening Closing New Wear limit

Wear limit Connecting rod/piston pin New radial clearance Wear limit ADDITIONAL INFORMATION:

GSX Limited (5629/5845) BOMBARDIER-ROTAX 947 Reed valve Water cooled, water injected Water cooled, water injected with regulator 3.5 mm (.139 in) 3.5 mm (.139 in) Not applicable Not applicable 3.5 mm (.139 in) Not applicable RAVE Electric start VROI (Variable Rate Oil Injection) Gear driven Direct driven BOMBARDIER-ROTAX FORMULA XP-S (synthetic) 2 82 mm (3.228 in) 88 mm (3.465 in) 82.25 mm (3.238 in) 88.25 mm (3.474 in) 82.50 mm (3.248 in) Not applicable 68 mm (2.677 in) 78.20 mm (3.079 in) 718.2 cm (43.81 in) 951.2 cm (58 in) 6.2:1 6.0:1 32.6 1.4 cc 45.3 2.0 cc 0.05 mm (.002 in) Not applicable 1 Semi-trapez 2 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) 0.10 mm (.0039 in) 0.09 mm (.0035 in) 0.20 mm (.008 in) 0.10 mm (.004 in) 0.08 mm (.003 in) 0.311 - 0.678 mm 0.390 - 0.737 (.012 - .027 in) (.015 - .029 in) 1.2 mm (.047 in) MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in) 147 5 BTDC Not applicable 65.5 5 ATDC Not applicable 159 Not applicable 0.25 - 0.35 mm (.010 - .014 in) Not applicable 0.020 - 0.033 mm 0.023 - 0.034 mm (.0008 - .0013 in) (.0009 - .0013 in) 0.050 mm (.002 in) 0.003 - 0.012 mm (.00012 - .00047 in) 0.015 mm (.00059 in)

13-02-1

Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED)

ELECTRICAL Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Generating coil Battery charging coil Trigger coil Ignition coil Engine rev limiter setting Battery Starting system Charging system VTS system ADDITIONAL INFORMATION: Engine cold @ 6000 RPM. Fuse Primary Secondary Make and type Gap mm (in) Degrees

GS (5626/5844) GSX Limited (5629/5845) 160 W @ 6000 RPM 180 W @ 6000 RPM or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM Digital CDI Digital DC-CDI NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) 2.59 (.102) 3.60 (.142) 20 1 22 1 @ 3500 RPM 40 - 76 Not applicable 0.05 - 0.6 0.1 - 1 Not applicable 190 - 300 0.33 - 0.62 8.4 - 15.6 k 7000 ( 50) RPM 7200 ( 50) RPM 12 V, 19 Ah (Yuasa/Exide) 5A 2 x 15 A Not applicable 7.5 A

CARBURETION Carburetor Main jet Pilot jet Spring Valve seat Low-speed screw High-speed screw Idle speed (in water) Idle speed (out of water) Type Minimum octane no. Type Quantity

GS (5626/5844) Mikuni BN-40I diaphragm Fuel accelerator pump 1 167.5 70 95 g 1.5 mm 1-1/4 turn 1/4

GSX Limited (5629/5845) Mikuni BN-46I diaphragm Fuel accelerator pump 2 165 82.5 2.0 mm 2 turn 1/4

Adjustment

Fuel Fuel return line orifice

0 1500 RPM 3000 RPM Regular unleaded gasoline 87 MAG and PTO: 0.8 mm (.031 in) 0.8 mm (.031 in)

ADDITIONAL INFORMATION:

COOLING Type Thermostat Monitoring beeper setting ADDITIONAL INFORMATION:

GS (5626/5844) GSX Limited (5629/5845) Open circuit Direct flow from jet propulsion unit None 86-94C (187-201F)

13-02-2

Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED)

PROPULSION Propulsion system Jet pump type Impeller rotation (seen from rear) Transmission Coupling type

GS (5626/5844) GSX Limited (5629/5845) Bombardier Formula Pump Axial flow single stage Counterclockwise Direct drive Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOL ESTER 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) 155.6 mm (6.126 in) New 0.0 - 0.4 mm (.000 - .016 in) Impeller/wear ring clearance Wear limit 1.0 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) Progressive pitch Progressive pitch Impeller pitch/material 11 - 22/stainless steel 16 - 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:

GS (5626/5844)

GSX Limited (5629/5845) 2 267 cm (105 in) 116 cm (45.7 in) 94 cm (37 in) 215 kg (474 lb) 237 kg (523 lb) 159 kg (351 lb)

CAPACITIES Fuel tank (including reserve) Fuel tank reserve Oil injection reservoir Jet pump impeller shaft reservoir ADDITIONAL INFORMATION: Capacity Oil level height

GS (5626/5844) GSX Limited (5629/5845) 56.5 L (15 U.S. gal) 11.4 L (3 U.S. gal) 6 L (1.6 U.S. gal) 80 mL (2.7 U.S. oz) 120 mL (4.0 U.S. oz) Up to plug

13-02-3

Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED)

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:

GSX Limited (5629/5845) Composite Aluminum Plastic/plastic/ Plastic/brass/aluminum/ plastic/plastic aluminum Thermoplastic Multi-layer wire screen Tubular wire screen Aluminum Not applicable Plastic Thermoplastic with polyethylene foam Polyethylene Polyethylene Polyurethane foam

GS (5626/5844)

STANDARD EQUIPMENT GS (5626/5844) GSX Limited (5629/5845) Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Standard Monitoring beeper Standard Speedometer Optional Standard Fuel/oil gauge (analog) Standard Not applicable Info Center Not applicable Standard Variable trim system (VTS) Optional Standard Reverse Not applicable Storage compartment Standard Rear grab handle Standard Extinguisher holder Standard Tool kit Standard ADDITIONAL INFORMATION: Info Center standard functions: Fuel level/low fuel level/low oil level/low voltage/high temperature/tachometer/speedometer/average speed/ peak speed/trip meter/hour meter/clock/lake temperature/chronometer/VTS indicator/maintenance information.

PERFORMANCE Estimated pump power Maximum fuel consumption at wide open throttle Cruising time at full throttle ADDITIONAL INFORMATION: Fuel tank without reserve Fuel tank reserve

GS (5626/5844) 26.3 kW (35.3 hp) 33.5 L/h (8.8 U.S. gal/h) 1 hour 21 minutes 21 minutes

GSX Limited (5629/5845) 55.8 kW (74.9 hp) 55 L/h (14.5 U.S. gal/h) 49 minutes 13 minutes

13-02-4

Section 13 TECHNICAL DATA Subsection 02 (GS AND GSX LIMITED)

TIGHTENING TORQUES Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) M8 M10 Crankcase/engine support nuts Engine mount/hull Cylinder head screws Cylinder head nuts Crankcase/cylinder screws Tuned pipe flange screws/nut Tuned pipe fixation screws Flame arrester screws Magneto housing cover screws Starter mounting screws Spark plugs Impeller Pump/hull nuts Venturi/pump housing screws VTS ring screws Pump housing cover screws Inlet grate screws Crankcase screws

Riding plate screws Cable retaining block bolts Steering cable/stem arm bolt Steering stem arm bolts Handlebar clamp bolts Steering cable ball joint (nozzle) Steering support bolts Handlebar grip screw ADDITIONAL INFORMATION: apply where indicated; (1) Loctite 242 (blue) (2) Loctite 271 (red) (3) Loctite 518 (4) Synthetic grease (5) Anti-seize lubricant
STEERING

GS (5626/5844) 24 Nm (17 lbfft) (4) 145 Nm (107 lbfft) (1) 110 Nm (81 lbfft) (5) 24 Nm (17 lbfft) (3) (4) 40 Nm 35 Nm (26 lbfft) (1) 25 Nm 24 Nm (17 lbfft) (1) (4) Not applicable 24 Nm (17 lbfft) (1) (4) 25 Nm (18 lbfft) (1) 25 Nm 10 Nm (89 lbfin) (1) 9 Nm 22 Nm (16 lbfft) (1) 24 Nm 70 Nm 31 Nm 21 Nm Not applicable 4 Nm 8 Nm 22 Nm 6 Nm 3 Nm 6 Nm 26 Nm 2 Nm (18 lbfin)

GSX Limited (5629/5845) 40 Nm (30lbfft) (4) 115 Nm (85 lbfft) (1) 115 Nm (85 lbfft) (1) 27 Nm (20 lbfft) (3) (4) (30 lbfft) (3) (4) 25 Nm (18 lbfft) (1) (18 lbfft) (1) 34 Nm (25 lbfft) (1) (4) 34 Nm (25 lbfft) (1) Not applicable 40 Nm (30 lbfft) (1) (18 lbfft) (1) Not applicable (80 lbfin) (5) 10 Nm (89 lbfin) (1) (17 lbfft) (5) (52 lbfft) (2) (23 lbfft) (1) (16 lbfft) (1) 13 Nm (10 lbfft) (1) (35 lbfin) (1) (71 lbfin) (1) (16 lbfft) (1) (53 lbfin) (26 lbfin) (53 lbfin) (19 lbfft) 7 Nm (62 lbfin)

JET PUMP

ENGINE

15 Nm 13 Nm

(11 lbfft) (10 lbfft)

(1)

Correct torques and use of Loctite must be strictly followed.

WARNING

13-02-5

Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED)

XP LIMITED
ENGINE
Engine type Induction type Type Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler)

0
XP Limited (5665/5667)
BOMBARDIER-ROTAX 947 Reed 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 88 mm (3.465 in) 88.25 mm (3.474 in) Not applicable 78.20 mm (3.079 in) 951.2 cm (58 in) 6.0:1 45.3 2.0 cc Not applicable 2 Semi-trapez 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) 0.09 mm (.0035 in) 0.20 mm (.008 in) 0.10 mm (.004 in) 0.08 mm (.003 in) 0.390 - 0.737 mm (.015 - .029 in) 1.2 mm (.047 in) MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in) Not applicable Not applicable Not applicable Not applicable 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)

Exhaust system

Exhaust valve Starting system Lubrication Number of cylinders Bore Standard First oversize Second oversize Fuel/oil mixture Oil injection pump Oil injection type

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 Opening Rotary valve timing Closing Rotary valve duration Rotary valve/cover clearance New Connecting rod/crankshaft pin radial clearance Wear limit New Connecting rod/piston pin radial clearance Wear limit ADDITIONAL INFORMATION:

13-03-1

Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED)

ELECTRICAL
Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Battery charging coil Trigger coil Ignition coil Engine rev limiter setting Battery Starting system Charging system VTS system ADDITIONAL INFORMATION: Fuse Primary Secondary Make and type Gap mm (in) Degrees

XP Limited (5665/5667)
180 W @ 6000 RPM or 5.0 A @ 6000 RPM Digital DC-CDI NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) 3.60 (.142) 22 1 @ 3500 RPM 0.1 - 1 190 - 300 0.33 - 0.62 8.4 - 15.6 k 7200 ( 50) RPM 12 V, 19 Ah (Yuasa/Exide) 5A 2 x 15 A 7.5 A

CARBURETION
Carburetor Main jet Pilot jet Spring Valve seat Low-speed screw High-speed screw Idle speed (in water) Idle speed (out of water) Type Minimum octane no. Type Quantity

XP Limited (5665/5667)
Mikuni BN-46I (diaphragm) Fuel accelerator pump 2 165 82.5 95 g 2.0 mm 2.0 turn 1/4 0 1500 RPM 3000 RPM Regular unleaded gasoline 87 MAG and PTO: 0.8 mm (.031 in)

Adjustment

Fuel

Fuel return line orifice ADDITIONAL INFORMATION:

COOLING
Type Thermostat Monitoring beeper setting ADDITIONAL INFORMATION:

XP Limited (5665/5667)
Open circuit Direct flow from jet propulsion unit None 86-94C (187-201F)

13-03-2

Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED)

PROPULSION Propulsion system Jet pump type Impeller rotation (seen from rear) Transmission Coupling type

XP Limited (5665/5667) Bombardier Formula Pump Axial flow single stage Counterclockwise Direct drive Split FR and RR SEA-DOO JET PUMP SYNTHETIC Oil type POLYOL ESTER OIL 75W90 GL5 Steering nozzle pivoting angle 20 Minimum required water level 90 cm (35 in) Drive shaft deflection (maximum) 0.5 mm (.020 in) Impeller outside diameter 155.6 mm (6.126 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 16 - 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:

XP Limited (5665/5667) 2 272 cm (107 in) 111 cm (43.7 in) 103 cm (40.6 in) 250 kg (551 lb) 159 kg (351 lb)

CAPACITIES Fuel tank (including reserve) Fuel tank reserve Oil injection reservoir Capacity Oil level height ADDITIONAL INFORMATION: Jet pump impeller shaft reservoir

XP Limited (5665/5667) 54 L (14 U.S. gal) 10 L (2.6 U.S. gal) 4 L (1.1 U.S. gal) 120 mL (4.0 U.S. oz) Up to plug

13-03-3

Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED)

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:

XP Limited (5665/5667)
Composite Aluminum Plastic/brass/aluminum/aluminum Thermoplastic Tubular 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 Fuel/oil gauge (analog) Tachometer Variable trim system (VTS) Reverse Storage compartment Rear grab handle Extinguisher holder Tool kit ADDITIONAL INFORMATION:

XP Limited (5665/5667)
Standard Standard Standard Standard Standard Standard Standard Standard Not applicable Standard Standard Standard Standard

PERFORMANCE
Estimated pump output Maximum fuel consumption at wide open throttle Fuel tank without reserve Fuel tank reserve ADDITIONAL INFORMATION: Cruising time at full throttle

XP Limited (5665/5667)
52.5 kW (70.4 hp) 55 L/h (14.5 U.S. gal/h) 48 minutes 11 minutes

13-03-4

Section 13 TECHNICAL DATA Subsection 03 (XP LIMITED)

TIGHTENING TORQUES
Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) M8 M10 Crankcase/engine support nuts Engine mount/hull Cylinder head screws Cylinder head nuts Tuned pipe flange screws/nut Tuned pipe fixation screws Magneto cover screws Starter mounting screws Spark plugs Impeller Pump/hull nuts Venturi/pump housing screws VTS ring screws Pump housing cover screws Inlet grate screws Riding plate screws Cable retaining block bolts Steering cable/lever Steering stem arm bolts Handlebar clamp bolts Steering cable ball joint bolt (nozzle) Steering support bolts Lever pivot bolt Handlebar grip screw Crankcase screws

XP Limited (5665/5667)
40 Nm 115 Nm 115 Nm 27 Nm 40 Nm 25 Nm 25 Nm 34 Nm 34 Nm 40 Nm 25 Nm 9 Nm 10 Nm 24 Nm 70 Nm 31 Nm 21 Nm 13 Nm 4 Nm 8 Nm 10 Nm 6 Nm 3 Nm 6 Nm 26 Nm 7 Nm 15 Nm 6 Nm 13 Nm (30 lbfft) (85 lbfft) (85 lbfft) (20 lbfft) (30 lbfft) (18 lbfft) (18 lbfft) (25 lbfft) (25 lbfft) (30 lbfft) (18 lbfft) (80 lbfin) (89 lbfin) (17 lbfft) (52 lbfft) (23 lbfft) (16 lbfft) (10 lbfft) (35 lbfin) (71 lbfin) (89 lbfin) (53 lbfin) (26 lbfin) (53 lbfin) (19 lbfft) (62 lbfin) (11 lbfft) (53 lbfin) (10 lbfft) (4) (1) (1) (3) (4) (3) (4) (1) (1) (1) (4) (1) (1) (1) (5) (1) (5) (2) (1) (1) (1) (1) (1) (1)

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

Correct torques and use of Loctite must be strictly followed.

WARNING

13-03-5

Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL)

GTS MODEL
ENGINE
Engine type Induction type Type Water injection fitting (head) Water injection fitting (cone) Fuel/oil mixture Oil injection pump Oil injection type Standard First oversize Second oversize

0
GTS (5819)
BOMBARDIER-ROTAX 717 Rotary valve Water cooled, water injected 3.5 mm (.139 in) 3.5 mm (.139 in) Electric start VROI (Variable Rate Oil Injection) Gear driven BOMBARDIER-ROTAX 2 82 mm (3.228 in) 82.25 mm (3.238 in) 82.50 mm (3.248 in) 68 mm (2.677 in) 718.2 cm (43.81 in) 6.2:1 32.6 1.4 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) 0.10 mm (.0039 in) 0.20 mm (.008 in) 0.10 mm (.004 in) 0.080 mm (.003 in) 0.311 - 0.678 mm (.012 - .027 in) 1.2 mm (.047 in) MAG side: 0.050 mm (.002 in) PTO side: 0.030 mm (.001 in) 147 5 BTDC 65.5 5 ATDC 159 0.25 - 0.35 mm (.010 - .014 in) 0.020 - 0.033 mm (.0008 - .0013 in) 0.050 mm (.002 in) 0.003 - 0.012 mm (.00012 - .00047 in) 0.015 mm (.00059 in)

Exhaust system

Starting system Lubrication Number of cylinders Bore

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 clearance 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 Rotary valve duration Rotary valve/cover clearance Connecting rod/crankshaft pin radial clearance Connecting rod/piston pin radial clearance
ADDITIONAL INFORMATION:

Opening Closing

New Wear limit New Wear limit

13-04-1

Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL)

ELECTRICAL
Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Generating coil Battery charging coil Ignition coil Engine rev limiter setting Battery Fuse Starting system Charging system Primary Secondary Make and type Gap mm (in) Degrees

GTS (5819)
160 W @ 6000 RPM or 4.0 A @ 2000 RPM Digital CDI NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) 2.59 (.102) 20 1 40 - 76 0.05 - 0.6 Not applicable 9 - 15 k 7000 50 RPM 12 V, 19 Ah (Yuasa/Exide) 5A 15 A

ADDITIONAL INFORMATION: Engine cold @ 6000 RPM.

CARBURETION
Carburetor Main jet Pilot jet Spring Valve seat Low-speed screw High-speed screw Idle speed (in water) Idle speed (out of water) Type Minimum octane no. Type Quantity

GTS (5819)
Mikuni BN-40I diaphragm Fuel accelerator pump 1 167.5 70 95 g 1.5 mm 1-1/4 turn 1/4 0 1500 RPM 3000 RPM Regular unleaded gasoline 87 0.8 mm (.031 in)

Adjustment

Fuel Fuel return line orifice

ADDITIONAL INFORMATION:

COOLING
Type Thermostat Monitoring beeper setting ADDITIONAL INFORMATION:

GTS (5819)
Open circuit Direct flow from jet propulsion unit None 86-94C (187-201F)

13-04-2

Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL)

PROPULSION
Propulsion system Jet pump type Impeller rotation (seen from rear) Transmission Coupling type Oil type Steering nozzle pivoting angle Minimum required water level Drive shaft deflection (maximum) Impeller outside diameter New Impeller/wear ring clearance Wear limit Impeller shaft end play (new) Impeller shaft radial play Impeller pitch/material

GTS (5819)
Bombardier Formula Pump Axial flow single stage Counterclockwise Direct drive Crown splines SEA-DOO JET PUMP SYNTHETIC POLYOL ESTER OIL 75W90 GL5 26 90 cm (35 in) 0.5 mm (.020 in) 139.5 mm (5.490 in) 0.0 - 0.4 mm (.000 - .016 in) 1.00 mm(.040 in) 0.12 - 0.54 mm (.005 - .021 in) 0.05 mm (.002 in) Progressive pitch, 11 - 22/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:

GTS (5819)
3 302 cm (119.0 in) 119 cm (46.9 in) 95 cm (37.4 in) 219 kg (483 lb) 224 kg (494 lb)

CAPACITIES
Fuel tank (including reserve) Fuel tank reserve Oil injection reservoir Jet pump impeller shaft reservoir Capacity Oil level height

GTS (5819)
47 L (12 U.S. gal) 11.4 L (3 U.S. gal) 4.5 L (1.2 U.S. gal) 80 mL (2.7 U.S. oz) Up to plug

ADDITIONAL INFORMATION:

13-04-3

Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL)

MATERIALS
Hull Inlet grate Impeller housing/stator/venturi/nozzle Air intake silencer Flame arrester Exhaust muffler Steering padding Fuel tank Oil injection reservoir Seat ADDITIONAL INFORMATION:

GTS (5819)
Composite Plastic Plastic/plastic/plastic/plastic Thermoplastic Multi-layer wire screen Aluminum Thermoplastic elastomer with polystyrene foam Polyethylene Polyethylene Polyurethane foam

STANDARD EQUIPMENT
Safety lanyard Digitally Encoded Security System Fuel tank reserve Monitoring beeper Fuel gauge/low oil warning light Tachometer Speedometer Variable trim system (VTS) Reverse Storage compartment Rear grab handle Extinguisher holder Tool kit ADDITIONAL INFORMATION:

GTS (5819)
Standard Standard Standard Standard Standard Optional Optional Not applicable Standard Standard Standard Standard Standard

PERFORMANCE
Estimated pump power Maximum fuel consumption at wide open throttle Cruising time at full throttle Fuel tank without reserve Fuel tank reserve

GTS (5819)
35.9 kW (48 hp) 33.5 L/h (8.8 U.S. gal/h) 1 hour 20 minutes

ADDITIONAL INFORMATION:

13-04-4

Section 13 TECHNICAL DATA Subsection 04 (GTS MODEL)

TIGHTENING TORQUES
Exhaust manifold screws Magneto flywheel nut Flywheel (PTO side) M8 M10 Crankcase/engine support nuts Engine mount/hull Cylinder head screws Crankcase/cylinder screws Tuned pipe flange screws/nut Tuned pipe fixation screws Flame arrester screws Magneto housing cover screws Starter mounting screws Spark plugs Impeller Pump/hull nuts Venturi/pump housing screws Nozzle/venturi screws Pump housing cover screws Inlet grate screws Riding plate screws Steering cable jam nuts Steering support/collar screws Steering stem screw Handlebar nuts Reverse gate screws Steering cable ball joint (nozzle) Reverse cable ball joint nut Handlebar grip screw Crankcase screws

GTS (5819)
24 Nm 145 Nm 110 Nm 24 Nm 40 Nm 35 Nm 25 Nm 24 Nm 24 Nm 25 Nm 25 Nm 10 Nm 9 Nm 22 Nm 24 Nm 70 Nm 31 Nm 21 Nm 20 Nm 4 Nm 8 Nm 10 Nm 10 Nm 15 Nm 40 Nm 26 Nm 20 Nm 2 Nm 7 Nm 13 Nm (17 lbfft) (107 lbfft) (81 lbfft) (17 lbfft) (30 lbfft) (26 lbfft) (18 lbfft) (17 lbfft) (17 lbfft) (18 lbfft) (18 lbfft) (89 lbfin) (80 lbfin) (16 lbfft) (17 lbfft) (52 lbfft) (23 lbfft) (16 lbfft) (15 lbfft) (35 lbfin) (71 lbfin) (89 lbfin) (89 lbfin) (11 lbfft) (30 lbfft) (19 lbfft) (15 lbfft) (18 lbfin) (62 lbfin) (10 lbf ft) (4) (1) (5) (3) (4) (3) (4) (1) (1) (1) (4) (1) (4) (1) (1) (1) (5) (1) (5) (2) (1) (1) (1) (1) (1) (1) (1) (2) (1)

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

Correct torques and use of Loctite must be strictly followed.

WARNING

13-04-5

Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED)

GTI AND GTX LIMITED

ENGINE Engine type Induction type Type Exhaust system Water injection fitting (head) Water injection fitting (cone) Water injection fitting (muffler) GTI (5836/5841) BOMBARDIER-ROTAX 717 Rotary valve

Exhaust valve Starting system Lubrication Number of cylinders Bore Standard First oversize Second oversize Fuel/oil mixture Oil injection pump Oil injection type

Stroke Displacement Corrected compression ratio Combustion chamber volume Cylinder head warpage (maximum) Piston ring type and quantity Ring end gap Ring/piston groove clearance Piston/cylinder wall clearance New Wear limit New Wear limit New (minimum) Wear limit

Cylinder taper (maximum) Cylinder out of round (maximum) Connecting rod big end axial play Crankshaft deflection Rotary valve timing Opening Closing New Wear limit

Rotary valve duration Rotary valve/cover clearance Connecting rod/crankshaft pin radial clearance New

Wear limit New Connecting rod/piston pin radial clearance Wear limit ADDITIONAL INFORMATION:

GTX Limited (5837/5842) BOMBARDIER-ROTAX 947 Reed valve Water cooled, water injected Water cooled, water injected with regulator 3.5 mm (.139 in) 3.5 mm (.139 in) Not applicable Not applicable 3.5 mm (.139 in) Not applicable RAVE Electric start VROI (Variable Rate Oil Injection) Gear driven Direct driven BOMBARDIER-ROTAX FORMULA XP-S (synthetic) 2 82 mm (3.228 in) 88 mm (3.465 in) 82.25 mm (3.238 in) 88.25 mm (3.474 in) 82.50 mm (3.248 in) Not applicable 68 mm (2.677 in) 78.20 mm (3.079 in) 718.2 cm (43.81 in) 951.2 cm (58 in) 6.2:1 6.0:1 32.6 1.4 cc 45.3 2.0 cc 0.05 mm (.002 in) Not applicable 1 Semi-trapez 2 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) 0.10 mm (.0039 in) 0.09 mm (.0035 in) 0.20 mm (.008 in) 0.10 mm (.004 in) 0.08 mm (.003 in) 0.311 - 0.678 mm 0.390 - 0.737 mm (.012 - .027 in) (.015 - .029 in) 1.2 mm (.047 in) MAG side: 0.050 mm (.002 in); PTO side: 0.030 mm (.001 in) 147 5 BTDC Not applicable 65.5 5 ATDC Not applicable 159 Not applicable 0.25 - 0.35 mm (.010 - .014 in) Not applicable 0.020 - 0.033 mm 0.023 - 0.034 mm (.0008 - .0013 in) (.0009 - .0013 in) 0.050 mm (.002 in) 0.003 - 0.012 mm (.00012 - .00047 in) 0.015 mm (.00059 in)

13-05-1

Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED)

ELECTRICAL Magneto generator output Ignition system type Spark plug Ignition timing (BTDC) Generating coil Battery charging coil Trigger coil Ignition coil Engine rev limiter setting Battery Starting system Charging system VTS system ADDITIONAL INFORMATION: Engine cold @ 6000 RPM. Fuse Primary Secondary Make and type Gap mm (in) Degrees

GTI (5836/5841) GTX Limited (5837/5842) 160 W @ 6000 RPM 180 W @ 6000 RPM or 4.0 A @ 2000 RPM or 5.0 A @ 6000 RPM Digital CDI Digital DC-CDI NGK BR8ES 0.5 - 0.6 mm (.020 - .024 in) 2.59 (.102) 3.60 (.142) 20 1 22 1 @ 3500 RPM 40 - 76 Not applicable 0.05 - 0.6 0.1 - 1 Not applicable 190 - 300 0.33 - 0.62 8.4 - 15.6 k 7000 ( 50) RPM 7200 ( 50) RPM 12 V, 19 Ah (Yuasa/Exide) 5A 2 x 15 A Not applicable

CARBURETION Carburetor Main jet Pilot jet Spring Valve seat Low-speed screw High-speed screw Idle speed (in water) Idle speed (out of water) Type Minimum octane no. Type Quantity

GTI (5836/5841) Mikuni BN-40I diaphragm Fuel accelerator pump 1 167.5 70 95 g 1.5 mm 1-1/4 turn 1/4

GTX Limited (5837/5842) Mikuni BN-46I diaphragm Fuel accelerator pump 2 165 82.5 2.0 mm 2 turn 1/4

Adjustment

Fuel Fuel return line orifice ADDITIONAL INFORMATION:

0 1500 RPM 3000 RPM Regular unleaded gasoline 87 MAG and PTO: 0.8 mm (.031 in) 0.8 mm (.031 in)

COOLING Type Thermostat Monitoring beeper setting ADDITIONAL INFORMATION:

GTI (5836/5841) GTX Limited (5837/5842) Open circuit Direct flow from jet propulsion unit None 86-94C (187-201F)

13-05-2

Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED)

PROPULSION Propulsion system Jet pump type Impeller rotation (seen from rear) Transmission Coupling type

GTI (5836/5841) GTX Limited (5837/5842) Bombardier Formula Pump Axial flow single stage Counterclockwise Direct drive Crown splines SEA-DOO JET PUMP SYNTHETIC Oil type POLYOL ESTER 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) 155.6 mm (6.126 in) New 0.0 - 0.4 mm (.000 - .016 in) Impeller/wear ring clearance Wear limit 1.0 mm (.040 in) Impeller shaft end play (new) 0.12 - 0.54 mm (.005 - .021 in) Impeller shaft side play 0.05 mm (.002 in) Progressive pitch Progressive pitch Impeller pitch/material 11 - 22/stainless steel 14 - 21/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:

GTI (5836/5841)

GTX Limited (5837/5842) 3 312 cm (122.8 in) 119 cm (47 in) 94 cm (37 in) 269 kg (593 lb) 288 kg (635 lb) 242 kg (534 lb)

CAPACITIES Fuel tank (including reserve) Fuel tank reserve Oil injection reservoir Jet pump impeller shaft reservoir ADDITIONAL INFORMATION: Capacity Oil level height

GTI (5836/5841) GTX Limited (5837/5842) 56.5 L (15 U.S. gal) 11.4 L (3.0 U.S. gal) 6 L (1.6 U.S. gal) 80 mL (2.7 U.S. oz) 120 mL (4.0 U.S. oz) Up to plug

13-05-3

Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED)

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 Limited (5837/5842) Composite Aluminum Plastic/brass/plastic/ Plastic/brass/aluminum/ plastic aluminum Thermoplastic Multi-layer wire screen Tubular wire screen Aluminum Not applicable Plastic Thermoplastic with polyethylene foam Polyethylene Polyethylene Polyurethane foam

GTI (5836/5841)

STANDARD EQUIPMENT GTI (5836/5841) GTX Limited (5837/5842) Safety lanyard Standard Digitally Encoded Security System Standard Fuel tank reserve Standard Monitoring beeper Standard Speedometer Standard Fuel/oil gauge (analog) Standard Not applicable Tachometer Not applicable Standard Info Center Not applicable Standard Reverse Standard Storage compartment Standard Glove box Standard Rear grab handle Standard Extinguisher holder Standard Tool kit Standard ADDITIONAL INFORMATION: Info Center standard functions: Fuel level/low fuel level/low oil level/low voltage/high temperature/tachometer/speedometer/average speed/peak speed/ trip meter/hour meter/clock/compass/exterior temperature/lake temperature/chronometer/maintenance information.

PERFORMANCE Estimated pump power Maximum fuel consumption at wide open throttle Cruising time at full throttle ADDITIONAL INFORMATION: Fuel tank without reserve Fuel tank reserve

GTI (5836/5841) 26 kW (34.9 hp) 33.5 L/h (8.8 U.S. gal/h) 1 hour 21 minutes 21 minutes

GTX Limited (5837/5842) 51 kW (68.4 hp) 55 L/h (14.5 U.S. gal/h) 49 minute 13 minutes

13-05-4

Section 13 TECHNICAL DATA Subsection 05 (GTI AND GTX LIMITED)

TIGHTENING TORQUES Exhaust manifold screw Magneto flywheel nut Flywheel (PTO side) M8 M10 Crankcase/engine support nuts Engine mount/hull Cylinder head screws Cylinder head nuts Crankcase/cylinder screws Tuned pipe flange screws/nut Tuned pipe fixation screws Flame arrester screws Magneto housing cover screws Starter mounting screws Spark plugs Impeller Pump/hull nuts Venturi/pump housing screws Pump housing cover screws Inlet grate screws Riding plate screws Cable retaining block bolts Steering cable/stem arm bolt Steering stem arm bolts Handlebar clamp bolts Steering cable ball joint (nozzle) Steering support bolts Handlebar grip screw Crankcase screws

GTI (5836/5841) 24 Nm (17 lbfft) (4) 145 Nm (107 lbfft) (1) 110 Nm (81 lbfft) (5) 24 Nm (17 lbfft) (3) (4) 40 Nm 35 Nm (26 lbfft) (1) 25 Nm 24 Nm (17 lbfft) (1) (4) Not applicable 24 Nm (17 lbfft) (1) (4) 25 Nm (18 lbfft) (1) 25 Nm 10 Nm (89 lbfin) (1) 9 Nm 22 Nm (16 lbfft) (1) 24 Nm 70 Nm 31 Nm 21 Nm 4 Nm 8 Nm 22 Nm 6 Nm 3 Nm 6 Nm 26 Nm 2 Nm (18 lbfin) 15 Nm 13 Nm (1) Loctite 242 (blue) (2) Loctite 271 (red) (3) Loctite 518 (4) Synthetic grease (5) Anti-seize lubricant

GTX Limited (5837/5842) 40 Nm (30 lbfft) (4) 115 Nm (85 lbfft) (1) 115 Nm (85 lbfft) (1) 27 Nm (20 lbfft) (3) (4) (30 lbfft) (3) (4) 25 Nm (18 lbfft) (1) (18 lbfft) (1) 34 Nm (25 lbfft) (1) (4) 34 Nm (25 lbfft) (1) Not applicable 40 Nm (30 lbfft) (1) (18 lbfft) (1) Not applicable (80 lbfin) (5) 10 Nm (89 lbfin) (1) (17 lbfft) (5) (52 lbfft) (2) (23 lbfft) (1) (16 lbfft) (1) (35 lbfin) (1) (71 lbfin) (1) (16 lbfft) (1) (53 lbfin) (26 lbfin) (53 lbfin) (19 lbfft) 7 Nm (62 lbfin) (11 lbfft) (1) (10 lbfft)

ADDITIONAL INFORMATION: apply where indicated;

STEERING

JET PUMP

ENGINE

Correct torques and use of Loctite must be strictly followed.

WARNING

13-05-5

Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

WIRING DIAGRAMS
WIRE COLOR CODES
First color of a wire is the main color. Second color is the tracer. Example: YELLOW/BLACK is a YELLOW wire with a BLACK tracer.

0
AMP PLUG CONNECTOR
All Models Except SPX and GTS These connectors are found on the MPEM. When servicing electrical system, special care must be taken when working with AMP Plug Connectors in order to prevent any malfunction of the system.

WIRE DIGIT CODES

All Models Except SPX and GTS First number indicates in which connector the wire is plugged in. Second number indicates the position of the wire in the connector. The letter at the end of the number (if applicable) indicates a common circuit in the MPEM printed circuit with another wire bearing the same letter. Example: 2-18 (g) The first number indicates that the wire is positioned in the connector no. 2 of the MPEM. The second number indicates that the wire is positioned in the terminal no. 18. The letter (g) indicates a common circuit with another wire(s) bearing the same letter (g) in the circuit.

Description
5 9 1

2 7 3 4

8
F00H0WB

PACKARD CONNECTOR
To remove terminal from connector housing, use Snap-on TT600-4 tool.

AMP PLUG CONNECTOR 1. Plug assembly 2. Cover assembly 3. Mating seal 4. Wedge lock 5. Header assembly 6. Seal plug 7. Power wire 8. Signal wire 9. Locking tab

F01B1JA

WARNING

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

14-01-1

Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

Removal
To remove the plug connector from the header assembly, press both tabs and pull plug.
1 2

Each plug assembly is mechanically keyed to mate only with identical mechanical keyed header on the MPEM.

F00H0NA

Step 1 : Press tabs (both sides) Step 2 : Pull plug

Installation
Apply a thin coat of DEOXIT contact lubricant (P/N 293 550 015) to the pins of the header on the MPEM only.
1

F00H12A

1. Mechanically keyed

Contact Removal
SIGNAL WIRE Insert a screwdriver blade between the connector and the wedge lock tab. Release the locking tab and at the same time, pry open the wedge lock to open position.
1
F00H11A

CAUTION

1. Apply a thin coat of DEOXIT contact lubricant

CAUTION

The wedge lock should never be removed from the connector for insertion or removal of the signal wire contacts

Do not apply lubricant excessively. Care must be taken so that the lubricant will not come in contact with the mating seal; the seal may loose its sealing capacities. Do not apply lubricant on contacts inside plug connector.

14-01-2

Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

1 2

F00H0OA

F00H0QA

1. Screwdriver between wedge lock and connector 2. Locking tab

1. Rotate wire back and forth 2. Pull wire

Repeat the same steps for the other locking tab retaining the wedge lock. The wedge lock is now in the open position.

POWER WIRE CONTACT NOTE: The wedge lock must be removed to extract power contact. Open the wedge lock. Pull both locking tabs and remove wedge lock from plug assembly.
1

F00H0PA

1. Wedge lock opened

While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.
F00H0RA

1. Pull locking tab (both sides)

Before extraction, push wire forward to relieve pressure on retaining tab. Insert a 4.8 mm (.189 in) wide screwdriver blade inside the front of the contact cavity.

14-01-3

Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

F00B0EA

CRIMPING TOOL (P/N 295 100 164)

F00H0ZA

Pry back the retaining tab while gently pulling wire back until contact is removed.

All circuits are sealed by a diaphragm in the rubber wire seal. When installing wire contacts in plug connector, the diaphragm is pierced as the contact passes through it. If the diaphragm is pierced and the cavity is not used, install a seal plug, large end first, into circuit cavity as far as it will go. NOTE: It is suggested that all unused circuit cavities be sealed with a seal plug, even if they are not pierced.
1

Contact Crimping
The size of the wires must be 20 to 16 AWG with a wire insulation diameter having a minimum dimension of 1.7 mm (.067 in) and a maximum dimension of 2.78 mm (.106 in). The wire strip length shall be 5.1 mm (13/64 in). NOTE: When stripping wires, ensure conductor is not nicked, scrapped or cut. Wire stripping tool jaws may leave marks on the surface of the wire insulation. If these marks occur at the location of the wire seal, leakage may result. Insulation surface within 25 mm (1 in) from the tip of the contact must be smooth. All contacts in AMP plug connectors must be crimped using the crimping tool (P/N 295 100 164).

2
F00H10A

CAUTION

1. Seal plug 2. Wire seal

If contacts are not crimped using the proper crimping tool, the wire seal may be damaged.

14-01-4

Section 14 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS)

CAUTION

Do not pierce the diaphragm with a sharp point for electrical troubleshooting. The resulting pinholes in the insulation will allow moisture to penetrate the system and possibly result in system failure.

Contact Installation
For insertion of signal contact, make sure the wedge lock is in the open position. NOTE: For insertion of power contact, the wedge lock may or may not be on the open position. Insert contact into appropriate circuit cavity and push as far as it will go. Pull back on the contact wire to be sure the retention fingers in the housing are holding the contact properly. After all required contacts have been inserted, the wedge lock must be closed to its locked position.

14-01-5